Fitting and caring for your surfaces.

General maintenance

As with all worktops, a reasonable standard of laboratory housekeeping helps keep the surfaces in good condition. Clean up all spillages as soon as possible — staining agents and aggressive chemicals should not be left in contact with the tops for a prolonged period.

Areas of chemical attack or staining can be removed with a polishing compound or very fine abrasive paper, though this will alter the finish of the surface. Performance will not be affected. A wax furniture polish helps retain the gloss finish.

Components should not be exposed to dry-ice or liquid nitrogen, and heat-insulation pads should be placed between a top and a steambath or hotplate to prevent thermal stress.

Fitting sinks — undermount & flush fit

Overhang / underslung sinks supplied loose can be fitted to a worktop with a suitably sized cut-out (call for a recommendation if unsure). Drill clearance holes for self-tapping screws through the sink flange with a masonry drill, and a pilot hole in the worktop to accept them. Apply a layer of silicone sealant to the flange and screw the sink securely into place. Remove excess silicone before it cures.

Fitting sinks — drop-on

Drop-on sinks should be fitted into a suitable hole (call for a recommendation if unsure) with a layer of silicone or epoxy under the flange. Remove excess before it cures.

Apply a radius fillet of grout to the joint between sink flange and worktop to ensure an easily-cleanable, fully sealed joint. Apply along the joint using the wooden sticks provided, then run the radius end of the stick around for a tidy finish. When the excess grout becomes rubbery, carefully remove it with a sharp flat chisel and wipe down with cellulose thinners.

Fitting sinks — drop-in

Drop-in sinks should be fitted into an appropriate rebated cut-out and bedded into a layer of silicone or epoxy, smoothed off level with the flange. Remove excess before it cures.

Wastes & overflows

Sinks can be supplied complete with a chemically-resistant polypropylene waste in grey, white or black. Wastes have a 73 mm diameter flange and a 1½″ BSP tail, and connect to the relevant Vulcathene industrial waste components. They can also be combined with a standing waste tube or an overflow kit.

Fitting edging & upstand

All edging and upstand should first be dry-fitted to check size and fit; minor adjustments can be made with 80-grit sandpaper. The underside of the edging/upstand and the area it fits to must be rubbed down with sandpaper and then cellulose thinners — both components carry a release coating from casting that must be removed before anything will bond.

Apply a thin layer of freshly-mixed grout to the underside, place in position and clamp down securely (use blocks to protect the surface). Remove squeezed-out grout with a sharp flat chisel when rubbery; after 10–15 minutes the grout hardens and clamps can be removed.

Apply a radius fillet of grout to the joint between edging and worktop for an easily-cleanable, fully sealed joint. This radius fillet is not required with flat sheet upstands that meet the top at a 90° angle.

Jointing tops

All joints are machined for a biscuited joint; all biscuits and grout are supplied with the tops. Clean and degrease joints with cellulose thinners before starting. Apply vinyl tape to the top surface adjacent to the joint, line up the two sections and push together to a gap of approx. 2–3 mm.

Apply freshly-mixed grout to the abutting edges, then pull together with sash-clamps until the joint line is under 1 mm wide — the narrowest joint is always the strongest. Level and clamp the front edge with levelling blocks and G-clamps either side. Level off excess grout to the top of the vinyl tape with a straight edge.

After 5 minutes carefully remove the vinyl tape without damaging the joint. After a further 4–5 minutes the grout becomes slightly rubbery; wipe down with cellulose thinners using strokes across the joint, not along it.

Drilling & cutting

Small holes can be drilled using masonry or tungsten-carbide-tipped drills; larger holes require diamond-plated holesaws. Small cuts can be made with diamond-plated jigsaw blades (available from Simmons). For substantial cutting, or cuts needing a cosmetic finish, return the tops to Simmons for factory cutting.

Epoxy resin grout

Grout is supplied as two components — resin and hardener — with a workable life of approximately 5 minutes once mixed. Mix only a manageable amount at a time and complete all preparatory work first. Measure resin and hardener at the ratio stated on the containers onto a mixing board and mix thoroughly with the wooden sticks provided until homogeneous.

A minimum room temperature of 5°C is required to initiate the cure; the warmer the room, the quicker the reaction. Latex gloves should be worn when using grout components and cellulose thinners.

Worktop supports

Provide continuous rails to the front and rear of worktops. Unsupported spans should not exceed 800 mm. Fume cupboard bases should have continuous perimeter support, and any base longer than 900 mm should also have central support.

Storage of tops & bases

Store all tops and bases flat — never leaning against a wall, as this can cause bowing. Corner protectors are provided for transport and handling; if components are stored for any period, remove the corner protectors.