Solid Surface Manual

8/17/2019 Solid Surface Manual

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ICPA-SS Quality Manual

SOLID SURFACE

QUALITY MANUAL


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ICPA SOLID SURFACE QUALITY MANUAL

TABLE OF CONTENTS

Topic Page#

i. Credits & Acknowledgements iii

I. IntroductionA. Purpose of Manual 1B. Commitment & Implementation 2C. Calibration Program 2

D. Product Testing & Certification 3

II. Raw Materials

A. Resin

1. Specifications & Certification 42. Batch Testing 43. Resin Material Specification Sheet 54. Work Instruction - Resin Inspection 65. Resin Incoming Inspection Test Report 7

B. Fillers & Granules1. Specifications & Certification 82. Alumina Tri-hydrate (ATH) 83. Color Granules 94. Batch Testing 10

5. Filler Material Specification Sheet 116. Work Instruction - Filler Inspection 127. Filler Receiving Inspection Log 13

C. Pigments1. Specifications & Certification 142. Batch Testing 143. Pigment Material Specification Sheet 154. Work Instruction - Pigment Draw Down Test 165. Pigment Receiving Inspection Log 17

D. Catalyst1. Specifications & Certification 18

2. Batch Testing 183. Catalyst Material Specification Sheet 19

4. Work Instruction - Inspection Instructions 205. Catalyst Receiving Inspection Log 21

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Topic Page#

III. Mixing & CastingA. Recipe 22

B. Mixing 23

C. Pouring 25D. Sample Plaque 25

E. Clean-up 25

F. Batch Record 26

IV. Demolding Procedures 27A. Open Mold

B. Closed Mold

C. Mold MaintenanceD. Mold Tracking

E. Mold Maintenance Tracking Log 28

V. Post-Curing 29

A. Importance

B. Temperature & Time

C. Oven ConsistencyD. Record of Completion 30

E. Batch Test Log 31

VI. Tracking Scrap & Customer Returns

A. Importance 32B. Weekly Scrap Log 33

VII. Finishing

A. Finish Classification & Quality Standards 34

B. Finishing Standards 35 - 38

VIIL. Glossary Glossary 1 - 16

IX. Appendix

A. Plant Audit Form Audit 1 – 10

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ICPA SOLID SURFACE QUALITY MANUAL

Credits & Acknowledgements

Company Name

AOC Resins Mark Campbell

Bill Jeffries

Avonite Frank ScottBP Amoco Research Center Bob Borja

Bradley Corporation Steve Case

Irwin FrankKlaus Fromme

Tom Pelt

Bob PiekarskiAnn Severin

CCP Brent BakerCentury Cast Bob Anderson

Custom Quality Marble Wes BenedictDale Malone

ICPA Pat Toner

Interplastic Siam LimTerry McCabe

Lou Ross

NAHB Research Center Chuck Arnold Norac Dennis Fink

Ross Weber

Huber Engineered Materials Jeff NalleyR&D Marble Inc. Dal KellerReichhold Inc. Paris Chen

Ken Lipovsky

R.J.Marshall Co. Dan MahlmeisterJack Simmons

Roma Marble Jim Steigmeyer

SAFAS Corporation Bern BrodyWillson Consulting Bill Willson

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PURPOSE OF THIS MANUAL

The purpose of this manual is to provide ICPA members with a working document to

assist in evaluating, implementing, managing and maintaining an ongoing program to

identify and achieve the minimum standards for producing quality certifiable solid

surface products by a vacuum casting process.

This manual is written from the perspective that within certain specific procedures and

parameters quality product can be manufactured consistently. It contains information

and forms required to accomplish and support this goal. This manual is also available in

electronic format so that the forms can be modified or adapted to suit one’s business.

The procedures and forms included in this manual will assist owners and supervisors to

evaluate, record, track and verify critical aspects of the manufacturing process. The

expectation is that in most instances the raw materials are within specification. Yet due

to improper or inaccurate processes, or conditions outside the normal range of application

(i.e. ambient temperature, humidity, etc.), significant problems arise, thus preventing the

manufacturing of quality products.

In terms of “Return on Investment” this manual will more than pay for itself in a short

period of time. When programs such as these are implemented some companies have

seen their scrap rate drop from above 10% to under 5%. A significant drop in warranty

claims should also occur over time.

It is in both the individual’s and the industry’s best interest to see that high quality

products are being manufactured by everyone. A company putting out inferior product

hurts not only the member but also the industry. The cost of “inferior” products can bevery high for the industry.

This manual contains the information to start or improve an in-house QC program. It

has been designed for off the shelf use by both the busy small business owner and larger

corporations. The manual helps to lay the groundwork for a Minimum Quality Control

System. The QC forms developed here should serve as the foundation for QC records as

part of an in-house program for members of the ICPA. Please use it as a management

tool provided by the ICPA for the betterment of the industry.

To quote from one of the “fathers” of the industry, Robert Brill, “The cast polymer process is a chemical manufacturing process; you must control it or it will control you”.

To control the process one needs to understand the critical components. The

manufacturing process is a ‘set’ of interlocking processes, which are ‘dependent’ one

upon the other for the ultimate success of producing a high quality solid surface product.

Feedback and insight is welcome on ways to improve this manual and help benefit

the industry.Page 1


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QUALITY COMMITMENT

To ensure the success of any quality program it is imperative that management is

committed to the program. The long-term success of any company depends on the

quality of product that it produces. Testing and certifying your solid surface material provides assurances to your customers of your material’s quality. Once a company

develops a reputation for an inferior product, it is hard to acquire either repeat or new

business. Yet, there is a business need to attain and maintain the desired quality at a

minimum cost. An effective quality assurance program helps to eliminate waste, cut

costs, and improve consistency in your shop. The fulfillment of this quality aspect is

related to the planned and efficient utilization of the technology, human and material

resources available to each company. This commitment must continue even as business

grows and schedules get tight. One must continue to remember that the consumer will

often use this product daily for many years and is depending on the manufacturer to

ensure quality. Management must constantly emphasize the need for high quality to all

employees by insisting that proper procedures be followed to achieve proper product

performance.

Calibration Program

For any quality program to be successful, one must first have a calibration program in

place for all their instruments. Measurements are only as good as the equipment that isused to take the readings. Scales, digital thermometers, pyrometers, viscometers,

spectrophotometers, etc need to be checked on a regular schedule. Stickers need to be

placed on each piece of equipment displaying the calibration date, due date and the

initials of the person performing the calibration. A calibration logbook could also be

used along with the stickers. Trained personnel can often perform this calibration in

house or calibration services can be contracted. Standards used for calibration should be

traceable to the NIST (National Institute of Standards and Technology). Procedures for

calibration can usually be found in the owner’s manual. Both lab and production

equipment need this service. Resin and/or filler have a way of migrating to locations

where they don’t belong. Having a calibration program in place is so important that it islisted first in this manual. The success of implementing the remaining sections of this

manual depends upon having a calibration program in place.

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PRODUCT TESTING & CERTIFICATION

Solid Surface material is known in the industry as a quality material, which due to its

inherent properties should last a lifetime. In order to ensure a quality material, it needs to

be tested periodically to verify that its properties are being maintained. This is especiallyimportant when changing to new raw materials or changing processes. Changing resins

or fillers can have a drastic effect on the final product. To ensure that field problems are

kept to a minimum, product testing is required prior to implementing changes. Having

consistent processes and materials is the key to ensuring quality parts. Periodic product

testing helps ensure that unknown changes have not taken place.

Product testing can often be done in house without sophisticated lab equipment. Test

fixtures can be developed to compare the material strength and impact resistance of two

different materials. Stain testing is also a relatively simple test. Doing comparison

testing in house can at least determine if the new raw material or process has a good

likelihood of improving the quality of the end product. Field-testing in a high usage area

also can reveal possible shortcomings of a product.

Alternative sources for comparison testing are local universities. Often they have the lab

equipment to perform more in depth testing. Testing should be performed to the

ANSI/ICPA SS-1-2001 standards. Records of this testing should be maintained in case

of field problems or to demonstrate consistent product quality to your customer.

Having independent testing certification adds credibility when selling your product.

A number of product approval agencies are available. These agencies can offer testing

and certification labels that can be placed on every product providing the consumer withthe assurance of a quality product. These certification programs require periodic auditing

of the procedures, as well as periodic testing performed on randomly selected products.

A list of these certifying agencies can be obtained from the ICPA. These agencies can

also perform testing to assist one in qualifying new raw materials.

Since solid surface material is use in the construction and plumbing industry, one also

needs to be aware of national, state, and local codes. These codes will vary depending on

the application and whether the product is installed in a residential or commercial

building. It is important to contact the local building inspectors in the region(s) where

you plan to install your product. They can help you understand the proper certificationrequired, if any, for your product.

Remember that solid surface is a quality material and should be tested periodically to

ensure this quality. The excellent reputation of this material will only continue if each

manufacturer does their part to ensure they are producing a quality product.

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RAW MATERIALS - RESIN

1. Specifications & Certification: The importance of identifying the proper

requirements expected in the resin cannot be over emphasized. The performance andquality of the final product is highly dependent on the properties of the resin that is

used. A Resin Material Specification Sheet should be developed including the critical

requirements of the resin as well as any special requirements. A sample of this

document can be found on page 5. This specification sheet should be discussed with

the vendor to ensure compliance. When material is received, the Certificate of

Analysis should be reviewed and matched with the containers (drums, totes, tank)

received. Lot numbers should be recorded on the inspection log and MSDS sheets

filed in a place accessible to all employees. If there is more than one batch number

involved – the batches must be grouped and the drums numbered and used

accordingly.

2. Batch Testing: The following tests are recommended to be performed on a sample

from each batch of resin. These tests verify that the correct resin is received and will

help production determine the characteristics of the mixture, such as gel time. The

goal is to ensure that there are not unpleasant surprises in performance during

production when considerable dollars in material and labor are at risk.

1. Color & Appearance – visual test

2. Viscosity @ 25°C (77°F)

- Brookfield Viscometer

3. Gel Time – see procedure on Resin Receiving Inspection Form

- Neat gel time @ 25°C (77°F)

- Filled gel time @ production temperature and conditions.

4. Time to Peak Exotherm

5. Peak Exotherm Temperature

An example of work instructions for the above tests is on page 6. The results of the

above testing should be recorded in a log accessible to production. An example Resin

Test Report is on page 7. Significant variation in the results of the above tests should be

discussed with the vendor to determine whether the proper material was delivered.

Production should also be alerted of any variations that might affect them when mixing

the resin.

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RESIN MATERIAL SPECIFICATION SHEET

DATE CREATED MATERIAL PART NUMBER

________ ___________

MATERIAL DESCRIPTION:

POLYESTER CASTING RESIN:

PURCHASE U/M: ISSUE U/M:

LB LB

CONDITION AS PURCHASED:

Hardness: Liquid

Finish:

Preservative: Shelf life is 90 days. Storage temerature should not exceed 90 F

Other: Purchase by tank load (approx 40,000lb) or in 275 gal.totes = 2475 lb or in 55 gal drums

ANALYSIS: Certification sheet to be supplied with each load including viscosity, gel time,

peak exotherm, & time to exotherm

PHYSICAL PROPERTIES: ____ lb per gal (sp.gr.=1.05-1.09) Viscosity = ___ - ____cps @ 77F (25C)

Gel time @ 77F = ___ - ___ min. using ___% of catalyst ___________

Peak exotherm = ____ - ____F; Time to Exotherm = ___ - ___ minutes

TYPICAL USES: Solid surface sheet stock, bowls, etc.

EMERGENCY SUBSTITUTES: POLYESTER CASTING RESIN:

REMARKS: VENDOR -

ORIGINAL SPEC:

PREPARED BY:

DATE LETTER CHANGE RMN ENG

Clear, Color:

ICPA-Solid Surface Q/A Manual Page 5 7 / 1 / 0 2


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Work Instruction – Resin Inspection

Work Instruction Title

Incoming Inspection for Solid Surface ResinWI NumberRevision

Department:

Area: Solid Surface Date

1.0 Purpose: Determine if shipments of solid surface resin meet specifications. 2.0 Scope: All solid surface resin 3.0 Responsibilities: Solid surface laboratory personnel 4.0 Work Instruction Steps:

4.1 The following QC checks MUST be performed on the resin before acceptance, andan “Incoming Inspection (Resin) Test Report” filled out.

4.1.1 The following documents are required: 4.1.1.1 Certificate of analysis for the shipment 4.1.1.2 Purchase order for the shipment

4.1.2 If purchased by a tank truck, check Resin temperature, for compliance

with the P.O. specified delivery temperature.4.1.2.1 At the external thermometers at the side or top of the tank.4.1.2.2 On a sample removed from the bottom of tank truck. 4.1.2.3 Record results on the Test Report

4.1.3 Draw a sample from each batch of resin received.

Adjust sample temperature to 25°C (77° F ).

4.1.3.1 Measure viscosity (follow Viscometer instructions noting spindle

used and rpm) @ 25°C (77° F). Record results on Test Report

4.1.3.2 Perform a Neat Gel test, on a100 grams resin sample. Use the %

and type of catalyst specified by the resin vendor at 25°C (77°F).

Record the Gel Time, Peak Exotherm time and Peak Exotherm

Temperature on the Test Report.4.1.3.3 Visually inspect and record color on the Test Report.

4.2 If the resin complies with specifications or results on the Certificate of Analysis 4.2.1 For tanks follow Tank Filling Check List. Sign the receiving forms and

start pumping resin into tank.

4.2.2 Drums or totes should be stored in an environment recommended by thevendor.

4.3 If the resin fails ANY of the above tests or temperature requirements (for tank loads),retest. If the shipment fails any of the above tests a second time, contact the vendor.

5.0 Safety Information:5.1 MSDS: on file in lab, MSDS Manuals and Master Book.

5.2 Disposal: 5.2.1 Un-catalyzed – through a licensed waste hauler only! 5.2.2 Catalyzed – Non-Hazardous can be disposed of in a dumpster.

6.0 Associated Documents:6.1 Solid Surface Incoming Test Report

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Resin Incoming InspectionTest Report

PURPOSE: Test Date:……………..

To verify that manufacturer’s test results provided with shipment documentation agree with the

delivered product, and the specifications listed on the purchase order.

REFERENCES:

Work Instructions for Solid Surface Resin

MATERIAL: Vendor: ……………………………………………..

PO #……………....Mfg Lot #……………………..Material …………………………………

TEST EQUIPMENT:

Timer, 250 & 500ml ml disposable beakers; mercury bulb thermometer 500º F Range; Infrared(IR) thermometer; Viscometer; Temperature controlled environment. Clean 2 1/2 gallon plastic

bucket with cover (if sampling from a tank truck); glass stirring rods.

PROCEDURE:

Verify manufacturer’s test results against purchase order requirements or material specificationsheets.

If tank load, record temperature on the truck tank thermometer. Draw off sample into the plastic bucket. Immediately take temperature with IR thermometer & record temperatures.

Perform and record the following tests on each batch:

Viscosity: resin @ 25° C (77°F)

Neat Gel: 100 grams of resin @ 25° C (77°F) ___% of ____________ catalyst

TEST DATA:

Tank Sample Neat Gel

Temp Temp %

Shrink

Color Viscosity Time Peak Exo.

Temp

Peak Exo.

Time

Mfg (filled)Test Results:

Spec. Requirements:

REMARKS: __________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________

……………………………………Technicians Signature

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RAW MATERIALS - FILLERS

1. Specifications & Certification: The importance of identifying the proper requirements of allcomponents added to the solid surface mix cannot be over emphasized. The performance,

color and quality of the final product is highly dependent on the properties of the filler that is

used. Even a change in the type of ATH used in the filler mixture can affect color, strength,

and stain resistance of the product. Changing fillers can also affect the pouring process bychanging both the viscosity and gel time of the mix. Some fillers are more susceptible to

humidity absorption, which also affects processing. A Filler Material Specification Sheetshould be developed including the critical requirements of the filler as well as any special

requirements. A sample of this document can be found on page 11. This specification sheet

should be discussed with the vendor to ensure compliance. When material is received, each

batch needs to be tested, and the material stored in such a manner that the oldest material isused first. Fillers should be stored in a dry location and kept sealed to prevent moisture

absorption. Material from the same batch should be stored together in case any problems are

discovered. Lot numbers should be recorded on the inspection log. If there is more than one batch number involved – the batches must be grouped, numbered and used accordingly.

2. Alumina Tri-hydrate (ATH): Solid Surface grade ATH is the predominate filler used in thesolid surface matrix. Since there are many types of ATH, your vendor should be contacted to

select the proper material for your application. ATH is an inorganic chemical made in a

refinery. Bauxite is the mineral used as the raw material in the process. High purity whiteAluminas reduce color contribution and provide improved translucency and chip definition in

granites. Lower priced Bayer Alumina has a gray appearance and contributes to the

background color. It can require higher levels of pigmentation, is more opaque, and reduces

chip definition in granites.

Although manufactures can be successful using any number of these Aluminas, there are

several rules of thumb that should be considered in the selection of fillers for manufacturingSolid Surface. Characteristics such as particle size distribution, PH stability, color, surface

area, matrix viscosity, smoke and flame retardant and binder adhesion to the substrate all

contribute to the final properties of the finished material.

a) Particle Size - Wide varieties of particle sizes are utilized ranging from coarse to very fine(usually 40 to 6 microns), either as a single hydrate distribution that can be narrow or

wide, or with combinations of two particle size distributions to create a bimodal

distribution, resulting in higher filler loadings (up to approximately 65%). Higher fillerloadings reduce drawing, curling, warping and thermal expansion, which diminishes part

fatigue. Also higher filler loading increases the overall dimensional stability of the

finished parts. Test data indicates that the smaller the particle size the better the stainresistance. Yet all ATH products currently utilized in Solid Surface manufacturing todaycan pass stain tests when properly manufactured and sanded.

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b) PH Stability - Alumina Trihydrate is PH stable meaning common household acids or

chemicals will not etch, attack or discolor the surface finish.

c) Color Consistency - Aluminas color specifications L*, a*, b* and Delta E should be

measured to ensure there is color uniformity between lots.

d) Surface Area - Choose hydrates that have good particle orientation, definition and surfacearea of 1.25 to 2.1 m*

2/gm. This provides improved binder adhesion to the substrate

reducing cracking, crazing and fatigue.

e) Matrix Viscosity - Bi-modal formulations reduce matrix viscosity allowing higher filler

loadings with improved dimensional stability, mold flow, and air-release.

f) Fire Retardant - Alumina Trihydrate has 3 moles of water and contains 34.6% waters of

hydration that is released at around 400 degrees F. Formulations utilizing AluminaTrihydrate meet Class I Smoke and Fire retardant regulations when properly formulated.

This characteristic is necessary to meet building codes.

g) Substrate Adhesion - Particle definition and surface area play major roles in binder

adhesion to the substrate. Good particle definition and surface area improves adhesion

and helps reduce fatigue failure from thermal expansion and contraction.

Questions about your fillers should be discussed with the supplier or manufacturer. It composes

approximately 60% of the solid surface matrix and contributes immensely to its finished

properties. It is imperative to evaluate your filler source and to understand how it impacts yourquality, processes and product performance. Communication with the supplier is the best source

for success and solutions.

3. Color Granules: Solid surface granules can be purchased separately or premixed with theATH. Just as with ATH, there are many sources of these granules. Many of the same

characteristics that apply to ATH also apply to granules, such as: particle size distribution, pHstability, color consistency batch to batch, and flame & smoke contributions.

a) Particle size distribution – Wide varieties of particle size distributions are

utilized to create different esthetic looks. The batch-to-batch consistency of the

granules with respect to particle size distribution is critical to maintaining a

controlled process. The particle size distribution affects the viscosity of the matrixand can affect the gel time of the matrix. An inconsistent particle size distribution

can also create air voids or particle settling which can lead to warping or

premature failure of the part, as well as a non-uniform appearance.

b) pH stability – Granules should be pH stable so that common household acids or

chemicals do not etch, attack or discolor the surface finish.

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c) Color consistency – Granule size and color consistency is important for matching

previously made Solid Surface designs. A sample plaque with a control ATH anda control resin should be made with all new lots of granules to assure uniformity

from batch to batch.

d) Fire Retardant – ATH is the main component that provides solid surface

materials a Class 1 smoke and fire rating. It is important when choosing granulesnot to compromise this rating.

4. Batch Testing: The following tests are recommended to be performed on a sample from each batch of filler, whether ATH, granules, or a blend of ATH & granules. These tests ensure

that the correct filler is received and will help production determine the characteristics of the

mixture, such as viscosity. The goal is to ensure that there are not unpleasant surprises in

performance during production when considerable dollars in material and labor are at risk.

a. Color & Appearance

b. Viscosity or Resin Demand Test

c. Test Plaque

An example of work instructions for the above tests is on page 11. The results of the above testing should

be recorded in a log accessible to production. An example Filler Receiving Inspection Log is on page 13.

Significant variation in the results of the above tests should be discussed with the vendor to determine

whether the proper material was delivered. Production should also be alerted of any variations that might

affect them when mixing the filler.

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FILLER MATERIAL SPECIFICATION SHEET


___________ ____________


Filler: (ATH, granules, pre-mix)Mixture of _____, _____, & ____ chips with ATH


LB LB


Hardness:

Finish:

Preservative:

Other: Purchase in 50lb bags

ANALYSIS: Sample tested at receipt of shipment.

PHYSICAL PROPERTIES: Background color, particle size & appearance

to match standard color plaques

TYPICAL USES:

EMERGENCY SUBSTITUTES:

REMARKS: Vendor:

ORIGINAL SPEC:

PREPARED BY:




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Work Instruction – Filler Inspection

Work Instruction Title Incoming Inspection : Solid Surface Mineral Fills

WI NumberRevision

Department:


1.0 Purpose: Determine if shipments of solid surface filler (ATH, granules, pre-mix blends)meet quality standards.

2.0 Scope: All solid surface fillers.

3.0 Responsibilities: Solid surface laboratory personnel.

4.0 Definitions:4.1 Spectrophotometer is a device used to analyze light energy reflected or transmitted by

a color sample, wavelength by wavelength. Measurements are defined as L*, a*, b*,

and ∆E.

5.0 Work Instruction Steps:5.1 Make a 500 gram (6”x6”) sample plaque using 35% of a control resin & 65% filler

ATH alone or a mix of ATH & granules). If the filler will be used with a pigment in

production, it is best to make both a pigmented & un-pigmented sample. Pigmentedsamples often reveal color characteristics that un-pigmented samples don’t; and vise-

versa.

5.2 Post cure sample plaques at 200°F for 2 hours. 5.3 Finish sample (using standard production finish techniques).

5.4 Visually compare to the Color Standard Sample Plaque for:

5.4.1 Size and color of chips (if applicable)

5.4.2 Amount of chips 5.4.3 Background color (especially important for un-pigmented colors) – Use alight box.

5.5 Measure the sample plaque with a spectrophotometer if available. The ∆E between

the sample and standard plaque should be less than 1.00 for solid colors and 1.5 forgranite colors. Eight to sixteen readings should be taken at various locations ongranite plaques to obtain an average reading.

5.5.1 If the samples match, mark the pallets as OK for storage.

5.5.2 If the samples do not match, make another sample and retest.

5.5.3 If the second sample fails, report the fill as defective material and contact

the vendor. 5.6 Record spectrophotometer readings and save sample plaques.

Note: At this time the most accurate test for color matching is visual comparison by a trained

technician using a light box. Spectrophotometer readings should be taken and recorded as an aid

to the technician and for setting future numerical color parameters.

6.0 Safety Information:6.2 MSDS: on file in Lab, MSDS Manuals and Master Book. 6.3 Disposal: Non-Hazardous – can be disposed of in dumpsters

7.0 Associated Documents: Filler Receiving Inspection Log.

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7 / 1 / 0 2


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RAW MATERIALS - PIGMENT

1. Specifications & Certification: Pigments can be used to provide the desired

background color of the final product. It is vital that the pigment is compatible with

the resin so as to not affect the performance and quality of the final product. APigment Material Specification Sheet should be developed including the critical

requirements of the pigment as well as any special requirements. A sample of this

document can be found on page 15. This specification sheet should be discussed with

the vendor to ensure compliance. When material is received, the Certificate of

Analysis should be reviewed and matched with the containers (pails, drums) received.

Lot numbers should be recorded on the inspection log and MSDS sheets filed in a

place accessible to all employees. If there is more than one batch number involved –

the batches must be grouped and the drums numbered and used accordingly.

2. Batch Testing: The following tests are recommended to be performed on a sample

from each batch of pigment. These tests verify that the correct pigment is received.

The goal is to ensure that the pigment provides the proper color when used in

production. It is extremely important that the pigment is mixed thoroughly before

testing as well as before use in production. Pigments by their nature do tend to

separate fairly rapidly.

a. Color & Appearance – visual test

b. Draw Down Test

An example of work instructions for the above tests is on page 16. The results of the

above testing should be recorded in a log accessible to production. An example Pigment

Receiving Inspection Log is on page 17. Significant variation in the results of the above

tests should be discussed with the vendor to determine whether the proper material was

delivered. Production should also be alerted of any variations that might affect them

when mixing the resin.

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PIGMENT MATERIAL SPECIFICATION SHEET


_________ ____________


Pigment Color:


LB LB


Hardness: Liquid or dry

Finish:

Preservative: Shelf life is 6 months (Consult supplier)

Other: Purchase in __ gal. containers

ANALYSIS: Certification sheet to be supplied with each shipment

PHYSICAL PROPERTIES: Color matches approved color sample

TYPICAL USES:


REMARKS: Vendor:

ORIGINAL SPEC:

PREPARED BY:




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Work Instruction

Work Instruction Title Incoming Inspection: Pigment Draw Down Test

WI NumberRevision

Department:


1.0 Purpose: Test pigment for proper color. 2.0 Scope: All solid surface pigments

3.0 Responsibilities: Solid surface laboratory personnel.

4.0 Materials Required:4.1 Wide blade putty knife honed smooth

4.2 Good quality 8-1/2x11 coated white paper cut in halves.4.3 Pad of paper

4.4 Reference pigment to use as the color standard

5.0 Work Instruction Steps:5.1 Thoroughly mix both pigments (incoming pigment and reference pigment).

5.2 Take samples of both pigments (10 to 20 grams).

5.3 Place coated paper on pad of paper5.4 Dab a small sample of each of the two pigments approximately ¾” apart at the top of

the paper.

5.5 Using the wide blade putty knife spread the two samples down the paper in one

smooth motion as shown below.5.6 The two samples should merge visually for comparison.

5.6.1 If pigments match, mark the new pigment container OK, and move to storage

area.5.6.2 If pigment does not match, re-mix pigments and re-test. If after the second test

the pigments still do not match, contact vendor.5.7 Clean knife

6.0Safety Information: #MSDS: on file in Lab, MSDS Manual and Master Book

7.0 Disposal: Non-Hazardous - when mixed with resin and catalyzed can be disposed of in adumpster

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C ol or _ _ _ _ _ _

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V en d or _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

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V en d or # _ _ _ _ _ _ _ _ _ _ _ _ _

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7 / 1 / 0 2


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RAW MATERIALS - CATALYST

1. Specifications & Certification: The catalyst is critical in providing the proper gel

time and the time to exotherm. It is vital that the catalyst is compatible with the resin

so as to not affect the performance and quality of the final product. The resin vendorshould be consulted on the best catalyst to use for their resin. A Catalyst Material

Specification Sheet should be developed including the critical requirements of the

catalyst as well as any special requirements. A sample of this document can be found

on page 19. This specification sheet should be discussed with the vendor to ensure

compliance. When material is received, the lot numbers should be recorded on the

inspection log and MSDS sheets filed in a place accessible to all employees. If there

is more than one lot number involved – the batches must be grouped and the gallon

containers numbered and used accordingly. Safety is a big concern when handling

catalysts. Proper employee training is critical.

2. Batch Testing: Since testing of catalysts is extremely difficult due the variance of the

age of the resin, the reliability of the vendor to provide the proper product is key. The

major test recommended is a visual inspection for clarity. If the catalyst is not clear, it

has probably exceeded its shelf life. The gel time of the current catalyst can be

checked against the new catalyst with the current resin (filled and unfilled). This will

determine if there will be an affect in production.

An example of work instructions is on page 20. The results of the above testing

should be recorded in a log accessible to production. An example Catalyst Receiving

Inspection Log is on page 21.

Page 18


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CATALYST MATERIAL SPECIFICATION SHEET


_______ ____________


CATALYST -


LB LB


Hardness: Liquid

Finish:

Preservative: Shelf life is 6 months. Store in refrigerator or below 80F& out of light.

Other:

ANALYSIS:

PHYSICAL PROPERTIES: Clear Liquid

Sp. Gr. = 1.1

TYPICAL USES:


REMARKS: PRIMARY VENDOR

ALTERNATE VENDOR - #1:

ALTERNATE VENDOR - #2 :

ORIGINAL SPEC:

PREPARED BY:




24/58


Work Instruction – Catalyst Inspection

Work Instruction Title

Incoming inspection Solid Surface CatalystWI NumberRevision

Department:


1.0 Purpose: Define inspection requirement for solid surface catalyst upon receipt. 2.0 Scope: All solid surface catalysts

3.0 Responsibilities: Solid surface laboratory personnel

4.0 Definitions:

5.0 Work Instruction Steps: 5.1 Verify label information against the raw material specification sheet and purchase

order.

5.2 Check color visually, it should be clear

5.3 Record Lot number, this gives the manufacture date. Check with your vendor on the

meaning or significance of the lot number.

Note: Manufacturer’s suggested shelf life equals 6 months when stored at temperatures

less than 80°F. Refrigeration is preferred. DO NOT store at temperatures above

90 °F.

Stock rotation: by lot number

6.0 Safety Information:

6.1. MSDS: on file in Lab,6.2. Disposal:

6.2.1 Unused: Contact manufacturer for disposal information of unused catalyst

6.2.2 Used: Non-Hazardous when mixed with resin and hardened, can be disposed ofin a dumpster.

7.0 Associated Documents:

7.1 Raw Material Specification sheets7.2 Purchase order

Page 20


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C a t al y s t R e c ei vi n

gI n s p e c t i onL o g

T y p e _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

D a t e

L o t #

P . O. #

QT Y

N

e a t

G el

T i m e

F i l l e d G el

T i m e

C omm en t s

P

a s s / F ai l

DMR #

V en d or # _ _ _ _ _ _ _ _ _ _ _

V en d or _ _ _ _ _ _

_ _ _ _ _ _ _

I C P A


M an u al

P a g e2 1

7 / 1 / 0 2


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MIXING AND CASTING

The purpose of this QA manual is to help the ICPA membership improve and maintain

quality products. Procedures and methods of operations require periodic review.

A machine batch casting operation has specific considerations that differ greatly fromautomated or continuous casting processes. Many of the procedures detailed below can

be used in all processes, but emphasis will be made on the machine batch process.

Key considerations for a batch casting operation are:

a. Temperature of the raw materials b. Exact weights and formulationsc. Blending of the raw materialsd. Catalyzation level and mixing timee. Vibration times (for solid colors)f. Cure rates

A successful process requires detailed planning. Keeping batch records of the mix

recipe, molding conditions, and results provide vital data for future success. Keeping

records also helps one fight the ongoing battle against seasonal weather changes.

A. Recipe:Batch documentation of the components that are added during the mixing process is

critical in performing problem analysis. This is also a requirement for certification.

Keeping records of the recipe is especially critical for repair and for later matching

special or custom colors. An example of a batch sheet including the recipe is on page 26.Spreadsheets (Excel) can be developed including macros which will calculate the amount

of each component based on the batch size. A typical matrix is composed of the

following:

Resin: 33 – 40%

Filler: 55 – 67%

Pigment: 0 – 5%

Catalyst: 1 – 2% of the resin weight

The operator needs to be able to adjust the percentage of catalyst to account for seasonal

variances and molding condition. The catalyst level should be maintained between 1.0%to 2.0% based on the resin quantity (not the mix quantity). As the catalyst level moves

outside of this range, one should change to a cooler/hotter catalyst type or blend.

Page 22


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Example Chart:

NEAT FILLED

Catalyst Gel Time/time to peak/peak exo Gel Time/time to peak/peak exo

MEKP-30 17.0 min 20.8 min 286°F 18.5 min 36.5 min 108°F


FS 100/9 9.2 min 11.7 min 309°F 10.8 min 27.8 min 120°F

AZOX 13.9 min 9.3 min 317°F 18.5 min 18.9 min 150°F

50/50 blend


AZOX

There is some disagreement as to the minimum and the maximum levels of catalyst to be

used. Check with your specific supplier for their recommended levels. DO NOT GO

BEYOND THESE LEVELS.

B. Mixing:Mixing procedures will depend on the type of mixer & mixing blades used. Developing

standard procedures is important to obtain consistent results from batch to batch. The

order in which components are added is key to ensuring a successful pour. Thoroughmixing of the pigment prior to dispensing it is extremely important for maintaining

consistent color from batch to batch. Although the exact procedure will depend on the

mixing equipment as well as the desired result, a typical mixing procedure is as follows:

1. Weight out ingredients per recipe listed on the batch record sheet.

2. Place resin and pigment in pot & mix thoroughly.

3. Add filler and mix well.

4. Stop mixer – lift lid – and scrape sides and paddle

5. Close mixer and mix thoroughly with vacuum. Longer mixing can be done at

this point in order to raise the temperature of the mix to obtain a desired gel

time. Keep in mind that allowing the mix to stand in the mixer for several

hours even without mixing will both increase the viscosity and decrease the gel

time. The resin becomes more absorbed by the filler, the longer the matrix is

allowed to stand or is mixed.

6. When ready to pour, add the catalyst to the mix, record start time and stir matrix

thoroughly with vacuum.

7. Pour into molds.

8. Record gel time

Page 23


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For small mixes where gel time is not a problem, some manufacturers add the catalyst

with the resin & pigment in step 2 above. This provides the most uniform mixing of the

catalyst with the resin. Catalyst should never be added to the mixer if there is dry filler

present; otherwise, the catalyst is absorbed by the filler resulting in inconsistent gelling.

The operator needs to be able to adjust the temperature of the mix to help control gel

time. Keeping batch records allows one to use historical data to predict gel time andavoid premature gelling.

The impact of temperature on resin gel time is quite significant. Studies have shown that

the relationship of gel time to the matrix temperature is an exponential curve. A general

rule of thumb from a base temperature of 77°F, the gel time changes as follows:

- Every 11° F decrease in temperature, the gel time doubles (2x).

- Every 18°F increase in temperature, the gel time halves (.5x)

Example:

If resin gel time at 77°F = 15 minutes

The approximate resin gel time at 66°F = 30.0 minutes

The approximate resin gel time at 95°F = 7.5 minutes

Changes in temperature will also significantly increase or decrease the matrix viscosity,

which greatly affects the pouring process. When working with granite fills especially

with large particles, significant settling will occur if the viscosity is low or the mix is too

thin.

There are too many matrix formulations to cover them all in this manual. The important

point of this section is for each manufacturer to document their procedures providing

better quality and consistency. Documentation also eases the cross-training process of

other workers and the dependency on the knowledge of a few people.

Updating procedures is an on-going process. If procedures are not current, employees

will no longer use them resulting in deteriorating or inconsistent product quality. From

time to time, an audit should be made to ensure compliance with written procedures.

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C. Pouring:The object of this process is to dispense the matrix into the molds within the gel time of

the matrix. Some mixers dispense by tipping the pot and pouring over the rim. Other

mixing pots have a valve on the bottom. Dispensing from the bottom of the pot allows

the use of the matrix head pressure to fill closed molds faster. Regardless of the pouring

method, the goal is to fill the mold(s) with a minimum of entrapped air and within thetime allowable prior to gelling. Often vibrators are placed on the mold to minimize

entrapped air. Vibration works well with solid colors, but over vibration will cause

settling of the heavier particles when working with granite fillers. The amplitude,

frequency and duration of the vibration will affect the color pattern of the final product

and therefore each needs to be specified in the procedure.

D. Sample Plaque:During the pouring process, a sample chip should be poured. This plaque can be any size

but should be a minimum of 4” x 4” x ½” thick to provide enough surface area fortesting. This sample can be either be cut out of a sheet or poured in a sample mold.

Sample molds can easily be constructed out of polyethylene material for easy release.

This chip can be used for the following tests:

1. Background color

2. Granule dispersion

3. Porosity

4. Barcol Hardness

This plaque should be marked with the batch number and kept with the batch during the

postcuring process.

E. Clean-up:Proper clean-up keeps equipment in good order as well as providing a good working

atmosphere. Cleaning can be done by hand or by pot washers offered by several

companies. To avoid scraping hardened matrix, time for clean-up must be accounted for

in determining the desired gel time of the matrix.

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S O

L I D S URF A C E BAT C H

RE C ORD

S er i al :

0 4 0 0 0 1

S h i f t

D

a t e _ _ _ / _ _ _ _ / _ _ _

T i m e

F or m ul a @

1 . 5 %

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l y s t

E m pi r e

Gr e y

1 0 0 l b

%

F i l l er T em p

X

R o omT em

p

R e si n (

)

3 5

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3 5 . 0 %

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6 4

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)

4 5 4

Gr

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Mi xT em p

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2 3 8

Gr

1 . 5 % ( of r e si n )

M ol d T em p

( 7 5 F Mi ni m um )

G el T i m e

V a c u um ( 2 4 i nH gmi n. )

S t a t u s

R e a s on & C omm en t s

P ar t D e s c

r i p t i on

P ar t #

W ei gh t

[ OK ] [ S cr a p ]

RHL AV DE C KT P B S ONL Y

X X X -X X X

2 7

[

] [

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L HL AV DE C KT

P B S ONL Y

X X X -X X X

2 7

[

] [

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B OWL UNDE RM

O UNT 1 6 x1 3

X X X -X X X

1 5

[

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X X X -X X X

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I C P A

- S ol i d S ur f a c

e Q/ A

M an u al

P a g e2 6

7 / 1 / 0 2


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DEMOLDING PROCEDURES & MOLD MAINTENANCE

A. Open Mold: Since shrinkage does not play a major role in demolding from an open

mold, parts such as sheet stock can be left to cure within the mold. The mold itself

can be used during the curing process to maintain the shape of the part. The batch

number should be recorded on all parts of the batch in a location that will not beremoved during finishing.

B. Closed Mold: Procedures for demolding parts from closed molds are very critical to

both ensure quality parts and preserve the quality of the mold. Establishing the proper

exotherm temperatures at which time to open the mold is critical. Demolding

temperatures should be noted on the demolding procedures. Opening the mold too

early can result in tearing the part due to its insufficient green strength. If the mold is

opened too late, the part will shrink on to the mold often resulting in cracked parts and

excessive wear on the mold. The shape of the mold and its draft angles play a

dominant role in demolding. Depending on the shape of the part, fixtures may be

required to maintain the shape of the part during curing and post curing. The batch

number should be recorded on all parts of the batch in a location that will not be

removed during finishing.

C. Mold Maintenance:

Once the molds are open and parts removed, residue must be removed from the mold

surface. Both the mold surface & the mold releases applied to it are abrasion-

sensitive. It is important to lift the residue from flanges with a plastic spreader. Care

must be taken to preserve the surface while removing the residue. Because of the

fillers used, solid surface matrices can abrade the mold, thus removing the mold

release and increasing the chance of problems with subsequent pours. The moldsurface should then be cleaned with a solvent such as PMC using 100% cotton cloths.

The cloth should be wet, but not dripping. Use a "wipe on, wipe off" technique. Wipe

up drips and puddling immediately with a second cloth. The solvents in the PMC will

chemically soften remaining residue. Wiping off with a second cloth will lift

contaminants from the mold. Do only an area that can be effectively dried before the

PMC flashes off. Changing cloths often will prevent smearing of residue across the

mold surface. Re-wet cloths as necessary. Residue will build up on the cloth and

should not be rubbed against the mold surface.

D. Mold Tracking:Usage of the mold should be tracked so that the mold can be periodically maintained.

Tracking mold usage allows for preventative maintenance rather than reactive

maintenance. A schedule for mold maintenance based on usage should be

established. Yet, any mold damage seen during demolding should be reported

immediately. An example of a mold tracking form is shown on page 28.

Page 27


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M

ol d M ai n t en an c eT r a ck

i n gL o g

M ol d #

D e s cr i p t i on

D a t eL a s t

M ai n t ai n e d

U s a g e

M axi m um U s a g e

B ef or eM ai n t ai ni n g

C omm en t s

I C P A

- S ol i d S ur f a c e

Q/ A

M an u al

P a g e2 8

7 / 1 / 0 2


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POSTCURING

A. Importance:

In order to obtain the optimum physical properties of solid surface material, parts

must be postcured. During the postcuring process, the chemical cross-linking process

is completed and the internal stresses built up during the curing process are relieved.

Since the center of the part cures at different times than the outside, the shrinkage

difference that takes place while the part is curing generates internal stresses.

Postcuring relieves these stresses.

B. Temperature and Time

Although postcuring depends on the thickness of the part as well as its composition

(resin used, etc), parts are normally postcured at temperatures between 180 and 200

degrees Fahrenheit for a minimum of an hour. Lower temperatures require longer

times. The temperature should be a minimum of 20°F above the glass transition

temperature (Tg ) of the resin. One should contact their resin supplier for this

information. It is also important that the part temperature does not exceed 230 -240°F, because the material properties begin to degrade above this temperature. The

specific postcuring time depends on the type of oven used, the geometry of the part

and the density differential of the material. It is important to insure that the material

temperature of the entire part reaches the postcuring temperature. Parts can be

postcured immediately after demolding while they are still exotherming or at a later

date. Studies have shown that either method produces quality parts.

When setting up postcuring procedures, barcol hardness readings can be used to

establish the time and temperature required. Studies should be run to determine the

minimum time required for a part to reach its maximum hardness reading at a giventemperature. Barcol readings should be taken when the part is at 77°F. The resin

manufacturer should be consulted to help set up these requirements.

During postcuring parts are soft and pliable. After demolding and throughout the

postcuring process, they must be placed on flat surfaces or special fixtures to maintain

the desired shape.

C. Oven Consistency:

Even heating and temperature distribution within the postcure oven is critical. When

first installed and periodically, one should test parts at various locations throughout

the oven to ensure even temperature distribution. Test plaques can be placed

strategically throughout the oven and their temperatures monitored during and after

the oven cycle. The temperatures of all test plaques need to fall within the postcuring

temperature requirements established with the resin vendor. If not designed properly,

ovens can have hot or cool spots in certain areas resulting in inconsistent curing or

burnt parts.

Page 29


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D. Record of Completion:

Once parts are postcured, it is important to mark them so everyone knows that the

operation was completed. It is easy to confuse non-postcured parts with postcured

parts. The cost of the minimum time spent marking each product is much less than

the cost of repairing a product in the field.

The sample plaque that was referred to in the “Mixing and Casting” section should be postcured along with the product from that batch. This plaque should be finished to

the same standards as production product. The plaque should be tested for Barcol

hardness, color, and granule distribution. These tests verify that proper curing

occurred, the correct color was achieved, and the granules were evenly distributed. A

spectrophotometer is very useful in qualifying the color and making color approval

less subjective. An example of a Batch Test Log is shown on page 31

Page 30


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B a t ch

T e s t L o g

B a t ch #

D a t e

C ol or

P o s t c ur e

T em p.

P o s t c ur e

T i m e

B ar c ol

H ar d n e s s

" L "

" a"

" b "

DE

P a s s

/ F ai l

C omm en t s

I C P A


M an u al

P a g e 3 1

7 / 1 / 0 2


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SCRAP REPORTING

One method of improving quality is to monitor scrap and look for ways to reduce it.

Programs to reduce scrap contribute directly to the bottom line. Reducing scrap not only

saves money, but also helps ensure on-time delivery and greater customer satisfaction.

Parts that are scrapped need to be remade, which doubles the cost of the part.

Establishing a scrap report is relatively easy. A spreadsheet can be developed to capture

the who, what, when, and why of each piece that is scrapped. An example of a

spreadsheet is shown on page 30. Although the flaw in a scrapped part (the what) is easy

to see, the why is often difficult to determine at the time the part is scrapped. Patterns or

trends can then be reviewed and procedures reviewed to prevent further occurrences.

Graphs can also be developed for a visual effect. Graphs and/or spreadsheets can be posted weekly and goals established so that everyone gets on board. Incentives can be

used to try to lower the scrap percentage.

Tracking scrap trends also helps to identify little problems that can later become larger

ones. Analysis of the scrap report allows you to attack the root causes of problems.

Solving these problems not only reduces scrap, but also provides a better product.

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S OL I D S URF A C E S C RAP ANAL Y S I S F ORWE E K _ _ _ _ _ _ _ _

D a t e

P ar t D e s cr

i p t i on

P ar t #

C ol or

Q t y

I ni t i al s

C o s t

R e a s on

R o o t C a u s e

B a t ch

S i z e

Mi x S i z e

Mi x

T em p

G el

T i m e

P o ur Ar e aR e p or t

F i ni sh i n gAr e aR e p or t

T OT AL

I C P A

- S ol i d S ur f a c e Q

/ A M an u al

P a g e 3 3

7 / 1 / 0 2


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FINISH CLASSIFICATION and QUALITY STANDARDS

The proper finishing of solid surface material is key to bringing out its natural beauty and

feel, as well as providing optimum stain and chemical resistance. Proper finishing

requires proper training. There are many techniques and equipment used throughout theindustry to obtain the desired finish. Many different types of sanders and sanding discs

are available on the market today. The purpose of this section is not to teach one how to

finish, but to ensure that quality standards are in place for the appearance and feel of the

end product. The best source of information on finishing techniques are the vendors that

provide the equipment.

The finishing process takes a lot of time and effort, much of which is done by hand. As a

person is doing this hand sanding, they can also be inspecting the bowl for any voids,

pits, cracks, chips, specs, porosity etc. These defects need to be patched and refinished.

The earlier that these defects are identified, the less costly they are to repair. The

workmanship and finish specifications can be found in section 3 of ANSI Z124.6 – 1997.

These appearance specifications will vary depending on the function of the surface.

Areas that are visible to the user or subject to water require higher quality standards than

non-visible areas. The ANSI standard attempts to distinguish between the various classes

of surfaces, but this can be very subjective.

In order to maintain consistency from one finisher to another, it is important to set up

appearance specifications for each type product. The finishing specifications shown on

pages 35 to 38 attempt to better categorize the finish requirements. Four classes of

surfaces are identified, ranging from the most visible and usable surfaces to the non-

visual or non-accessible regions. To complement this specification, each product shouldhave an associated drawing showing which surfaces are class A, B, C, and D. All

products might not have all four classes. Since these classes are also subject to

interpretation, it is important that a company standard be established which is agreeable

to all including key customers. Since customer satisfaction is the ultimate goal of any

business, it is important to obtain input from them.

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FINISHING STANDARDS

1.0 Purpose: To define the surface finish and aesthetic expectations for solid surface product.

2.0 Scope: All solid surface product. Requirements will be defined by product, material and

part number when applicable.

3.0 Responsibilities: Solid surface finishers have the responsibility to finish product to meetthe requirements of this standard. Finishers shall inspect their work to assure that the

requirements of this standard are met before being passed on to the assembly or shippingdepartment. Assembly and shipping personnel should also be aware of the finish criteria and

stop production of product that does not conform.

4.0 Definitions:• Surface classification – surfaces will be defined as an A, B, C or D surface depending upon

the customer exposure to the surface. Each model will have a drawing defining the A, B, C

or D surface. If no definition exists, the default is an A surface.• Cracks – actual fractures at or under the surface.

• Chipped areas – surface damage causing loss of material greater than 1/64” (.016”) in twoor more dimensions.

• Chipped areas that create a notch – a chip that creates a sharp notch that is likely to lead toa fracture or crack.

• Blisters – any unsupported surfaces that fracture upon the application of manual pressurewith a rounded plastic tool.

• Surface porosity – presence of numerous voids in the surface.

• Molding irregularities – any visible distortion related to forming such as dimples, domes,short fills, or sink marks.

• Pits – small craters in the surface with widths and depths being approximately equal.

• Pinholes – very small holes in the surface.

• Voids – large holes in the surface of the part caused by trapped gas.

• Specks – Particles of foreign matter which produce irregularities in the surface, not includingspeck or flecks incorporated in the surface to produce a decorative pattern.

• Orange peel – irregular surface texture.

• Particle flow pattern (milk lines) – absence or over saturation of stone in an area.

• Stone particle size – size of the decorative granules put in the product to create a pattern.

• Part – the product that comes out a single mold per molding cycle.

• Color deviation – defined by the L, a, b and ∆E generated by testing a sample and

comparing it to the accepted standard for that color.• Visual patch – any repair that can be discerned by the naked eye at 18 inches.

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5.0 Procedure:The finish and appearance of all solid surface parts shall meet the requirements defined in

this standard. Class A, B, C and D surfaces shall be defined per product.

5.1 General Finish Standards5.1.1 Class A Surfaces – the most visual and touchable surface to the customer.

It must be smooth both visually and to the touch.

Defect or Blemish Type MaximumNumber allowed

in a 3” diameter

Maximum numberallowed on entire

A surface

Cracks 0 0

Chipped areas 0 0

Blisters 0 0

Surface Porosity 0 0

Molding Irregularities 1 1

Pits - 1/16” (.062) 0 0

Orange peel - visual at 18” or to touch 0 0

Particle flow pattern (milk lines) 0** 0**

Stone particle size - 5/64” –1/4” (.078”-

.250”). Must be at least 12” apart.

1 3

Color deviation from standard – ∆E NA 1.5

Absence of stone -


41/58


5.1.2 Class B Surfaces – not as visual to the customer but still accessible andwould be cause for rejection if major blemishes were present.

Defect or Blemish Type MaximumNumber allowed

in a 3” diameter

Maximum numberallowed on entire

B surface

Cracks 0 0

Chipped areas 0 0

Blisters 0 0

Surface Porosity 0 0


Pits - 1/16” (.062) 0 0

Orange peel - visual at 18” 0 0

Particle flow pattern (milk lines) Allowed Allowed


.250”). Must be at least 12” apart.

1 5

Visual patches 0 0

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5.1.3 Class C Surfaces – a visual surface that requires finishing but has limitedaccessibility and visibility.

Defect or Blemish Type Maximumnumber allowed

in a 3” diameter

Maximumnumber allowed

on entire C

surfaceCracks 0 0

Chipped areas 0 0

Blisters 0 0


Pits - 1/16” (.062) 1 5

Voids - 1/16”-3/32” (.062”-.094”) 6 unlimited

Voids - 1/16”-1/8” (.094”-.125”) 3 12

Orange peel - visual at 18” or to touch 0

Particle flow pattern (milk lines) Allowed


.250”)

2 8

Visual patches 0 0

5.1.4 Class D Surfaces – a non-visual surface that does not require finishing butdoes have requirements. All edges adjacent to the D surface must have the

flash removed.

Defect or Blemish Maximum allowed

Patches that are not blended with same material andsame color

0

Cracks 0

Chipped areas that create a notch (Functional areas

only)

0

Voids > than .125” deep or larger than 1.5” diameter 0

Void in sprue area – Sprue must be level with the

surrounding material.

0

Page 38


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ICPA-SS Quality Manual Glossary Page 1 of 16

ICPA SOLID SURFACE GLOSSARY

ABSORPTION -

The permeation of a gas or liquid into a solid by molecular action.

For example: water absorption.

ACCELERATOR –

An additive that acts in concert with the promoter to speed up the gel or curing

time of thermosetting plastics such as polyester resin.

ACETONE -

In a cast polymer context, acetone is primarily useful as a cleaning solvent for

removal of uncured resin. It is a very flammable liquid. It should be

evaluated to determine if its current usage can be reduced due to its flammable

nature and fire hazard potential.

ACTIVATOR –

A chemical additive used to initiate the chemical reaction in a specific

mixture.

ACUTE EFFECT –

An adverse effect with severe symptoms occurring very quickly, as a result of

a single excessive overexposure to a substance.

ACUTE TOXICITY –

The adverse effects resulting from a single excessive overexposure to asubstance.

ADDITIVE –

Substance added to the cast polymer mix to impart special performance

qualities, such as ultraviolet absorbers, flame retarding materials.

AIR RELEASE –

The act of air, entrapped during the processing of cast polymer, coming

to the surface and breaking.

ALUMINA TRI-HYDRATE (ATH) –

May also be known as hydrated alumina, a white powder used

as a fire and smoke retarding filler in solid surface polyesters.

AMBIENT –

Indicative of the surrounding environmental conditions such as temperature,

pressure, atmosphere, etc.


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AMBIENT TEMPERATURE –

The temperature of the medium surrounding an object. The term is often used

to denote prevailing room temperature.

ASTM –

American Society for Testing and Materials. A body that standardizes testing procedures and sets specifications for materials.

APPARENT SPECIFIC GRAVITY –

Ratio of weight in air, at a given temperature of a solid portion of a porous

material, to the weight of an equal volume of distilled water.

ASPHYXIANT –

A vapor or gas that can cause unconsciousness or suffocation by reducing the

ambient oxygen level below that necessary to sustain life.

AUTO-IGNITION TEMPERATURE –

The lowest temperature required to initiate or cause self sustained combustion

in the absence of a spark or a flame.

BARCOL HARDNESS –

Measure of the hardness of a laminate or casting; obtained by measuring

resistance to penetration of a sharp steel point under a spring load.

BATCH (OR LOT) –

Identifying for all material produced during one operation possessing identicalcharacteristics throughout.

BENZOYL PEROXIDE (BPO) –

Catalyst used in conjunction with aniline promoters or where heat is used to

decompose the peroxide. Note that heat is not required to gel and cure when

used in conjunction with amine promoted resins, such as body putty and boat

resins.

BINDER –

A material which acts as an adhesive to hold particles of dry material together,

usually polymeric in nature. Example: resins act as binders to hold the filler

together.

BLEND –

Physical mixture of two or more components.


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BLISTER –

A raised area on the surface of a cast part caused by internal pressure. This is

any unsupported surface that fractures upon the application of manual pressure

with a rounded plastic spoon.

BOILING POINT -

The temperature at which a liquid turns to a vapor state.

BUBBLE –

A spherical, internal void within a cast part. Manufacturers refer to this as

entrapped air.

BULK DENSITY –

The weight of a material per unit volume, usually expressed in pounds per

cubic foot.

CAST –As related to cast polymer, the term means to form a cast part by troweling or

pouring a matrix composition into a mold, where it cures into a hard

composite which takes the shape of the mold.

“C” or CEILING –

In terms of exposure concentrations, this is the number that should never be

exceeded.

CARCINOGEN –

A substance or agent capable of producing cancer in animals.

CAST POLYMER –

Non-reinforced composite (resin used without reinforcing fibers). Combines

polymers, fillers and additives as composites to meet specific application

requirements.

CATALYST –

In the scientific sense, a substance that causes or accelerates a chemical

reaction without being consumed in the reaction. Within the composites

industry, free radical initiators such as MEKP are often referred to as

‘catalyst’. This usage is scientifically inaccurate since the initiator is

consumed during usage.

CATALYST (PEROXIDE)

For unsaturated polyester, a substance added to the resin or gel coat in

controlled quantities to make it gel and cure. The catalyst is decomposed by


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the accelerator or by heat to create free radicals, which in turn initiate

polymerization.

CATALYST INJECTION –

Used with continuous cast systems to add the catalyst just prior to pouring into

the mold; therefore, eliminating the need to clean the system within the gel

time of the polyester.

cc - cubic centimeter –

A volume measurement usually associated with small quantities of a liquid.

One quart has 946 cubic centimeters.

CENTIPOISE (CPS) –

Unit of measure used to designate a fluid’s viscosity. At 70°F, water is one

cps, while peanut butter is 250,000 cps. Remember this concept when

evaluating resin and matrix viscosity.

CHEMICAL RESISTANCE –

The resistance of a solid surface matrix to chemicals or compounds over a

range of temperatures.

CHRONIC EFFECT -

An adverse effect with symptoms that develop or recur very slowly, or over a

long period of time.

CHRONIC TOXICITY –

The adverse effects resulting from prolonged or repeated exposures to asubstance, usually used as an indicator of relative toxicity for exposures over

great lengths of time.

COBALT –

Used as the promoter for methyl ethyl ketone peroxide catalyzed polyesters.

Cobalt comes in form of a salt such as cobalt octoate.

COMBUSTIBLE -

A term used to classify liquids, gases, or solids that will burn readily. This

term is often associated with ‘flash point’, which is the temperature at which a

given material will generate sufficient vapors to combust when brought into

contact with a flame.


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COMPOSITE –

A mixture in which two or more distinct, structurally complimentary

substances combine to produce some functional properties not present in any

individual component; sample: filler / resin.

COMPOUND –

An intimate admixture of materials necessary for the finished product.

CONCENTRATION –

A figure used to define relative quantity of a particular material, such as a

mixture of 5 ppm Acetone in air.

CONTAMINANT –

An impurity or foreign substance that may affect one or more properties of

composite material.

CURE –Polymerization or irreversible transformation from the liquid to the solid state

with maximum physical properties, including hardness.

CURE TIME –

Time required for the liquid resin to reach a solid (the majority of a

polymerized state) after the catalyst has been added.

CURING AGENT –

Catalytic or reactive agent that initiates polymerization when added to a resin.

CYCLE –

The time it takes for a mold to move from one point to the corresponding

point in the next repeated sequence.

DEAERATE –

To remove the entrapped air from a matrix by subjecting it to vibration or a

vacuum.

DECOMPOSITION –

The breakdown of materials or substances into other substances or parts of

compounds. Usually caused by heat or chemical reactions.

DEGREE OF CURE –

The extent to which curing or hardening of a thermosetting resin has

progressed. Can be measured with a Shore D or Barcol meter in the plant and

by more advanced equipment in the laboratory.


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DELAMINATION –

In-plane separation of laminate ply or plies due to adhesion failure.

DEMOLD –

To remove a part from a tool, or a tool from an intermediate model.

DENSITY –Weight per unit of volume, usually expressed as pounds per cubic foot.

DERMAL –

Used on or applied to the skin.

DERMAL TOXICITY –

The adverse effects resulting from exposure of a material to the skin. Usually

associated with lab animal tests.

DIETHYLANILINE (DEA) –A promoter used in conjunction with BPO catalyst or as an accelerator for

cobalt/MEKP systems.

DILUTE –

To reduce the concentration level (thinning).

DIMETHYLANILINE (DMA) –

A promoter used in conjunction with BPO catalyst or as an accelerator for

cobalt/MEKP systems. More effective that DEA, but also more toxic.

DISPERSING AGENT –

Materials added to a suspending medium to promote and maintain the

separation of discrete, fine particles of solids or liquids.

DROP WEIGHT TEST –

Produces a measure of impact resistance where weights are dropped on the

specimen from varying heights. Part of the ANSI Z-124 standard.

EVAPORATION RATE –

The rate at which a liquid loses mass at a given temperature, pressure and

humidity. The faster a material will evaporate, the sooner it will become

concentrated in the air, creating either an explosive/combustible mixture or

toxic concentration or both.

EXOTHERMIC HEAT –

Heat energy generated exclusively by a chemical reaction.


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EXTENDERS –

Low-cost materials used to dilute or extend higher-cost resins without

excessive reduction in properties.

FATIGUE –

Reduction of a material’s mechanical properties caused by repeated stress over

time.

FADING –

Loss of color in the pigmented product over time.

FILLERS –

Relatively inert organic materials which are added to the resin for special flow

characteristics, to extend volume, provide fire resistance and to lower the cost

of the article being produced.

FINES –In the classification of powdered or granular materials according to particle

size, fines are the portion of the material which are smaller than a specified

size, usually under 100 mesh.

FLASH POINT –

The temperature at which a liquid will generate sufficient vapors to promote

combustion. Generally, the lower the flash point, the greater the danger of

combustion.

This is the lowest temperature at which a substance emits enough vapors to

form a flammable or ignitable mixture with air near the surface of thesubstance being tested.

FLAMMABLE –

Any liquid that has a flash point of 100 Degrees F. or below. Also, any

solid which can sustain fire and ignite readily.

FLOW METER –

An instrument designed to measure the movement of liquid.

FREE RADICALS –

Highly reactive molecular fragments capable of initiating chemical reactions,

such as polymerization of polyester resins. Normally generated by the

decomposition of the catalyst.

GEL –

A partial cure stage in plastic resin where the liquid material reaches a

viscous, jelly-like state and starts to transform into a solid.


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GELATION –

The stage where resin, due primarily to age, goes from a liquid state to a

semisolid state. The transition of a liquid to a solid.

GEL TIME –

The length of time that a catalyzed polyester remains workable after thehardener (catalyst) is added.

GENERAL EXHAUST -

A term used to define a system for exhausting or ventilating air from a general

work area. Not as site specific as localized exhaust.

HAPS –

Hazardous Air Pollutants as defined by the U.S. government.

HARDENER –Substance that reacts with resin to promote or control curing action.

This term usually applies to a catalyst for epoxy resin.

HAZARDOUS CHEMICALS -

Any chemical which is either a physical or health hazard or both.

HEAT –

Term used colloquially to indicate any temperature above ambient (room)

temperature, to which a part or material is or will be subjected.

HYBRID RESIN –

Resin with two or more types of chemistries combined.

HYDROPHOBIC –

Moisture resistant capabilities, moisture repelling.

INCOMPATIBLE –

Materials which could cause unwanted results or dangerous reaction from

direct contact with one another. Term is also used in regards to some liquids

which are not soluble in one another.

INGESTION –

Taking in a substance through the mouth.

INHALATION -

The breathing in of a substance in the form of a gas, liquid, vapor, dust ,

mist, or fume.


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INHIBITOR -

A chemical added to another substance to delay an unwanted change from

occurring, or to lengthen the gel time or cure time.

IRRITANT -

A chemical which causes a reversible inflammatory effect on the site ofcontact, however is not considered a corrosive. Normally, irritants affect the

eyes, skin, nose, mouth or respiratory system.

ISOTROPIC –

Arrangement of reinforcing materials in a random manner, resulting in equal

strength in all directions.

LC - Lethal Concentration. –

In lab animal tests, this is the concentration of a substance which is sufficient

to kill the test animal.

LC 50 - Lethal Concentration 50 -

In lab animal tests, this is the concentration of a substance required to kill 50%

of the group of animals tested.

LD - Lethal Dose -

The concentration of a substance required to kill the lab animal used for

the test with a specific material.

LD 50 - Lethal Dose 5

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