IntecStone 12mm porcelain slabs come rectified from factory ready to install on floor or walls or fabricated for countertop applications.
Fabricated countertops can be installed without a backer board or sub top directly over open cabinet tops. The use of a backer board is recommended however especially if a mitered edge will be used to build up the edge to clear drawer and door fronts.
Fabricated countertops should be installed with an LFT (Large Format Tile) thin set such as Customs Building products Pro Lite. The tops must have 100% coverage of thin set material and CANNOT be installed using the spot technique.
Seams and joints at countertop and backsplash (if same material is used for backsplash) can be filled with either an epoxy or grout.
Seams are recommended at all 90 degree returns inside and out with a minimum 3/16" (5mm) radius on inside corners.
Chip and seam repairs can be performed similar to natural stone and quartz materials. The same color epoxy mixed for seams can be used for these applications as well as any and all the trade tricks are utilized for other countertop product repairs.
Cutting speed and efficiency will be maximized when using blades specific to porcelain and ultra-compact materials.
We have found that using a foam or cement board on top of the saw table can minimize vibration and chipping while cutting and help the panel from moving during cutting procedures.
Cutting speeds and blade rpm will vary by machine being used but for starting points, the following can used as your guidelines:
• 1900 – 2200 rpm (depending on equipment and blade diameter)
• Always reduce feed rate by 50% for at least first 6" and last 9" of every cut. The plunge rate for straight cuts should be about 7" per minute.
• For longer straight cuts, speeds up to and exceeding 90 - 100 inches per minute can be achieved.
• For shorter cuts or when cutting smaller pieces, these speeds may need to be reduced by up to 40%.
• For miter cuts, we have found that the above mentioned rpms may be maintained while feed rates will drop to between 25 – 40 inches per minute again depending on size of material and length of miters as well as machinery being used. The plunge rate when cutting miters is about 6" per minute.
Water jet cutting can yield very high quality cuts and sustain very high cut rates. Cutting parameters depends on the desired finish. As far as feedrate, 24IPM should be fine at 60,000 psi. Pierce pressure should be lowered to 20,000 psi with an increase of pierce time to allow the lower pressure to create that initial hole. When jetting it is always best to start inside of an already made hole like a blade cut. If that is not possible, then we say to start the initial hole at least 1 inch away from the finished piece being cut.
Under mount sinks should always be braced or supported to the cabinet sides whenever possible.
Edges and cutouts can and should be finished with a polished edge similar to natural stone countertops. The white marble colors should be polished using white polishing pads to avoid color transfer during the process.
While shades should be very close, it is always recommended to never mix shades without inspecting material before fabricating to ensure that they will be a cohesive blend.
