Design Guide Durcon / Epoxy Resin Handbook / Durcon Incorporated. Printed in USA.

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2 Durcon / Epoxy Resin Handbook / 2

3 INTRODUCTION...4 GENERAL PRACTICES...6 I. Drawing Requirements...6 II. Epoxy Formulation...7 III. Colors...7 IV. Edges...8 V. Surfaces...9 VI. Thickness VII. Joints VIII. Cutouts IX. Curbs (Backsplashes) X. Service Chases (Box Curbs) XI. Islands/Peninsulas XII. Shelving/Pegboards XIII. Fume Hood Bases (Worksurfaces) XIV. Sinks XV. Cupsinks XVI. Troughs XVII. Sink Units (Worksurfaces) XVIII. Installation XIX. Laboratory Specifications XX. Reference Information XXI. Contact Information XXII. Glossary XXIII. Notes Contoura, ContouraTop and ControlTop are trademarks of Laboratory Tops, Inc. Laboratory Tops, Inc., LabTops, ClassicTop, SolTra, DropIn and ADA DropIn are registered trademarks of Laboratory Tops, Inc. Durcon / Epoxy Resin Handbook / 3

4 INTRODUCTION LABORATORY COUNTERTOP SELECTION As appeared in R&D Magazine The laboratory worksurface is by far the single most visible and interacted with component of any laboratory. Since the late 1980 s, when epoxy resin replaced cement asbestos as the industry standard for lab worksurfaces, manufacturers have strived to refine countertop designs to perform beyond the chemical, heat and load bearing requirements of the research lab. It is now possible to select between modular designs, colors and many additional safety and aesthetic options to individually tailor each laboratory s efficiency, accuracy, comfort and precision for various applications. Designing for Precision/Reconfiguration Typically, new laboratory worksurfaces are required for new facilities, the reconfiguration of existing space or for a complete retrofit. Workspaces designed with a degree of flexibility are recommended due to R&D labs project specific nature (the useful life of an R&D lab is on average very short and may require alterations as often as every three to five years). Long-term savings can be achieved by forecasting future requirements and specifying appropriate countertops (and supporting cabinetry) in the initial construction of the facility. Worksurface Evaluation Criteria The lab owner in conjunction with the architect, the lab manager and in some cases the lab user should specify the type (or types) of worksurfaces required in the initial design phase of a lab project. Worksurface evaluations should be based upon individual lab requirements for: Resistance to the chemicals to be used Heat resistance Liquid absorption Load bearing capabilities Impact and abrasion resistance Electrical conductivity Liquid containment and liquid disposal (especially in sink areas and fume hoods) Ease of maintenance Ergonomics Availability ADA compliance Color Overall appearance Special requirements (i.e., irregular shapes, minimal joints, etc.) Each lab design project will have unique worksurface requirements; however, depending upon laboratory classification, some general guidelines can be supposed: Durcon / Epoxy Resin Handbook / 4

5 Chemistry Use Area (i.e., Organic, Inorganic, Bio-chemical, Analytical) consideration should be given to chemical resistance, ease of cleaning, color suitability, strength, abrasion resistance and thermal shock resistance. Physics Use Area consideration should be given to physical strength, abrasion resistance, impact resistance and heat resistance. Biology Use Area consideration should be given to stain resistance, ease of cleaning, abrasion resistance plus bacteria and fungus resistance. Special Purpose Use Areas Where Chemical Resistance is a Prime Consideration (i.e., pathology/ hematology and other special biochemical areas) consideration should be given to impermeability and ease of cleaning. Special Purpose Use Areas Where Chemical Resistance is Not a Prime Consideration: Electronics consideration should be given to physical strength and other task specific characteristics. Electrical consideration should be given to insulation characteristics, dielectric strength and physical strength. Mechanical (i.e., metallurgical, geological, etc.) consideration should be given to resistance to physical abuse. Radioactive consideration should be given to contamination by radioactive material. Thermal consideration should be given to temperature requirements.* Certainly other classifications exist and practical combinations of the above laboratory types are numerous. For safety, evaluate worksurface needs based upon the usage in the hardest impacted areas of the lab. Typically fume hoods and sink areas see the majority of harsh chemicals and reactions. The Selection Process Once the worksurface requirements have been specified, various materials and styles can be evaluated for compliance. The three most popular work surfaces used today are epoxy resin, plastic laminate and phenolic resins. To facilitate the selection process, many worksurface manufacturers perform and publish the results of physical properties tests as well as chemical resistance tests that evaluate worksurface resistance to the chemicals commonly used in lab environments as well as standard measurements for hardness, flammability and deflection. These tests are provided as guidelines. Carefully evaluate results between various material types and between individual material manufacturers as occasionally results are impacted due to dissimilar testing methods. A variety of resources are available to help identify and evaluate worksurface materials and manufacturers. SEFA (Scientific Equipment and Furniture Association) is a non-profit organization dedicated to the enhancement of member company performance and the improvement of the quality and timely completion of laboratory facilities. The SEFA web site, provides a wealth of lab design information and links to member s web pages as well as government regulating agencies. Durcon / Epoxy Resin Handbook / 5

6 General Practices I. Drawing I. Drawing Requirements Requirements A. Complete A. Complete drawing drawing set set required. required. Include: Include: Title 1. Sheet Title Sheet Fixture 2. Fixture List/Information List/Information Sheet Sheet Floor 3. Floor Plans Plans Elevation 4. Elevation Details Details Top 5. Details Top Details Detail 6. Detail Sheets Sheets Cut 7. sheet Cut sheet submittal submittal package package with cutout with cutout requirements requirements (service (service fixtures, fixtures, sinks, sinks, grommets, grommets, etc.) etc.) B. B. Specify worksurface dimensions from the the edges and and not not from any any other surface such such as as the the backsplash. Durcon s backsplash point Durcon s of origin point for all of origin drawings for all is the drawings lower left is the hand lower corner left hand of a piece corner or assembly. of a piece or C. Ensure assembly. that top lengths and cutout locations match elevations (if discrepancies are detected, worksurface drawings supercede all others). C. Ensure that top lengths and cutout locations match elevations (if discrepancies are detected, D. On worksurface large projects drawings try to supercede standardize all the others). sizes of multiples of any type of unit (this allows us the option to mold instead of glue to reduce cost and provide a better product). D. On large projects try to standardize the sizes of multiples of any type of unit (this allows us the E. Detail the drawing to make clear top material of each piece: option to mold instead of glue to reduce cost and provide a better product). e = epoxy E. Detail the drawing to make clear top material of each piece: eg = epoxy greenstone 1. e = epoxy pl = plastic laminate 2. eg = epoxy greenstone ss = stainless steel 3. pl = plastic laminate p = phenolic or compact laminate 4. ss = stainless steel F. Specify piece size and weight limitations. 5. p = phenolic or compact laminate Separate worksurface pieces can be molded up to 96" x 72" F. Specify piece size and weight limitations. Epoxy resin tops 1" thick weigh approximately 11 lbs per sq. ft. 1. Separate worksurface pieces can be molded up to 96 x Epoxy resin tops 1 thick weigh approximately 11 lbs per sq. ft. G. Epoxy tops must be adequately supported throughout worksurface runs (cabinets, cleats, stringers, aprons, etc. can all provide support). Durcon / Epoxy Resin Handbook / 6

7 H. Special cutouts such as stainless steel sinks, grommets and vandal resistant fixtures require a cut sheet and fixture orientation to ensure correct positioning (templates will not be accepted). I. Minimize double facing on pegboards and shelves. We do not double face shelves that are less than 18 above the worksurface. J. Reagent shelves should not be drawn over tops. Separate drawings eliminate confusion. K. Specify pallet size limitations if necessary. L. Indicate on each elevation if tops are being installed prior to struts or uprights. M. Specify if tops are to be palletized by room, floor, etc. when P.O. and drawings are submitted. II. Epoxy Formulation A. Traditional Industry s standard material that provides the greatest combination of physical and chemical resistance property as well as heat and flame resistance. B. Greenstone Based on traditional formula with at least 10% post-consumer recycled content. Complies with LEED Credit MRC 4.1. C. Durastone Based on traditional formula with granite chips substituted for pigment. III. Colors A. Specify colors clearly (example: Platinum Gray, Pearl, Gray) to ensure the correct color is provided for the project. B. Standard colors include: 1. Black Onyx 2. Gray 3. Graphite 4. Forest Green 5. Tan 6. Steel Blue 7. Alpine White C. Custom Colors Custom colors are available. A color chip must be submitted to Durcon when requesting a custom color. Allow a minimum of six weeks for shipment after customer approval of Durcon s epoxy resin custom color sample. D. Color Pricing 1. Black Onyx - base price 2. Please contact a Durcon representative for current pricing for Standard and Custom color options. Durcon / Epoxy Resin Handbook / 7

8 Edges R. Available edges: IV. Edges A. Available edges: B. Supply S. Supply edge edge finishing finishing requirements requirements for each for each piece piece including: including: 1. RAD RAD = = 1/4" 1/4 Machined Radius Radius 2. BEV = 1/8" 1/8 Machined Bevel 3. CONT CONT = = 1/2" 1/2 Molded Molded Radius Radius 4. U U = = Unfinished Durcon / Epoxy Resin Handbook / 8

9 C. Specify non-standard ClassicTop corner details (ContouraTop corners are molded). T. Specify 1. A blended non-standard radius ClassicTop corner is standard corner details unless (ContouraTop otherwise specified. corners are molded). A 2. blended Larger radius corner can be is specified. standard An unless up-charge otherwise will apply. specified. D. Specify Larger edges radius to can receive be specified. drip grooves An up-charge (note: drip will grooves apply. are not standard on Contoura and U. Contoura Specify edges ControlTops, to receive Fume drip Hood grooves Bases (note: and drip Marine grooves Edge are Tops). not standard on Contoura and Contoura ControlTops, Fume Hood Bases and Marine Edge Tops). E. Standard overhang for Classic worksurfaces is 1 from face of cabinet body. Contoura worksurfaces V. must Standard maintain overhang a 1 overhang for Classic (minimum) worksurfaces on all is 1" sides from to face clear of casework cabinet body. corners. Contoura worksurfaces must maintain a 1" overhang (minimum) on all sides to clear casework corners. V. Surfaces Surfaces A. Select between: W. Select 1. Flat between: - Maximum worksurface space with the greatest configurational flexibility. Flat 2. ClassicTop - Maximum - worksurface 1/8 machined space bevel with or 1/4 the greatest machined configurational radius edge flexibility. ClassicTop 3. Contoura - 1/8" - Integrally machined molded bevel or 1/2 1/4" top machined edge radius radius and edge 1-1/2 exposed corner radius (not Contoura suitable - Integrally for every molded application). 1/2" top edge radius and 1-1/2" exposed corner radius (not suitable for every application). 4. Should maintain a 1 overhang on all sides to clear casework corners. Should 5. Marine maintain - Worksurface a 1" overhang with a on 1/4 all raised sides to liquid clear containment casework corners. rim (eliminating the need for drip Marine grooves). - Worksurface with a 1/4" raised liquid containment rim (eliminating the need for drip grooves). 6. ClassicTop Marine Marine Dished Dished worksurfaces with with a 1/8" a 1/8 machined machined bevel bevel or a or 1/4" a 1/4 machined machined radius are available. radius are available. Durcon / Epoxy Resin Handbook / 9

10 B. Integrally molded ClassicTop Marine edges shall be used unless configuration precludes the use of standard molds (please contact Durcon for recommended marine worksurface sizes as a substantial savings can be obtained by utilizing existing molds [or if it is a specification requirement]). 1. Where molding is not an option, the method of marine edge application is determined by Durcon to ensure maximum slab utilization (see below). 2. Standardization of sizes of marine edge tops allows for the option of molding instead of gluing resulting in reduced costs and a better product. C. Applied ClassicTop Marine edges are 1/4 thick Durcon Epoxy Resin containment strips glued to the top edge with an epoxy adhesive. D. ClassicTop Marine Edges may also be applied ¼ thick L shaped strips. E. Cut and seam ClassicTop Marine edges are integrally molded marine worksurface sections applied to the side of the worksurface with a factory butt joint. EPOXY ADHESIVE JOINT 1" [25mm] 1" [25mm] or 1-1/4" 32mm] L SHAPE APPLIED MARINE EDGE STANDARD APPLIED MARINE EDGE EPOXY ADHESIVE JOINT 1" [25mm] 1" [25mm] 1" [25mm] or 1-1/4" 32mm] APPLIED MARINE EDGE 1" [25mm] or 1-1/4" 32mm] INTEGRAL MARINE EDGE STANDARD APPLIED MARINE EDGE STANDARD MARINE EDGE 1" [25mm] EPOXY ADHESIVE JOINT 1" [25mm] or 1-1/4" 32mm] CUT AND SEAM MARINE EDGE ALTERNATIVE APPLIED MARINE EDGE Durcon / Epoxy Resin Handbook / 10

11 Contoura F. Contoura ControlTop ControlTop marine marine worksurfaces worksurfaces feature feature an integrally an integrally molded molded 1/2" radius 1/2 radius outer outer edge and edge a and worksurface a with a 1/4" worksurface raised liquid containment with a 1/4 raised rim. liquid containment rim. 1. Contoura v. Control Contoura marine Control worksurface marine worksurface edges will edges not be will applied. not be Please applied. contact Please Durcon contact for Durcon for available sizes. available sizes. 2. Contoura vi. Control Contoura worksurfaces Control worksurfaces should maintain should a maintain 1 overhang a 1" on overhang all sides on to all clear sides casework to clear casework corners. corners. Use G. curb Use for curb containment for containment back on edge back of edge ClassicTop of ClassicTop Marine Marine and Contoura and Contoura Control Control marine marine worksurfaces. Stacking loose curbs on top of marine edges is acceptable but will add to the cost. worksurfaces. Stacking loose curbs on top of marine edges is acceptable but will add to the cost. RECOMMENDED ACCEPTABLE Durcon / Epoxy Resin Handbook / 11

12 H. X. Specify Specify worksurface worksurface dimensions dimensions from from the the bottom bottom left left hand hand corner corner of of the the countertop, countertop, not not from from any any other other surface surface (Example: (Example: do not do measure no measure from from backsplash). the backsplash). X. Specify worksurface dimensions from the bottom left hand corner of the countertop, not from any other surface (Example: do not measure from backsplash). Y. Avoid seams in knee spaces and wet areas. I. Y. Avoid seams in in knee spaces and wet areas. Thickness VI. Thickness Thickness A. Z. Specify Specify top top thickness. thickness. Z. 1" Specify thick 1. 1 solid thick top thickness. epoxy solid epoxy resin is resin the is industry the industry standard. standard. 3/4" and 3/4 1-1/4" and 1-1/4 thick worksurfaces thick worksurfaces are available are for special applications. 1" thick available solid epoxy for special resin is applications. the industry standard. 3/4" and 1-1/4" thick worksurfaces are available for special Specify applications. marine worksurface thickness from the raised outer edge. The industry standard for marine tops is 1" thick. 2. Specify 1-1/4" thick marine outer worksurface edges are thickness also available. from the raised outer edge. The industry standard for Specify marine marine tops worksurface is 1 thick. thickness 1-1/4 thick from outer the edges raised are outer also edge. available. The industry standard for marine tops is 1" Specify thick. 1-1/4" fume thick hood outer worksurface edges are thickness also available. from the raised outer edge. Durcon fume hood bases are available in the 3. Specify industry fume standard hood 1-1/4" worksurface thickness. thickness 1" thick from outer the edges raised are outer also edge. available Durcon for special fume hood applications (see Specify fume hood worksurface thickness from the raised outer edge. Durcon fume hood bases are available Section bases XII). in the industry are standard available 1-1/4" in the thickness. industry standard 1" thick outer 1-1/4 edges thickness. are also 1 thick available outer for edges special are applications also (see Section available XII). for special applications (see Section XII). Joints VII. Joints Joints AA. Durcon does not allow for joints unless joint allowance is specified by customer. A. We recommend providing our minimum.06 Joint Allowance at all seams both at open ended and closed AA. ended Durcon elevations, does Use not with longest allow the for exception stock joints lengths unless to specific possible joint allowance customer to minimize is requirements. specified joints. by customer. 1. Use longest Do Use stock not longest space lengths stock notches, possible lengths holes, to possible minimize or cutouts minimize joints. at joint. joints. 2. Do not space Maintain Do not notches, space a minimum holes, notches, or 2 cutouts holes, of material or cutouts joint. between at joint. joints and all cutouts. 3. Maintain a Maintain Do minimum not place a minimum 2 joints of material over 2 of knee between material spaces joints between or pull and boards. joints all cutouts. and all cutouts. 4. Do not place Do not joints place finish over joints a knee run with over spaces a knee piece or spaces pull smaller boards. or than pull boards Do not finish Do not a run finish with a a run piece with smaller a piece than smaller 24. than 24. Durcon / Epoxy Resin Handbook 12 / 2007 Durcon Incorporated 9

13 VIII. Cutouts A. Specify cutout locations from the bottom left hand corner of the worksurface section to the centerlines of the cutout. Side View Sink Cutouts 1" Typical Sink Lip?" Side View DropIn Top View?" Sink Cutouts 1" Typical Undermount Sink Lip?" 48"?" 0.5" Typical Overhang DropIn 24" 15" 9" Undermount 0.5" Typical Overhang 5" Top View 48" 24" 15" 9" 2" 11" 31" 5" 2" 13" Specify Sink and Fixture Hole Location by the Centerline 11" 31" 13" Specify Sink and Fixture Hole Location by the Centerline Durcon / Epoxy Resin Handbook / 13

14 B. The standard location for a DropIn Sink cutout begins 3-1/2 from the worksurface s edges (subject CC. The standard location for a DropIn Sink cutout begins 3-1/2" from the worksurface s edges (subject to to casework constraints). C. DD. The The standard standard location location for for an an Undermount Sink Sink cutout cutout begins begins 4-1/2 4-1/2" from from the the worksurface s edges edges (subject (subject to casework to casework constraints). constraints). D. EE. Tooled inner corners are are standard. Specify if if a a squared inner corner is is required (an (an extra charge will be be applied applied for for hand hand sanding sanding square square inner inner corners). corners). In In certain certain applications applications enlarging enlarging the the cutout cutout for for clearance will eliminate the need to square the corners. clearance will eliminate the need to square the corners. E. FF. Centerline required on on all all cutouts (example: DropIn cutouts can can cause confusion when when measured from from edge edge to edge). to edge). F. GG. Special Special cutouts cutouts for for items items such such as stainless as stainless steel steel sinks, sinks, grommets grommets and and vandal vandal resistant resistant fixtures fixtures require require a cut sheet. a cut sheet. Curbs (Backsplashes) IX. Curbs (Backsplashes) HH. Loose curbs A. Loose The standard curbs height of loose curbs is 4". Loose 1. The curbs standard can be height fabricated of loose to any curbs height. is 4. We 2. recommend Loose curbs can a curb be thickness fabricated equal to any to height. the worksurface thickness for 1" and 3/4" thick tops. To maximize workspace, 3. We recommend 1-1/4" thick a curb epoxy thickness countertop equal installations to the worksurface should utilize thickness 1" thick for 1 curb and material. 3/4 thick tops. Curb To length maximize is determined workspace, by 1-1/4 worksurface thick epoxy length countertop unless otherwise installations specified. should utilize 1 thick Curb curb length material. will be shortened at finished edges: 1/8" 4. Curb for machined length is bevel determined edges by worksurface length unless otherwise specified. 1/8" 5. Curb for machined length will radius be shortened edges at finished edges: 1/2" 6. 1/8 for Contoura for machined edges bevel edges The 7. top 1/8 edge for machined of ClassicTop radius loose edges curbs can be supplied with a 1/8" machined bevel or a 1/4" machined radius. 8. 1/2 Please for Contoura specify preference edges on drawings. We recommend 9. The using top edge curb of for ClassicTop containment loose on curbs back can edge be of supplied marine with worksurfaces a 1/8 machined (See illustration bevel or in a Section 1/4 IV.) machined radius. 10. Please specify preference on drawings. We recommend using curb for containment on back edge of marine worksurfaces (See illustration in Section IV.) Durcon / Epoxy Resin Handbook / 14

15 ContouraTop and Contoura Control marine worksurfaces loose curbs are supplied with a standard 1/4" machined radius unless otherwise specified. A 1/8" machined bevel also available. Loose curb transitions are engineered as butt joints (not mitered). If mitered joints are required, they must be fabricated on site to allow for field conditions. If specified, Durcon will supply backsplashes in sufficient lengths to allow miter cuts to be made on site. Design Guide 1/4" machined B. ContouraTop radius and require Contoura additional Control epoxy marine filler worksurfaces at intersecting loose corners. curbs This are filler supplied must be with carefully a standard applied to create smooth 1/4 machined transitions. radius unless otherwise specified. A 1/8 machined bevel also available. C. Loose curb transitions are engineered as butt joints (not mitered). 1. If mitered joints are required, they must be fabricated on site to allow for field conditions. If ContouraTop and specified, Contoura Durcon Control will marine supply worksurfaces backsplashes loose in sufficient curbs are lengths supplied to allow with a miter standard cuts to 1/4" be machined made radius unless otherwise specified. A 1/8" machined bevel also available. on site. Loose curb transitions are engineered as butt joints (not mitered). D. 1/4 machined radius require additional epoxy filler at intersecting corners. This filler must be If mitered carefully joints applied are required, to create smooth they must transitions. be fabricated on site to allow for field conditions. If specified, Durcon will supply backsplashes in sufficient lengths to allow miter cuts to be made on site. 1/4" machined radius require additional epoxy filler at intersecting corners. This filler must be carefully applied to create smooth transitions. Durcon / Epoxy Resin Handbook / Durcon Incorporated

16 II. Integral (coved curb) backsplashes are available for ClassicTop and Classic E. Integral (coved curb) backsplashes are available for ClassicTop and Classic MarineTop only (utilize loose curbs for ContouraTops). 1. MarineTop only (utilize loose curbs for ContouraTops). Standard height of an integral curb is 4". 2. Standard height of an integral curb is 4. II. Integral 6" and (coved 8" tall curb) integral backsplashes curbs are are available available upon for request ClassicTop (an up-charge and Classic will apply) and 8 tall integral curbs are available upon request (an up-charge will apply). Custom MarineTop height integral only (utilize curbs loose can be curbs created for ContouraTops). up to 8 (an up-charge will apply). 4. Custom height integral curbs can be created up to 8 (an up-charge will apply). Integral Standard curbs are height 1" thick of an at integral the worksurface curb is 4". and taper to 3/4" thick at the top edge. 5. Integral curbs are 1 thick at the worksurface and taper to 3/4 thick at the top edge. 6" and 8" tall integral curbs are available upon request (an up-charge will apply). Custom height integral curbs can be created up to 8 (an up-charge will apply). Integral curbs are 1" thick at the worksurface and taper to 3/4" thick at the top edge. Utilize 6 F. and Utilize 8 long 6 and integral 8 long curb integral tops curb to reduce tops to costs reduce and costs minimize and seams minimize (3 minimum seams (3 minimum length recommended). length ClassicTop Coved recommended). Curb worksurfaces are available in seamless lengths up to 98". G. ClassicTop 4" Coved integral Curb curbs worksurfaces are available are in available depths up in to seamless 38". lengths up to 98. Utilize 6 1. and 4 integral 8 Integral long integral curbs heights are curb available tops between to in reduce depths 4" and costs up 8" to are and 38. available minimize in seams depths (3 up minimum to 31". length recommended). ClassicTop ClassicTop Marine 2. Integral Coved Coved curb Curb Curb worksurfaces heights worksurfaces between are are available 4 available and 8 in are in seamless available seamless lengths in lengths depths up up to up to 98". to 99". 31. Durcon measures curb height of coved curb marine edges H. ClassicTop Marine 4" integral from the Coved curbs top of Curb worksurfaces are the available marine in edge are depths (not available up from to in 38". the worksurface). seamless lengths up to 99. Durcon Marine worksurfaces measures curb with Integral height 4" tall integral curb of coved heights curbs between are marine available edges 4" and in from molded 8" are the available depths top of the of in depths 24", marine 30" up and edge to 33.9" 31". (not only. from the ClassicTop worksurface). Marine Coved Curb worksurfaces are available in seamless lengths up to 99". Durcon measures curb height of I. coved Marine curb worksurfaces marine edges with from 4 tall the integral top of the curbs marine are available edge (not in from molded the depths worksurface). of 24, 30 and 33.9 Marine only. worksurfaces with 4" tall integral curbs are available in molded depths of 24", 30" and 33.9" only. Marine worksurfaces with integral curb heights between 4" and 8" are available in a molded depth of 30" only. Marine J. Marine worksurfaces with with integral integral curb curb heights heights between between 4" and 4 8" and are 8 available are available in a molded in a molded depth depth of 30" only. of 30 only. Durcon / Epoxy Resin Handbook / 16

17 High/Low coved curb transitions (example: standing height to sitting height in a worksurface run). K. High/Low coved curb transitions (example: standing height to sitting height in a worksurface run). Protect regular height cabinet s exposed side with a loose curb installed (widthwise) on top of the low 1. worksurface. Protect regular height cabinet s exposed side with a loose curb installed (widthwise) on top of Recommend the low worksurface. a 1" worksurface overhang on the side of the regular height cabinet. 2. Recommend a 1 worksurface overhang on the side of the regular height cabinet. Durcon / Epoxy Resin Handbook / 17

18 Service Chases (Box Curbs) Service Chases (Box Curbs) X. Service Chases (Box Curbs) JJ. Epoxy service chases require the curb to be mounted away from the wall to allow space for piping and JJ. Epoxy fixture service mounts. chases require the curb to be mounted away from the wall to allow space for piping and A. fixture Epoxy service mounts. chases require the curb to be mounted away from the wall to allow space for piping and fixture mounts. B. The standard practice is is to install the cabinet away from the wall and mount the worksurface and The backsplash standard as practice normal. is Span to install the horizontal the cabinet space away from from the the wall wall to and the mount top of the backsplash worksurface with and backsplash as normal. Span the horizontal space from the wall to the top of the backsplash with an an epoxy backsplash resin as ledge normal. cap. Span the horizontal space from the wall to the top of the backsplash with an epoxy epoxy resin resin ledge ledge cap. cap. Allow ledge cap to overhang face of curb 1/4" (minimum). 1. Allow Allow ledge ledge cap cap to to overhang overhang face face of of curb curb 1/4" 1/4 (minimum). (minimum). An epoxy resin closure panel can be created for exposed open ends (closure panels fit inside the 2. service An An epoxy epoxy chase resin resin and closure closure are measured panel panel can can from be be created created the bottom for for exposed exposed of the service open open ends ends cap to (closure (closure the top panels panels of the fit fit cabinet/access inside the panel service inside and the chase from service and the are chase wall measured to and the are back from measured of the the bottom curb). from the Please of the bottom service draw of and cap the specify to service the material top cap of to the the of cabinet/access all top closure of panels. the cabinet/access and Durcon from will the not wall panel supply to and the from panels back the of unless the wall curb). to specified. the Please back draw of the and curb). specify Please material draw and of all specify closure panels. Durcon will not supply panels unless specified. Allow material enough of all space closure between panels. sinks Durcon and will front not of supply ledge panels caps for unless fixtures specified. (note: Durcon recommends 2-1/2" Allow enough from back space I.D. wall between of sink sinks to centerline and front of ledge fixture caps hole. for fixtures (note: Durcon recommends 3. Allow enough space between sinks and front of ledge caps for fixtures (note: Durcon 2-1/2" from back I.D. wall of sink to centerline of fixture hole. recommends 2-1/2 from back I.D. wall of sink to centerline of fixture hole. Islands/Peninsulas Islands/Peninsulas XI. Islands/Peninsulas KK. Without Service Strip KK. Without A. Service Without Strip Service Strip Durcon / Epoxy Resin Handbook / 18

19 1. Worksurface joints on islands and peninsulas should be made from Worksurface joints on Worksurface islands and joints peninsulas on islands should and peninsulas be made should from the be front made edge from to Worksurface the back edge. joints Lengthwise on islands and peninsulas Worksurface should joints be on made islands from and the peninsulas front edge should to the be back made edge. from Lengthwise Worksurface joints joints should on islands be avoided and if peninsulas joints avoided if possible. possible. should be made from the front edge to the back edge. Lengthwise joints should be avoided if B. With possible. Struts or Service Strip LL. With Struts or Service Strip LL. With Struts 1. or Location Service of Strip joints should be determined by the sequence (location) of the struts or service Location of joints should be determined by the sequence (location) of the struts or service Location strip. strip. of joints should be determined by the sequence (location) of the struts or service strip. Indicate 2. Indicate if tops if are tops being are being installed installed prior to prior uni-strut to uni-strut or upright or upright assembly assembly an installation as an installation Indicate joint is joint required if tops is required are if tops being if are tops installed are be to installed prior be installed to after uni-strut uni-struts after or uni-struts upright and other assembly and other uprights as uprights an are installation installed. are installed. joint is required if tops are to be installed after uni-struts and other uprights are installed. Minimum 3. Minimum top length top length of 36" of (if 36 possible). (if possible). Minimum top length of 36" (if possible). If tops 4. If must tops must be cut be under cut under 36" wide 36 because wide because of pre-installed of pre-installed uprights uprights or other or conditions, other conditions, If lengthwise tops must be cut under 36" wide because of pre-installed uprights or other conditions, lengthwise joints joints should should be considered. be considered. lengthwise joints should be considered. Place 5. Place joints joints beside beside uni-strut uni-strut and upright and upright cutouts. cutouts. Avoid Avoid placing placing joints joints through through the cutouts the cutouts Place (this raises joints costs beside due uni-strut to additional and upright machining cutouts. requirements). Avoid placing joints through the cutouts (this raises (this raises costs costs due to due additional to additional machining machining requirements). requirements). Customer is to draw the joints when uni-strut or uprights are present. Customer 6. Customer is draw is to draw the joints the joints when when uni-strut uni-strut or uprights or uprights are present. are present. Double direction joints are to be pre-approved by customer s project manager. Double 7. Double direction direction joints joints are to are be to pre-approved be pre-approved by customer s by customer s project project manager. manager. Example of Joint Location: Tops Installed Before Unistruts Assembled Example of Joint Location: Tops Installed Before Unistruts Assembled Example of Joint Location: Tops Installed Before Unistruts Assembled Example of Joint Location: Tops Installed after Unistruts Assembled Example Example of Joint of Joint Location: Location: Tops Tops Installed Installed after after Unistruts Unistruts Assembled Assembled MM. Double C. Double Uni-strut Uni-strut MM. Double Uni-strut Specify 1. Specify a separate a separate worksurface worksurface section section (core top) (core for top) the for space the space between between the uni-struts the uni-struts (lengthwise). Specify separate worksurface section (core top) for the space between the uni-struts (lengthwise). (lengthwise). Abut Abut 2. Abut worksurfaces worksurfaces worksurfaces to each to each to side side each (with (with side uni-strut uni-strut (with uni-strut cutouts). cutouts). cutouts). Durcon / Epoxy Resin Handbook / 19

20 Shelving/Pegboards XII. Shelving/Pegboards Shelving/Pegboards A. NN. Reagent Reagent shelves shelves should should not not be be drawn drawn over over tops. tops. Separate Separate drawings drawings required required to to eliminate eliminate confusion. confusion. NN. Reagent shelves should not be drawn over tops. Separate drawings required to eliminate confusion. OO. Machined double-faced shelves and pegboards can be supplied upon request. B. Machined OO. double-faced Machined double-faced shelves and pegboards shelves and can pegboards be supplied can upon be supplied request. upon request. Specify all double-faced surfaces as D/F. C. Specify all double-faced Specify all double-faced surfaces as D/F. surfaces as D/F. PP. We do not double-face shelves that are less than 18" above worksurface unless specified otherwise. D. We do not PP. double-face We not double-face shelves that shelves are less that than are 18 less above than worksurface 18" above worksurface unless specified unless otherwise. specified otherwise. QQ. An up-charge will apply to all double-faced surfaces. E. An up-charge QQ. An will up-charge apply to all will double-faced apply to all double-faced surfaces. surfaces. Fume XIII. Hood Fume Bases Hood (Worksurfaces) Fume Hood Bases Bases (Worksurfaces) (Worksurfaces) A. RR. Select Select Between: Between: RR. Select Between: 1. Classic Classic Fume Fume Hood Hood Bases Bases are are seamlessly seamlessly molded molded in in a a variety variety of of sizes sizes and and containment options to fit most fume Classic hood cabinets. Fume Hood Bases are seamlessly molded in a variety of sizes and containment options to fit to fit most fume most hood fume cabinets. hood cabinets. 2. If non-standard size bases are required, custom fume hood worksurfaces may be created by utilizing If non-standard the cut and size seam bases or are the required, applied custom marine fume edge methods hood worksurfaces referred to may in Section be created IV. by utilizing the cut and If seam non-standard or the applied size bases marine are edge required, methods custom referred fume to hood in Section worksurfaces IV. may be created by utilizing 3. Classic Fume the Hood cut and Bases seam have or a the 3/8 applied raised liquid marine containment edge methods rim. referred to in Section IV. Classic Fume Hood Bases have a 3/8" raised liquid containment rim. 4. Durcon supplies Classic either Fume a 1/8 Hood machined Bases have bevel a 3/8" or a raised 1/4 machined liquid containment radius along rim. the front edge. Durcon supplies either a 1/8" machined bevel or a 1/4" machined radius along the front edge. Sides Sides are squared and finished. are squared Durcon and finished. supplies either a 1/8" machined bevel or a 1/4" machined radius along the front edge. Sides are squared and finished. Durcon / Epoxy Resin Handbook / 20

21 XIV. Sinks A. DropIn Sinks - Standard installation requires a beveled rabbet cut through the worksurface so that the lip of the rabbet cut supports the protruding sink rim. The sink rim is inset into the top below the bevel. No under sink supports are required. Flush or top mount installation can be specified for special applications. DropIn Sink Cutaway View Beveled Rabbet Cut Supports Sink Inside Length & Width Dims. Apply from Upper Rim of Basin Sink Depth is to Edge of Outlet Hole Sink Supports Not Required 1. Supply Durcon with the DropIn Sink model number or inside sink dimensions. 2. Supply the sink s centerline measured from the worksurface s bottom left corner. 3. For sink sizes and drain location please refer to Durcon s Sink Schedule. 4. DropIn Sinks with corner drain outlets are recommended whenever practical. 5. Corner outlets increase storage area under the sinks by locating plumbing to the rear and side of the sink cabinet. 6. Corner outlets help prevent draining difficulties resulting from items in the sink covering or blocking the outlet. 7. Corner outlets allow for a larger usable sink area when an overflow is to be used. Durcon / Epoxy Resin Handbook / 21

22 DropIn Sinks with corner drain outlets are recommended whenever practical. Corner outlets increase storage area under the sinks by locating plumbing to the rear and side of the sink cabinet. Corner outlets help prevent draining difficulties resulting from items in the sink covering or blocking the outlet. Corner outlets allow for a larger usable sink area when an overflow is to be used. Americans with Disabilities Act (ADA) DropIn Sinks are shallow basin DropIn Sinks with corner drains. This design maximizes under sink space to help meet ADA requirements. Design Guide The U.S. Department of Justice's Americans with Disabilities Act home page B. Americans with Disabilities Act (ADA) lists DropIn sink area Sinks compliance are shallow as: basin DropIn Sinks with corner drains. This design maximizes under sink space to help meet ADA requirements. i Height. Sinks shall be mounted with the counter or rim no higher than 34 in C. The U.S. Department (865 mm) of above Justice s the Americans finish floor. with Disabilities Act home page ii Knee Clearance. Knee clearance lists sink that area is at compliance least 27 in as: (685 mm) high, 30 in (760 mm) wide, and 19 in (485 mm) deep shall be provided underneath sinks iii. Height Sinks Depth. shall Each be sink mounted shall be with a maximum the counter of or 6-1/2 rim in no (165 higher mm) than deep. 34 in (865 mm) iv above Clear the finish Floor floor. Space. A clear floor space at least 30 in by 48 in (760 mm by 1220 mm) complying with shall be provided in front of a sink to allow forward approach. The Knee Clearance. Knee clearance that is at least 27 in (685 mm) high, 30 in (760 clear floor space shall be on an accessible route and shall extend a maximum of 19 in (485 mm) wide, mm) and underneath 19 in (485 mm) the sink. deep shall be provided underneath sinks Depth. Each sink shall be a maximum of 6-1/2 in (165 mm) deep. Please note: State and Local ADA Requirements override federal statutes Clear Floor Space. A clear floor space at least 30 in by 48 in (760 mm by 1220 mm) complying with shall be provided in front of a sink to allow forward approach. The clear floor space shall be on an accessible route and shall extend a maximum of 19 in (485 mm) underneath the sink. Please note: State and Local ADA Requirements override federal statutes Durcon Incorporated 19 Durcon / Epoxy Resin Handbook / 22

23 D. Undermount TT. Undermount - Standard - installation Standard installation requires a requires beveled a cutout beveled in the cutout worksurface in the worksurface 1 smaller 1" than smaller than the inside (length and width) dimensions of the sink unit. A ½ worksurface lip overhanging the sink on all the inside (length and width) dimensions of the sink unit. A ½ worksurface lip overhanging the sides is standard. Undermount sinks require sink support(s). Durcon does not supply undermount sink sink on all supports. sides is standard. Undermount sinks require sink support(s). Durcon does not supply undermount sink supports. 1. Supply the sink model number or inside sink dimensions. Supply the sink model number or inside sink dimensions. 2. Supply the sink s centerline measured from the worksurface s bottom left corner. Supply the sink s centerline measured from the worksurface s bottom left corner. 3. For sink sizes and drain location please refer to Durcon s Sink Schedule. For sink sizes and drain location please refer to Durcon s Sink Schedule. 4. Undermount Sinks with corner drain outlets are recommended whenever practical. Undermount Sinks with corner drain outlets are recommended whenever practical. 5. Corner outlets help prevent draining difficulties resulting from items in the sink covering or Corner outlets help prevent draining difficulties resulting from items in the sink covering or blocking blocking the outlet. the outlet. 6. Corner outlets allow for a larger usable sink area when an overflow is to be used. Corner outlets allow for a larger usable sink area when an overflow is to be used. 7. Custom undermount sink depths can be created by trimming to required depths (an Custom undermount sink depths can be created by trimming to required depths (an upcharge will upcharge apply). will apply). Double Undermount Sink installation: E. Two Double sink cutouts Undermount may be Sink used installation (eliminating - Two the sink expense cutouts of may gluing be sinks used together). (eliminating the expense of gluing sinks together). i. Separate undermount sink cutouts require a minimum 2" 1. Separate undermount worksurface sink cutouts space require between a minimum the sinks. 2 worksurface space between the sinks. Ii. Separate sinks eliminate the need to replace both sinks if one sink fails. A single 2. Separate cutout for sinks double eliminate undermount the need sink to installation replace both requires sinks if gluing one sink or fails. clamping the sinks together (an up-charge will apply). 3. A single cutout for double undermount sink installation requires gluing or clamping the sinks together (an Iii. Specify up-charge if long will or apply). short sides of sink walls are to be glued together. 4. Specify if long Iv. Specify or short drain sides location of sink for walls each are sink to be in double glued together. sink assembly (only necessary for corner and end drain sinks). 5. Specify drain location for each sink in double sink assembly (only necessary for corner and end drain sinks). Durcon / Epoxy Resin Handbook / 23

24 Cupsinks UU. Cupsinks are designed for convenient disposal of liquid waste in fume hoods or on the bench top. Durcon XV. offers Cupsinks a variety of cupsink styles and shapes (see literature for details). Flush mounted cupsinks are standard. Please specify if an alternative installation method is required. A. Cupsinks are designed for convenient disposal of liquid waste in fume hoods or on the bench top. Durcon offers a variety of cupsink styles and shapes (see literature for details). Flush mounted cupsinks are standard. Please specify if an alternative installation method is required. 1. Flush-mounted cupsinks are are standard. This This installation requires a rabbet a cut cut in in the the worksurface. The cupsink worksurface. is installed The so cupsink that the is installed upper rim so is that flush the with upper the rim worksurface. is flush with the worksurface. 2. Top Top mount mount installation can can be be specified specified to to provide provide a 1/4" a 1/4 waste waste barrier barrier around around the the cupsink cupsink basin (required in certain regions). Top mount installation requires a simple through cut in the worksurface. basin (required in certain regions). Top mount installation requires a simple through cut in the Top worksurface. mount retrofits require gluing a 1/4" tall cupsink rim over an installed flush mounted cupsink s rim. 3. Top mount retrofits require gluing a 1/4 tall cupsink rim over an installed flush mounted cupsink s rim. Durcon / Epoxy Resin Handbook / 24

25 Troughs XVI. Troughs VV. Sectional Troughs provide convenient liquids disposal for multiple users. These long shallow A. Sectional undermount Troughs basins provide can be convenient trimmed liquids to size disposal or joined for together multiple to users. create These longer long runs shallow as they are installed. Maximum length of sectional troughs is 18' (with end drain). undermount basins can be trimmed to size or joined together to create longer runs as they are installed. Sectional Maximum trough length end caps of sectional are applied troughs before is shipment. 18 (with end drain). 1. Outlet Sectional openings trough are end machined caps are by applied Durcon. before shipment. 2. Sectional Outlet openings troughs require are machined a sink support by Durcon. for each section. Durcon does not supply sink supports. 3. Trough Sectional installation troughs kits require to join a sink sections support are supplied for each section. at an additional Durcon does cost. not supply sink WW. DropIn supports. Troughs are one-piece units that are installed from the top and supported by the surrounding worksurface (see literature for dimensions). 4. Trough installation kits to join sections are supplied at an additional cost. XX. One Piece Undermount Troughs with molded end caps and a molded outlet opening are available (see B. DropIn literature Troughs for dimensions). are one-piece units that are installed from the top and supported by the surrounding worksurface (see literature for dimensions). One piece undermount troughs require sink supports. Durcon does not supply sink supports. C. One Piece Undermount Troughs with molded end caps and a molded outlet opening are available (see literature for dimensions). Sink Units D. One (Worksurfaces) piece undermount troughs require sink supports. Durcon does not supply sink supports. YY. Classic MarineTop XVII. Sink Units (Worksurfaces) The back splash provides moisture containment on the backside of the unit (recommend not stacking A. Classic backsplash MarineTop on marine edges [see illustration in Section IV]). The back splash provides moisture containment on the backside of the unit (recommend not stacking backsplash on marine edges [see illustration in Section IV]). Durcon / Epoxy Resin Handbook / 25

26 Recommend drain drain grooves grooves be no be less no less than than 2" apart 2" apart O.C. O.C. Recommend drain grooves be no less than 2 apart O.C. Recommend drain grooves be no less than 2" apart O.C. Recommend 12" maximum length for DropIn Sink drain grooves to maintain 1/8" per foot incline. Recommend 12 maximum length for DropIn Sink drain grooves to maintain 1/8 per foot incline. Recommend ZZ. DrainTops 12" maximum - Contoura length Control for DropIn sink unit Sink with drain raised grooves rib drain to board maintain 1/8" per foot incline. Recommend ZZ. DrainTops 12" maximum - Contoura length Control for DropIn sink Sink unit drain with grooves raised rib to drain maintain board 1/8" per foot incline. B. ZZ. DrainTops - Contoura - Contoura Control Control sink sink unit unit with with raised raised rib rib drain drain board board DrainTop Profile Liquid Containment Raised Rib Drainboard Liquid Containment Classic Edge Trimmable Back Fixture Space 1/4" Ribs Sizes Available to Fit Most Applications Sink Area 3/4" Ctrs Durcon Incorporated 23 Durcon / Epoxy Resin Handbook / 26

27 XVIII. Installation A. Durcon recommends utilizing experienced epoxy installers for epoxy resin worksurfaces and sinks. B. Notify installer if tops are being installed prior to uni-struts or uprights. C. Installation and Maintenance Manual available upon request. D. MSDS Sheets for Smooth-On and Durcon Epoxy are available upon request. E. Smooth-On is available upon request. Durcon estimates usage at 1 qt. per 100 sq. ft. Durcon / Epoxy Resin Handbook / 27