1. Unloading – Instructions

Before unloading, the products received with the Purchase Order (PO) must be checked and verified against the order details.

Proper unloading and storage of the boards helps prevent structural bending, scratches, and damage to the edges and corners. The product must be checked against the Purchase Order (PO) before unloading. If any damage or discrepancy is noticed during unloading or inspection, the company must be informed immediately.

A. Manual Unloading (Handling by Hand)

• To prevent the boards from bending, carry them with the edges held vertically rather than carrying them flat.
• While unloading, ensure that the boards do not rub against each other or against other surfaces.
• Wear clean gloves to prevent dirt, sweat, and oil from coming into contact with the boards.

B. Immediate Stacking & Storage

• Immediately after unloading, place the boards completely flat on a clean and level surface and store them in a suitable location.
• Do not lean non-palletized boards vertically against walls, as this may cause deformation.
• Do not store the sheets in areas exposed to temperatures above 40°C or direct sunlight.

2. Cutting – Instructions

A. Cutting Using Power Tools

• For cutting, select a sharp blade suitable for cutting plastic for use with a circular saw or jigsaw. A swing cutter may also be used. Select a motor with the appropriate RPM.
• Secure the board firmly on the workbench to prevent vibration during cutting.
• Allow the blade to cut naturally. Do not push the board too quickly, as excessive friction may damage the edges.

B. Designs & Complex Cutting

• Use a jigsaw or CNC router for lattice designs, curves, and intricate shapes.
• When making an internal cut-out, first create a hole in the waste area using a 10 mm drill bit.
• Excessive heat can burn, discolor, or cause dimensional changes in PVC.

C. Edge Finishing

• Smooth and finish the edges using an appropriate grade of sandpaper.

3. Glue Usage – Recommendations

• PUR Hot Melt (Recommended): Provides strong bonding and fast curing. Does not absorb water.
• Solvent-Based Adhesives: More economical, but there is a higher possibility of warping.
• Water-Based Adhesives: Not recommended. Avoid water-based adhesives, as the moisture content may cause the sheets to warp easily.

4. Hardware Fitting

• Use wood screws or twin-fast screws with sharp threads.
• For damp or moisture-prone areas, use stainless-steel or coated exterior-grade screws.
• Avoid drywall screws and nail fixing, as they may not hold securely in the foam core.

A. Drilling & Preparation

• Drill a pilot hole before inserting each screw.
• Maintain a distance of 20 mm to 50 mm from the edges to prevent edge splitting.

B. Screw Fixing

• Torque Setting: Set the drill to a low torque setting.
• 90-Degree Angle: Drive the screw precisely at a 90-degree angle.
• Over-tightening can damage the internal foam cells and cause the screw hole to strip.
• Provide an appropriate combination of screws, hooks, and back supports according to the required weight-bearing capacity and span.

C. Concealing Screw Heads

• Use PVC screw caps or plugs for a clean and finished appearance.

5. Lamination

General Precautions During Lamination

• Use laminates of the same thickness, same brand, and same batch on both sides of the sheet.
• Apply the same quantity of adhesive evenly on both sides.
• Uneven tension between the two laminated surfaces is one of the primary causes of warping.

Potential causes include:

• Time differences between laminating the two sides.
• Differences in the quantity of adhesive applied or curing conditions.
• Uneven adhesive application across the sheet surface may cause bending after lamination.
• Uneven temperature or pressure during the lamination process.
• Differences in laminate quality or thickness may also contribute to bending or warping.

6. Assembly & Load Span

• If a frame or laminate sheet is applied to one side of the board, the same should be applied to the opposite side to maintain balance.
• When using the board for ceilings, partitions, or similar applications, provide adequate structural support.
• Proper care must be taken during hinge installation.

Hinge Installation

• Use parallel-thread screws or Euro screws. Angled screw fixing is not recommended.
• For improved grip, using screw plugs in pre-drilled holes is recommended.
• For tall or heavy doors, use hinges with a suitable load-bearing capacity. Use straighteners/reinforcements according to the span and height of the door.