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Processing, Application and Maintenance

How is it Stored?
  • When it arrives at the warehouse, it should be removed from packaging,
  • Both sides should be wiped with a dry cloth,
  • Since substances that adhere to the mirror surface cause corrosion, they should be wiped off,
  • Special wedges should be placed between the plates to provide air circulation,
  • Painted surfaces should not be allowed to have contact with rubber,
  • They should be stored in places that have good ventilation,
  • They should not be stored in places that are damp and chemicals are present, or in outdoor areas,
  • Caution should be applied to make sure the mirror panels do not contact each other during storage and transport,
  • The long edges should be placed on wedges vertically at an angle to the lateral of 10°,
  • Paper or dust should be placed between plates,
  • The packages should be covered with plastic.
How is it Cut?

Flotal can be cut just like sheet glass by scratching with diamond and breaking or by cutting on automatic cutting tables.

The process of cutting is the first step in processing a mirror. The cutting oil is as important as the diamond (cutting relay) that is used in cutting the mirror. The cutting oil has many purposes in the mirror processing.

  • It enables deep cuts to form during the cutting.
  • It properly lubricates the cutting relay.
  • It reduces the cutting pressure. (High cutting pressure increases the formation of hairline glass particles.)
  • It enables the cut depth to be guided as wanted and provides a smooth edge cut.
  • Reduces the formation of hairline glass particles.
  • If cutting oil is used in a small amount under low pressure it can cause unwanted breakage or burrs during detachment.

Every cutting oil has certain solvent features. If improper cutting oils are used (petrol, low quality oils, gas oil, etc.) the mirror paint will dissolve and defects may occur in the mirror as a result. These defects are not visible when the process is first done but will be revealed when the mirror is in use.

As a general rule volatile (evaporating) cutting oils are used for cutting mirrors. It has been observed that using dry or nonvolatile oils for cutting causes defects especially around the edges of mirrors.

Due to the fact that cutting oil contains solvents, it is not appropriate for mirror plates to be collected in a stack touching each other after the cutting is done. Plastic separators must be place in between the cut pieces. Thus the cutting oil that remains on the mirror after cutting can evaporate quickly.

The mirror cutting tables and tools must always be kept clean and after cutting caution should be applied to make sure no nicks and burrs are left of the mirror edges.

How is it Processed?
  • Edge processing procedures like opening canals, drilling holes, grinding, beveling, removing burrs (band lapping) and corner breaking can be done on Flotal.
  • After each of these processes Flotal must be washed, and the cleaning water must be completely removed from the mirror.
  • The grinding and beveling processes are shaving the mirror (glass) edges with diamonds.
  • The size of each diamond that is used in this shaving process must be thicker than D=65.
  • The number of cycles in the stone motors must be at least 2500 c/min.
  • When a new stone is attached, it is recommended that they are only used on the glass grinding process for the first ½ - 1 hour to protect the mirror coating.
  • The processing stones are cooled by adding coolant.
  • The mechanical stress that is applied to the mirror edges with cooling solvents is reduced to a minimum to achieve a smooth grind.
  • Excessive mechanical stress with damage the coating layer and as a result water and dust can get in between the glass and coating and cause corrosion to start.
  • Glass particles (dust) cause the processing fluid’s pH value to exceed 10 while the mirror edges are being shaved. The basic coolant with high pH value will cause corrosion to start on the mirror edges. This pH increase needs to be prevented with proper coolant materials, the pH values needs to be kept under 9 and the coolants and glass dust (particles) need to be removed after the post-process wash before they dry on the mirror.
  • A variety of bacteria develop during use in the water to which coolant has been added during processing. These bacteria breakdown sulfate ions over time and form hydrogen sulfur gas. Hydrogen sulfur gas causes the silver layer to tarnish. Suitable biocides can be added to the coolant to prevent this. Since regular use of biocides can cause resistance to develop a shock dose should be used if there is a high presence of bacteria.
  • In order to settle and remove the glass powders that are generated by the grinding and beveling process a suitable flocking and siphoning system is used.
  • The flocking agent must not be very acidic and must not contain chloride.
  • The flocking agent that is used must not have a chemical effect on the coolant (water added to the coolant).
  • In order to prevent the solvents used in processing the mirrors from being under a corrosive effect, the solvents that remain on the mirror after the grinding and beveling process must be washed off before drying with deionizer or pure water.
  • Flotal cannot be tempered and laminated.
  •      

    Removing burrs

    This is achieved by shaving the mirror edges at an average angle of 45°.

        
  •      

    Plain grinding

    The process of shaving the mirror edges at a 45° angle and smoothing the cutting surface completely by polishing.

        
  •      

    Herringbone grinding or C grinding

    Achieved by forming circular cuts on the edges of the mirror that have been grinded.

        
  • Shining

    The uninterrupted shining of the cutting surface that has dulled after the grinding process with a second process along the edge axis.

        
  • Breaking corners

    The mirror corners being cut in different sizes.

        
  •      

    Beveling

    The edge process being done by forming a curved angle between the mirror cutting surface and the mirror surface. As the curve increases the beveling angle increases. A single bevel can be done on the glass edge as well as bevels in different angles and widths according to demand.

        
  •      

    Drilling Holes

    The hole drilling process in a mirror is done with special drills. Just like the mirror cutting process a clean surface free of nicks and burrs is necessary for drilling. The smallest mistake can cause the mirror to break. On the condition of being no less than the mirror thickness, the distance of the holes that will be drilled in the mirror edges to the edge of the mirror and between the two holes should be a minimum of 5mm. Every hole that is drilled will decrease the durability of the glass.

        
  •      

    Opening a Canal

    This is a surface processing method to achieve the desired motifs using computerized programs with automatic mirror processing machines.

        
How is it Applied?


    • The imperfections on application surfaces and surfaces that are not smooth must be corrected as they can cause appearance defects,
    • Mirror applications should not be done on newly plastered or painted surfaces before they are dry,
    • A gap should be left to prevent accumulation of moisture by providing air circulation between the mirror and application surface,
    • Elastic materials should be placed between the frame and the mirror for mirrors that are placed inside a frame so that the edges are not jammed and broken,
    • In order to prevent mirrors from being squeezed together and broken in multi piece mirror applications a gap (connection) must be left,
    • To achieve a good image in vertical mirror applications care should be taken to make sure the mirror is at a 90° angle to the ground.

The Use of Double Sided Tape and Silicone

 
  • The doubles sided tape and silicone used in the mirror applications must not contain solvents, acid and bases that could affect the paint and coatings on the backs of mirrors,
  • The application surface must be cleaned of dust, oil and similar contaminants and must be dry,
  • Adhesives/tapes used to attach the mirrors must be used vertically,
  • The application surface must be strong enough to bear the weight of the mirror,
  • The application surface must be coated in paint and varnish that will not bleed resin if plywood and similar materials are used,
  • Application should not be done on cold surfaces,
  • Between 18°C and 35°C ambient temperature should be preferred for application,
  • In double sided tape applications the mirror thickness should not exceed 3-4 mm,
  • Rather than long strips, smaller and more frequent strips should be used in double sided tape applications,
  • Tape should not be used on flat surfaces like wardrobe doors and regular doors,
  • Tape should not be used laterally or by point in double sided tape applications,
  • Silicone applications should be vertical on the back surface of the mirror to provide air circulation,
  • Silicone should not be used laterally or by point in silicone applications,
  • In mirror applications neutral cured alkoxy base, condensation cured alkoxy base, 1 or 2 component hybrid silicones should be used,
  • Acid silicones and water/rubber/polyurethane based adhesives should not be used,
  • In very damp spaces the mirror edges should be sealed with silicone to prevent future corrosion.
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    The Use of Profiles and Screws

    In mirror applications using tabs and profiles,

    • Caution is necessary to make sure they are of a cut and strength that can bear the mirror plate,
    • When metal tabs and profiles are used a washer should be placed between the mirror and the metal to prevent contact.

    In applications using lock screws,

    • A neoprene or plastic washer needs to be placed between the screw that will pass through the holes drilled in the mirror and similar elements and the mirror.
  •      

    The Mirror and Mirror Connection

    In mirror applications that reach the ceiling a gap must be left between the mirror edge and the ceiling to provide ventilation for the back surface of the mirror.

  •      

    Mirror and Floor Connection

    If mirror starts at the flooring it is preferred that wedges are placed inside the profile for application.

  •      

    Mirror and Ceiling Connection

    In mirror applications that reach the ceiling a gap must be left between the mirror edge and the ceiling to provide ventilation for the back surface of the mirror.

  •      

    Mirror Connections with Vertical Elements

    If the walls are covered in wood timber the mirror is fixed with wood strips without requiring an additional frame. The frame and wall connections of mirrors placed next to windows can easily be concealed with curtains.

Safety Applications for Mirrors

  • Safety Film should be used to minimize accidents and injury in places where the risk of mirrors breaking is high. If the mirror breaks the film will hold the pieces together to reduce risk of injury. In addition to minimizing risk it prevents back surface paint scratches and corrosion in damp conditions.
  • Safety film is applied to the back side of mirrors. A mirror that has safety film on it should be positioned on the surface with double sided tape or mechanical stabilizers.
  • It is especially recommended that safety film be used in headboard mirror applications, mirror applications that are up to 80 cm above the ground and in places like gyms, dance and beauty salons, daycare centers, schools, hotel lobbies and shopping centers where there is a high volume of people traffic.
  • The safety film that is applied to the mirror must be in compliance with the TS EN 12600 2B2 standard.
How is it Cleaned?
  •      

    The mirrors must be cleaned with a moist and soft cloth,

        
  •      

    You should not try to get out strong stains when the mirror is dry, stains must be removed by lightly rubbing with a cloth that has been submerged in clean hot water and wrung out thoroughly,

        
  •      

    No cleaner should be sprayed directly on the mirror surface,

        
  •      

    Be careful to make sure no water is left at the bottom edge of the mirror,

        
  •      

    Corrosive chemicals, ammonia based, acidic and alkaline cleaning substances should not be used for cleaning mirrors

        
  •      

    Mirrors should not be cleaned with materials that can scratch the surface like scrapers.