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Planning your installation

It is very important to plan your installation before commencing with cutting or fabricating the AluSplash Panel Sheet.

Some handy tips to consider prior to installation

  • Ensure that you wear appropriate Personal Protective Equipment (PPE)
  • Read through all the installation steps below
  • Measure the area where you plan to install the AluSplash Panel
  • Measure twice, to double check
  • Always use a two-man lift to carry panels around to avoid injury.
  • Ensure everything is leveled
  • Make sure you have all the fabrication materials and tools ready before commencing work.
  • Decide on installation method you plan to use.
  • After cutting and before installation, always do a dry fit to ensure everything measures up and components fit together nicely.
  • If things get difficult, get professional help.
  • All electrical works must ONLY be carried by a certified electrician.

Tools & Material required for Installation

Recommended Cutting & Routing Tools

  1. Circular saw (using aluminium cutting blade)
  2. Hand held Aluminium Routing Machine (Recommended Festool PF 1200)
  3. Jigsaw (using aluminium cutting blade)
  4. Hole saw or Drill (using HSS drill bits)

tools
Always use a vacuum swarf extraction to prevent build up on panel or cutting equipment.


Other material required for Installation

  1. Measuring tape
  2. Sand Paper
  3. Glazier's Suction Cup x 2
  4. Handy Knife
  5. Masking Tape
  6. Builders Angel
  7. Leveling tool
  8. Neutral Cure Silicon Adhesive
  9. Silicon Gun
  10. Metal File
  11.  VHB Double Side Tape
  12. 3mm packers
  13. Metal seam roller- for rolled over edge finish

Sheet Inspection

1. It is important to inspect the panels prior to installation for damages that could have been caused during transportation or handling. Do not fabricate damaged sheets unless the damage section can be removed. Always check the protective film on the decorated surface for any drag marks or deep scratches that may have penetrated into the coated surface. If any visible damages are evident on the decorated surface of the panel upon delivery, do not use the panel and contact the distributor or retailer from whom the panel was purchased from immediately.

2. It is also important to inspect panels prior to installation for any shade difference between different production batches. Panels from different batches may have some visual shade difference, these should not be installed next to each other!

It is important to understand that shade variations between different batches produced possible and occur. Despite our best efforts it is not 100% avoidable.

Shade variation also occurs on other products such as tiles, marbles, granite, colored glass and acrylic splashbacks. The extent of the shade variation may vary from color to color depending on viewing angle, surface area and lighting source.

3. AluSplash surface is protected with film, which is marked with an arrow, indicating the direction of installation. All panels must be installed in the same direction as the arrow to avoid visual colour or gloss variation.

3 Types of Installation Methods to Consider

    1. Continuous and Grout free method: This method gives a clean, seamless, and continuous finish. To achieve this seamless finish, the Panels need to be routed using a hand routing tool so that it can be folded around internal or external corners. Refer to section of Routing & Folding below to see how to route and V Groove the panels correctly.
      level high (Level of Proficiency: Intermediate to High)
    2. Butt Join method: This method is easy, fast and simple to carry out by anyone with an intermediate level of proficiency. With this method, the flat panels are butt joint together at the corners and do not require any routing or folding, hence joints will be visible and does not give a seamless and continuous look. It is important to take into consideration minor thermal expansion of the panel sheets during heating and cooling, hence a 3mm gap must be maintained between the panel sheets when butt joining to allow the panels to expand and contract and for caulking and sealing. 
      level high (Level of Proficiency: Intermediate to Intermediate)
    3. J-Profile Slide in method: This method is the easiest and fastest of the three suggested installation methods. It only requires a basic level of proficiency for installation. J profiles are screwed to the plaster wall or tile wall and the AluSplash Panel simply slides in. (Level of Proficiency: Basic)
      level high (Level of Proficiency: Intermediate to Basic)

3 types

Routing & Folding

AluSplash Panels can be routed using a handheld routing machine like a Festool PF1200 or similar or a flatbed CNC router to route a “V” shaped groove on the reverse side of the panel sheet. When routing, the groove should not be made all the way to bottom, a thin layer of core (0.8 mm) must be retained at the base allowing enough room for easy folding. This is to prevent the paint on coated surface and the aluminium from cracking or crazing during the folding process. Always use a vacuum to extract the swarf build up on the panel or clear the swarf regularly to avoid build up on the panel.

For more information on appropriate routing speeds and other technical information of Festool PF1200 hand held router, please visit www.festool.com

Form milling cutter with cylindrical shaft for hand routing

Routing Folding

6- Easy Steps to a Perfect Installation

Step 1: Area preparation
Ensure that the wall or tile surface is smooth, clean and free from any cracked plaster, grease, large holes, and paper tears. Use a Sand paper to smoothen the wall surface and patch up any holes with a plaster filling. The application surface must be flat, square, dry, clean and smooth. If covering an existing tile wall make sure that the tiles are securely attached to the wall.

Step 2: Measuring
Take your measurements with precision. Measure twice! Protect the AluSplash panel and place it face down on a clean surface. Report your measurements on the backside of the panel. Use masking tapes to mark out location of any Power points on the wall if any. All electrical works must ONLY be carried out by a certified electrician. Measure the distance from the top of the working counter top and bottom of the upper cabinets and measure the distance from wall to wall (See diagram below). If using behind a gas cooktop with an open flame, ensure a 60mm distance is respected between the panel and edge of the cook top. For use behind a vitro-ceramic or induction cook top a 30mm distance must be maintained.

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Step 3: Cutting and fitting
Work on the reverse side of the panel. Cut and fit your panel just like a wooden board. Measure the distance from the wall to the power points and from the bottom of the worktop to the power points and clearly mark out the exact position of the power point on the panel, then use a drill or a hole saw followed by a jigsaw to cut out the hole for the power socket.

Step 4: Dry test and remove the film off reverse side of the panel
Apply the panel against the wall without using any bonding material to test its positioning using a glazier’s suction cup to assist with handling. Once satisfied remove the protection film on the side of the panel that will face the wall (reverse side). AluSplash Panels are usually coated with two different colors on either side of the panel. It is important to know which is the right side that will face out and which side will face the wall. Do not remove the film from the decorated side which will face out at this stage. Only remove the film on the reverse side of the panel that will be stuck against the wall. Remember to leave a 1.5mm (0.06”) gap on each side if using the Butt Joint Method.

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Step 5: Apply the Double Sided Tape & Silicone
Apply the double-sided VHB tape on the wall in straight strips at an interval of 400mm (15.75”) to each other. Next apply a neutral cure silicone adhesive with a caulking gun in a Zigzag pattern between the strips of double-sided tapes.

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Step 6: Panel Installation
Apply the panel against the wall, then peel away the protective film. Do not use excessive force while peeling the protective film, as it may shift the installed panel. After the film has been removed, it is recommended that all Alusplash panels should be protected with Vuplex® spray. Once the protective film is removed off the decorative side, apply masking tape around the 1.5mm gaps where the silicon is to be filled, to ensure a clean finish. Apply silicon into the 1.5mm gaps between panels and between panels and overhead cabinets and bench tops to avoid any water infiltration. It is very important to ensure the edges are sealed with silicon and edges are not left exposed to water or steam. Failure to comply may cause the panel to delaminate and void the warranty.

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