EcoTop Fabrication Instructions

EcoTop works much like a hardwood or solid surface, therefore no specialized equipment is required for fabrication. Here are some recommendations:

• Always work in a well-ventilated area, use eye and ear protection, and wear a dust mask.
• If possible, use a triple-chip carbide blade.
• Increase cutting rate if you detect excess heat.
• Fully support the EcoTop slab at all times during the cutting process to eliminate the
  opportunity for the blade to bind due to a shift in weight.
• When shaping EcoTop with a router, use carbide bits.
• Plan accordingly to maintain cutting pace when cutting tight spots such as an
  inside corner.
• We recommend you take a few practice runs on a piece of scrap material before cutting.
• Coarse shavings indicate proper cutting rate.
• EcoTop should be secured using mechanical fasteners and silicone.
• Wood screws provide tremendous fastening strength.
• Pilot holes must be drilled slightly larger than the shaft of the screw and not larger than
  the outside edge of the screw.
• Insert screws slowly to ensure they don't snap or overheat.
• Screw heads may become hot immediately after insertion.
• Exercise caution when touching them.
• EcoTop can also be tapped to accommodate threaded fasteners or threaded inserts.
• Fasteners may be press-fit or cast in place with an epoxy compound.

Seaming and Bonding
Please note color and sheet thickness may vary from sheet to sheet. It is very important to keep the top even, due to the fact that EcoTop is bonded layers of paper. Like a wood veneer, excessive sanding in one area can leave a ghostlike line as a result of sanding through the top layer.

EcoTop seams may be visible and should be considered in the design process. Plan seams away from sink cutouts and cook top cutouts.

To join sections, use the following instructions:
On a sturdy, level surface, set out spacer bars of uniform thickness and place the EcoTop sections on them. Leave a gap between the two sections that is slightly less than the width of a straightedge router bit. Secure a straightedge to the section and use the straight edge as a fence to run the router through the gap, allowing the bit to shave a thin section of both edges simultaneously. This procedure is known as the mirror cut/joint. This will create edges that match perfectly.

Prepare for the mechanical strengthening and aligning of the joint using one of the following two methods.

Using a biscuit joiner, cut slots for standard wood biscuits or rout the necessary holes for the type of tight-joint fasteners typically used to connect sections of post form laminate counters. Glue the joint using a slow drying two-part epoxy. CA5 adhesive may also be used. Tint the epoxy by mixing in some of the sanding dust from a previous step. Once the joint has cured, lightly sand it to blend the seam with the surrounding area. It is possible to seal joints with standard caulking sealants. Typical areas for this treatment are the underside of the backsplash and around under-mounted sinks. Use a moderate amount of caulk in a color compatible to the EcoTop panel. Clear caulk may also be used. When doing a built up edge we suggest double stacking the material, not a V groove drop-down edge. We also recommend using screws at a maximum width of 12" to secure the two pieces along with one of the previously mentioned adhesives.

Sanding and Finishing
EcoTop comes with a natural finish on both surfaces. Exposure to shipping and handling may cause slight scratches in the surface. EcoTop is a natural product and unlike other solid surfaces that have been machined to very high tolerances, it may have a surface quality with slight imperfections such as low and high areas. With this in mind, it is recommended that sanding be kept to a minimum.

If machining marks exist on cut edges, a belt sander with 100-grit sandpaper may be used as a first step, finishing with 180-grit sandpaper.

If a satin sheen is desired, surface sanding should begin with an abrasive no coarser than a fiber abrasive pad such as 3M Scotch Brite, red or grey. (Red = fine / grey = superfine) Place the abrasive pad on the surface and position the random orbit sander pad at the center. Buff the entire surface until a uniform sheen is achieved. Wipe thoroughly with a damp cloth.

A final treatment of EcoTop Finish is recommended. This is an all-natural, eco-friendly and sustainable finish. Apply a thin coat to the surface with a clean soft cloth. Let finish stand for a minimum of 20 minutes and wipe off any excess finish. Surface may then be buffed by hand or car-polishing bonnet to achieve a deep satin luster.