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<strong>PR</strong>ODUCT INFORMATION<br />

<strong>Processing</strong> <strong>and</strong> <strong>working</strong> <strong>instructions</strong><br />

<strong>HPL</strong> <strong>and</strong> <strong>HPL</strong> <strong>elements</strong><br />

TIPS IN ADVANCE: “PLEASE NOTE!”<br />

The stress on tools when <strong>working</strong> with DUROPAL <strong>HPL</strong> is relatively high, due to the corresponding hardness<br />

of the surface, which is laminated with melamine resin. Working with DUROPAL <strong>HPL</strong> therefore requires<br />

tools with carbide-tipped blades, <strong>and</strong> for certain processes even diamond-tipped tool blades. In order to<br />

achieve the best results when <strong>working</strong> with unbonded panels, please note the following requirements:<br />

• Always work on a firm, level surface<br />

• Vibrations <strong>and</strong> flapping of the panels should be avoided at all times<br />

• Sharp blades <strong>and</strong> smooth tool function are important. Damage, splintering or bulging of the décor side<br />

is usually due to incorrect processing or unsuitable tools. Caution: Any nicks or notches created will<br />

lead to the formation of cracks in the event of later temperature or humidity fluctuations!<br />

If the décor surface is pushed over the supporting surface, take care to use a guide or support which<br />

moves along with the DUROPAL <strong>HPL</strong>. When machining with the aid of power tools, corrugated support<br />

surfaces can also be used as an alternative, which will ensure that the contact area is kept to a minimum.<br />

1. STOrAgE AND TrANSPOrT<br />

1.1 Transport<br />

When transporting loose sheets, please take care to ensure that the sheets are lifted correctly during<br />

loading <strong>and</strong> unloading. The décor side should be face up when removed from the vehicle. Smaller, individual<br />

panels should be carried with the décor side held towards the body. In the case of<br />

larger sizes, sagging of the panels can be avoided by carrying them arched around the<br />

lengthwise axis or transporting them with the décor side rolled up facing inwards. Avoid<br />

any type of movements which might cause abrasion of the panels. When transporting<br />

large quantities of panels, it is advisable to stack them on pallets, although always with<br />

adequate protection of the décor side.<br />

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<strong>instructions</strong>


<strong>PR</strong>ODUCT INFORMATION<br />

1.2 Storage<br />

DUROPAL <strong>HPL</strong> must be protected against damp <strong>and</strong> should be kept in storage areas<br />

with normal climatic conditions. Stacks of panels should be stored horizontally - or<br />

inclined at an angle of 80°, in which case care should be taken to ensure that the panels<br />

are supported over the entire surface, <strong>and</strong> prevented from slipping by a counterweight<br />

on the ground. The panels should always be placed with the décor sides facing each<br />

other. Please follow the acclimatisation <strong>instructions</strong> before use – see “Preliminary treatment”!<br />

1.3 Storage of DUrOPAL real metal laminates<br />

The panels should ideally be stored in closed rooms under normal interior room conditions (temperature<br />

18–25 °C, relative air humidity 50–65 %). The panels must always be stored horizontally, with the edges<br />

flush, on a level surface, <strong>and</strong> be covered with plastic film. Where this is not possible, the panels should be<br />

inclined at an angle of 80°, in which case care should be taken to ensure that the panels are supported<br />

over the entire surface, <strong>and</strong> prevented from slipping by a counterweight on the ground. The top panel must<br />

be completely covered by a cover board.<br />

DUROPAL real metal laminates are supplied with a laminated film which is heat-resistant up to<br />

80 °C. This protective film should be removed after six months at the latest, otherwise damage<br />

may occur to the metal surface.<br />

1.4 Storage of DUrOPAL <strong>HPL</strong> <strong>elements</strong><br />

Store on a dry, level surface under normal climatic conditions wherever possible, e.g. in a warehouse, so<br />

that the Duropal <strong>HPL</strong> <strong>elements</strong> are not exposed to the direct effects of water or moisture. Avoid exposure to<br />

direct sunlight.<br />

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<strong>PR</strong>ODUCT INFORMATION<br />

2. CUTTINg TO SIZE<br />

2.1 DUrOPAL <strong>HPL</strong> sheets<br />

Many tools are suitable for cutting DUROPAL <strong>HPL</strong>, although all of them must have<br />

certain properties.<br />

H<strong>and</strong>saw<br />

For individual cuts, saws with fine-toothed blades <strong>and</strong> minimal teeth alteration are<br />

recommended. Always cut at a steep angle to the sheet surface.<br />

Electric nibbler<br />

Particularly suitable for curved cuts, <strong>and</strong> can also be used for stationary installation on bench-tops.<br />

H<strong>and</strong>-held circular saw<br />

Always turn the décor side down when processing. Always use a fence in order to obtain straight,<br />

neat cuts.<br />

Electric jig saw<br />

Always turn the décor side down when processing. Ensure that the undersurface is clean, <strong>and</strong> ideally<br />

protected by felt.<br />

Circular saw bench<br />

The décor side must always face upwards. The panel requires good contact pressure in the area of the saw<br />

blade, e.g. by means of a batten or ideally height-adjustable pressure rollers. Accurate saw guidance <strong>and</strong><br />

correct blade protrusion must be ensured at all times. A circular table saw can also be used to cut sheets in<br />

stacks. Carbide-tipped saw blades have a long service life, but must be h<strong>and</strong>led very carefully because of<br />

their high sensitivity to shocks <strong>and</strong> impacts.<br />

Tooth spacing: 10 – 15 mm<br />

Speed: 3,000 – 4,000 rpm<br />

Cutting speed: 50 – 100 m/s<br />

Feed speed: 10 – 30 m/min<br />

Saw blades with carbide-tipped, concave teeth cutting with both sides produce the cleanest cut edges.<br />

Saw blades below 2 mm in thickness are in most cases not rigid enough, <strong>and</strong> will result in imperfect edges.<br />

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<strong>PR</strong>ODUCT INFORMATION<br />

The usual tooth shapes<br />

The flat tooth, the simplest variant, is easy <strong>and</strong> inexpensive to re-sharpen.<br />

The replaceable tooth is the universal tooth shape for sizing <strong>and</strong> cutting for counter rotation.<br />

The benefits come from the cut width separation <strong>and</strong> the tip advance.<br />

The Duplovit tooth offers a low tip advance <strong>and</strong> double-sided shaft angle due to its hollow<br />

grinding. The benefits also come from the double-sided engagement of the teeth, although there<br />

is no cut width separation. Maintenance is also more complex.<br />

The Duplovit tooth with double-sided chamfer is the special shape <strong>and</strong> usually the only<br />

possibility of obtaining a clean upper <strong>and</strong> lower cutting edge without use of a scoring blade.<br />

Maintenance is even more complex.<br />

The roof Duplovit is a combination of roof <strong>and</strong> Duplovit tooth. The face-angled tooth ensures<br />

preliminary cutting <strong>and</strong> holds the saw blade very stable laterally. The Duplovit tooth with its tip<br />

advance <strong>and</strong> double-sided shaft angle ensures neat edging with long tool life. Advantages:<br />

• optimum edges thanks to the four-way cut separation<br />

• universal saw blade for craft businesses<br />

The trapezoid flat tooth: Besides the individual tooth shapes, there are also tooth shapes in<br />

groups, called grouped teeth. The trapezoid flat tooth has a slightly higher flat tooth chamfered<br />

on both sides, followed by a slightly lower flat tooth without chamfer. This produces a very good<br />

cut edge due to the 5-way cut separation, although maintenance is again very complex.<br />

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<strong>PR</strong>ODUCT INFORMATION<br />

2.2 Cutting Duropal <strong>HPL</strong> <strong>elements</strong> on one <strong>and</strong> both sides on core material<br />

Cutting with circular saws<br />

The quality of the cut edge also depends on the height setting of the saw blade. If in the case of core<br />

materials laminated both sides the upper cut edge is not clean, a higher setting of the saw blade is<br />

recommended, <strong>and</strong> in the case of an unclean lower cut edge, a lower setting of the saw blade.<br />

The best stop position must be determined in advance in individual cases. The best results are obtained<br />

with a pre-scoring saw. The combination of other factors also affects the quality of the cut edges:<br />

• Tooth shape<br />

• Number of teeth<br />

• Cutting speed<br />

• Feed speed<br />

• Entry <strong>and</strong> exit angle<br />

2.3 Cutting of Duropal window boards<br />

Use vibration-free, carbide-tipped circular saws or fine-toothed, slightly straight-set h<strong>and</strong>saws.<br />

2.4 End caps for Duropal window boards<br />

The end caps made from ABS plastic simplify the sealing of the exposed edges, <strong>and</strong> are available in all<br />

profile variants <strong>and</strong> the matching colours of white <strong>and</strong> beige.<br />

The end caps should be matched to the size of the window board. Coat the end caps <strong>and</strong> the edges with<br />

adhesive, e.g. Sikafex-221, leave to dry for approx. 2 minutes <strong>and</strong> then press the end caps firmly into<br />

place. The adhesive hardens after about one hour, producing a visually attractive <strong>and</strong> proper sealing of<br />

the exposed edges.<br />

2.5 Cutting <strong>and</strong> feed speed<br />

See the chapter “Technical information” for a description of how the cutting <strong>and</strong> feed speed determine the<br />

quality of the cut.<br />

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<strong>PR</strong>ODUCT INFORMATION<br />

3. CUT EDgE FINISHINg AND PrOFILINg OF DUrOPAL <strong>HPL</strong> ELEMENTS<br />

Sawing should generally take place from the panel surface (décor side).<br />

3.1 Manual edge finishingg<br />

a) File, s<strong>and</strong>paper, scraper<br />

These materials are well suited for the finishing of edges. When finishing edges, always<br />

file in the correct direction from the décor towards the core material. The edges should<br />

be finished with fine files, s<strong>and</strong>paper (100 – 150 grade) or scrapers. Routered edges<br />

should first be slightly finished using s<strong>and</strong>paper, then drawn off with the scraper <strong>and</strong><br />

finally finished with fine s<strong>and</strong>paper. Ensure that any s<strong>and</strong>ing particles are completely<br />

removed.<br />

b) Plane<br />

For manual planing, we recommend the use of metal planes with HSS blades,<br />

<strong>working</strong> at a cutting angle of approx. 15°.<br />

c) H<strong>and</strong> router<br />

Protruding DUROPAL <strong>HPL</strong> panel edges can be milled flush with the aid of this tool. In order to protect<br />

the surface when <strong>working</strong>, the surface on which the h<strong>and</strong> router is supported should be coated with a<br />

non-abrasive material. Routing waste should be carefully removed before every new step.<br />

Diameter of router: 10 – 25 mm<br />

Speed of rotation: 20,000 rpm<br />

Cutting speed: 10 – 25 m/s<br />

Carbide-tipped router cutters are particularly suitable, <strong>and</strong> for larger diameters can also be fitted with<br />

cutting inserts. Better tool utilisation can be achieved with the aid of height adjustability <strong>and</strong> parallel-axis<br />

cutting. To look after your tools, ensure a panel overhang of no more than 2-3 mm.<br />

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<strong>PR</strong>ODUCT INFORMATION<br />

3.2 Edge finishing with stationary machines<br />

Spindle moulder<br />

Routing <strong>and</strong> cutting heads with replaceable carbide-tipped blades <strong>and</strong> inserts are most suitable for these<br />

tools. The use of cylindrical tools must be determined individually according to use:<br />

• Parallel-axis cutting for panels laminated on one or both sides<br />

• Cutters inclined on one side for panels laminated on one side only<br />

• Herringbone-tooth cutters for panels laminated on both sides<br />

If only DUROPAL high-pressure laminates are being milled, a speed of 12,000 rpm should be selected<br />

for a thickness of up to approx. 5 mm <strong>and</strong> a tool diameter of 100 mm. (Also note in this connection the<br />

maximum speed of the tool!)<br />

If the panels are bonded, a lower speed of 3,000-6,000 rpm is recommended.<br />

The tool life per height setting often differs significantly according to the type <strong>and</strong> shape of the tool,<br />

<strong>and</strong> also the cut quality required <strong>and</strong> the core material used.<br />

For large production runs, it is an advantage to use tools with diamond-tipped cutters. is a beneficial<br />

solution.<br />

router used as spindle moulder<br />

Routers used as spindle moulders need single- or double-cutting carbide-tipped tools with a cutting speed<br />

of 10-15 m/s. This tool should also be used for internal recesses (see chapter “Internal recesses <strong>and</strong><br />

cut-outs”).<br />

Core panels laminated on one side can be guided for vertical milling on a template – core panels laminated<br />

on both sides <strong>and</strong> loose DUROPAL high-pressure laminate on the other h<strong>and</strong> are best milled all round<br />

with only one clamping device. A 2 mm cutting allowance is sufficient in most cases. For curved edges, the<br />

milling requirement can be minimised by pre-cutting the approximate shape in advance using a b<strong>and</strong> saw.<br />

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<strong>PR</strong>ODUCT INFORMATION<br />

Surface planer<br />

Feed speed: 5 – 15 m/min<br />

Cutting speed: 12 – 15 m/s<br />

Speed of rotation: 3,000 rpm<br />

For large production runs, carbide-tipped blades should be used, since normal jointer blades have only<br />

a short tool life.<br />

Double-end profilers<br />

This process is characterised by economic processing, particularly for large production runs. The equipment<br />

from the spindle moulder (see above) is also advisable in this case.<br />

3.3 Edge finishing of Duropal window boards<br />

Edge s<strong>and</strong>ing is recommended in order to avoid stress cracking under temperature <strong>and</strong>/or humidity stress.<br />

3.4 Profiling of the edges of <strong>elements</strong><br />

The profiling of element edges, e.g. for the post-forming or soft forming process, requires tools such as the<br />

h<strong>and</strong> router, spindle moulder or the double-end profiler.<br />

4. DrILLINg OF DUrOPAL <strong>HPL</strong> AND DUrOPAL <strong>HPL</strong> ELEMENTS<br />

4.1 general<br />

Please note: Drill holes in DUROPAL <strong>HPL</strong> should always be 0.5 mm larger than the screw<br />

diameter. The screws need this slight clearance all round to prevent cracks forming in the<br />

area around the drill hole in the event of temperature <strong>and</strong> humidity fluctuations. Raised<br />

countersunk head screws require rosette washers. For our DUROPAL window boards,<br />

use only plastic washers.<br />

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<strong>PR</strong>ODUCT INFORMATION<br />

4.2 Drilling tools<br />

Twist bits<br />

Twist bits specially designed for plastics have a large pitch (steep twist) with wide cutting grooves).<br />

Tip angles of 60°- 80° are ideal for drilling DUROPAL <strong>HPL</strong>.<br />

Combi-bits<br />

Combi-bits or carbide disc drills are suitable for larger diameter drill holes.<br />

Step bits<br />

Step bits are ideal for drill holes of any type; this technique avoids double drilling.<br />

Hole cutters<br />

Hole cutters with guide pins should be used for larger drill hole diameters. If using adjustable hole cutters<br />

with guide pins, the hole must be drilled from both sides.<br />

4.3 Drilling technique<br />

When adjusting the drilling rate, ensure that the melamine surface of the DUROPAL <strong>HPL</strong> is not damaged.<br />

The cutting speed for HSS drills is approx. 0.8 m/s, <strong>and</strong> for carbide-tipped drills up to 1.6 m/s. The advisable<br />

feed rate is 0.02-0.05 mm/rev, corresponding to 1,000 revolutions for 20-50 mm drilling depth/min.<br />

The possible accumulation of material at the exit of the drill bit can be avoided by using a hardwood or<br />

laminate underlay. For large production runs, even better results can be achieved using drilling jigs, which<br />

are equipped with drilling bushes on both sides to enable firm clamping. For countersinking, the guideline<br />

speeds should be halved.<br />

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<strong>PR</strong>ODUCT INFORMATION<br />

5. INTErNAL rECESSES AND CUT-OUTS OF DUrOPAL <strong>HPL</strong> ELEMENTS<br />

5.1 general<br />

The corners of cut-outs should never have sharp angles, since these would quickly<br />

become damaged. Sharp edges can only be achieved by the joining of different cut<br />

pieces.<br />

Internal corners must always be rounded, with a minimum radius of 5 mm. In the case of<br />

internal recesses <strong>and</strong> cut-outs of over 250 mm side length, the radius must gradually be<br />

increased in accordance with the length of the side.<br />

Rounded internal recesses can be produced directly with a router, although for exact results, the corresponding<br />

radius should be pre-drilled. Ensure that the edges are free of notches. When planning to install<br />

heat sources, e.g. halogen lamps, the cut-out should be designed to include sufficient extra clearance,<br />

or should be insulated.<br />

The DUROPAL <strong>HPL</strong> surface should not be subjected to prolonged exposure to temperatures in excess<br />

of 70 °C. The different expansion coefficients should also be noted if using a combination of different<br />

materials.<br />

5.2 <strong>Processing</strong> of Duropal <strong>HPL</strong> worktops<br />

Due to the high-quality lamination of the top <strong>and</strong> reverse side, DUROPAL <strong>HPL</strong> worktops are reliably<br />

protected against the penetration of water <strong>and</strong> steam. During processing however, unprotected edges<br />

<strong>and</strong> joints can be created. Such exposed areas should therefore always be sealed during the course<br />

of the final assembly of the DUROPAL <strong>HPL</strong> <strong>elements</strong>. Otherwise the general <strong>instructions</strong> of 5.1 apply.<br />

5.3 Tools<br />

Please see chapters 2, 3 <strong>and</strong> 4. The tools <strong>and</strong> usage possibilities described also apply for the production<br />

of internal recesses <strong>and</strong> cut-outs.<br />

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<strong>PR</strong>ODUCT INFORMATION<br />

6. TECHNICAL INFOrMATION<br />

6.1 Tool information<br />

Material Work step Tool<br />

<strong>HPL</strong> Panel cutting<br />

<strong>HPL</strong> on raw<br />

chipboard panel<br />

<strong>HPL</strong> on raw<br />

chipboard panel<br />

<strong>HPL</strong> on raw<br />

chipboard panel<br />

<strong>HPL</strong> on raw<br />

chipboard panel<br />

<strong>HPL</strong> on raw<br />

chipboard panel<br />

<strong>HPL</strong> on raw<br />

chipboard panel<br />

<strong>HPL</strong> on raw<br />

chipboard panel<br />

<strong>HPL</strong> on raw<br />

chipboard panel<br />

<strong>HPL</strong> on raw<br />

chipboard panel<br />

Cutting to size<br />

Cutting to size<br />

Routing edges<br />

Routing edges<br />

Grooving<br />

Circular<br />

saw bench<br />

Circular<br />

saw bench<br />

Double-end<br />

profiler (scoring<br />

<strong>and</strong> cutting)<br />

Spindle moulder<br />

or automatic<br />

edge-finisher<br />

Double-end profiler<br />

(re-milling)<br />

Circular<br />

saw bench<br />

Cutting speed<br />

in m/s<br />

40 – 60<br />

40 – 60<br />

40 – 60<br />

40 – 60<br />

40 – 60<br />

40 – 60<br />

Grooving Spindle moulder 40 – 60<br />

Grooving<br />

Double-end<br />

profiler<br />

Grooving Router<br />

Grooving<br />

Drill<br />

Automatic dowelling<br />

machine<br />

40 – 60<br />

Speed in rpm Feed in m/min<br />

approx.<br />

3,000 – 4,000<br />

approx.<br />

3,000 – 4,000<br />

approx.<br />

6,000<br />

approx.<br />

6,000 – 9,000<br />

approx.<br />

6,000<br />

approx.<br />

3,000 – 4,000<br />

approx.<br />

6,000<br />

approx.<br />

6,000 – 9,000<br />

approx.<br />

12,000 – 18,000<br />

approx.<br />

3,000 – 6,000<br />

10 – 30<br />

By h<strong>and</strong><br />

approx. 10<br />

Mechanically<br />

approx. 6 - 20<br />

approx.<br />

6 - 20<br />

approx.<br />

3 - 8<br />

approx.<br />

3 - 8<br />

approx.<br />

6 - 20<br />

approx.<br />

3 - 8<br />

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<strong>PR</strong>ODUCT INFORMATION<br />

6.2 Feed speed<br />

Time for<br />

travel<br />

in s<br />

Feed speed in m/min. for processing lengths in m<br />

1 2 3 4 5 6 7 8 9<br />

1 60 120 180 240 300 360 420 480 540<br />

2 30 60 90 120 150 180 210 240 270<br />

3 20 40 60 80 100 120 140 160 180<br />

4 15 30 45 60 75 90 105 120 135<br />

5 12 24 36 48 60 72 84 96 108<br />

6 10 20 30 40 50 60 70 80 90<br />

7 9 17 26 34 43 52 60 69 77<br />

8 7,5 15 22,5 30 37,5 45 52,5 60 67,5<br />

9 6,7 13 20 27 34 40 47 54 60<br />

10 6 12 18 24 30 36 42 48 54<br />

Example: <strong>Processing</strong> length 5 m, feed speed 50 m/min. – time for travel: 6 s<br />

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<strong>PR</strong>ODUCT INFORMATION<br />

6.3 Cutting speed<br />

Cutting speed v in m/s in relation to tool diameter <strong>and</strong> speed<br />

Tool diameter<br />

in mm<br />

Cutting speed v in m/s<br />

400 20 40 60 80 100 120 140<br />

380 19 38 57 76 95 114 133<br />

360 18 36 54 72 90 108 126<br />

340 17 34 51 68 85 102 119<br />

320 16 32 48 64 80 96 112<br />

300 1) 15 30 45 60 75 90 105<br />

280 14 28 42 56 70 84 98<br />

260 13 26 39 52 65 78 91 104<br />

240 12 24 36 48 60 72 84 96 108<br />

220 11 22 33 44 55 66 77 88 99 110<br />

200 10 20 30 40 50 60 70 80 90 100 120<br />

180 2) 9 18 27 36 45 54 63 72 81 90 108 135<br />

160 8 16 24 32 40 48 56 64 72 80 96 120 144<br />

140 7 14 21 28 35 42 49 56 63 70 84 105 126<br />

120 6 12 18 24 30 36 42 48 54 60 72 90 108 126<br />

100 5 10 15 20 25 30 35 40 45 50 60 75 90 105<br />

80 4 8 12 16 20 24 28 32 36 40 48 60 72 84<br />

60 3 6 9 12 15 18 21 24 27 30 36 45 54 63<br />

40 2 4 6 8 10 12 14 16 18 20 24 30 36 42<br />

20 1 2 3 4 5 6 7 8 9 10 12 15 18 21<br />

10 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 6 7,5 9 10,5<br />

Speed n of the tool<br />

shaft in rpm x 1,000<br />

1 2 3 4 5 6 7 8 9 10 12 15 19 20<br />

Examples:<br />

1) Carbide-tipped circular saw blade<br />

2) Synchronously adjustable router head with clamped herringbone-shaped reversible carbide tips<br />

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<strong>PR</strong>ODUCT INFORMATION<br />

7. WOrKINg WITH DUrOPAL <strong>HPL</strong> AND DUrOPAL <strong>HPL</strong> ELEMENTS<br />

7.1 general<br />

DUROPAL <strong>HPL</strong> with a thickness of less than 2 mm needs a flat, stress-free core material with minimum flex.<br />

A smooth surface is an essential requirement for a permanently good result. The right adhesives, application<br />

quantity, pressure <strong>and</strong> press temperature are equally important.<br />

Since DUROPAL <strong>HPL</strong> may be subject to slight dimensional changes, depending on the air humidity <strong>and</strong><br />

temperature, these properties must always be taken into account when <strong>working</strong> with DUROPAL <strong>HPL</strong>.<br />

7.2 Core material<br />

The following table describes the suitability of different materials as cores <strong>and</strong> their application possibilities.<br />

With all such information, it should be noted that the properties of a core materials of different composition<br />

(e.g. honeycomb with frame) can have an effect on the surface texture of the DUROPAL <strong>HPL</strong>. This should<br />

be checked in advance <strong>and</strong> taken into account.<br />

Material/properties <strong>and</strong> suitability as core material<br />

Chipboard panels<br />

On free supporting constructions, the necessary thickness must be taken into account.<br />

The fixing of the flat bonded element depends on the thickness <strong>and</strong> size of the panel.<br />

The surface quality of the DUROPAL <strong>HPL</strong> element depends largely on the structure of the<br />

chipboard panel construction, i.e. the shape of the chips, resin content, density, <strong>and</strong> in<br />

particular on the s<strong>and</strong>ing quality of the surface. Multi-ply chipboard panels are suitable<br />

as core materials. The panels should be evenly s<strong>and</strong>ed on both sides in order to prevent<br />

bowing <strong>and</strong> visual surface defects.<br />

In order to enable a short bonding <strong>and</strong> pressing time, ensure good surface absorption<br />

properties if you are using water-based bonding system. The surface must also have a<br />

resistance to delamination strength of at least 1.2 N/mm2 to avoid detachment of the<br />

laminate (DIN 52 366). Please contact us in the event of any further questions on these<br />

special chipboard panels.<br />

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<strong>PR</strong>ODUCT INFORMATION<br />

MDF panels Particularly suitable for profiling, although not self-supporting in low thicknesses.<br />

Hard fibre panels<br />

Plywood panels<br />

Veneered panels<br />

Not self-supporting. Surface textures containing paraffin must be s<strong>and</strong>ed before bonding, but are<br />

usually supplied already treated. Density 850 kg/m3, other properties according to EN 622.<br />

Self-supporting. In order to ensure a smooth surface preferably use laminboard with narrow strips<br />

<strong>and</strong> a softwood covering layer.<br />

Thin panels are not self-supporting, the fixing method depends on the thickness <strong>and</strong> size.<br />

Softwoods such as poplar <strong>and</strong> abachi are suitable for bonding.<br />

Solid timber Should only be used for small areas. Risk of deformation!<br />

Honeycomb<br />

structure<br />

Foam materials<br />

7.3 Preliminary treatment<br />

Suitable as a component of composite core materials or in combination with a framework<br />

construction.<br />

Self-supporting for vertical surfaces, also suitable as a component of composite panels. Excellent<br />

heat insulation. Hard foams on a synthetic resin basis, such as polystyrene, PVC, phenol, polyurethane,<br />

are suitable for bonding. Please consult the manufacturer in all cases before bonding.<br />

The DUROPAL <strong>HPL</strong> <strong>and</strong> the core materials must always be conditioned together, in order to equalise the<br />

moisture content of the components. Materials with too high a moisture content tend to contract after a<br />

period of drying. This can result in cracks <strong>and</strong> distortion. Materials which are too dry are difficult to work<br />

<strong>and</strong> can later exp<strong>and</strong>, once again leading to distortion. The correct conditioning is achieved at a room<br />

temperature of approx. 18–25 °C <strong>and</strong> 50–65 % relative humidity.<br />

The following points must also be observed:<br />

• adequate air circulation around the DUROPAL <strong>HPL</strong> for at least 10 days.<br />

• alternatively the core panels <strong>and</strong> laminates can be stored for at least three days, stacked in the same<br />

order as they will later be bonded together. In this case, the air humidity should be similar to that in<br />

which the panels will later be used.<br />

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<strong>PR</strong>ODUCT INFORMATION<br />

• DUROPAL <strong>HPL</strong> which is intended for a DUROPAL <strong>HPL</strong> element should be stacked for at least three days<br />

with the reverse sides facing each other. Joint conditioning together with the core material can then be<br />

dispensed with, provided that this has been stored properly. If the DUROPAL <strong>HPL</strong> will later be exposed<br />

to consistently low relative air humidity, the conditioning should be carried out accordingly, e.g.<br />

20 hours at 40 °C or 10 hours at 50 °C. The adhesives should be stored at room temperature. Bonding<br />

must be carried out immediately after conditioning.<br />

Please note: This information applies only for processing in normal climatic conditions. For extreme<br />

conditions, please consult us.<br />

7.4 Stress equalisation<br />

When two different materials are bonded together, tension always occurs. Core materials must therefore<br />

be laminated on both sides with materials which are subject to the same dimensional changes under the<br />

effects of heat <strong>and</strong> moisture. This applies particularly if the finished composite panel is to be self-supporting,<br />

<strong>and</strong> will not be held by any rigid construction. As the size of the surface increases, more care needs<br />

to be taken in selecting a surface to balance it, as well as the density, symmetry of structure <strong>and</strong> rigidity of<br />

the core.<br />

The best results will be achieved by selecting the same DUROPAL <strong>HPL</strong> type in identical thickness for the lamination<br />

on both sides. When using <strong>HPL</strong> with film (for protection of the surface), care must again be taken<br />

to ensure a symmetrical arrangement. The DUROPAL <strong>HPL</strong> cut-outs must always have the same direction of<br />

grain. DUROPAL <strong>HPL</strong> must be bonded to the core material using the same s<strong>and</strong>ing direction on both sides.<br />

It is best to use our <strong>HPL</strong> balancing material of equal thickness or also best suited for this purpose.<br />

7.5 Working with DUrOPAL real metal laminates<br />

The <strong>working</strong> of different types of materials into composite <strong>elements</strong> always leads to stresses between the<br />

different materials. Core materials must therefore be laminated on both sides with materials which are subject<br />

to the same dimensional changes under the effects of heat <strong>and</strong> moisture. Particular care must be taken<br />

to maintain symmetry of structure if the composite element is to be self-supporting. When <strong>working</strong> with<br />

DUROPAL real metal laminates, the correct direction of the décor pattern must also be followed. To make<br />

this easier, the protective film is marked with direction arrows to show the direction of the décor.<br />

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<strong>PR</strong>ODUCT INFORMATION<br />

7.6 Bonding<br />

Please note: For the gluing <strong>and</strong> bonding of DUROPAL <strong>HPL</strong>, adhesives should be used which have<br />

good adhesive strength <strong>and</strong> adequate resistance to extremes of temperature <strong>and</strong> moisture.<br />

7.6.1 Adhesives, overview<br />

• Dispersion adhesives (e.g. PVAc adhesives = white adhesives)<br />

• Condensation resin adhesives (e.g. urea, resorcinol <strong>and</strong> phenolic resin adhesives)<br />

• Contact adhesives (e.g. polychloroprene [PCP] adhesives)<br />

• Mixed adhesives (e.g. epoxy, unsaturated polyester <strong>and</strong> polyurethane adhesives)<br />

• Hot-melt adhesives (for special applications only)<br />

For the suitability of adhesives, please consult the following table:<br />

Wood-based<br />

core materials<br />

(panels or<br />

honeycomb)<br />

Paper<br />

honeycomb<br />

Foams <strong>and</strong><br />

honeycomb<br />

made of:<br />

Dispersion adhesives<br />

e.g. PVAc<br />

adhesives<br />

Condensation<br />

resin adhesives<br />

e.g. urea, resorcin<br />

<strong>and</strong> phenol<br />

resin adhesives<br />

Contact adhesives<br />

e.g. polychloroprene,<br />

nitrate rubber<br />

adhesives<br />

Mixed adhesives<br />

e.g. epoxy,<br />

polyurethane<br />

adhesives<br />

Hot-melt<br />

adhesives<br />

n n n n n<br />

n n n n n<br />

n 2) n 2)<br />

• Polystyrene n 1) n 1)<br />

• PVC<br />

• Phenol n n n n n<br />

• Polyurethane n 2) n n n n<br />

1) Without ingredients which attack polystyrene<br />

2) PVC or polyurethane <strong>and</strong> adhesives must be suitable for each other<br />

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<strong>PR</strong>ODUCT INFORMATION<br />

7.6.2 guideline values for the stress resistance of adhesives (empirical)<br />

Adhesive type<br />

Dispersion adhesives:<br />

Temperature resistance<br />

(approximate values) 1)<br />

PVAc adhesives -20 to +70 °C D 1/D 2<br />

2-component PVAc adhesives -20 to +100 °C D 3<br />

Condensation resin adhesives:<br />

Urea resin with high<br />

elongation agent component<br />

-20 to +120 °C D 2<br />

Melamine/urea resin -20 to +120 °C D 3/D 4<br />

Phenol, resorcin resin -20 to +140 °C D 3/D 4<br />

Contact adhesives:<br />

Contact adhesives<br />

without hardener<br />

Contact adhesives<br />

with hardeners<br />

Contact adhesives<br />

with resin hardeners<br />

Reaction adhesives:<br />

Epoxy, unsaturated polyester<br />

<strong>and</strong> polyurethane adhesives<br />

-10 to +50 °C D 1<br />

-10 to +100 °C D 2<br />

Stress resistance in accordance<br />

with DIN EN 204 2)<br />

Consul manufacturer Consul manufacturer<br />

-20 to +100 °C D 3/D 4<br />

Hot-melt adhesives -10 to +60 °C D 1<br />

Special hot-melt adhesives -10 to +90 °C D 1<br />

The specified guideline values refer only to the bonded joint.<br />

1) The specified plus values refer to short-term stress (up to 30 min.) up to these maximum temperatures.<br />

2) The core material <strong>and</strong> edge protection must comply with the relevant stresses..<br />

The figures on temperature resistance apply only for short-term stress to the bonded joint.<br />

The long-term resistance of the composite element depends on several factors, such as the type <strong>and</strong> class<br />

of the DUROPAL <strong>HPL</strong>, air humidity, temperature effects <strong>and</strong> the core material. Since the adhesives within<br />

the groups listed how different properties <strong>and</strong> are under continual further development, the manufacturer<br />

should always be consulted for special applications.<br />

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<strong>PR</strong>ODUCT INFORMATION<br />

7.6.3 Bonding procedure<br />

Preparation work: Clean both sides of the core material <strong>and</strong> the DUROPAL <strong>HPL</strong> thoroughly.<br />

Dust, grease, oil or perspiration can leave marks on the surface after bonding.<br />

These can be easily removed with organic solvents (e.g. acetone, white spirit or petrol).<br />

Further <strong>instructions</strong> on cleaning <strong>and</strong> care of DUROPAL <strong>HPL</strong> are given in the chapter of<br />

the same name “DUROPAL <strong>HPL</strong>”.<br />

Bonding should be carried out at a temperature of approx. 18-25 °C <strong>and</strong> a relative air humidity of 50-65<br />

%. We recommend carrying out a test under the same conditions which will prevail during bonding. For all<br />

types of solvents <strong>and</strong> hardeners, please follow the safety <strong>instructions</strong> of the professional trade associations.<br />

7.6.4 Edging of DUrOPAL window boards<br />

The DUROPAL window board is a wood-based material. Wood-based materials can show signs of<br />

swelling under the effect of moisture. It is therefore advisable to seal all exposed cut edges properly<br />

before installation: this applies particularly for the Eco type.<br />

Sealing can be carried out using high-quality DUROPAL <strong>HPL</strong> edging strips or end caps, <strong>and</strong> also with<br />

simpler edging materials. According to available experience, Sealing with waterproof <strong>and</strong> temperature-<br />

resistant adhesives or a sealant such as Sikaflex-221 is also sufficient in some cases to prevent the<br />

penetration of moisture (please follow the corresponding usage <strong>instructions</strong> for the adhesive or sealant).<br />

For the sealing of exposed cut edges, every carton pack contains the corresponding DUROPAL <strong>HPL</strong><br />

edging strip. In instances where work has to be carried out more quickly, we offer the types Reno <strong>and</strong><br />

Hydro window boards with significantly improved swelling properties, which can also be installed without<br />

corresponding edge sealing. However, if the front profile edge is to be plastered in, or if the possibility<br />

exists that it might come into direct contact with water, the edge in the profile area must also be properly<br />

sealed for the types Reno <strong>and</strong> Hydro. This also applies if the original width has to be cut down. In this case,<br />

the rear long edge must be sealed for all types.<br />

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<strong>PR</strong>ODUCT INFORMATION<br />

In order to achieve good results, please stick to the guideline values of the following table.<br />

It should also be taken into account that these values depend on the <strong>working</strong> <strong>and</strong> climate conditions,<br />

as well as the type of core material <strong>and</strong> the adhesive quality.<br />

guideline values for bonding<br />

Adhesive type<br />

Dispersion adhesives:<br />

PVAc adhesives<br />

2-component<br />

PVAc adhesives<br />

Condensation<br />

resin adhesives:<br />

Urea resin,<br />

melamine/urea resin<br />

Phenolharz,<br />

Resorcinharz<br />

Contact adhesives:<br />

with <strong>and</strong> without<br />

hardener<br />

Adhesive<br />

application<br />

in g/m 2<br />

90 – 150 on <strong>HPL</strong><br />

or core material<br />

90 – 150 on <strong>HPL</strong><br />

or core material<br />

90 – 150 on <strong>HPL</strong><br />

or core material<br />

100 – 180 on <strong>HPL</strong><br />

or core material<br />

150 – 200 on <strong>HPL</strong><br />

<strong>and</strong> core material<br />

Waiting time<br />

(open) 1) in min.<br />

1 - 30<br />

1 – 30 depending<br />

on component<br />

composition<br />

Pressing<br />

pressure<br />

2) 3)<br />

in bar<br />

approx.<br />

3<br />

approx.<br />

3<br />

2 - 20 3 - 5<br />

approx. 2 – 15 3 - 5<br />

Depending on<br />

ambient temperature<br />

<strong>and</strong> adhesive type<br />

(finger test)<br />

Pressing temperature /<br />

pressing time 4) Proce -<br />

dure<br />

20 °C 40 °C 60 °C<br />

8 - 60<br />

min.<br />

4 - 12<br />

min.<br />

45 - 160<br />

sec.<br />

According to manufacturer’s<br />

specifications<br />

15 –<br />

180 min.<br />

5 – 30<br />

min.<br />

1 – 12<br />

min.<br />

Depending on hardener system<br />

approx.<br />

8 hrs.<br />

Pressing time<br />

depending on<br />

hardener system<br />

At least 5 At least 1 min. pressed c)<br />

with added hardener These are special adhesive settings for which no general guideline values can be specified.<br />

Reaction adhesives:<br />

Epoxy, unsaturated<br />

polyester <strong>and</strong> polyurethane<br />

adhesives<br />

Hot-melt adhesives<br />

100 – 250 on <strong>HPL</strong><br />

or core material<br />

180 – 300<br />

180 – 300 on <strong>HPL</strong><br />

or core material<br />

Depending on type<br />

Extremely short<br />

Stack<br />

pressure,<br />

store flat<br />

Pressure<br />

roller<br />

Depending on type <strong>and</strong> hardener<br />

system<br />

195 – 220 °C<br />

(adhesive application temperature)<br />

1) According to DIN 16920, the waiting time (open) = the time between application of the adhesive <strong>and</strong> placing the surfaces<br />

together for bonding. To this is added the waiting time (closed) = the time between placing the adhesive surfaces together<br />

<strong>and</strong> achievement of the full pressing pressure or other measures causing bonding (hardening) (e.g. the hardening tempera-<br />

ture). When bonding in the heating press, the full pressure must be applied immediately after loading the press, in order to<br />

prevent distortion of the composite <strong>elements</strong> or premature drying of the adhesive coating.<br />

2) 1 bar ≈ 1 kp/cm 2 = 0,1 N/mm 2 ≈ 100 k Pa<br />

3) calculate the pressing pressure for hydraulic presses, see the Appendix (Item 8)<br />

4) The pressing time is not always identical to the time until reaching final strength. Depending on the procedure, an adequate<br />

time interval must be left after pressing before further processing.<br />

099 PI <strong>Processing</strong> <strong>and</strong> <strong>working</strong> <strong>instructions</strong> Page 20 of 34<br />

a)<br />

a)<br />

b)<br />

b)<br />

d)<br />

e)


<strong>PR</strong>ODUCT INFORMATION<br />

Pressing temperature<br />

To produce tension-free DUROPAL <strong>HPL</strong> <strong>elements</strong>, a pressing temperature of approx. 20 °C is recommended.<br />

At higher temperatures, the setting times can be reduced. A temperature of 60 °C should not be<br />

exceeded during pressing, since this may result in bowing <strong>and</strong> a change in the surface texture. For special<br />

bonding at higher pressing temperatures, please note the following guideline values, in order to avoid<br />

damage to the material. In case of bonding systems which require a higher temperature, please consult us.<br />

Temperature Time<br />

70 °C 10 min<br />

80 °C 5 min<br />

90 °C 3 min<br />

100 °C 2 min<br />

Applying the adhesive <strong>and</strong> the pressing procedure<br />

Spread the adhesive evenly <strong>and</strong> sparingly over the complete surface. For DUROPAL <strong>HPL</strong> <strong>elements</strong>, both<br />

sides must be coated with the same amount of adhesive in order to avoid bowing. This applies particularly<br />

to water-based bonding systems.<br />

general calculation of the pressing pressure for hydraulic presses<br />

For the setting of the correct pressing pressure with different panel dimensions, it is important is to calculate<br />

the piston pressure <strong>and</strong> the corresponding manometer pressure.<br />

Please use the following formula for the calculations:<br />

Necessary pressure in bar Panel area in cm² = manometer pressure<br />

x<br />

Number of pistons Piston area in cm² in bar<br />

Piston area = r²π<br />

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<strong>PR</strong>ODUCT INFORMATION<br />

The application of the individual adhesives is explained below:<br />

a) Dispersion adhesives<br />

These include PVAc adhesives <strong>and</strong> 2-component PVAc dispersion adhesives. Apply the adhesive with a<br />

toothed spreader or h<strong>and</strong> roller. This can also be done with adhesive application machines or four-roller<br />

machines. Cold pressing is carried out using screw clamps, spindle presses or single-/multi-daylight presses,<br />

<strong>and</strong> warm pressing with single- or multi-daylight presses, short cycle presses, roller presses or double-belt<br />

presses. Take care to observe the pressing times/temperatures accurately with sparing <strong>and</strong> even adhesive<br />

application.<br />

b) Condensation resin adhesives<br />

These include urea resin, melamine-urea resin, phenolic resin <strong>and</strong> resorcinol resin. Phenolic- <strong>and</strong> resorcinol<br />

resin are used principally for DUROPAL <strong>HPL</strong> <strong>elements</strong> which require high resistance to exposure to flames.<br />

Condensation resin adhesives require corresponding additives in order to make the adhesive joint elastic.<br />

The guideline values can vary according to the hardener type. Impurities consisting of remains of adhesive<br />

or hardener cannot be removed from the DUROPAL <strong>HPL</strong> surface after bonding without damaging the material.<br />

Ensure therefore that these are completely removed before bonding. For cold <strong>and</strong> warm pressing, the<br />

same tool specifications apply as for dispersion adhesives.<br />

c) Contact adhesives<br />

Without hardener: When applying with a toothed spreader, the application direction on the core material<br />

<strong>and</strong> laminate should be at right-angles to one another. The adhesive can also be applied with a brush,<br />

or by spraying <strong>and</strong> pouring systems. In all cases, great care <strong>and</strong> good ventilation must be ensured when<br />

<strong>working</strong>. Contact adhesives require a short, powerful contact pressure. The open time can be reduced by<br />

accelerated drying of the adhesive films, although over-drying should be avoided. Dried-on adhesive films<br />

can be reactivated by heat, e.g. infrared radiation.<br />

The pressing procedure is carried out as described.<br />

With hardener: This adhesive enables higher stress <strong>and</strong> temperature resistance of the joint. For further<br />

information, please consult the manufacturer.<br />

d) Mixed adhesives<br />

General <strong>working</strong> recommendations cannot be given here, since this category is divided into different types<br />

<strong>and</strong> used only for special bonding.<br />

e) Hot-melt adhesives<br />

These are used principally for edge bonding.<br />

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<strong>PR</strong>ODUCT INFORMATION<br />

7.6.5 Post-forming<br />

The core material<br />

It is important to use a material which has an even distribution of the chip sizes or thickness over the whole<br />

cross-section, e.g. chipboard panels or MDF. Coarse chips in the central layer of the panel can lead to<br />

formation of cracks in the <strong>HPL</strong>, depending on the quality of the milling.<br />

Profile milling<br />

Ensure that the profile has even transitions between rounded <strong>and</strong> flat areas, <strong>and</strong> is properly s<strong>and</strong>ed.<br />

The radius of a post-formed product is defined as the radius of the profiled core material.<br />

Conditioning<br />

Follow the recommendations on storage <strong>and</strong> preliminary treatment. The postforming results can be adversely<br />

affected by deviations from these recommendations, particularly in an over-dry environment.<br />

Bonding procedures for post-forming <strong>and</strong> coating<br />

In order to avoid the formation of cracks, any surplus adhesive must be completely removed. This applies<br />

particularly at transitions between rounded <strong>and</strong> flat areas. The same special adhesive should be used for<br />

DUROPAL <strong>HPL</strong> <strong>and</strong> the balancing material, e.g. PVAc adhesive or contact adhesive.<br />

Procedures depending on system configuration (example)<br />

Das Durchlaufverfahren ist in folgende Schritte gegliedert<br />

• Sawing <strong>and</strong> profile milling of the core material<br />

• Pressing of the DUROPAL <strong>HPL</strong> (st<strong>and</strong>ard type P = post-formable) <strong>and</strong> balancing material<br />

• Router the edge of the balancing material<br />

• Application of the adhesive to the underside <strong>and</strong> edge of the DUROPAL <strong>HPL</strong> (approx. 120–180 g/m 2 )<br />

• Post-forming at 160-210 °C. A test is advisable. For continuous post-forming, the feed speed should be<br />

11-17 m/min<br />

• Removal of any projecting DUROPAL <strong>HPL</strong> by using a coarse cutter, followed by fine cutter at an angle<br />

of approx. 30°.<br />

Heat transmission<br />

In principle, two different methods can be used:<br />

• Infra red heat: stationary or continuous.<br />

• Direct heat: stationary.<br />

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<strong>PR</strong>ODUCT INFORMATION<br />

Both systems require sufficient heat to enable the subsequent post-forming. Thin DUROPAL high-pressure<br />

laminates require only a short heating period, <strong>and</strong> must be processed correspondingly faster. With continuous<br />

post-forming, the bending should begin at the end of the heating input. Any machine systems should<br />

be run up to their ideal dosing before the actual post-forming procedure, since every material responds<br />

better to a different speed <strong>and</strong> temperature. It is important that the DUROPAL <strong>HPL</strong> is exposed to uniform<br />

heat throughout the whole cross-section before the bending process is started. The corresponding required<br />

temperature depends on the laminate thickness, the surface texture <strong>and</strong> the bend profile.<br />

For continual processing machines, the maximum heating output must be set at the corresponding variable<br />

speed. Continuous post-forming should be carried out if possible using a fixed bending block.<br />

For stationary machines, a test run should be carried out in order to determine the optimum heat effect in<br />

relation to the bending speed. This should ideally be started at a high temperature, <strong>and</strong> the speed adjusted<br />

accordingly. With heating rails, the initial duration should be kept short, <strong>and</strong> maintained continuously<br />

during post-forming.<br />

Avoid too low a temperature in order to prevent the formation of cracks. Discoloration can occur if the<br />

temperature effects are too high, sometimes also accompanied by cracking, deformation or blistering.<br />

Post-forming properties of DUrOPAL real metal laminates<br />

All DUROPAL real metal laminates are produced in post-forming quality. At a thickness of 0.8 mm, a radius<br />

of 8 mm or larger can be produced for brushed surfaces, <strong>and</strong> a radius from 10 mm upwards for smooth<br />

surfaces.<br />

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<strong>PR</strong>ODUCT INFORMATION<br />

8. WOrKINg rECOMMENDATIONS FOr DUrOPAL <strong>HPL</strong>-SOLID<br />

DUROPAL <strong>HPL</strong>-Solid has a high weight factor. Its material value is considerable!<br />

Please therefore note the following recommendations for treatment <strong>and</strong> processing<br />

recommendations for the treatment <strong>and</strong> processing of DUrOPAL <strong>HPL</strong>-Solid<br />

8.1 Transport <strong>and</strong> storage<br />

8.1.1 Transport<br />

• When transporting stacks of panels, always use adequately large, level <strong>and</strong> stable pallets.<br />

• The pallets must be secured against slipping. The panels in the stack must also be secured against<br />

slipping.<br />

• Foreign bodies <strong>and</strong> abrasive impurities in the panel stack must be avoided, since these could cause<br />

indentations <strong>and</strong> damage to the panels.<br />

• When loading <strong>and</strong> unloading, lift the panels individually by h<strong>and</strong> or with suction lifters, without allowing<br />

them to slide against each other.<br />

8.1.2 Storage<br />

• The material should ideally be stored in closed rooms under normal interior room conditions<br />

(temperature 18-25 °C, relative humidity 50-65 %).<br />

• The material must always be stored horizontally, with the edges flush, on a level surface,<br />

<strong>and</strong> be covered with plastic film.<br />

• The top panel must be completely covered by a covering panel.<br />

• Stacks of panels must be wrapped in protective foil.<br />

8.2 Conditioning<br />

• DUROPAL <strong>HPL</strong>-Solid should be stored before use together with the core material for at least eight days<br />

at 20 °C <strong>and</strong> 50 % relative humidity.<br />

• Please ensure that the materials do not become too damp.<br />

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<strong>PR</strong>ODUCT INFORMATION<br />

8.3 <strong>Processing</strong><br />

8.3.1 Cutting<br />

• For cutting, we recommend the use of carbide- or diamond-tipped saw blades, as also used for the<br />

processing of DUROPAL <strong>HPL</strong>.<br />

• With DUROPAL <strong>HPL</strong>-Solid, a lower feed speed should be used than for DUROPAL <strong>HPL</strong> <strong>elements</strong>.<br />

• For compact laminates with décor on both sides, damage to the lower décor layer can be effectively<br />

avoided by changing the exit angle. This can be achieved by varying the height setting of the saw blade.<br />

• Good results can also be achieved by placing plywood, hard fibre panels or DUROPAL <strong>HPL</strong> under the<br />

panels.<br />

• Optimum cut quality of the lower edge can be achieved by using a pre-scoring device.<br />

8.3.2 routing <strong>and</strong> drilling<br />

• For routing, we recommend carbide- or diamond-tipped routers with high rotational accuracy, in order to<br />

minimise chatter marks. The use of special router heads has proven useful for processing large quantities<br />

of panels.<br />

• Due to the high cutting pressure, secure tool guides <strong>and</strong> fences are essential.<br />

• Cutting marks on the milling surface are unavoidable. These can be reduced by using a mechanical<br />

router <strong>and</strong> by milling in the same direction. Any remaining marks can then be removed by s<strong>and</strong>ing <strong>and</strong><br />

polishing.<br />

• Further improvements in the appearance of the edge can be achieved by treatment with silicon-free<br />

furniture oils.<br />

• Projecting corners <strong>and</strong> edges should be chamfered in order to avoid the risk of injury.<br />

• Drills used for plastics are most suitable for drilling.<br />

• Splintering of the DUROPAL <strong>HPL</strong>-Solid on the outlet side can be avoided by <strong>working</strong> on a firm surface<br />

<strong>and</strong> gradually reducing the feed speed.<br />

• Drills with a tip angle of 50-60° should preferably be used for through-holes.<br />

• Ensure when centre-drilling that a minimum of panel material remains.<br />

• This requires a minimum remaining thickness for blind holes of at least 1.5 mm, <strong>and</strong> at least 3 mm<br />

for holes parallel to the surface.<br />

• In all DUROPAL <strong>HPL</strong>-Solid, threads can be cut <strong>and</strong> self-tapping screws used without any problems.<br />

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8.3.3 Internal recesses <strong>and</strong> cut-outs<br />

• For internal recesses <strong>and</strong> cut-outs, particular care should be taken to round off the corners.<br />

• The internal radius must be at least 5 mm.<br />

8.3.4 Bonding of material<br />

• Bonded joints must be made so as not to hinder the dimensional changes of the DUROPAL <strong>HPL</strong>-Solid.<br />

• Care must also be taken to ensure that the panels are all bonded in the same direction.<br />

8.3.5 Post-forming<br />

• The area to be formed must be milled out on one side to approx. 1 mm, depending on the desired radius.<br />

• During the milling process, overheating must be avoided <strong>and</strong> exact tool <strong>and</strong> tool guidance ensured,<br />

in order not to impair the post-forming properties.<br />

• DUROPAL <strong>HPL</strong>-Solid is formed in a stationary postforming press under exposure to heat.<br />

• After cooling of the formed DUROPAL <strong>HPL</strong>-Solid, the remaining cavity is filled out with hardening<br />

synthetic resin while still in the stationary postforming system, or reinforced by the insertion of adapters.<br />

8.3.6 Fixings<br />

• For the attachment of rigid objects (e.g. profiles, rails, fittings), the through-holes in DUROPAL <strong>HPL</strong>-Solid<br />

should be drilled slightly larger.<br />

• In the case of blind holes (e.g. splay dowels), the holes for the objects to be attached should also be<br />

made slightly larger. In this case too, the use of a lubricant between the object <strong>and</strong> the DUROPAL <strong>HPL</strong>-<br />

Solid is advisable.<br />

• Self-tapping screws with a low pitch produce good screw-holding values. The holes must however<br />

always be pre-drilled in all cases! The hole diameter should be one thread depth smaller than the outer<br />

diameter of the screw. When inserting screws, the drill hole must be at least 1 mm deeper than the<br />

penetration depth of the screw. Screws should be lubricated before insertion.<br />

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• The highest screw retention strength is achieved by using splay dowels – These must not however have<br />

any cutting burrs. The remaining thickness of the DUROPAL <strong>HPL</strong>-Solid must be at least 1.5 mm! The use<br />

of expansion plugs parallel to the panel plane is not recommended.<br />

• For a through-attachment, the drill holes should be made at least 2-3 mm larger than the diameter of<br />

the attachment fitting. The necessary freedom of movement can also be achieved by the use of elastic<br />

sleeves (e.g. of polyamide).<br />

8.3.7 Doors<br />

• Small doors (e.g. for furniture) made of DUROPAL <strong>HPL</strong>-Solid can be fitted with two hinges.<br />

• Large doors for toilet cubicles <strong>and</strong> changing rooms should be attached by more than two hinges,<br />

in order to provide the necessary dimensional stability.<br />

• The necessary expansion play for the DUROPAL <strong>HPL</strong>-Solid must be taken into account in the selection<br />

of the hinges. To reduce the play, the door leaf should be cut lengthwise from the panel.<br />

• The frame construction must be stable, level <strong>and</strong> stress-free; the door latches, locks <strong>and</strong> any necessary<br />

rubber seals must also not introduce any constant tensions into the door leaf.<br />

• The continual effect of increased air humidity <strong>and</strong>/or high temperature on one side of the door can<br />

lead to distortion of the panel. Adequate circulation must therefore be ensured.<br />

8.3.8 Assembly<br />

• The sub-construction <strong>and</strong> DUROPAL <strong>HPL</strong>-Solid change under the effect of relative air humidity <strong>and</strong><br />

temperatures. Care must be taken during assembly to ensure adequate play of the attachment, so that<br />

the underneath construction <strong>and</strong> panelling can move accordingly.<br />

• The following should also be noted for panelling:<br />

• The stability of panelling is determined by the sub-construction <strong>and</strong> thickness of the panelling material.<br />

• The sub-construction must be protected against corrosion <strong>and</strong> rotting.<br />

• Adequate rear-ventilation must be ensured. In case of inadequate back-ventilation, this can result in<br />

distortion due to different climatic conditions on the front <strong>and</strong> rear side. If no adequate back-ventilation<br />

can be provided due to construction reasons Duropal <strong>HPL</strong>-Solid MR with a moisture barrier must be<br />

used in order to counteract any bowing.<br />

• DUROPAL <strong>HPL</strong>-Solid muss must be left with the necessary freedom of movement (expansion <strong>and</strong><br />

contraction).<br />

• A particular advantage of DUROPAL <strong>HPL</strong>-Solid is that joints or divisions of the panels can be arranged<br />

so that installations are also accessible at a later date.<br />

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8.3.9 Joints<br />

• If two DUROPAL <strong>HPL</strong>-Solid panels are joined using tongue <strong>and</strong> groove, the<br />

following approximate values apply: Groove width a approx. d/3<br />

Groove side thickness b approx. d/3<br />

Tongue length c ≥ 10 mm<br />

Panel thickness d ≥ 10 mm<br />

• Because of possible dimensional changes, DUROPAL <strong>HPL</strong>-Solid must be<br />

installed with adequate play between the tongue <strong>and</strong> groove.<br />

• DUROPAL <strong>HPL</strong>-Solid below 10 mm thickness should not be joined using a tongue <strong>and</strong> groove joint.<br />

• It is advantageous to use a joint with a “false tongue” is also advantageous, since it enables the<br />

complete use of the panel size, <strong>and</strong> simplifies processing.<br />

• According to the anticipated stress, corner connections should be made using only brackets or corner<br />

rails.<br />

9. Cleaning <strong>and</strong> care of DUrOPAL <strong>HPL</strong><br />

Please note our <strong>instructions</strong> on the cleaning <strong>and</strong> care of DUrOPAL <strong>HPL</strong>!<br />

The following information refers to the surfaces of decorative DUROPAL <strong>HPL</strong> to EN 438 <strong>and</strong> <strong>elements</strong><br />

made using it. The cleaning <strong>instructions</strong> apply both for soiling under normal use <strong>and</strong> for heavier soiling<br />

which might occur during the fitting <strong>and</strong> installation of DUROPAL <strong>HPL</strong> <strong>elements</strong>. DUROPAL real metal laminates<br />

should be cleaned using a soft cloth <strong>and</strong> a mild cleaning agent without any abrasive components.<br />

Stubborn marks can be removed with white spirit. The use of acetone is not recommended.<br />

general <strong>instructions</strong><br />

DUROPAL <strong>HPL</strong>, due to its resistant, hygienic <strong>and</strong> sealed surface, requires no special care. It is easy to<br />

clean. Special cleaning substances are not required. Furniture polishes <strong>and</strong> cleaning agents containing<br />

wax should not be used. The mildest possible substances should be used for cleaning. Materials containing<br />

abrasive components should not be used under any circumstances. Sometimes special cleaners have to be<br />

used for cleaning which can be corrosive or inflammable, or contain solvents. In such cases, the applicable<br />

accident prevention regulations must be observed, <strong>and</strong> the rooms adequately ventilated. The product designation<br />

markings applied in the factory consist of a water-soluble ink, <strong>and</strong> should therefore be removed<br />

using only water.<br />

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Cleaning recommendations<br />

Cleaning <strong>instructions</strong> <strong>and</strong> example explanations of special problems are given below. The mildest method<br />

should always be used first.<br />

Slight, recent soiling<br />

Normal soiling, longer-acting<br />

Heavy, stubborn soiling, old stains<br />

Dust, dirt, dust-grease mixture, pencil, chalk<br />

Paper towels; soft, clean cloths (dry or damp); sponge etc.<br />

When cleaning damp, wipe dry with absorbent paper towels.<br />

Clean, hot water, clean cleaning rags or cloths, soft sponge or brush. Micro- fibre cloths soaked in<br />

hot water are particularly suitable.<br />

Apply normal cleaning agents without abrasive components, washing-up liquid, soft or hard soap<br />

<strong>and</strong> leave to soak in according to the level of soiling, <strong>and</strong> then remove completely in order to prevent<br />

streaks from forming. Wipe dry with clean, <strong>and</strong> absorbent cloths (ideally paper towels), changing the<br />

cloths frequently.<br />

grease, oil, fingerprints, felt <strong>and</strong> marker pens, inks, nicotine deposits,<br />

rubber abrasion marks<br />

Cleaning method as for dust, dirt, pencil, chalk.<br />

Cleaning method as for dust, dirt, pencil, chalk. Organic solvents such as acetone, white spirit,<br />

petrol, nail-varnish remover.<br />

Leave detergent or paste produced from detergent <strong>and</strong> water to act overnight; liquid cleaner with<br />

very fine polishing powder.<br />

Do not use on high-gloss surfaces<br />

Mild bleaching agent (with care).<br />

Should only be used occasionally! Bleaching agent should be removed completely after<br />

a short action time (10 – 15 minutes)!<br />

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Limescale remains, water marks, rust<br />

Cleaning method as for dust, dirt, pencil, chalk.<br />

Cleaning method as for dust, dirt, pencil, chalk.<br />

Leave detergent or paste produced from detergent <strong>and</strong> water to act overnight; liquid cleaner<br />

with very fine polishing powder.<br />

Do not use on high-gloss surfaces!<br />

Mild bleaching agent (with care).<br />

Should only be used occasionally! Bleaching agent should be removed completely after a<br />

short action time (10 – 15 minutes)! In case of particularly stubborn limescale, cleaning agents<br />

containing acids can also be used (10% acetic or citric acid).<br />

Coffee, tea, fruit juices, sugar solutions<br />

Cleaning method as for dust, dirt, pencil, chalk.<br />

Cleaning method as for dust, dirt, pencil, chalk.<br />

Leave detergent or paste produced from detergent <strong>and</strong> water to act overnight; liquid cleaner with<br />

very fine polishing powder.<br />

Do not use on high-gloss surfaces!<br />

Mild bleaching agent (with care).<br />

Should only be used occasionally! Bleaching agent should be removed completely after<br />

a short action time (10 – 15 minutes)!<br />

Wax remains, wax crayons<br />

Cleaning method as for dust, dirt, pencil, chalk.<br />

Cleaning method as for dust, dirt, pencil, chalk. Organic solvents such as acetone, white spirit, petrol,<br />

nail-varnish remover. Paraffin <strong>and</strong> wax remains should be removed mechanically. Avoid scrapers.<br />

Use a plastic or wooden spatula. Iron off remains using blotting paper.<br />

Leave detergent or paste produced from detergent <strong>and</strong> water to act overnight; liquid cleaner<br />

with very fine polishing powder.<br />

Do not use on high-gloss surfaces!<br />

Mild bleaching agent (with care).<br />

Should only be used occasionally! Bleaching agent should be removed completely after<br />

a short action time (10 – 15 minutes)!<br />

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<strong>PR</strong>ODUCT INFORMATION<br />

Lipstick, shoe polish, floor polish, wax polish, marker<br />

Cleaning method as for dust, dirt, pencil, chalk.<br />

Cleaning method as for dust, dirt, pencil, chalk. Organic solvents such as acetone, white spirit,<br />

petrol, nail-varnish remover.<br />

Leave detergent or paste produced from detergent <strong>and</strong> water to act overnight; liquid cleaner<br />

with very fine polishing powder.<br />

Do not use on high-gloss surfaces!<br />

Mild bleaching agent (with care).<br />

Should only be used occasionally! Bleaching agent should be removed completely after<br />

a short action time (10 – 15 minutes)!<br />

Bacteriological soiling<br />

(soap remains, skin cells, pathogens, blood, urine, excrement)<br />

Cleaning method as for dust, dirt, pencil, chalk.<br />

Cleaning method as for dust, dirt, pencil, chalk.<br />

Additional treatment with disinfectant according to the applicable conditions. Steam-cleaning<br />

is possible.<br />

Leave detergent or paste produced from detergent <strong>and</strong> water to act overnight; liquid cleaner<br />

with very fine polishing powder.<br />

Do not use on high-gloss surfaces!<br />

Mild bleaching agent (with care).<br />

Should only be used occasionally! Bleaching agent should be removed completely after<br />

a short action time (10 – 15 minutes)!<br />

Darker patches after treatment with solvents (streaking)<br />

Cleaning method as for dust, dirt, pencil, chalk.<br />

Cleaning method as for dust, dirt, pencil, chalk.<br />

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Water-soluble paints, stains, emulsion paints, adhesives, dispersions (PVAc)<br />

Cleaning method as for dust, dirt, pencil, chalk.<br />

Water or organic solvents<br />

Cleaning method as for dust, dirt, pencil, chalk.<br />

Soften with water or organic solvents, then peel or rub off.<br />

Paints, varnishes <strong>and</strong> adhesives containing solvents<br />

(paint residue, splashes, spray paints <strong>and</strong> stamping ink)<br />

Organic solvents.<br />

Organic solvents such as acetone, white spirit, petrol.<br />

In case of production processes using adhesives <strong>and</strong> paints, prior consultation with the manufacturer<br />

is recommended on which cleaning agent is most suitable for the removal of possible soiling caused<br />

during production.<br />

Soften with water or organic solvents, then peel or rub off.<br />

Paint residue can also sometimes be removed mechanically after drying.<br />

Two-component paints <strong>and</strong> adhesives such as synthetic resins, e.g. urea resin<br />

These must be removed immediately! Water or organic solvents. Cleaning is only possible before<br />

hardening!<br />

Remove immediately after contact with water or organic solvents.<br />

In case of production processes using adhesives <strong>and</strong> paints, prior consultation with the manufacturer<br />

is recommended on which cleaning agent is most suitable for the removal of possible soiling caused<br />

during production.<br />

No cleaning possible! Remains of hardened condensation <strong>and</strong> reaction resin adhesives cannot<br />

generally be removed after hardening.<br />

Silicone, sealants, furniture care substances<br />

Rub dry; silicone-remover.<br />

Silicone-remover.<br />

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<strong>PR</strong>ODUCT INFORMATION<br />

Important <strong>instructions</strong><br />

During use, please clean the DUROPAL <strong>HPL</strong> surface regularly. Special cleaning substances are not<br />

generally required. Streaks can occur when cleaning with organic solvents containing oil (e.g. white spirit),<br />

as well as with cold water <strong>and</strong> frequently used cloths or window leathers. To ensure cleaning does not<br />

result in dark patches <strong>and</strong> streaks, the surface should be rinsed with hot water <strong>and</strong> then wiped dry using<br />

normal household paper towels. Avoid using furniture polishes <strong>and</strong> cleaning agents containing wax as<br />

these tend to impair the surface textures of the DUROPAL <strong>HPL</strong> surfaces <strong>and</strong> build up into a dirt-retaining<br />

layer. For regular cleaning, please do not use any abrasive agents; furniture polishes, furniture cleaning<br />

<strong>and</strong> bleaching agents should also be avoided.<br />

Cleaning agents containing strong acids or salts will damage the surface (limescale removers based on<br />

formic <strong>and</strong> aminosulphuric acid, drain cleaner, hydrochloric acid, silver polish <strong>and</strong> oven-cleaner).<br />

Please note when cleaning with solvents:<br />

• Follow accident prevention regulations<br />

• Open the windows<br />

• Do not expose to naked flames<br />

If you have any questions, please feel free to contact us at any time.<br />

Closing statement:<br />

All the information contained here is based on the current status of the science <strong>and</strong> technology.<br />

It does not constitute a guarantee. It is the personal responsibility of the individual user of the products<br />

described in this data sheet to observe the existing laws <strong>and</strong> regulations.<br />

A service of<br />

PFLEIDERER Industrie GmbH • Product Management<br />

Holzstraße 6 - 10 • D-33332 Gütersloh • Telephone: 0 52 41 / 8 71 - 0 • Telefax: 0 52 41 / 8 71 - 9 87<br />

e-mail: produktmanagement@pfleiderer.com • Internet: www.industrie.pfleiderer.com<br />

099 PI <strong>Processing</strong> <strong>and</strong> <strong>working</strong> <strong>instructions</strong> Page 34 of 34

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