Countertop

Technical Guide

Countertop
Technical Guide
 Countertop Technical Guide

Index
0.1 Formats and Thicknesses
0.2 Color Range
0.3 Product Features
1. Handling Neolith Countertops
2. Inspection of the slabs
3. Machining parameters
4. Cut-out recommendations
4.1 General Recommendations
4.2 Bridge Saw, combi machine or similar
4.3 Waterjet
4.4 CNC Machine
5. Edges and profiles recommendations
5.1 Polishing
5.2 Countertop edges
5.3 Sinks
6. Installation
6.1 Reinforcement
6.2 Preparing cabinets
6.3 Overhangs
7. Recommended tools for machining countertops
8. Cleaning and maintenance of Neolith countertops
8.1 Maintenance
8.2 Suggested detergents to clean general stains
9. Guide for repairing Neolith surface defects caused by chipping

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0.1 Formats and Thicknesses

3.200 x 1.500 mm 3.600 x 1.200 mm

Only in 6 and 12 mm Only in 3 and 6 mm
0.2 Color Range

Arctic White Beton

Nieve Phedra

Avorio Cement

Perla Lava

Basalt Grey
Humo

Basalt Black
Moka

Belgian Blue
Chocolate
Barro
Nero
Basalt Beige
Cobalto
Arena
Mela
Estatuario
Arancio
Calacatta
Timber Oak
Onyx
Timber Night
Marfil
Timber Ash
Travertino Navona
Timber Ice
Travertino Clasico
Textil White
Pulpis

Textil Black
Iron Grey

Pietra di Osso
Iron Moss

Pietra di Luna Iron Copper

Pietra di Piombo Iron Corten

Nero Zimabwe Iron Ash

Nero Assoluto Iron Blue

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0.3 Product Features
Neolith is the largest sintered compact surface available in the market. It is 100% natural product composed
of feldspar, silica, clay and other natural minerals and it emulates what nature takes millennia to produce
in just a few hours, through an exclusive and high technological sintering process. Neolith offers the most
efficient solutions for the most demanding architectural projects, as well as an extensive combination of
colors and finishes, making it a designer product that can be used in numerous applications for interiors,
exteriors and furnishings.

Neolith presents physical properties that excel for its use on any application, furthermore, its colors made
of 100% natural pigments, withstand the passage of time and remain unvariable.

Technical Features:

Lightweight: The thickness of the slabs makes it a very light product and thus facilitates
transportation and handling and reduces the load factor on cladding. 7kg/m2 for the 3mm option.

Waterproof: Neolith sintering process confers the slabs less than 0,08% porosity. It does not absorb
any water and it is resistant to stains, making it ideal for humid places.

UV Resistance: Being 100% natural, its colors do not fade away when being exposed to sun light
or other extreme weather conditions.

Resistant to High temperatures: It does not burn in contact with fire nor does it emit smoke or toxic
substances when being subjected to high temperatures

Resistance to wear and tear: Its hard surface makes it resistant to scratches and abrasion when
being exposed to extreme weather conditions (such as sand storms or other similar aggressions).

Bending resistance: It has a high share rate, making it resistant to heavy loads and pressure as well
as suitable for some curved applications.

Environmental-friendly: Composed entirely of natural material, completely recyclable. Up to 52%

of recycled content. Greenguard, CE, NSF1 certifications. Its use in buildings grants LEED points to
the project.

Easy To Clean: Resistant to any kind of chemical cleaning agent such as bleach or ammonia. When
used in exterior cladding, this characteristic proves of high-added-value in areas with high pollution
levels and risk of graffiti criminality.

Hygienic: Given its practically nul-porosity, it does not trigger any bacteria or fungus which may
lead to allergies or illnesses.
1. Handling
Neolith slabs must be loaded, unloaded and transported by means of a forklift, gantry crane or other
lifting device. In every case of handling and transport, the slabs should be balanced considering its center
of gravity.
In the attached table is an overview of the weight per slab and weight per square meter.

FORMAT (mm) 3600 x 1200 3200 x 1500

THICKNESS (mm) 3 3+ 6 6+ 3+3 6+3 6+6 6+ 12
Kg/m 2
7 8 13 15 17 23 27 17 30

Full Slab Weight (Kg) 32 36 55 59 72 94 116 85 143

Table 1: Formats and Weights per thickness

Always pay attention when moving and manipulating the slabs, to avoid chipping or breakage of the slab.
To lift and move individual slabs, The Size recommends the following type of clamp:

Image 1: Clamp Image 2: Neolith slab handling with Clamp

This clamp can be purchased through TheSize. Please contact TheSize for more details.
In the case that this type of clamp is not readily available, use a 2 cm. thick plank of roughly 3 meters x
20 cms. Place the plank in between the slab you want to lift. Make sure the plank is placed on the backside
of the slab.

1) Place the clamp over the slab and

the plank.
2) Fix the clamp and lift the slab with
caution.
3) Try to avoid sudden changes of
direction.

Image 3: Plank in the backside of the slab Image 4: Handling with Clamp
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To move several slabs at once it is recommended to use canvas slings. Metallic slings should not be used
to handle Neolith slabs.

Image 5: Canvas Slings

X
Image 6: Moving a Neolith Slab Image 7: Moving a Neolith Slab

X
Image 8: Placing a Neolith Slab on a bench Image 9: Placing a Neolith Slab on a bench
2. Inspection of the slabs
Before commencing fabrication, TheSize recommends to clean the slab thoroughly and perform a careful
visual inspection of the slab for:

• Pigment contaminations.
• Blisters, cracks & fissures.
• Warping.
• Tonality.
• Any other anomaly that might be considered a defect.

This should be a standard procedure before commencing fabrication: No claims will be accepted of
mechanized or installed slabs that had defects upon delivery.

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3. Machining Parameters

Recommendations for 12 mm slabs only.

Before fabrication starts it is important to remove 2 cm from each side of the slab in the following order:

1st

3rd 4th

2nd
Image 11: Correct order to remove slabs sides

When cutting 12mm slabs with a disc, it is important to reduce the cutting speed at the beginning and the
end of the cut to about 50%.

200 mm 200 mm
Speed 50% Speed 50%

Image 12: Cutting speed recommendations for 12 mm

These recommendations apply to 12mm slabs only. All other thickness can be cut without taking
in account these steps.
Blades:
Speed (mm/min) Speed (mm/min)
Thickness (mm) Ø DIsc (mm) RPM Surface Speed (m/min)
straight miter
300 2500
3 mm 2,5 - 3,0 1,7 - 2,1 350 2200 40
400 1900
300 2500
5, 6 and 3+3 mm 2,2 - 2,7 1,5 - 1,9 350 2200 40
400 1900
300 2500
5+3 mm 2,0 - 2,4 1,4 - 1,7 350 2200 40
400 1900
300 2500
12 mm 1,0 - 1,5 0,7 - 1,0 350 2200 40
400 1900
Table 3: Blade Parameters

During cutting it is important to use the maximum flow of water for cooling. Make sure the flow of water
is directed to the cutting area.
Verify that the cutting table is straight, level and free of any debris. Check that there is sufficient support
for the slab. Large unsupported areas can cause chipping when cutting.
Lighter models (Arctic White, Estatuario, Nieve and Avorio) are tougher on the blades because of certain
raw materials; THESIZE recommends lowering the cutting speeds for these models to avoid overheating
of the disc.

Waterjet:
Pressure (Bars) Speed (mm/min) Abrasive feed (kgs/min)
3800 700 0,38
Table 4: Waterjet parameters for all thicknesses

The indicated values are suggestions only, cutting speeds or abrasive feeds can be adjusted to
obtain a cleaner finish.

CNC:
Tool RPM Speed (m/min)
Core Drill 4.500 - 5.500 20
Finger Bit 4.500 - 5.500 200
Rebate Bit 8.000 - 10.000 300
Table 5: CNC Parameters

• Rebate Bit: First drill a whole to work from using the core drill bit. Do not lower the rebate bit
directly onto the surface. During the first two passes only remove 0,5mm; afterwards, 2mm can
be removed per pass.
• Finger Bit: Do not use the oscillation option while cutting; this might provoke chipping

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4. Cut-out Recommendations
4.1 General Recommendations:

When fabricating a cut-out, please bear in mind that the minimum distance between a cut-out and the edge
of the slab should be at least 5 cm.
• The distance between
a hole for a faucet and
the cut-out should be
5 cm at least 5cm.
5 cm
• All corners need to
have at least a 3mm
radius.

5 cm • Never leave 90º

angles.

Image 13: General recommendations for cut-outs

4.2 Bridge Saw, Combi machine or similar:

Recommendations:
• Drill all the corners of the cut-out.
• Lower the sawblade with minimum speed onto the surface. (10mm/m)
• Make sure the blade is sharpened and has maximum cooling.

4.3 Waterjet:

It is recommended to start inside the cut-out and approach the cutting line afterwards.

Image 14: Cut-outs with Waterjet

It is recommended to perform the piercing, when the water jet initially penetrates the slab, as close as
possible to the edges of the slab.
From the initial piercing, one should cut to the edge of the slab or parallel to the edge of the table and
follow this direction to finish the piece.
It is not recommended to cut toward the center of the table.

To minimize breakage, one should cut

the outer corners of any square form as
follows:

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4.4 CNC Machine:

First drill a hole inside the cutout using the core drill bit. Afterwards, use the finger bit to approach the
cutting line.

Image 15: Cut-outs with CNC

When approaching the cutting line, use a curved approach; do not use a perpendicular approach, this might
create a notch.
Place suction cups around and underneath the cut out as shown in the picture (dotted lines). Furthermore,
place the maximum amount of suction cups underneath the slab to prevent the slab from moving.

Image 16: Cut-outs with CNC. Suction cups placement

5. Edges and Profiles recommendations
5.1 Polishing:

Edges can be polished using standard granite or marble polishing discs. Start off with the lowest grit and
finish with the highest grit.
IMPORTANT
Polished edges should be treated with a specific waterproofing for this product category in order
to permanently seal the edge. TheSize recommends Nanotop from Lithofin.

Image 17: Polishing discs for wet and for dry usage

5.2 Countertop edges:

TheSize recommends the following edge for Neolith countertops. It has been proven to be the perfect
compromise between aesthetics and functionality reducing drammatically the edge chipping incidences.

R 0,5 mm

2 mm

R 0,5 mm

The edge is made up off a 2mm bevel and two rounded

edges with a 0,5mm radius. The radius is hardly visible
but it increases the impact resistance of the edge.
Image 18: Recommended edge section

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Image 19: Recommended edge detail

Another type of edge that is more resistant to impacts is a radius bevel:

The bigger the radius the better it will withstand

R 2 mm impacts but it will also show more of the base colour
of the slab. In areas with a high risk of impact (sinks for
example) a 2mm Radius Edge could be considered; it
is the best option between aesthetics and durability.

The edges portrayed here can also be applied

on mitered edges.
Image 20: Recommended edge section

5.3 Sinks:

To minimize the risk of chipping, TheSize recommends the following finish for undermount sinks:

Image 21: Recommended sink section

The countertop meets the edge of the sink, fitting flush with the sink bowl. (zero/flush reveal). In areas
with high risk of impact it is recommended to use a top mount sink.
6. Installation
6.1 Reinforcement:

Fabricate back to front supports under the countertop every +/- 600 mm.
All seams should be reinforced underneath.
Cut-outs not supported by a solid sub-surface should be reinforced with a suitable material such as granite
strips, aluminum bars or high density polyurethane foam strips.

Image 22: Recommended reinforcements

6.2 Preparing cabinets:

Preparation:
1. Place all the manufactured sections of the countertop on the cabinets without adhesive. Check that
all the sections are the correct size, shape relative to the cabinets and the walls.
2. Use wedges to level the countertop and fill in the spaces between the countertop and the cabinets
with natural silicone.
3. Check that the countertop is straight and level.
4. Make a last visual examination to ensure that the countertop is to your satisfaction.

Sealing between the countertop and wall:

1. Clean the space of any debris.
2. Fill the space generously with natural silicone.

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6.3 Overhangs:

Countertops extend out from the face frame of the cabinets and just over the cabinet doors. This is called
the overhang. Standard cabinet frames are 60cm deep with 1,5cm to 2,5 cm thick doors. Most countertops
have a 2,5 cm overhang to make a standard depth of +/- 63 cm.

Standard Overhang Extended Overhang Extended Overhang w/Support

<10 cm >10 cm

Image 23: Overhangs

If you have the space, and would like to create additional countertop space, you can extend your overhang.
It is important to keep in mind that countertops with an extended overhang might require additional
support:

Maximum overhang:
• Without apron edge:
12 mm countertops 15 cm.
5+3 cm countertops 10 cm.

• Mitered edge with reinforcement:

12 mm and 5+3 countertop 30 cm*

* Taking in account that the countertop has been reinforced all around the edge and front to back support every 600 mm.
7. Recommended tools for machining countertops

Ø 125
60: 720-041
120: 720-042
220: 720-043
400: 720-044

Ø 180
60: 720-018
120: 720-019
220: 720-020
Silicon carbide discs: 320: 720-021
Blades: Ø 300 Ref. 411-053 400: 720-023
Ø 350 Ref. 411-055 Silicon Carbide velcro discs for dry use. 600: 720-022
Segmented blade for porcelain. Ø 400 Ref. 411-056 Grit 60, 120, 220, 400. 800: 720-183

Thin Grit G40, Ref. 720-008

Hard Grit. G100, Ref. 720-009

Electroplated diamond grinding Felt pad:

disc, type, G100 and G40: Ø 125 Ref. 720-181
Ø 180 Ref. 720-064
Refining and trimming edges.

Ø 100
30: 720-291
100: 720-292
200: 720-293
Beveling and pre-grinding edges: Silicon carbide discs: 400: 720-294
800: 720-295
Cup wheels, medium, grain 60. Silicon Carbide velcro discs for wet use. 1500: 720-296
Ref. 720-061 Ref. 720-298 3000: 720-297

Core drill 20-35 mm:

Electroplated diamond, cutting drill bits. Finger bit:
Ref. Ø35: 411-018 Ref. 720-107

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 Ø 6 Ref. 853-099
Ø 8 Ref. 853-098
Drill bits 6-12 mm Ø 10 Ref. 853-097

Electroplated diamond, cutting drill bits. Core drill (CNC):

Use the drill without the hammer action. Use water for cooling. Ref. 720-165

4” Diamond blade: Rebate Cutter:

Segmented bladde for porcelain. Recommended speed 11.000 Ref. 720-210
RPM. Ref. 411-051

Ø 300 Ref. 411-066

Ø 350 Ref. 411-067
Ø 400 Ref. 411-068

Neolith Colored Glue: Ultracompact Disc:

Check color availability and references Segmented blade for porcelain.
8. Cleaning and maintenance of Neolith Countertops
8.1 Maintenance:

Neolith countertops can be washed with warm water, to which a detergent can be added, used in the
dose recommended by the manufacturer. (Avoid products containing hydrofluoric acid and its derivatives).
Rinse with warm water and dry with a cloth or similar.
If liquids are spilled, it must be dried immediately. The faster you clean and dry spills, the easier it is to
remove stains.
It is not advisable to use waxes, oily soaps, impregnating agents or other treatments (hydro-oil repellent)
on the product, because its application is not necessary at all.
Some of the detergents currently on the market contain waxes or polishing additives that, after several
washes, can leave an oily film on the surface of Neolith.

TIP:
During treatment, closely examine the spot. If the spot is still there, but is lighter or reduced, you know the
treatment is working. Keep applying until the stain is completely gone.

Image 24: Lemon juice on an Arctic White countertop

Special consideration with the ceramic knives:

Ceramic knives may scratch Neolith’s surface in every finish, the same way they scratch other surfaces of
the same product category and other categories.

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8.3 Suggested detergents to clean general stains:

Some products may not be removed by normal cleaning operations and specific procedures must be used,
depending on their nature. The amount of time the substance remains on the surface is very important, as
it is advisable to clean the area as soon as possible. This will prevent it from drying out and allows to be
cleaned easily.
Here are some of the substances listed for removing stains.

Types of Stains Types of detergents

Grease Alkaline / Solvent
Oil Solvent
Ink Oxidant / Solvent
Rust Acid
Lime Acid
Cement Acid
Wine Alkaline / Acid
Coffee Alkaline / Solvent
Rubber Solvent
Plaster Acid
Epoxy glues Solvent
Candle wax Solvent
Iodine Oxidant
Blood Oxidant
Ice cream Alkaline
Resins Solvent
Fruit juice Oxidant
Permanent marker Solvent
Aluminum scratches Acid
Image 25: Coffee stains on an Arctic White countertop

Acid: Acidic cleaning products: descalers, cement removers…

Alkaline: Basic cleaning products: ammonia, degreasers…
Solvent: Universal solvent, thinner, turpentine, acetone, alcohol...
Oxidant: Diluted hydrogen peroxide or bleach …

Warning:
Always follow the manufactures’ recommended dosage and time
9. Guide for repairing Neolith surface defects caused by chipping
Ceramic surfaces can get damaged for a variety of reasons. Most often it’s due to an impact from a heavy
object such as cooking pots.

Image 26: Surface and edge chipping

Step 1:

This guide explains how to repair a chipped surface. Bear in mind that it is not a perfect repair; it is very
difficult to match the tonality and texture of the surface with epoxy acrylate resins.

Step 2:

Mix the two part epoxy, adding the color to tint the epoxy to match your Neolith countertop.
TIP:
Plan on repairing all of the chips at one time, because the two part epoxy will cure quickly. Also, only mix
enough so you can fill the chips and have a little left over: epoxy cannot be stored once mixed.

Image 27: Repairing Kit

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Step 3:

Use a piece of Neolith to mimic the surface finish and proceed to fill the chip with the already mixed resin.

Image 28: Repairing process

Step 4:

Using a cloth soaked in acetone, additional texture can be added to the resin to further mimic the
surrounding surface.
Make sure the level of the resin does not surpass the adjacent surface.
Clean the excess resin on the surface before it hardens, using a cloth soaked in acetone.

Image 29: Repairing process

Step 5:

Once the resin hardens, grind down the surplus resin on the edge mechanically, surface repairs are best
grinded down manually to avoid damaging the surface.

Image 30: Repairing process

Do not hit your Neolith countertop with a blunt and heavy objects. It could chip or even break (the
edges are the most sensitive to physical damage).

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10. Durability Comparison Table:

Concept Neolith Neolith polished Quartz Surfaces Natural Stone Laminate

Stain Resistance
Heat and Burn
Resistance
Resistance to
Household
Chemicals
Low Maintenance
Non Absorbent
and Nonporous
Scratch
Resistance
Mold and Mildew
Resistance
Color Fasteness
Immunity to
Freeze and Thaw
Table 6: Durability comparison Table
THESIZE SURFACES S.L.
P.I. Camí Fondo, Supoi 8. C/ Dels Ibers. 31
CP-12550 Almassora (Castellón) Spain
+34 964 652 233
[email protected]
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www.neolith.com