Appendix A - Work Instructions and Specifications Document - Task 2

Work Instructions and specifications

Task:

To apply and finish laminate to a coffee table top

Work specifications:

• Coffee table top dimensions:
• Diameter - 60 cm
• Thickness - 2.5 cm
• Lamination requirements - Laminate edging and joints
• Type of lamination - Wood veneer
• Adhesive - Polyurethane adhesive
• Adhesive application method - Use a Scraper

Materials used:

• Wood veneer
• Polyurethane adhesive

Tools and equipment used:

• Laminate roller - To ensure wood veneer is smoothly and firmly adhered to the coffee table top
• Laminate trimmer - Used to trim the excess wood veneer from the edges of the coffee table after the veneer has been adhered.
• Laminate cutters - Necessary for cutting the wood veneer to the precise dimensions required before application.
• Scraper - Useful for applying adhesive, smoothing out any excess adhesive and ensuring a clean, flush finish between the wood veneer and the table top.
• Mallet - Used gently to help in adjusting the veneer into place if needed.

Work instructions:

Step 1 -Surface preparation

• Ensure the coffee table top is clean, dry, and free of any dust, dirt, or grease
• Sand the surface lightly with fine-grit sandpaper to create a slightly rough texture for better adhesive bonding.
• Remove all sanding dust with a tack cloth or a damp cloth.

Step 2 - Measure and cutVeneer

• Measure the diameter of the round coffee table top
• Measure the diameter of the round coffee table top and its thickness to determine the length of veneer needed for the edges
• Add a few extra centimetres to the diameter and perimeter measurements to allow for trimming
• Transfer the measurements to the wood veneer for both the top and the edges
• Use laminate cutters to precisely cut the veneer for the table top and strips for the edges. Ensure the cuts are clean to avoid chipping

Step 3 - Apply adhesive

• Stir the polyurethane adhesive thoroughly
• Use a brush to apply a thin, even layer of adhesive to the coffee table top, its edges, and the corresponding areas on the back of the veneer
• Ensure all surfaces are adequately covered with adhesive

Step 4 - Apply veneer

• Carefully position the round veneer over the coffee table top, aligning it properly.
• Slowly lower the veneer onto the surface to avoid air bubbles.
• Start applying the veneer strips to the edges, ensuring they align seamlessly with the top veneer.
• Use gentle pressure and a mallet if necessary to adjust and secure the veneer along the edges.
• Use a laminate roller to firmly press both the top and edge veneers onto the coffee table.
• Roll from the centre of the top outward and along the edges to ensure all air is expelled and the veneer is fully adhered

Step 5: Laminate Edging

• Apply veneer to one edge of the coffee table, ensuring it aligns seamlessly with the top veneer.
• Use gentle pressure and a mallet if necessary to adjust and secure the veneer along the edges.

Step 6: Laminate Joints

• Position two pieces of veneer to create a joint on one edge of the coffee table.
• Ensure the joint is aligned correctly and press firmly.
• Use the laminate roller to ensure a smooth finish and that the joint is secure.

Step 7 - Trim excess veneer

• Trim the excess veneer from the edges of the table top using a laminate trimmer
• Be precise and ensure the trimmer is set correctly to avoid damaging the table or veneer

Step 8 - Finishing touches

• Use a scraper to smooth out any excess adhesive and ensure a clean, flush finish between the wood veneer and the edges of the table top
• Sand the edges if necessary, to achieve a seamless and smooth transition

Step 9 - Final inspection and cleaning

• Inspect the coffee table for any loose edges, air bubbles, or imperfections. Address any areas needing additional adhesive and pressure
• Clean up any adhesive residues from the surface using a suitable solvent as recommended by the adhesive manufacturer.

Step 10 - Allow for curing

• Allow the adhesive to fully cure according to the manufacturer's instructions, before using the coffee table

Step 11 - Clean-up and tool maintenance

• Collect and dispose of all offcuts and debris properly
• Wipe down all work surfaces and tools with a damp cloth to remove adhesive residue
• Store tools in a dry, clean environment.

Quality requirements

• The surface must be smooth and free from defects before applying the veneer.
• The adhesive must reach the appropriate tackiness level as specified by the manufacturer to ensure strong bonding.
• The veneer must be cut precisely to match the dimensions of the coffee table, allowing for minimal waste and accurate fitting.
• The veneer should be applied without any bubbles or wrinkles, ensuring a smooth, flat surface.
• The finished edges should be smooth, with no rough or jagged areas.
• The overall finish should be aesthetically pleasing, enhancing the appearance of the coffee table

Safety instructions

• Wear appropriate PPE while performing the task
• Handle sharp tools like laminate cutters and trimmers with care to prevent injuries
• Follow manufacturer instructions for using and maintaining tools to avoid malfunction and accidents
• Use adhesives in a well-ventilated area to minimize inhalation of potentially harmful fumes
• Store adhesives safely, ensuring they are tightly closed and away from heat sources
• Ensure all spills, especially adhesives, are cleaned up immediately to prevent slips and falls
• Use proper lifting techniques when moving the coffee table or large pieces of veneer to avoid back injuries

Appendix D - Material Calculation Template - Task 2

Material Calculation
Task 2 - Apply and finish laminate to a coffee table top
Diameter of the table top
Thickness of table top
Calculate the material required to laminate and finish the coffee table top
Other material required for the task