06 61 16 Solid Polymer Fab.pdf

Annex Addition to B3010

SECTION 06 61 16 Page 1

SECTION 06 61 16

SOLID POLYMER (SOLID SURFACING) FABRICATIONS

PART 1 GENERAL

1.1 REFERENCES

See Scope of Work for additional information.

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 (2003) Standard Test Method for Tensile

Properties of Plastics

ASTM D 696 (2003) 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 (2008a) 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 (1995) Plastic Lavatories

IAPMO Z124.6 (1997) Plastic Sinks

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

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

Laminates

NSF INTERNATIONAL (NSF)

NSF 51 (2007) Food Equipment Materials

TILE COUNCIL OF AMERICA (TCA)

TCA Hdbk (2007) Handbook for Ceramic Tile Installation

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1.2 GENERAL DESCRIPTION

Work in this section includes 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. Variation in component size and location of openings to be plus or minus 3 mm( 1/8 inch).

1.3 SUBMITTALS

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

submittals not having a "G" designation are for Contractor Quality Control approval. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 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-02 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-03 Samples

Material; G

A minimum 50 by 50 mm( 2 by 2 inch) sample of each color and pattern for selection and approval. Samples shall indicate full range of color and pattern variation. Approved samples shall be retained as a standard for this work.

SD-04 Test Reports

Solid polymer material

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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-05 Certificates

Fabrications Qualifications

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

1.4 DELIVERY, STORAGE AND HANDLING

Materials shall not be delivered to project site until areas are ready for installation. Components and materials shall be delivered 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. Protective coverings shall be provided to prevent physical damage or staining following installation, for duration of project.

1.5 WARRANTY

Manufacturer's warranty of ten years against defects in materials, excluding damages caused by physical or chemical abuse or excessive heat, shall be provided. Warranty shall provide for material and labor for replacement or repair of defective material for a period of ten years after component installation.

1.6 QUALIFICATIONS

To insure warranty coverage, solid polymer fabricators shall be certified to fabricate by the solid polymer material manufacturer being utilized. All fabrications shall be marked 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.

PART 2 PRODUCTS

2.1 MATERIAL

Solid polymer material shall be 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 0.25 mm(

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 6 mm( 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:

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PROPERTY REQUIREMENT TEST PROCEDURE

(min. or max.)

Tensile Strength 422 kg/cm ASTM D 638

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

Thermal Expansion .0000386cm/cm/degC ASTM D 696

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)

6.4 mm sheet 910 mm, 227 g ball, no failure

12.7 mm sheet 3550 mm, 227 g ball, no failure

19 mm sheet 5070 mm, 227 m 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

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

Boiling water No Change NEMA LD 3-3.05 Surface Resistance

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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 288 kg/cm ASTM D 638

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

Thermal Expansion .0000386cm/cm/degC ASTM D 696

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)

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6.4 mm sheet 910 mm, 227 m ball, no failure

12.7 mm sheet 3550 mm, 227 m ball, no failure

19 mm sheet 507 mm, 227 m 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

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

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

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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, color schedule. 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 semigloss;

gloss rating of 25-50 polished; gloss rating of 55-80 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. This adhesive shall be used 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. Sealant shall be used to seal all expansion joints

SECTION 06 61 16 Page 8 between solid polymer components and all joints between solid polymer components and other adjacent surfaces such as walls, floors, ceiling, and plumbing fixtures.

2.2.4 Conductive Tape

Conductive tape shall be manufacturer's standard foil tape, 0.1 mm( 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 sink/bowl clips, inserts and fasteners for attachment of undermount sinks and lavatories.

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. Factory cutouts shall be provided for sinks, lavatories, and plumbing 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

Joints and seams shall be formed 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.

2.3.3 Counter and Vanity Top Splashes

Backsplashes and end splashes shall be fabricated from 13 mm( 1/2 inch) thick solid surfacing material and shall be 100 mm( 4 inches) high provided to dimensions and shapes as indicated on the drawings. Backsplashes and end splashes shall be provided for all counter tops and vanity tops at locations indicated on the drawings. Backsplashes shall be shop fabricated and be field attached.

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2.3.3.1 Permanently Attached Backsplash

Permanently attached backsplashes shall be attached straight with seam adhesive to form a 90 degree transition attached with seam adhesive and to form a radiused coved transition from countertop to backsplash.

2.3.3.2 End Splashes

End splashes shall be provided loose for installation at the jobsite after horizontal surfaces to which they are to be attached have been installed.

2.3.4 Window Stools

Window stools shall be fabricated from 13 mm (1/2 inch) thick solid surfacing, solid polymer material. Dimensions, edge shape, and other details shall be as indicated on the drawings and selected from manufacturer's available pre-fabricated standards.

2.3.5 Counter and Vanity Tops

All solid surfacing, solid polymer counter top and vanity top components shall be fabricated from 13 mm (1/2 inch)thick material. Edge details, dimensions, locations, and quantities shall be as indicated on the Drawings.

Counter tops shall be complete with 100 mm( 4 inch) loose attached, 90 degree transition and loose endsplashes at all locations where indicated on the drawings. Attach 50 mm (2 inch) wide reinforcing strip of polymer material under each horizontal counter top seam.

2.3.5.1 Vanity Tops With Bowls

A. One-Piece Vanity Top and Bowl

One-piece vanity top and bowl fabrications shall be a standard pre-fabricated product provided by the solid polymer manufacturer. Each unit shall include a vanity top with integral backsplash and sink bowl.

PART 3 EXECUTION

3.1 COORDINATION

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 insure 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.

Contractor shall appropriate staging areas for solid polymer fabrications.

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3.2 INSTALLATION

3.2.1 Components

All components and fabricated units shall be installed plumb, level, and rigid. Field joints between solid polymer components to provide a monolithic appearance shall be made using solid polymer manufacturer's approved seam adhesives, with joints inconspicuous in the finished work.

Metal or vitreous china sinks and lavatory bowls shall be attached to counter tops using solid polymer manufacturer's recommended clear silicone sealant and mounting hardware. Solid polymer sinks and bowls shall be installed using a color-matched seam adhesive. Plumbing connections to sinks and lavatories shall be made in accordance with Section 22 00 00

PLUMBING, GENERAL PURPOSE

3.2.2 Silicone Sealant

A clear, silicone sealant or caulk shall be used 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 plumbing 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.

3.2.3 Plumbing

Plumbing connections to sinks and lavatories shall be made in accordance with PLUMBING (spec section), GENERAL PURPOSE and plumbing codes.

3.3 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. The Contractor shall submit maintenance data as specified in the Submittals paragraph, under SD-10.

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