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Fabrication Manual Manual FabricationFabrication ManualManual AndAnd TechnicalTechnical ReferenceReference GuideGuide 2010 Written by Gordon Shell WelcomeWelcome toto thethe worldworld ofof EOSEOS™™3cm3cm SolidSolid SurfaceSurface “The only “Solid” Solid Surface” Click on title to view Video Clips Introduction • It started with a great idea... Make a thicker solid surface – Eos Solid Surface bridges the gap between seamless solid surface and high-end laminate. Our patent pending 3cm (1 1/4") material offers all the advantages of premium solid surface, in a thicker, more durable material at a surprisingly low price. – By eliminating up to 75% of the labor required for traditional 1/2" solid surface, Eos combines the massive look of granite with a lower price point and faster delivery. The end result is a true value in the classic sense a higher quality product at a competitive price, offering you the flexibility to create the countertop you have always wanted. – In addition, 2cm (3/4”) EOS™ sheet goods offer a great, low cost, low labor alternative to laminate, cultured marble, and other materials in the bath, window sill, hospitality, medical, retail, etc. market. Introduction • Eos offers you: – The massive look of natural stone without conspicuous seams. – A food safe, non-porous surface that is easy to clean and maintain. – Seamless integrated bowls and backsplashes. – Greater heat resistance. – A 10-year transferable product warranty. – A surface that is renewable and repairable. – All the advantages of premium solid surface, at a surprisingly low price. • Eos Solid Surface is ideal for both residential and commercial applications. With a large color palette to choose from, unlimited designer options, enhanced durability backed by a 10-year product warranty, Eos is changing the solid surface industry. • We welcome you aboard the ever growing network of Eos Solid Surface Fabricators. What you will find contained in this fabrication manual is basic guidelines for the purpose of reference consisting of proper use and handling of Eos materials to ensure a long-lasting beauty and ultimate satisfaction for your customers. Introduction • FLEXIBILITY – Custom Sheet sizes, thickness, and color Regardless of the size, thickness, or color of your project EOS™ Surfaces llc. can provide material to fit your specification; our plant has the ability to create sheets with custom length, width, thickness, and/or color. EOS™ Surfaces llc. has helped fabricators and contractors save money by reducing labor, reducing waste, and fulfilling color specifications by providing custom material. If you have a project that EOS™ Surfaces can custom build to your spec contact your regional manager ASAP, contact info is available @ www.eos-surfaces.com Preface • This manual is supplied as a reference guide to the EOS™ fabricator/ craftsman. • EOS™ 2cm and 3cm sheet goods are intended for fabrication by experienced solid surface fabricators and/or experienced woodworkers. • The tools required to fabricate EOS™ are both powerful and sharp and can be dangerous in the hands of inexperienced individual(s). • For your safety and the safety of those around you, read and understand the instruction manual and precautions for each tool used in fabrication. • EOS Surfaces LLC assumes no responsibility for injuries that occur during the fabrication of EOS™ sheet or shape products. Table of Contents • Chapter 1 Material handling, safety, storage, and inspection • Chapter 2 Tools and accessories for EOS™ • Chapter 3 Cutting EOS™ 3cm Solid Surface • Chapter 4 Seaming EOS™ • Chapter 5 Under-mounting bowls in EOS™ • Chapter 6 Finishing EOS™ • Chapter 7 Installing EOS™ • Chapter 8 Food Service and special applications • Chapter 9 Specifications EOS™ Spec Web Page • Chapter 10 Product Non-conformity guide • Chapter 11 EOS™ warranty To go directly to any chapter click on the desired chapter. Return to this page at anytime by clicking on the EOS logo in the upper corner or the page Material inspection, handling Safety, and Storage • Inspection of Material In order to ensure shipments arrive from your Regional Distribution Center in good condition, it is the responsibility of the fabricator to conduct a visual inspection of the material being received. Any visible damages must be notated on the carrier’s paperwork upon delivery. Carrier damage along with any concealed damage for example color match, scratches or any other problem must be immediately reported to EOS™ Solid Surface Customer Service Department 1-800-719-3671 ext. 4. Material inspection, handling Safety, and Storage • Damaged or defective material If it is determined that a shipment contains damaged or defective material, a report should be filed with both the carrier and EOS™ Surfaces. Digital pictures of the damage or defect can be sent to [email protected] or [email protected] Claims can also be called into EOS™Surfaces @ 1-800-719-EOS1 Upon receipt of claim, EOS™ Surfaces will offer either replacement materials or credit for material to resolve claim. Please refer to Chapter 10 for product non-conformity specifications. INSPECT SHEETS AND SHAPE PRODUCTS CAREFULLY BEFORE BEGINNING FABRICATION. EOS™ REPLACEMENT POLICY DOES NOT ALLOW FOR REIMBURSMENT FOR LABOR COSTS ON DEFECTIVE MATERIAL. Material inspection, handling Safety, and Storage • Handling 2cm and 3cm EOS™ Palleted Sheets EOS™ Sheet goods are shipped flat on wooden or steel pallets, 3cm sheets will be stacked to a maximum of 12 sheets per pallet, 2cm sheets will be stacked to a maximum of 18 sheets per pallet. A forklift with a minimum lifting capacity of 5000lbs and fork extensions are recommended for moving complete pallets. Material is shipped from EOS™ Distribution warehouse with steel banding to safely secure the sheets to the pallet, Do not attempt to move un-banded pallets. Always secure the sheets to the pallet with “tie-down straps”, if the steel banding is not in place. Material inspection, handling Safety, and Storage • Handling individual EOS™ 2cm and 3cm sheets • EOS™ sheets are heavy and should never be carried by no less than 2 adults • 3cm sheets 30”x121” weigh 285lbs each • 2cm sheets 30”x121” weigh 195lbs each • Because of the weight and the sharp edges on EOS™ sheets, proper shoes and gloves should be worn. • The use of mechanical slab lifters is highly recommended (see pictures and descriptions on following pages for suggestions), these lifters are available thru stone and solid surface suppliers. • Hand cups provide a quick and convenient way to handle EOS™ sheets, confirm with the supplier that the cups that you purchase are rated for the weight of each sheet. Always follow the instructions provided, carefully. Material inspection, handling Safety, and Storage • Pinch lifters can be used to lift individual sheets with overhead crane systems or can be adapted to fit most fork lifts. Material inspection, handling Safety, and Storage • Vacuum lifting systems are a great way to lift slabs directly from the pallet to the saw or work table. Material inspection, handling Safety, and Storage • When moving slabs or completed projects long distances the use of panel carts or dollies is highly recommended Material inspection, handling Safety, and Storage • It is recommended that EOS™ sheets are stored on flat horizontal racks with proper support not exceeding 48” span between supports. • A good racking system optimizes the storage area and efficiency of your operation, providing many years of reliable service. • Racks should meet local OSHA safety standards (see following slides for guidelines) • In order to easily verify material, EOS™ should be stored by color and LOT number. Material inspection, handling Safety, and Storage • EOS™ Sheets should NEVER be stored outside. • EOS™ Sheets should NEVER be stored in direct sunlight. • EOS™ Sheets should be stored in a dry, temperature controlled environment, storage area temperatures should not fall below 40° F (3°C). EOS™ materials that are stored out-doors are void of any warranty coverage Material inspection, handling Safety, and Storage • General Recommendations “as written by OSHA on the safe handling of heavy slab material” “ • Employers who are engaged in the handling and storage of slabs must prevent caught-by, struck-by, and/or crushed-by hazards in their workplace. The following are general recommendations: • Pre-plan work to identify the hazards, safe work practices, and the equipment that will be used to perform the work safely. • Develop and implement heavy stone slab handling procedures for transporting, loading and unloading slabs from containers and storage areas. • Provide mechanical handling equipment appropriate to the task. • Inspect material handling equipment before use to assure that it is in good condition. Defective equipment must be immediately reported and repaired or replaced before use. • Instruct and train employees on the proper material handling procedures. • Ensure that employees follow safe stone slab handing procedures. Material inspection, handling Safety, and Storage • Recommendations for Storage of Heavy Slabs The following recommendations will minimize the potential hazards associated with “Slab racks" and other storage racks for storing heavy slabs: • Design storage racks to withstand the loads and forces imposed on them. • Design a storage rack system to secure slabs from shifting, sliding and collapsing, or provide secondary bracing or a restraint system to secure slabs from shifting, sliding and collapsing. • Ensure that the "slab racks" are properly installed.
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