General Fabrication Principles

HI-MACS® Layout

Before cutting the sheets you have ordered and received from your HI-MACS® distributor, calculate the number, lengths, widths and elevation to double check the amount of material you will need to finish the entire project. If you calculate too closely, you may create yield problems and dye lot concerns if more material must be ordered. You must also remember to consider cutouts, backsplash materials and buildup strips. As you look at all of these factors consider the cutout sizes and locations, substructure requirements, seam locations, possible inlay issues and specialty fabrication, such as a cove backsplash or thermoformed surface requirement.

Layout of HI-MACS® Fabrication

Layout of HI-MACS® Fabrication

• Place materials on the work benches. Inspect dye lots and run numbers.
• Remove peel coat and inspect for color variation, match and defects.
• Review cuts and dry fit seams when applicable before cutting! Remember that this is a review and inspection process.
  Wet the edges between sheets to be seamed to help determine color match.
• Review all safety and shop procedures before cutting and machining the HI-MACS® sheet materials.

Cutting and Staging

Cutout Optimizing

Before cutting the sheets you have ordered and received from your HI-MACS® distributor, calculate the number, lengths, widths and elevation to double check the amount of material you will need to finish the entire project. If you calculate too closely, you may create yield problems and dye lot concerns if more material must be ordered. You must also remember to consider cutouts, backsplash materials and buildup strips. As you look at all of these factors consider the cutout sizes and locations, substructure requirements, seam locations, possible inlay issues and specialty fabrication, such as a cove backsplash or thermoformed surface requirement.

Cutting and Staging Overview

• Remember to avoid handling materials alone. Use two people to move the sheet into position for cutting.
• Cut the HI-MACS® sheet materials for your job specifications. If you are using a table saw, make sure it has out feed supports. If using a vertical panel saw, remember to watch for errant materials after cutting.
• Place cut materials on your workbench and create the 13mm inside corner with the appropriate router and template. Remember that a 13mm bit creates only a 6mm radius.
• Stage your components and assemblies on a flat, rigid plane surface.
  If using more than one bench to stage your project, make certain these benches are of the same height!
  Your supporting work tables should have supports every 610mm.
  This will ensure a flat and safe working area as you assemble your tops.
• Save any extra materials or out falls for buildup strips, cutting boards and repair materials.
  Remember to leave a good size piece of color matched material at the jobsite in case of repair.
  A good spot to place this is under the sink cabinet. Pre-drill two holes in the material at your shop.
  During installation, place a screw into the drilled holes and position the piece to the side wall of the cabinet.

Seam Locations and Cutout Positioning

• Keep seams 76-100mm from any inside or outside corners and 76-100mm from any cutout for stove, sink or other consideration of cutout.
• When having to layout and fabricate a countertop, remember to maintain the seam 76-100mm from the inside corners. Traditionally, solid seams are the hardest and leave the least amount for error. It is very important when seaming solids that you thoroughly clean the seams and prepare a precise mirror cut. Seaming with matrix colors, whether it be Sands, Pearls, Quartz or Granite series HI-MACS®, are more forgiving, by virtue of the many colors of particulate.
• Your best seam will typically be 2mm thick or less. Anything up to about 5mm is acceptable, but may be more visible depending on color used.
  Any seam greater than 5mm will be visible and produce a line the same color as the adhesive used.
  Since the adhesive is solid in color, it becomes very visible with colors containing particulate.

Using the Following Procedures Will Ensure a Great Seam

• Industry standards suggest that two acceptable methods will ensure a great seam.
• Mirror cut the two pieces to be seamed together and do so at the same time.
  This is performed by setting a straight edge in place on one of the pieces to be seamed and also clamping down the two pieces to be seamed. Maintain a gap approximately 6mm greater than the shank of the bit.
  It will take approximately 3mm off each of the pieces that will be seamed. A square base router will help the accuracy.
  With one controlled pass of the router, you will make these two “mirror” edges simultaneously. The two pieces will fit together exactly.
• You can also achieve extremely accurate cuts by using C.N.C., Vertical Panel Saws, or Auto “V” Groovers.
• If you scuff-sand the edges with a 90 degree block plane or right angle block and 60 grit sand paper, you will ensure a greater bonding surface than if you do not.
• Make sure to clean the joining edges with denatured alcohol and a clean white rag.
• Apply a strip of box tape or packing tape to the underside of the area to be joined, half on each side of the two pieces.
  This will create a bridge. Leave about 3mm between pieces before applying the tape.

Clamping Tips

• Remember clamping pressures. You do not want to use excessive pressure. If you do, you will create a dry seam. This is when you squeeze all the glue from the seam joint.
• Clamp pressures should be tight enough to allow a bead of adhesive to squeeze out.
• The adhesive will shrink slightly, so do not completely clean off the joint of excess adhesive.
• Look for glue voids and air pockets. Take care of this before the seam adhesive sets up.
• Inspect the seam to ensure a tight fit.
• Let the adhesive cure for a minimum of 40 minutes in normal conditions or until hard to your fingernail touch.
• Remove the excess adhesive by “Leveling” the seam with a router with a set of skis and a small leveling bit.
  Do not use a belt sander to perform this operation. Excessive heat will weaken the integrity or fail the seam all together.
• Finish sanding all surfaces to specified finish.

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Reinforcement Typical Standards

• Seam reinforcement materials should be comprised of 13mm HI-MACS® materials.
• The reinforcement must be continuous along the entire seam. This 3°± reinforcement strip must be beveled to 45 degrees and sanded smooth to reduce the stress riser.
• Avoid stress risers. A stress riser is a sharp or rough cut or corner that weakens over time as the top expands and contracts. This weakening effect will eventually fail the top and a crack in the countertop will occur.
• Locate reinforced seams where full support is available. Reinforcements can sometimes get in the way of the overall support structure.
• Keep the nearest edge of the seam support a minimum of 3°± from inside corners.