Engineered Real Wood Veneer Wallcoverings Direct Application Guide

Transcription

1 Engineered Real Wood Veneer Wallcoverings Direct Application Guide

2 2 SANFOOT FABRICATION GUIDE

3 Table of Contents Chapter 1 Preparation Inspection Storage Environmental Conditions Preparation of SanFoot Primers Adhesives Chapter 2 Wall Preparation Dry Wall / New Dry Wall Level 4 Finish Level 5 Finish Plastered Walls Damaged Dry Wall Painted Walls Optimum Installation Recommendations Chapter 3 Test Area Approval Chapter 4 Installing SanFoot Chapter 5 Adhesives. Application of Adhesives Primers and Adhesives Reference Table SANFOOT FABRICATION GUIDE 3

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5 Chapter 1 - Preparation SanFoot Preparation Please read these instructions completely before proceeding with any installation. For assistance with the installation procedures contained herein, please contact Inspired Surfaces Ltd. on +44 (0) The installation process is critical to the aesthetic appeal and acceptance of SanFoot. Surface preparation, adhesive and primer selection, environmental conditions and quality workmanship are the key elements for a successful installation. SanFoot comes from the factory pre-finished with urethane sealer and finish. Inspection of product: Please inspect for damage before signing for receipt of product. If damage is noted, please advise freight carrier immediately when signing for the product from the freight carrier. Examine all sheets of SanFoot Engineered Real Wood Veneer upon receipt for quality and compliance with the approved specification before storing or starting installations. Any shortage of materials must be reported within three days after receipt of material. The installing contractor must verify that the correct specified species of wallcovering is present on the job site. Furthermore, the installer must also review the hanging instructions that accompany each order of SanFoot. If there is a failure to follow the specifier s supplied wall finish schedule and material design boards, Inspired Surfaces Limited assume NO responsibility for any incorrect hanging locations, incorrect wallcovering species numbers and species grains that are hung in the wrong direction. SANFOOT PRODUCT INSPECTION Ash, Flat Cut SANFOOT FABRICATION GUIDE 5

6 Chapter 1 - Preparation Storage: SanFoot should be kept in the manufacturer s packaging until 24 to 48 hours before installation. Store in a clean, dry, secure area that has low humidity and a stable temperature range of 7 to 30 Celsius. Environmental Conditions: Areas to receive SanFoot should be environmentally controlled by the permanent Heating, Ventilation and Air Conditioning (HVAC) system. Maintain a temperature range of 18 to 30 Celsius, with not more than 50% relative humidity for a period of not less than 4 days prior to installation and maintained thereafter. Preparation of SanFoot Engineered Real Wood Veneer: Remove SanFoot sheets from the box and allow the sheets to relax and acclimatise to the environment for approximately 24 to 48 hours. If the air is dry, or if the sheets must remain out of the box for an extended period of time, cover with a sheet of vinyl to prevent the veneer from drying out. It is best to lay the sheets face down, during this period, and not directly on the floor. After preliminary inspection, arrange SanFoot sheets in numerical sequence as labelled on the back of each. Along with the sequence number, each sheet also has a flitch number and the word bottom printed on the back. All sheets should be installed in sequence order and in the same direction with all bottoms down or all bottoms up based upon appearance preference. In most cases the installation should start at the top left descending left to right, on 2.7m or 3m walls. Where the wall is taller, first sheet installation should start at top left descending top to bottom then left to right. 1. Flitch Number 2. Orientation and sequence number 6 SANFOOT FABRICATION GUIDE

7 Chapter 1 - Preparation Primers: Prime all surfaces (including oil-based paint, oil-based primers and latex or oil-based stain-kill coatings) with specified primers listed below. Prime all surfaces according to manufacturer s directions. For best results, apply primer with a roller and leave to cure for at least 2 days before installing SanFoot Natural Wood Veneer Wallcovering. Please consult with Inspired Surfaces Limited before proceeding with any unusual conditions. The use of the primer will prevent the adhesive from being excessively absorbed into the drywall and stop dry pockets, plus a primer promotes strippability to SanFoot. Moisture content in the wall substrate should be in a range of 7% to 9% or less. Check with a moisture meter if necessary. If a situation is encountered where the walls were previously painted or primed, the surface should be lightly sanded to break the seal prior to applying an approved primer. One test strip of SanFoot should be hung to assure a strong bond between the existing paint/ primer and the primer before proceeding with the installation. Any failure caused by the existing painted/primed surface is the responsibility of the installing contractor and not of Inspired Surfaces Limited The following acrylic primers are approved for use with SanFoot: 1. Pro-935 (R 35) by Roman Decorating Products; For use over new or clean drywall. 2. Pro-937 (Ultra Primer) by Roman Decorating Products; For use over drywall or plaster walls with loose paint or chalky surfaces. 3. Pro-977 (Ultra Primer) by Roman Decorating Products Do not use alkyd/oil base primers with SanFoot Natural Wood Veneer Wallcovering. Adhesives: Use the following approved clay-based adhesives with SanFoot: 1. Pro-732 Extra Strength HD Clay by Roman Decorating Products 2. Pro-774 Heavy Duty Clay Strippable by Roman Decorating Products Inspired Surfaces Limited does not recommend the use of clear or clear strippable type adhesives. SANFOOT FABRICATION GUIDE 7

8 Chapter 2 - Wall Preparation Preparing the wall surface Dry Wall / New Drywall All drywall finishing s should comply with the Association of Wall and Ceiling industries International (AWCI), Painting and Decorating Contractors of America (PDCA) specifications, Level 4 (walls) or Level 5 (walls and ceilings) as a guide. By incorporating the appropriate level of finish of the recommended specification into the project documents, the architect, general contractor, and building owner can better anticipate the final appearance of the decorative wall or ceilings covered with SanFoot Natural Wood Wallcovering. We would recommend either of the following two finish levels: Level 4 Level 4 All joints and interior angles shall have tape embedded in joint compound and shall be immediately wiped with a joint knife leaving a thin coating of jointing compound over all joints and interior angles. Two separate coats of jointing compound shall be applied over all flat joints and one separate coat of jointing compound shall be applied over interior angles. Fastener heads and accessories shall be covered with three separate coats of jointing compound. All joint compound shall be smooth and free of tool marks and ridges. NOTE: It is recommended that the prepared surface be coated with a drywall primer prior to the application of final finishes. This level should be specified where flat paints, light textures or wallcoverings are to be applied. In critical areas, flat paints applied over light texture tend to reduce joint telegraphing. The texture and sheen level of wallcoverings applied over this level of finish should be carefully evaluated. Joints and fasteners must be adequately concealed if the wall covering material is light weight, contains limited pattern, has a high gloss finish, or any combination of these finishes is present. All surfaces shall be clean, smooth and dry prior to applying primer and the application of SanFoot. 8 SANFOOT FABRICATION GUIDE

9 Chapter 2 - Wall Preparation Level 5 All joints and interior angles shall have tape embedded in joint compound and shall be immediately wiped with a joint knife leaving a thin coating of jointing compound over all joints and interior angles. Two separate coats of jointing compound shall be applied over all flat joints and one separate coat of jointing compound shall be applied over interior angles. Fastener heads and accessories shall be covered with three separate coats of jointing compound. A thin skim coat of joint compound trowel applied, or a material manufactured especially for this purpose and applied in accordance with the manufacturers recommendations, applied to the entire surface. The surface shall be smooth and free of tool marks and ridges. All surfaces shall be clean, smooth and dry prior to applying primer and the application of SanFoot. Level 5 NOTE: it is recommended that the prepared surface be coated with a drywall primer prior to the application of final finishes. This highest quality finish is the most effective method to provide a uniform surface and minimize the possibility of joint telegraphing and fasteners showing through the final decoration. SANFOOT FABRICATION GUIDE 9

10 Chapter 2 - Wall Preparation Plastered Wall The required finish level of the surface plaster should be to the same standards that have been set out in the Dry Wall application section and also listed below, either of the two finish levels are acceptable paying particular attention to the comments in the paragraphs which are listed below in the first instance. New plaster should be to a thickness of 1.27cm to 1.9cm, ideally new plastered walls should age days before painting or installing SanFoot. All walls should be prepared as per product / manufacturer s guidelines, taking particular note to the following All interior and exterior corners should be finished using the correct metal angle bead and Joint tape, any Fastener heads or accessories shall be covered to minimize the possibility of jointing and telegraphing. The surface shall be smooth and free of tool marks and ridges, sand any minor imperfections to leave a smooth finish. NOTE: This highest quality finish is the most effective method to provide a uniform surface and minimize the possibility of joint telegraphing and fasteners showing through the final decoration. Skim coat A skim coat of jointing compound is intended to conceal small imperfections in the joints and on the surface of the gypsum board, smooth the texture of the paper, minimize the differences in surface porosity, and create a more uniform surface to which the final decoration can be applied. A skim coat is essentially a film of joint compound and is not a readily measurable thickness. There is no specific thickness that constitutes as a proper skim coat. A skim coat trowel applied with the intent being that the consistency (viscosity) of the joint compound be such that it can be applied by a trowel. Other tools may be used for application so long as the trowel consistency is achieved. The objective of the application is to achieve total coverage of the entire surface with the skim coat. This is typically accomplished by delivering the compound to the surface and using a drywall board knife to force the compound into the surface pores and imperfections while shearing off excess compound from the surface. A skim coat will not approximate a plastered surface. Once the skim coat dries, the gypsum board paper may show through and the treated joints, filled voids, and fasteners heads will likely be visible. 10 SANFOOT FABRICATION GUIDE

11 Chapter 2 - Wall Preparation Damaged Dry Wall Prime damaged areas such as torn drywall facing paper, skim coat repairs and old adhesive using the recommended Primer / Sealer. Repair any surface damage and make all surfaces sound before installation. Painted Walls: Alkyd/Oil Surface Surfaces painted with alkyd/oil paint will not allow the moisture to be absorbed into the drywall. Therefore, a wall liner must be applied before proceeding with hanging SanFoot Natural Wood Veneer Wallcovering. Allow sufficient time for the moisture in the adhesive used to install the wall-liner to evaporate and cure. A paper wall liner is all that is needed in this application. Acrylic/Latex Surface Sand painted surfaces to break the seal. All painted surfaces must be to ensure strong bond of SanFoot. Allow freshly painted drywall to cure at least 14 days prior to priming and installing SanFoot. By incorporating the appropriate levels of finish of the recommended specification into the project documents, the architect, general contractor and building owner can better appreciate the final appearance of the decorative wall covered with SanFoot Natural Wood Veneer Wallcovering. Painted Plaster All efflorescence crystals should be removed before starting the installation. All undulations in the plaster must be smoothed to a flat finish. Installation over previously painted plaster surfaces must be installed with attention to the type of paint applied to the surface and the number of coats it has received over time. SANFOOT FABRICATION GUIDE 11

12 Chapter 2 - Wall Preparation Optimum installation recommendations The following are the optimum installation recommendations from Roman s test hang results on Sanfoot Wood Veneer Sheets: 1. Specification for Optimum Installation New Dry-Wall: i) Prime new dry wall with two (2) coats of Roman PRO-977 Ultra Primer applied at the recommended spread rate. Allow each coat to dry overnight. ii) Apply one (1) coat of Roman PRO-935 (R-35) Adhesion Promoting Primer at the recommended spread rate. Allow to dry overnight. iii) Apply Roman PRO-732 Extra Strength Clay Adhesive at the recommended spread rate to the back of the wood veneer sheet / panel. Book for 5 minutes then hang and smooth using a plastic smoothing tool. 2. Specification for Optimum Installation Existing Dry-Wall:* i) Remove existing wall covering using Roman Piranha Wall Paper Stripper. Follow directions on container. ii) Seal existing dry wall with one (1) coat of Roman Rx-35 (PRO-999) applied at the recommended spread rate. Allow to dry overnight. iii) Apply two (2) coats of Roman PRO-977 Ultra Primer applied at the recommended spread rate. Allow each coat to dry overnight. iv) Finally, apply one (1) coat of Roman PRO-935 (R-35) Adhesion Promoting Primer at the recommended spread rate. Allow to dry overnight. v) Apply Roman PRO-732 Extra Strength Clay Adhesive at the recommended spread rate to the back of the wood veneer sheet / panel. Book for 5 minutes then hang and smooth using a plastic smoothing tool. * The combination of the Roman Rx-35 Sealing Primer and PRO-977 Primer will adequately seal the dry wall surface and provide a minimum Level 4 surface smoothness needed for optimum installation of the wood veneers (i.e., eliminate bubbling, edge curling, seam lifting, telegraphing of substrate imperfections, etc.). The inclusion of the Roman PRO-935 (R-35) Primer is to provide the added anchoring for the adhesive. 12 SANFOOT FABRICATION GUIDE

13 Chapter 2 - Wall Preparation Optimum installation recommendations We caution application over the following specific surfaces, as these substrates / environmental conditions are not optimal for Direct Application. 1. New or Clean Drywall where damp, mould or mildew is a concern: i) Romans ECO line of products is specifically formulated to prevent mildew growth on the dry film of the adhesive and primer. ii) All surfaces must be clear of any mould and mildew prior to application. 2. Use Over Damaged Drywall: i) Repair any drywall damage and seal existing dry wall with one (1) coat of Roman RX35 (PRO-999) applied at the recommended spread rate. Allow to dry overnight. ii) Apply two (2) coats of Roman PRO-977 Ultra Primer applied at the recommended spread rate. Allow each coat to dry overnight. iii) Apply one (1) coat of Roman PRO-935 (R-35) Adhesion Promoting Primer at the recommended spread rate. Allow to dry overnight. Apply Roman PRO-732 Extra Strength Clay Adhesive at the recommended spread rate to the back of the wood veneer sheet / panel. iv) Book for 5 minutes then hang and smooth using a plastic smoothing tool. 3. Wood Composite Board: i) Seal with 1 coat of RX35. Apply at recommended spread rate and allow to dry overnight. ii) If composite board still appears porous, apply a second coat of RX35 at recommended spread rate and allow to dry overnight. iii) Install wallcovering with PRO Over plaster walls showing loose paint: not recommended. All surfaces must be sound before installation. 5. Over chalky surfaces: i) Seal with 1 coat of RX35. Apply at recommended spread rate and allow to dry overnight. ii) If surface still appears porous and chalky, apply a second coat of RX35 at recommended spread rate and allow to dry overnight. iii) Install wallcovering with PRO-732. If the painted surface cannot be broken by sanding, then a wall liner must be installed before applying SanFoot over painted plaster to allow the moisture to be wicked away. SANFOOT FABRICATION GUIDE 13

14 Chapter 2 - Wall Preparation Optimum installation recommendations Concrete, Ceramic Tile, Marble or other Unlevelled and Irregular Surfaces Contact Inspired Surfaces Limited for more information. MDF Board, Particleboard, other Wood Composite Products or Hardwood Plywood All surfaces should be free of all excess dust, oils or other foreign matter and be maintained as smooth as possible. All seam joints should be mudded and sanded to fill all gaps for a smooth surface. All surface areas will need to be primed with Pro 935 by Roman Decorating Products before starting the installation of SanFoot. Keep in mind that your substrate will not allow a lot of moisture to be absorbed, therefore, you will use a little less adhesive in this application than over drywall. Contact Adhesive over Non-Porous Surfaces Substrates that may require the use of contact adhesive are: painted metal, stainless steel, plastic laminate and other non-porous surfaces. Never use contact adhesive on drywall or plaster. 1. Preparation: Always be sure that both surfaces are clean and free of all dust. SanFoot and the substrate of choice should be stored in the same surroundings for 24 to 48 hours before starting the installation. This will allow both products to acclimatize together before bonding. 2. Adhesive: When using a contact adhesive, always use 100% coverage on both the back of the veneer sheet and the face of the substrate. Let the adhesive have the correct amount of dry open time. You don t want to trap gases that can later cause blisters. The time can vary depending on the airflow around your work area, and ambient temperature and humidity at the time of installation. Follow all instructions on the label of the contact adhesive being used. 3. Bonding: When contact adhesive is being used the best method of pressure is a lot of pressure all at one time. This pressure can be reached by using an acrylic smoothing tool covered with a felt cloth when using pre-finished SanFoot sheets. Starting in the centre of the surface to be bonded, pull the smoother toward you going with the grain. Apply pressure with both hands, pushing down as hard as possible. Keep doing this as you move over 7-10 cm at a time (your smoother should be cm wide) until you have rubbed down the entire surface. Do not use a J-Roller to apply pressure. 14 SANFOOT FABRICATION GUIDE

15 Chapter 2 - Wall Preparation Optimum installation recommendations 4. Time: Don t rush your work. In order for contact cement to work, a chemical reaction must take place. This reaction produces gas and you need to allow this gas to escape from the edges. Many jobs appear perfect and then blisters start to appear. Reasons for this may include: i) Insufficient adhesive coverage ii) Not enough pressure was applied to form an intimate bond iii) Insufficient amount of open time SANFOOT FABRICATION GUIDE 15

16 Chapter 3 - Test Area Approval Test Area Approval: At no additional cost to the owner, the Wallcovering Installation Contractor shall install no less than three (3) full-width sheets, of each pattern specified, in an area designated by the Architect, Designer or Owner. The test installation area shall be reviewed for conformance to the manufacturer s standard installation instructions and recommended adhesives. Only the Architect, Designer or Owner shall approve the test installation. The Contractor shall replace any unsatisfactory sheets as directed by, and until the test area is accepted by the Architect, Designer or Owner. Use of an unspecified adhesive, primer or any additional finishes will void the manufacturer s warranty at time of installation. Future problems that may occur as a result of incorrect installation procedures are not the responsibility of Inspired Surfaces Limited. The approved test area shall remain as part of the finished installation work and as a standard of comparison for the installation throughout the project. The Contractor shall not install specified material beyond the test area, prior to the approval of the test area, by the Architect, Designer or Owner. Proceeding beyond this point will be done at the installer s risk and will absolve Inspired Surfaces Limited of all responsibility. 16 SANFOOT FABRICATION GUIDE

17 Chapter 4 - Installing SanFoot Installing SanFoot Natural Wood Wallcovering: Apply the sheets to the wall in sequence, filling in over doors and windows from consecutive sheets. After applying each sheet of Sanfoot Natural Wood Veneer Wallcovering on the wall, smooth with an acrylic smoothing tool, or with smoothing tools which will not mar the finish, but ensure that all air bubbles are eliminated and there is a good bond between the SanFoot and the substrate. Smooth the entire surface area of the sheet to ensure all air pockets are eliminated. Air bubbles must be removed, and installation errors corrected, before the adhesive dries. Remove excess adhesive from each sheet as you go along prior to installing the next sheet. Use a clean, moist, natural sponge to remove excess adhesive and dry the surface with a lint free towel. It is very important to change water frequently in order to maintain cleanliness and not streak the appearance. Adhesive residue will be very difficult to remove so insure that ALL adhesive is removed and the SanFoot is cleaned with a moist sponge. Clean each sheet as it is installed. Do not install SanFoot with temporary lighting. Installation with permanent lighting is recommended. Sufficient lighting will greatly enable your ability to see air pockets or bubbles and other installation problems that may occur. For best results, all joints / seams should be overlapped and double cut with a Stanley Blade or equivalent, using a new blade every cut. For installation of SanFoot sheets that are three metres (3m) and longer, Inspired Surfaces Ltd. requires all joint seams to be double cut in order to achieve a tight acceptable joint seam. Vertical joints should not occur less than 6.35cm from all external and internal corners, if at all possible, based on the corner being in square. Leaving SanFoot overlapped at the seams is not acceptable. DOUBLE CUTTING SANFOOT SANFOOT FABRICATION GUIDE 17

18 Chapter 4 - Installing SanFoot Installing SanFoot Natural Wood Wallcovering: The following holds true on all corners that are square: Wrapping an outside corner with SanFoot is done in the same manner as heavy-duty vinyl wallcovering, with one exception. When bending around an outside corner wet the face of the pre-finished SanFoot with clean water and a clean lint-free rag. NOTE: If the corner is not straight and true, please contact Inspired Surfaces Ltd. for additional instructions. The moisture added will allow the wood to bend around the corner without breaking. Follow these same steps for an inside corner as well. Air bubbles must be removed and installation errors must be corrected before adhesive dries. Sufficient lighting will greatly assist in seeing bubbles and other installation problems. After installing three (3) sheets of SanFoot Natural Wood Veneer Wallcovering, inspect the material for proper installation (see Chapter 3 - Test Area Approval for more information). If problems occur, stop and contact Inspired Surfaces Limited. Proceeding beyond this point will be done at installer s risk and will absolve Inspired Surfaces Limited of all responsibility. 18 SANFOOT FABRICATION GUIDE

19 Chapter 5 - Adhesives Application of Adhesive: Use one of the approved adhesives. Prepare the wall surface as specified before beginning and use only specified adhesive(s). Apply adhesive at full strength - whip or stir to thin to desired consistency. Do not dilute adhesive with water. Apply a uniform layer of adhesive to the back of the SanFoot sheets with standard 0.9 cm to 1.9 cm nap paint roller, ensure there are no uncoated areas, book the sheets for 10 to 15 minutes before hanging. Allow the proper time for the adhesive to tack after it has been applied to the back of the sheets. This is important to prevent bubbling after installation. Depending on the condition of the primed substrate, the installer may choose to size the wall surface with a thin coating of the specified adhesive and allow it to tack prior to hanging. It is suggested that the installer test an area first to determine if an adhesive size is needed. Primers and Adhesive Reference Table The table on the following pages can be used for further reference on your upcoming project. For any further queries, please contact Inspired Surfaces Limited. SANFOOT FABRICATION GUIDE 19

20 Chapter 5 - Adhesives Substrate Method Application Adhesive Application Application Guidelines PRO Primer New Dry Wall or Block Wall Hand Applied Direct PRO (R35) Adhesion promoting primer PRO Extra strength clay adhesive PRO (RX35) Primer Sealant PRO Primer Existing Dry Wall or Block Wall Hand Applied Direct PRO (R35) PRO Adhesion Promoting Primer Extra Strength Clay Adhesive PRO Ultra Clear Strippable Clay Adhesive PRO Heavy Duty Clear Heavy duty clear non strippable Over Plastered walls showing loose paint Not recommended, All surfaces must be sound before installation Over Chalky Surfaces Hand Applied Direct Pro (RX35) PRO Primer Sealant Extra Strength Clay Adhesive Wood Composite Board Hand Applied Direct Pro -999 (Rx - 35 ) PRO Primer Sealant Extra Strength Clay Adhesive As per Manufactures Guide Lines As per Manufactures Guide Lines 20 SANFOOT FABRICATION GUIDE

21 Chapter 5 - Adhesives Substrate Method Application Adhesive Application Application Guidelines Hand Applied Cold Press Press Titebond Cold Press PVA Adhesive Titebond Cold Press for Veneer is a high quality solution for large scale bonding of veneers to flat surfaces. It is specifically formulated for cold press laminating of wood to solid woods, particleboard, MDF, plywood and other porous materials. Titebond Cold Press offers a moderate speed of set, a translucent glue line and contains none of the harmful or corrosive fumes typical of most contact cements. It also prevents bleed through on open-grained and unbacked wood veneers. Hand Applied Hot Press Press PVA Adhesive MDF, Plywood or ParticleBoard Titebond GREEN choice Neoprene Plus Contact Cement is a fast grab, non-flammable adhesive that spreads easily over large surfaces. This adhesive specializes in bonding decorative veneer, to wood based composites. Its fast set and professional strength allows for immediate trimming, cutting filling or machining after application. Hand Applied Spray Contact Adhesive TensorGrip LP64 is a spray contact adhesive is suitably designed and developed to give a perfect pebble mist spray pattern. Bonding gloss laminates or paperback veneers to a variety of substrates including MDF, chipboard, plywood and many other timber sheet materials. TensorGrip LP64 is designed for permanent bonding of materials where high grab and superior bond strength are required. SANFOOT FABRICATION GUIDE 21

22 Chapter 5 - Adhesives Substrate Method Application Adhesive Application Application Guidelines MDF, Plywood or ParticleBoard Hand Applied Spray Contact Adhesive TensorGrip LP61 is suitable for bonding HPL, veneers and almost all other decorative face laminates to a variety of substrates including MDF, chipboard, plywood and many other timber sheet materials. This unique formulation is designed for permanent bonding of materials where high grab and superior bond strength are required. Aluminium, Steel, Mica, Plexi, Glass Hand Applied Spray Contact Adhesive Clear Contact (3M 4693h) 3M Scotch Weld High Performance Industrial Adhesive 4693H is a high viscosity, solvent based, synthetic rubber adhesive. 22 SANFOOT FABRICATION GUIDE

23 Notes SANFOOT FABRICATION GUIDE 23

24 Inspired Surfaces Ltd. 26 Brunel Road Earlstrees Industrial Estate Corby Northamptonshire United Kingdom NN17 4JW Telephone: +44 (0) version 4