Usage & Fabrication Manual
Usage and Fabrica on Guidelines INDEX MACHINING……………………………………………………………………………..…………………….…………………….2 General Rules Cu ng Stamping and Die Cu ng Sawing Drilling Holes Rou ng and Milling SURFACE TREATMENT………………………………………………………………….………………………………………..3 Surface Prepara on Screen Prin ng Pain ng Varnishing Glues and Adhesives PHOTO MOUNTING AND LAMINATING………………………………………………..………………………………..5 THERMOFORMING………………………………………………………………………………………………………………….
Usage and Fabrica on Guidelines MACHINING Foam can be used in the fabrica on of variety of ar facts using common tools and machinery as recommended in this sec on. General Rules When machining Foam with high-speed equipment, using carbide pped tools is recommended. Lower speeds usually work be er and always use sharp tools to ens ure smooth edges. Cu ng Sheets of Foam up to 3 mm thick can be cut with a u lity knife. Table and band saws, including routers, can be used to cut thicker gauges.
Usage and Fabrica on Guidelines Drilling Holes Holes may be drilled through Foam using the same methods employed for drilling wood. Carbide pped drills are recommended with a point angle between 90 degrees and 110 degrees and with a spiral angle of 30 degrees. (see illustra on 3). High feed and drilling speeds may hinder the efficiency of the drill by crea ng heat buildup. For best results, use sharp bits and lower speeds. Rou ng and Milling Foam may be slo ed, beveled, rabbeted, etc.
Usage and Fabrica on Guidelines Pain ng In addi on to screen prin ng, Foam also has the perfect surface for paint adhesion. There is no need to prime the surface before pain ng. Most conven onal tools and pain ng methods will work successfully with Foam. However, for best results, follow the surface prepara on guidelines introduces earlier. The surface of Foam will accept acrylic-based lacquers, urethane and vinyl based paints. Please refer to Table 2 for a list of pre-approved paint manufactures.
Usage and Fabrica on Guidelines Glues and Adhesives There are a variety of solvent-based glues and adhesives in the market that can be used bonding Foam to itself and other materials. For best results, InteFoam sheets must be dry, clean and free of oil or grease. MEK (Methyl Ethyl Ketone). THP (Tetra Hydro Furan) or common PVC pipe glues work well. Make sure glue joints have a close fit tolerance.
Usage and Fabrica on Guidelines THERMOFORMING Foam is a thermoplas c. It becomes so when exposed to intensive heat. This characteris c gives the material thermoforming capabili es. However, since it is expanded PVC foam, it is important to know that it lacks the draw depth of solid PVC sheets. Heat bending, pressure and vacuum forming are among the methods that may be used to thermoform Foam.
Usage and Fabrica on Guidelines WELDING There are several methods for welding plas cs. The most common are bu welding and hot air welding or gas welding. Note that welds on expanded PVC foam are usually not as strong as those of solid PVC Bu Welding Bu welding is recommended for gauges 4mm and over. This method allows fusion by simply joining two ends together under pressure a er ends have been heated to an op mum bonding state. This pressure must be maintained un l the material is completely cooled.
Usage and Fabrica on Guidelines Free Hanging Signs When installing free hanging signs such as aisle markers in supermarkets, bookstores, and home centers, locate holes 1” or more from the ver cal edge and at least ¾” from the horizontal edge. Use grommets to prevent wear and stress. The suppor ng chains should be installed at a 30 degree to 45 degree angle. (see illustra on 8) If perfectly ver cal chains must be installed, use a plas c or aluminum clip-on “U” channel and posi on holes as desired.
Usage and Fabrica on Guidelines WEATHERABILITY Due to the natural UV inhibitors in white Foam, it tends to perform very well in outdoor condi ons. Colors have the tendency to fade over me when exposed to direct sunlight. However, Foam colors perform the best in the industry. Several years of research have resulted in formula ons that make Foam colors stand out. We recommend performing your own tes ng by pu ng Foam and other manufactures’ color chips, side by side, under the same environmental condi ons.
Foam TECHNICAL SPECIFICATIONS: I. TYPICAL PROPERTIES PROPERTY PHYSICAL Specific Gravity Water Absorp on Shore D Hardness TEST METHOD UNIT VALUE ASTM D 792 ASTM D 570 ASTM D 2240 g/cm^3 % __ 0.75 .30 52 ASTM D 638 ASTM D 638 ASTM D 790 ASTM D 256 ASTM D 149 psi .% Psi lb/in^2 kv/mm 3,000 15 130,000 7 12 °F In/in/°F Btu in/hr ^2 °F 140 35 x 10^-6 0.
Material Safety Data Sheet Manufacturer 1. PRODUCT INDENTIFICATION Product Name Product Code Chemical Family Chemical Name CAS No PVC Sheet Inte001 Vinyl Polymers Polyvinyl Chloride Sheet N/A Integral Skin Expanded Foam PVC Sheet Clear PVC Sheet Rigid PVC Sheet (Type I and II) Expanded Foam PVC Sheet Proprietary 512-874-3760 Formula Technical Informa on 2. PRODUCT INGREDIENTS No. 1 2 3 4 Components PVC Sheet Calcium Carbonate Titanium Dioxide Proprietary CAS No.
4. FIRE HAZARD DATE AND FIGHTING METHOD Flash Point Autoigni on Flammable Limits in Air (LEL, %) (UEL, %) Ex nguishing Media Special Fire Figh ng Procedure n/a n/a n/a n/a Dry chemical, foam water, or carbon dioxide In the event of a fire, wear NIOSH approved, posi ve pressure, self-contained breathing apparatus (SCBA) and full protec ve clothing. Evacuate all personnel from anger area. Use dry chemical, foam, water or carbon dioxide to ex nguish fire.
9. EXPOSURE CONTROLS & PERSONAL PROTECTION RECOMMENDATIONS Eye Protec on Skin Protec on Respiratory Protec on Engineering Control Required Work/Hygiene Procedure Exposure Guidelines No. Components OSHA-PEL ACGIH-TLV Wear safety glasses during sheet cu ng or fabrica ng process.
. REGULATORY INFORMATION Regulatory Informa on: PVC Sheet OSHA Status Not listed, non-hazardous EPA Clean Air Act Status Not listed EPA Clean Water Act Status Not listed TSCA Status All ingredients are listed on TSCA Inventory (40CFR710) CERCLA RQ Not Listed SARA Title III: PVC Sheet Sec on 302* None *Reportable quan ty of extremely hazardous substance, Sec. 302 *Threshold planning quan ty, extremely hazardous substance, Sec. 302 Sec on 313** None **Toxic chemical, Sec. 313.
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