BASIC FABRICATION GUIDE

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BASIC SAFETY AND FABRICATION GUIDE

Safety Guidelines

These manuals are designed to give basic guidelines to help ensure that Century Quartz Stone Surfaces products are to be handled, stored, fabricated, and installed correctly with experienced and qualified installers.

The information contained herein is strictly for purposes of reference and as such, Century Quartz Stone Surfaces and its affiliates assume no liability for its accuracy or suitability or the use of such information for product lines other than Century Stone Inc.,


All work carried out by any user of this Basic Fabrication and safety guide on any Century Quartz Stone slab must be done in accordance with all laws and regulations  including but not limited to, occupational health and safety laws relating to the protection of the environment.


Century Stone Quartz surfaces are composed of 93% quartz, a natural mineral that is

commonly found in granite. The other 7% are a combination of Polymer, pigments, and other additives. The polymer acts as a binder, which holds the quartz together in the process of manufacturing quartz slabs.  

Follow OSHA Law & Regulations to develop workplace health and safety standards including State and Local regulations for proper safety ventilation. Any Quartz Stone contains silica which can be hazardous to your health. Always shape and cut material with wet tools, reducing the amount of airborne particles to be inhaled.

Silica monitoring of dry cutting, dry grinding, and dry sweeping indicate that the levels of respirable crystalline silica are typically above the permissible exposure limit (PEL) as set forth in OSHA regulation, 29CFR1910.1000(e),  for respirable crystalline silica.


In order to minimize the amount of respirable crystalline silica in the air, dry cutting

and grinding needs to be eliminated. This can be accomplished by purchasing tools that

can be operated in a wet environment. By switching to pneumatic tools or electric tools

that are designed for wet operation, repairable crystalline silica dust generated during

cutting and grinding can be significantly reduced.


Safety accessories must be used;

  • Respiratory dust masks

  • Ear plugs, safety glasses

  • Steel toe rubber boots

  • Waterproof aprons

  • Gloves

  • Back supports

  • All electrical applications out lets must be ground fault interrupters (GFCI)

  • Keep work area clean. Cluttered areas and benches invite accidents

  • Visitors should be kept at a safe distance from the work area.

For additional information, check the OSHA website at www.OSHA.gov.


Basic Fabrication Guidelines:

VISUAL INSPECTION

Century Quartz Stone slabs supplied by Century Stone Inc., have gone through a quality control check to detect possible defects on the surface. However, fabricators are responsible for determining if the slabs are fit for use. Please contact Century Stone Inc. immediately if the slab is defective. A full visual inspection is essential and should be done prior to cutting material.

This manual does not replace normal industry standards for the fabrication and craftsmanship – a basic knowledge of stone / quartz fabrication is required. Any failure by a Fabricator to comply with the recommended methods of fabrication of countertops from slabs may result in claims by a end user against the Fabricator and refusal of a claim made by a End user under the Residential 15 years warranty.


The following guidelines should be followed to ensure a high quality product:

  • Before fabricating, always visually inspect slabs to ensure that an acceptable color match is achieved.

  • Do not change the original surface finish of the slabs by re-polishing, honing, sealing, or otherwise altering the factory finish.

  • Storage – Slabs must be stored in a manner that prevents warping. Support are required Slabs should be stored so that the product is kept in a perfectly uniform manner that minimizes warping

  • Slabs must always be stored in a way that the polished surface is not exposed to the sun, and must not exposed too long outside in adverse weather conditions in a long hot summer and cold winter.


Cutting Slabs:

To avoid overheating the slab, only water-fed tools must be used for cutting, drilling, and polishing Century Quartz Stone

Water flow should be consistent to ensure adequate cooling of the blade. To ensure a clean and consistent cut, blade rotation speed (rpm) and the traverse speed of the saw must be set up according to the guidelines provided by the blade and saw manufacturer

Do not cut square corners (cross cut) as this will create stress points in the slab and may result in cracking.

When cutting an inside corner, always use a core bit to avoid damaging the corner area with the cutting disc, sharp inside corners create a stress point


Cutouts:

For square cut outs for sinks and cooktops proceed preparing cutout always with core bit at four corners. All cuts should be done using only wet diamond cutting tools to avoid generating excessive heat, which could also result in hairline cracks. The larger the radius of the corner cut-outs is the stronger the corner will be.

Top and bottom of edge profiles and cutouts are recommended to have a minimum 1/8” radius or chamfer


Seams:

The surfaces to be seamed must be unpolished, flat, dry and clean. All seams should be made level by adjusting the material before adhesive sets.

Make sure there is a minimum distance of 6” between the edge of a cutout and seam.

  • Never position a seam over the dishwasher.

  • Never position a seam in the middle of a cutout.

  • There should be no seams on an overhang of a peninsula or island.

  • Notches or grinder grooves along the edge of slab parts or laminated edges to be seamed may be used to enhance adhesion

  • Always dry fit your seams, they should fit tightly, be level across and lengthwise of the seam from front to back and across. Shimming may be required at seam area as well as other areas of the countertop in order to level the seam area

  • Prepare clamping materials, quality vacuum seam clamping systems are recommended to provide a quality seam

  • Apply tape to face of Quartz at seam areas on both parts

  • Position slabs to be seamed at about 1/4“ apart

  • Prepare polyester knife grade adhesives. Century Stone Inc., recommend that fabricators always follow the individual adhesive manufacturer’s recommendations for the use of their adhesives.

  • Mix polyester knife grade adhesive manually to proper color needed for job

  • Apply adhesive with putty knife for polyester knife grade adhesive or use manufacturer’s recommendations. Recommend to apply adhesive to both sides of slab/parts

  • Apply adhesive the entire length and thickness of the seam area

  • Clamping system should be kept in place for a minimum of 30 minutes, until adhesive has hardened completely across the entire seam length, or per manufacturer’s recommendations

  • Remove seam clamping system, only after adhesive has fully cured along the entire length of the seam

  • Scrape excess adhesive using a razor blade from the seam area per manufacturer’s recommendation. Always take care not to scratch material with razor blade; material is scratch resistant, not scratch proof. Properly clean all seam areas with denatured alcohol


MITERED EDGES

Mitered edges should be done at a 45˚ angle to ensure maximum strength. The joint should be clean, flush, and parallel. Please be aware that mitered edges have the greatest area of weakness and are most prone to chipping. Our recommended minimum edge profile is a 1⁄8” bevel or rounded.

Ensure that the adhesive is thoroughly distributed throughout the joint for maximum strength.


Laminations / Double Edges

Cut lamination strips from the same slab as the countertop. When laminating, it is important to make sure that the lamination piece is the full length of the top piece and cut at 45˚ on the outside corners. Notches or grinder grooves along the edge and countertop slab to be seamed may be used to enhance adhesion.

Proper distribution of adhesive is important to visual quality and strength of seam.


SINK/COOKTOP INSTALLATION

All under-mount sink cutouts must have the inside edges polished to match the surface. All under-mount sinks should be sealed to the countertop using 100% silicone. Please be sure to use a professional sink-setter or support rail system.

When installing the sink and the cooktop, make sure they do not apply pressure on the cutout. Anchors should be installed as per the fixture manufacturer’s recommendations. Do not secure mechanical fasteners (screws, nails, etc.) directly into the material.

Twin bowl installations (Top or Under-mount) where the hole is in the countertop require extra care to ensure that there is sufficient material left for strength. Extra support is required to ensure that no cracking occurs.

All cast iron sinks (Top or Under-mount) must be supported underneath the cabinet. No anchors should be used to mount to quartz surface under any circumstance.


Installation:

The fabricated countertop is to be moved and handled vertically, avoiding twists and collisions. Prior to installation, visually inspect the countertop for any surface imperfections such as scratches, cracks or aesthetic defects. Make sure the substrate is on an even and true plane. If the counter is to rest on cabinets, make sure they are set level and flush, adjusting the leveling feet if necessary. Dry set all the countertops carefully to make sure all seam are perfectly matching and level. Stand the counter top vertically polished surface against the wall, then apply adhesive (100% clear silicone or equivalent) to the substrate or cabinets of all the edges. Carefully then lowering the stone onto the substrate or cabinet.

Apply also continuous bead at bottom of backsplash, to be adhered to countertop surface. Apply continuous 1/8” beads to backsplash horizontally at bottom of backsplash


Overhangs: Support is required on overhangs over 8” for 3/4” thick and for 1 ¼ thick slabs over 12” Overhangs exceeding the maximum requirement should be supported with brackets/corbels.

Please make your customer aware that any successive trades must not use the new countertop as a workbench, a stepping or a standing platform, and that any trades using solvents or adhesives should take due care to avoid and / or remove any spills created by their solvents or adhesives.

We strongly recommend that your customer confirm, in writing, their satisfaction with the material and workmanship at the end of the job to cover you against damages caused by others.

 

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