Instructions for Use 3 mm - Varicor

PROCESSING INSTRUCTIONS
VARICOR ® 3 MM

Contents Page
1. Varicor ® 3 mm
1.1 Properties / Features 3
1.2 Material Limits 3
2. Before Processing
2.1 Inspection upon receipt of goods 4
2.2 Storage / Handling 4
2.3 Processing Tools 4
2.4 Dimensions / Tolerances / Density 5
2.5 Preparation for work 5
2.5.1 Inspection of colour consistency 5
2.5.1.1 Production numbers (red label) 5
2.5.1.2 Colour code (yellow label) 5
2.5.1.3 - Table for checking the colour consistency 6
of panels of the same colour
- Table for checking the colour consistency
for bending panels with moulded pieces
2.5.2 Tips prior to processing 6
3. General processing guidelines
3.1 Surface bonding with the substructure 7
3.2 Bonding Varicor ® 3 mm with Varicor ® 3 mm 7
3.3 Bonding Edges 8
3.3.1 Bonding the edge under Varicor ® 8
3.3.2 Bonding the edge in front of the sandwich panel 8
3.4 Straight worktop joints 9
3.5 Corner joints in worktops 9
3.6 Cutout 9
3.6.1 Hot top cutout 10
3.6 1.1 Gas hot top 10
3.7 Bonding Varicor ® moulded pieces 10 / 11
3.8 Drill holes / Connections 11
3.8.1 Drill holes 11
3.8.2 Screw connections 11
3.10 Surface finish 11 / 12
3.11 Back splash 12
3.12 Wall panelling 12
3.13 Bending 13
4. Repairing Varicor ® 3 mm
4.1 Scratches in the Varicor ® 3 mm surface 14
4.2 Brand marks or face outs 14
4.3 Crack or open joint in the 3 mm surface 14
4.4 Ordering and using a repair set 14
4.5 Components of the repair set 15
4.6 Using the repair set 15
4.6.1 Repairing a crack 15
5. Cleaning and Care of Varicor ® worktops
=> see www.varicor.com / English / Planning and Working)
6. Service 16
Page 2 of 16

1. VARICOR ® 3MM
Varicor ® 3 mm is a solid surface material made of a mineral filler based on purified bauxite bonded with a
resin which was specially developed for the product. Varicor ® 3 mm can be processed like wood. It can be
sawed, drilled, milled and ground with hard tipped tools. Varicor ® 3 mm is a homogeneous material which
does not possess any fibres as opposed to e.g. wood. Thus its material properties are three dimensionally
identical. Varicor ® 3 mm panels are available in different decorative designs as specified in our program of
delivery.
1.1 Properties / Features
__________________________________________________________
The individual components, homogeneous structure and surface finish impart Varicor® certain properties
which are briefly described below.
The component resin imparts:
• Elasticity
• Resistance to chemicals
• Waterproofness
• Thermal bending
Mineral filler as a further component causes the following effects:
• Mineral appearance
• Mechanical machinability with hard tipped tools
• Chemical stability
The surface finish has an impact on the optical effect. Pleasantness to touch, insensibility to soil and wear –
these properties directly depend on the selected degree of grinding.
1.2 Material limits
______________________________________________________________________________
Protect Varicor ® 3 mm from excessive temperatures with suitable thermal insulating material. Do not place
any hot objects directly on the Varicor ® 3 mm surface.
Temperatures above 140° C case signs of wear due to the release of the water bound in the filler.
Cutouts with inner radii less than 10 mm are not permissible because otherwise stress cracks may occur.
When the radius is less than 10 mm, a stress crack can form because a starting point is existing. This point
does not exist when the radius is equal to or greater than 10 mm.
Only use a holohedral, sturdy substructure which is bonded to Varicor ® 3mm and a counteracting plate
made of 0.8 mm HPL by a PVAC glue (white glue).
Due to its machinability with hard tipped tools, Varicor ® 3 mm is not scratch-proof. Signs of wear and tear
are more clearly visible on dark colours. This applies particularly for the colours emerald, vulcano and mare.
These colours were specially developed for use in decorative areas accordingly, they should not be used in
these areas.
Because Varicor ® 3 mm and Varicor ® 12 mm panels possess different expansion coefficients, these two
materials can only be bonded with silicone / PUR.
Due to different expansion coefficients of the various components, changes in temperature may lead to a
distortion of the composite material. By screwing the composite board onto the substructure (e.g. a base
cabinet) this effect will be compensated.
Page 3 of 16

2. BEFORE PRCESSING
2.1 INSPECTION UPON RECEIPT OF GOODS
Check all of the positions before you sign the freight bill.
Ensure that the delivery is complete and check the supplied panels,
moulded pieces, adhesive and accessories for damage.
Note down any damage or missing amounts on the freight bill
and have this note acknowledged by the driver. Damages which
are not acknowledged on the freight bill are not accepted by
freight forwarding insurance companies. Subsequent complaints
cannot be taken into account.
2.2 STORAGE / HANDLING
The panels must be stored in a horizontal position, on the shipping
pallet if possible. Ensure that the panels are protected from influence
of weather (extreme heat). Unpacked moulded pieces must be stored
on boards and clean surface.
Always transport the panels in an upright position. Attention, the
panels are sharp-edged. Avoid cuts by wearing gloves.
2.3 PROCESSING TOOLS
Commercial wood processing tools are suited for processing Varicor ®
3 mm. Please note the following:
Use hard tipped or diamond tools.
Due to their density, Varicor ® 3 mm chips and dusts are heavier than
wood dust. Use an appropriate suction unit to prevent excessive dust
loads. Varicor ® 3 mm dust is not toxic and does not contain any un-
healthy substances (please observe the MAC values).
When required, it is possible to request a clearance certificate via your
Varicor ® 3 mm dealer.
Cutting the material to size:
Use bench saws to cut the material to size. Band saws and jig saws
cause jaggings which can lead to stress cracks.
We recommend:
• Two types of tooth forms with a tooth pitch of 10 – 16 mm and a
cutting angle of 8° - 10° (Fig. 1).
Both tooth forms (Fig. 2 + 3) enable format cuts without jaggings
(e.g. for the preparation of adhesive joints). The trapezoidal flat tooth
(Fig. 3) enables considerably longer life times.
• A rate of advance of 4 – 6 m/min. (e.g. for a saw blade with a
diameter of 300 mm x 72 teeth) at 3.000 – 4.000 revolutions/min.
Page 4 of 16

2. BEFORE PRCESSING
2.4 DIMENSIONS / TOLERANCES / DENSITY
The panels are supplied with the following tolerance dimensions at 20 °C:
Length 3,758 mm + 10 mm / - 10 mm
Width 640 mm / 800 mm + 5 mm /- 2 mm
Thickness 3 mm + / - 0.4 mm
The specific weight of Varicor ® 3 mm is 1.55 g/cm³.
2.5 PREPARATION FOR WORK
2.5.1 INSPECTION OF COLOUR CONSISTENCY
In mineral materials, differences in colour can arise among the various
production lots which are attributed to the high content of natural
products. To ensure that two parts of the same colour can be bonded
without any visible deviations in colour, all Varicor ® 3 mm products
are marked with a production number system (red label). Plain colours
are additionally colour-coded (yellow label).
2.5.1.1 PRODUCTION NUMBERS (RED LABEL)
Example: 76.173.12
76: Casting tool number
173.12: Batch number
The production numbers must be compared before various panels of
the same colour are bonded. The last five digits must be concurrent,
this guarantees colour consistency.
In case of doubt put the panels one to another, moisten the surface
and compare them.
2.5.1.2 COLOUR CODE (YELLOW CODE)
Example: 90 63 51
The colour code is a special Varicor ® 3 mm customer service which
can be used to determine whether single coloured parts from various
production lots can be bonded with an acceptable deviation in colour.
The colour code is made up to 3 pairs of figures, expressed as a six
digit number. The difference between the individual pairs of figures
is calculated to determine the deviation in colour of the parts to be
bonded.
Example: Colour code Panel A, colour white: 92 63 51
Colour code Panel B, colour white: 93 61 51
Difference 1 + 2 + 0 = 3
Use the table on the following side to determine which parts can be
bonded together.
Page 5 of 16

2. BEFORE PRCESSING
2.5.1.3 TABLE FOR CHECKING THE COLOUR CONSISTENCY
OF PANELS OF THE SAME COLOUR
Bonding with
Plain Coloured
Panel
Plain Coloured
Panel
Granulated
Panel
2.5.1.4 TABLE FOR CHECKING THE COLOUR CONSISTENCY
FOR BONDING PANELS WITH MOULDED PIECES
The moulded pieces can be bonded with the panel as a substructure (UB),
built-in (EB) or attached (AL) version.
Bonding with
Plain Coloured
Panel
Plain Coloured
Moulded Piece
(UB/AL version)
Plain Coloured
Panel
Plain Coloured
Moulded Piece
(EB version, flush)
Granulated
Panel
Granulated
Panel
Granulated
Moulded Piece
(UB version)
Production numer
- red label -
Five last digits identical
(or alternative colour
code)
Production numer
- red label -
Not applicable
Not applicable
2.5.2 TIPS PRIOR TO PROCESSING
Production numer
- yellow label -
Sum of the difference
= max. 3
Max. 2 per pair of
figures
Five last digits identical There is no colour
code for these colours
Production numer
- yellow label -
Sum of the difference
= max. 7
Max. 4 per pair of
figures
Sum of the difference
= max. 3
Max. 2 per pair of
figures
Granualted mouldes pieces identical appearance of
the panel and the moulded piece in granulated
design (incl. tubes) cannot be guaranteed. Inspect
the parts before starting processing.
The production numbers of the panels and the moulded pieces which
belong to one unit should be noted in the customer order. These
numbers are required later for supplementing material or producing
repair sets. Moreover, we recommend fastening a scrap of the panels
(approx. 10 x 10 cm) of each production number with silicone to an
accessible area of the unit.
All of the materials which will be bonded together must be stored at
the same temperature (at least 18 °C) to avoid stress and deformation
of the material. The same applies for the adhesive.
The face side of all Varicor ® 3 mm panels is covered with a protective
foil. Peel off the foil before processing and check the surface for colour
consistency and damage.
Page 6 of 16

3. GENERAL PROCESSING GUIDELINES
3.1 SURFACE BONDING WITH THE SUBSTRUCTURES
Use uncoated chipboards of density ≥ 650 kg m³ as carrier material.
When coating the carrier material with Varicor ® 3 mm, the underside
must be covered with a 0.8 mm thick HPL board as counteracting plate
and steam barrier. PVAC glue is suitable as a bonding agent, D3 quality
(white glue), e.g. of comp. Kleiberit Type D3, ref. 303.
Before bonding, the individual components must be temporised to room
temperature.
Apply PVAC glue to the chipboard over the whole surface; then lay on
the Varicor ® 3 mm panel and the counteracting plate and place the
bonded panel into the veneering press.
Amount of adhesive: approx. 150 – 180 g/m³
Pressing pressure: approx. 3 kp/cm²
Attention: always press cold
Pressing time: in accordance with the data stated by the
adhesive manufacturer
(approx. 20 – 30 min.)
Due to different expansion coefficients of the various components
to be combined, changes in temperature can lead to a distortion
of the composite material. Screwing the composite panel to the
substructure (e.g. a base cabinet) this effect will be compensated.
Prior to further processing the coated panel, please store them horizontal
in a stock for one hour.
3.2 BONDING VARICOR ® 3 MM WITH VARICOR® 3 MM
A separate, matching colour Varicor® adhesive is available for every
decorative design which enables you to realise jointless and almost
invisible adhesive bonds. Some properties of the two existing types of
adhesive, standard and rapid adhesive, are explained below:
Based on the printed filling date, both types of adhesive will expire as
follows:
At room temperature at approx. 20 °C 3 months
In the refrigerator at approx. 6 °C 6 months
In the freezer at approx. – 20 °C 12 months except cartridge
glue
Standard adhesive:
The following must be ensured to obtain optimum bonding:
Minimum temperature of adhesive, material and room must not be
under 18 °C. Lower temperatures lead to faulty bonds. Bonding agent
dries, but does not harden.
Please observe the hardening times of six hours at 20 °C and/or four
hours at 25 °C before further processing.
Application of the bonding agent on one side is sufficient.
Rapid adhesive:
This adhesive was mainly developed for assembly purposes at building
sites. Processing temperatures at least 13°C.
Please observe the following hardening times:
60 minutes at 20° C
120 minutes at 13° C
For large adhered surfaces, always apply the adhesive to both sides of
the surface to be bonded. Always make sure that the adhesive joints are
thin because the rapid adhesive tends to form bubbles. The adhesive
joints may gleam slightly because the rapid adhesive contains a different
bonding agent than the panel.
Please observe the instructions for bonding enclosed with the
bonding systems.
Page 7 of 16

3. GENERAL PROCESSING GUIDELINES
3.3 BONDING EDGES
There are several different ways to attach the Varicor ® 3 mm edges to
the workplace.
3.3.1 BONDING THE EDGE UNDER VARICOR ®
Two different work procedures are available to bond the edge under-
neath the Varicor ® 3 mm coating:
1. Attaching the edge after coating the chipboard
• Fold a coated plate near the edge to a width of 4 mm.
• Let a surplus of 4 mm of the Varicor ® 3 mm coating.
Remove dust with clean, dry compressed air.
• Apply Varicor ® adhesive to the projecting length and apply PVAC
glue on the back of the Varicor ® 3 mm edge over the whole surface.
• Fix the edge with the aid of bonds and clamps.
• Once the Varicor ® adhesive has hardened, furnish the edge with
a 3 mm radius.
• Pressing time: as specified by the manufacturer of the adhesive.
The edge can also be bonded over the whole surface with Varicor ®
adhesive to the substructure. It is possible to apply the Varicor ®
3 mm edge with hot-melt adhesive using a special edge bonding
machine. First apply the Varicor ® adhesive to the excess length
of the Varicor ® 3 mm coating!
2. Attaching the edge prior to coating the surface
• Apply PVAC glue to Varicor ® 3 mm edge strips and glue them to the
edge of the chipboard. Varicor ® 3 mm strips must project slightly.
• Adjust the Varicor ® 3 mm edge to the length of the carrier material.
• Attach 10 mm wide adhesive tape on the upper side of the chipboard
with the bonded Varicor ® 3 mm edge.
• Apply the PVAC glue to the chipboard.
• Peel off the adhesive tape and apply the Varicor® adhesive to the
Varicor ® 3 mm edge.
• Lay on the Varicor ® 3 mm coating and the HPL counteracting plate.
• Press the individual materials together.
• Once the Varicor ® adhesive has hardened, furnish the edge with
a 3 mm radius.
3.3.2 BONDING THE EDGE IN FRONT OF THE SANDWICH
PANEL
• Format the sandwich panel.
• Cut Varicor ® 3 mm edge to the edge of the sandwich panel with
bonds.
• Once the Varicor ® adhesive has hardened, furnish the edge with
a 3 mm radius.
Attention: In this case there is a risk that the bonded joint is more
obvious because it runs along the edge.
Important:
Seal all of the open edges of the substructure with hot melt
adhesive edges or sealant to prevent the absorption of water.
Page 8 of 16

3. GENERAL PROCESSING GUIDELINES
3.4 STRAIGHT WORKTOP JOINTS
• Cut the panel butt joints exactly to size.
• Always use worktop connectors to adhere several worktops together.
• Cut a 3 mm thick and 12 mm deep groove directly below the Varicor ®
3 mm coating to fix the bonding of the two worktops to be joined.
A continuous match splint, 20 x 3 mm is glued into this groove.
• Clean the glued surface with sanding paper, remove dust with
compressed air.
• Apply PVAC glue to the edge of the chipboard and insert it into the
grooves.
• Apply sealant, e.g. Helmipur SH 100 (*) or similar sealant on the
Varicor ® 3 mm edge as well as on the upper side of the match splint
and insert in into the groove.
• Join the panels manually and fix them with the worktop connectors.
• Remove overflowing sealant.
• Please observe the bonding instructions enclosed with the bonding
agent.
3.5 CORNER JOINTS IN WORKTOPS
• To fix the corner joint: Cut a 3 mm thick and 12 mm deep groove
directly below the Varicor ® 3 mm coating near the straight edge
of both worktops.
• A continuous match splint, 20 x 3 mm, is glued into this groove.
• Mill a recess for worktop connectors
• Clean the glued surface with sanding paper, remove dust with
compressed air.
• Apply PVAC glue to the edge of the chipboards and into the grooves.
• Join the panels manually and fix them with the worktop connectors.
• Remove overflowing sealant.
3.6 CUTOUTS
Please observe the following when making cutouts:
• Minimum distance of 80 mm between two cutouts (Fig. 9).
• Minimum distance of 50 mm between a cutout for moulded pieces
and the back wall and/or chamfer with back splash (Fig. 10).
• Minimum distance of 40 mm between a moulded piece or a cutout
and the front worktop edge (Fig. 10).
• The distance between an adhesive joint and a cutout should be at
least 100 mm (Fig. 11).
• All of the cutouts must be milled, do not use a jig saw.
• Radii in corners and cutouts must be at least 10 mm.
• In areas with strong temperature impacts, e.g. hot top, make radii
at least 15 mm or larger.
Please observe the separate instructions for the hot top installation.
(*) Ruderer Klebetechnik, D-85604 Zorneding, Phone: +49.81 06 / 24 21-0
Page 9 of 16

3. GENERAL PROCESSING GUIDELINES
3.6.1 HOT TOP CUTOUT
The following points must be observed for the installation of heat sources
(hot top, grill, integrated deep-fryer etc):
• Flush installation is prohibited because otherwise there is a risk that
hot pots will project beyond the hot top and come into direct contact
with the Varicor ® 3 mm panel. In addition, the heat expansion of the
hot top leads to stress in the hot top cutout. This can lead to the
formation of cracks. Only use attached hot tops in the cooking areas.
• When gas hot tops and raised cooking plates which radiate extreme
heat are installed, the hot top must be set up on 12 mm thick Varicor ®
strips, see section 3.6.1.1.
• The hot top cutouts must always be made with a hand router to avoid
stress cracks. Do not use a jig saw.
• Always make the radii in the corners of the hot top cutouts as large
as possible, at least 15 mm.
• The cutout of the hot top must be designed with a margin of at least
4 mm all around the hot top. Check the dimensions of the template
supplied by the appliance manufacturer and correct the cutout appro-
priately. Furnish the Varicor ® 3 mm cut edge with a 3 mm radius.
• Seal the substructure near the cutout with sealing material (silicone /
PUR etc.) to prevent the penetration of moisture.
• Insulate the Varicor ® 3 mm panel with insulating tape made with sili-
cone foam down to the substructure. Finally, insulate the complete cut-
out over the insulating tape additionally with aluminium adhesive tape.
• Do not place hot pots directly on the Varicor ® 3 mm surface.
• Ensure a minimum distance of 15 mm between the lower edge of the
heat source (e.g. hot top) and the upper edge of the lower cabinet to
avoid heat accumulation and to enable air circulation.
3.6.1.1 GAS HOT TOP
When gas hot tops, grills, integrated deep-fryers etc. which radiate
extreme heat are installed, the hot top must be set up on 12 mm thick
Varicor ® strips (Fig. 14).
All intensive heat sources (hot tops, deep-fryer, grill) must be spaced
at least 50 mm from the back wall or the back splash to avoid damages
caused by excessive heat effects.
3.7 BONDING IN VARICOR ® MOULDED PIECES
• The distance between two cutouts must be at least 80 mm.
• Draw the planned position of the sink on the surface
• The middle axis of the sink is marked on the back of the sink on the
right and on the left.
• Pre-cut the sink cutout with an overhead template, make the cutout
approx. 3 mm smaller than the inner dimension of the sink.
• Using a rebate cutter, cut away approx. 30 mm of the substructure
all around the cutout, leaving only 3 mm of the Varicor ® coating.
• Check the fit of the sink. Ensure a distance of max. 2- 3 mm between
the Varicor ® sink edge of the substructure.
• The space between the sink and the substructure is filled up later
during gluing in with Varicor ® adhesive up to 8 mm. This increases
the adhered surface and buckling strain will be avoided.
• Remove dirt from the adhered surfaces on the sink and on the panel
(sanding paper grain 180, for dark colours 240).
• Apply adhesive to panel and glue sink underneath.
(FOLLOWING)
Page 10 of 16

3. GENERAL PROCESSING GUIDELINES
3.7 BONDING IN VARICOR® MOULDED PIECES (FOLLOWING)
• Fix sink with clamping device so that it completely covers the cutout;
panel must protrude longitudinally by at least 500 mm on both sides.
• Fill up the gap between the Varicor ® sink and edge of the wooden
substructure with Varicor ® adhesive to enlarge the adhered surface.
• Remove the clamping device only after the adhesive has hardened.
• Grind the edge of the sink with 3 mm radius cutter until flush.
3.8 DRILLHOLES / CONNECTIONS
3.8.1 DRILLHOLES
Make smaller diameter drillholes with hard tipped drills (up to max.
13 mm diameter). Make larger drillholes, such as e.g. holes for taps,
overflow power box etc. with a Forstner bit or a keyhole saw. Seal the
open cut edges of the substructure with a sealant to prevent the penetration
of moisture.
3.8.2 SCREW CONNECTIONS
Do not screw threads and screws directly into Varicor ® 3 mm. This also
applies for thread inserts for screwing in because these can lead to the
formation of cracks. If it is required to screw bolts through the Varicor ®
3 mm panel into the substructure, please pre-drill the screw hole in the
Varicor ® 3 mm panel accordingly.
Select a drill hole which is clearly larger than the shaft of the screw.
The conical design of the screwhead may not jam in the Varicor ® 3 mm
drillhole. Round head wood screws with plastic washers are best suited
for this purpose.
3.9 SURFACE FINISH
The surface finish is responsible for stain resistance, pleasance to the
touch and optic of the material, this means the finer the surface, the
more insensitive it is to soiling.
The face side of the Varicor ® 3 mm panel is furnished with a machine
finish grain 400. The face side of the moulded pieces have a final finish
grain 320.
After processing, such as e.g. bonding, cutting etc., the surface of the
respective areas must re-obtain a higher degree of gloss.
The following points are important for preparing the Varicor ® 3 mm surface:
The listed polishing sequences apply for areas which were severely
stressed during processing. If the surfaces were not processed (no
binding, no cutting, no scratches etc.) the polishing sequence can be
shortened, this means processing of the surface from grain 400.
We recommend to treat dark surfaces with “Glanz S” (care product for
stainless steel) before the delivery of the application ** (3).
(FOLLOWING)
Page 11 of 16

3. GENERAL PROCESSING GUIDELINES
3.9 SURFACE FINISH (FOLLOWING)
Always use an excentric polisher and not a vibrating grinder for the
surface finish. The grain sequences which we recommend are listed
in the table below:
Degree of gloss Festool* 3M* Jöst*
Silky-matt Brilliant P 150 266 L, 100 micron Superpad P 150
The best surface is the one, the end consumer can reproduce repeatedly.
For surfaces subject to heavy use, we recommend a silky-matt finish.
Recommend the cleaning milk which you use – and thus enable your
customers to reproduce the surface finish which you created.
3.10 BACK SPLASH
Plastic profiles which are clipped into a screwed on plastic strip are recommendable
as back splashes. Adhere the matching Varicor ® 3 mm
strip to the plastic profile with sealing lip. The plastic profiles are
available in various colours.
Please note that creating a back splash by gluing with the Varicor ®
glue a 12 mm sheet on a sheet of 3 mm is not possible due to different
expansion coefficients.
3.11 WALL PANELLING
Brilliant P 180 266 L, 80 micron Superpad P 220
Brilliant P 240 266 L, 60 micron Superpad P 320
Brilliant P 320 266 L, 30 micron Superpad P 400
Brilliant P 400 Superpad SG 600
Grinding mat
Platinum S 800
Apply cleansing milk.
Polish by using
excentric and felt disk
High gloss as for silky-matt
up to P 400
Grinding mat
Platinum S 800
Apply cleansing milk.
Polish by using
excentric and felt disk
as for silky-matt
up to 30 micron
Superpad SG 800
Apply cleansing milk.
Polish by using
excentric and felt disk
as for silky-matt
up to P 400
Platinum pad S 600 15 micron Superpad SG 1200
Platinum pad S 800 9 micron Superpad SG 1500
Platinum pad S 1200 Superpad SG 2000
Hard felt with polishing
paste and lamb's
wool pad
Hard felt with polishing
paste and lamb's
wool pad
Superpad SG 2500
Hard felt with polishing
paste and lamb's
wool pad
For example niche rear wall panelling.
Adhere the Varicor ® 3 mm panel to the substructure over the whole
surface. In case of wooden substructures, the underside must be
covered with an 0.8 mm HPL board as counteracting plate and steam
barrier. Depending on the selection of the carrier material, ask your
adhesive supplier in advance about the appropriate adhesive for the
respective underground. After bonding, there must not be any hollow
spaces between Varicor ® 3 mm and the substructure. Protect the
substructure against penetration of moisture.
An expansion joint must be set horizontally every 800 – 1.000 mm for
wall-high panelling (Fig. 19).
It is possible to join the individual panels at the expansion joints with
tongue and groove, however avoid rigid joints.
Fix the sandwich panel on the wall with suitable profiles (Fig. 20 (*)).
Seal open joints with silicone or polyurethane to prevent penetration
of moisture.
Sources of supply:
(1) Festool, D-Wendlingen (3) HWR Chemie, D-Emmering: Glanz S (+49 8141 5 10 30)
(2) 3M Deutschland, Neuss: Polish paste, type Finesse (4) Jöst GmbH, D-Waldmichelbach
Page 12 of 16

3. GENERAL PROCESSING GUIDELINES
3.12 BENDING
• Heat up hot plates to 100 °C.
• Check the edges of the Varicor ® 3 mm strips to be bent for jaggings,
damage, remove when required.
• Warm up Varicor ® 3 mm.
• Heating time: 4 min.
Please carefully observe the heating times:
Heating times that differ from the above mentioned (too short
or too long) can lead to cracks or break of the material during
the bending process.
• Lay the warmed up Varicor ® 3 mm strips around the bending form,
do not bend it abruptly.
• Allow the strips to cool off in the form, do not cool suddenly.
• The Varicor ® 3 mm strips must be able to slide in the form due to
its longitudinal deformation behaviour, this means do not clamp
them fixedly (Fig. 22)
• The bent part springs back again by approx. 5% after it is taken out
of the form. Make the bending form narrower by this measure.
Material thickness 3 mm
Heating time 4 min.
Decors:
Bright plain colours
Limits to inner bending radius
in hot bending at 100°C
Bright fine and dark granulated
colours
20 - 30 mm
50 - 60 mm
Page 13 of 16

4. REPAIRING VARICOR® 3 MM
In the event of damage must first be analysed and then the causes must be
eliminated. A few examples are given below:
4.1 SCRATCHES IN THE VARICOR ® 3 MM SURFACE:
In this case, it suffices to polish the surface of the unit as well as
appropriately inform the end user about handling Varicor ® 3 mm.
4.2 BRAND MARKS OR FADE OUTS
If these marks are only superficial, it suffices to polish the surface
of the unit as well as appropriately inform the end user about handling
Varicor ® 3 mm
If the marks are however deeper, they can only be eliminated by
repair. Depending on the size, insert a matching coloured piece of
Varicor ® 3 mm.
Two methods are suited for the elimination of smaller spots
(< approx. 2 cm²) (Fig. 23, 24):
Small damages can be repaired with a repair kit.
• Mill out the damaged spot 3 mm deep with a groove cutter.
• Pour in matching repair kit so that the material overflows somewhat.
• Use a tooth pick to trace the contours and remove closed air bubbles.
• Hardening of the repair kit is at least 24 hours.
• Remove excess repair kit by grinding.
If the damage is very large, a so-called inlay must be used.
The damage spot is fully cut out with a 15° slant cutter so that the
substructure
remains. Please drill a hole with Ø 5 mm in the substructure to allow
closed air to escape when the inlay is inserted. Glue in an identically
coloured piece of material according to the counter profile with Varicor ®
adhesive.
After the adhesive has completely hardened, grind the area until it is flush
(Fig. 25, 26).
4.3 CRACK OR OPEN JOINT IN VARICOR ® 3 MM
Determine and eliminate the cause. Causes are frequently mechanical
stress, knocks, thermal stress, insufficient substructure, deficient
insulation of the hot top, missing expansion joints, missing connection
to the substructure as well as processing procedures which do not comply
with the instructions stated in the processing manual.
If the cause can be eliminated, repair is possible. If the cause cannot be
eliminated, it is not possible to guarantee a lasting repair.
A lasting repair can only be guaranteed when processing was conformity
in compliance with the instructions enclosed in the repair set.
4.4 ORDERING AND USING A REPAIR SET
In order to guarantee a repair which is almost identically coloured, it
is absolutely required to state the production code (red label) of the
involved part when ordering the repair set. If a scrap of the used
material is available it should be sent in to us, minimum size 10 x 10 cm.
Before you send us this scrap, grind it as the part of the unit requiring
repair and compare the parts while they are wet for deviations in colour.
The repair set will be matched in colour to the sample. Slight deviations
in colour may occur during repair on site.
Page 14 of 16

4. REPAIRING VARICOR ® 3 MM
4.5 COMPONENTS OF THE REPAIR SET
The repair set contains a bottle of repairing compound in the correspond-
ding colour tone and the respective hardener.
For marbled colours, a small bottle of contrast colour is additionally
included in the set. This enables the creation of marble structures in
connection with the repairing compound.
4.6 USING THE REPAIR SET
Detailed repair instructions are enclosed in every repair set.
ATTENTION.
The unit requiring repair and the repair set must be stored and processed
at min. 18° C and max. 30 °C.
4.6.1 REPAIRING A CRACK
• Using a groove cutter, diameter 3 – 4 mm, rout the crack 3 mm deep
along its contour. Not easily accessible spots can be opened with a
boring machine or a chisel.
• Filling up the existing groove with Varicor ® repairing compound so
that it overflows because the material shrinks greatly during harde-
ning. Use a tooth pick to trace along the flanks of the groove to
remove any existing air bubbles.
• Hardening time of the repairing compound at 20 °C is approx. 24 h.
• Do not remove the overflow repairing compound by grinding until it
has fully hardened.
• Match the appearance of the surface to the surrounding surface by
a corresponding finish.
• Recreate the surface patina with oil-bearing liquids (e.g. stainless
steel polish, cleaning milk)
Page 15 of 16

6. SERVICE
Our customer-oriented approach, high skill levels, many years of experience
and long-term business relations are your guarantee of having chosen the
right partner in us:
• Individual, personal advice
• Project-related customer servicing by our highly qualified Varicor ®
technical representatives
• Skilled support and advice during the development of customised
moulding and solutions
• Clarification of technical questions and challenges by Varicor ® ’s inhouse
application engineer
• Own after-sales service staff
• Marketing and advertising support
• Practical, professional product and processing training
• Detailed technical and product-specific information and literature
Varicor ® Processing Tools
• CNC files *
Varicor ® Planning Aids
• Tender texts *
• CAD files of technical drawings *
Certificates
• Copies of certificates available on request. You will also find a list of the
certificates under the heading “Planning and Working – Technical Data”
on our website
* All files are available as download under the heading “Planning and
Working” on our website www.varicor.com.