icestone fabrication guidelines

FABRICATION GUIDELINES

Version 4.0

About IceStone

IceStone has been crafting its premium durable surfaces in the historic Brooklyn Navy Yard since 2003. Made from 100% recycled glass, portland cement, and non-toxic pigment, IceStone® durable surfaces are the sustainable surface material of choice for fabricators, contractors, designers and homeowners nationwide.

We believe that quality craftsmanship, social responsibility, and environmental stewardship are equally essential to the success of our business and yours. To learn more about IceStone’s mission and certifications, please visit www.icestoneusa.com.

Sincerely,

The IceStone Team

TABLE OF CONTENTS

SECTION 1: 4 Disclaimer5 Applications5 StandardSlabSizeandWeight6 TechnicalSpecificationsandCertifications7 DustInhalationExposure7 CertifiedFabricator&WarrantyProgram8 ProperHandling&InventoryStorage12 LoadingLooseSlabs14 IndoorStorageOnly14 Transportation

SECTION 2: 15 FabricationInstructions15 FabricationTools&SafetyEquipment16 MarbleInstituteofAmericaStandards16 ColorMatching,BatchNumbering,andSlabIdentification18 RemovingBowFromWarpedSlabsviaRewetting19 BasicFabrication20 CutoutsandReinforcingRodSupports21 SoapDispenserPlacement22 RadiusCorners22 EdgeProfiles23 ApronsandBuiltUpEdges23 RecommendedEdgePolishingSequence23 StructuralSupport24 DishwasherSupport24 CantileversandOverhangs24 InstallationOverview25 Seaming26 Sealing26 HeatTolerance27 SurfaceRepair28 PopOuts29 Microporosity

SECTION 3: 31 ForYourCustomer32 CareandMaintenance34 WarrantyRegistrationForm35 ContactInformation

4ICESTONE

FABRICATIONGUIDELINESREVISEDJUNE2015

Disclaimer

IceStonedurablesurfacesareonlysoldtoCertifiedFabricators.PleasecontactCustomer

ServiceifyouareinterestedinbecomingaCertifiedFabricator.Thefabricationandinstallation

ofIceStoneslabsissimilartoquarriedstone,buthasuniquerequirementsthatmustbefollowed

foroptimumperformance.

IceStone,LLCisnotresponsibleforvariationbetweensamplesorprintedmaterialsandslabs

receivedupondelivery.Pleaseensurethatyouandyourclientshaveuptodatesamples

thataccuratelyreflectIceStone’scurrentpaletteandproduction.Allsamplesaredatedfor

yourconvenience.

AllslabsmustbeinspecteduponreceiptaccordingtoIceStone’sTerms&Conditions.

Variationinglasssize,shape,color,andgaugeareinherenttoIceStoneslabs,whicharehand

craftedusingrecycledmaterials.Projectlayoutandthefinalquantityofslabsneededshouldbe

determinedbeforeslabsarriveatthefabricationshop.Slabsmustalsobeinspectedforcolor

matchingpriortofabrication,andexaminedagainforoverallqualitywhiledry-fittingatthejob

site.AnydefectiveareasintheslabmustbereportedtoIceStone,LLCimmediatelywithpanel

IDnumber,color,shipmentdate,nonconformitydetailsanddigitalphotos.IceStonewillnot

reimburselaborormaterialcostswhendefectiveslabsarecutandinstalledwithoutadequate

inspection.

Afterinstallation,pleaseaskthecustomertoinspectthejobtoensuresatisfaction.Provide

thecustomerwiththemostrecentIceStoneCareandMaintenanceGuidelines,whichcanbe

obtainedbyvisitingIceStone’swebsiteorbycontactingCustomerService.

ThismanualispublishedbyIceStone,LLCandsupersedesallpreviousmanuals.Contentis

subjecttochange.ForthemostrecentversionofFabricationGuidelines,pleasevisitIceStone’s

website:www.icestoneusa.com.

IceStone®isaregisteredtrademarkofIceStone,LLCofBrooklyn,NY.

5SECTION1 ABOUTICESTONEDURABLESURFACES

Applications

IceStonesurfacescanbeusedas:

• Kitchencountertops

• Bathroomvanities

• Backsplashes

• Receptionareas

• Conferencetables

• Cashtransactionareas

• Windowsills,desktops,andmore

Commercial Food Service CountertopsDO NOT installIceStonesurfacesunderheatlampsorareaswherethesurfacewillbeexposed

toextendedperiodsofdirectheat.Heattrays,heatsinks,soupwarmers,etc.,shouldnotbe

installedinIceStonesurfaces.

Standard Slab Size and Weight

Width x Length 52.5inchesx96.5inches(approx.35squarefeet)

Thickness 1.25inches

Weight 16.3pounds/squarefoot(approx.570lbs/slab)

* Please note that the slab dimensions are nominal and are only to be used for storage and transportation purposes. Actual usable slab surface will be slightly less per side, and varies from slab to slab. Please inspect the perimeter before cutting.

Pre-cuthalfslabsareavailableinselectareas.ContactyourIceStonedistributorforavailability.

96.5” 1.25”

52.5

”

Halfslabs=26”x96.5”x1.25”

6 ICESTONEFABRICATIONGUIDELINES

REVISEDJUNE2015

Technical Specifications and Certifications

Property Test Standard IceStone Results

CompressiveStrength ASTMC–109 13,000psi-16,000psi

FlexuralStrength ASTMC–203 890psi

SpecificGravity ASTMC–97 2.31g/cm3

Porosity/Absorption ASTMC–642 0.18%unsealed

ChemicalDurabilityASTMC–1260forASRreactibility

0.49%300cycles

FreezeThaw ASTMC–666 0.05%

StainResistance ASTME–84Yes,whenusedwithrecommendedsealers

FireRating ASTME–84

Class1(A)Flamespreadindex0Fuelcontribution0Smokedensityindex0

CoefficientofStaticFriction ASTMC–1028

0.69Polisheddry0.61Polishedwet0.71Honeddry0.62Honedwet0.85Sandblasteddry0.77Sandblastedwet

FoodEquipmentMaterials NSF–51 Certified

Published HPD

Health ProductDeclaration TM

Collaborative


Dust Inhalation Exposure

Tominimizedustconcentrationsinbreathingzones,IceStonerequiresusingeitherwetdiamond

toolsorwaterjetswhencuttingandpolishingIceStoneslabs,aswellasproperlocalventilation

andcollectionequipment.FineparticlesthatmaybegeneratedwhilefabricatingIceStone

surfaceswithwetdiamondtoolsorwaterjetsfallwithinthecategoryofnuisancedusts.If

ventilationmethodsareinadequatetokeepdustlevelsbelowspecifiedlimits,wearaproperly

fittedparticulaterespiratorapprovedbytheNationalInstituteforOccupationalSafetyand

Health.PleasereviewIceStone’sSafetyDataSheetformoreinformation.

Certified Fabricator & Warranty Program

IceStoneoffersfreecertificationtrainingstofabricators.OnlyCertifiedFabricatorscanpurchase

IceStoneandbenefitfromexclusivediscountsandadditionaltraining.CertifiedFabricatorsmust

followallprocedureslistedinthemostrecentversionoftheIceStoneFabricationGuidelinesand

Care&MaintenanceGuidelines.TobecomeaCertifiedFabricator,pleasevisitourwebsiteor

contactCustomerService.

OnlyinstallationsbyCertifiedFabricatorsareeligibleforIceStone’sCommercial10-Year

andResidential10-YearLimitedWarranties.Thehomeorbuildingownermustregistertheir

installationonIceStone’swebsitewithin30daysofinstallation.


REVISEDJUNE2015

Proper Handling & Inventory Storage

IceStoneslabsweighapproximately570lbs,andafullcrateoftwelveslabscanweighasmuch

as7,100lbsincludingtheA–framecrate.Besureforkliftscanhandlethisweightbeforemoving

anycratesormaterial.

SLAB STORAGE PROCEDURE

AthoroughmaterialinspectionisrecommendedbeforesecurelystoringIceStoneslabs;inspect

yourdeliveryuponreceiptandsubmitanydamageclaimsimmediately.

1. Unloaddeliverycratefromtheflatbedor

LTLboxtruckusingaforklift.Alwaysmove

crateswithaforklift.Donotpush,pullor

dragcrates.IceStonecratesarefordelivery

purposeonly.DonotstoreIceStoneslabs

ondeliverycrates.

2. Movecratestodesignatedindoorareafor

slabinspectionandrelocationtopiperacks

orA-Frames.

3. Followtheprocedureforopeningsmalland

largecrates(pages10to11).

4. Placethefirstslabonthepiperackor

A-Framewiththepolishedfaceagainst

theframeorrack.

5. Placethesecondslabwiththepolished

sidefacingout(thebackofthesecondslab

shouldbeagainstthebackofthefirstslab).


6. Placethethirdslabwiththepolishedface

againstthepolishedfaceofthesecond

slab.Theunpolishedfaceofthethirdslab

willfaceout.Ensurethatthebottomedges

ofslabsaretouching.Unloadalltheslabs

followingthisprocedure.

7. Whenstoredonpiperacks,slabshould

notbevertical;instead,positiontheslab

atanapproximately20degreeanglefrom

verticalposition.

11.Whenaddingorremovingslabs

frominventory,alwaysfollowthe

aboveprocedure.

8. Afterunloading,inspectionandrelocation,

beginclampingprocess.

9. Usetwobarclampsspaced24”fromtop

righthandandtoplefthandedgesofthe

slab.Tightentheclampstofirstresistance.

Donotovertighten.

10.Usetwobarclampsspaced24”from

bottomrighthandandbottomlefthand

edgesofthesameslab.Tightentofirst

resistance.Donotovertighten.


REVISEDJUNE2015

UNLOADING A SMALL CRATE

1. Unscrewandremovetopplank.

2. PullupflapofTyvekprotectivewrapand

drapeoverbackside.

3. Attachfirstclamparoundallslabs.

4. Attachsecondclamparoundsideofcrate

andallslabsexceptslabtobeunloaded.

5. Unscrewandremovesupportsandgate

fromonesideofcrate. To remove gate,

use specially marked screws.

6. Lowerclamparoundslabandengage.

7. Removefirstclampexposingslabto

beremoved.

8. Carefullyliftslab. 9. Toremovemoreslabs,attachclamp

aroundsideofcrateandallslabsexcept

slabtobeunloaded.Repeatsteps6-9.

Clamp#2

Clamp#1


UNLOADING A LARGE CRATE

This crate is outfitted with a safety device designed to keep IceStone slabs from falling and causing injury.

Attention:

Active PositionTransit Position Inactive Position

1 - 2

4

5 - 6

3

4

2

13

5

6

1. FoldbacktheprotectiveTyvekwrap

2. Rotatesafetybarfromtransittoactiveposition

3. Pushawedgeinbetweentheslabstocreateaspacefortheclamp

4. Positiontheclampatcenterofslabandengageclampswitch

5. Rotatesafetybartoinactiveposition(usecautionaroundslab)

6. Liftslab

7. Repeatsteps2-6tounloadtherestoftheslabs

wedge


REVISEDJUNE2015

Loading Loose Slabs

Slabsthatarenotinacratecanbeloadedonto:

• AmetalA-framethatismechanicallysecuredtotheflatbedofatruck,

• AmetalorwoodenA-framesecuredtothebedofapickuptruck,or

• AportableA-framethatcanberemovedfromaboxtruck,loaded,andthenplacedbackinthe

boxtruckandsecured

Inallofthesecases,atleasttwoverticalstrapsarerequiredtosecuretheslabstotheA-frame.

IceStonewillnotloadlooseslabsontoaboxtruckthatdoesnothavearemovableA-frame,

astheheightofboxtruckspreventsloadingwithaboomoroverheadcrane.Whethera

truck,A-frame,orstrapmeetstherequirementsforcarryingand/ortransportingourslabsis

completelyatthediscretionofIceStone,LLC.

1. Atleasttwopeoplemustguidetheslab

tothedesignatedtruck.Iftheslabisbeing

movedwithanoverheadcrane,oneworker

shouldoperatethecrane,whiletheother

steadiestheslabastoreduceextraneous

movementswhichcouldresultincracking.

Iftheslabisbeingmovedviaaboom,one

workershouldoperatetheforklift,whilethe

otherworkersteadiestheslab.

2. Whenmaneuveringtheslabontothetruck,

atleastoneworkermusthelpthedriverrest

theslabontheA-frameorbackerslabinorder

tomakesuretheslabremainslevelthroughout

theprocess.


3. Oncetheslabisonthetruck,thedriver

shouldsecuretheslabusingatleasttwo

verticalstrapstohelpevenlydistribute

thepressurealongtheslab.Tightenthe

strapsjustenoughtorestrictmovementof

theslabduringtransportation.Anyexcess

tighteningmayleadtocracks.

4. Addpaddingwherethestrapmeetsthe

slabatthetopandatthebottom.The

paddingwillreducethetensionontheslab

duringtransit.

5. ThispictureillustratesanIceStoneslabon

aA-framesecuredtothetruckagainsta

backerslab.Slabsshouldbeloadedface

toface,backtoback.Alllooseslabsof

IceStonemustbeloadedonaA-frame

thatissecuredtoatruck.Whilebacker

slabsarenotmandatory,itdoesoffermore

protectionthanaslabbeingflushagainsta

metalorwoodenA-frame.


REVISEDJUNE2015

Indoor Storage Only

IceStonemustbestoredindoors.Eventarpedslabscanstain,etch,warp,orcrackwhen

exposedtoweatherelements.Theslabshownin FIGURE 1 wasstoredoutsideanddamagedby

acidicrainfallcondensationunderatarp.

VEHICLE LOADSItistheresponsibilityofthedrivertoensurethattheloadiswithinthelegalcarryingcapacity

ofthevehicle.Allowapproximately570lbsperIceStoneslab,plustheweightofanyotheritems

alreadyloadedonthevehicle.

SECURING THE LOADItistheresponsibilityofthedrivertoensurethattheloadisfullysupportedandsafelysecured

tothevehiclepriortoleavingIceStone’spremises.IceStonewillnotsecuretheloadtoyour

vehicle.AlltransportingA-framesmustbesecuredtothetruck.IceStonereservestherightto

refuseloadingmaterialonatruckinwhichA-framesarenotsecuredtothebedofthetruck.

AnytimeIceStonematerialisbeingtransportedwhenexposedtooutdoorelements,thematerial

mustbetarped.

FIGURE 1 Example of a slab that was etched from condensation

15SECTION2 FABRICATIONINSTRUCTIONS

• Stone (pony) Clamps

• Fabrication Stands

• Air Compressor

• Seaming Clamps

• Water Source

• Reinforcing Rods and Adhesives

• Forklift Truck with Boom and Lifting Clamp

• Bridge Saw

• Electric/Pneumatic Polisher (variable speed

preferred)

• Diamond Grinding Wheel

• Diamond Polishing Pads

• Grinding Stone

• Core Bits

• Diamond Contour Blade

• Wet Profiling Machine (edge router)

• Stone Carts/Dollies

• A–Frame Storage Racks

WhenmachiningIceStoneslabsonCNCs,takethefollowingprecautionstoreducethepossibilityofdiscoloration:• Removepiecesassoonastheyarecompleted

• Avoidleavingvacuumpodsengagedovernightorforprolongedperiodsoftime

• Cleanvacuumpodsroutinely

• Replacewornordeterioratingvacuumpods

Fabrication Instructions

Fabrication Tools & Safety EquipmentBelowisalistofcriticaltoolsandsafetyequipmentneededtofabricateIceStoneefficiently:

Basic Tools

Advanced Tools Basic Safety Equipment

• First–Aid Kit

• Safety Glasses

• Steel–Toe Footwear

• Respiratory Protection

• Work Gloves

• Aprons

• Ear Plugs

• Face Masks

• Water Jet

• CNC

• Automated Profiler

• Diamond Jig Saw

• Radial Arm Polisher


REVISEDJUNE2015

Marble Institute of America Standards

IceStonerecommendsfollowingtheFabricationandInstallationGuidelinesoftheMarble

InstituteofAmerica(http://www.marble-institute.com)andtheConcreteCountertopInstitute

(http://www.concretecountertopinstitute.com)asapplicabletoquarriedstone.Traditional

stonefabricationequipment,suchasCNCmachines,bridgesaws,routers,andpolishers(with

diamondpadsandbits)shouldbeusedwithwater.Avarietyoffabricationmachineryisused

ineveryshop,soitisimportanttoexploretoolingandfabricationtechniquestoidentifythebest

practicesforyourshop’sequipment.Forbestresults,IceStonerecommendsusinghighquality

diamondbladesandtoolingsuitableforusewithhardgranite.

Color Matching, Batch Numbering, and Slab Identification

VISUAL SLAB INSPECTION

Fabricatorsareresponsibleforimmediatelydeterminingiftheslabsarefitforuse.Iftheslabis

defective,contactCustomerServiceimmediatelyand DO NOT cutormodifyslabsinanyway

beforeexchangingthematerialwithIceStone,LLC.Onceaslabhasbeencutand/orinstalled,it

cannotbereturnedtoIceStone,LLCforcreditorrefund.

AvisualinspectionforimperfectionsandcolormatchingisessentialwhenworkingwithIceStone

surfacesandshouldbestandardpracticebeforecutting.Inspectinlightingconditionssimilarto

thoseattheinstallationsite.Usethefollowingasachecklistduringinspection:

• Cracks

• Slab–to–slabcolormatch

• Colorinconsistencywithintheslab

• Warping/bowing

• Consistentglosslevels

• Glasssegregationontheedges (seeFIGURE 2)


COLOR MATCHING

Duetotheuniquenatureofrecycledglass,notwoIceStoneslabsareexactlyalike,andwillexhibit

variationsincolor,shade,glasssizeandglassparticledistribution.Thesevariationsarenotstructural,

andarepartoftheinherentcharacterofthematerial.

Beforefabricating,alwaysvisuallyinspectslabstoensurethatanacceptablecolormatchis

achieved.Wheninspectingslabsforcolor,usesimilarlightingconditionsaswillbefoundatthe

jobsite.Slabsthatarebeingseamedtogethermustbefromthesamebatchdate.

BATCH NUMBERING AND SLAB IDENTIFICATION

Thebatchnumberisstampedonthetwoshortsidesofeachslab.IceStone,LLCreferstothebatch

numberasthe“PanelID”,whichisan8digitcodethatrepresentsthedateandsequenceinwhicha

particularslabwascast.Forinstance,apanelIDof04180942meansthattheslabwasbatchedon

April18th,2009,andtheslabwastheforty-secondmadethatday.RecordPanelIDsforwarranty

registrationandincaseissuesariseduringthetransportation,fabrication,installation,anduseof

thematerial.

FIGURE 3Each IceStone slab has a Panel ID number, circular quality control inspection stamp, color name, thickness measurement (1.25” or 3cm), and Made in USA stamp.

FIGURE 2Example of acceptable glass segregation on the left and unacceptable glass segregation on the right.


REVISEDJUNE2015

Removing A Bow From Warped Slabs by Rewetting

BowingoccurswhenanIceStoneslabbecomeswarpedorcurvedandisnolongerflat.Bowing

canoccurwhentheslabisnotclampedproperly.Measurebowbyusinga96”straightedgeand

acaliper.Holdthestraightedgesteadyalongthetopofthebackside(unpolishedface)ofthe

slab.Measurethebowalongthetopoftheslab,atthemidpointofthelongside

(seeFIGURE 4).

Slabsthathavebowedbeyondtheacceptablelevelof3.0mm(onthelengthoftheslab)needto

beremovedfromtheinventoryandrewettedfollowingoneoftheproceduresbelow:

REWETTING OPTION 1

1. Placebowedslabonabridgesawtable.

2. Saturatetheslabwithrunningwaterfor10minutes.

3. Leaveslabonbridgesawtableforonehour.

4. Afteranhour,measurethebowagain.Iftheslabstillmeasuresabowgreaterthan3.0mm,

repeatthefirstthreesteps.

REWETTING OPTION 2

1. PlacebowedslabonanA-frameagainstaflatslabofgranite,withtheunpolishedfaceofthe

IceStoneslabfacingout.

2. Useahosetocontinuouslysaturatetheslabwithrunningwaterfor10minutes.

3. Turntheslabaroundsothatthepolishedsideisfacingout,clampittoanotherslabof

IceStoneorgranitewithC-clampsfollowingourclampingprocedures.

4. Afteranhour,measurethebowagain.Ifthebowisstillgreaterthan3.0mm,repeatthefirst

threesteps.

Afterthebowontheslabiseliminated(orreducedtoanacceptablelevel),wipethefaceofthe

slabdrybeforemovingbacktoinventoryandclamping.

Figure 7: Demonstration on how to properly measure a slab for bowing.

FIGURE 4Use a caliper to properly measure slabs for bowing.


Basic Fabrication

Traversetheslabnofasterthan4linearfeetperminute(see FIGURE 5),ashigherfeedrateswill

resultinexcessiveedgeorglasschipping.

WhenroutingIceStonesinkopeningsoredgeprofiles,donotusesegmentedbits,asthey

increasetheriskofchipping(seeFIGURE 6).

HAZING

Duringthefabricationprocess,slurrymaydryonthesurfaceoftheslabcausingavisualhaze.

Toavoidtheeffectsofhazing,saturatethesurfaceoftenduringfabrication.Thishazecanalso

beremovedafterfabricationusinganon-scratchScotch-Britepador000steelwool.

FIGURE 5Run blades and tooling at a high RPM and flood slab with water at all times.

Figure 9: Proper process to route a sink opening.

FIGURE 6Routing IceStone sink openings


REVISEDJUNE2015

Cutouts and Reinforcing Rod Supports

IceStone,LLCrequiresthatallroughandfinishedopeningsbesupportedwithreinforcingrods

atboththefrontandbackbridgestospanaminimumof6.0inchesbeyondeithersideofthe

opening.Openingsincludebutarenotlimitedtocooktops,surfacemountsinks,undermount

sinks,downdraftvents,etc.

IceStone,LLCrecommendsthatreinforcingrodsbe1/8inchx1/2inchFiberglassRodderstock

(orapprovedequivalent)setverticallyina3/16inchwidex5/8inchdeepbladekerf(orspaceleft

bythesawbladeaftercutting)coveredinTenaxMicto2PartEpoxy.IceStone,LLCrecommends

fiberglassratherthanmetalroddingbecausefiberglasswillnotoxidizeovertimeandwillphysically

bondtotheadhesive(seeFIGURE 7 AND 8).

Under Counter Sink Mounting Specifications

Stainlesssteelsinkbasinsdesignedforundercounterapplicationshouldbemechanically

anchoredtotheundersideoftheIceStonecountertopusing3/8”x5/8”diametercaulk-in-anchors

with10-24machinescrews(FIGURE 9) orwithadhesivetypehardware (FIGURE 10)orwithapproved

equivalent.Heaviercastironenamelandquartzcompositesinkbasinsrequirebuilt-incabinet

supportaspermanufacturer’sinstallationinstructionsandshouldnotbemechanicallyattachedto

theIceStonecountertop.

FIGURE 7Fiberglass rod and roll.

FIGURE 8Saw kerfs for rodding.

FIGURE 10Peel and stick sink mounting clip.

FIGURE 9Undermount sink mounted with mechanical anchors.

Figure 12: Caulking anchors are installed on the underside of a countertop.

Figure 13: Image of an adhesive type mounting hardware supporting an undermount sink.


Allundermountsinksshouldbeadheredtotheundersideofthecountertopusing

100%silicone.Donotusesolvent–basedadhesivesorplumbers’putty;theywillstain

IceStonesurfaces.

Allsinkbasinsshouldbeinstalledfollowingmanufacturer’sinstructionsandbyusing

manufacturer’ssuppliedmountinghardwarewheneverpossible.

Alwaysfollowmanufacturer’sspecificationsforsinkbasinroughopeningandfixturedrilling

diametersandlocations.Usemanufacturer’sprovidedtemplateswheneverpossible.

AllundercountersinkbowlcutoutsmusthavetheinsideedgepolishedtomatchtheIceStone

surface.

Soap Dispenser Placement

Handpumpsoapandlotiondispensersshouldbeplacedsothatthespoutdripsintoasink

bowlorbasinandnotonthecountertop.Avoidusingswiveldispensers.Foamsoapsare

recommended.

FIGURE 11Soap dispenser should drip directly into sink bowl.


REVISEDJUNE2015

Radius Corners

IceStonesurfacesrequireradiuscornersonallcutouts.TheinsidecornersofIceStonecutouts

andcountertopsmustbeshapedtoaminimumof1/4inchradiustorelievecornerstresses.

Miteredor90degreecornerseamsdonotneedaradius.AlloutsidecornersofIceStone

surfacesmustbetooledtoaminimumof1/8inchradius.

Edge Profiles

AlwaysavoidinstallingIceStonewith90ºedges,asthismayleadtoglasschippingand

pop–outs.EdgeprofilesrecommendedbytheMarbleInstituteofAmericaareappropriatefor

IceStonesurfaces,includingtheonesshownbelow.

Glasssegregationinsomeedgeprofilesmaybepronounced.Thiscanbeaddressedusingafull

bullnose,radiusorplatneredge.

RadiusEdge HalfBullnoseEdge OgeeEdge

PencilEdge FullBullnoseEdge PlatnerEdge


Aprons and Built Up Edges

Toavoidthevisualeffectofglasssegregation,allbuiltupedgesshouldbemitred.IceStoneslabs

shouldnotbestacklaminatedatvisibleedges.Laminatingmaycreateanundesiredlookifthere

isglasssegregationintheslabedge.Thejointshouldbeclean,flushandparallel.

Recommended Edge Polishing Sequence

Edgepolishingshouldbeperformedwithsufficientpressure.Onlyusepolishersthathavea

speedof2,000rpmorhigher,andhighqualityindustrialdiamondabrasivepolishingpads.Polish

usingasequenceofincreasinglyfinerpadstoachieveasmooth,highquality,highglossfinish:

#50,#100,#200,#500,#1000,#2000,#3000andbuffingpad.

Structural Support

FOUR SIDED PERIMETER SUPPORT

IceStonesurfacesarestrongenoughthattheydonotrequireadditionalsubstratesupportifa

foursidedperimeterframeexistsforacountertopinstallation.However,fronttobacksupportis

requiredforevery36inches.

THREE SIDED PERIMETER SUPPORT

Additionalsupportisrequiredforstructuresthathaveperimetersupportonthreesides,suchas

vanitybases,desksandframelesscabinets.Installationswithdepthslessthan26inchesrequire

supportsevery24inches.Installationswithdepthsover26inchesrequiresupportsevery18

inches.

FIGURE 12Example of properly built up edge (left), and improper stack lamination (right).


REVISEDJUNE2015

Dishwasher Support

DishwashersshouldnotbeattacheddirectlytoIceStonesurfaces.Reviewthedishwasher

manufacturer’sspecificationsforthepropersidemountinginstallationprocedure.You

canalsoattachthedishwashertothecabinetsbyusingadishwashermountingbracket.

Cantilevers and Overhangs

Cantileversandoverhangs9inchesorlessdonotrequireadditionalsupport.

Cantileverslargerthan9inchesrequireadditionalsupportat24inchintervals.Supportscanbe

korbels,legs,columnsorreinforcingrods.

Installation Overview

IceStonesurfaceshaveasimilarstructuralstabilitytoquarriedstone.Werecommendthe

installationguidelinesspecifiedintheMarbleInstituteofAmerica’sDimensionStoneDesign

Manual(http://www.marble-institute.com).Therecommendationsbelowwillofferadditional

guidanceasyouinstallIceStonedurablesurfaces:

• UsequalitytransportA–frames

• AlwayscarryIceStoneslabsontheverticaledgetoavoidflexing

• Aminimumoftwoinstallersarerequiredforallprojects

• Installonlyonlevelandplumbbasecabinetry

• Topsurfacesofthecabinetsmustbewithin1/8”(3mm)offlatandlevelwhenmeasured

acrossadistanceof10’-0”(3m)

• Useshimswhennecessary

• Use100%siliconecaulking(orapprovedsubstitute)toadherecountertopstoallsubstrates

FIGURE 13Use a dishwasher mounting bracket to attach the dishwasher.


ToensureaccuracybeforeinstallingIceStonedurablesurfaces,useatemplatejustasyouwould

withquarriedstoneorquartzproducts.Whentemplating,usetraditional‘stick’templatesor

digitaltemplatingsystemstoensureaccuratefabrication.

1. Alwaysremoveexistingsurfacetopspriortotemplate.

2. Checkallwallsandbasecabinetrytoensureeverythingisplumbandlevel.Scribetothewall

whenthebackedgeisnotsquare.

3. Markallcenterlinesonthetemplatewheretherewillbesinkcutouts,cook-toprough

openings,fixturedrillingsorelectricaloutlets.

4. Notethedimensionsfromcabinettocabinetthroughoutthekitchen.

5. Doublecheckallmeasurementsandmarkings.

6. WhennestingtemplatespriortocuttingDONOTmarkIceStoneslabswithinkpens

orgreasepencils.

Seaming

Inordertoachieveaminimallyvisibleseam,IceStonesurfacesshouldbeseamedwithacolor

matchedtwo–partpolyester,epoxyoracrylicjointadhesive.Theadhesivemustbepigmented

tomatchtheslabbeinginstalled.Seamsshouldbenomorethan1/16inchinwidth.Useseam

setterstoachievebestresults.TenaxRivo50A&Bpartknifegradeepoxycanbetintedtocolor

matchwithTenaxTepoxEpoxycolors.TenaxRivo50A&BareVOCcompliantunderCalifornia

regulation.

Priortoinstallation,makesurethat:

• Seamsaresupportedtoassuredurabilityovertime.Unsupportedseamsmaybuckleorsag.

• IceStonesurfacesareproperlysealedandwaxed.

• Basecabinetsarepermanentlyanchoredinplaceandareonatrueplanecompletelyleveled

acrossallplanes.

• Aspaceof1/8inchexistsbetweenwallswheretheslabwillbeinstalledandthematerial

(installationsrequireatleast1/16”ateachwall).

• Surfacesareplacedlevelontopofcabinetsorbase;shimifnecessarytoensurefit.

• Reviewallsafetyinstructionsandwarningsbeforeusinganyseamingproducts.

Alwaysuse100%siliconeadhesivetosecuretheslabtocabinetryorbases.Donotuse

cementitiousgroutbetweenIceStonecountertopsandbacksplashes.


REVISEDJUNE2015

Sealing

IceStone,LLCrequiresthatfabricatorssealthesurfacebeforeoratthetimeofinstallation.

Applyoneoftherecommendedsealersbelowaccordingtothemanufacturer’sinstructions.If

thesurfacewaseversealedwithasolvent-basedsealer,youcannotuseawater-basedsealerfor

subsequentapplications.Ifthesurfacewassealedwithawater-basedsealer,consistentlyusea

water-basedsealerforsubsequentapplications,oruseasolvent-basedsealer.

RECOMMENDED SEALER COMPARISONRecommended Sealers Tenax ProtexStoneTech BulletProof

Water Based •Solvent Based •Penetrating Sealer • •Minimal Odor •Low Volatile Organic Compounds (VOCs) •Staining Protection • •Etching Protection none; wax after sealing none; wax after sealing

Manufacturer Tenax/Tenax USA Dupont

Telephone Number 1-800-341-0432 1-877-786-6383

Website www.tenaxusa.com www.dupont.com

Youcanapply CHENG Concrete Countertop Wax aftersealingforaddedprotection.

Heat Tolerance

IceStonesurfacescanwithstandincidentalheatcontactupto450°F.However,pleasenotethat

thesealerandwaxappliedtothesurfacemightnotbeheatresistent,sohotplatesortrivets

shouldbeusedunderpotsandpansrecentlyremovedfromaheatsource.Cooktopappliances

thataresurfacemountedrequireadequateinsulationtopreventthermalconductivitybetween

theappliancesandtheIceStonesurface.Followmanufacturersinstructionsregardinginsulation

forfreestandingrangesandovens.Under-counterovensshouldnotbeinstalledunderIceStone.

Watch how to seal on IceStone’s YouTube channel:

youtube.com/user/IceStoneLLC


Surface Repair

Scratches and Etch Marks

Minorscratchesandmarkscanbebuffedoutofthesurfaceusingapowderedmixtureand

cottoncloth.BrandsofpowderedbuffingmixtureincludeDia-GloorAkemiLiquidPolish.

Rubvigorouslyinsmallcirclesuntiltheareaissmooth.

Greaterdamagewillrequireuseofalowrpmelectricpolisheranddrypolishingdiamondpads.

BecausetheglassintheIceStonesurfaceisharderthanthecement,startwiththehighest

abrasive(3000g)andworkdown(2000g,1000g)untilthedamageisgone,thenreversethe

steps(1000g,2000g,3000g)untilthemarksaregone.Sealthesurfaceafterremovingthe

marks.

YoucanapplyCHENGConcreteCountertopWaxaftersealingforaddedprotectionandtohelp

minimizetheappearanceofminorsurfacemarks.

Removing Stains

UsingapoulticeisaneffectivemethodofremovingstainsfromIceStone.Makesuretotestthe

poulticeonaninconspicuousareatoensuretherewillbenodiscolorationfromtheprocedure.

Toremovestains,youwillneedthefollowing:

• Acetone

• Water

• PlasticWrap

• Painter’stape

• DryTreatHannafinnOxy-Klenza(fororganicstains)

• RecommendedSealer

• *Optional:CHENGConcreteCountertopWax

Watch how to remove stains on IceStone’s YouTube channel:


Watch how to remove etching on IceStone’s YouTube channel:


1. Removeresidualsealerandwaxfromthesurfacewithacetone.

2. Identifythestainingagent.

3. Selecttheappropriatepoulticeforthestain.DryTreatHanafinnOxy-Klenza™workswell

formostorganicstains.Ifyouhavequestionsaboutaparticularstainingagent,contact

IceStoneCustomerService.

4. WhenusingOxyKlenza,mixwithwaterintoathickpasteandapplytothestain.Coverwith

withplasticwrap,usingpainter’stapetoholdinplace.Letsitfor24hours,thenremoveand

rinsewithcleanwater;airdry.

5. Ifthestainstillpersists,repeatinstructionsinstep4.

6. Alwayssealthesurfaceafterremovingstaining.YoucanapplyCHENGConcreteCountertop

Waxaftersealingforaddedprotection.


REVISEDJUNE2015

Pop Outs

Shellaccanbeusedtofillanylargevoidsover2.0mmintheIceStonesurface.ContactIceStone

toordershellacpiecesthatmatchthecoloroftheIceStonesurface.

Tofillpopouts,youwillneedthefollowingmaterials:

• Shellacpiecesthatmatchthematrixcolor

• Smallmetalspatula

• Razorblade

• Electricburnerorheatgun

1. Heatthemetalspatulabyrestingtheblade

ontheelectricburner.

2. Usehotmetalspatulatopressshellacinto

thevoid.Ifthepopoutisparticularlylarge,

breakoffsmallpiecesofshellacsothat

thecavityisfilled.Usethemetalspatula

tomeltmoreshellacuntilthevoidisfull.

Thereshouldbenoairbubbles.

3. Wait1minuteuntiltheshellachascooled

andhardened.Useasharprazorbladeto

scrapeoffexcessshellacfromthesurface

oftheslab.Voidshouldbefilled,leveled

withtherestofthesurface,andsmooth.

4. Ifthevoidwasnotsuccessfullyfilled,usea

razortoremovetheshellacfromthevoid

andtryagain.

5. Wipesurfacearoundshellacwithaclean

ragandacetone.

Watch how to fill in pop-outs on IceStone’s YouTube channel:



1. Mixthedrypatchingkitinthemetalbowl

toensurepigmentsaredispersedevenly.

2. Add40gramsofcleancoldwaterto

themixture.

3. Stiruntilthemixtureissmooth.The

mixtureshouldbethickerthanpancake

batterbutnotasthickaspeanut

butter.Addmorewater(5gatatime)

ifnecessary.Thelesswaterused,the

strongertheconcretewillset.

4. Wetthewholesurfacewithaspraybottle

ofwater.Emptyhalfofthemixtureinone

lineinthemiddleoftheIceStone.Onebag

ofpatchingpowdermakesenoughslurry

for2slabs.

5. Withcircularmotionsspreadtheslurry

evenlyoverthefaceoftheslabwiththe

groutfloat,makingsurethewholesurface

iscovered.

Microporosity

IceStone,LLChasdevelopedapatchingmethodthatisrecommendedforanysmallsurface

problemslikepinholesorslightdiscoloration.Thepatchingkitisavailablebyorderfrom

IceStone,LLC.Iftherearelargevoidsinthesurface(largerthan2.0mm),followthePopouts

procedurelistedonpage28.

Youwillneedthefollowingmaterialsandtools:

• Patchingkit(acolormatchedcementitiousmixprovidedbyIceStone)

• Plasticspatulaorspoonforstirring

• Metalmixingbowl

• Water

• Groutfloat

• Cleanrag

Watch how to fill microporosity on IceStone’s YouTube channel:



REVISEDJUNE2015

6. Scrapeexcessslurryintothemixing

bowl.Makesurethepatchdriesina

consistentlythinlayer.Areaswithtoo

muchpatchwillappeardiscoloredand

willrequirereworking.

7. Waituntilthepatchhascompletelydried.

Oncedry,wipeoffallthedriedmaterial

fromthesurfacewithacleancottoncloth.

Theporesshouldbefilledandlevel.

31SECTION3 FORYOURCUSTOMER

For Your Customer

Thenextfewpagesincludetheinformationyouwillneedtoprovide to your end user upon installation.Makeacopy,downloadonourwebsiteaticestoneusa.com,[email protected].

• Care & Maintenance Guidelines• Warranty Registration Form

32

ABOUT YOUR ICESTONE SURFACEIceStoneismanufacturedwithoutanypetrochemicalsorresins,makingitanenvironmentallyresponsible

choiceforcountertopsinthehomeoroffice.CareofIceStoneissimilartothatofnaturalstone.Likeall

surfaces,IceStonewillshowsignsofwearandtearovertime.Withsensiblecare,youcanmaintainthebeautyand

qualityofyourIceStonesurface.

CARING FOR YOUR ICESTONEGENERAL CLEANING

Usetheproductsrecommendedinthese

guidelines.Cleaningproductsshouldbefree

ofchlorinebleach,ammonia,acidand

citrusscents.

WIPE UP SPILLS

Beespeciallyattentivetospillssuchascoffee,

wine,fruitjuicesandotheracidicliquids,wiping

themuppromptlywithadampclothandwater.

USE TRIVETS AND CUTTING BOARDS

Placeatrayundercoffeemachines,soap,

andsoapdispensers—aswithallsurfaces,

usetrivetsandcuttingboardstohelpprotect

thesealerandthesurface.

PROTECT YOUR SURFACEIceStoneisverydense,butstillporous,so

surfacesmustbesealed.IceStonerequires

thatthefabricatorsealsbeforeoratthe

timeofinstallation.

AtypicalIceStoneinstallationrequiresannual

resealing.Todetermineifitistimetoreseal

yourIceStone,dabacottonballinwaterand

evenlywipethesurfaceinastraightline.

Sealingissimple!Whileyoucancertainlycall

inaprofessional,mosthomeownersopttodo

itthemselves.Wehavemadeiteveneasier

byprovidingavideotutorialonsealingonthe

IceStoneYouTubechannel:

www.youtube.com/user/IceStoneLLC

YoucanapplyCHENG® Concrete Countertop

Waxaftersealingforaddedprotection.

TIME TO RESEAL Ifthewatermarkiswideandflat.

SEALER IS INTACTIfthewatermarkisraisedandhasirregularedges.

IceStone Care & Maintenance Guidelines 1/2

33SECTION3 FORYOURCUSTOMER

CONTACT USThankyouforselectingIceStonesurfaces.Wearecontinuouslyresearchingnewproductsthatmakeiteasierforyou

tocareforyoursurface.Pleasevisitourwebsiteorcallusforthelatestinformationaboutcareandmaintenance.

REPAIRSREMOVING TOUGH STAINSStainingiscausedbyliquidsthathavepenetrated

anddiscoloredthesurface.Moststainscan

beremovedbyusingapoultice.Refertoour

videoillustratingstainremovalonourYouTube

channel:www.youtube.com/user/IceStoneLLC

REMOVING SURFACE MARKS/ETCHINGEtchingiscausedbyacidicliquidsthathave

discolored,dulled,and/orerodedthesurface.

Ifetchingoccurs,contactIceStoneCustomer

Service:[email protected]

WARRANTYIceStoneoffersaResidential10-yearLimited

WarrantyandaCommercial5-yearLimited

Warrantyforinstallationsthatarefabricated

andinstalledbyanIceStoneCertifiedFabricator.

Registeryourwarrantyonourwebsiteand

receivee-mailremindersaboutmaintainingyour

IceStone.

RECOMMENDED PRODUCTSYoucanpurchaserecommendedproducts

atourwebstoreatwww.icestoneusa.com

* Usingproductsotherthanthoserecommendedon

IceStonecanresultinlessthanoptimalperformance

ofthematerial.

CLEANERSSeventh Generation®All-Purpose Cleaner | Free & Clear

Method®All-Purpose Natural Surface Cleaner | Lavender

Method®Daily Granite Cleaner

SEALERSIceStonerecommendsStoneTech® Bulletproof,®

ahigh-performancewater-basedsealant.Ifyour

IceStonesurfacewassealedwithasolvent-based

product,werecommendTenax® Protex

whenresealing.

IceStone,LLC|BrooklynNavyYard|63FlushingAve,Building12|Brooklyn,NY11205|icestoneusa.com

[email protected]|718.624.4900

IceStone Care & Maintenance Guidelines 2/2

34

IceStone Warranty Registration Form

Building/Homeowner Name:

Type of Installation: Commercial Residential

If Commercial, Project Name:

Project address:

Building/Homeowner Phone Number: ( ) -

Building/Homeowner Email Address:

IceStone Color(s) Installed:

Type of Construction: NewConstruction Remodel

Estimated Square Footage Installed:

Usage (ie.KitchenCountertop,bathroomvanity,outdoorapplication,receptiondesk,etc)

Did you receive the Care and Maintenance Guidelines? (circle one) : Yes/No

Fabricator Company Name:

Installer Company Name:

Purchase Date: / /

Installation Date: / /

Panel ID Number(s):

Brand of Sealer Used:

Brand of Wax Used:

Would you like to receive email updated on IceStone Care & Maintenance Guidelines? Yes/No(Choose“Yes”forreminderstodoawatertesttodetermineifitistimetoresealyoursurface)

Please go to icestoneusa.com/customer-service/warranty to register your warranty. Alternatively, complete the form below and send via email to [email protected] or fax to 718.624.4002. Your warranty must be registered within 30 days of installation.

Street Apt/Suite

City State/Province Zip/PostalCode

Country

IceStone,LLC|BrooklynNavyYard|63FlushingAve,Building12|Brooklyn,NY11205|icestoneusa.com

[email protected]|718.624.4900

Thank You & Contact Us

Westrivetodesignsurfacesolutionsthatwon’tcompromisehumanorenvironmentalhealth.

Tothatend,everyIceStoneslabisfreeoftoxicpigmentsandharmfulcarcinogens,andcontains

justthreecoreingredients:pigment,cement,and100%recycledglass.Safeforouremployees

andsafeforourcustomers.

IceStone,LLCwasfoundedonthebeliefthatmanufacturingsustainable,highdesignproducts

couldrevitalizeandrevolutionizeAmericanmanufacturingandhaveapositiveimpactonthe

environment.IceStonehasdivertedover10millionpoundsofglassfromlandfillssince2003,

andwethankyouforhelpingussavetheworld,onecountertopatatime.

IceStone Customer [email protected]

718.624.4900ext.0

T7186244900| F7186244002|[email protected]

BrooklynNavyYard,63FlushingAve,Building12,Brooklyn,NY11205

©June2015IceStone

www.icestoneusa.com

icestone fabrication guidelines

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