Fabrication & Installation

Design trains and certifies fabricators and installers who are provided detailed information regarding proper procedures; the following is a general overview, not a comprehensive guide to proper use.
To minimize material usage and facilitate installation, a corner block of Solid Surface should be made square (butt) rather than mitered. The edges to be joined should be straight, smooth and clean. Some seams need to be reinforced (see fabrication manual for details). Joints should only be made with Joint Adhesive. Cutouts should be made with a router equipped with a sharp carbide bit, with a minimum diameter of 3/8” (10 mm). All corners of a cutout must be rounded to 5mm radius and the edges smoothed, both on top and bottom, all around a cutout. “L” and “U” Shaped corners need smooth, 3/16” (5mm) radius inside corners. For hob cutouts, corners should be reinforced with a corner block. See fabrication manual for more details.
Some Solid Surface colors that feature random veins and irregular patterns require special considerations regarding the seams. Please refer to the related technical bulletin for best practices in fabrication of these colors.
Sealants and adhesives
Solid Surface is compatible with many commercially available caulks and sealants. 100% silicone products are recommended. Vertical panels of may be installed over suitable substrates, including water-resistant gypsum board, marine-grade plywood and ceramic tiles. In case a support is needed, apply perimeter frame or full support direct to using large beads of flexible adhesive leaving a space with a minimum thickness of 1/16” (1.5mm) For making seams in countertops, repairs and custom edges, color-coordinated Joint Adhesive should be used. When used in accordance with manufacturer’s instructions, it provides a smooth and inconspicuous joint. Joint Adhesive is available from Design or its distributors.
The minimum expansion clearance in inches for Solid Surface is 2.2 x 10-5 in./in. oF x (length of the piece of Solid Surface in inches) x (biggest temperature range expected in oF) In mm the minimum expansion clearance is 3.9 x 10-5 mm/mm oC x( length of the piece of Solid Surface in mm ) x (biggest temperature range expected in oC). Joints to be caulked should be a minimum of 1/16” (1.5mm) wide to allow satisfactory sealant penetration and expansion.
Products dimensions are nominal. If tolerances are critical, review your needs with a specialist.

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