General Fabrication Manual Guides and Tips

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1 General Fabrication Manual Guides and Tips Table of Contents 1 Handling and Storage of Trendstone Quartz Slabs 2 2 Preparation 3 3 Seams & Edges 5 4 Cutouts 9 5 Overhangs/Supports 10 6 Care & Maintenance 12 7 Warranty Information 13

2 1 Handling and Storage of Trendstone Quartz Slabs a) Handling Always take care and maintain attention when moving slabs. You must have a minimum of two workers to relocate slabs(s) no matter what kind of equipment you use. Never stand under slabs when moving slabs. Stay at arm s length at all times. Dimensions and Weight Thickness Size (mm) Weight kg/slab Unit Weight (kg/m2) 20mm 3200 x x mm 3200 x x b) Slab Storage It is recommended that all Trendstone Quartz slabs be stored indoors. If slabs are stored outside they must be kept covered and be stored with the polished faces unexposed. UV light from the sun can react with the resins in the slabs and permanently damage the appearance and change the colour. Refer below diagram for how the slabs are to be stored. The first slab against the frame should be on the back side and the next slab should be polished face to polished face. Then the following should be back to back and so on. Trendstone Quartz General Fabrication Manual Page 2

3 2 Preparation a) Health and Safety Information Information hereunder provides the most important safety issue pertaining to the fabrication and installation of quartz stone products. Please read this carefully to understand how silica dust could cause silicosis and severely and permanently damage your health. Quartz is a pure mineral that has the chemical formula SiO₂ and is crystalline and transparent in structure. Trendstone Quartz is composed of approximately 93% quartz by weight. No inherent health risks are present in its solid slab form. However, respirable crystalline silica dust represents a potential health hazards when they are inhaled by a person. The silica dust is created during all operations using dry techniques such as sawing, sanding, drilling or routing. Dry sweeping can also create silica dusts and cause for developing to silicosis. Overexposure of silica dust can cause silicosis by the formation of scar tissue in the lungs. Silicosis can be disabling, non reversible and sometimes produce fatal lung disease. Symptoms of silicosis include coughing, difficulty in breathing and progressive impairment of lung functions. Shop operations in a wet environment using proper ventilation and filtration systems would greatly reduce risk of inhaling deadly airborne dust and prevent shop employees from potential health risks. Personal Protection Wear safety glasses Wear appropriate gloves Air purifying respirator Note: All fabrication should be done wet. b) Inspection The manufacturers of Trendstone Quartz aim to provide the highest quality materials to our fabricators to ensure customer satisfaction. Each individual slab is checked after manufacture to ensure they meet export standards. In addition, it is the fabricators responsibility to conduct a visual inspection for defects on every slab prior to manufacture. Trendstone Quartz General Fabrication Manual Page 3

4 Tips: All slabs must be inspected by stone masons prior to manufacture. Remove plastic cover and carefully inspect slabs for any surface irregularities or pre-existing defects before cutting slabs. Manufacturer will not accept claims for pre-existing visible defects after slabs have been cut. Manufacturer will not be responsible for any labour costs incurred for fabrication/installation of defective materials. c) Fabrication and Installation Check List Residential 10-year limited warranty of Trendstone Quartz surface products will not cover damages caused by improper fabrication or installation. d) General Installation 1) Be sure to check the sequence numbers on the slabs upon delivery of the product for the best colour-consistency. 2) The top of the cabinets must be flat and true to within 3mm (1/8 ) of a flat surface for every 3m length. 3) To prevent seam failure, clean the side or edges with acetone or similar before applying adhesive. 4) Allow 3mm (1.8 ) minimum clearance between countertops and walls for every 3m. 5) Never install mechanical fasteners such as screws, nails etc directly into the Trendstone Quartz surface. 6) Support overhangs exceeding 300mm (12 ) for 20mm (¾ ) thickness material. 7) Radius all inside corners to a minimum of 6mm (¼ ) radius for one piece L-shape, U- shape etc to reduce corner stresses. However, 2-piece L-shaped tops and 3-piece U- shaped tops with seams do not need to have an inside corner radius. 8) Remove all nicks, tool marks, protective sheet residue etc using acetone and/or white nylon pad with non-abrasive cleaning products eg. Aquamix Nanoscrub 9) Seams going through any cutouts are not recommended. It is acceptable for the drop-in sink. 10) Use only approved 2-part epoxy, polyester or acrylic adhesives. 11) Avoid Stress Risers, (i.e. gap, sharp angled inside corner etc). Stress risers weaken the overall performance and eventually can cause a crack in the quartz countertop. 12) For quartz tops a 4mm clearance space gap should be on all sides of the cooktop cutouts to allow for heat expansion and contraction. Trendstone Quartz General Fabrication Manual Page 4

5 3 Seams & Edges a) Seam Placement Careful planning is the key factor in a successful job. When planning a job, having the right seam placement will help you minimize the use of material and time. In addition the right placement will help to ensure your customers to enjoy the beauty of Trendstone Quartz countertop without problems for years to come. All seams are recommended to be at least 150mm from any cutouts. Tips: Always discuss seam placement with customers at the time of templating. The characteristic of visible seams may irritate some customers if they were not informed properly. NOTE: There should be no seams over a dishwasher!! It is not recommended to have a seam going through a cooktop. Trendstone Quartz General Fabrication Manual Page 5

Due to the weight of quartz and mechanical bonding strength, the

6 The following inside corner seams are acceptable. There should be no seams on an overhang of a peninsula or island bench. Due to the weight of quartz and mechanical bonding strength, the overhangs with seamed joints will eventually fail. Trendstone Quartz General Fabrication Manual Page 6

7 Radius inside corners to a minimum of 6mm (¼ ) will reduce corner stresses. Two-piece L-shaped and 3-piece U-shaped tops with seams in the corners do not need to have radius corners. Radius all top and bottom straight edge profiles to a minimum of 1.5mm radius. Radius all outside corners to a minimum of 3mm radius. Square inside corners of any cutouts will not be covered under warranty. Trendstone Quartz General Fabrication Manual Page 7

8 b) Popular Edge Profiles The help reduce risk of edge chipping we recommend double pencil round (i.e. Pencil round top and bottom). Trendstone Quartz General Fabrication Manual Page 8

4 Cutouts a) Sink and Bowl Cut Outs For a setback to a cut out: 40mm (1½ ) minimum from the back. 90mm (3½ ) minimum from the front (undermount). 60mm (2¼ ) minimum from the front (drop-in).

9 4 Cutouts a) Sink and Bowl Cut Outs For a setback to a cut out: 40mm (1½ ) minimum from the back. 90mm (3½ ) minimum from the front (undermount). 60mm (2¼ ) minimum from the front (drop-in). Sink and bowl cut out templates are an important part for fabricating countertops and can save you time and materials by fabricating in your shop for faster and accurate processing. b) Cook Tops Potential Problems: The cooktop area is the area where various problems could occur. The following is a list of possible damages you should consider. Heat expansion and contraction. Stress riser points in the cutouts. Always radius corners of cut-outs minimum 6mm Faulty cooktops, dispensing too much heat. Not enough space between the cooktop and the countertop. Recommended minimum 4mm. Trendstone Quartz General Fabrication Manual Page 9

5 Support a) Overhang Support Overhangs of 30cm (12 ) or less do not need to be supported for 20mm (¾ ) thickness. Overhangs of 40cm (15 ) or less do not need to be supported for 30mm (1¼ ) thickness.

10 5 Support a) Overhang Support Overhangs of 30cm (12 ) or less do not need to be supported for 20mm (¾ ) thickness. Overhangs of 40cm (15 ) or less do not need to be supported for 30mm (1¼ ) thickness. Overhang of 30 45cm (12-18 ) need to be supported with plywood substrate, material frame or Corbels for 20mm (¾ ) Overhang of 48 60cm (15-24 ) need to be supported with plywood substrate, material frame or Corbels for 20mm (¾ ) b) Overhang Support Corbels Usually made out of wood to match the cabinets or they can be made for many other materials to match the cabinets or countertop. Trendstone Quartz General Fabrication Manual Page 10

Corbels need to be 50% longer than the width. Brackets must be installed every 600mm (2 ) or less. Determine the number of brackets to fabricate by measuring the cabinets.

11 Corbels need to be 50% longer than the width. Brackets must be installed every 600mm (2 ) or less. Determine the number of brackets to fabricate by measuring the cabinets. Brackets must be long enough to reach within 127mm (5 ) of the countertop edge. Fabricate the backer plates that will be used to mount the brackets to the cabinet. For 20mm (¾ ) thickness overhangs of 45cm (18 ) or more need to be supported with solid substrate and a leg or column attached to the floor. For 30mm (1¼ ) thickness overhangs of 60cm (24 ) or more need to be supported with a leg or column. Trendstone Quartz General Fabrication Manual Page 11

12 6 Care and Maintenance TrendStone Quartz is an engineered stone manufactured from up to 93% quartz, one of the hardest materials on earth, which is combined with advanced polymer resins and pigments and then compacted under heavy pressure to form a naturally strong and non-porous stone slab. This process also makes TrendStone Quartz surfaces a very stain resistant easy care surface. But it is important to point out that although TrendStone Quartz has high stain resistant it is not stain proof. But with general care and common sense TrendStone Quartz will offer many years of service and enjoyment. Below is a list of tips and recommendations that will assist in caring for your new TrendStone Quartz surface. Tips for general day to day cleaning; - Small amount if mild detergent with a damp soft sponge or - Methylated spirits diluted with water in a spray bottle (approx. 60/40). Spray over the surface and wipe over with paper towel or Windex and paper towel. For more stubborn stains; - First remove any solids that may be adhered from the surface with a plastic scrapper. Then try some detergent and water and work with a soft sponge (do not use the scourer side of the sponge). If the stain still remains try a cleaning product, such as Windex or jiff cream cleanser. If the stain still persists you can try gumption. Mix the gumption with some water to a slurry consistency and work into the stain with a damp soft sponge (do not use the scourer side of the sponge). Apply the sponge at light to medium pressure as gumption is an abrasive cleaner and very heavy scrubbing could alter the polished surface. Whenever using a cleaning product/process it is always recommended to test on a small less noticeable area before use so as to avoid any unwanted damage to the stone surface. - For further assistance in removing persistent stains please contact a specialist such as a stone fabricator / stone restorer. Some general do s and don ts.. - Do wipe up spills as quickly as possible. - Do not place harsh chemicals such, e.g. oven cleaners, paint strippers on your stone surface as these types of harsh chemicals will damage your stone. - Whilst Quartz surfaces are heat resistant and can withstand moderately high temperatures it is recommended that to avoid any risk of thermal shock that you do not place crock hot pots or electric skillets directly on to your TrendStone Quartz surface especially near edges of counter tops and over seams. Always use Trivets/Hot pads. - Do not use harsh scourers on your stone surfaces. - Do not cut on your TrendStone Quartz surface. Always use a cutting board. Trendstone Quartz General Fabrication Manual Page 12

13 TrendStone Quartz Surfaces Limited 10 Year Warranty RESIDENTIAL LIMITED WARRANTY Project Stone Australia Pty Ltd warrants to the original owners of installed TrendStone Quartz for a period of ten (10) years from the date of installation in your residence that the TrendStone Quartz material will be free from manufacturing defects. TrendStone Quartz is suitable for interior applications only. If a manufacturing defect occurs during the warranty period, Project Stone Australia Pty Ltd may at its own discretion repair or replace material (i.e. unprocessed TrendStone Quartz slab) at free of charge to a qualified stone mason as a gesture of goodwill to facilitate a resolution for any claims. Replacement material is referring to unprocessed stone and therefore does not include transport, fabrication, installation or any other associated cost in regards to installation of the replacement. Although Project Stone Australia Pty Ltd shall make its best effort to repair or replace with a best possible colour match, we cannot guarantee that the repair or replacement will be an exact colour match to the original. It is the responsibility of the stone fabricator to ensure that slabs are checked thoroughly for any manufacturing defects, spots, colour variances, size, thickness and straightness of slabs prior to manufacture. WHAT THIS LIMITED 10 YEAR WARRANTY COVERS: Project Stone Australia Pty Ltd warrants under this limited 10 year warranty exclusively to the original purchaser of the TrendStone Quartz for only the repair or replacement of the defective product only and does not include any cover for associated costs. Only TrendStone Quartz products that have been distributed by Project Stone Australia Pty Ltd. TrendStone Quartz that has been permanently installed in your residence. TrendStone Quartz products that have been maintained according to the TrendStone Quartz Care and Maintenance Guide, which is available from our website TrendStone Quartz products that have been installed by an experienced qualified stone fabricator using best industry practices. If you are making a warranty claim, you, the customer, are responsible for proving that the product is TrendStone Quartz and was installed by a Qualified Stone Mason/TrendStone Quartz Installer. WHAT THIS LIMITED 10 YEAR WARRANTY DOES NOT COVER: Does not cover the use of the product for commercial purposes, e.g. purposes other than residential home interior applications. Does not cover installations such as boats, recreational vehicles and flooring. Does not cover products installed outdoors, such as outdoor kitchens, BBQ tops, heated areas such as saunas, steam rooms. Color variances, thermal shock, chemical abuse, impact damage or incorrect use or improper fabrication. Trendstone Quartz General Fabrication Manual Page 13

14 Small blemishes, such as blotches or spots are inherent in the manufacturing process. In the event visual blemishes, blotches or a concentration of colour pigments, the contracted fabricator should report this to the distributor prior to fabrication. Any additional or supplemental repairs or modifications such as, for example, any plumbing, electrical, tile or wall surface modifications that may be necessary when repairing/replacing the TrendStone Quartz product covered under this limited 10 year warranty. Such repairs and modifications shall be the responsibility of the customer. Does not cover products that have not been paid for in full. Does not cover damage/defects as a result of e.g., exposure to outside weather and climate conditions, abnormal use or conditions, or abuse in any way. Abnormal use or conditions includes, but is not limited to, damage from mishandling or misuse, damage from excessive heat or uneven exposure to weather conditions, excessive exposure to ultraviolet light, physical or chemical abuse (such as oven cleaners, floor and paint strippers and other harsh chemicals) and damage from improper care and maintenance. Project Stone Australia Pty Ltd is not responsible for damage or injury caused in whole or in part by acts of nature, job site conditions, architectural and engineering design, structural movement, acts of vandalism, or accidents. Does not cover seam/joint performance. This limited 10 year warranty is non-transferable and does not cover claims made by subsequent owners of your home. Does not cover damage as a result from improper storage, handling or fabrication by Fabricators/Installers. Does not cover products that you, the customer decide you do not like after installation due to color, edging styles or other opinions based on personal preference. Does not cover cracks around sinks/hot plate cut outs as these are normally as a result of improper installation. Does not cover damage caused by standing on or applying excessive force to the countertop. Never stand on your countertop, especially around the sink/cook top cutouts as well as unsupported sections e.g., breakfast bars, dishwasher provision etc. Whilst TrendStone Quartz is highly scratch and stain resistant they are not stain and scratch proof. We recommend any spills be wiped up immediately and never cut directly on your bench top or drag heavy/sharp objects across your bench top. This warranty does not include generally excepted wear and tear over the life span of the product. Do not place crock hot pots or electric skillets directly to your Trendstone Quartz surfaces. Always place them on a trivet or cutting board to protect your countertop. Trendstone Quartz is a stone product. As with any stone product, excessive exposure to heat may cause cracks due to thermal shock. Thermal shock can result from heat generating sources such as hot water pipes, cook tops and dishwashers. We recommend that all pipes be thermally insulated and tap holes are sufficiently oversized to avoid heat transfer. Dishwashers can generate significant amounts of heat. It is therefore recommended that moisture resistant MDF board is installed as a heat barrier between the dishwasher and the Trendstone Quartz. Cook tops should be installed as per manufactures guidelines and Australian Standards. Sufficient space should be allowed between the cook top and surrounding quartz bench top edge to minimize heat transfer. Trendstone Quartz General Fabrication Manual Page 14

15 REGISTRATION: To register for this limited 10-year warranty please fill out the warranty registration form and post to the below address. To obtain a registration form please contact Project Stone Australia Pty Ltd at the phone number or address below or download from the website TO OBTAIN SERVICE UNDER THIS WARRANTY: To obtain the best service under this limited 10 year warranty, contact the source from whom you purchased TrendStone Quartz. Please retain your invoice/sales receipt or produce proof of purchase and installation of TrendStone Quartz. This document must state date of installation and fabricator details. For more information about this warranty, please contact PROJECT STONE AUSTRALIA PTY LTD Radley Street, Virginia QLD 4014 Australia Ph: Fax: info@projectstone.com.au / In order to obtain service under this limited 10 year warranty, you must notify, in writing, Project Stone Australia Pty Ltd along with the Fabricator/Installer of the TrendStone Quartz product within 28 days to arranging inspection at your residence. Also, you must reasonably cooperate with your installer and Project Stone Australia Pty Ltd representatives in their efforts to provide service under this limited 10- year warranty. Except as provided in this limited 10 year warranty, Project Stone Australia Pty Ltd shall not be liable in either tort or contract for any loss of direct, consequential or incidental damages arising out of the use or in ability to use the product in residential applications covered by this warranty. This is the only warranty offered by Project Stone Australia Pty Ltd and only for TrendStone Quartz products. No one other than Project Stone Australia Pty Ltd is authorized to make any warranty or promise with respect to TrendStone Quartz. Trendstone Quartz General Fabrication Manual Page 15

16 Trendstone Quartz General Fabrication Manual Page 16

17 Trendstone Quartz General Fabrication Manual Page 17

Inspection Remove the plastic sheet from the slab before cutting. Clean and examine the slab in direct light for:

Inspection Remove the plastic sheet from the slab before cutting. Clean and examine the slab in direct light for: Installation Guidelines: It is strongly recommend that Q Quartz slabs are stored indoors and allowed to acclimate for a minimum of 48 hours before fabrication. There is a higher risk of breakage during