Glass Laminating System: Catalyst, Resin, Pigments & Tools

1. START

2. CATALYST & SEPARATE GLASS ADHESION SYSTEM RESIN PIGMENTS PIPETTES DOUBLE SIDED ADHESIVE TAPE SCALPEL SYRINGE POLYURETHANE SHAPED POURING FUNNEL GRADUATED POURING JUGS WEDGES SUCKER Tools and materials required.

3. Laminating resin is supplied in tins: 20kg and 200kg. • Laminating colour pigments are supplied in plastic bottles: 250ml and 1 litre. • There are ten basic colour pigments: yellow, orange, pink, red, green, blue, violet, brown, white and black. • To get opaque colours use a basic pigment colour and add white or black. The result is quick and uniform. • The proportion of catalyst is between 1% and 2%. The more catalyst you use, the quicker the resin cures. • The required volume of resin is calculated using the area of glass to be laminated and the thickness of tape: • 1mm tape, multiply the area in square meters by 1000 to get millilitres (ml). • Example: Size of glass 1.2metres x 0.8metres = 0.96m2 • Resin calculation: 0.96m2 x 1000 = 960ml. • Catalyst calculation: 2% out of 960ml. = 19.2ml. • 1.5mm tape, multiply the area in square meters by 1500 to get millilitres (ml). • Example: Size of glass 1.2metres x 0.8metres = 0.96m2 • Resin calculation: 0.96m2 x 1500 = 1440ml. • Catalyst calculation: 2% out of 1440ml. = 28.8ml. • Points to note: • When using opaque colours it is advisable to use 1.5 mm thickness tape. • For printed glass, you must increase the resin volume by approximately 10-20%. • For toughened (tempered) glass, check that curved glass faces do not come together by adding 20% resin. • The pigment proportion may vary between 0.5% and 4% depending on the kind of glass being laminated: transparent, translucent or opaque.

4. Attach one face of the double sided adhesion tape along the glass border you are laminating. Leave a small opening in each corner (2mm approximately). Thoroughly clean the glass surfaces to be laminated using cleaning products which do not contain oil or silicon.

5. Place the second piece of glass carefully into position ensuring the edges and corners are correctly aligned. • Use a sucker to lift the upper glass slightly taking the pressure off the protective film, this will aid complete removal of the tape. • Remove the protective film from 3 sides, leaving one long side intact then press the edges together firmly forming an envelope effect. • The correct volume of laminating resin will then be poured through the long side into the glass envelope. Fold back approximately 4 Centimetres of protective film from the double sided tape before locating the second piece of glass.

6. Insert two or more wedges in the side of the panel which still has the protective film in place. • Locate the shaped pouring funnel in the centre of the open side of the panel ready to fill the panel with resin.

7. Add the catalyst to the resin and stir thoroughly, avoid creating air bubbles. Ratio is 2% of mix. Then add the glass adhesion system – ratio 1% of mix. • Leave the mix to stand for a short time to allow any air bubbles to release. • If necessary, use a filter to remove any unwanted particles. • The mix is now ready for use. • Pour into the jug the calculated amount of resin. Stir well before use – preferably 24 hours in advance and leave to rest. • Cover it or put a cap on to keep any dust or particles out. • Colouring the resin: • Shake the pigment bottle well. • Stir in the colour pigment until you achieve the desired colour.

8. When the resin is horizontal then remove the filler in-tray. Be careful not to spill any remaining resin. • Then remove the wedges using a sucker to lift the upper glass. • Incline the glass envelope between 20 & 40 degrees and pour the resin onto the shaped pouring funnel. • The resin will flow down slowly. After the resin reaches the lower holes in the corners seal with polyurethane to prevent air bubbles. • Hold the upper glass with a sucker and remove the protection film from the upper side of the panel. • Lower the glass carefully onto the tape. • Squeeze both glasses together to ensure it is completely closed and sealed.

9. Lower the panel to the horizontal position allowing the resin to fill the void • Air bubbles are easily removed using a syringe. • Push the needle through the double sided tape nearest the bubble and suck out the bubble using the syringe. • Seal the hole afterwards with polyurethane. When the resin reaches the open corners seal with polyurethane.

10. Leave the panel on a flat horizontal surface. The resin takes approximately 72 hours to cure completely. • The panel cannot be moved or manoeuvred during this time.

11. Matt side up! • When laminating etched or sandblasted glass: • Do not apply the laminating resin to the treated surface otherwise this will become totally transparent. • Leave these surfaces facing out. • When laminating large panels: • You must ensure that the 2 panels do not contact each other in the middle due to bowing of the glass. If this happens you can use long wedges on both sides of the filler in-tray to the centre of the panel. • As the resin fills the panel slowly withdraw the wedges taking them out. Panels must not touch! Do not move until fully cured! • Curing time: • The laminated panel must not be moved for at least 72 hours. POINTS TO NOTE:

12. Add 20% more resin! • Toughen/Tempered glass: • When laminating curved glass add 20% extra resin to compensate. Triple Lamination! • Laminating three toughened panels together: • When laminating 3 panels together the curing time will remain the same. • Adhesion tapes: • Ensure that you only use good quality adhesion tapes that are designed for laminating. If air gets into the system the resin will not cure. • Adhesion tapes should be stored at 20ºC to maintain adhesion properties. Tape must be airtight!

13. Colour uniformity: • When laminating large colour panels it is advisable to use a heavier gauge of glass to avoid bowing of the glass in the centre. • If bowing occurs the colour depth and tone will vary depending on the thickness of the resin. • The centre will be a lighter colour than the edges Concentration of colour • Colour change: • To obtain an exact colour match it is recommended to use extra clear glass and where possible make a test panel first using the same glass and laminating resin. • The thicker the glass normally means that the finished colour will be slightly greener. The thicker the glass the greener the finish

14. General Safety Information: • Health & Safety Data sheets are available for all products, contact CRI on (0044) 1795 668199 • Use engineering controls to reduce air contamination to permissible exposure level. • Provide adequate general and local exhaust ventilation. • Do not smoke, eat or drink in the work area. • Do not breathe vapours. • Wear suitable approved safety goggles. • Use protective gloves. • Use a solvent resistant bucket to clean tools. • Provide eye wash station. • Wear appropriate clothing to prevent any possibility of liquid contact and repeated or prolonged vapour contact. • The Catalyst is Butanox M-50 (Metiletil Cetone Peroxide). Note: oxidizing agent – flammable – insoluble in water. • Storage: • Resin must not be kept near direct heat. • Do not leave resin products exposed to direct sunlight. • Store in dry and ventilated area. • Each container must be closed properly after use. Resin, resin products and Cleaning chemicals are flammable. • To prolong the shelf life of resins keep sealed at all time when not in use.