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    Beautiful and Durable

Panel Thickness and Installation Guide

Panel Thickness and Installation Guide

 

GENERAL DESCRIPTION:

Fossil CHPL (Custom High Pressure Laminate) is available in panel sizes up to 5’ x 12’ and can be tiled to create seamless murals of unlimited size.  Panel thickness ranges from .028” post-forming laminate to 1” solid structural panels.  Fossil panels can be cut into virtually any shape such as ovals, circles, arched tops, human, animal or freeform shapes. Design possibilities include cut-outs within a panel, shaped edges and even 3-D layering.  CHPL (Custom High Pressure Laminate) panels can also be made “double-sided”, with graphic images on both sides.  Grades over 1/2” are self-supporting and can be fitted with threaded inserts … perfect for easily attaching to walls, railings and posts without visible hardware.  Fossil offers a complete line of pedestals and mounting hardware.  Fossil products are made entirely in the U.S.A.

Panel Thickness Options

0.028" Used in place of 0.048 laminate when the mounting surface is curved. Can wrap a column with a diameter as small as 10”. Manufactured with a sanded back for proper adhesion to substrate. Requires bonding to a backer material. When used in humid or damp conditions, edges must be sealed to prevent water damage. (Weight 0.25 lbs. / sq. ft.)

0.048”
Our standard laminate. Typically used for counters, tables, wall panels and murals. Manufactured with a sanded back for proper adhesion to substrates. Requires bonding to a backer material. When used in humid or damp conditions, edges must be sealed to prevent water damage. (Weight 0.43 lbs. / sq. ft.)

1/16” (0.063”)
Similar to 0.048 laminate, but itʼs non-sanded back offers more resistance to moisture. Typically used for wall panels and murals. Requires bonding to a backer material. When used in humid or damp conditions, edges must be sealed to prevent water damage. Edges and back are smooth, polished black. (Weight 0.45 lbs. / sq. ft.)

0.090”
Typically used for interpretive and wayfinding graphics. This is the National Parks standard for their NPS frames. Requires support of a backer material. Enclose in a frame with back support or mechanically fasten and epoxy directly to a surface that will not bend. When used in humid or damp conditions, edges must be sealed to prevent water damage. Edges and back are smooth, polished black. (Weight 0.7 lbs per sq. ft.)

1/8” (0.125”)
Typically used for interpretive and wayfinding graphics. Good choice for double-sided panels for flip-books. Requires support of a backer material. Enclose in a frame with back support or mechanically fasten and epoxy directly to a surface that will not bend. Edges and back are smooth, polished black. No minimum order required. (Weight 0.91 lbs. / sq. ft.)

1/4” (0.25”)
Typically used for interpretive and wayfinding graphics. Good choice for double side panels for flip-books. If larger than 12”x12” will require support of a backer material. Enclose in a frame with back support or mechanically fasten and epoxy directly to a surface that will not bend. Edges and back are smooth, polished black. (Weight 1.8 lbs. / sq. ft.)

3/8" (0.375”)
If larger than 18”x18” will require support of a backer material. Enclose in a frame with back support or mechanically fasten and epoxy directly to a surface that will not bend. Edges and back are smooth, polished black. (Weight 2.7 lbs. / sq. ft.)

1/2" (0.5”)
Our most popular thickness for outdoor signage. Perfect for attaching to walls, railings and post without visible hardware. Because itʼs self supporting it does not require a frame or backing material. Panels can be fitted with threaded inserts for easy installation. Mounting hardware is easily concealed. Edges and back are smooth, polished black. (Weight 3.6 lbs. / sq. ft.) No minimum order required.

3/4" (0.75”)
Typically used for free-standing elements where strength is critical. Can be used as a table top or for construction of graphic structures. Self supporting and does not require a frame or backing material. Panels can be cut, drilled, profiled to shape or fitted with threaded inserts for easy installation. Mounting hardware is easily concealed. Edges and back are smooth, polished black. (Weight 5.4 lbs. / sq. ft.)

1" (1.0”)
Typically used for free-standing elements where strength is critical. Can be used as a table top or for construction of graphic structures. Self supporting and does not require a frame or backing material. Panels can be cut, drilled, profiled to shape or fitted with threaded inserts for easy installation. Mounting hardware is easily concealed. Edges and back are smooth, polished black. (Weight 7.2 lbs. / sq. ft.)

INSTALLATION AND FABRICATION FUNDAMENTS (.028”, .048”, 1/16”, .090”)

 When working with Laminate Grades, the following techniques will produce a quality application.

  1. Proper conditioning of CHPL panels minimizes the negative effects of warping, shrinking and expansion of assembled panels. Panels must be stored horizontally and ideally all components should be conditioned at 70° F to 75° F and 45% to 50% relative humidity for 48 hours prior to assembly. When using CHPL panels thicker than .048”, leave 1/8” space around the panel to allow for expansion and contraction. Due to the organic composition of CHPL, environmental factors that cause expansion, contraction and warping are natural, as such these tendencies can not be warrantied. Choosing the appropriate thickness of CHPL and proper installation will minimize these natural forces.
  2. Bonding FOSSIL laminate panels to substrate materials should be done according to the proven principles of veneering. Typically the material is glued to the desired substrate, and then trimmed to final dimensions. When requested, Fossil will ship materials untrimmed.
  3. Always bond laminate to a suitable substrate such as medium to high-density fiberboard, particleboard, or metals. It should not be glued directly to plaster walls, gypsum wallboard, plywood or concrete.
  4. Recommended adhesives include solvent or water-based contact cement, white glue (PVA), epoxy, and hot melt glue. Consult your adhesive supplier for your specific application requirements. More information contained in “ADHESIVES FOR CHPL” section below.
  5. All saw blades and router bits used for cutting should be carbide or diamond tipped. Feed rate should be slow and tool speed should be high. Before cutting, protect the panel surface from scratches by using a peel coat or painters tape. It is recommended that laminate edges be protected by lubricating them with a wax stick prior to tooling.
  6. All edges of laminate should be filed smooth with file direction towards substrate to help prevent stress cracks and to minimize chipping.
  7. Inside corners of cutouts should have a minimum radius of 1/8” and be filed smooth. This reduces the likelihood of stress cracks.
  8. When nails or screws are used, it is advisable to first drill an oversized hole through the laminate. This reduces the likelihood of stress cracks. 
  9. When used outdoors or in humid conditions, edges must be sealed with a water proof material. Fossil panels are extremely resistant to water on the top surface, extreme water conditions although not covered under our warranty, can be minimized by applying a water resistant coating to the back and sides of the panel. 
  10. Do not use interior grades in humid conditions or in direct sunlight. 

INSTALLATION AND FABRICATION FUNDAMENTS (1/8”, 1/10”, 1/4”, 3/8”, 1/2”, 3/4”, 1”)

  1. When fabricating with CHPL (Custom High Pressure Laminate) panels or mounting panels beside each, proper conditioning of all components minimizes the negative effects of warping, shrinking and expansion of assembled panels. Panels must be stored horizontally and all ideally all components should be conditioned at 70° F to 75° F and 45% to 50% relative humidity for 48 hours prior to assembly. Leave 1/8” space around CHPL (Custom High Pressure Laminate) panels thicker than .048” to allow for expansion and contraction. Due to the organic composition of CHPL (Custom High Pressure Laminate), environmental factors that cause expansion, contraction and warping are natural, as such these tendencies can not be warrantied. Choosing the appropriate thickness of CHPL (Custom High Pressure Laminate) and proper installation will minimize these natural forces.
  2. Panels can be sawed, routed, drilled, and tapped with conventional wood-working equipment. Saw blades and router bits should be carbide or diamond tipped and kept sharp to produce chip free edges. Feed rate should be slow and tool speed should be high. Before cutting, protect the panel surface from scratches by using a peel coat or painters tape. Edges can be finished by sanding with coarse sandpaper (80 grit) followed by a fine sandpaper (180 – 220 grit). This will remove saw striations and provide a smooth appearance to the edges. A final edge treatment using Thompson's® Waterproofing Wood Protector will further enhance and protect the edge aesthetics. Inside corners of cutouts should have a minimum radius of 1/8” and be filed smooth. This reduces the likelihood of stress cracks. Self-tapping screws or nails can be used in predrilled holes. Do not screw into or use splines in the edges of panels. Panels can be joined using metal brackets or clips, although it is sometimes necessary to use shims to level out the joint. Mitered edges should be avoided.
  3. Panels between 1/8” and 3/8” thick must be enclosed in a frame with back support or mechanically fastened and epoxied directly to a surface.
  4. Panels over 1/2" thick must be mechanically fastened and not glued, or epoxied to a surface. We recommend using a spacer between the panel and the surface that you are mounting too. Doing so helps protect the panel from standing water damage and reduces ice build up underneath that could cause the panel to be forced away from the mounting surface. While Fossil panels are extremely resistant to water on the top surface, extreme water conditions although not covered under our warranty, can be minimized by applying a water resistant coating to the back and sides of the panel. When attaching CHPL panels to a mounting plate using “Threaded Inserts”, use the largest mounting plate possible to minimize warping of the panel. When using “Threaded Studs”, do not use silicone in the holes. You must use a permanent epoxy or the panel will warp and pull the studs out of the hole.
  5. Do not use interior grades in humid conditions or in direct sunlight.

 

MANUFACTURING TOLERANCES

We take great pride in our work and as such, you will find that our manufacturing tolerances are world class.

- Printing Tolerance: Less than (+/-) .0208 per ft. (0.25" -12').

- Panel Thickness Tolerance: Less than (+/-) 5% per panel (.025 for 1/2” panel).

- Panel Size (HxW) Tolerance: Less than (+/-) 0.02 per panel.

- Fabrication Tolerance: If you are using Fossil CHPL (Custom High Pressure Laminate) as assembly components and have critical cuts or tolerances, make us aware when placing your order so that we can achieve your desired results.

- Visual Tolerance: Graphic panels and hardware will be free of any visual imperfections that would interfere with the normal viewing and enjoyment of either.

Adhesives for CHPL (Does not apply to CFBL panels)

There are many factors in determining the best adhesive for your application.  It is not only determined by our CHPL panel, but by the material that you are adhering it to, temperature, humidity, moisture, job site conditions etc.  That being said, we have received excellent feedback in regards to 3M products.  We have heard that bonding results are considerable better when applying from a canister and not a can.  Please share your results with us.  We suggest visiting their website and actually calling them at 1-800-362-3550.  Below are some links that you may find useful:

3M info on adhesives by categories of applications:

http://solutions.3m.com/wps/portal/3M/en_US/Adhesives/Tapes/

3M online resource questionnaire “Ask a 3M specialist”:

http://solutions.3m.com/wps/portal/3M/en_US/Adhesives/Tapes/Support/Contact-Us/

Fossil used “3M Hi-Strength Postforming 94 CA adhesive” to bond it’s panels together:

http://solutions.3m.com/wps/portal/3M/en_US/Adhesives/Tapes/Products/~/3M-Hi-Strength-Postforming-94-CA-Adhesive?N=5396314+3294310811&rt=rud

Avoid “3M Super 77™ Multi-Purpose Spray Adhesive”.  We have reports of failures using this product.

http://solutions.3m.com/wps/portal/3M/en_US/Adhesives/Tapes/Products/~/3M-Super-77-Multi-Purpose-Spray-Adhesive?N=5396314+3294310584&rt=rud

DISCLAIMER:

This information is presented to assist you in determining what grades of Fossil CHPL (Custom High Pressure Laminate) material may meet the requirements of your project.  Purchaser shall determine the suitability of the product for its’ intended use, and purchaser assumes all risks and liability whatsoever in connection therewith. All statements, technical advice and recommendations contained herein are based on tests and information believed to be reliable, but the accuracy there of is not guaranteed, and is made in lieu of all warranties, express or implied: seller's and manufacturer's only obligation shall be to replace the quantity of product proven to be defective. Neither seller nor manufacturer shall be liable for any injury, loss or damage, direct or consequential, arising out of the use of or the inability to use the product. (Updated:  06-09-2017)

graphics that survive