2017 TECHNICAL MANUAL

Transcription

1 2017 TECHNICAL MANUAL DESIGN, HANDLING & MACHINING

2 INDEX 02 TECHNICAL MANUAL PRODUCT 02. HANDLING & STORAGE P 04 P INSPECTION 04. CUTTING & FITTING P 16 P TOOLS 06. APPENDIX POLISHED FINISH P 26 P 28 TECHNICAL MANUAL

3 01. PRODUCT 01. PRODUCT 1.1 Range of products DIGITAL DESIGN PLANETARY COLORS SATIN POLISHED SATIN POLISHED Calacata Gold Calacata Gold Kedra White Calacata White Calacata White Snow Snow Cream Cream Mystic Mysrtic Caviar Caviar Graphite Graphite Sand Sand Cocoa Cocoa 04 05

4 01. PRODUCT 01. PRODUCT 1.2 Formats Slab 1500 x 3200 x 12 mm Total Area 4,80 m 2 Weight Weight m Kg 31,250 Kg Slab 59 x 126 x 0, x 3200 x 12 mm Total Area Weight Weight sq ft 51,68 sq ft 150 kg 2,90 kg 59 x 126 x 0, Thicknesses 12 mm - 1/

5 02. HANDLING & STORAGE 02. HANDLING & STORAGE KEDRA slabs should be supported with vulcanized scissor clamps to stop them from getting scratched or from falling over. To move them, a forklift truck, overhead crane or another suitable lifting system should be used, following the manufacturer s instructions and recommendations at all times. 2.1 Transportation with a scissor clamp Special care must be taken when handling or moving the slabs so as to avoid any damage. Avoid contact with metal surfaces. Kedra slab handled with a clamp

6 02. HANDLING & STORAGE 02. HANDLING & STORAGE In the case of long narrow sections, secure them to a wood or aluminium bar with C clamps before moving them anywhere. This will prevent them from bending. Handling a slab fixed to a bar with C clamps. Never put more than two slabs in one clamp. In the case of polished slabs, only one slab should be put in the clamp, first removing the protective plastic. Avoid contact with metal surfaces

7 HANDLING & STORAGE HANDLING & STORAGE Moving a Kedra countertop. 12 Lifting a Kedra countertop onto a workbench. Wrong Wrong Right Right TECHNICAL MANUAL 2017 TECHNICAL MANUAL

8 HANDLING & STORAGE HANDLING & STORAGE 2.4 Storing the slabs To avoid any damage to the slabs, they should be rested lengthwise against metal bars with a rubber protection. Keep the slabs in their original packaging for as long as possible. To transport the slabs, A-frames should be used that are big enough to hold their entire surface, otherwise the slabs might break. Right Wrong Support for storing slabs. To store the slabs, they should be rested against at least three evenly-distributed supports, covering their entire length. Storing Kedra slabs in the workshop. 2.5 Transport by road Right 14 Wrong TECHNICAL MANUAL 2017 When Kedra slabs are transported by road, they should be secured with straps to prevent a gust of wind from lifting and damaging them. TECHNICAL MANUAL

9 03. INSPECTION 03. INSPECTION Before starting the fabrication process, the slabs should be cleaned and inspected visually to make sure that they have no flaws. Claims will not be admitted if the slabs have been fitted or machined with prior flaws. To check for flaws, they should be perpendicularly placed at a distance of one metre and visually inspected in natural light. Quality 1 Usable area of slab 59x126X0,50 Anomaly of similar shade <0,12 Anomaly of different shade <0,04 The slabs should have a maximum curvature of <0,08, checked by resting them on a flat horizontal surface and measuring the highest curvature point with a feeler gauge. 3.1 Identification of slabs All the slabs come with a label containing details of their characteristics. Reference model Type of packaging Total no. slabs Traceability Total m

10 04. CUTTING & FITTING 04. CUTTING & FITTING 5.1 Cutting with a disc The exact model of disc to use will depend on the manufacturer, but it must always be in perfect condition since this will affect the quality of the results. Always follow the manufacturer s recommendations regarding the RPM and cutting speed. First cut a strip from each side to ensure a good edge and square corners. The cutting disc should always be water cooled, because Kedra slabs are made of a hard compact material. Always cut the first and last 12 at half the manufacturer s recommended cutting speed in order to ensure a perfect cut For 45º mitred cuts, the cutting speed should be 1 ½ min

11 CUTTING & FITTING CUTTING & FITTING Turn the slab round so that the cut-outs to be made are on the inner side. This will provide a greater resistance when the material is being cut. The bigger the radius, the greater the slab s structural resistance. If, on the other hand, there is a small radius, this will make the corners fragile and the slab may break. Never leave 90º angles. Wrong Right Leave at least 2 between the perimeter of any cut-outs and the edge of the slab. Wrong Wrong Right Before proceeding to make the angles, the corners must be drilled using a drill bit of over 0,12. The corners of cut-out sections should have a radius of at least 0,12. 0, Next, use a bridge saw to cut from one hole to the next. Make sure the right speed is used, so as not to break the slab. 20 TECHNICAL MANUAL 2017 TECHNICAL MANUAL

12 04. CUTTING & FITTING 04. CUTTING & FITTING 4.3 Cantos y Juntas When large cut-outs are made, to prevent the slab from breaking, always leave a strip of uncut material to hold the countertop together. This strip can be removed when the countertop has been fitted. Always leave a distance of more than 2 between the cut-out and the edge. The bigger the distance, the higher the resistance. 5.2 Using waterjet cutting equipment 2 First cut a strip from each side to ensure a good edge and square corners. The whole surface of the slab should be supported by the cutting bed. Finish all cuts working toward the edge of the slab. Be particularly careful during the first and last 12 because these sections should be cut at half the recommended cutting speed As shown in the illustration, start inside the section to be cut out and move toward the cutting line at half the recommended cutting speed. Always use carpenter s squares to stop the slab from moving. Important All the cut-out s corners should have a minimum radius of 0,12. Never leave angles of 90º. Depending on the kitchen design, whenever possible, the radii should be bigger than 0,12. This will ensure a more rigid countertop. Right Wrong Wrong Wrong 22 23

13 04. CUTTING & FITTING 04. CUTTING & FITTING All the joints must be made with a microbevel. Overhangs should never jut out more than 4 from the edge of the supporting structure, otherwise the slab might break. 4.4 Protecting the edges <4 When the edges are finished off, a sealant must be applied to ensure a watertight seal. When the edges are polished, make sure that the right discs are used. 4.5 Fitting If it is designed with a bigger overhang, the necessary supports must be incorporated to ensure stability. Support for the slab: If boards are used as a support, instead of a continuous surface, boards should be fitted at intervals across the whole surface to form crossbeams with a distance of 12 between them. 4.6 Outdoor countertops Fit the countertop onto a brick or stone supporting structure, using a C2-type adhesive cement. Given the countertop s outdoor location, wood will be more prone to damage and so it should not be used. 12 Avoid this type of separate section. To bond the mitre joints, use a UV-resistant adhesive suitable for outdoor use

14 05. TOOLS 05. TOOLS 5.1 TIPS FOR USING WATER-COOLED CUTTING DISCS. 1.- Make sure that the disc is suitable for cutting high-density porcelain tile materials. 2.- The right rotational speed for the blade s diameter should be used. 3.- Work at the right RPM. 4.- Make sure that the machine arbor has the same diameter as the disc hole. Never make the disc hole bigger without first contacting your supplier. 5.- Observe all necessary occupational safety precautions. 6.- The disc should always be cooled with plenty of water. 7.- Check the water tanks from time to time and make sure that they do not get clogged up so as to guarantee a regular flow of water. 8.- Avoid any lateral pressure on the disc. 26 MANUAL TECHNICAL TÉCNICO MANUAL

15 06. APPENDIX. POLISHED FINISH 06. POLISHED FINISH 6.1 Cleaning and care For everyday cleaning, wipe the surface with a cloth moistened in soap and water. In the case of dry stains, rinse them with hot water and then wipe the area with a clean cloth. Do not use scouring pads or wire wool. The best solution is to use a fine-fibre scouring pad similar to that used for glassware, vitroceramic hobs or non-stick pans. Never use products with a ph of over 11 or abrasive products. Bleach should be diluted in water and never left in contact with a polished surface, since it could damage the finish. Always rest pots and pans on a pot stand or protective mat. Use a chopping board when cutting or slicing food. Do not throw kitchen utensils onto the surface or drag them across it. 6.2 Handling polished slabs A vulcanized scissor clamp must be used to load, unload and transport the slabs, together with a forklift truck, overhead crane or lifting device. Always bear in mind the slabs centre of gravity when transporting them. Cover all metal surfaces that come into contact with a polished slab in foam adhesive tape. Make sure the slabs do not come into contact with metal surfaces. 28 MANUAL TECHNICAL TÉCNICO MANUAL

16 06. POLISHED FINISH 06. POLISHED FINISH 6.3 Mechanical fabrication procedures Slabs with a polished and satin finish should be cut with water-cooled cutting equipment. 6.4 Warning when using waterjet cutting equipment To avoid possible damage, before proceeding to cut the slab, make sure that the initial perforated hole is sufficiently far away from the working area. 6.5 Polishing the edges To ensure a better shine and to avoid possible damage, the edges should be polished with watercooled polishing equipment. 6.6 Handling polished slabs Polished slabs are more prone to bending and so special care must be taken when moving them, particularly during transportation. To reduce such risks, make sure that the slabs are properly secured. For further information, consult Kedra s technical manual. Remove the protective plastic before fixing the scissor clamp onto the slab. Do not put more than one slab in a clamp. The slab must be handled with care to prevent it from breaking or getting damaged. It must not enter into contact with metal surfaces without the necessary protection

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