NEW LEAFâ&#x201E;¢ PERFORMANCE VENEERS FABRICATION & INSTALLATION GUIDELINES
FABRICATION MANUAL New Leaf ™ Performance Veneers have improved on nature, by taking the beauty, depth and dimension of natural wood grain and elevating it to a level of consistency and performance unimaginable with traditional veneers. The result is a beautifully predictable veneered surface that eliminates the old problems of traditional veneer and sets a new standard for enduring natural style. New Leaf is a distinctive engineered veneer material composed of color-through backer topped with the decorative veneer surface. The surface has been pre-stained and prefinished with our patent-pending, UV-cured polyurethane topcoat. Finished sheets are trimmed, and the backs are sanded to facilitate bonding. New Leaf is delivered as a pre-stained, pre-finished, backed veneer surface which is ready to install on any interior horizontal or vertical surface where one would use traditional veneer. The product information and fabrication techniques contained within the New Leaf Performance Veneer Fabrication Guide are provided to promote “best practice” when using the product. New Leaf Performance Veneer is composed primarily of wood fiber and installations should be engineered to accommodate these characteristics. Other fabrication/installation techniques that are not covered in this manual may be employed providing sufficient engineering considerations are used.
GENERAL SAFETY Safety is a critical concern for any shop and a key part of a successful business. The following safety rules should be incorporated into your safety program to help prevent an accident. Safety training, knowledge, product use, and environment are the responsibility of the facility owner and the shop employees. CAUTION: Always follow manufacturer’s product, equipment and/or tools recommendations and instructions carefully. • Read directions carefully before fabricating/installing New Leaf Performance Veneer. • Read and follow instruction manual before operating the different tools. • Keep all guards in place and in working order. • Insure all tools are properly grounded. Never remove the third prong. • Keep work area clean, uncluttered and well lit. • Don’t use electric power tools in a damp or wet work area. • Keep visitors at a safe distance from the work area. • Use the right tools. Don’t force a tool or attachment to do a job it was not designed to perform. • Always use safety glasses or approved eye protection and/or face shield, ear/noise protectors and safety shoes. • Wear the proper apparel, no loose clothing or jewelry. • Secure all work with the proper clamp or vise to a stable work surface. • Don’t overreach. Keep proper footing and balance at all times. • Maintain tools in top condition. Disconnect tools before servicing and when changing accessories such as blades, bits, cutters, etc. • Keep and use solvents, adhesives, and other materials in a safe, ventilated place. • Dust collection should be utilized when cutting, routing, and sanding. • Dust collection should be utilized when cutting, routing, and sanding. Tools should be used with dust collection at all times.
FABRICATION MANUAL ADHESIVE SAFETY A variety of different adhesive types can be used effectively with New Leaf Performance Veneer. These different “families” of adhesive require different types/levels of protection and/or precautions. ALWAYS refer to the specific Technical Data Sheet AND Material Safety Data Sheet for usage instructions and health/safety concerns, respectively. For information concerning Wilsonart® Adhesives, contact www.wilsonartadhesives.com or the Wilsonart Hotline at 1-800-433-3222.
FABRICATION WARNING: Drilling, sawing, sanding, or machining wood products generates wood dust, a substance known to the State of California to cause cancer. Avoid inhaling wood dust or use a dust mask or other safeguards for personal protection. [California Health and Safety Code Section 25249.6]
PRECONDITIONING In preparation for fabrication, it is always recommended to ensure proper acclimation between the New Leaf Performance Veneer and the substrate. Recommended and optimum temperature is approximately °75 F ( °24 C), and New Leaf and substrate should be conditioned at 45% to 55% relative humidity. For proper acclimation, all components including face and backing/balancing performance veneer, substrates, and adhesives should be acclimated for 48 hours before bonding and fabrication.
SUBSTRATES New Leaf Performance Veneer must be bonded to substrates of reliable quality. Industrial 45# density particleboard or medium density fiberboard (MDF) are recommended. High pressure laminate, plaster, concrete, gypsum boards or plywood should not be considered and are not warranted, suitable substrates. New Leaf Performance Veneer may not be used a structural member.
TOOLING • • • •
Panel Saws • Trim Routers • J-Rollers • Jig Saws •
Table Saws Fine Ribbed Files Shears CNC
POSTFORMING New Leaf Performance Veneer is recommended for flat surfaces only. Do not use in postforming equipment or applications.
FABRICATION Fabrication should follow approved methods. Assembled pieces should meet the specifications of KCMA (Kitchen Cabinetmakers Manufactures Association), ANSI A-161.2-1998 (revised), and “Architectural Woodwork Quality Standards, Guide Specifications and Quality Certification Program” guidelines of the Architectural Woodwork Institute where applicable. FAB Tips: Keep all New Leaf Performance Veneer seams and edges clean. Remove dirt, pencil, marker, finger prints, New Leaf Performance Veneer identification ink, etc… prior to adhering material.
FABRICATION MANUAL ROUTING Standard trim routers with basic double fluted down spiral cutters and bottom bearing guides are recommended trimming New Leaf. For best results, always keep bits clean and sharp at all times. High tool speed and low feed rates are advisable. Various other types of carbide tip bits are also recommended such as slight round-over or no file bits to finish the edge to minimize filing. Light finishing of the New Leaf Performance Veneer edge can be achieved with a fine-ribbed file and/or sanding block with a finishing sandpaper. FAB Tips: Keep all tooling sharp and clean. (2 – Flute Carbide Spiral – Down bit is recommended)
PANEL/TABLE SAWS For saws, such as table or panel saws use sharp, carbide tipped blades with 60 or more triple-chip design teeth and with low to 5° negative hook angle. It is essential that the face of the New Leaf face upward while cutting. Use a hold-down to prevent any vibration. When cutting double sided panels, the use of a scoring blade will help in minimizing chipping. FAB Tips: New Leaf Performance Veneer surface comes as a finished product. It is not intended to be stained or refinished.
CUT-OUTS/DRILLING To avoid stress cracking, do not use square-cut inside corners. All corners should have a minimum of ¼” (6.35mm) radius and all edges should be routed smooth. Drill oversized holes for screws or bolts. Screws or bolts should be slightly countersunk into the face side of the New Leaf Performance Veneer substrate. All edges and corners should be sanded or filed smooth and free of chips or nicks. FAB Tips: A ½” diameter 2-flute carbide flush-trim bit provides a 1/4” inside corner radius.
ADHESIVE New Leaf Performance Veneer must be bonded to a substrate of reliable quality, such as particleboard, medium density fiberboard or plywood with one A-face. High Pressure Laminate, plaster, concrete and gypsum board should not be considered suitable substrates. New Leaf Performance Veneer may not be used as structural members. Wilsonart® Adhesives are recommended for most bonding conditions. PVA (polyvinyl acetate) adhesives are preferred due to their rigid bond, but contact adhesives are also acceptable. Follow the techniques recommended by the adhesive manufacturer.
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