Cornell ES 10-234 User manual

INSTALLATION INSTRUCTIONS
1 1/2 HOUR FIRE RATED LAMINATED
COUNTERTOP INSTALLATION
ES 10-234
REVISION: #0002ECO# 1558
BY: JD
DATE: 10/23/2012
Note:
The details shown below illustrate standard countertop configurations. When projections beyond either
side of the wall exceed 6” additional support must be supplied beneath the countertop by others.
Before permanently installing the countertop into the opening it is advisable to check it for proper fit.
Unpack the countertop from the shipping crate and lay it on a clean flat surface. Be careful to properly
support countertops in the center when lifting to prevent cracking especially if they are long and narrow.
Measure the opening size and check this dimension against the drawings provided and the actual size of
NO CLIP ANGLES
SUPPLIED THIS SIDE
SUPPORT ANGLES SUPPLIED
ONLY WHEN THIS DIMENSION
EXCEEDS 6"
SUPPORT ANGLES
ALWAYS SUPPLIED
THIS SIDE OF
COUNTERTOP
COIL SIDE
PUBLIC SIDE
COIL SIDEPUBLIC SIDE
APPLY RTV FLAME
RETARDANT SILICONE
SEALANT TO THIS SURFACE
PRIOR TO INSTALLING
COUNTERTOP
APPLY RTV FLAME
RETARDANT SILICONE
SEALANT TO THIS SURFACE
PRIOR TO INSTALLING
COUNTERTOP
4'-0" MAX.
6" MIN.
FOR UNITS THAT EXTEND LESS
THAN 6" TO FLUSH WITH THE WALL
ON THE PUBLIC SIDE.
1 5/8"
4'-0" MAX.
6" MIN.
4" STD.
STANDARD UNIT CONFIGURATION

INSTALLATION INSTRUCTIONS
1 1/2 HOUR FIRE RATED LAMINATED
COUNTERTOP INSTALLATION
ES 10-234
REVISION: #0002ECO# 1558
BY: JD
DATE: 10/23/2012
the countertop. The standard countertop is built to allow a 1/8” clearance dimension between the edges
of the countertop at all points where it contacts the wall. The portion of the countertop projecting through
the wall opening should be 1/4” less than the actual wall opening. The countertop can now be placed into
the opening to check the fit.
Remove the countertop and begin preparation of the opening for the permanent installation. The upper
face of the wall opening on which the countertop will sit should be smooth, level and free of dust, dirt or
other debris. When ready to install the countertop apply the flame retardant silicone sealant, supplied
with the hardware, to the upper face of the wall. This material should be applied using a standard
caulking gun and applying a generous bead down the entire length of the wall opening. The number of
beads required should be determined by the thickness of the wall. Please be careful to hold the beads
back from the edge of the opening so the sealing material does not squeeze out and run down on to the
face of the finish wall. As soon as the sealant is applied the countertop should be installed, adjusted and
leveled before the sealant begins to set up. A block of wood and a rubber mallet may be used to gently
tap on top of the countertop to set it in place and assure proper contact and adhesion to the silicone
sealant. Use caution in this procedure so as not to mar or damage the laminate surface.
Next install the support angles beneath the countertop at the locations shown in the details. These
angles and fasteners are supplied as part of the hardware package and should be installed according to
the layout in the details shown below. When fastening the clip angles to the underside of the countertop
be certain to use the shorter fasteners supplied. Do not over-tighten these fasteners as the core material
will strip out very easily. A small amount of wood glue may be applied to these fasteners to hold them
securely in position. Additional support must be provided by others when the projection dimension on
either side of the opening exceeds 6” or the countertop may become unstable in the opening.
CLIP ANGLE LAYOUT –UNDERSIDE OF COUNTERTOP SHOWN
“H” type countertop is shown; layout is typical for “T” and rectangular configurations also.
Note:
When overhang on the public side is less than 6” the clip angles are not supplied because they may be
visible and detract from the overall appearance of the installation. Coil side clip angles are always
supplied and must be used to properly attach the countertop to the wall.
18" MAX.6"
3"

INSTALLATION INSTRUCTIONS
1 1/2 HOUR FIRE RATED LAMINATED
COUNTERTOP INSTALLATION
ES 10-234
REVISION: #0002ECO# 1558
BY: JD
DATE: 10/23/2012
TWO-PIECE LAMINATED COUNTERTOP INSTALLATION
Please read these instructions carefully before attempting countertop installation!
1. Lay countertop sections face side down, on the floor in front of the coil side of the opening. Use
cardboard, foam or some other material to protect the face of the countertop from being scratched. If
a “tee” shaped countertop is being used the wider side of the countertop should be toward the
opening. Whatever material is used it should allow the two sections of the countertop to be lined up
flat with each other so the Tite-joint fasteners and the biscuit joints can be installed. Measure the
countertop and the opening to verify that the countertop will fit properly. The length of the countertop
where it fits between the walls should be about ¼ inch less than the width of the opening.
2. Assemble the two halves of the countertop with the Tite-joint fasteners and the biscuit joints as shown
in the drawing on the next page of this document. The biscuits should fit snugly in the recesses
provided in the countertop to properly align the two halves. If the biscuits do not fit tightly, they may
be moistened with a small amount of water in order to obtain a snug fit. A small amount of
woodworkers’ glue may be applied to the biscuits before inserting them into the slots if desired.
When installing the tite-joint fasteners tighten them only enough to hold them in place when the
countertop is turned over. These will be tightened after the countertop is mounted in the opening. A
piece of masking tape can also be placed over the openings for the fasteners to prevent the locking
sleeves from falling out when the countertop is turned over. Be extremely careful when handling
the countertop with the Tite-joint fasteners in place! Any bending or twisting at the splice may
fracture the laminate and/or the substrate. A set of clamps and wood blocking should be used on
either side of the countertop to hold the seam rigid until it can be lifted into the opening. These may
be applied over the Tite-joint fasteners because they will be removed once the countertop is in the
opening. Do not over-tighten these fasteners.
3. Next, apply the adhesive provided to the opening in the wall. This will secure the countertop in
position after it is in place. Use enough adhesive to allow some give so the two halves of the
countertop can be lined up to make a smooth, even joint. Be careful to keep the adhesive back
slightly from the edges of the opening so it does not squeeze out once the countertop is installed.
Carefully lift up the countertop, slowly turn it face side up, and position it in the opening. NOTE: Be
extremely careful when handling the countertop. Do not bend it at the splice or the laminate and
the substrate may fracture at the Tite-joint fasteners. Once the countertop is in the opening the
clamps and wood blocking can be removed until the seam is tightened.
4. Line up the two halves of the countertop at the splice and then begin tightening the Tite-joint
fasteners. Do not over-tighten these fasteners! Over-tightening will cause the laminate to buckle
and/or the substrate to fracture. These are only used to pull the countertop halves together snugly at
the seam until the adhesive sets up. Once the countertop is positioned properly in the opening and
the seam is tight the wood blocking and clamps can be reapplied to the countertop to maintain seam
alignment. The adhesive should be allowed to cure, preferably overnight, before installing the
countertop clip angles to the countertop and wall or the counter door on the opening.

INSTALLATION INSTRUCTIONS
1 1/2 HOUR FIRE RATED LAMINATED
COUNTERTOP INSTALLATION
ES 10-234
REVISION: #0002ECO# 1558
BY: JD
DATE: 10/23/2012
7/16"
5/16"
TIGHTENING NUT
DRAW BOLT
LOCKING SLEEVE
T
O
T
G
I
H
N
E
T
N
T
U
HOLE LAYOUT AND DIMENSION
TWO TITE JOINT FASTENERS AND
TWO #20 BISCUIT JOINTS. UP TO 24" WIDE
THREE TITE JOINT FASTENERS AND
FOUR #20 BISCUIT JOINTS. OVER 24" WIDE
2"
4" 4"
2"
2"
4"
2"
4"4" 4"
L
C
FASTENER LAYOUT
KNAPE & VOGT
#516' TITE-JOINT FASTENER
1. INSERT TIGHTENING NUT AND THREAD DRAW BOLT INTO NUT 2. JOIN BOTH SILLS TOGETHER AND INSERT
LOCKING SLEEVE 3. TIGHTEN NUT WITH TIGHTENING TOOL OR NAIL
HOLE LAYOUT TYPICAL IN EDGES OF BOTH
PIECES FOR DRAW-BOLT AND BISCUIT JOINT
5/8"
2 1/2"
5/16"
7/8"
1 1/2"

INSTALLATION INSTRUCTIONS
1 1/2 HOUR FIRE RATED LAMINATED
COUNTERTOP INSTALLATION
ES 10-234
REVISION: #0002ECO# 1558
BY: JD
DATE: 10/23/2012
Field Over-Laminating Instructions for UL Classified Countertop
Cornell’s UL classified laminated countertop assemblies may be field over-laminated in order to provide a
seamless surface between a Cornell UL classified countertop and non fire rated countertops that will be
installed adjacent to these units. The classified countertop assembly provided by Cornell shall not be
modified in any way other than preparation of the existing surfaces in the field that are required to be
over-laminated. Acceptance of this procedure is subject to approval by the Authority Having Jurisdiction
(AHJ) and it is advisable to check the acceptability prior to proceeding with the over-lamination process.
The materials used and field installation of the over-laminate must be applied according to the following
requirements and installation instructions in order to maintain the original listing of the UL classified
countertop.
The following are the only acceptable laminate materials that can be used in the over-lamination process.
All materials used are to be maximum .050 thick general purpose laminate provided by the following
manufacturers.
“Wilsonart” general purpose laminate manufactured by the Ralph Wilson Plastic Co.
“Formica” general purpose laminate manufactured by Formica Corporation
“Nevamar” general purpose laminate manufactured by Panolam Industries
“Pionite” general purpose laminate manufactured by Panolam Industries
The following are the only acceptable adhesives to be used to apply the second layer of laminate to first
layer of the UL listed countertop. Wilsonart #810 or #811 contact adhesive or Borden’s catalog # PVA-
104A/M304L.
Important:
All surfaces intended to be over-laminated in the field must be prepared to insure proper adhesion of the
second layer of laminate to the first. The original layer of laminate applied to the classified countertop
should be thoroughly sanded to roughen the surface to allow a proper bond with the new surface. It
should be clean, free of oil or grease, and uniform in thickness prior to applying the second laminate
layer. The adhesive listed above should be applied to the laminate surfaces according to the
manufacturer’s instructions and the second layer of laminate should then be applied over the first layer
on the UL classified countertop and the adjoining non-rated countertop supplied by others.
Please Note:
The job site contractor applying the over- laminate surface will be held responsible for de-
lamination of the field applied material due improper preparation or installation of the over-
laminated surfaces. Failure to use the required materials and procedures listed above will result
in voiding of the UL classification of the fire rated countertop assembly.