Installation Guide

CORIAN
®
SOLID SURFACE
FABRICATION/INSTALLATION FUNDAMENTALS
NA/ENGLISH
Corian® Solid Surface Fabrication/Installation Fundamentals 3/6
4. General Care of Corian
®
Solid Surface
• Do not flex sheets when lifting or carrying Corian® sheet.
• If Corian® products are exposed to extreme temperatures, then they
must be allowed to reach room temperature, approximately 65–
70°F (18–20°C), before commencing work with the materials.
5. Preparing Job Site for Installation
• Survey site and determine best working options.
• Any alteration work may best be done away from the actual
installation site.
• e cutting and sanding of Corian® products creates dust that
should be contained as much as feasible.
• All sanders should allow for extraction into a vacuum system.
• Use polyethylene sheeting and drop cloths to protect all areas where
appropriate.
• Use a fan to exhaust dust and fumes to outside. Turn off HVAC
system or cover vents and cover any unnecessary light fixtures.
6. Preparing Structural Support/Base Units/Cabinets
• When replacing old tops, care must be taken in removing them. All
screws, nails and any sharp edges should be removed from the tops
and be disposed of in a safe manner.
• e existing support structure should be checked for strength and
stability. If any remedial work is required to bring them up to
standard, it should be carried out at this stage.
• All electrical, gas and water appliances should be disconnected/
connected by licensed and qualified persons when applicable.
• When installing new structural support/base units/cabinets, etc.,
prepare as follows:
• ey should be leveled and plumbed, fixed to each other and then
secured to the back wall. e tops of all the cabinets must be within
1
/8" (3 mm) of a flat surface over a 10' (3 m) run and must be flush
with each other.
• Corner base units may require wood strips fastened against the back
wall to support the Corian® top. Some corner cabinets with revolving
shelves require additional support in front. See Corian® Solid Surface
Fabrication/Installation Fundamentals – Structural Support (K-25291).
• All cutouts must have 1" x 4" (25 mm x 102 mm) front-to- back
support no closer than 1" (25 mm) and no further than 3" (76 mm) from
each side of the cutout. Be sure to use the High Strength Corner Block
method for all cook top and heat generating appliance cutouts. More
detail on High Strength cutouts can be found in Corian® Solid Surface
Fabrication/ Installation Fundamentals – Cutting and Cutouts (K-25289).
• Check the position for any dishwashers. Be sure there is support for
the top front and back across the opening. Supports must pass the
Span Test Corian® Solid Surface Fabrication/Installation Fundamentals
– Structural Support (K-25291).
• Notch out support strips to allow for seam reinforcement strip as
necessary.
• With base units that have solid tops (dust covers), the central
portion should be removed, leaving a perimeter of approximately
2"–3" (51–76 mm). is will allow heat to dissipate but not weaken
the base unit construction. is is strongly recommended. It is
acceptable if the client will not agree to the removal.
Figure C-1
• If Corian® sheet overhangs any structure without support see
Corian® Fabrication/Installation Fundamentals – Structural
Support (K-25291) for overhang allowances.
• Determine on the support structure/base/cabinet units where the
field seams are to be made in the countertops. Protect the inside of
cabinets from joint adhesive that may drip inside during seaming.
• If countertop perimeter support is not built into the countertop, it
must be installed now. See Corian® Solid Surface Fabrication/
Installation Fundamentals – Structural Support (K-25291) for details.
If the perimeter support is built into the countertop, shim between
support strips and cabinets as needed. en fasten strips to cabinets.
If the support structure does not provide proper support for the top, then
support strips must provide all the necessary support. If there is any doubt,
perform the Span Test as outlined in the Corian® Solid Surface Fabrication/
Installation Fundamentals – Structural Support (K-25291).
7. Preparing horizontal tops and seams
e Corian® Solid Surface top can now be trial-fitted onto the prepared
structural support. All parts may not fit, as some fabricators purposely
oversize the tops for on-site adjustment. Space should always be allowed,
as Corian® products need room to expand. Each top requires at least
1
/16"
(1.5 mm) at each wall, i.e. left, right and back wall. However, do not
leave gaps larger than necessary. Larger gaps are unsightly and very
difficult to fill with silicone or hide with backsplashes.
8. Scribing (tops without coved backsplashes)
Before preparing seams in the top, check to see if any scribing to the back
or side walls is required. To scribe the top, follow the instructions below.
Steps to completion:
1. Mark the back edge of the Corian® Solid Surface top to the wall
using the pattern template made on the job.
2. To remove excess material, an electric plane, a router with a straight
cutter or a belt sander can be used, whichever is preferable.