PaperStone™ Fabrication & Finish Instructions
PaperStone works much like hardwood and solid surface, and no specialized equipment is needed.
Tooling and Cutting Guidelines
· Always work in a well-ventilated area, using eye and ear protection, and wearing a dust mask.
· Use a triple-chip carbide blade.
· Cut paperstone Dry: increase cutting rate if you detect excess heat.
· Fully support the PaperStone slab at all times during the cutting process to eliminate the opportunity for the blade to bind due to a shift in weight.
· When shaping PaperStone with a router, use sharp carbide bits.
· Plan ahead to maintain cutting pace when cutting tight spots such as inside corners.
· We suggest a few practice runs on a piece of scrap material.
· Coarse shavings indicate proper cutting rate.
· PaperStone should be secured using mechanical fasteners and silicone.
· Wood screws provide tremendous fastening strength.
o Pilot holes must be drilled that are slightly larger than the shaft of the screw and just smaller than the threads of the screw.
o Insert screws slowly to ensure that they don't snap or overheat. Screw heads may become hot immediately after insertion. Exercise caution when touching them.
· PaperStone can also be tapped to accommodate threaded fasteners or threaded inserts.
o Fasteners may be press-fit or cast in place with an epoxy compound.
Preparation for Seaming
· Please note color and sheet thickness may vary from sheet to sheet.
· It is very important to have the top even due to the fact that PaperStone is bonded layers of paper. Similar to over sanding a wood veneer, excessive sanding in one area of a PaperStone piece can leave a ghost like line if fabricator sands into or through the top layer or paper.
· PaperStone seams will be visible and should be considered in the design process. Plan seams away from sink cutouts and cook top cutouts.
· On a sturdy, level surface, set out spacer bars of uniform thickness and place the PaperStone sections on them. Leave a gap between the two sections slightly smaller than the width of a straight-edge router bit.
· Secure a straight edge to the section and use the straight edge as a fence to run the router through the gap so that the bit shaves a thin section of both edges at once. This procedure is known as the mirror cut/joint. This will create edges that match perfectly.
· Prepare for the mechanical strengthening and aligning of the joint with either:
o Biscuits: Using a biscuit joiner, cut slots for standard wood biscuits or Lamello 250 x K20 plastic biscuits, or;
o Draw Bolt Fasteners: Rout holes appropriate for the type of Draw Bolt fasteners being used (Kv Tite-Joint or similar, typically used to connect sections of post form laminate counters.)
· Glue the joint using a slow drying two part epoxy. CA5 adhesive may also be used. Advanced craftspeople sometimes tint the epoxy by mixing in some of the sanding dust from a previous step. Once the joint has cured, lightly sand it to blend the seam with the surrounding area.
· It is possible to seal joints with standard caulking sealants.
o Typical areas for this treatment are the underside of the backsplash and around under-mounted sinks.
o Use a moderate amount of caulk in a color compatible to the PaperStone panel.
o Clear caulk may also be used.
· We also recommend placing screws at a maximum width of 12” to secure the two pieces along with one of the afore-mentioned adhesives.
· When doing a built up edge, we suggest double stacking the material rather than making V groove, drop-down edge. The material must be glued and screwed
Edge Build Up
· Edge Build up is not recommended by manufacture. It will void the warranty. If you are building up an edge, use a combination of Epoxy at seam and Screws to fasten for support underneath. Support with screws every 12”. Pilot holes must be drilled that are slightly larger than shaft and smaller than thread.
· PaperStone comes with a natural finish on both surfaces.
· Slight scratches that are easily removed with light sanding may result from shipping and handling.
· PaperStone is a natural product. Unlike other solid surfaces that have been machined to very high tolerances, may have a surface quality with slight imperfections such as low and high areas. With this in mind, it is recommended that sanding be kept to a minimum. LESS IS MORE!
· If machining marks exist on cut edges, a belt sander with 80 grit sand paper may be used as a first step, finishing with 180 grit sandpaper.
· If a satin sheen is desired, surface sanding should begin with an abrasive no coarser than a fiber abrasive pad such as 3M Scotch Brite red or grey (red = fine / grey = superfine). Place the abrasive pad on the surface and place the random orbit sander pad at the center. Wipe thoroughly with a damp cloth.
· Before sealing process, be very sure to wipe down entire PaperStone surface to remove all sanding dust.
· A final treatment of PaperStone Sealer is recommended. It is an all-natural eco-friendly and sustainable finish. To use PaperStone Sealer, place the bottle under a stream of warm water to make the fluid mix and flow more easily. Apply a thin coat to the surface with a clean soft cloth. Let finish stand for a minimum of 20 minutes and wipe off any excess finish. Surface may then be buffed by hand or a car polishing bonnet to achieve a deep satin luster. Use lots of elbow grease to make sure that wax finish is not too thick. Finish up using a clean, soft cloth to give an even, rich luster. For best results, do not use finished area for at least 12 hours so that the finish can harden.
· PaperStone Sealer is made entirely from natural waxes (bee and carnauba) and vegetable products (soybean oil). All of the ingredients are natural and food safe.
· PaperStone Sealer is recommended for all food service related applications. PaperStone Sealer will help to preserve UV protection for exterior applications.
· PaperStone Sealer is an all-natural preserver that rejuvenates and protects your composites, also ideal for all natural wood grains and contains only food-safe ingredients. It is made in the USA.
· A twelve ounce bottle of PaperStone Sealer will cover approximately 120 to 150 square feet.