STANDARDS MANUAL SEATINGSeating Construction Standards Manual A.Raw materials A1.Solid wood...
Transcript of STANDARDS MANUAL SEATINGSeating Construction Standards Manual A.Raw materials A1.Solid wood...
Seating Construction Standards Manual A.Raw materialsA1.Solid wood
A2.Veneer
A3.Plywood
A4.Hardware‐screws, dowels, floor glides, Swivel mechanism, Sleeper sofa mechanisms
A5.Foam
A6.Webbing
A7.Springs
A8.Zipper
A9.Metalwork
A10.Fabric specification
B.Frame Construction standardsB1.Legs
B2.Headboards
C.Upholstery standardsC1.Stitching and welting
C2.Loose cushion
C3.Non‐reversible seat cushion
C4.Types of seats
C5.Pattern aligning
C6.Ergo chairs
C7. Curved seating upholstery
C8. Throw pillows
D.FinishingD1.Wood finishing standards and color chart
D2.Metal finishing standards and color chart
E.Item Standard dimension tolerancesE1.Sofa and lounge chair
E2.Ottoman
E3.Dining side chair
E4.Dining side chair with upholstery and back
E5.Dining arm chair
E6.Bench
E7.Bed bench
E8.Desk chair
E9.Ergo chair
F.Packaging standardsF1. Packaging materials
F2. Packaging method standard
A. Raw Materials
A1.Solid Wood Components
‐All furniture legs and frames should be made of solid hardwood.
‐Chinese Eucalyptus (Used for general frames for seating)
‐European Beech (Used in public space seating for exposed wood frames)
‐European Birch (Used in public seating for wood frames covered by upholstery)
‐Wood should be premium quality hardwood, kiln dried (7‐10%), straight grain woods that are
free from defects.
‐All products must be inspected by supplier and guaranteed to be delivered pest free.
A2.Veneer
‐Natural or engineered wood veneers of the specified species and cut are required on all vertical surfaces. No printed veneers, engraved veneers, vinyl, melamine, or laminate, unless specified. ‐Veneer thickness should be a minimum of 0.6 mm ‐If not specified, face veneers should be Grade 1 flat cut, quartered or high quality engineered veneers. ‐ All must match color and grain in themselves and HPL’s to present a uniform appearance. Varies by specification. See wood finish chart for veneer selection based upon wood finish code. No substitution of specified veneer is to be made unless approved by sample and written notification. ‐Veneer must be dried to a moisture content of 7‐10%. ‐Standard veneer lay‐up: Slip‐match (unless otherwise requested)
‐Veneer is to be matched per panel
A3. Plywood
Plywood is a type of manufactured wood made from thin sheets of wood. The layers are glued together so that adjacent plies have their wood grain at right angles to each other for greater strength. There are usually an odd number of plies, to make the board less prone to warping. Guideline for Plywood ‐Standard panel thickness:1/4”, 3/4", 1”; ‐Standard panel size: 48” x 96” Bent plywood ‐ Curing Process
Radio Frequency ‐ best suited to smaller, unfinished components, radio frequency curing is similar to a microwave oven where electricity cures the moisture in the glue and veneer.
Induction Heating ‐ providing better control than the rf process, induction heating is used rather than electricity and can typically reach pressures up to 350psi. This process allows for pre‐sanded face veneers and is ideal for manufacturing larger finish grade products.
All bent plywood must be dried to a moisture content of 8‐12%.
A4. Hardware‐screws, dowels, floor glides, Swivel mechanism, Sleeper sofa mechanisms
Wood Screw
Long, Tapered body, sharp point, and aggressive thread and stainless steel or non‐oxidizing coating:
‐ Pre‐drilled holes in hardwood are required for all wood screws. ‐ Maximize screw length.
Dowels
‐ Spiral and multi‐groove dowels are requested instead of plain dowels.
‐ Strength in dowels increases with dowel thickness ‐ dowel should always be less than 50% of panel thickness. ‐ Dowel holes diameter in ends should be same or smaller than dowel depends on different base materials.
‐ Glue: Provide commercial, furniture grade to produce superior strength. Remove excess glue from visible areas before
finishing.
‐
Floor glides
Nylon Glide
‐ For items without doors, that don’t connect to other units.
‐ Black color.
Nylon Adjustable Leveler
‐ For heavy items with doors or items that connect to other units.
‐ Black color.
Wood leg
Nylon glide Nail in version, or screw in version acceptable
Wood leg
Insert Nut
Adjustable nylon glide
Metal Glide
‐ For items without doors, that don’t connect to other units.
‐ Used on wood floor.
‐ Nickel finish.
Metal Adjustable Leveler
‐ For heavy items with doors or items that connect to other units.
‐ Used on wood floor.
‐ Nickel finish.
Wood leg
Metal glide
Wood leg
Insert nut
Adjustable metal glide
Swivel mechanism
Sleeper sofa mechanisms Sleeper Mechanism: Contract quality, Leggett and Platt Classic 3500 with Anti‐Tilt Mechanism.
Instruction Label: Permanently apply operating instruction label to the webbing.
Sleeper Mattress: Beige ticking, 268 kg per m³ (1.3 lbs per ft³) density, 13.6 kg (30 lbs) compression. Springs are 3‐1/2
inch, 13 gauge.
A5.Foam ‐Comply with US CA117 minimum requirements (or equivalent) or governing codes that meet or exceed the following requirements. ‐Seat Cushions: 29.2 kg/m³ (1.8 lbs./ft³) minimum foam density, ILD (compression) 11.8 to 13.6 kg (26 to 30 lbs). ‐Seat cushion foam for public spaces ‐ 2.5 lb. per ft. minimum. ‐Backs: 24.3 kg/m³ (1.5 lbs/ft³) minimum foam density, ILD (compression) 6.8 kg (15 lbs) ‐Solid Foam Core: Cover with 2.5 cm (1 inch) layer of polyester batting. ‐Memory Quality: Provide sufficient foam quality to retain 85% memory for five years. Upholstered Arms: ‐Reinforce inside arms with cardboard or synthetic woven fabric padded with 2.5 cm (1 inch) of foam. ‐Cover outside arms with synthetic woven fabric covered by fabric. ‐Upholstered Outside Back: Provide foam pad and cover with fabric.
A6.Webbing
‐Webbing to be polypropylene ‐Staple and fold‐Staple one end just inside the bevel using 6‐9 staples. Fold the webbing over the staples to create a double layer, and staple this down as well, interspacing the first row. ‐Stretch and staple‐Stretch webbing across the frame using a webbing stretcher. The webbing should be tight but not enough to distort the frame. Anchor this end of webbing by staple and fold. ‐Over and under‐When attaching the side to side webbing, go over and under the front‐to‐back webbing to create a weave. ‐Seats must have sufficient webbing to support springs ‐Back rest must have woven webbing but can be partially webbed.
A7. Springs
‐Provide springs of sufficient quality to retain 95% memory for five years. ‐Provide a sufficient quantity of springs to ensure even weight distribution during use. ‐Seat Springs: 8 gauge ‐Back Springs: 11 gauge ‐Attach springs with steel clips. ‐Cover seat springs with steel wire flexolator or equal product.
A8. Zipper
Concealed Zipper
This is the standard for throw pillows and cushions.
Standard zipper is neutral beige, or black. Unless zipper of closer color match is available.
A9.Metalwork
‐ All stainless should be of a gauge appropriate to piece and have no objectionable weld joints. ‐Polishing must be done to a satisfactory finish, to allow for proper plating adhesion. ‐Plated and powder coated components must pass the salt test. ‐ Metal finishes must have clear enamel matte coating, clear rust inhibitor, baked enamel, or powder coated finish for humidity protection to prevent rust and corrosion. Manufacturer to ensure materials are non‐corrosive and suitable for use in high humidity and salt air locations as required. Electroplating‐ Electroplating is a process that uses electric current to reduce dissolved metal cations so that they form a
coherent metal coating on an electrode. Electroplating changes the actual surface properties of the metal.
Powdercoating‐ Powder coating is a type of coating that is applied as a free‐flowing, dry powder. The coating is applied
electrostatically and is then cured under heat to allow it to flow and form a "skin". It creates a hard finish that is tougher
than conventional paint. Powder coating can be non metallic, or contain metallic particles.
A10.Fabric specification
‐Abrasion Resistance: Pass minimum test requirement of 30,000 double rubs minimum, using Wyzenbeck (back and
forth) or Martindale (circular).
‐Flammability: Comply with US CA117 minimum requirements (or equivalent) or governing codes that meet or exceed
these requirements.
‐Finish Protection: Treated with water and soil treatment. Provide acrylic or latex backing and laminate for stability.
*Must be treated on the roll, not treated after applied to the frame.
‐Colorfastness to Light: Pass AATCC 16 Option 1 or 3‐2003: 40 hours, Grade 4.
‐Crocking: 4.0 dry 3.5 wet or better
‐Pill: Brush Pill ASTM D3511‐02, Class 4.5
‐Seam Slippage: ASTM D3597‐02‐D434‐95 for upholstery and panel fabrics, 2.4 kg/cm² (35 lbs per inch²)
‐Tensile Strength: Upholstery 3.5 kg/cm² (50 lbs per in²), panel 2.4 kg/cm² (35 lbs/inch²)
‐Latex or Acrylic Backing: Back fabrics with an exposed seam in seat cushion for stability.
‐Fabric Cleaning: Clean with water based methods.
‐Fabric Quality Specs: slubs on fabric are not acceptable, unless if it's part of their charms/ patterns.
‐Leather: Top quality, aniline dyed struck‐through leather, free of blemishes, scratches and holes for upholstery.
scar on leather slub on fabric
NFPA 260:
Test Method: A sample is placed over a standard foam substrate and exposed to a burning cigarette. Standard to Pass: Class I ‐ Char length less than 1 3/4"
Class II ‐ Char length over 1 3/4"
California Technical Bulletin 117 - Section E: (The standard industry code for seating-All fabrics must pass)
Test Method:2" x 6" sample is exposed at a 45 degree angle to a 5/8" pencil thin flame for 1 second. Standard to Pass: Sample must not burn more than 5" in 3.5 seconds.
B.Frame Construction standards
B1.Legs
Construction and Dimension standards ‐ Leg size for dining chair and vanity legs minimum at dining chair 1.75” at top tapered to 1.25” at base. ‐ Edge of all legs to have 3mm radius to prevent stain from chipping from sharp edge. ‐ Items larger than a dining chair (such as a sofa or lounge chair to have legs no taller than 6” height and minimum leg size of 2.25” at top, 1” at base. If design calls for 8” height legs must be American ash or European beech and a minimum of 2.5” at the top tapered to 1.25” at the base. ‐ Legs to not leave a cantilevered edge of more than 6” ‐ All dining and barstools must have stretchers. Barstools must have 4 stretchers. 3 sides with metal caps. ‐ All legs to be mortise and tenon joint with corner blocks, screwed and glued in the sides, and center with a large bolt. ‐ All chair leg corner blocks to be applied with finger grooves.
BORE AND DOWEL JOINT (Chair Stretcher Construction) Commercial glue to be used with all dowels. Conuntersink screw hole must be finished.
B2. Headboards Headboard standard‐wood cleat
‐Verify all headboards and side panels fit through hotel doors, through corridors and into elevators
C. Upholstery Standards
C1.Stitching and welting
‐Seam Depth & Stitches: Provide sufficient seam depth and stitches to eliminate seam slippage (opening).
‐Thread Quality: Provide thread of sufficient quality for contract use.
Stitching and Welting
I. Top Stitching
‐ The standard type of stitching of used in upholstery. Unless otherwise specified, this will be used.
II. Baseball Stitching
‐ This is an alternate stitch pattern used in upholstery (on request).
III. Single Welt
‐ Fabric is to be cut on the bias (Unless otherwise specified). ‐ Single welt can to be stapled to the edges of panels and seat boards, or stapled and hot glued inside the 3/16” x 3/16” grooves/channels of frames.
‐ Use 5/32” diameter cord for welting.
‐ Staple heads are to be hidden or painted to match fabric.
Welt that is sewn to the seat/ back cushion: welt has to be sewn on the stitch line. No stitch line should be seen in final result; welt should be tight and no gaps in between
C2. Loose cushions
Type of Loose Cushion
‐ Cushions that are separated from the item, allowing for a softer, more comfortable on back and seat. The covers can easily be removed and dry‐cleaned.
C3. Non‐reversible seat cushion
‐Cushions that can be separated from the item but attached with a velcro strap, allowing for a softer, more comfortable on back and seat.
C4.Types of seats
A. Spring Seatboard
B.Tight Webbed Seat on Frame
C. Webbed seatboard
A. Plain Seatboard
B. Drop in seat deck
F.Stretched Leather Back
G.No Sag Spring Deck
Note: All lounge chair and sofa with tight cushion and back must have No sag spring.
C5.Pattern Alignment
Pattern aligning specification
Directional fabric (fabric with lines) has to have line match from top, front, and bottom
Pattern fabric on seat cushion has to match top to front.
Top and bottom of seat cushion need to mimic to each other, Bottom of seat cushion does not have to match to front
Pattern fabric on back cushion should mimic the center of seat cushion
Pattern fabric on seat deck should mimic pattern in the seat cushion Fabric pattern or lines matching on zipper application
C6. Ergonomic chairs
Style: Provide task style with adjustable height and swivel, 5 prong spider base with dual wheel casters. Provide arms
unless otherwise acceptable to designer.
Clearance: Design to fit under desk with adequate legroom and clearance for arms, when applicable.
C7. Curved seating upholstery
‐Curved or formed seating must be upholstered tightly, so there is zero air gap between the foam and the fabric. This
includes leather and vinyl.
‐Glue should be of appropriate heat and wear resistance to withstand commercial use for 5‐10 years of service.
‐Upholstery should be free of wrinkles, applied smoothly to foam.
Example of same chair upholstered properly. Upholstery fabric conforms tightly to foam.
Example of unacceptable curved upholstery.
Has air between foam and vinyl.
C8. Throw Pillows
‐Standard Fill is a synthetic polyfill insert. Pillows with bolster shape or hard box corners may also be constructed with
upholstery foam with an over layer of batting for softness. Alternate fills such as down, feather are only to be used when
specified. Insert always provided, pre stuffed. Insert To be fully lined.
‐Cover must be removeable, All zippers must be concealed, and non‐corrosive, and of similar color to fabric.
‐Vinyl or non‐breathable fabrics to have small ½”grommet at the back near a seam edge for air escape. Grommet color
to be determined by designer.
‐Fabric must be a minimum of 39” wide. Pattern to be centered on pillow.
‐Button tufts, flanges, and welts to be the same fabric as the main face, unless specified otherwise.
‐Pillow size is based upon the dimension of the unstuffed cover. The insert will decrease the visual width by about 3”‐4”
in the center.
Pillow types: (custom types available)
Square Rectangular Box Bolster
Sizing based upon specification. Typical sizing as follows: (Custom sizes available)
Square (16”x16”, 18”x18”, 20”x20”, 22”x22”, 24” x24”and 27”x27”)
Rectangular (13”x19”, 15”x26”, 20”x27”, and 21”x37”)
Boxed (18”x18”x3”, 11”x17”x3”, and 26”x26”x5”)
Bolster (6”dx22” and 9”dx24”)
Decorative pillow sizes are based on the size of the fabric that is cut to make the pillow. For instance, to make a 20”
pillow, we cut two 21” square pieces of fabric. The extra inch allows for a ½” around the pillow edge to be sewn into the
seam, leaving an empty pillow shell that is approximately 20” from corner to corner. Once filling is added to the pillow,
added at 3‐4” of thickness, the pillow will not measure 20” wide. Due to filling, the pillow plumps out, pulling the sides in
giving a measurement closer to 17”‐18” of actual width from side to side.
Decorative Edge finish options:
(Knife edge is standard unless a decorative edge finish is specified)
Small self welt (.25”) Large self welt (.5”) Small self flange (1.5”) Large self flange (3”)
Tassel corner Trim edge Trim edge (right and left)
Tufts:
Button tufts are available in (1) one, (2) two, or (4) button patterns. Typically, the button Is covered with the face fabric,
unless specified otherwise. Typical button diameter is 1/2”‐ 3/4”.
D. Finish Standards
D1.Wood Finishing Standards ‐Casegood to be finished with commercial grade MPU finished of sufficient thickness and hardness to have a scratch resistant surface. ‐Casegood should be even finished throughout the entire inner and outer surfaces, void of dark and/or light areas. ‐No glue or overspray areas should be visible. ‐Veneered and hardwood finishes on each casegood, regardless of amount of each and placement, should match is finish color and tone. ‐Finishes must be completely cured prior to packaging for shipment. ‐All surfaces should be absent of dust particles, dirt, grease, finger prints and/or other material and blemishes prior to packaging for shipment. ‐Color of like finishes must be color‐fast, uniform and compatible between pieces manufactured in the same plant; between pieces made in various plants, and from one production cut to another. ‐Each finishing material must be formulated and individually batch‐checked to insure compatibility with the batch and every other material used to produce a color‐fast finishing system. MPU Finish (Modified Polyurethane Finish) This is primarily to create a finish system that offers a repairable top layer while the subsequent layers offer moderate protection so the applied color, glazing and highlighting is well protected. MPU Characteristic: Good wearability. Good heat resistance. Good solvent and household resistance. Good flexibility. Typical MPU finish steps: 1.Base stain application 2.Drying and sanding 3.Second color stain coat 4.Drying 5.Sanding(must be free of exposed glue) 6.Pad stain or Spatter stain or Glaze (applied by hand or sprayed) 7.Drying and sanding 8.Sealer topcoat 9.Drying and light sanding 10.Topcoat Note : Finishing steps may vary depending on the required application. Check moisture content prior to finishing. Best moisture content is 8‐ 10%, 12% maximum. All visible areas (inside and outside of product) must in same finish unless other specification. Finish on unseen areas are specified below unless otherwise stated. ‐Headboard back‐Stain and sealer ‐Cabinet back panel outside face‐Stain and sealer ‐All goods bottom face‐Stain and sealer ‐Bed slats and inner rail face‐Stain and sealer ‐Pedestal table back of top panel and sub top bottom face‐Stain, sealer and sealer ‐Side panels beside drawer face‐Need to be same as product surface finish 2” from the face side.
Color Chart ‐Wood
Standard Finish colors have an identifying code. The first letter “W”relates to the term wood. The second letter relates to the color family. “R” for red toned finishes, “B” for brown wood tones, and “G” for grey wood finishes. “S” are solid paint colors. The third is a number that correlates to the individual color, in order from light to dark. Example: WB1 is the lightest brown wood color in the standard set. WR5 is a red tone that is a medium darkness. After the color code is the material code. “C”‐Wilsonart China High pressure Laminate (Wilsonart code noted) “U”‐Wilsonart USA High pressure Laminate (Wilsonart code noted) “V”‐Veneer (species and cut, or engineered number with supplier information noted) “S”‐ Solid wood (species noted) All formulas of approved stain and paint on all substrates are to be retained by the finish department, for use for all projects. No substitutions of pre‐approved master sample materials for standard finishes will be accepted unless approved via sample and written request. If a custom finish is required for a specific project the veneer, hardwood, and laminate details to match that finish, along with the stain formulas must be recorded, and kept on record for future use. Those records are made after the laminate, veneer and hardwood samples have been approved by the designer, or manager. EXAMPLE COLOR SET OF MATERIALS
D2.Metal finishing standards
All stainless and aluminum parts should be of a gauge appropriate to piece and have no objectionable weld joints.
Metal finishes must have clear enamel matte coating, clear rust inhibitor, baked enamel, or powder coated finish for
humidity protection to prevent rust and corrosion.
Manufacturer to ensure materials are non‐corrosive and suitable for use in high humidity and salt air locations as
required.
Standard metal codes are specified using the following designations:
1. Each “color” is represented by a Letter.
2. Each “finish” is represented by a Letter. (P‐Polished, B‐Brushed, X‐Powdercoated)
E. Item Standard dimension tolerances
E1.Sofa and Lounge Chairs
E2.Ottoman
E3.Dining side chair
E4.Dining side chair with upholstery and back
E5.Dining arm chair
E6.Bench
E7.Bed bench
E8.Desk chair
E9.Ergo chair
E10.Table heights Vs. Seat height
E11.Sleeper Sofa sizing
Opening size for mechanism is 2” wider than unit size. Mattress is 8” less wide than unit width. Back must be 11” deep minimum. Depth must be 35.5” minimum. Apron top must be 13” high minimum, to hide mechanism. Feet must be 3” high.
F. Packaging standards
F1. Packaging Materials
Cardboard Cartons
‐5 layer B flute, 275 lbs per square inch. Edge crush strength no less than 8KN/m
‐Double wall thickness
‐Cartons are to be full flap top and bottom
‐Cartons to be marked with logo and information per provided template (see F3)
Foam wrap
‐Non sticky surface
‐2mm thickness minimum
Styrofoam sheets
‐3/4” thick standard
‐Main face density no less than 13kG, edge and corner density no less than 18KG
Cardboard and Styrofoam corner pad
‐Sandwich construction: corrugated 5 layer cardboard exterior with Styrofoam corner interior pad.
‐Used on corners of box style goods, and legs.
Compressed Cardboard L Column
‐Density no less than 300KG
‐Bond to inside vertical edges of carton, to provide vertical carton support.
‐Used in seating and other items with large voids of space inside the carton.
Wood skid
‐Used on the bottom of cartons that contain an item with legs. This prevents the legs from poking through the boxes,
when stacked.
‐Can be particle board, MDF or plywood.
F2. Packaging standard
All items:
Step 1‐Clean and inspect prior to packaging, insure QC passed sticker is present.
Step 2‐Wrap the item with foam wrap
Step 3‐Apply Styrofoam sheets to main flat surfaces.
Step 4‐Apply corner pads to all legs, and corners.
Step 5‐Tape firmly in place.
Step 6‐For items with legs, bond the compressed L column supports with hot melt glue inside the 4 edges of the carton.
8 10 2
Step 7‐For items with legs, add plywood to the bottom of the carton, and secure in place.
Step 8‐Item is inserted in Carton, taking care of correct direction of “this side up” arrows.
Step 9‐Mark each item with carton counts by hand on box marking.