OSUT_1_06_61_16_Solid_Polymer_Fabrication.pdf

OUST-AR RANGE PROJECTS FY19

SECTION 06 61 16

SOLID POLYMER (SOLID SURFACING) FABRICATIONS

08/09

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

ASTM INTERNATIONAL (ASTM)

ASTM D 2583 (2007) Indentation Hardness of Rigid Plastics by Means of a Barcol Impressor

ASTM D 570 (1998; R 2005) Standard Test Method for Water Absorption of Plastics

ASTM D 638 (2008) Standard Test Method for Tensile Properties of Plastics

ASTM D 696 (2008) Standard Test Method for Coefficient of Linear Thermal Expansion of Plastics Between -30 degrees C and 30 degrees C With a Vitreous Silica Dilatometer

ASTM E 84 (2009c) Standard Test Method for Surface Burning Characteristics of Building Materials

ASTM G 21 (1996; R 2002) Determining Resistance of Synthetic Polymeric Materials to Fungi

INTERNATIONAL ASSOCIATION OF PLUMBING AND MECHANICAL OFFICIALS

(IAPMO)

IAPMO Z124.3 (2005) Plastic Lavatories

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA LD 3 (2005) Standard for High-Pressure Decorative Laminates

NSF INTERNATIONAL (NSF)

NSF 51 (2009e) Food Equipment Materials

TILE COUNCIL OF AMERICA (TCA)

TCA Hdbk (2007) Handbook for Ceramic Tile Installation

1.2 SYSTEM DESCRIPTION

a. Work under this section includes countertops and other items utilizing solid polymer (solid surfacing) fabrication as shown on the drawings and as described in this specification. Do not change source of supply for materials after work has started, if the appearance of finished work would be affected.

b. In most instances, installation of solid polymer fabricated components and assemblies will require strong, correctly located structural support provided by other trades. To provide a stable, sound, secure installation, close coordination is required between the solid polymer fabricator/installer and other trades to ensure that necessary structural wall support, cabinet counter top structural support, proper clearances, and other supporting components are provided for the installation of wall panels, countertops, shelving, and all other solid polymer fabrications to the degree and extent recommended by the solid polymer manufacturer.

c. Appropriate staging areas for solid polymer fabrications. Allow variation in component size and location of openings of plus or minus 1/8 inch.

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Detail Drawings; G Installation; G

Detail Drawings indicating locations, dimensions, component sizes, fabrication and joint details, attachment provisions, installation details, and coordination requirements with adjacent work.

SD-03 Product Data

Solid polymer material Qualifications Fabrications

Product data indicating product description, fabrication information, and compliance with specified performance requirements for solid polymer, joint adhesive, sealants, and heat reflective tape. Both the manufacturer of materials and the fabricator shall submit a detailed description of operations and processes in place that support efficient use of natural resources, energy efficiency, emissions of ozone depleting chemicals, management of water and operational waste, indoor environmental quality, and other production techniques supporting sustainable design and products.

SD-04 Samples

Material; G

A minimum 4 by 4 inch sample of each color and pattern for approval. Samples shall indicate full range of color and pattern variation. Approved samples shall be retained as a standard for this work.

; G

A minimum 1 foot wide by 6 inch deep, full size sample for each type of counter top shown on the project drawings. The sample shall include the edge profile and backsplash as detailed on the project drawings. Solid polymer material shall be of a pattern and color as indicated on the drawings. Sample shall include at least one seam. Approved sample shall be retained as standard for this work.

SD-06 Test Reports

Solid polymer material

Test report results from an independent testing laboratory attesting that the submitted solid polymer material meets or exceeds each of the specified performance requirements.

SD-07 Certificates

Fabrications Qualifications

Solid polymer manufacturer's certification attesting to fabricator qualification approval.

SD-10 Operation and Maintenance Data

Clean-up

A minimum of six copies of maintenance data indicating manufacturer's care, repair and cleaning instructions.

Maintenance video shall be provided,if available. Maintenance kit for matte finishes shall be submitted.

1.4 QUALITY ASSURANCE

1.4.1 Qualifications

To ensure warranty coverage, solid polymer fabricators shall be certified to fabricate by the solid polymer material manufacturer being utilized.

Mark all fabrications with the fabricator's certification label affixed in an inconspicuous location. Fabricators shall have a minimum of 5 years of experience working with solid polymer materials.

1.4.2 Mock-ups

Submit Detail Drawings as specified in the Submittals paragraph, under SD-02. Prior to final approval of shop drawings, provide a full-size mock-up of a typical countertop where multiple units are required. The mock-up shall include all solid polymer components required to provide a completed unit. The mock-up shall utilize finishes in patterns and colors indicated on the drawings. Should the mock-up not be approved, re-work or remake it until approval is secured. Remove rejected units from the jobsite. Approved mock-up may remain as part of the finished work.

1.5 DELIVERY, STORAGE, AND HANDLING

Do not deliver materials to project site until areas are ready for installation. Deliver components and materials to the site undamaged, in containers clearly marked and labeled with manufacturer's name. Materials shall be stored indoors and adequate precautions taken to prevent damage to finished surfaces. Provide protective coverings to prevent physical damage or staining following installation, for duration of project.

1.6 WARRANTY

Provide manufacturer's warranty of ten years against defects in materials, excluding damages caused by physical or chemical abuse or excessive heat.

Warranty shall provide for material and labor for replacement or repair of defective material for a period of ten years after component installation.

PART 2 PRODUCTS

2.1 MATERIAL

Provide solid polymer material that is a homogeneous filled solid polymer;

not coated, laminated or of a composite construction; meeting IAPMO Z124.3 and IAPMO Z124.6 requirements. Material shall have minimum physical and performance properties specified. Superficial damage to a depth of 0.01 inch shall be repairable by sanding or polishing. Material thickness shall be as indicated on the drawings. In no case shall material be less than 1/4 inch in thickness.

2.1.1 Cast, 100 Percent Acrylic Polymer Solid Surfacing Material

Cast, 100 percent acrylic solid polymer material shall be composed of acrylic polymer, mineral fillers, and pigments and shall meet the following minimum performance requirements:

PROPERTY REQUIREMENT TEST PROCEDURE

(min. or max.)

Tensile Strength 5800 psi (min.) ASTM D 638

Hardness 55-Barcol ASTM D 2583 Impressor (min.)

Thermal Expansion .000023 in/in/F (max.) ASTM D 696

PROPERTY REQUIREMENT TEST PROCEDURE

(min. or Boiling water No Change NEMA LD 3-3.05 Surface Resistance

High Temperature No Change NEMA LD 3-3.06 Resistance

Impact Resistance NEMA LD 3-303 (Ball drop)

1/4" sheet 36", 1/2 lb ball, no failure

1/2" sheet 140", 1/2 lb ball, no failure

3/4" sheet 200", 1/2 lb ball, no failure

Mold & Mildew No growth ASTM G 21 Growth

Bacteria Growth No Growth ASTM G 21

Liquid Absorption (Weight in 24 hrs.) 0.1% max. ASTM D 570

Flammability ASTM E 84

Flame Spread 25 max.

Smoke Developed 30 max

Sanitation "Food Contact" approval NSF 51

2.1.2 Acrylic-modified Polymer Solid Surfacing Material

Cast, solid polymer material shall be composed of a formulation containing acrylic and polyester polymers, mineral fillers, and pigments. Acrylic polymer content shall be not less than 5 percent and not more than 10 percent in order to meet the following minimum performance requirements:

PROPERTY REQUIREMENT TEST PROCEDURE

(min. or max.)

Tensile Strength 4100 psi (min.) ASTM D 638

Hardness 50-Barcol ASTM D 2583 Impressor (min.)

Thermal Expansion .000023 in/in/F (max.) ASTM D 696

Boiling water No Change NEMA LD 3-3.05 Surface Resistance

PROPERTY REQUIREMENT TEST PROCEDURE

(min. or High Temperature No Change NEMA LD 3-3.06 Resistance

Impact Resistance NEMA LD 3-303 (Ball drop)

1/4" sheet 36", 1/2 lb ball, no failure

1/2" sheet 140", 1/2 lb ball, no failure

3/4" sheet 200", 1/2 lb ball, no failure

Mold & Mildew No growth ASTM G 21 Growth

Bacteria Growth No Growth ASTM G 21

Liquid Absorption (Weight in 24 hrs.) 0.6% max. ASTM D 570

Flammability ASTM E 84

Flame Spread 25 max.

Smoke Developed 100 max

Sanitation "Food Contact" approval NSF 51

2.1.3 Material Patterns and Colors

Patterns and colors for all solid polymer components and fabrications shall be those indicated on the project drawings. Pattern and color shall occur, and shall be consistent in appearance, throughout the entire depth (thickness) of the solid polymer material.

2.1.4 Surface Finish

Exposed finished surfaces and edges shall receive a uniform appearance.

Exposed surface finish shall be matte; gloss rating of 5-20 or as indicated on the drawings.

2.2 ACCESSORY PRODUCTS

Accessory products, as specified below, shall be manufactured by the solid polymer manufacturer or shall be products approved by the solid polymer manufacturer for use with the solid polymer materials being specified.

2.2.1 Seam Adhesive

Seam adhesive shall be a two-part adhesive kit to create permanent, inconspicuous, non-porous, hard seams and joints by chemical bond between solid polymer materials and components to create a monolithic appearance of the fabrication. Adhesive shall be approved by the solid polymer manufacturer. Adhesive shall be color-matched to the surfaces being bonded where solid-colored, solid polymer materials are being bonded together.

The seam adhesive shall be clear or color matched where particulate patterned, solid polymer materials are being bonded together.

2.2.2 Panel Adhesive

Panel adhesive shall be neoprene based panel adhesive meeting TCA Hdbk, Underwriter's Laboratories (UL) listed. Use this adhesive to bond solid polymer components to adjacent and underlying substrates.

2.2.3 Silicone Sealant

Sealant shall be a mildew-resistant, FDA and OSHA Nationally Recognized Testing Laboratory (NRTL) listed silicone sealant or caulk in a clear formulation. The silicone sealant shall be approved for use by the solid polymer manufacturer. Use sealant to seal all expansion joints between solid polymer components and all joints between solid polymer components and other adjacent surfaces such as walls, floors, ceiling, and fixtures.

2.2.4 Conductive Tape

Conductive tape shall be manufacturer's standard foil tape, 4 mils thick, applied around the edges of cut outs containing hot or cold appliances.

2.2.5 Insulating Felt Tape

Insulating tape shall be manufacturer's standard product for use with drop-in food wells used in commercial food service applications to insulate solid polymer surfaces from hot or cold appliances.

2.2.6 Heat Reflective Tape

Heat reflective tape as recommended by the solid polymer manufacturer for use with cutouts for heat sources.

2.2.7 Mounting Hardware

Provide mounting hardware, including equipment and fixture clips, inserts and fasteners for attachment of undermount and dropin type.

2.3 FABRICATIONS

Components shall be factory or shop fabricated to sizes and shapes indicated, to the greatest extent practical, in accordance with approved Shop Drawings and manufacturer's requirements. Provide factory cutouts for equipment and fixtures where indicated on the drawings. Contours and radii shall be routed to template, with edges smooth. Defective and inaccurate work will be rejected.

2.3.1 Joints and Seams

Form joints and seams between solid polymer components using manufacturer's approved seam adhesive. Joints shall be inconspicuous in appearance and without voids to create a monolithic appearance.

2.3.2 Edge Finishing

Rout and finish component edges to a smooth, uniform appearance and finish. Edge shapes and treatments, including any inserts, shall be as detailed on the drawings. Rout all cutouts, then sand all edges smooth.

Repair or reject defective or inaccurate work.

2.3.5 Window Stools

Fabricate window stools from 3/4 inch thick solid surfacing, solid polymer material. Dimensions, edge shape, and other details shall be as indicated on the drawings.

PART 3 EXECUTION

3.1 INSTALLATION

3.1.1 Components

Install all components and fabricated units plumb, level, and rigid. Make field joints between solid polymer components using solid polymer manufacturer's approved seam adhesives, to provide a monolithic appearance with joints inconspicuous in the finished work. Attach equipment and fixtures to counter tops using solid polymer manufacturer's recommended clear silicone sealant and mounting hardware. Solid polymer fixtures or equipment shall be installed using a color-matched seam adhesive.

3.1.2 Silicone Sealant

Use a clear, silicone sealant or caulk to seal all expansion joints between solid polymer components and all joints between solid polymer components and other adjacent surfaces such as walls, floors, ceiling, and fixtures.

Sealant bead shall be smooth and uniform in appearance and shall be the minimum size necessary to bridge any gaps between the solid surfacing material and the adjacent surface. Bead shall be continuous and run the entire length of the joint being sealed.

3.1.3 Equipment and Fixtures

Make connections to adjacent items in accordance with related specifications Sections.

3.2 CLEAN-UP

Components shall be cleaned after installation and covered to protect against damage during completion of the remaining project items.

Components damaged after installation by other trades will be repaired or replaced at the General Contractor's cost. Component supplier will provide a repair/replace cost estimate to the General Contractor who shall approve estimate before repairs are made. Submit maintenance data as specified in the Submittals paragraph, under SD-10.

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