® DuPont™ Corian Fabrication Manual 22001122 www.corian.com Fabrication Manual 01/2012 Table of Contents §01-01 SAFETY GUIDELINES p. 1–3 §01-02 SAFETY DATA SHEETS p. 1–2 §02 CUSTOMER PRODUCT QUALITY SPECIFICATIONS . Sheet Product Specifications p. 1-3 o Colour p. 3-6 o Warpage p. 7 . Shape Inspection p. 8 o Colour p. 9 o Drain hole p. 9 . Product Specifications for Joint Adhesives p. 9 §03 HANDLING & STORAGE . Handling o Handling Sheets p. 1-3 o Handling Shapes p. 4 o Handling Accessories p. 4 . Storage o Storing Sheets p. 5-6 o Storing Shapes p. 7 o Storing Accessories p. 7-8 §04 TOOLS & ACCESSORIES . Routers p. 1 . Router Bits p. 2 . Saws and Blades p. 2-3 . Sanding and Finishing p. 4 . Straight Edges p. 4 . Clamping Systems p. 4-5 . Other Stationary Tools for High Productivity p. 5 §05 SITE PREPARATION AND TEMPLATING . Site Inspection p. 1 . Templates p. 1-3 . E-Templates p. 3 The information contained in this fabrication manual is given free of charge by E. I. du Pont de Nemours and Company Inc. or its affiliated companies. It is based on technical data which E. I. du Pont de Nemours and Company Inc. or its affiliated companies believe to be reliable and is intended for use by persons having knowledge of this technical area at their own discretion and risk. Seller assumes no responsibility for results obtained or damage incurred from the use of this Technical Bulletin either in whole or in part by a buyer of DuPont™ Corian® solid surfaces. The DuPont oval logo, DuPont™ and Corian® are registered trademarks or trademark of E. I. du Pont de Nemours and Company Inc. or its affiliated companies. Copyright E. I. du Pont de Nemours and Company Inc. All rights reserved. Printed in Belgium. 1/5 Fabrication Manual 01/2012 Table of Contents §06 POSITIONING OF SEAMS . Examination of Plans p. 1 . Selection of Seam Positions p. 1-3 . Re-Inforced Seams p. 3 . Creating Drainer Grooves p. 3 §07 CUTTING DUPONT™ CORIAN® . Cutting List p. 1 §08 CUT-OUTS IN DUPONT™ CORIAN® . Cut-Out Templates p. 1-2 . Types of Cut-Outs p. 3 o High Strength Cut-Out p. 3-12 o Standard Cut-Out p. 13-14 §09 DUPONT™ CORIAN® ADHESIVE SYSTEMS . DuPont™ Corian® Joint Adhesive p. 1 . 50 ml Joint Adhesive System p. 1-3 . Bulk Joint Adhesive System p. 3-5 . Adhesive Disposal p. 5 §10 FRAME & SUPPORT . Types of Frames p. 1 . Constructing the Frame Underlayment p. 2-3 . Full Underlayment Support p. 3 . Fabricating and Installing Overhang Countertops p. 4 o Support Types p. 4-5 o Fabrication and Installation p. 6-7 . Supporting Inside Corners over Carrousel Cabinets p. 8 §11 SEAMING DUPONT™ CORIAN® . Edge Preparation p. 1-2 . Seaming Sheet-to-Sheet p. 2-3 . Standard Reinforced Seams p. 3-5 . Lamelo Biscuit Seams p. 5-6 . Tongue and Groove Seams p. 7 . Wavy Seams p. 7-9 The information contained in this fabrication manual is given free of charge by E. I. du Pont de Nemours and Company Inc. or its affiliated companies. It is based on technical data which E. I. du Pont de Nemours and Company Inc. or its affiliated companies believe to be reliable and is intended for use by persons having knowledge of this technical area at their own discretion and risk. Seller assumes no responsibility for results obtained or damage incurred from the use of this Technical Bulletin either in whole or in part by a buyer of DuPont™ Corian® solid surfaces. The DuPont oval logo, DuPont™ and Corian® are registered trademarks or trademark of E. I. du Pont de Nemours and Company Inc. or its affiliated companies. Copyright E. I. du Pont de Nemours and Company Inc. All rights reserved. Printed in Belgium. 2/5 Fabrication Manual 01/2012 Table of Contents §12 INLAYS . Inlay Materials p. 1 . Inlays of DuPont™ Corian® o Piece Inlays of DuPont™ Corian® p. 2-3 o Liquid Inlays p. 3 o Solid Inlays p. 3 o DuPont™ Zodiaq® Inlays p. 4 §13 EDGE DETAILS & DOWNTURNS . Preventing Crack Starters p. 1 . Rebating for the Edge Downturn p.1-2 . Constructing the Straight Edge Downturn p. 2-4 . Internal Corner Construction Methods p. 4-9 . External Corner Construction Methods p. 10-11 . Using the Laminated Method for Internal Corners p. 11-12 . Using the Corner Insert Method (Laminated) for Internal Corners p.12-13 . Using the Corner Insert Method (Thermoformed) for Internal Corners p. 13-14 . Using the Laminated Method for External Corners p. 14-15 . Using the Thermoformed Method for External Corners p. 15 . Waterfall Edge p. 15-16 . Edge Treatments p. 16-17 . Downturn Support p. 17-18 §14 BACKSPLASHES . Butted Backsplash p. 1-2 . Coved Backsplash Methods p. 2-3 . Using the Countertop Method p. 4-5 . Using the Cove Alternative Method p. 6-7 §15 FASTENING OTHER PRODUCTS TO DUPONT™ CORIAN® . DuPont™ Corian® to Timber / Plywood / MDF / Gypson p. 1 . DuPont™ Corian® to Metal p. 1-2 . DuPont™ Corian® to Glass p. 2-3 . DuPont™ Corian® to Acrylic p. 3-4 §16 DUPONT™ CORIAN® SHAPES . Tools Required p. 1 . “S” Method (undermount) p. 2-3 The information contained in this fabrication manual is given free of charge by E. I. du Pont de Nemours and Company Inc. or its affiliated companies. It is based on technical data which E. I. du Pont de Nemours and Company Inc. or its affiliated companies believe to be reliable and is intended for use by persons having knowledge of this technical area at their own discretion and risk. Seller assumes no responsibility for results obtained or damage incurred from the use of this Technical Bulletin either in whole or in part by a buyer of DuPont™ Corian® solid surfaces. The DuPont oval logo, DuPont™ and Corian® are registered trademarks or trademark of E. I. du Pont de Nemours and Company Inc. or its affiliated companies. Copyright E. I. du Pont de Nemours and Company Inc. All rights reserved. Printed in Belgium. 3/5 Fabrication Manual 01/2012 Table of Contents §17 THERMOFORMING DUPONT™ CORIAN® . Tools Required (Oven Details) p. 1 . Oven Preparation p. 1-3 . Platten Heater p. 3 . Material Preparation p. 3-4 . Mould Preparation p. 5-7 . Thermoforming with Standard Oven and Clamping System p. 7 . Thermoforming with Heated Plates and Vacuum Membrane Press p. 8-11 . 3-Dimensional Thermoforming p. 11-15 §18 VERTICAL APPLICATIONS . Wall Preparation p. 1 . Scribing p. 2 . Seaming p. 2-4 . Adhering DuPont™ Corian® to Surfaces p. 4-5 . Skirting p. 5-6 §19 FINISHING & POLISHING . Tools Required p. 1 . Sanding p. 1-4 §20 TRANSPORTATION & INSTALLATION . Packing for Transport p. 1 . Racking for Transport p. 1-2 . Installation o Basic Procedures and Cross Check p. 2 o Detailed Steps of Completion p. 3-16 . Warranty Information p. 17 §21 FOOD & COUNTER SERVICES . Preventing Cracked Cut-Outs p. 1-4 . Preventing Countertop Cracking and Warp p. 4-5 . Preventing Seam Separation p. 6-7 . Installing Stainless Steel Hob Surround p. 8-10 The information contained in this fabrication manual is given free of charge by E. I. du Pont de Nemours and Company Inc. or its affiliated companies. It is based on technical data which E. I. du Pont de Nemours and Company Inc. or its affiliated companies believe to be reliable and is intended for use by persons having knowledge of this technical area at their own discretion and risk. Seller assumes no responsibility for results obtained or damage incurred from the use of this Technical Bulletin either in whole or in part by a buyer of DuPont™ Corian® solid surfaces. The DuPont oval logo, DuPont™ and Corian® are registered trademarks or trademark of E. I. du Pont de Nemours and Company Inc. or its affiliated companies. Copyright E. I. du Pont de Nemours and Company Inc. All rights reserved. Printed in Belgium. 4/5 Fabrication Manual 01/2012 Table of Contents §22 REPAIRING DUPONT™ CORIAN® . Minor Repairs p. 1 . Drilling & Filling p. 1-2 . Plug repair (R.P.S. System) p. 2-4 . Pie Cut Repairs p. 4-8 . Section Replacement p. 9-10 . Repair Cracked Seams with Inserts p. 10-12 . Repair Large Areas with DuPont™ Corian® Inlays p. 12-15 . Replacing DuPont™ Corian® Shapes p. 16 . Repairs to Veined DuPont™ Corian® Installations p. 17-21 . Installing Stainless Steel Cook Top Rings p. 22 §23 COMPILATIONS OF SPECIAL WARRANTY ISSUES . Warranty p. 1-3 . Specific Warranty Stipulations p. 4-7 . Warranty Guidelines p. 8 §24 TRAINING & DEVELOPMENT CENTRE p. 1-2 §25 TECHNICAL BULLETINS . Table of Contents o DuPont™ Corian® Illumination Series Fabrication p. 1-6 o Fabrication of DuPont™ Corian® Stone Collection Colours p. 7-11 o DuPont™ Corian® Lustra Colours p. 12-17 o DuPont™ Corian® Metallix Colours p. 18-24 §26 SUPPLIERS LIST . Power Tools p. 1 . Air Tools p. 1 . Saw Blades & Bits p. 1 . Diamond Blades and Diamond Cutters p. 1 . V-Grooving Machine p. 1 . C.N.C. Router Manufacturers p. 2 . Saw Manufacturers p. 2 . Dust Collection Manufacturers p. 2 . Abrasives p. 2 Note: Chapter §01-03 - SAFETY INFORMATION ON DUST AND FUMES This chapter will no longer be part of the DuPont™ Corian® Fabrication Manual and will be replaced by a Technical Bulletin. The information contained in this fabrication manual is given free of charge by E. I. du Pont de Nemours and Company Inc. or its affiliated companies. It is based on technical data which E. I. du Pont de Nemours and Company Inc. or its affiliated companies believe to be reliable and is intended for use by persons having knowledge of this technical area at their own discretion and risk.