Solid Surface Manual

SOLID SURFACE
QUALITY MANUAL
ICPA-SS Quality Manual
ICPA SOLID SURFACE QUALITY MANUAL

TABLE OF CONTENTS
Topic
Page#
i. Credits & Acknowledgements
iii
I. Introduction
A. Purpose of Manual
B. Commitment & Implementation
C. Calibration Program
D. Product Testing & Certification
1
2
2
3
II. Raw Materials

A. Resin
1. Specifications & Certification
2. Batch Testing
3. Resin Material Specification Sheet
4. Work Instruction - Resin Inspection
5. Resin Incoming Inspection Test Report
4
4
5
6
7
B. Fillers & Granules

2. Alumina Tri-hydrate (ATH)
3. Color Granules
4. Batch Testing
5. Filler Material Specification Sheet
6. Work Instruction - Filler Inspection
7. Filler Receiving Inspection Log
8
8
9
10
11
12
13
C. Pigments
2. Batch Testing
3. Pigment Material Specification Sheet
4. Work Instruction - Pigment Draw Down Test
5. Pigment Receiving Inspection Log
14
14
15
16
17
D. Catalyst
2. Batch Testing
3. Catalyst Material Specification Sheet
4. Work Instruction - Inspection Instructions
5. Catalyst Receiving Inspection Log
18
18
19
20
21
Page i
Topic
Page#
III. Mixing & Casting

A. Recipe
B. Mixing
C. Pouring
D. Sample Plaque
E. Clean-up
F. Batch Record
22
23
25
25
25
26
27
IV. Demolding Procedures

A. Open Mold
B. Closed Mold
C. Mold Maintenance
D. Mold Tracking
E. Mold Maintenance Tracking Log
28
V. Post-Curing
A. Importance
B. Temperature & Time
C. Oven Consistency
D. Record of Completion
E. Batch Test Log
30
31
VI. Tracking Scrap & Customer Returns

A. Importance
B. Weekly Scrap Log
32
33
29
VII. Finishing
A. Finish Classification & Quality Standards
B. Finishing Standards
34
35 - 38
VIIL. Glossary
Glossary 1 - 16
IX. Appendix
A. Plant Audit Form
Audit 1 10
Page ii
ICPA SOLID SURFACE QUALITY MANUAL
Credits & Acknowledgements

Company
Name
AOC Resins
Mark Campbell
Bill Jeffries
Frank Scott
Bob Borja
Steve Case
Irwin Frank
Klaus Fromme
Tom Pelt
Bob Piekarski
Ann Severin
Brent Baker
Bob Anderson
Wes Benedict
Dale Malone
Pat Toner
Siam Lim
Terry McCabe
Lou Ross
Chuck Arnold
Dennis Fink
Ross Weber
Jeff Nalley
Dal Keller
Paris Chen
Ken Lipovsky
Dan Mahlmeister
Jack Simmons
Jim Steigmeyer
Bern Brody
Bill Willson
Avonite
BP Amoco Research Center
Bradley Corporation
CCP
Century Cast
Custom Quality Marble
ICPA
Interplastic
NAHB Research Center
Norac
Huber Engineered Materials
R&D Marble Inc.
Reichhold Inc.
R.J.Marshall Co.
Roma Marble
SAFAS Corporation
Willson Consulting
Page iii
PURPOSE OF THIS MANUAL

The purpose of this manual is to provide ICPA members with a working document to
assist in evaluating, implementing, managing and maintaining an ongoing program to
identify and achieve the minimum standards for producing quality certifiable solid
surface products by a vacuum casting process.
This manual is written from the perspective that within certain specific procedures and
parameters quality product can be manufactured consistently. It contains information
and forms required to accomplish and support this goal. This manual is also available in
electronic format so that the forms can be modified or adapted to suit ones business.
The procedures and forms included in this manual will assist owners and supervisors to
evaluate, record, track and verify critical aspects of the manufacturing process. The
expectation is that in most instances the raw materials are within specification. Yet due
to improper or inaccurate processes, or conditions outside the normal range of application
(i.e. ambient temperature, humidity, etc.), significant problems arise, thus preventing the
manufacturing of quality products.
In terms of Return on Investment this manual will more than pay for itself in a short
period of time. When programs such as these are implemented some companies have
seen their scrap rate drop from above 10% to under 5%. A significant drop in warranty
claims should also occur over time.
It is in both the individuals and the industrys best interest to see that high quality
products are being manufactured by everyone. A company putting out inferior product
hurts not only the member but also the industry. The cost of inferior products can be
very high for the industry.
This manual contains the information to start or improve an in-house QC program. It
has been designed for off the shelf use by both the busy small business owner and larger
corporations. The manual helps to lay the groundwork for a Minimum Quality Control
System. The QC forms developed here should serve as the foundation for QC records as
part of an in-house program for members of the ICPA. Please use it as a management
tool provided by the ICPA for the betterment of the industry.
To quote from one of the fathers of the industry, Robert Brill, The cast polymer
process is a chemical manufacturing process; you must control it or it will control you.
To control the process one needs to understand the critical components. The
manufacturing process is a set of interlocking processes, which are dependent one
upon the other for the ultimate success of producing a high quality solid surface product.
Feedback and insight is welcome on ways to improve this manual and help benefit
the industry.
Page 1
QUALITY COMMITMENT
To ensure the success of any quality program it is imperative that management is
committed to the program. The long-term success of any company depends on the
quality of product that it produces. Testing and certifying your solid surface material
provides assurances to your customers of your materials quality. Once a company
develops a reputation for an inferior product, it is hard to acquire either repeat or new
business. Yet, there is a business need to attain and maintain the desired quality at a
minimum cost. An effective quality assurance program helps to eliminate waste, cut
costs, and improve consistency in your shop. The fulfillment of this quality aspect is
related to the planned and efficient utilization of the technology, human and material
resources available to each company. This commitment must continue even as business
grows and schedules get tight. One must continue to remember that the consumer will
often use this product daily for many years and is depending on the manufacturer to
ensure quality. Management must constantly emphasize the need for high quality to all
employees by insisting that proper procedures be followed to achieve proper product
performance.
Calibration Program
For any quality program to be successful, one must first have a calibration program in
place for all their instruments. Measurements are only as good as the equipment that is
used to take the readings. Scales, digital thermometers, pyrometers, viscometers,
spectrophotometers, etc need to be checked on a regular schedule. Stickers need to be
placed on each piece of equipment displaying the calibration date, due date and the
initials of the person performing the calibration. A calibration logbook could also be
used along with the stickers. Trained personnel can often perform this calibration in
house or calibration services can be contracted. Standards used for calibration should be
traceable to the NIST (National Institute of Standards and Technology). Procedures for
calibration can usually be found in the owners manual. Both lab and production
equipment need this service. Resin and/or filler have a way of migrating to locations
where they dont belong. Having a calibration program in place is so important that it is
listed first in this manual. The success of implementing the remaining sections of this
manual depends upon having a calibration program in place.
Page 2
PRODUCT TESTING & CERTIFICATION

Solid Surface material is known in the industry as a quality material, which due to its
inherent properties should last a lifetime. In order to ensure a quality material, it needs to
be tested periodically to verify that its properties are being maintained. This is especially
important when changing to new raw materials or changing processes. Changing resins
or fillers can have a drastic effect on the final product. To ensure that field problems are
kept to a minimum, product testing is required prior to implementing changes. Having
consistent processes and materials is the key to ensuring quality parts. Periodic product
testing helps ensure that unknown changes have not taken place.
Product testing can often be done in house without sophisticated lab equipment. Test
fixtures can be developed to compare the material strength and impact resistance of two
different materials. Stain testing is also a relatively simple test. Doing comparison
testing in house can at least determine if the new raw material or process has a good
likelihood of improving the quality of the end product. Field-testing in a high usage area
also can reveal possible shortcomings of a product.
Alternative sources for comparison testing are local universities. Often they have the lab
equipment to perform more in depth testing. Testing should be performed to the
ANSI/ICPA SS-1-2001 standards. Records of this testing should be maintained in case
of field problems or to demonstrate consistent product quality to your customer.
Having independent testing certification adds credibility when selling your product.
A number of product approval agencies are available. These agencies can offer testing
and certification labels that can be placed on every product providing the consumer with
the assurance of a quality product. These certification programs require periodic auditing
of the procedures, as well as periodic testing performed on randomly selected products.
A list of these certifying agencies can be obtained from the ICPA. These agencies can
also perform testing to assist one in qualifying new raw materials.
Since solid surface material is use in the construction and plumbing industry, one also
needs to be aware of national, state, and local codes. These codes will vary depending on
the application and whether the product is installed in a residential or commercial
building. It is important to contact the local building inspectors in the region(s) where
you plan to install your product. They can help you understand the proper certification
required, if any, for your product.
Remember that solid surface is a quality material and should be tested periodically to
ensure this quality. The excellent reputation of this material will only continue if each
manufacturer does their part to ensure they are producing a quality product.
Page 3
RAW MATERIALS - RESIN

1. Specifications & Certification: The importance of identifying the proper
requirements expected in the resin cannot be over emphasized. The performance and
quality of the final product is highly dependent on the properties of the resin that is
used. A Resin Material Specification Sheet should be developed including the critical
requirements of the resin as well as any special requirements. A sample of this
document can be found on page 5. This specification sheet should be discussed with
the vendor to ensure compliance. When material is received, the Certificate of
Analysis should be reviewed and matched with the containers (drums, totes, tank)
received. Lot numbers should be recorded on the inspection log and MSDS sheets
filed in a place accessible to all employees. If there is more than one batch number
involved the batches must be grouped and the drums numbered and used
accordingly.
2. Batch Testing: The following tests are recommended to be performed on a sample
from each batch of resin. These tests verify that the correct resin is received and will
help production determine the characteristics of the mixture, such as gel time. The
goal is to ensure that there are not unpleasant surprises in performance during
production when considerable dollars in material and labor are at risk.
1. Color & Appearance visual test
2. Viscosity @ 25C (77F)
- Brookfield Viscometer
3. Gel Time see procedure on Resin Receiving Inspection Form
- Neat gel time @ 25C (77F)
- Filled gel time @ production temperature and conditions.
4. Time to Peak Exotherm
5. Peak Exotherm Temperature
An example of work instructions for the above tests is on page 6. The results of the
above testing should be recorded in a log accessible to production. An example Resin
Test Report is on page 7. Significant variation in the results of the above tests should be
discussed with the vendor to determine whether the proper material was delivered.
Production should also be alerted of any variations that might affect them when mixing
the resin.
Page 4
RESIN MATERIAL SPECIFICATION SHEET

DATE CREATED
MATERIAL PART NUMBER
________
___________
MATERIAL DESCRIPTION:
POLYESTER CASTING RESIN:
PURCHASE U/M:
ISSUE U/M:
LB
LB
CONDITION AS PURCHASED:
Hardness: Liquid
Finish: Clear, Color:
Preservative: Shelf life is 90 days. Storage temerature should not exceed 90 F
Other: Purchase by tank load (approx 40,000lb) or in 275 gal.totes = 2475 lb or in 55 gal drums
ANALYSIS:
Certification sheet to be supplied with each load including viscosity, gel time,
peak exotherm, & time to exotherm
PHYSICAL PROPERTIES:
____ lb per gal (sp.gr.=1.05-1.09) Viscosity = ___ - ____cps @ 77F (25C)

Gel time @ 77F = ___ - ___ min. using ___% of catalyst ___________
Peak exotherm = ____ - ____F; Time to Exotherm = ___ - ___ minutes
TYPICAL USES:
Solid surface sheet stock, bowls, etc.
EMERGENCY SUBSTITUTES:
REMARKS:
POLYESTER CASTING RESIN:
VENDOR -
ORIGINAL SPEC:
PREPARED BY:
DATE
LETTER
ICPA-Solid Surface Q/A Manual
CHANGE
RMN
Page 5
ENG
7/1/02
Work Instruction Resin Inspection

Work Instruction Title
Incoming Inspection for Solid Surface Resin
Date
Department:
Area: Solid
WI Number
Revision
Surface
1.0 Purpose: Determine if shipments of solid surface resin meet specifications.

2.0 Scope: All solid surface resin
3.0 Responsibilities: Solid surface laboratory personnel
4.0 Work Instruction Steps:
4.1 The following QC checks MUST be performed on the resin before acceptance, and
an Incoming Inspection (Resin) Test Report filled out.
4.1.1 The following documents are required:
4.1.1.1 Certificate of analysis for the shipment
4.1.1.2 Purchase order for the shipment
4.1.2 If purchased by a tank truck, check Resin temperature, for compliance
with the P.O. specified delivery temperature.
4.1.2.1 At the external thermometers at the side or top of the tank.
4.1.2.2 On a sample removed from the bottom of tank truck.
4.1.2.3 Record results on the Test Report
4.1.3 Draw a sample from each batch of resin received.
Adjust sample temperature to 25C (77 F ).
4.1.3.1 Measure viscosity (follow Viscometer instructions noting spindle
used and rpm) @ 25C (77 F). Record results on Test Report
4.1.3.2 Perform a Neat Gel test, on a100 grams resin sample. Use the %
and type of catalyst specified by the resin vendor at 25C (77F).
Record the Gel Time, Peak Exotherm time and Peak Exotherm
Temperature on the Test Report.
4.1.3.3 Visually inspect and record color on the Test Report.
4.2 If the resin complies with specifications or results on the Certificate of Analysis
4.2.1 For tanks follow Tank Filling Check List. Sign the receiving forms and
start pumping resin into tank.
4.2.2 Drums or totes should be stored in an environment recommended by the
vendor.
4.3 If the resin fails ANY of the above tests or temperature requirements (for tank loads),
retest. If the shipment fails any of the above tests a second time, contact the vendor.
5.0 Safety Information:
5.1 MSDS: on file in lab, MSDS Manuals and Master Book.
5.2 Disposal:
5.2.1 Un-catalyzed through a licensed waste hauler only!
5.2.2 Catalyzed Non-Hazardous can be disposed of in a dumpster.
6.0 Associated Documents:
6.1 Solid Surface Incoming Test Report
Page 6
Resin Incoming Inspection

Test Report
PURPOSE:
Test Date:..
To verify that manufacturers test results provided with shipment documentation agree with the
delivered product, and the specifications listed on the purchase order.
REFERENCES:
Work Instructions for Solid Surface Resin
MATERIAL: Vendor: ..
PO #....Mfg Lot #..Material
TEST EQUIPMENT:
Timer, 250 & 500ml ml disposable beakers; mercury bulb thermometer 500 F Range; Infrared
(IR) thermometer; Viscometer; Temperature controlled environment. Clean 2 1/2 gallon plastic
bucket with cover (if sampling from a tank truck); glass stirring rods.
PROCEDURE:
Verify manufacturers test results against purchase order requirements or material specification
sheets.
If tank load, record temperature on the truck tank thermometer. Draw off sample into the plastic
bucket. Immediately take temperature with IR thermometer & record temperatures.
Perform and record the following tests on each batch:
Viscosity:
resin @ 25 C (77F)
Neat Gel:
100 grams of resin @ 25 C (77F) ___% of ____________ catalyst
TEST DATA:
Tank
Sample
Temp
Temp
%
Shrink
Color
Viscosity
Time
Neat Gel
Peak Exo.
Temp
Peak Exo.
Time
Mfg (filled)Test Results:

Spec. Requirements:
REMARKS: __________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
Technicians Signature
Page 7
RAW MATERIALS - FILLERS

1. Specifications & Certification: The importance of identifying the proper requirements of all
components added to the solid surface mix cannot be over emphasized. The performance,
color and quality of the final product is highly dependent on the properties of the filler that is
used. Even a change in the type of ATH used in the filler mixture can affect color, strength,
and stain resistance of the product. Changing fillers can also affect the pouring process by
changing both the viscosity and gel time of the mix. Some fillers are more susceptible to
humidity absorption, which also affects processing. A Filler Material Specification Sheet
should be developed including the critical requirements of the filler as well as any special
requirements. A sample of this document can be found on page 11. This specification sheet
should be discussed with the vendor to ensure compliance. When material is received, each
batch needs to be tested, and the material stored in such a manner that the oldest material is
used first. Fillers should be stored in a dry location and kept sealed to prevent moisture
absorption. Material from the same batch should be stored together in case any problems are
discovered. Lot numbers should be recorded on the inspection log. If there is more than one
batch number involved the batches must be grouped, numbered and used accordingly.
2. Alumina Tri-hydrate (ATH): Solid Surface grade ATH is the predominate filler used in the
solid surface matrix. Since there are many types of ATH, your vendor should be contacted to
select the proper material for your application. ATH is an inorganic chemical made in a
refinery. Bauxite is the mineral used as the raw material in the process. High purity white
Aluminas reduce color contribution and provide improved translucency and chip definition in
granites. Lower priced Bayer Alumina has a gray appearance and contributes to the
background color. It can require higher levels of pigmentation, is more opaque, and reduces
chip definition in granites.
Although manufactures can be successful using any number of these Aluminas, there are
several rules of thumb that should be considered in the selection of fillers for manufacturing
Solid Surface. Characteristics such as particle size distribution, PH stability, color, surface
area, matrix viscosity, smoke and flame retardant and binder adhesion to the substrate all
contribute to the final properties of the finished material.
a) Particle Size - Wide varieties of particle sizes are utilized ranging from coarse to very fine
(usually 40 to 6 microns), either as a single hydrate distribution that can be narrow or
wide, or with combinations of two particle size distributions to create a bimodal
distribution, resulting in higher filler loadings (up to approximately 65%). Higher filler
loadings reduce drawing, curling, warping and thermal expansion, which diminishes part
fatigue. Also higher filler loading increases the overall dimensional stability of the
finished parts. Test data indicates that the smaller the particle size the better the stain
resistance. Yet all ATH products currently utilized in Solid Surface manufacturing today
can pass stain tests when properly manufactured and sanded.
Page 8
b) PH Stability - Alumina Trihydrate is PH stable meaning common household acids or

chemicals will not etch, attack or discolor the surface finish.
c) Color Consistency - Aluminas color specifications L*, a*, b* and Delta E should be
measured to ensure there is color uniformity between lots.
d) Surface Area - Choose hydrates that have good particle orientation, definition and surface
area of 1.25 to 2.1 m*2/gm. This provides improved binder adhesion to the substrate
reducing cracking, crazing and fatigue.
e) Matrix Viscosity - Bi-modal formulations reduce matrix viscosity allowing higher filler
loadings with improved dimensional stability, mold flow, and air-release.
f) Fire Retardant - Alumina Trihydrate has 3 moles of water and contains 34.6% waters of
hydration that is released at around 400 degrees F. Formulations utilizing Alumina
Trihydrate meet Class I Smoke and Fire retardant regulations when properly formulated.
This characteristic is necessary to meet building codes.
g) Substrate Adhesion - Particle definition and surface area play major roles in binder
adhesion to the substrate. Good particle definition and surface area improves adhesion
and helps reduce fatigue failure from thermal expansion and contraction.
Questions about your fillers should be discussed with the supplier or manufacturer. It composes
approximately 60% of the solid surface matrix and contributes immensely to its finished
properties. It is imperative to evaluate your filler source and to understand how it impacts your
quality, processes and product performance. Communication with the supplier is the best source
for success and solutions.
3. Color Granules: Solid surface granules can be purchased separately or premixed with the
ATH. Just as with ATH, there are many sources of these granules. Many of the same
characteristics that apply to ATH also apply to granules, such as: particle size distribution, pH
stability, color consistency batch to batch, and flame & smoke contributions.
a) Particle size distribution Wide varieties of particle size distributions are
utilized to create different esthetic looks. The batch-to-batch consistency of the
granules with respect to particle size distribution is critical to maintaining a
controlled process. The particle size distribution affects the viscosity of the matrix
and can affect the gel time of the matrix. An inconsistent particle size distribution
can also create air voids or particle settling which can lead to warping or
premature failure of the part, as well as a non-uniform appearance.
b) pH stability Granules should be pH stable so that common household acids or
chemicals do not etch, attack or discolor the surface finish.
Page 9
c) Color consistency Granule size and color consistency is important for matching
previously made Solid Surface designs. A sample plaque with a control ATH and
a control resin should be made with all new lots of granules to assure uniformity
from batch to batch.
d) Fire Retardant ATH is the main component that provides solid surface
materials a Class 1 smoke and fire rating. It is important when choosing granules
not to compromise this rating.
4. Batch Testing: The following tests are recommended to be performed on a sample from each
batch of filler, whether ATH, granules, or a blend of ATH & granules. These tests ensure
that the correct filler is received and will help production determine the characteristics of the
mixture, such as viscosity. The goal is to ensure that there are not unpleasant surprises in
performance during production when considerable dollars in material and labor are at risk.
a. Color & Appearance
b. Viscosity or Resin Demand Test
c. Test Plaque
An example of work instructions for the above tests is on page 11. The results of the above testing should
be recorded in a log accessible to production. An example Filler Receiving Inspection Log is on page 13.
Significant variation in the results of the above tests should be discussed with the vendor to determine
whether the proper material was delivered. Production should also be alerted of any variations that might
affect them when mixing the filler.
Page 10
FILLER MATERIAL SPECIFICATION SHEET

DATE CREATED
___________
____________
Filler: (ATH, granules, pre-mix)

Mixture of _____, _____, & ____ chips with ATH
PURCHASE U/M:
ISSUE U/M:
LB
LB
Hardness:
Finish:
Preservative:
Other: Purchase in 50lb bags
ANALYSIS:
Sample tested at receipt of shipment.
Background color, particle size & appearance

to match standard color plaques
TYPICAL USES:
REMARKS:
Vendor:
ORIGINAL SPEC:
PREPARED BY:
DATE
LETTER
CHANGE
RMN
Page 11
ENG
7/1/02
Work Instruction Filler Inspection

Incoming Inspection : Solid Surface Mineral Fills

Department:
Area:
WI Number
Revision
Date
Solid Surface
1.0 Purpose: Determine if shipments of solid surface filler (ATH, granules, pre-mix blends)
meet quality standards.
2.0 Scope: All solid surface fillers.
3.0 Responsibilities: Solid surface laboratory personnel.
4.0 Definitions:
4.1 Spectrophotometer is a device used to analyze light energy reflected or transmitted by
a color sample, wavelength by wavelength. Measurements are defined as L*, a*, b*,
and E.
5.1 Make a 500 gram (6x6) sample plaque using 35% of a control resin & 65% filler
ATH alone or a mix of ATH & granules). If the filler will be used with a pigment in
production, it is best to make both a pigmented & un-pigmented sample. Pigmented
samples often reveal color characteristics that un-pigmented samples dont; and viseversa.
5.2 Post cure sample plaques at 200F for 2 hours.
5.3 Finish sample (using standard production finish techniques).
5.4 Visually compare to the Color Standard Sample Plaque for:
5.4.1 Size and color of chips (if applicable)
5.4.2 Amount of chips
5.4.3 Background color (especially important for un-pigmented colors) Use a
light box.
5.5 Measure the sample plaque with a spectrophotometer if available. The E between
the sample and standard plaque should be less than 1.00 for solid colors and 1.5 for
granite colors. Eight to sixteen readings should be taken at various locations on
granite plaques to obtain an average reading.
5.5.1 If the samples match, mark the pallets as OK for storage.
5.5.2 If the samples do not match, make another sample and retest.
5.5.3 If the second sample fails, report the fill as defective material and contact
the vendor.
5.6 Record spectrophotometer readings and save sample plaques.
Note: At this time the most accurate test for color matching is visual comparison by a trained
technician using a light box. Spectrophotometer readings should be taken and recorded as an aid
to the technician and for setting future numerical color parameters.
6.2 MSDS: on file in Lab, MSDS Manuals and Master Book.
6.3 Disposal: Non-Hazardous can be disposed of in dumpsters
7.0 Associated Documents: Filler Receiving Inspection Log.
Page 12
Lot #
P.O. #
Type _____________
Date
ICPA - Solid Surface Q/A Manual
"a"
"b"
DE
Filler Receiving Inspection Log

"L"
Vendor ________________
QTY
Page 13
Pass/Fail
DMR#
Vendor# _____________
Comments
7/1/02
RAW MATERIALS - PIGMENT

1. Specifications & Certification: Pigments can be used to provide the desired
background color of the final product. It is vital that the pigment is compatible with
the resin so as to not affect the performance and quality of the final product. A
Pigment Material Specification Sheet should be developed including the critical
requirements of the pigment as well as any special requirements. A sample of this
document can be found on page 15. This specification sheet should be discussed with
the vendor to ensure compliance. When material is received, the Certificate of
Analysis should be reviewed and matched with the containers (pails, drums) received.
Lot numbers should be recorded on the inspection log and MSDS sheets filed in a
place accessible to all employees. If there is more than one batch number involved
the batches must be grouped and the drums numbered and used accordingly.
2. Batch Testing: The following tests are recommended to be performed on a sample
from each batch of pigment. These tests verify that the correct pigment is received.
The goal is to ensure that the pigment provides the proper color when used in
production. It is extremely important that the pigment is mixed thoroughly before
testing as well as before use in production. Pigments by their nature do tend to
separate fairly rapidly.
a. Color & Appearance visual test
b. Draw Down Test
An example of work instructions for the above tests is on page 16. The results of the
above testing should be recorded in a log accessible to production. An example Pigment
Receiving Inspection Log is on page 17. Significant variation in the results of the above
tests should be discussed with the vendor to determine whether the proper material was
delivered. Production should also be alerted of any variations that might affect them
when mixing the resin.
Page 14
PIGMENT MATERIAL SPECIFICATION SHEET

DATE CREATED
_________
____________
Pigment Color:
PURCHASE U/M:
ISSUE U/M:
LB
LB
Hardness: Liquid or dry
Finish:
Preservative: Shelf life is 6 months (Consult supplier)
Other: Purchase in __ gal. containers
ANALYSIS:
Certification sheet to be supplied with each shipment
Color matches approved color sample
TYPICAL USES:
REMARKS:
Vendor:
ORIGINAL SPEC:
PREPARED BY:
DATE
LETTER
CHANGE
RMN
Page 15
ENG
7/1/02
Work Instruction
Incoming Inspection: Pigment Draw Down Test

Department:
Area:
WI Number
Revision
Date
Solid Surface
1.0 Purpose: Test pigment for proper color.

2.0 Scope: All solid surface pigments
3.0 Responsibilities: Solid surface laboratory personnel.
4.0 Materials Required:
4.1 Wide blade putty knife honed smooth
4.2 Good quality 8-1/2x11 coated white paper cut in halves.
4.3 Pad of paper
4.4 Reference pigment to use as the color standard
5.1 Thoroughly mix both pigments (incoming pigment and reference pigment).
5.2 Take samples of both pigments (10 to 20 grams).
5.3 Place coated paper on pad of paper
5.4 Dab a small sample of each of the two pigments approximately apart at the top of
the paper.
5.5 Using the wide blade putty knife spread the two samples down the paper in one
smooth motion as shown below.
5.6 The two samples should merge visually for comparison.
5.6.1 If pigments match, mark the new pigment container OK, and move to storage
area.
5.6.2 If pigment does not match, re-mix pigments and re-test. If after the second test
the pigments still do not match, contact vendor.
5.7 Clean knife
6.0Safety Information: #MSDS: on file in Lab, MSDS Manual and Master Book
7.0 Disposal: Non-Hazardous - when mixed with resin and catalyzed can be disposed of in a
dumpster
Page 16
Lot #
P.O. #
QTY
Page 17
Comments
Vendor ________________
Pigment Receiving Inspection Log

Color _____________
Date
DMR#
Vendor# _____________
Pass/Fail
7/1/02
RAW MATERIALS - CATALYST

1. Specifications & Certification: The catalyst is critical in providing the proper gel
time and the time to exotherm. It is vital that the catalyst is compatible with the resin
so as to not affect the performance and quality of the final product. The resin vendor
should be consulted on the best catalyst to use for their resin. A Catalyst Material
Specification Sheet should be developed including the critical requirements of the
catalyst as well as any special requirements. A sample of this document can be found
on page 19. This specification sheet should be discussed with the vendor to ensure
compliance. When material is received, the lot numbers should be recorded on the
inspection log and MSDS sheets filed in a place accessible to all employees. If there
is more than one lot number involved the batches must be grouped and the gallon
containers numbered and used accordingly. Safety is a big concern when handling
catalysts. Proper employee training is critical.
2. Batch Testing: Since testing of catalysts is extremely difficult due the variance of the
age of the resin, the reliability of the vendor to provide the proper product is key. The
major test recommended is a visual inspection for clarity. If the catalyst is not clear, it
has probably exceeded its shelf life. The gel time of the current catalyst can be
checked against the new catalyst with the current resin (filled and unfilled). This will
determine if there will be an affect in production.
An example of work instructions is on page 20. The results of the above testing
should be recorded in a log accessible to production. An example Catalyst Receiving
Inspection Log is on page 21.
Page 18
CATALYST MATERIAL SPECIFICATION SHEET

DATE CREATED
_______
____________
CATALYST -
PURCHASE U/M:
ISSUE U/M:
LB
Hardness: Liquid
Finish:
Preservative: Shelf life is 6 months.
Other:
LB
Store in refrigerator or below 80F& out of light.
ANALYSIS:
Clear Liquid
Sp. Gr. = 1.1
TYPICAL USES:
REMARKS:
PRIMARY VENDOR
ALTERNATE VENDOR - #1:
ALTERNATE VENDOR - #2 :
ORIGINAL SPEC:
PREPARED BY:
DATE
LETTER
CHANGE
RMN
Page 19
ENG
7/1/02
Work Instruction Catalyst Inspection

Incoming inspection Solid Surface Catalyst
Date
Department:
Area: Solid
WI Number
Revision
Surface
1.0 Purpose: Define inspection requirement for solid surface catalyst upon receipt.
2.0 Scope: All solid surface catalysts
3.0 Responsibilities: Solid surface laboratory personnel
4.0 Definitions:
5.1 Verify label information against the raw material specification sheet and purchase
order.
5.2 Check color visually, it should be clear
5.3 Record Lot number, this gives the manufacture date. Check with your vendor on the
meaning or significance of the lot number.
Note: Manufacturers suggested shelf life equals 6 months when stored at temperatures
less than 80F. Refrigeration is preferred. DO NOT store at temperatures above
90 F.
Stock rotation: by lot number
6.1. MSDS: on file in Lab,

6.2. Disposal:
6.2.1 Unused: Contact manufacturer for disposal information of unused catalyst
6.2.2 Used: Non-Hazardous when mixed with resin and hardened, can be disposed of
in a dumpster.
7.0 Associated Documents:
7.1 Raw Material Specification sheets
7.2 Purchase order
Page 20
Lot #
QTY
Neat Gel
Time
Page 21
Filled Gel
Time
Comments
Vendor _____________
Catalyst Receiving Inspection Log

P.O. #
Type ________________
Date
DMR#
Vendor# ____________
Pass/Fail
7/1/02
MIXING AND CASTING

The purpose of this QA manual is to help the ICPA membership improve and maintain
quality products. Procedures and methods of operations require periodic review.
A machine batch casting operation has specific considerations that differ greatly from
automated or continuous casting processes. Many of the procedures detailed below can
be used in all processes, but emphasis will be made on the machine batch process.
Key considerations for a batch casting operation are:
a.
b.
c.
d.
e.
f.
Temperature of the raw materials

Exact weights and formulations
Blending of the raw materials
Catalyzation level and mixing time
Vibration times (for solid colors)
Cure rates
A successful process requires detailed planning. Keeping batch records of the mix
recipe, molding conditions, and results provide vital data for future success. Keeping
records also helps one fight the ongoing battle against seasonal weather changes.
A. Recipe:
Batch documentation of the components that are added during the mixing process is
critical in performing problem analysis. This is also a requirement for certification.
Keeping records of the recipe is especially critical for repair and for later matching
special or custom colors. An example of a batch sheet including the recipe is on page 26.
Spreadsheets (Excel) can be developed including macros which will calculate the amount
of each component based on the batch size. A typical matrix is composed of the
following:
Resin:
33 40%
Filler:
55 67%
Pigment:
0 5%
Catalyst:
1 2% of the resin weight
The operator needs to be able to adjust the percentage of catalyst to account for seasonal
variances and molding condition. The catalyst level should be maintained between 1.0%
to 2.0% based on the resin quantity (not the mix quantity). As the catalyst level moves
outside of this range, one should change to a cooler/hotter catalyst type or blend.
Page 22
Example Chart:
Catalyst
NEAT
Gel Time/time to peak/peak exo
MEKP-30
17.0 min
20.8 min
286F
18.5 min 36.5 min 108F
MEKP-9
10.1 min
12.3 min
311F
12.5 min 33.0 min 120F
FS 100/9
9.2 min
11.7 min
309F
10.8 min 27.8 min 120F
13.9 min
9.3 min
317F
18.5 min 18.9 min 150F
8.7 min
322F
15.0 min 19.4 min 146F
AZOX
50/50 blend
MEKP-9
AZOX
10.0 min
FILLED
Gel Time/time to peak/peak exo
There is some disagreement as to the minimum and the maximum levels of catalyst to be
used. Check with your specific supplier for their recommended levels. DO NOT GO
BEYOND THESE LEVELS.
B. Mixing:
Mixing procedures will depend on the type of mixer & mixing blades used. Developing
standard procedures is important to obtain consistent results from batch to batch. The
order in which components are added is key to ensuring a successful pour. Thorough
mixing of the pigment prior to dispensing it is extremely important for maintaining
consistent color from batch to batch. Although the exact procedure will depend on the
mixing equipment as well as the desired result, a typical mixing procedure is as follows:
1. Weight out ingredients per recipe listed on the batch record sheet.
2. Place resin and pigment in pot & mix thoroughly.
3. Add filler and mix well.
4. Stop mixer lift lid and scrape sides and paddle
5. Close mixer and mix thoroughly with vacuum. Longer mixing can be done at
this point in order to raise the temperature of the mix to obtain a desired gel
time. Keep in mind that allowing the mix to stand in the mixer for several
hours even without mixing will both increase the viscosity and decrease the gel
time. The resin becomes more absorbed by the filler, the longer the matrix is
allowed to stand or is mixed.
6. When ready to pour, add the catalyst to the mix, record start time and stir matrix
thoroughly with vacuum.
7. Pour into molds.
8. Record gel time
Page 23
For small mixes where gel time is not a problem, some manufacturers add the catalyst
with the resin & pigment in step 2 above. This provides the most uniform mixing of the
catalyst with the resin. Catalyst should never be added to the mixer if there is dry filler
present; otherwise, the catalyst is absorbed by the filler resulting in inconsistent gelling.
The operator needs to be able to adjust the temperature of the mix to help control gel
time. Keeping batch records allows one to use historical data to predict gel time and
avoid premature gelling.
The impact of temperature on resin gel time is quite significant. Studies have shown that
the relationship of gel time to the matrix temperature is an exponential curve. A general
rule of thumb from a base temperature of 77F, the gel time changes as follows:
- Every 11 F decrease in temperature, the gel time doubles (2x).
- Every 18F increase in temperature, the gel time halves (.5x)
Example:
If resin gel time at 77F = 15 minutes
The approximate resin gel time at 66F = 30.0 minutes
The approximate resin gel time at 95F = 7.5 minutes
Changes in temperature will also significantly increase or decrease the matrix viscosity,
which greatly affects the pouring process. When working with granite fills especially
with large particles, significant settling will occur if the viscosity is low or the mix is too
thin.
There are too many matrix formulations to cover them all in this manual. The important
point of this section is for each manufacturer to document their procedures providing
better quality and consistency. Documentation also eases the cross-training process of
other workers and the dependency on the knowledge of a few people.
Updating procedures is an on-going process. If procedures are not current, employees
will no longer use them resulting in deteriorating or inconsistent product quality. From
time to time, an audit should be made to ensure compliance with written procedures.
Page 24
C. Pouring:
The object of this process is to dispense the matrix into the molds within the gel time of
the matrix. Some mixers dispense by tipping the pot and pouring over the rim. Other
mixing pots have a valve on the bottom. Dispensing from the bottom of the pot allows
the use of the matrix head pressure to fill closed molds faster. Regardless of the pouring
method, the goal is to fill the mold(s) with a minimum of entrapped air and within the
time allowable prior to gelling. Often vibrators are placed on the mold to minimize
entrapped air. Vibration works well with solid colors, but over vibration will cause
settling of the heavier particles when working with granite fillers. The amplitude,
frequency and duration of the vibration will affect the color pattern of the final product
and therefore each needs to be specified in the procedure.
D. Sample Plaque:
During the pouring process, a sample chip should be poured. This plaque can be any size
but should be a minimum of 4 x 4 x thick to provide enough surface area for
testing. This sample can be either be cut out of a sheet or poured in a sample mold.
Sample molds can easily be constructed out of polyethylene material for easy release.
This chip can be used for the following tests:
1. Background color
2. Granule dispersion
3. Porosity
4. Barcol Hardness
This plaque should be marked with the batch number and kept with the batch during the
postcuring process.
E. Clean-up:
Proper clean-up keeps equipment in good order as well as providing a good working
atmosphere. Cleaning can be done by hand or by pot washers offered by several
companies. To avoid scraping hardened matrix, time for clean-up must be accounted for
in determining the desired gel time of the matrix.
Page 25
Date___ / ____ / ___
)
)
)
)
Formula @
Empire Grey
X
Resin (
Filler (
Pigment (
Catalyst (
Part Description
RH LAVDECK TP BS ONLY
LH LAVDECK TP BS ONLY
BOWL UNDERMOUNT 16x13
Serial:
1.5%
100lb
35
64
454
238
Part #
XXX-XXX
XXX-XXX
XXX-XXX
XXX-XXX
XXX-XXX
Reason & Comments
Room Temp
Humidity
Resin Temp
Mix Temp
Mold Temp (75F Minimum)
Gel Time
Vacuum (24inHg min.)
Filler Temp
Time
Shift
SOLID SURFACE BATCH RECORD
%
35.0%
64.0%
1.0%
1.5%(of resin)
04 0001
Catalyst
lbs
lbs
Gr
Gr
Weight
27
27
15
15
15
Status
[ OK ] [Scrap]
[
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]
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]
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Page 26
7/1/02
DEMOLDING PROCEDURES & MOLD MAINTENANCE

A. Open Mold: Since shrinkage does not play a major role in demolding from an open
mold, parts such as sheet stock can be left to cure within the mold. The mold itself
can be used during the curing process to maintain the shape of the part. The batch
number should be recorded on all parts of the batch in a location that will not be
removed during finishing.
B. Closed Mold: Procedures for demolding parts from closed molds are very critical to
both ensure quality parts and preserve the quality of the mold. Establishing the proper
exotherm temperatures at which time to open the mold is critical. Demolding
temperatures should be noted on the demolding procedures. Opening the mold too
early can result in tearing the part due to its insufficient green strength. If the mold is
opened too late, the part will shrink on to the mold often resulting in cracked parts and
excessive wear on the mold. The shape of the mold and its draft angles play a
dominant role in demolding. Depending on the shape of the part, fixtures may be
required to maintain the shape of the part during curing and post curing. The batch
number should be recorded on all parts of the batch in a location that will not be
removed during finishing.
C. Mold Maintenance:
Once the molds are open and parts removed, residue must be removed from the mold
surface. Both the mold surface & the mold releases applied to it are abrasionsensitive. It is important to lift the residue from flanges with a plastic spreader. Care
must be taken to preserve the surface while removing the residue. Because of the
fillers used, solid surface matrices can abrade the mold, thus removing the mold
release and increasing the chance of problems with subsequent pours. The mold
surface should then be cleaned with a solvent such as PMC using 100% cotton cloths.
The cloth should be wet, but not dripping. Use a "wipe on, wipe off" technique. Wipe
up drips and puddling immediately with a second cloth. The solvents in the PMC will
chemically soften remaining residue. Wiping off with a second cloth will lift
contaminants from the mold. Do only an area that can be effectively dried before the
PMC flashes off. Changing cloths often will prevent smearing of residue across the
mold surface. Re-wet cloths as necessary. Residue will build up on the cloth and
should not be rubbed against the mold surface.
D. Mold Tracking:
Usage of the mold should be tracked so that the mold can be periodically maintained.
Tracking mold usage allows for preventative maintenance rather than reactive
maintenance. A schedule for mold maintenance based on usage should be
established. Yet, any mold damage seen during demolding should be reported
immediately. An example of a mold tracking form is shown on page 28.
Page 27
Mold #
Description
Usage
Maximum Usage
Before Maintaining
Mold Maintenance Tracking Log
Date Last
Maintained
Page 28
Comments
7/1/02
POSTCURING
A. Importance:
In order to obtain the optimum physical properties of solid surface material, parts
must be postcured. During the postcuring process, the chemical cross-linking process
is completed and the internal stresses built up during the curing process are relieved.
Since the center of the part cures at different times than the outside, the shrinkage
difference that takes place while the part is curing generates internal stresses.
Postcuring relieves these stresses.
B. Temperature and Time
Although postcuring depends on the thickness of the part as well as its composition
(resin used, etc), parts are normally postcured at temperatures between 180 and 200
degrees Fahrenheit for a minimum of an hour. Lower temperatures require longer
times. The temperature should be a minimum of 20F above the glass transition
temperature (Tg ) of the resin. One should contact their resin supplier for this
information. It is also important that the part temperature does not exceed 230 240F, because the material properties begin to degrade above this temperature. The
specific postcuring time depends on the type of oven used, the geometry of the part
and the density differential of the material. It is important to insure that the material
temperature of the entire part reaches the postcuring temperature. Parts can be
postcured immediately after demolding while they are still exotherming or at a later
date. Studies have shown that either method produces quality parts.
When setting up postcuring procedures, barcol hardness readings can be used to
establish the time and temperature required. Studies should be run to determine the
minimum time required for a part to reach its maximum hardness reading at a given
temperature. Barcol readings should be taken when the part is at 77F. The resin
manufacturer should be consulted to help set up these requirements.
During postcuring parts are soft and pliable. After demolding and throughout the
postcuring process, they must be placed on flat surfaces or special fixtures to maintain
the desired shape.
C. Oven Consistency:
Even heating and temperature distribution within the postcure oven is critical. When
first installed and periodically, one should test parts at various locations throughout
the oven to ensure even temperature distribution. Test plaques can be placed
strategically throughout the oven and their temperatures monitored during and after
the oven cycle. The temperatures of all test plaques need to fall within the postcuring
temperature requirements established with the resin vendor. If not designed properly,
ovens can have hot or cool spots in certain areas resulting in inconsistent curing or
burnt parts.
Page 29
D. Record of Completion:
Once parts are postcured, it is important to mark them so everyone knows that the
operation was completed. It is easy to confuse non-postcured parts with postcured
parts. The cost of the minimum time spent marking each product is much less than
the cost of repairing a product in the field.
The sample plaque that was referred to in the Mixing and Casting section should be
postcured along with the product from that batch. This plaque should be finished to
the same standards as production product. The plaque should be tested for Barcol
hardness, color, and granule distribution. These tests verify that proper curing
occurred, the correct color was achieved, and the granules were evenly distributed. A
spectrophotometer is very useful in qualifying the color and making color approval
less subjective. An example of a Batch Test Log is shown on page 31
Page 30
Batch #
Date
Color
Postcure
Temp.
Postcure
Time
"L"
Batch Test Log

Barcol
Hardness
Page 31
"a"
"b"
DE
Pass/Fail
Comments
7/1/02
SCRAP REPORTING
One method of improving quality is to monitor scrap and look for ways to reduce it.
Programs to reduce scrap contribute directly to the bottom line. Reducing scrap not only
saves money, but also helps ensure on-time delivery and greater customer satisfaction.
Parts that are scrapped need to be remade, which doubles the cost of the part.
Establishing a scrap report is relatively easy. A spreadsheet can be developed to capture
the who, what, when, and why of each piece that is scrapped. An example of a
spreadsheet is shown on page 30. Although the flaw in a scrapped part (the what) is easy
to see, the why is often difficult to determine at the time the part is scrapped. Patterns or
trends can then be reviewed and procedures reviewed to prevent further occurrences.
Graphs can also be developed for a visual effect. Graphs and/or spreadsheets can be
posted weekly and goals established so that everyone gets on board. Incentives can be
used to try to lower the scrap percentage.
Tracking scrap trends also helps to identify little problems that can later become larger
ones. Analysis of the scrap report allows you to attack the root causes of problems.
Solving these problems not only reduces scrap, but also provides a better product.
Page 32
Date
Part Description
Pour Area Report
Finishing Area Report
TOTAL
Color
Qty
Initials
Cost
Reason
Root Cause
SOLID SURFACE SCRAP ANALYSIS FOR WEEK ________
Part#
Page 33
Batch
Size
Mix
Mix Size Temp
Gel
Time
7/1/02
FINISH CLASSIFICATION and QUALITY STANDARDS

The proper finishing of solid surface material is key to bringing out its natural beauty and
feel, as well as providing optimum stain and chemical resistance. Proper finishing
requires proper training. There are many techniques and equipment used throughout the
industry to obtain the desired finish. Many different types of sanders and sanding discs
are available on the market today. The purpose of this section is not to teach one how to
finish, but to ensure that quality standards are in place for the appearance and feel of the
end product. The best source of information on finishing techniques are the vendors that
provide the equipment.
The finishing process takes a lot of time and effort, much of which is done by hand. As a
person is doing this hand sanding, they can also be inspecting the bowl for any voids,
pits, cracks, chips, specs, porosity etc. These defects need to be patched and refinished.
The earlier that these defects are identified, the less costly they are to repair. The
workmanship and finish specifications can be found in section 3 of ANSI Z124.6 1997.
These appearance specifications will vary depending on the function of the surface.
Areas that are visible to the user or subject to water require higher quality standards than
non-visible areas. The ANSI standard attempts to distinguish between the various classes
of surfaces, but this can be very subjective.
In order to maintain consistency from one finisher to another, it is important to set up
appearance specifications for each type product. The finishing specifications shown on
pages 35 to 38 attempt to better categorize the finish requirements. Four classes of
surfaces are identified, ranging from the most visible and usable surfaces to the nonvisual or non-accessible regions. To complement this specification, each product should
have an associated drawing showing which surfaces are class A, B, C, and D. All
products might not have all four classes. Since these classes are also subject to
interpretation, it is important that a company standard be established which is agreeable
to all including key customers. Since customer satisfaction is the ultimate goal of any
business, it is important to obtain input from them.
Page 34
FINISHING STANDARDS
1.0 Purpose: To define the surface finish and aesthetic expectations for solid surface product.
2.0 Scope: All solid surface product. Requirements will be defined by product, material and
part number when applicable.
3.0 Responsibilities: Solid surface finishers have the responsibility to finish product to meet
the requirements of this standard. Finishers shall inspect their work to assure that the
requirements of this standard are met before being passed on to the assembly or shipping
department. Assembly and shipping personnel should also be aware of the finish criteria and
stop production of product that does not conform.
4.0 Definitions:
Surface classification surfaces will be defined as an A, B, C or D surface depending upon

the customer exposure to the surface. Each model will have a drawing defining the A, B, C
or D surface. If no definition exists, the default is an A surface.
Cracks actual fractures at or under the surface.
Chipped areas surface damage causing loss of material greater than 1/64 (.016) in two
or more dimensions.
Chipped areas that create a notch a chip that creates a sharp notch that is likely to lead to
a fracture or crack.
Blisters any unsupported surfaces that fracture upon the application of manual pressure
with a rounded plastic tool.
Surface porosity presence of numerous voids in the surface.
Molding irregularities any visible distortion related to forming such as dimples, domes,
short fills, or sink marks.
Pits small craters in the surface with widths and depths being approximately equal.
Pinholes very small holes in the surface.
Voids large holes in the surface of the part caused by trapped gas.
Specks Particles of foreign matter which produce irregularities in the surface, not including
speck or flecks incorporated in the surface to produce a decorative pattern.
Orange peel irregular surface texture.
Particle flow pattern (milk lines) absence or over saturation of stone in an area.
Stone particle size size of the decorative granules put in the product to create a pattern.
Part the product that comes out a single mold per molding cycle.
Color deviation defined by the L, a, b and E generated by testing a sample and
comparing it to the accepted standard for that color.
Visual patch any repair that can be discerned by the naked eye at 18 inches.
Page 35
5.0 Procedure:
The finish and appearance of all solid surface parts shall meet the requirements defined in
this standard. Class A, B, C and D surfaces shall be defined per product.
5.1 General Finish Standards
5.1.1 Class A Surfaces the most visual and touchable surface to the customer.
It must be smooth both visually and to the touch.
Defect or Blemish Type
Cracks
Chipped areas
Blisters
Surface Porosity
Molding Irregularities
Maximum
Number allowed
in a 3 diameter
0
0
0
0
1
Maximum number
allowed on entire
A surface
0
0
0
0
1
Pits - <1/64 (.016)

Pinholes and small specks 1/64-1/32
(.016-.031)
Medium specks 1/32-1/16 (.031.062)
Large specks >1/16 (.062)
Orange peel - visual at 18 or to touch
2 defects total*
2 defects total*
8
4
2 defects total*
0
0
0
0
Particle flow pattern (milk lines)

Stone particle size - 5/64 1/4 (.078.250). Must be at least 12 apart.
0**
1
0**
3
Color deviation from standard E

Absence of stone - <.700 diameter
Visual patches
NA
1
0
1.5
3
0
* areas that come in contact with water can have not have any pits, pinholes or medium specks.
** unless indicated otherwise on the surface drawing for that product
Page 36
5.1.2 Class B Surfaces not as visual to the customer but still accessible and
would be cause for rejection if major blemishes were present.
Maximum
Number allowed
in a 3 diameter
Maximum number
allowed on entire
B surface
Cracks
Chipped areas
Blisters
Surface Porosity
Pits - <1/64 (.016)
0
0
1
16

(.016-.031)
Medium specks 1/32-1/16 (.031-.062)
8
4
0
0
8
3/3 areas or 50
total
3/3 areas or 25
total
3/3 areas or 12
total
0
0
Allowed
1
0
Allowed
5
Orange peel - visual at 18

Stone particle size - 5/64 1/4 (.078.250). Must be at least 12 apart.
Visual patches
Page 37
5.1.3
Class C Surfaces a visual surface that requires finishing but has limited
accessibility and visibility.
Maximum
number allowed
in a 3 diameter
Maximum
number allowed
on entire C
surface
0
0
Cracks
Chipped areas
0
0
Blisters
Pits - <1/64 (.016)
(.016-.031)
Voids or medium specks 1/32-1/16
(.031-.062)
0
1
48
24
0
16
unlimited
unlimited
12
Unlimited
Voids - 1/16-3/32 (.062-.094)

Voids - 1/16-1/8 (.094-.125)
6
3
unlimited
12
Orange peel - visual at 18 or to touch

0
Allowed
Stone particle size - 5/64 1/4 (.078.250)

Visual patches
5.1.4
Class D Surfaces a non-visual surface that does not require finishing but
does have requirements. All edges adjacent to the D surface must have the
flash removed.
Defect or Blemish
Patches that are not blended with same material and
same color
Cracks
Maximum allowed
0
Chipped areas that create a notch (Functional areas

only)
Voids > than .125 deep or larger than 1.5 diameter
Void in sprue area Sprue must be level with the
surrounding material.
Page 38
0
0
ICPA SOLID SURFACE GLOSSARY

ABSORPTION The permeation of a gas or liquid into a solid by molecular action.
For example: water absorption.
ACCELERATOR
An additive that acts in concert with the promoter to speed up the gel or curing
time of thermosetting plastics such as polyester resin.
ACETONE In a cast polymer context, acetone is primarily useful as a cleaning solvent for
removal of uncured resin. It is a very flammable liquid. It should be
evaluated to determine if its current usage can be reduced due to its flammable
nature and fire hazard potential.
ACTIVATOR
A chemical additive used to initiate the chemical reaction in a specific
mixture.
ACUTE EFFECT
An adverse effect with severe symptoms occurring very quickly, as a result of
a single excessive overexposure to a substance.
ACUTE TOXICITY
The adverse effects resulting from a single excessive overexposure to a
substance.
ADDITIVE
Substance added to the cast polymer mix to impart special performance
qualities, such as ultraviolet absorbers, flame retarding materials.
AIR RELEASE
The act of air, entrapped during the processing of cast polymer, coming
to the surface and breaking.
ALUMINA TRI-HYDRATE (ATH)
May also be known as hydrated alumina, a white powder used
as a fire and smoke retarding filler in solid surface polyesters.
AMBIENT
Indicative of the surrounding environmental conditions such as temperature,
pressure, atmosphere, etc.
Glossary Page 1 of 16
AMBIENT TEMPERATURE
The temperature of the medium surrounding an object. The term is often used
to denote prevailing room temperature.
ASTM
American Society for Testing and Materials. A body that standardizes testing
procedures and sets specifications for materials.
APPARENT SPECIFIC GRAVITY
Ratio of weight in air, at a given temperature of a solid portion of a porous
material, to the weight of an equal volume of distilled water.
ASPHYXIANT
A vapor or gas that can cause unconsciousness or suffocation by reducing the
ambient oxygen level below that necessary to sustain life.
AUTO-IGNITION TEMPERATURE
The lowest temperature required to initiate or cause self sustained combustion
in the absence of a spark or a flame.
BARCOL HARDNESS
Measure of the hardness of a laminate or casting; obtained by measuring
resistance to penetration of a sharp steel point under a spring load.
BATCH (OR LOT)
Identifying for all material produced during one operation possessing identical
characteristics throughout.
BENZOYL PEROXIDE (BPO)
Catalyst used in conjunction with aniline promoters or where heat is used to
decompose the peroxide. Note that heat is not required to gel and cure when
used in conjunction with amine promoted resins, such as body putty and boat
resins.
BINDER
A material which acts as an adhesive to hold particles of dry material together,
usually polymeric in nature. Example: resins act as binders to hold the filler
together.
BLEND
Physical mixture of two or more components.
BLISTER
A raised area on the surface of a cast part caused by internal pressure. This is
any unsupported surface that fractures upon the application of manual pressure
with a rounded plastic spoon.
BOILING POINT The temperature at which a liquid turns to a vapor state.
BUBBLE
A spherical, internal void within a cast part. Manufacturers refer to this as
entrapped air.
BULK DENSITY
The weight of a material per unit volume, usually expressed in pounds per
cubic foot.
CAST
As related to cast polymer, the term means to form a cast part by troweling or
pouring a matrix composition into a mold, where it cures into a hard
composite which takes the shape of the mold.
C or CEILING
In terms of exposure concentrations, this is the number that should never be
exceeded.
CARCINOGEN
A substance or agent capable of producing cancer in animals.
CAST POLYMER
Non-reinforced composite (resin used without reinforcing fibers). Combines
polymers, fillers and additives as composites to meet specific application
requirements.
CATALYST
In the scientific sense, a substance that causes or accelerates a chemical
reaction without being consumed in the reaction. Within the composites
industry, free radical initiators such as MEKP are often referred to as
catalyst. This usage is scientifically inaccurate since the initiator is
consumed during usage.
CATALYST (PEROXIDE)
For unsaturated polyester, a substance added to the resin or gel coat in
controlled quantities to make it gel and cure. The catalyst is decomposed by
the accelerator or by heat to create free radicals, which in turn initiate

polymerization.
CATALYST INJECTION
Used with continuous cast systems to add the catalyst just prior to pouring into
the mold; therefore, eliminating the need to clean the system within the gel
time of the polyester.
cc - cubic centimeter
A volume measurement usually associated with small quantities of a liquid.
One quart has 946 cubic centimeters.
CENTIPOISE (CPS)
Unit of measure used to designate a fluids viscosity. At 70F, water is one
cps, while peanut butter is 250,000 cps. Remember this concept when
evaluating resin and matrix viscosity.
CHEMICAL RESISTANCE
The resistance of a solid surface matrix to chemicals or compounds over a
range of temperatures.
CHRONIC EFFECT An adverse effect with symptoms that develop or recur very slowly, or over a
long period of time.
CHRONIC TOXICITY
The adverse effects resulting from prolonged or repeated exposures to a
substance, usually used as an indicator of relative toxicity for exposures over
great lengths of time.
COBALT
Used as the promoter for methyl ethyl ketone peroxide catalyzed polyesters.
Cobalt comes in form of a salt such as cobalt octoate.
COMBUSTIBLE A term used to classify liquids, gases, or solids that will burn readily. This
term is often associated with flash point, which is the temperature at which a
given material will generate sufficient vapors to combust when brought into
contact with a flame.
COMPOSITE
A mixture in which two or more distinct, structurally complimentary
substances combine to produce some functional properties not present in any
individual component; sample: filler / resin.
COMPOUND
An intimate admixture of materials necessary for the finished product.
CONCENTRATION
A figure used to define relative quantity of a particular material, such as a
mixture of 5 ppm Acetone in air.
CONTAMINANT
An impurity or foreign substance that may affect one or more properties of
composite material.
CURE
Polymerization or irreversible transformation from the liquid to the solid state
with maximum physical properties, including hardness.
CURE TIME
Time required for the liquid resin to reach a solid (the majority of a
polymerized state) after the catalyst has been added.
CURING AGENT
Catalytic or reactive agent that initiates polymerization when added to a resin.
CYCLE
The time it takes for a mold to move from one point to the corresponding
point in the next repeated sequence.
DEAERATE
To remove the entrapped air from a matrix by subjecting it to vibration or a
vacuum.
DECOMPOSITION
The breakdown of materials or substances into other substances or parts of
compounds. Usually caused by heat or chemical reactions.
DEGREE OF CURE
The extent to which curing or hardening of a thermosetting resin has
progressed. Can be measured with a Shore D or Barcol meter in the plant and
by more advanced equipment in the laboratory.
DELAMINATION
In-plane separation of laminate ply or plies due to adhesion failure.
DEMOLD
To remove a part from a tool, or a tool from an intermediate model.
DENSITY
Weight per unit of volume, usually expressed as pounds per cubic foot.
DERMAL
Used on or applied to the skin.
DERMAL TOXICITY
The adverse effects resulting from exposure of a material to the skin. Usually
associated with lab animal tests.
DIETHYLANILINE (DEA)
A promoter used in conjunction with BPO catalyst or as an accelerator for
cobalt/MEKP systems.
DILUTE
To reduce the concentration level (thinning).
DIMETHYLANILINE (DMA)
A promoter used in conjunction with BPO catalyst or as an accelerator for
cobalt/MEKP systems. More effective that DEA, but also more toxic.
DISPERSING AGENT
Materials added to a suspending medium to promote and maintain the
separation of discrete, fine particles of solids or liquids.
DROP WEIGHT TEST
Produces a measure of impact resistance where weights are dropped on the
specimen from varying heights. Part of the ANSI Z-124 standard.
EVAPORATION RATE
The rate at which a liquid loses mass at a given temperature, pressure and
humidity. The faster a material will evaporate, the sooner it will become
concentrated in the air, creating either an explosive/combustible mixture or
toxic concentration or both.
EXOTHERMIC HEAT
Heat energy generated exclusively by a chemical reaction.
EXTENDERS
Low-cost materials used to dilute or extend higher-cost resins without
excessive reduction in properties.
FATIGUE
Reduction of a materials mechanical properties caused by repeated stress over
time.
FADING
Loss of color in the pigmented product over time.
FILLERS
Relatively inert organic materials which are added to the resin for special flow
characteristics, to extend volume, provide fire resistance and to lower the cost
of the article being produced.
FINES
In the classification of powdered or granular materials according to particle
size, fines are the portion of the material which are smaller than a specified
size, usually under 100 mesh.
FLASH POINT
The temperature at which a liquid will generate sufficient vapors to promote
combustion. Generally, the lower the flash point, the greater the danger of
combustion.
This is the lowest temperature at which a substance emits enough vapors to
form a flammable or ignitable mixture with air near the surface of the
substance being tested.
FLAMMABLE
Any liquid that has a flash point of 100 Degrees F. or below. Also, any
solid which can sustain fire and ignite readily.
FLOW METER
An instrument designed to measure the movement of liquid.
FREE RADICALS
Highly reactive molecular fragments capable of initiating chemical reactions,
such as polymerization of polyester resins. Normally generated by the
decomposition of the catalyst.
GEL
A partial cure stage in plastic resin where the liquid material reaches a
viscous, jelly-like state and starts to transform into a solid.
GELATION
The stage where resin, due primarily to age, goes from a liquid state to a
semisolid state. The transition of a liquid to a solid.
GEL TIME
The length of time that a catalyzed polyester remains workable after the
hardener (catalyst) is added.
GENERAL EXHAUST A term used to define a system for exhausting or ventilating air from a general
work area. Not as site specific as localized exhaust.
HAPS
Hazardous Air Pollutants as defined by the U.S. government.
HARDENER
Substance that reacts with resin to promote or control curing action.
This term usually applies to a catalyst for epoxy resin.
HAZARDOUS CHEMICALS Any chemical which is either a physical or health hazard or both.
HEAT
Term used colloquially to indicate any temperature above ambient (room)
temperature, to which a part or material is or will be subjected.
HYBRID RESIN
Resin with two or more types of chemistries combined.
HYDROPHOBIC
Moisture resistant capabilities, moisture repelling.
INCOMPATIBLE
Materials which could cause unwanted results or dangerous reaction from
direct contact with one another. Term is also used in regards to some liquids
which are not soluble in one another.
INGESTION
Taking in a substance through the mouth.
INHALATION The breathing in of a substance in the form of a gas, liquid, vapor, dust ,
mist, or fume.
INHIBITOR A chemical added to another substance to delay an unwanted change from

occurring, or to lengthen the gel time or cure time.
IRRITANT A chemical which causes a reversible inflammatory effect on the site of
contact, however is not considered a corrosive. Normally, irritants affect the
eyes, skin, nose, mouth or respiratory system.
ISOTROPIC
Arrangement of reinforcing materials in a random manner, resulting in equal
strength in all directions.
LC - Lethal Concentration.
In lab animal tests, this is the concentration of a substance which is sufficient
to kill the test animal.
LC 50 - Lethal Concentration 50 In lab animal tests, this is the concentration of a substance required to kill 50%
of the group of animals tested.
LD - Lethal Dose The concentration of a substance required to kill the lab animal used for
the test with a specific material.
LD 50 - Lethal Dose 50 The single dose concentration of a substance required to kill 50% of the lab
animals tested.
L.E.L - Lower Explosive Limit The lowest concentration, or percentage in air, of a vapor or gas, that will
produce a flash fire when an ignition source is introduced.
LOCAL EXHAUST The system for ventilating or exhausting air from a specific area such as in
polishing operations or spray booths. More localized than general exhaust.
MACT
Acronym for Maximum Achievable Control Technology. Standards
established by the EPA in response to the 1990 Clean Air Act, Section 112.
These standards set forth regulations for reduced emissions of Hazardous Air
Pollutants (see HAP).
MASTERBATCH
A large volume of mix that can be tapped on demand to make smaller quantity
batches for molding. This relates to a large uncatalyzed batch of solid surface
mix.
MATRIX
Combination of resin and filler used in the casting industry. Also the cured
filled layer to a marble or solid surface part.
MELTING POINT
The temperature at which a solid changes to a liquid.
MEK (SOLVENT)
Abbreviation for Methyl Ethyl Ketone; a colorless flammable liquid
commonly used in spray gun clean up procedures. NOT TO BE CONFUSED
WITH MEKP.
MEKP
Methyl Ethyl Ketone Peroxide. Catalyst normally used in the cast polymer
industry.
MICROSPHERES
Tiny spheres of organic and inorganic materials which are used as fillers to
impart low density to plastics.
MIL
The unit used in measuring film thickness and the diameter of fiber strands,
glass wire, etc., (one mil = .001 inch).
mg - MILLIGRAM A unit of measurement of weight. There are 1000 mg in one gram of a
substance.
mg/m3 - MILLIGRAMS PER CUBIC METER A unit of measurement usually associated with concentrations of dusts, gases,
or mists in the air.
mppcf - MILLION PARTICLES PER CUBIC FOOT A unit of measure usually used to describe airborne particles of a substance
suspended in air.
MOLD RELEASE
A substance applied to the mold or added to the compound to ease part
release.
MOLECULES
Chemical units composed of one or more atoms.
MONOMER
A compound capable of polymerization with itself or with a compatible resin.
They are also to be used to dissolve or dilute polyester.
MUTAGEN A substance or agent capable of altering the genetic material in a living cell.
NANOMETER
Abbreviated (nm) and equal to one millimicron or one billionth of a meter,
used to measure wavelengths of light.
NFPA - National Fire Protection Association
An organization which promotes fire protection/prevention. They publish
many of the standards used by local fire officials.
NPG
Registered trademark (of Eastman Chemical Company) for neopentyl glycol,
OLFACTORY
Relating to the sense of smell.
ORAL
Used in or taken through the mouth into the body.
ORAL TOXICITY A term used to denote the degree at which a substance will cause adverse
health effects when taken through the mouth. Normally associated with lab
animal tests.
ORANGE PEEL
A rough wavy surface texture similar to that of an orange peel.
ORIFICE
An opening, generally referred to regarding spray tip size.
ORIGINAL EQUIPMENT MANUFACTURER (OEM)
Companies that design and build products bearing their name.
OXIDIZER A substance which yields oxygen readily to stimulate the combustion of an

organic material.
OXIDIZING AGENT
A chemical or substance which provides the oxygen for an oxidative reaction.
PEL - Permissible Exposure Limit An exposure concentration established by the Occupational Safety and Health
Community which indicates the maximum concentration for which no adverse
effects will follow.
PEROXIDES
Category of compounds containing an unstable O-O (or O-OH) group:
Oxygen to Oxygen atoms; used as initiators.
PIGMENT
The ingredient used to impart color.
PIGMENT SEPARATION
A mottled (varied color) appearance of the surface.
PINHOLES
Very small holes in the surface of the parts.
PLASTICS
High molecular weight thermoplastics or thermo-setting polymers that can be
molded, cast, extruded or laminated into objects.
POLYESTER (UNSATURATED)
A resin formed by the reaction between dibasic acids and dihydroxy alcohols
(glycols), one of which must be unsaturated (typically maleic anhydride) to
permit cross-linking.
POLYMER
A large chemical chain composed of many repeating groups such as
polystyrene.
POLYMERIZATION
The chemical reaction of linking molecules or chains of molecules.
POLYVINYL ALCOHOL (PVA) (PVAL) or (PVOH)
A water soluble release agent.
POROSITY
Small air bubbles in a composite too numerous to count. Generally smaller in
size than pinholes,
POSTCURE
Exposure of the cured resin to higher temperatures than during molding;
necessary in most resins to attain complete cure and ultimate mechanical
properties.
PREMIX
Mixture of resin, pigment, filler and catalyst for molding.
PRE-RELEASE
Premature release of the laminate from the mold.
PPM - Parts Per Million
A unit of measurement for the concentration of a gas or vapor in the air.
Usually expressed as number of parts per million parts of air.
PPB - Parts Per Billion
As above, only expressed a number of parts per billion parts of air.
PROCEDURES
The act or manner of proceeding in any action or process; conduct. Also a
written document which describes what and how things should be done.
REACTIVITY
The term which describes the tendency of a substance to undergo a chemical
change with the release of energy, often as heat.
REDUCING AGENT
In an oxidation reaction, this is the material that combines with oxygen or
provides the oxygen.
RELEASE AGENT
See Mold Release
RESIN
The term resin may be used generically to refer to unsaturated polyester
casting resin. It is class of natural or synthetic polymers, solubilized or semisolid, generally of high molecular weight having no definite melting point.
Used in reinforced products to surround and hold fibers, also in casting to
surround and hold fillers.
RESIN RICH
Localized area filled with excess resin as compared to the prescribed
resin/filler ratio.
RESIN STARVED
Localized area of particulate matter lacking sufficient resin for proper wet out.
RESPIRATORY SYSTEM
The breathing system, including the lungs, and air passages, plus their
associated nervous and circulatory components.
SENSITIZER
A substance which on first exposure causes little or no reaction, however,
with repeated exposure will induce a marked response not necessarily limited
to the exposure site. Usually associated with skin sensitization.
SOLID SURFACE
A blend of unsaturated polyester, acrylic, or acrylic-polyester blend
resin, alumina tri-hydrate (ATH), mineral fillers, pigment and catalyst.
SOLVENT
Liquid used to dissolve and/or clean materials.
SPEC
Specification of properties, characteristics or requirements that a particular
material or part must have to be acceptable to a potential user.
SPECIFIC GRAVITY
The weight of a material compared to the weight of an equal volume of water.
A material with a specific gravity of greater than 1.0 will sink to the bottom of
water; whereas, a material with a specific gravity of less than 1.0 will float on
top of water.
STABILIZER
An additive for polymers which aids maintenance of certain performance
properties.
STANDARDS
Anything taken by general consent as a basis of comparison. An approved
model.
STEL - Short Term Exposure Limit

The maximum allowable concentration of a substance that one can be exposed
to for less than 15 minutes and not produce adverse health effects.
STRESS CRACK
External or internal cracks in a composite caused by tensile stresses. Cracking
may be present internally, externally or in combination.
STRYENE MONOMER
An unsaturated aromatic hydrocarbon used in plastics. In polyester, it is the
reactive diluent.
TERATOGEN
A substance or agent, that when exposed to a pregnant female will cause
malformation of the fetus. Usually associated with lab animal tests.
THERMAL CONDUCTIVITY
Ability to transfer heat.
THERMAL STRESS CRACKING
Crazing or cracking of a composite from overexposure to elevated
temperatures or cyclic temperature variation.
THIXOTROPIC
A condition in which material possesses a resistance to flow at rest, but will
flow when agitated (mixed, pumped, or sprayed).
THIXOTROPIC INDEX (T.I.)
An indication of sag resistance determined by dividing the low shear viscosity
by the high shear viscosity.
TLV - Threshold Limit Value

A term used by the Occupational Safety and Health community to describe the
airborne concentration of a material to which nearly all persons can be
exposed to day in and day out, and not develop adverse health effects.
TOXICITY
The sum of adverse effects of exposure to materials, generally by mouth, skin,
or respiratory tract.
TWA - Time Weighted Average
The airborne concentration of a material to which a person can be exposed
over an 8-hour work day. (An average).
UEL - Upper Explosive Limit

The highest concentration of a gas or vapor in air that will sustain or support
combustion, when an ignition source is present.
VAPOR DENSITY
A term used to define the weight of a vapor or gas as compared to the weight
of an equal volume of air. Materials lighter than have a vapor density of less
than 1.0; whereas, materials heavier than air have a vapor density greater than
1.0.
VAPOR PRESSURE
A number used to describe the pressure that a saturated vapor will exert on top
of its own liquid in a closed container. Usually, the higher the vapor
pressure, the lower the boiling point; and therefore, the more dangerous the
material can be if it is flammable.
VISCOSITY
A fluids resistance to flow.
VOLATILE MATERIAL
Material vaporizing under specific conditions short of decomposition.
Nonvolatile materials remain as a liquid or solid.
VOLATILE ORGANIC COMPOUNDS (VOC)
Carbon containing chemical compounds (e.g., solvents or liquids) that
evaporate readily at ambient or process temperatures. Environmental, safety
and health regulations often limit exposure to these compounds. Thus low
VOC content may be preferable.
WAX
A paraffin used as a mold release agent or surfacing agent.
WORKING LIFE (POT LIFE)
The period during which a compound, after mixing with a catalyst solvent or
other compounding ingredients, remains suitable for its intended use.

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SOLID SURFACE

ICPA-SS Quality Manual

ICPA SOLID SURFACE QUALITY MANUAL

i. Credits & Acknowledgements

II. Raw Materials

B. Fillers & Granules

III. Mixing & Casting

IV. Demolding Procedures

VI. Tracking Scrap & Customer Returns

ICPA SOLID SURFACE QUALITY MANUAL

Credits & Acknowledgements

PURPOSE OF THIS MANUAL

PRODUCT TESTING & CERTIFICATION

RAW MATERIALS - RESIN

RESIN MATERIAL SPECIFICATION SHEET

MATERIAL PART NUMBER

____ lb per gal (sp.gr.=1.05-1.09) Viscosity = ___ - ____cps @ 77F (25C)

Solid surface sheet stock, bowls, etc.

POLYESTER CASTING RESIN:

ICPA-Solid Surface Q/A Manual

Work Instruction Resin Inspection

Incoming Inspection for Solid Surface Resin

1.0 Purpose: Determine if shipments of solid surface resin meet specifications.

Resin Incoming Inspection

100 grams of resin @ 25 C (77F) ___% of ____________ catalyst

Mfg (filled)Test Results:

RAW MATERIALS - FILLERS

b) PH Stability - Alumina Trihydrate is PH stable meaning common household acids or

FILLER MATERIAL SPECIFICATION SHEET

MATERIAL PART NUMBER

Filler: (ATH, granules, pre-mix)

Sample tested at receipt of shipment.

Background color, particle size & appearance

ICPA-Solid Surface Q/A Manual

Work Instruction Filler Inspection

Incoming Inspection : Solid Surface Mineral Fills

ICPA - Solid Surface Q/A Manual

Filler Receiving Inspection Log

RAW MATERIALS - PIGMENT

PIGMENT MATERIAL SPECIFICATION SHEET

MATERIAL PART NUMBER

Certification sheet to be supplied with each shipment

Color matches approved color sample

ICPA-Solid Surface Q/A Manual

Incoming Inspection: Pigment Draw Down Test

1.0 Purpose: Test pigment for proper color.

Pigment Receiving Inspection Log

ICPA - Solid Surface Q/A Manual

RAW MATERIALS - CATALYST

CATALYST MATERIAL SPECIFICATION SHEET

MATERIAL PART NUMBER

Store in refrigerator or below 80F& out of light.

ICPA-Solid Surface Q/A Manual

Work Instruction Catalyst Inspection

Incoming inspection Solid Surface Catalyst

6.1. MSDS: on file in Lab,

Catalyst Receiving Inspection Log

ICPA - Solid Surface Q/A Manual

MIXING AND CASTING

Temperature of the raw materials

18.5 min 36.5 min 108F

12.5 min 33.0 min 120F

__ lb per gal (sp.gr.=1.05-1.09) Viscosity = _ - ____cps @ 77F (25C)

100 grams of resin @ 25 C (77F) _% of __________ catalyst

Date_ / / _