Richlite Fabrication Guide Cirque Distribution

RICHLITE FABRICATION GUIDE CIRQUE DISTRIBUTION

Enhancing innovative design through sales, distribution and support of premium architectural, maker and specialty building materials.

TABLE OF CONTENTS

FABRICATION GUIDE and OVERVIEW...... 4 TROUBLESHOOTING...... 26

DELIVERY, HANDLING and STORAGE...... 5 CANTILEVER GUIDELINES...... 27

PLANNING...... 7 PROPERTIES...... 28

CUTTING ...... 9 MSDS...... 29

ROUTING...... 11 WARRANTY...... 30

DRILLING ...... 13 IMPORTANT LINKS...... 33

CNC MACHINING...... 14

SEAMING...... 16

ASSEMBLIES...... 18

SURFACE FINISHING...... 19

APPLIED FINAL FINISHES...... 22

CARE and MAINTENANCE...... 24 RICHLITE FABRICATION GUIDE

The following document describes how Richlite paper composite is received, handled, and fabricated. These guidelines should ensure that your experience with Richlite is informed and positive. Richlite is not like any other material available and by following the instructions below, it is not difficult to fabricate and the results are tremendously rewarding. Please note, these are general guidelines and it is recommended that any fabrication techniques be tested by the individual fabricator as each situation may have differeing parameters that will affect performance. These guidelines do not imply any warranty of work provided by independent companies and are super- seded by the Richlite® material warranty.

FABRICATION GUIDE 3 FABRICATION OVERVIEW Richlite® is a versatile material that can be used in numerous applications and multiple fabrication settings.

Provided only as a sheet-good with factory surfaces and factory rough edge cuts, Richlite is a laminate made from paper saturated with a phenolic resin and is used in a number of applications including: wainscoting, flooring, shelving, window sills, industrial parts, countertops and exterior rainscreens. Its structure behaves and wears like ultra hard wood and is considered structurally superior to stone and solid surface. Woodworking tools and solid surface tools with sharp carbide bits are preferred but wet tools will work. Richlite doesn’t melt/burn away like plastic or burn away like wood. It is not a heat sink like metal and heat can build up quickly and ruin tooling like metal blades and bits. Be careful with feeds and speeds from hand drilling (push hard and spin slow) to CNC.

Countertops work best at full thickness at 1/2”, 3/4”, 1”, 1.25”. You can stack or mitre an edge but generally it is more cost effective and easier to fabricate with a full thickness countertop. The material is through body color and seams are visible but should not be felt. It is extremely important to get the deck seams as level as possible and use plastic biscuits or splines made from Richlite. You can double stack an edge. Typical solid surface adhesive will NOT work on Richlite.

Richlite can be sanded down but it will alter the initial quality and look of the brand new product. Sand the edges as much as you please but sanding the deck or surface should be kept to a minimum and NO SANDING should be done on any surface exposed to the elements. “Less is more” when it comes to sanding.

The most durable finish we have is a completely unsanded mill finish material with Richlite Color Enhancer applied. The worst mistake you can make while fabricating the material is oversanding. The second worst is not wiping off the color enhancer in a timely fashion..

FABRICATION GUIDE 4 ORDERING, DELIVERY, HANDLING and STORAGE

DELIVERY Richlite is drop-shipped from the Richlite factory (Tacoma, WA). • Richlite material is shipped on heat treated pallets, covered in ply- wood and/or Cor-X. • A forklift will most likely be required at the receiving location. Full pallets are approximately 3,000 Lbs. Single sheets are heavy; 400 pounds for a 1”x 5'x12'. Pallets are banded with metal strapping and require tin snips to open. • Consider accessibility to site or shop, including hours of operation as there will be additional charges for Limited Access Deliveries, Lift Gate, Residential Delivery, Notification/Appointment Required. If not notified prior to shipping, additional charges will be incurred from the freight company. HANDLING • Although they are impact resistant, when sheets rub across one an- other they can get “rubs” or dry/slick looking areas. A wipe down with a clean soft cloth and water will take care of most rubs or dry looking areas. Grit between the panels is to be avoided at all costs and don’t allow the corners to drag across the surface of the panels below. • Be careful of the factory edges as they are quite sharp. INSPECTION Every effort has been made to provide high quality material, free of defects. However, you, the fabricator, must: • Inspect material immediately upon receipt. • Conduct a final (pre-cutting) inspection prior to fabrication. • List of what to look for: Color: Color, shade and grain of the panel may vary from samples. Patina and oxidation will affect product color (lighter colors in particular). See product details document for more details. Striations: Striations are normal in the product. Striations appear as mottling running in a grain pattern following the length of the panel..

FABRICATION GUIDE 5 INSPECTION (continued) Striations (continued): Occasionally, slightly darker straight lines will appear running the length of the panel. These are normal lines initi- ated from the paper making process (unfortunately, there is very little Richlite can do with these lines). Wrinkles: These will generally appear as a very dark jagged line running diagonally across the panel. This is not normal and should be returned as warranty. Surface Conditions: Most marring or light scratches can easily be cleaned up with a wet rag. Please contact your distributor if you see bigger bumps or divots. Thickness: Tolerance is +/- 4%. REPLACEMENT If the material is defective or flawed you can either avoid flaws via part placement on sheet or order replacement material and initiate a request for credit. Do not notify the factory. Notify your Richlite distributor via e-mail and include: • Photos of the material in question. • A copy of the invoice for the effected material (PO#, SO#, Invoice#, Etc.) should be listed on the invoice. • A written description of the defect. • Any other pertinent information. Your distributor will respond with either a return authorization and/or approval or denial of a credit. Credit memos will typically include the original cost, plus freight for the replacement material and freight for the returned material (if applicable). The credit memo will be issued upon confirmation the warranty material was returned. IMPORTANT NOTE: Richlite does not supply credits for fabrication or material handling costs. Pre-fabrication inspection is critical to insure that defective material is not fabricated. STORAGE • Do not store Richlite uncovered. Place a piece of 7mm plastic or the Cor-x® that came with the shipment on top of the Richlite. • Store between 40-80 degrees Fahrenheit. • Do not over stack. Richlite weighs 6.5 lbs per square foot at 1” thick. • Store flat, do not store on edge.

FABRICATION GUIDE 6 PLANNING

SELECTING THE "A" SIDE There is no “A” or “B” side to Richlite. Evaluate both sides of the sheet to determine which side is more desirable to use. Small voids and bumps may occasionally occur on the surface of the panels. Those that cannot be avoided will require extra care when sanding. COLORS Different colors have different attributes during fabrication. Black is the most forgiving in all aspects. The dark colors will stack/seam with a less noticeable line. The pattern, striations and mottling are more noticeable in the lighter colors and the seam will be more noticeable. Also, keep in mind that the surface color is not the same as the edge. GRAIN DIRECTION Richlite has a mottled appearance, which patterns in a striated effect lengthwise. This feature is most apparent in the lighter tones, but can be seen in darker colors including black. Consider the effect of grain direction when planning cuts. SEAM PLACEMENT Seams will show and will look similar to those of wood or veneers and should be incorporated into design layout. For both structural and aesthetic reasons, seams should be placed at natural positions such as corners or midpoints. Structurally, the seams may be placed exactly at a 90 degree (perpendicular) corner. Consider the impact of the striations when determining seam placement. EDGE DESIGN Any edge treatment or design can be applied to Richlite. All common profiles available to fabricators in both wood and stone tooling can be applied to Richlite countertop edges. THICKNESS The minimum recommended thickness for horizontal use is 3/4”. 1/2” can be used only with proper engineering and fastening to insure material stability. Material thickness less than 3/4” is typically suitable for vertical use only, such as in back splashes or wainscoting. A double .

FABRICATION GUIDE 7 PLANNING (continued) THICKNESS (continued) stacked edge requires a special technique different than solid surface. A mitered edge will not look exactly the same as solid full thickness material or a stacked edge. The miter joint is also weaker when using 1/2” Richlite versus solid surface. STACKED EDGE There is a residue on the surface of Richlite that doesn’t interfere with finish but it WILL cause epoxy to fail. When stacking an edge versus gluing a seam, the surface material is taking epoxy. This surface, the underside of the deck and the top of the stack edge, need to be sanded by hand or with an orbital with anything between 80 and 150 grit before gluing. CANTILEVERS and SPANS Richlite is extremely strong, and due to the engineering of the product, can be cantilevered in many applications. Generally, 3/4” will remain stable with a 12” overhang, 1” with an 18” overhang, 1 1/2” up to 24”. See General Guidelines (page 31) for exact information on strength when designing to maximize span or cantilever. IMPORTANT NOTE: Richlite only provides general guidelines and specific applications and designs are the responsibility of the architect and structural engineer.

FABRICATION GUIDE 8 CUTTING

ROUGH CUTTING Rough cutting Richlite is a quick way to process panels that do not require a finished edge. Some examples include exterior paneling, non- visible fabricated edges, mating assemblies and industrial applications. Due to the weight of the material, stationary cutting with a circular saw, panel saw or CNC router is preferred over table saws. While CNC routers are a good tool for certain operations as noted below, rough cutting and routing by hand is a very efficient way to process Richlite. The factory rough cut edge is to exact stated dimension and not oversized. • Festool® track saw is the preferred cutting setup. • Standard circular saws can be used but will often leave saw marks due to less stable nature and lower rpm motors. • Single pass cutting can be achieved if the proper blades are used. Ap- propriate feed speeds are critical in this situation and will be a function of thickness, and even in some cases color. FINISH CUTTING Finish cuts can be made with a high quality circular saw like a Festool® track saw or worm drive high horsepower unit. Feed speeds and high rpm’s will ensure a clean cut. Making a pass with the appropriate feed speed, using a sharp proper blade with high rpm's can provide a cut that need to be minimally sanded to achieve a quality edge treatment. • An even rate of speed will prevent burn marks which if present, can be routed off with some difficulty. • For mated seams, routing or finish cutting will result in a tighter seam. • Sliding table saw speeds suggested between 3,450 RPMs and 4,000 RPMs. • Jig saws and hole saws are not recommended as a tool for Richlite as the blades tend to wear out very quickly.

FABRICATION GUIDE 9 CUTTING (continued) SUGGESTED EQUIPMENT Saws • Festool® model TS 75 or TS 55 • Worm drive circular saw • Sliding table saw • Panel saw

Saw Blades • carbide, 60 - 80 tooth, low to negative degree hook. • For curves, jigsaw cobalt steel blades

FABRICATION GUIDE 10 ROUTING

Routing is recommended as saw marks can be very difficult to remove with a palm sander and a proper routing setup can often provide a high quality finish that minimizes sanding and finish work. Rough cuts to be routed should be made as close as possible to finished dimensions, leaving only enough material to make a final pass or to finish with a router or sander. FINISH EDGE ROUTING After cutting with a saw, a finished edge can be cut with a router. • 1/32” of material or less for finish pass. • Large diameter bits and larger horsepower routers will provide a smoother finish cut. • Smooth and consistent feed speeds without hesitation will avoid burning the edge. PLUNGE ROUTING For inside shapes and large holes, plunge routing is the best solution. • Large shapes and interior cutouts can be cut using templates. • Use a stepped cut and do not plunge all the way through the material. A good rule of thumb is to use no more than the diameter of the bit as your depth of cut per pass. • When cutting out a small hole make multiple passes and use a jig to ensure a safe operation. Routing Drainboards: Do not rout any area deeper than what would leave 1/2” minimum thickness. PROFILE ROUTING Any standard wood or stone decorative, round-over, or chamfer router bit profile can be cut into Richlite. Use a sharp carbide bit and an even rate of speed to prevent burning. Multiple passes may be required for removing large amounts of material and deep profile shapes. Sand the edge detail with a random orbital sander, by hand or with sponge sanding blocks. You can not oversand the edge like you can the surface and finishing the edge doesn’t take the same caution as the surface.

FABRICATION GUIDE 11 PROFILE ROUTING (continued) You need to be careful sanding a full bullnose or generous roundover. Don’t allow the orbital to walk up onto the deck or cause a scalloped edge between the end of the deck and the start of the round edge. Due to the way Richlite is manufactured, sharp square edges can be achieved but are prone to impact damage. At minimum, a 1/16” chamfer or radius is suggested.

SUGGESTED EQUIPMENT Routers • 2 - 3 1/4 Horsepower, Variable speed • Solid carbide straight flute bits • Standard carbide profile bits

FABRICATION GUIDE 12 DRILLING

THROUGH HOLE DRILLING Through-hole drilling is very similar to drilling into wood or MDF. Speed rate should be set to avoid burning or polishing the inside of the hole. Holes drilled completely through Richlite® should consider tolerances of overall parts being fabricated. Part assemblies that are casework construction, attached to metal or wood, or exterior applications such as cladding should have oversized holes to accommodate the expansion and contraction of the materials. Richlite® is very stable and strong and the other materials can be damaged if not considered for movement. PILOT HOLE WITH NO TAPPING Drill a pilot hole that is slightly smaller than the screw thread. Because of its density, Richlite® is nearly impossible to screw into without a pilot hole. The pilot hole should be slightly longer than the screw. You may not be able to penetrate the hole further after your screw reaches the end of the pilot hole. Richlite® is VERY dense and will snap screws if you are not careful. PILOT HOLE FOR TAPPING Richlite is able to be drilled and tapped and has very good screw hold- ing ability with this process. Plastic expansion inserts are not recommended as they tend to be engineered for soft compressible material and will not grip properly in Richlite®. Standard tap drill specifications for metals can be used on Richlite®. EQUIPMENT • For small holes use titanium or cobalt bits if possible • Step drilling up from smaller sizes to larger will insure accurate hole dimensions and location accuracy. • Hole saws are not recommended for use on Richlite® due to its density and heat retention. However, for larger holes a bi-metal hole saw or carbide-tipped hole saw can be used but may tend to wear out quickly due to heat buildup. Routing is preferable to hole saws for thicker material and larger holes.

FABRICATION GUIDE 13 CNC MACHINING

CNC machining is an excellent way to fabricate curves and cut under- mounted sink cutouts. Richlite® is a very dense product so it is very important to have a specific router bit for cutting it to protect the machine, the router bit and the safety of the operator. Feed rates with CNC routers and machining centers vary depending on the tool. Please con- sult your machine tool sales person for more information regarding the specific application of cutting cellulose sheet phenolic resin panels. CUTTING • To rout any Richlite material thicker than 1/4", use a step cut process in increments of 1/4" to 3/8" at a time. • Consider leaving a small “onion skin” (about 0.02” thick) at the bot- tom to help hold pieces in place. • Remove dust from groove after each pass. • Rough cut to 1/64” over-sized from final dimensions. Final pass to cut the remaining 1/64” at full depth in a single cut to clean and polish the edge and reduce the amount of finish sanding needed. • Do not come straight down at the starting point, always lead in and out of cuts at a 45 degree angle with a lead in of twice the material thickness. • If the material is smaller than what the machine can safely hold down, use an onion skin technique and leave 1/16" short from the table so you can route the piece off with a bearing router. • When cutting out holes, use a pocketing program to avoid projectiles. • Due to slight inconsistencies in panel thickness edge profiles are best put on with a hand router. • Spraying bits with Bostik DRICOTE will lengthen tool life consideraby.

FABRICATION GUIDE 14 FEED and SPEED RECOMMENDATIONS Materials 3/4" and thicker Rotation speed 16,000RPM, working speed 4400mm/min (175ipm), lowering speed 8000mm/min (315ipm). Recommended to use a down cut spiral for rough cutting and finish cut with a 1/2" compression 2 flute bit. Cutter lengths should be 1/4" longer than the material thickness.

Materials thinner than 3/4" Rotation speed 18,000RPM, working speed 5000mm/min (200ipm), lowering speed 2000mm/min (75ipm). Recommended to use a 3/8" down cut spiral for rough cutting and finish cut with a 3/8" diameter straight flute bit. Cutter lengths should be 1/4" longer than the material thickness.

Drilling Rotation 4000RPM, lowering speed for 5mm bit is 1500mm/min (60ipm), slower for larger bits.

FABRICATION GUIDE 15 SEAMING

Seams should be level, flat and very tight revealing a hairline mark that can be seen but not felt on the surface. Structurally, seams should run the entire depth of a counter to be considered sound. Because Richlite is pressed and is not cast or extruded, the thicknesses may vary from sheet to sheet or even within a sheet. Therefore, the surface on either side of a seam must always be indexed from the top and the difference sanded on the underside. Whenever using epoxy, make sure that the joint gluing surfaces are roughed-up, 100 grit or less, for better glue adhesion. SEAMING TECHNIQUES Biscuits with epoxy • Do not use traditional wood biscuits as they will not expand nor provide a mechanical advantage. Place Lamello K20 biscuits every 6” starting with the first biscuit 3” from the edge. It is important to do a dry fit because if it is not a tight fit during the dry fit it will not be a tight fit once epoxy is used. Cut slots in the center of the material, in- dexing from the top. Biscuits are engineered with a directional “tooth” that will be difficult to remove in the direction opposite the tooth. To remove the biscuit after dry fit, grab the point end of the biscuit and pull in an arc away from the opposite end. Splines with epoxy • An excellent choice for strength. Cut so that when installed in the slot, the grain (paper layers) in the spline follows the same direction as the grain in the sheet. Dry-fit all seams prior to applying any epoxy. Tight Joint Fastener or “Dog Bones” with or without epoxy • Use in non-structural situations only. Ideal for field installations by out-of-house installers or subcontractors. With CNC tooling the fit may be good enough in some instances to not use any filler or epoxy. Epoxy Only • Make sure that the joint gluing surfaces are roughed-up, 100 grit or less, for better glue adhesion. Do not over-tighten clamps to keep enough glue in the seam. Vacuum clamp fixtures are ideal to hold the surface seam flat due to the lack of a spline or biscuit.

FABRICATION GUIDE 16 SEAMING (continued)

EQUIPMENT • Biscuit Joiner - Minimum power- 6.5 amps. Don’t try to plunge all the way in on the first push. Cut 20% of the way in and let the material and blade cool for a second or two with the machine running; repeat. Hold the cutter onto the material TIGHTLY ! • Use plastic biscuits only like Lamello K20. Do not use standard #20 biscuits as lack of water in epoxy does not expand biscuit. • 3/4” Richlite splines • Mechanical joint fasteners (Knape & Vogt “Tite Joint Fastener”, “Dog Bones”)

FABRICATION GUIDE 17 BUILT UP ASSEMBLIES

Richlite is currently being specified in applications where stack laminations are required. Examples include mold and die units, part assemblies, extra thick design elements, and countertop or casework built up edges. • It is critical for this application to have the mating surfaces of the material abraded before gluing. This applies to both stack laminations as well as mitered or butt-joined fabrications. If the surface is not abraded sufficiently with 100 grit sandpaper prior to glue up, there will most likely be failure in the joint at some point as the mill finish and machine cut edge are both highly resistant to proper adhesion regardless of adhesive used due to the low porosity of the material. • The built up edge needs to be at least 1-1/2” deep to insure enough surface area for the mating parts to adhere and not create an imbalance on the front edge of the material. Any edge less than this will be prone to movement and instability. • Mitered edges are acceptable and require the same abrasion technique on all mating surfaces. Any mitered should be backed by a support block of Richlite. • The edge of Richlite is not the same as the face of the panel and a built up / stacked edge will not look the same as a mitered edge. • Built-up or mitered material must be 1/2” thick or more. There are no maximum build-up dimensions. • Two part water resistant epoxies formulated for thermoset resins or phenolics are recommended for this application. Most other countertop adhesives WILL NOT be appropriate for use with Richlite. • Screw clamps must be used to set the built-up edge to ensure a good bond with structural epoxies. SPRING CLAMPS WILL NOT WORK. EQUIPMENT Two-Part Epoxies • Industrial Epoxy formulated for Thermoset Resin or Phenolic Resin • Suggested for Best Performance: System Three T-88, 12-24 hour cure • 5 Minute General Purpose Epoxy: Devcon DEV-20845 • Loctite E-120HP, Hysol

FABRICATION GUIDE 18 SURFACE FINISHING

MATERIAL SURFACE OPTIONS The most durable finish we have is a completely unsanded mill finish with Richlite Color Enhancer applied. However, there are other options for how the surface of the product can be finished. OPTION 1: MILL SURFACE Richlite® is shipped from the factory with a Mill Surface. This finish has a slight texture that is created in the manufacturing process and acts like a light skin over the faces of the panel. No finish is applied as a surface treatment. For exterior applications, a dry factory finish is recommended. Sanded surfaces, when placed in an exterior environment, will oxidize more rapidly and appear chalky and dry. Pros: more durable, no additional work for surface preparation or finishing; scratching and wear are less apparent over time. Cons: material that has been handled may have slight abrasions, not repairable or restorable to exact finish from factory. Example applications: industrial parts and sub-assemblies, exterior cladding, interior wall panels, benches and seating, high wear areas, assemblies, furniture and industrial work surfaces. OPTION 2: LEATHERED Richlite® Leathered requires the addition of any of the finishes listed in the Final Finishes section. The final surface remains more durable as the skin from pressing has not been removed or altered. Pros: high durability, only additional work is application of final finish, scratching and wear are less apparent over time. Cons: material that has been handled may have slight abrasions, not repairable or restorable to exact finish from factory. Example applications: interior wall panels, seating, high wear area assemblies and furniture, work surfaces and countertops. When used with Osmo® finish, very good for high water use areas. En- hancer is more appropriate for dry applications. See applied finish application for detailed instructions.

FABRICATION GUIDE 19 LEATHERED TECHNIQUE 1. Sand with Scotch-Brite™ Maroon pad on a random orbital sander in 12” circular motion to mildly abrade the mill finish and to remove marring or surface imperfections. 2. Leave any scratches alone as most will disappear with finish and aggressive machining will make a more polished spot in your final overall surface. 3. Clean with soap and water. 4. Apply finish of choice (see next section for options).

OPTION 3: HONED Any of the finishes in the Applied Finishes section can be applied to a Richlite Honed finish which will have light 150 grit sandpaper swirls evi- dent. The Honed finish is a more “satin” finish that is very nice for mill- work and countertop applications. It is not recommended for exterior applications and does require an applied finish to be put on after sanding to achieve proper performance. If sanded with no applied finish, the surface will start to appear “chalky” and will also pick up oils from fingerprints, food, etc. While Richlite can be polished to a high finish, this is not recommended as it will show scratches and wear very quickly from use. Pros: more polished and satin finished look and feel, good abrasion and wear resistance, paper patterns and natural look more pro- nounced, can be refinished and surface repairs are easy. Cons: slightly less durable surface finish prone to abrasions and hard material wear. Example applications: interior wall panels, seating, high wear area assemblies and furniture, work surfaces and countertops. When used with Osmo® finish, very good for high water use areas. En- hancer is more appropriate for dry applications. See applied finish application for detailed instructions below.

FABRICATION GUIDE 20 HONED TECHNIQUE It is not recommended to sand on job site due to the high amount of dust generated when sanding Richlite. As mentioned before, an unsanded surface wears the best, but if interested in doing the full sand and seal technique, use a random orbital sander with 150 grit sandpaper, applying light and even pressure. The worst mistake you can make in fabricating the material is oversanding. Remember, Richlite is made with layers of paper and if you sand too aggressively you will create something to the effect of a “topography” map by burning through a layer of paper and certainly a more burnished area that will have a different sheen. 1. Using a random orbital sander with 150 grit sandpaper, sand the length of the sheet moving lightly and evenly. There is no need to apply pressure, just enough to keep the sander on the surface. 2. Turn 90 degrees and sand perpendicular to the initial pass. 3. Wipe sanding grit from the panel and follow with Scotch-Brite™ Maroon pad in 12” circular motions to even out linear sanding pattern. The Scotch-Brite is not nearly as aggressive as sandpaper and can be used more liberally. 4. Clean with soap and water, or wipe down with a solvent. 5. Let dry and apply finish (see next section for options).

EQUIPMENT • 150 Grit Sanding Discs. This is very important as higher or lower grit will not provide the finish to match the manufacturer provided samples in the specifier boxes. • Maroon Dynabrade® or Scotch-Brite™ Maroon Pad Sanders • Random Orbit Sander 5” • Pneumatic sanders must be turned down or feathered to reduce power. • Belt sanders are not recommended! Heat retention will burn Richlite edge surfaces.

FABRICATION GUIDE 21 APPLIED FINAL FINISHES

APPLIED FINAL FINISH OPTIONS RICHLITE COLOR ENHANCER Richlite Color Enhancer is a food safe gel polyurethane finish. It is recommended for both residential and commercial projects and should be applied in a shop environment. The Enhancer will mechanically wear off in a matter of months or years depending on use and it can be reapplied in the field. When selecting to finish the surface with Richlite Color Enhancer, either sand the surface as detailed above or apply to an unsanded surface. Although not recommended, if the surface is being finished in the field, it is important to mask adjacent edges and walls to protect them from the finish. The Enhancer flashes VERY quickly. It flashes even faster: in the hot sun; on hot material; under warm or circulating air or under blowing AC. It will create a HORRIBLE mess if too much is left on the surface of the material for more than a few moments. Also it can’t be feathered too well or pushed into dry areas which may result in lap marks and streaks similar to an incorrectly applied dye based wood stain. APPLICATION TECHNIQUE 1. Using clean white rags, apply the finish liberally across the entire surface, including the edges. Work quickly to avoid streaking. 2. Follow with clean dry rags, wiping in a large circular motion to remove excess finish. Move quickly with lots of clean rags and when the rag becomes saturated, use a fresh rag to avoid streaking. If streaks are visible, let the surface dry and Scotch-Brite™ again to attain an even surface. 3. Buff to an even, matte finish. 4. Apply one to three coats, allowing 20 minutes between coats. Sanding is not required between coats. The second coat is more forgiving. 5. Clean with soap and water after dry.

FABRICATION GUIDE 22 OTHER FINISHES (continued) OSMO POLY-X The easiest finish to apply is OSMO Polyx. It is an acceptable substitute and recommended for many DIY projects. PolyX, PolyX Professional, or Top Oil from Osmo® is a great choice for all around applications. The finish is a hard wax-oil combination that is highly refined so that it does not separate. It performs like an air cured wood finish and does not stay waxy or soft like most oil-wax products. It also acts as a better repellent to water marks, stains, etc. This is the preferred finish for residential use as it has low VOCs and can be field applied. It is compatible with the Richlite enhancer and can be used to spot repair on top of both enhancer and itself. The cure times are longer than a solvent-based product but will set up to the hardness of such finishes at full cure. APPLICATION TECHNIQUE DO NOT USE THE INSTRUCTIONS ON THE OSMO® can as these instructions are for the floor application of the product and not for Richlite. 1. First sand or abrade the surface as detailed above. Apply the finish as desired, including the edges. The Osmo has a much longer dry time so you can work at a normal speed compared to the Richlite En- hancer product. 2. Follow with clean dry rags, wiping in a large circular motion to remove excess finish. 3. Buff to an even, matte finish. When the rag becomes saturated, use a fresh rag to avoid streaking. Osmo® will blend into previous coats and can be used as spot repair for both itself and Richlite Enhancer in the field. Apply one coat, allowing 12-48 hours for curing. It can be put into use sooner but it is best to leave it as long as possible. Full cure takes 48-72 hours. A second coat can be applied for a slightly higher sheen but is not required. TEAK OIL / MINERAL OIL Many finishes have been used successfully by fabricators and installers. Richlite can be painted or finished with most wood or stone finishes. Teak oil, urethanes, and stone finish products have been used by customers with success in the field. Mineral oil can be used as a “finish” but requires frequent maintenance. Because Richlite is non-porous the oil does not penetrate the surface and water marks may appear from glasses and tableware. Paper products left on a desk surface will pull oil from the surface and leave dry areas. If you are using soap and water to clean your countertops, be aware the soap will expedite the removal of oil and the countertops will start to appear dry and chalky.

FABRICATION GUIDE 23 CARE and MAINTENANCE

INTERIOR GENERAL PRECAUTIONS Paper composite countertops are pretty low maintenance. Nonporous, they’re stain resistant and easy to clean. However, it is VERY IMPOR- TANT to note the counter will develop a patina over time. This is especially true around the sink where soap is used. • For day-to-day cleaning, use a damp cloth or sponge to wipe the surface. Skip the soap—alkaline soap, such as regular dish soap will gradu- ally dull the surface. • Avoid using bleach products or abrasive powdered cleaners. It is good to avoid using the abrasive side of sponges as this may also scratch the surface of a Richlite countertop. • Richlite is stain resistant to most common substances on interior applications. As with most any material however, there is a potential for some staining. With stubborn stains, try a nonabrasive household cleaner (avoid using bleach products). A unique stain remover is plain yogurt, applied only on the stain area. Let sit over night for 3-4 applications, wiping away in the mornings, to lighten stains. • In residential applications, some raw meat juice (such as liver), high- alkaline fruit or vegetables (such as papaya and red beets), red wine and high-alkaline soaps (such as automatic dishwasher powder and oven cleaners) may cause staining when left in contact for a prolonged time. • The lighter colors in the Richlite color range will show stains more than the darker colors. Additionally, grout (high alkaline) will lighten darker-colored Richlite counters and darken the lighter tones. • Paper composite counters are only heat resistant to 350 degrees: Hot pads or trivets are a must to avoid burning the surface. That said, surface nicks, scratches, and scorch marks can be sanded out of the top with an abrasive pad and then finished with food-safe mineral oil.

FABRICATION GUIDE 24 CARE and MAINTENANCE (continued) Mill Surface Maintenance • Often requires very little maintenance due to textured surface. • Warm water and sponge for daily cleaning. Mild soap can be used if needed. • Cleaning agents may affect the surface which is not protected by an applied finish. • Repairs – very difficult to repair as the textured surface will show any changes and cannot be reproduced. Leathered Surface Maintenance • Warm water and sponge for daily cleaning. Mild soap can be used if needed. • Howard Naturals Wood Cleaner and Polish or mineral oil can be used to renew the look and feel of the finish. • Repairs – OSMO® PolyX is a very good spot repair product that can be applied by the end user. Wipe on a small amount and buff into adjacent areas. Allow to dry 24-48 hours before full use. It is compatible with Richlite enhancer and blends very well to a similar finish. • Do not sand the surface as it will disturb the Factory Surface which cannot be reproduced. Minimal Scotch-Brite™ work can be done prior to applied finishes. Honed Surface Maintenance • Warm water and sponge for daily cleaning. Mild soap can be used if needed. • Howard Naturals Wood Cleaner and Polish or mineral oil can be used to renew the look and feel of the finish. EXTERIOR GENERAL PRECAUTIONS • For exterior applications, flashing and proximity to metal or water may require additional attention or maintenance. • Graffiti/Spray Paint: paint and graffiti removal products can be used. Pressure Washing can be used for extreme situations but may alter the factory surface slightly. A more matte finish will be left by this process. Over time the variation will blend with the natural oxidation process. • Applied finishes or sealers are not recommended as they will tend to flake and deteriorate from UV exposure. • Normal wear and tear due to elements will change the surface over time and oxidize in a similar way to cedar siding.

FABRICATION GUIDE 25 TROUBLESHOOTING

FIELD VERSUS SHOP WORK Richlite can be a dusty fabrication process and fabricating or finishing in the field is not recommended. Both the dust created and the Richlite Color Enhancer in a home can create air quality issues that can pose a problem for end-users. OVERSANDING Richlite is made with cellulose fibers (layers of paper). If you sand too aggressively in one area for too long, you will create something to the effect of a “topography” map by burning through a layer of paper. It is most noticeable in darker colors. Be cautious with seams and uneven surface areas (bumps or divots). After applying finish, these may even out, but the lines will never disappear. The contouring is especially noticeable in the Slate Black product and is less so in the Black Diamond. REPAIR • Use router dust mixed with epoxy in thick paste form to do small spot repairs. Depth of repair may need to be made deeper for repair to take. • Use melamine or laminate patch for very small spot repairs. • Sealing will require the use of blue tape on seams to ensure that over- flow of adhesive does not compromise the surface finish. • Refinishing should be advised by the fabricator who installed the counter. In most cases, it is preferable if the trained installer refinishes the surface. • Light scratch marks and burn marks can be refinished using a Scotch- Brite™ Maroon pad on a random orbital sander. • It is important to note, the refinished area will noticeably lighten compared to the surrounding surface area. Richlite surfaces are made of paper which, like wood, patinas – or darkens – over time, especially in the lighter colors other than Black. The area will eventually patina and match the remainder of the counter surrounding it. In order to avoid affecting one spot, a full sanding and refinishing the entire counter is required, but this is an intensive and not an inexpensive process versus spot treatment.

FABRICATION GUIDE 26 CANTILEVER and SPAN GENERAL GUIDELINES

CANTILEVER SPAN l=length y = max b=breadth (width of countertop) (overhang) d=thickness F=Force# deflection b=12" b=18" b=25" b=30" b=36" b=42" b=48" b=60" l=12" d=.75" F=100 lbs y= .070" .047" .033" .028" .023" .020" .017" .014" l=18" d=.75" F=150 lbs y= .356" .244" .171" .142" .118" .101" .089" .071" l=18" d=1.0" F=150 lbs y= .150" .100" .072" .060" .050" .043" .037" .030" l=18" d=1.25" F=150 lbs y= .076" .050" .037" .030" .025" .022" .019" .015" l=18" d=1.5" F=150 lbs y= .044" .029" .021" .018" .015" .013" .011" .009" l=24" d=1.0" F=150 lbs y= .356" .244" .171" .142" .118" .101" .089" .071" l=24" d=1.25" F=150 lbs y= .181" .120" .087" .072" .060" .051" .045" .036" l=24" d=1.5" F=150 lbs y= .105" .070" .050" .042" .035" .030" .026" .021"

SIMPLE SPAN l=length y = max b=breadth (width of countertop) (the span) d=thickness F=Force# deflection b=12" b=18" b=25" b=30" b=36" b=42" b=48" b=60" l=24" d=.75" F=100 lbs y= .035" .023" .017" .014" .012" .010" .008" .007" l=36" d=1.0" F=150 lbs y= .075" .050" .036" .030" .025" .021" .018" .015" l=36" d=1.25" F=150 lbs y= .038" .025" .018" .015" .012" .010" .009" .007" l=48" d=1.5" F=200 lbs y= .070" .046" .033" .028" .023" .020" .017" .014" l=48" d=1.75" F=200 lbs y= .044" .029" .021" .017" .014" .012" .011" .008"

IMPORTANT NOTE: Calculating spans and cantilever's incorporate numerous variables; including thickness of material, the length of the overhang, the breadth (or width of the Most Acceptable countertop), and of course the abount of weight it needs to support. Because all these different Acceptable variables and the fact that different areas of the country have different code regulations, it is Not Acceptable important that the specifier appropriately calculate the specifications based off Richlite properties defined in the properties section. Least Acceptable

FABRICATION GUIDE 27 21 RICHLITE® PROPERTIES

Properties of Richlite‚ Natural Fiber Composite

Electrical Properties Dielectric Strength (Volts/mil)………………………………………………………………………..…...150 Dielectric Constant…………………………………………………………………………………….….9.24 Disipation Facto…………………………………………………………………………………….….….0.29 Thermal Properties Coeff. Of Thermal Expansion In X Dir (min/in.∞F)…………………………………………………….….5.2 Coeff of Thermal Expansion In Y Dir (min/in.∞F)………………………………………………………..12.8 Coeff of Thermal Expansion In Z Dir (min/in.∞F)…………………………………………………..45.9/73.5” Thermal Conductivity (Cal cm/cm2 sec ∞C)………………………………………………………….0.00051 Tensile Strength X Direction(psi)………………………………………………………………………………………..19,200 Y Direction (psi)……………………………………………………………………………………….13,100 Compressive Strength X Direction (psi)……………………………………………………………………………………….18,400 Strain @ Failure………………………………………………………………………………………...7.09% Y Direction (psi)……………………………………………………………………………………….15,900 Strain @ Failure………………………………………………………………………………………..7.15% Z Direction (psi)……………………………………………………………………………………….30,000 Strain @ Failure………………………………………………………………………………………...ª20% Flexural Strength (Face In Tension) X Direction (psi)……………………………………………………………………………………….22,000 Y Direction (psi)……………………………………………………………………………………….17,300 Flexural Strength (Edge In Tension) X Direction (psi)……………………………………………………………………………………….20,400 Y Direction (psi)……………………………………………………………………………………….16,100 Izod Impact (Face Impact) X Direction (ft. lb. Per Inch of width)……………………………………………………………………2.48 Y Direction (ft. lb. Per Inch of width)……………………………………………………………………1.46 Izod Impact (Edge Impact) X Direction (ft. lb. Per Inch of width)……………………………………………………………………0.68 Y Direction (ft. lb. Per Inch of width)……………………………………………………………………0.62 Abrasion Resistance – Taber Abraser (CS-17) (1/4x”x4”x4”) Weight Loss per 1000 revs…………………………………………………………………………..0.0112% Wear per 1000 revs (Inches)…………………………………………………………………………0.00011 Coefficient of Friction (Unpolished)……………………………………………………………………...0.2 Burning Rate………………………………………………………………………………………………....Very Slow Aging………………………………………………………………….Improves Mechanical and Electrical Properties Sunlight………………………………………………………………………………………………..Darkens Surface Clarity…………………………………………………………………………………………………………..Opaque Weak Acids…………………………………………………………………………None to slight depending on Acid Strong Acids…………………………………………………………………..None to slight for reducing and organic Decomposed by oxidizing acids Weak Alkali…………………………………………………………………Slight to marked depending on alkalinity Strong Alkali………………………………………………………………………………………………Decomposes Organic Solvents………………………………………………………………………………………………….None Metal Inserts……………………………………………………………………………………………………….Inert

“The two values for C.O.L.T.E. represent coefficients below and above glass transition temperature (130∞F) respectively.

FABRICATION GUIDE 28 MATERIAL SAFETY DATA SHEET                                                                                

    29  Richlite® Surface material Lifetime Limited Warranty for Interior Residential Use

Richlite Company Richlite Company warrants to the owner of the original installation that its Richlite® 624 E. 15th St. Surface material will be free from material defects for a lifetime. This warranty applies Tacoma, WA 98421 only to the original owner and is not transferable. 888 383 5533 www.richlite.com The obligation of Richlite Company and its distributors is limited, at their option, to repair or replace material found to be defective and excludes shipping charges and costs of removal and reinstallation. This is a product only warranty, not a fabrication and/or installation warranty.

Richlite Company makes no express or implied warranty, including the fitness for a particular purpose even if that purpose is known to Richlite Company. It excludes implied warranty of merchantability. Richlite Company shall assume no risk or liability for results obtained by the use of products covered by this warranty, whether used singly or in combination with other materials. This warranty does not cover any damage to Richlite® surfaces caused by improperly installed, used or maintained appliances which are either built into Richlite® or placed or stored on Richlite® surfaces.

Laws and building safety codes governing the design, engineering and construction of installations vary widely. Richlite Company assumes no responsibility or obligations with respect to the selection of product for the installation or the design, engineering and construction of the installation. Architects, engineers, and designers alike need to review technical specifications of Richlite® surfaces to determine if Richlite® surfaces suit the intended purpose.

This warranty does not cover any conditions or damages resulting from accidents, alterations, misuse, abuse, acts of God, excessive humidity, excessive heat and temperature, fading, patina, or discoloration over time. Richlite® surfaces are a paper- composite material and will patina over time. “Patina” is a natural occurrence in the product and Richlite Company makes no express or implied warranty covering the extent of the patina in the Richlite® surface. This warranty also does not cover any condition or damage resulting from removal of the product or reinstallation in the same or different application.

This warranty does not apply to conditions caused by normal wear and tear upon the product.

To obtain warranty service, contact the dealer from whom you purchased the product. Your dealer will work with their regional distributor and Richlite Company to prompt- ly repair or replace any defective pieces. Warranty claims must be accompanied by proof of purchase, as well as details regarding the nature of the problem, location of the product, etc.

This warranty is exclusive and in lieu of all other obligations, liabilities or warranties. In no event shall Richlite Company or its distributors be liable or responsible for incidental or consequential damages or for any other direct or indirect damage, loss, cost, expense or fee. Some states do not allow the exclusion or limitation of incidental or consequential damages, so this exclusion or limitation may not apply to you. This warranty gives you specific legal rights, and you may also have other rights that vary from state to state.

30 Richlite® Surface material 20 Year Limited Warranty for Interior Commercial Use

Richlite Company Richlite Company warrants to the owner of the original installation that its Richlite® 624 E. 15th St. Surface material will be free from material defects for 20 years. This warranty applies Tacoma, WA 98421 only to the original owner and is not transferable. 888 383 5533 www.richlite.com The obligation of Richlite Company and its distributors is limited, at their option, to repair or replace material found to be defective and excludes shipping charges and costs of removal and reinstallation. This is a product only warranty, not a fabrication and/or installation warranty.

This warranty does not apply to conditions caused by normal wear and tear upon the product.

31 Richlite® Surface material 10 Year Limited Warranty for Exterior Residential and Commercial Use

Richlite Company Richlite Company warrants to the owner of the original installation that its Richlite® 624 E. 15th St. Surface material will be free from material defects for 10 years. This warranty applies Tacoma, WA 98421 only to the original owner and is not transferable. 888 383 5533 www.richlite.com The obligation of Richlite Company and its distributors is limited, at their option, to repair or replace material found to be defective and excludes shipping charges and costs of removal and reinstallation. This is a product only warranty, not a fabrication and/or installation warranty.

This warranty does not apply to conditions caused by normal wear and tear upon the product.

32 IMPORTANT LINKS

Scotch-Brite Pads http://www.shop3m.com/scotch-brite-hookit-production-clean-and-finish-disc-5-in-x-nh-a-vfn.html Fasteners https://www.fastenal.com/products?term=thread+rolling+screws&r=~|sat tr03:^%22Indented%20Hex%20Washer%22$|~%20~|sattr04:^%22Hex%20 -%20Unslotted%22$|~ Osmo http://www.osmona.com/interior/Original_polyx.shtml System Three Epoxy http://www.systemthree.com/store/pc/T-88-c27.htm Howard Wood Cleaner http://www.howardproducts.com/prod-wood-cleaner-polish.php

FABRICATION GUIDE 33