ACE. XL Product Guide
Applications
+ FLOOR AND WALL FINISHING: Architectural finishings, shelves and functional details.
+ STAIR / STEPS: Workable to create stairs and steps of all kinds.
+ INDOOR FURNITURE: Visible surfaces for interior decorating: drawers, cupboards and shelves. Mass produced or made to measure.
+ TABLE INDOOR/OUTDOOR: Tables and coffee tables of all sizes for indoor and outdoor use. Material may be worked vertically.
+ OUTDOOR FURNITURE: Indoor and outdoor furniture: tables, benches, flowerbeds.
+ BATHROOM VANITY TOP: Bathroom vanity top, also with washbasin covering.
+ KITCHEN COUNTER TOP: To cover worktops and kitchens of any shape and size.
+ DOOR & CLOSET: Doors, cabinets and closets: thin and workable vertically.
Cleaning and Maintenance
Routine cleaning must be performed using specific detergents for removing dirt and stains, upon condition that they do not contain wax and do not form films.
Rinsing with clean water is essential for effective cleaning. Due to this, we do not recommended the use of products that do not call for rinsing.
Very light or intense black colours, especially those with a Polished finish, are easy to sanitise but are relatively delicate when it comes to certain types of stain. The latter can leave traces and marks that are more visible if compared to products with intermediate shades: cleaning must be performed in a timely and accurate manner.
Particular types of stain need extra-duty cleaning with specific detergents.
Depending on the type of stain, you can use the following products:
+ Acid, for inorganic stains (e.g. concrete, limescale, rust, cement-based or coloured grout, wall-paint).
+ Bases for organic stains (Coca Cola, ice-cream, coffee, wine, beer, animal and vegetable fats, mustard, mayonnaise, ketchup, jam, lipstick, wax).
+ Solvents for Synthetic stains (silicone-based and mechanical oil, resin, glaze).
With regards to any polished finish, the use of abrasive tools should be avoided:
if you need to use an acid detergent to remove your stain, always dilute the product in water and use half of the acid concentration recommended by the manufacturer.
It is also essential to reduce slab-acid contact time.
Rinse with plenty of water immediately after cleaning.
The use of common aggressive acids (such as muriatic acid for instance) must be avoided. These products do remove residues of grout but they can also irreparably damage the tile’s surface. Also pay attention to all products containing hydrofluoric acid (HF) since they irreparably damage all ceramic surfaces.
If you are using grout to fill your joints, it is recommended to perform thorough cleaning after installation, using an acid and buffered solution.
In order to prevent issues and accidental damage, we recommend the following:
+ Prevent accidental collision with slab corners, edges and surfaces;
+ Do not apply continual and particularly heavy loads on surfaces, especially protruding ones. In particular, do not climb onto or stand on tops for any reason.
+ Avoid using ceramic knives on your surfaces. As far as the Polished finish is concerned, also avoid using steel knives. In all cases, when using knives, it is recommended to protect your surface with a cutting board;
+ Avoid direct contact with very hot surfaces, such as pans or coffee pots. Use hot pads;
+ Minimise contact time of your surfaces with concentrated cleaning agents, both of an acid or basic nature: this recommendation applies to all finishes, especially the Polished one.
+ Never use abrasive detergents to clean your surfaces.
Slab Shaping
The recommendations below apply to slabs in 12mm thicknesses. Before any kind of shaping, slabs must be thoroughly cleaned and inspected to ensure they are free from marks, cracks, chipping or other manufacturing defects.
Any complaints regarding the material must be made prior to cutting, machining or laying. Once the product has been cut, machined or laid, no claims will be accepted for any reason whatsoever. After this, they should be destressed by making a cut of 2 or more cm right around the perimeter of the slabs, as far as this is compatible with the requirements of the intended shaping.
Circular Saw Cutting of slabs 12mm thickness
Cutting Parameters
Thickness: 12mm
Cutting speed (m/min): 1.5
Saw Blade Ø (mm) RPM: 400 2000-2150
+ Use a diamond saw blade suitable for cutting porcelain stoneware.
+ Use a supporting surface large enough to hold the slab straight and flat.
+ Make the destressing cut.
+ To make a recess for a sink, drill holes in all the inside corners with a drill bit of radius at least 6mm, and then cut to join up the holes.
+ Make the straight cuts needed to create a countertop to the correct size.
+ Bevel the insides of the hole.
+ The saw blade must rotate in the cutting direction.
+ Cool the saw blade with a constant jet of water with the highest possible flow rate, directing it at the cutting zone.
+ Halve the saw blade speed at the start and end of the cut.
+ Cut at least 1.5mm more than the thickness of the slab to obtain a clean cut.
+ Cut at the minimum speed, and in automatic mode, if the saw blade falls straight onto the slab.
+ Never create right-angled (90˚) internal corners, L-shaped kitchen worktops with straight edges, straight-edge sink holes, or straight internal edges.
+ For slabs 6.5 mm thick without mesh backing, before creating holes and recesses a layer of high density rubber about 12mm thick should be applied to the back.
Numeric control machining
ACE. XL Slabs can be machined with numeric control machinery (CNC). The most complex CNC stations offer the possibility to angle the head to create many different types of shapes and outlines. This machine is used mainly to obtain recesses for hobs and sinks, edge finishing for flush-mounted tops, holes, edges and curved cuts.
The tool must be diamond finished and suitable for processing porcelain stoneware. The choice of utensil is linked to the specific processing in question. Do not make any cuts or holes with utensil oscillation. During machining, use plenty of well-aimed water, both inside and outside the utensil.
Water jet machining
ACE. XL Slabs can easily be cut with water-jet machines: this method is used for all cutting, shaping and drilling operations with a high degree of precision. Check that the metal support grid is in a good condition and flat, and that the piece is appropriately fixed to prevent it from moving, which could compromise the quality of the cut. If the machine allows, it is also possible to cut at 45°. By adjusting the machining parameters, it is possible to obtain a sharper or rounder edge. For openings in the slab, start cutting inside the hole and then proceed towards the perimeter of the cut. Keep a minimum radius of 5mm for internal angles.
Cutting Parameters
Thickness Speed (m/min): 1
Pressure (Bar): 2800
Abrasive Rat (kg/min):0.4
Countertop Shaping
+ Leave at least 5 cm between holes and the edges of the destressed slab and between the edge of the sink hole and the tap hole.
+ Never leave 90˚ corners and create a radius of at least 6mm for the corners of holes in slabs of 6-6.5 mm and at least 8 mm in slabs of 12 mm.
+ To create L-shaped tops, combine two rectangular pieces; do not create diagonal joints and avoid weight imbalances between the two parts of the countertop.
+ For joining the edges of the slabs, use a two-component epoxy or multi-etane adhesive, or other suitable adhesive, matching the colour of the slab. Follow the adhesive manufacturer’s full instructions.
+ After making the holes, before gluing the countertop into place apply a layer of plywood about 2cm thick on the top of the unit underneath, to increase the slab’s stability and rigidity. The application of this underlay also allows a 45° edge to be supported.
+ If working on existing stone or solid surface countertops, the slab can be applied directly to the surface.
+ Once completed, countertops must be handled with the aid of specially created wooden cross- bars and crates, to ensure the maximum stability.
Flush-mounted sinks/Sinks and Hobs
+ For all types of sinks, the basic wooden structure should be built first, ready for waterproofing and then covering with the slabs.
+ Holes for flush-mounted sinks and hobs must only be created in 12 mm slabs, cutting to a depth of no more than 6 mm in the mounting zone.
+ For the support of all types of sinks, a structure fixed to the cabinets must be used. The sink must not be supported directly by the stoneware top.
+ For undermount sinks, the exposed edges of the stoneware slab around the sink compartment must be finished with a rounded edge of at least 3 mm radius. The edges must also be treated with a suitable sealer/sealer for porcelain stoneware.
Countertop Manufacturing
+ To create L-shaped tops, combine two rectangular pieces; do not create diagonal joints and avoid weight imbalances between the two parts of the countertop.
+ For joining the edges of the slabs, use a two-component epoxy or multi-etane adhesive, or other suitable adhesive, matching the colour of the slab. Follow the adhesive manufacturer’s full instructions.
+ After making the holes, before gluing the countertop into place apply a layer of plywood about 2cm thick on the top of the unit underneath, to increase the slab’s stability and rigidity. The application of this underlay also allows a 45° edge to be supported.
+ If working on existing stone or solid surface countertops, the slab can be applied directly to the surface.
+ Once completed, countertops must be handled with the aid of specially created wooden cross- bars and crates, to ensure the maximum stability.
+ Countertop overhangs cannot be created without mesh mounting or in the 6.5 mm thickness.
+ Overhanging countertops must be created using mesh-mounted slabs of 12 mm, and the overhang must be no more than 30 cm wide.
Straight Edges in slabs 12 mm thickness
Full length shaped edges or glued apron edge profiles can be created by hand or using an edge polisher, CNC machine or other professional equipment. Regardless of the chosen method, always start by defining a straight or rounded bevel of at least 1mm for the top corners of the profile obtained. 5-axis numerical control machines are required to program the bevelling of curved corners.
In order to simplify the cleaning of stains, the edges of the slab should be finished with a specific toner/sealer for porcelain stoneware after processing.