(Notes and comments are shown in italics. These should be removed before printing this specification. References to CORIAN® Surfaces drawings and bulletins can be retained for a closed CORIAN spec but should be removed 
for an open spec.)

	[THIS SECTION MAY ALSO BE LOCATED UNDER
	MASTERFORMAT HEADING 09540, "SPECIAL SURFACES." ]

SECTION 06650
SOLID  POLYMER FABRICATIONS

I.  GENERAL

1.01  DESCRIPTION	
[ADD TO OR DELETE PER PROJECT REQUIREMENTS]

A.  Work described in this section:
	
	1.	Tub and shower walls
	2.	Toilet & Shower partitions
	3.	Wall cladding/wainscoting
	4.	Bumper rails
	5.	Interior steps
	6.	Seats
	7.	Laboratory countertops
	8.	Reception areas/nurses' stations
	9.	Table tops
	10.	Bar tops
	11.	Cold cafeteria surfaces
	12.	Hot cafeteria surfaces
	13.	Countertops with sinks
	14.	Free standing island countertops with sinks
	15.	Lavatory tops with seamed bowls
	16.	Lavatory tops with undermount bowls
	17.	Lavatory tops with integral bowls
	18.	Window sills
	19.	Thermoforming
	20.	Cove backsplashes
	21.	Color inlays

B.   Related work specified elsewhere:

	1.	(Finish carpentry.)(Architectural woodwork.)
	2.	Tile work.
	3.	Wall coverings.
	4.	Casework.
	5.	Plumbing.
1.02  REFERENCES	
A.	Applicable Standards: Standards of the following, as referenced herein:
1. American National Standards Institute (ANSI)
2. American Society for Testing and Materials (ASTM)
3. National Electrical Manufacturers Association (NEMA)
4. Federal Specifications (FS)	

1.03  SUBMITTALS	
A.	Shop drawings:  Indicate dimensions, component sizes, fabrication details, attachment provisions and coordination requirements with adjacent work.	
B.	Samples:  Submit minimum 2" x 2" (50 mm x 50 mm) samples.  Indicate full range of color and pattern variation.  Approved samples will be retained as standards for work.	
C.	Product data:  Indicate product description, fabrication information and compliance with specified performance requirements.	
D.	Maintenance data:  Submit manufacturer's care and maintenance data, including repair and cleaning instructions.  Include in project close-out documents.	

1.04  QUALITY ASSURANCE	
A.	Allowable tolerances:
1.  Variation in component size:   1/8" (3 mm).
2.  Location of openings:   1/8" (3 mm) from indicated location.	

1.05  DELIVERY, STORAGE AND HANDLING	
A.	Deliver no components to project site until areas are ready for installation.  Store components indoors prior to installation.	
B.	Handle materials to prevent damage to finished surfaces.  Provide protective coverings to prevent physical damage or staining following installation for duration of project.	

1.06  WARRANTY	
A.	Provide manufacturer’s 10 year warranty against defects in materials. Warranty shall provide material and labor to repair or replace defective materials. Damage caused by physical or chemical abuse or damage from excessive heat will not be warranted.	

II.  PRODUCTS

2.01  SOLID  POLYMER FABRICATIONS	
A.	Preferred products:  1.	
	                                   2.	
	[RETAIN BELOW FOR PERFORMANCE SPECIFICATION]	
B.	Material:  Homogeneous filled acrylic; not coated, laminated or of composite construction; meeting ANSI Z124.3 & .6, Type Six, and Fed. Spec. WW-P-541E/GEN.
1.  Material shall have minimum physical and performance properties specified in the
     following Section U.
2.  Superficial damage to a depth of 0.010" (,25 mm) shall be repairable by sanding and 
     polishing.	
C.	Tub and shower walls; 1/4" (6 mm) thick, standard panels of solid polymer material, consisting of four 1/4" x 57" x 29 5/16", ___________ color. (Technical Bulletin H-20371, H-03836, Technical Drawing:  MASON1, WETWALLS, DRYWALLS, WETWLNGS)	
D.	Toilet and Shower partitions:  Panels and pilasters of 3/4" (19 mm) thick solid  polymer material, __________ color.  Pilasters attached at floor and ceiling.  Provide with hardware for attachment of panels to pilasters as indicated on the Architect's Drawings.  (Technical Bulletin:  H-03836)	
E.	Wall cladding / wainscoting , 1/4" (6 mm) thick, with [ butt joints] or [1/8" (3 mm) wide joints] sealed with color matching silicone sealant; adhesively applied to solid substrates; ___________ color.	
F.	Bumper rails:  Fabricated of [1/2"(13 mm)][3/4”(19mm)] solid polymer material to size and shape with edge details as specified on the Architect’s Drawings; adhesively joined with inconspicuous seams; __________ color.  Install bumper rails without exposed fasteners. 	
G.	Interior Steps:  Stringers of 1" plywood, one on each end, others as needed to provide 12" maximum spacing between stringers.  Stringer ends to be covered with [1/4" (6 mm)][1/2" (13 mm)] thick solid polymer material; _______ color.  Tread of 1/2" (13 mm) thick solid  polymer material; sand with 120 grit sandpaper; _______ color.  Horizontal support of 1" plywood.  Riser of 1/4" (6 mm) thick solid  polymer material; ________ color, with vertical kicker (typically 1/4" plywood.)  Details are for up to 3 steps only.  Larger assemblies require 2" x 12" stringers as specified on the Architect’s Drawings. (Technical Drawing:STEPS)	
H.	Seats:  Seating surfaces of [(1/2" (13 mm)][3/4”(19mm)] thick solid polymer material; _______ color.  Attach to support structure with silicone sealant and/or thru bolts as specified on the Architect’s Drawings.  [Technical Drawing:  SEATS]	
I.	Laboratory countertops:  [1/2" (13 mm)] [3/4" (19 mm)] thick solid polymer material, adhesively joined with inconspicuous seams; edge details as specified on the Architect’s Drawings; ________ color; [complete with specified bowls].  Surfaces to be unaffected by Class I reagents and repairable after exposure to Class II reagents.( [Architect Note - See DuPont literature on Corian for list of typical Class I and Class II reagents.](Technical Bulletin:  H-16309)	
J.	Reception areas/nurses' stations:  Horizontal surfaces of [1/2" (13 mm)][3/4" (19 mm)] thick solid polymer material adhesively joined with inconspicuous seams; edge details as indicated on the Architect’s Drawings; ________ color.  Vertical surfaces shall be [1/4" (6 mm)][1/2" (13 mm)][3/4" 919 mm)] material as shown on the Architect’s Drawings;_______color.	
K.	Table tops:  [1/2" (13 mm)][3/4" (19 mm)] thick solid polymer material, adhesively joined with inconspicuous seams; edge details as indicated on the Architect’s Drawings; ___________ color.  [Technical Bulletin:  H-26278]	
L.	Bar tops:  [1/2" (13 mm)][3/4"(19 mm)] thick solid polymer material, adhesively joined with inconspicuous seams; edge details as indicated on the Architect’s Drawings; __________ color.  [Technical Bulletin:  H-26278, CTDC 122]	

	

	
(*)SPECIAL REQUIREMENTS FOR HOT AND COLD APPLICATIONS.
	
M.	(*) Cold cafeteria surfaces:  [1/2" (13 mm)][3/4" (19 mm)] thick solid polymer material, adhesively joined with inconspicuous seams; edge details as indicated on the Architect’s Drawings;  ________ color.   [Technical Bulletins:, CTDC 119, 124, 125] 
1.  Make cutouts to templates furnished by the cold appliance manufacturer.
2.  Reinforce joints and cutouts as recommended by the surfacing manufacturer.
3.  Provide insulation between solid polymer material and adjacent cold pans.
4. Thermally isolate hot applications from cold.	
N.	(*) Hot cafeteria surface:  [1/2" (13 mm)][3/4" (19 mm)] thick solid polymer material, adhesively joined with inconspicuous seams; edge details as indicated on the Architect’s Drawings; __________ color.  [Technical Bulletins:, CTDC 119, 124, 125]
1.  Provide expansion joints in countertop as detailed on the Architect’s Drawings.
2.  Make cutouts to templates furnished by the hot appliance manufacturer.
3.  Reinforce joints and cutouts as recommended by the surfacing manufacturer.
4.  Provide insulation between Solid   polymer material and adjacent hot water pans 
     and food warmers.
5.  Thermally isolate hot applications from cold.
6.  Provide venting of cabinets.  (Architect must design and specify.)	

O.	Countertops with sinks: [1/2" (13 mm)][3/4" (19 mm)] thick countertop of solid polymer material; edge details as indicated on the Architect’s Drawings, complete with [undermount][seamed “S” mount][bevel mount][single bowl][double bowl][double bowl with molded drainboard] sink.  Provide counter complete with backsplash of size shown on the Architect’s Drawings.  Countertop and backsplash shall be _______ color.  Sink shall be _______ model and _______ color.  (Note:  when bevel mounting the same color sink/bowl as the sheet, the "step-down" or recessed mount is recommended.)	
P.	Free standing island countertops with sinks:  [1/2" (13 mm)][3/4" (19 mm)] thick countertop of solid polymer material; edge details as indicated on the Architect’s Drawings; complete with [undermount][seamed “S” mount][bevel mount][single bowl][double bowl][double bowl with molded drainboard] sink.  Island shall be _______ color.  Sink shall be _______ model and _______ color.  (Note:  when bevel mounting the same color sink/bowl as the sheet, the "step-down" or recessed mount is recommended.)	
Q.	Lavatory tops with seamed bowls; [1/2" (13 mm)][3/4" (19 mm)] thick countertop of solid polymer material, having edge details as indicated on the Architect’s Drawings, complete with [seamed “S”undermount] [bevel mount] bowl.  Provide countertops complete with backsplashes of size shown on the Architect’s Drawings.  (Technical Bulletin H-16307)  Countertop and backsplash shall be ______ color.  [specify number] bowl(s) shall be _____ model and ______ color.  (Note:  when bevel mounting the same color sink/bowl as the sheet, the "step-down" or recessed mount is recommended.)	
R.	Lavatory tops with undermount bowls:  [1/2" (13 mm)][3/4" 19 mm)] thick countertop of solid polymer material; edge details as indicated on the Architect’s Drawings, complete with [specify number] undermount bowl[s].  Provide countertops complete with backsplashes of size shown on the Architect’s Drawings. Use undermount hardware according to manufacturer's instructions.  (Technical Bulletin H-16307,]  Vanity top and backsplash shall be ________ color.  Bowl[s] shall be _____ model and ______ color. (For ADA compliance, refer to Technical Drawings ADABOWL, ADATEMP for installation details.) 	
S.	Lavatory tops with integral bowls:  molded countertop of solid polymer material [19 1/2" (500 mm)][22" (560 mm)], complete with integrally molded bowl[s] of Solid   polymer material; edge details as indicated on the Architect’s Drawings.  Provide with cove backsplash [and endsplashes] as shown on the Architect’s Drawings.  ______ model and ______ color.  [Technical Bulletin 128].	
T.	Window sills:  [1/2" (13 mm)][3/4" (19 mm)] thick solid polymer material, adhesively joined with inconspicuous seams; edge details as indicated on the Architect’s Drawings; _______ color.  [Technical Bulletin:  130].	

U.	Performance characteristics:  [see Technical Bulletin:  133 for CORIAN values].	

PROPERTY	REQUIREMENT	TEST PROCEDURE	
	  (min or max)		
Tensile Strength	5000 psi min	ASTM D638	
Tensile Modulus	1.0 x 106 psi min	ASTM D638	
Flexural Strength	7000 psi min	ASTM D790	
Flexural Modulus	1.0 x 106 psi min	ASTM D790	
Elongation	0.3% min.	ASTM D638	
Hardness	90-Rockwell "M" scale min.
52-Barcol Impresser min. 	ASTM D758
ASTM D2583	
Thermal Expansion	3.5 x 10-6 in/in/deg C. max.
1.95 x 10-6 in/in/deg F. max.	ASTM D696	
Color Stability	No change,100 hours min.	NEMA LD3-3.10	
Wear and Cleanability	Passes	ANSI Z124.3	
Abrasion Resistance	No loss of pattern max. weight loss (1000cycles) =0.9g.	NEMA LD3-3.01         ANSI Z124.3	
Boiling water Surface Resistance	No Change	NEMA LD3-3.05	
High Temperature Resistance	No Change	NEMA LD3-3.06	
Impact Resistance
Notched Izod
Gardner	
0.24 ft.-lbs.min.
9.0 ft-lbs min.	
ASTM D256, Method A
ASTM D3029	
Ball drop
1/4" sheet
1/2" sheet
3/4" sheet	
  36" min, 1/2 lb ball, no failure
140" min, 1/2 lb ball, no failure
200" min, 1/2 lb ball, no failure	NEMA LD3-303	
Bowls (point impact)	No cracks or chips	ANSI Z124.3 and 124.6	
Stain Resistance	Passes	ANSI Z124.3	
Weatherability	No change,min. 1000 hours	ASTM D1499	
Fungi and Bacteria	No Attack	ASTM G21, ASTM G22	
Specific Gravity	1.6 min		
Water Absorption
Weight
(% max.)	
24 hrs.
0.05
0.10	
Long Term
0.50(1/4")
0.90(3/4")	
ASTM D570

			
			
Flammability		     ASTM E84	
		solid  colors			
	1/4"	1/2"	3/4"    		
Flame spread	
25 max	
25 max	
25 max		
Smoke
Developed	
30 max	
30 max	
30 max		
Class	  1	  1	  1		
		particulate patterns			
	1/4" 	1/2"	3/4"  		
Flame spread	
25 max	
25 max	
25 max		
Smoke Developed	
30 max	
30 max	
30 max		
Class	 1	 1	 1		
Pittsburgh Protocol Toxicity (as used by NY State)	solids-80 gms minimum rating
patterns-65 gms minimum			"LC50" Test	

2.02  ACCESSORY PRODUCTS
	
A.	Joint adhesive:  Manufacturer's standard two-part adhesive kit to create inconspicuous, non-porous joints, with a chemical bond.  (Technical Bulletin:  CTDC 102)	
	(RETAIN BELOW FOR TUB/SHOWER SYSTEMS)	
B.	Panel Adhesive:  Manufacturer's standard neoprene-based panel adhesive meeting ANSI A 136.1-1967 UL® listed.  (Technical Bulletin:  CTDC 102)	
C.	Sealant:  Manufacturer's standard mildew-resistant, FDA/UL® recognized silicone sealant in color matching or clear formulations.  (Technical Bulletin:  102, 127)	
	(RETAIN BELOW FOR UNDERMOUNT SINKS AND BOWLS)	
D.	Sink/Bowl mounting hardware:  Manufacturer's approved bowl clips, brass inserts and fasteners for attachment of undermount sinks/bowls.	

	

2.03 FABRICATION
	
A.	For warranty coverage, fabricator/installer shall be approved by solid polymer manufacturer.	
B.	Fabricate components in shop to greatest extent practical to sizes and shapes indicated, in accordance with approved shop drawings and solid polymer manufacturer requirements.  (Technical Bulletin: CTDC 117)	
C.	Form joints between components using manufacturer's standard joint adhesive.  Joints shall be inconspicuous in appearance and without voids.  Attach 2" (50 mm) wide reinforcing strip of solid polymer material under each joint. [Technical Bulletins: CTDC 124, 129, 134]	
D.	Provide holes and cutouts for plumbing and bath accessories as indicated on the drawings.	
E.	Rout and finish component edges to a smooth, uniform finish.  Rout all cutouts, then sand all edges smooth.  Repair or reject defective or inaccurate work.	
F.	Finish:  All surfaces shall have uniform finish.  [Technical Bulletins:CTDC100, 123, 132]
1.  [Matte ,with a gloss rating of 5 - 20.] (This the standard finish and is the lowest 
     maintenance finish.)
2.  [Semigloss, with a gloss rating of 25-50] (Adds an upcharge. Select semigloss to bring out the depth of colors in the darker Sierra and Jewel tones. Will requires more maintenance.)
3. [ Polished, with a gloss rating of 55 - 80.] (A high gloss finish, ideal for applications that require maximum smoothness and reflectance.  Recommended for light duty only.  Will require more maintenance)	
G.	(Optional)  Thermoforming:  Comply with forming data from manufacturer.  (Technical Bulletin CTDC 110]
1.  Construct matching molds of plywood to form component shape.
2.  Form pieces to shape prior to seaming and joining.
3.  Cut pieces larger than finished dimensions.  Sand edges.  Remove all nicks and 
     scratches.
4.  Heat entire component uniformly prior to forming.
5.  Prevent blistering, whitening and cracking of solid polymer material during forming.	
H.	(Optional)  Cove backsplashes:  Fabricate 1/2" (13 mm) radius cove at intersection of counters and backsplashes.  Form backsplashes using [1/2" (13 mm)][3/4" (19 mm)] solid polymer material.  Fabricate in shop or field.  [Technical Bulletin: CTDC 112]	
I.	(Optional)  Colored inlays: Fabricate using manufacturer’s approved method.
(Technical Bulletin CTDC 103)
1.  Rout 1/8” max deep groove for inlay to pattern indicated on Architect’s Drawings.
2.  Fill groove using methods approved by manufacture, avoiding air bubbles or 
     voids.  Overfill inlay area.
3.  Allow area to fully cure.  Do not overheat inlay while sanding.  Finish and
     touch up to uniform appearance.	

[Refer to DuPont Corian Fabrication and Installation manual E-88639.  Technical information and a listing of the DuPont registered Corian fabricator/installers can be provided by the local DuPont Corian distributor.]

III.  EXECUTION
(USE DETAILS BELOW FOR LARGE OR INTRICATE PROJECTS.)
NOTE:  MOST SOLID POLYMER MANUFACTURERS RECOMMENDS A CERTIFIED FABRICATOR BE USED FOR FABRICATION AND/OR INSTALLATION, TO ENSURE WARRANTY COVERAGE AND  A QUALITY INSTALLATION.

3.01  JOB MOCK-UP
	
A.	Prior to final approval of shop drawings, erect one full size mock-up of each component at project site for architect review.	
B.	Should mock-up not be approved, rework or remake until approval is secured.  Remove rejected units from project site.	
C.	Approved mock-ups shall remain as part of finished work.	

3.02  INSTALLATION
	
A.	Install components plumb and level, in accordance with approved shop drawings and product installation details.	
B.	Form field joints using manufacturer's recommended adhesive, with joints inconspicuous in finished work.  Keep components and hands clean when making joints.	
C.	Adhere undermount/submount/bevel mount sinks/bowls to countertops using manufacturer's recommended adhesive and mounting hardware.  [Technical Bulletin H-16307]	
D.	Adhere topmount sinks/bowls to countertops using manufacturer recommended adhesives and color-matched silicone sealant.	
E.	Provide backsplashes and endsplashes as indicated on the drawings.  Adhere to countertops using manufacturer's standard color-matched silicone sealant.	
F.	Keep components and hands clean during installation.  Remove adhesives, sealants and other stains.  Components shall be clean on Date of Substantial Completion..	
G.	Make plumbing connections to sinks in accordance with Division 15.  Mechanical.	
H.	Protect surfaces from damage until Date of Substantial Completion.  Repair or replace damaged work that cannot be repaired to architect's satisfaction and invoice for the cost of repairs.  Architect to pre-approve cost estimate before repairs are made.	
I.	Fabricator/Installer is to provide a commercial care and maintenance video, review maintenance procedures and warranty details with the director of maintenance upon completion of project.