Fabrication & Maintenance
PaperStone can be machined using the same tools and techniques used with fine hardwoods and solid surfaces. The information presented here should be used in conjunction with an experienced fabricator. For fabricators new to working with PaperStone we recommend that you talk to a qualified distributor or fabricator for in-depth coverage of the topics introduced here.
PANEL SIZE
The standard PaperStone panel is 60" x 144". Other panel sizes are available.
PANEL THICKNESS
PaperStone panels are available in 3/4", 1" and 1-1/4" thicknesses.
Cutting Methods
PaperStone works much the same as hardwood and solid surface. Always observe shop safety procedure and wear protective eyewear and clothing. Avoid inhalation of dust.
Cut PaperStone dry. Slow the blade speed or increase the feed rate if you detect excess heat. Fully support PaperStone before you begin cutting since the blade could bind when the slab shifts as the cut proceeds. We recommend using a triple chip carbide-tipped saw blade if possible and carbide-tipped router bits.
Seaming and Bonding
Seams in PaperStone may show and should be incorporated into the design. Because seams show, built-up edges are not recommended. Plan seams so they are not next to sinks.
On a sturdy, level surface, set out spacer bars of uniform thickness and place the PaperStone sections on them. Leave a gap between the two sections that is slightly less than the width of a straight-edge router bit. Secure a straightedge to the section and use the straightedge as a fence to run the router through the gap so that the bit shaves a thin section of both edges at once. This procedure is known as a mirror cut/joint. This will create edges that will perfectly match.
Prepare the mechanical strengthening and aligning of the joint using one of the following two methods. Using a biscuit joiner, cut slots for standard wood biscuits or rout the necessary holes for the type of tight-joint fasteners typically used to connect sections of post-form laminate counters. Glue the joint using a slow-drying two-part epoxy. CA5 adhesive may also be used. Tint the epoxy by mixing in some of the sanding dust from a previous step. Once the joint has cured, lightly sand it to blend the seam with the surrounding area.
You can also seam using a 'superglue' type product like CA5 from 3M. With CA5 you can attach two clean edges with a butt joint and clamp it. This will produce a very strong and tight joint but it cannot be tinted. It is possible to seal joints with standard caulking sealants. Typical areas for this treatment are the underside of the backsplash and around undermounted sinks. Use a moderate amount of caulk in a color compatible to the PaperStone panel. A clear caulk may also be used.
Sanding and Finishing
PaperStone comes with a natural finish on both sides. Exposure during shipping and handling may leave slight scratches. It is a natural product that unlike other solid surfaces that have been machined to very high tolerances, it may have small imperfections such as low and high areas. PaperStone is bonded sheets of paper and excessive sanding could wear through the topmost layer. For this reason we recommend that sanding and finishing be minimal.
Natural products possess inherant characteristics that may give them slight variations from panel to panel. A natural patina may emerge over time. We have found that a satin sheen provides the most beautiful and easily maintained day-to-day surface. Sanding should start with an abrasive no coarser than a fiber abrasive pad such as a 3M Scotchbrite™ red or grey (Red = fine; Grey = superfine). Place the abrasive pad on the surface and place the random orbit sander pad at the center. Buff the entire surface until a uniform sheen is achieved. Wipe thoroughly with a damp cloth to remove dust and loose particles.
If machining marks exist on cut edges, a belt sander with 80 grit sandpaper may be used as a first step finishing with 180 grit sandpaper. When finishing Obsidian or Slate, sanding may begin with 180 grit sandpaper and finished with the fiber abrasive pad.
A final treatment of PaperStone Finish is recommended despite its extremely low porosity. It is an all-natural, eco-friendly and sustainable product. All of the ingredients are natural and food safe.
Directions for Use:
To use PaperStone Finish, place the bottle under a stream of warm water to make the fluid mix and flow more easily. Apply a thin coat to the surface with a soft cloth. Let it stand for 20 minutes and then wipe off any excess. Finish up using a clean, soft cloth to give an even, rich luster. For best results, do not use finished area for at least 12 hours so that the finish can harden.
PaperStone Finish
PaperStone Finish is made entirely from natural waxes (bee and carnauba) and food grade mineral oil. Carnauba wax is a resin produced by the wax palm tree Copernicia Cerifera. This tree grows in various parts of South America. However, only the trees in the Northeastern tropical rain forests of Brazil produce the premium quality wax. It is produced by the tropical carnauba tree as protection from the incredibly harsh conditions of the tropical rain forest - intense heat, harsh equatorial sun and constant moisture and humidity. Any surface coated with carnauba wax will be similarly protected. Carnauba has a very strong grain structure and is the hardest wax known to man. In addition to being incredibly durable, carnauba dries to a deep, natural shine. In contrast, bees wax, paraffin and many synthetic waxes tend to cloud and occlude.
PaperStone Finish is recommended for all food service related applications. PaperStone Finish will help to preserve UV protection for exterior applications.
PaperStone Cleaner is an all-natural preserver that rejuvenates and protects your composites, also ideal for all natural wood grains. Contains only food-safe ingredients. It is made in the USA.
A twelve ounce bottle of PaperStone finish will cover approximately 120 to 150 square feet.