Polyester

Hardness

Hardness is measured by a testing process called a Sward Test.  Using a Sward Test, glass is used as the base of a rating scale where glass equals 100.  Nitro-cellulose lacquer (the most commonly used) is rated at 20, KP Manufacturers and Smed Manufacturing use an acid cure lacquer that is rated at 28.  A modified urethane rates as 60 and polyester rates at 80.  As you can see, polyester is over 2 3/4 times harder than our standard lacquers and 4 times harder than a standard nitro-cellulose lacquer.

Clarity

Most lacquers today have a certain amount of nitro-cellulose present in them and as many people know, nitro-cellulose will turn yellow over time.  polyester, however, does not contain nitro-cellulose and does not yellow over, dramatically enhancing the clarity of the finish.

Sheen

The sheen of the polyester top coat is between 90 and 95 degrees.  This is due to the polishing process and also that the top is 100 percent filled.  A filled top is one that shows no grain porosity and has a smooth finish to the touch.

Keep in mind that the darker the colour the less the grain structure will show.  For example, a wood stained black will show as a solid black.  Light is absorbed by the black and does not reflect back, thus you will not be able to see the grain structure.  The darker the finish the more light surface scratches will show.  It is not that the finish scratches more, it is just that the light surface scratches are more visible against a darker background.

Application

Polyester will not, by itself, naturally adhere to wood or metal.  The first thing that is done before the polyester is applied is to apply a barrier coat (after staining and prepping of wood surfaces and metals) to ensure that the entire surface is secured.  This barrier coat migrates into the wood pores and attaches itself to the wood surface.  After a light scuff of the wood surface, polyester is then applied to the surface.  The polyester will mechanically or chemically adhere to the barrier coat.

Thickness

The most common question is “how many coats of polyester are applied?”, the answer is one.  Polyester is sprayed as a wet on wet application.  Once the first application is tacky the second application is then applied.  Most traditional lacquers have a mil build up of around 3 – 6 mils, while polyester has a standard build of 20 mils and can have a build of 50 mils in some unique applications.  The top coat is baked in a controlled environment of monitored heat and humidity.  This generally takes three days for shrink back and cure of the product to occur.

Solid Content

A standard lacquer is sprayed at around 30% solids.  Polyester is sprayed with a solid content of 98% solids thus allowing us to obtain the high build up of material quickly.  Since there is such a high solid content in the material there is over 400% higher raw material costs than traditional acid cure lacquers.  In order to actually spray this product we have had to develop a plural compound pump which mixes three products together internally at a very high fluid pressure.  Because of such high solids in the product a high fluid pressure is required.  Polyester is sprayed with a fluid pressure of 1200 psi where most common pumps spray at a fluid pressure of 30 psi.

Sanding

 After the topcoat has been allowed to air dry, for at least three days, the pieces are then sanded to 600 European grit.  Pieces that are under 6 inches or 150mm thick are face sanded by machine.  Then, sequences of polishes and creams are applied to further enhance the surface appearance and lustre.  These polishes and creams are power buffed and hand rubbed in order to obtain maximum results.

Shipping

Since there is a large mil build with this finish many pieces are reassembled after finishing to ensure their fit is maintained with other pieces.  Once the piece is completed it is wrapped with soft blankets, lowered into a plywood crate, sealed, and then shipped to the point of destination.

Why use polyester?

The one thing that a polyester finish will do that most other finishes will not do is magnify and bring to life the wood surface.  Again because of the mil build, wood pieces with an especially pronounced interlock grain , such as figured Anigre, Makore, etc., will become almost holographic in appearance.  Most standard finishes at some point in time will need to be refinished.  Usually this happens every four to five years.  polyester is a product that if light scratches do appear over time from general use, they can be sanded and buffed out.  This is normally done after hours.

Investment

Polyester protects your investment.  When you go to the trouble of designing and purchasing an exquisite piece of furniture, why not protect it by encasing it in polyester.  The closest and easiest way to relate this would be to compare it to house paint of all things.  If you bought $3.00 a gallon house paint you would end up painting your house every year because of wear and tear and the life of the paint.  If you bought $20.00 a gallon house paint you would end up painting your home every 10 – 15 years because the product is that much better.  You do not buy a BMW with a Lada finish.

Respect

Anyone that has or may have seen a polyester conference table will admit that this room will demand respect.  Many law firms and corporations have confirmed that people will tend to have a certain amount of awe and respect for a table with the polyester finish.  For example, if you had a plastic laminate meeting room table it would generally be exposed to all the daily meetings and consequently most of the abuse from incidental bumps and scratches.  A table that has a polyester finish will likely be in a room where dramatic impact is intended.

Logos

A recent development in polyester is the ability to inlay corporate logos and graphic designs into conference tables and faces of desks finished with polyester.  There are four basic methods; traditional (intarsia and marquetry), painted, tile, and multiple layered veneer logos.  Each method represents a unique character and cost.  Check with your local representative for more information and samples.

Care

To clean polyester all that is needed is a very damp cloth.  A damp cloth is one that when you twist the cloth tightly, no droplets of water will fall.  Simply wipe the table clean and it should look great.  If you have very stubborn marks or stains you may try a very mild glass cleaner or a mild dish detergent and water then rinse with clean water and dry.  The one thing to be careful of is that the cleaner does not leave streaks.

Maintenance

Once every two or three years you can also wax the table or other pieces that may have the polyester finish.  We recommend a product such as liquid car wax.  You would basically wax the surface as you would a car, with light automotive non-abrasive buffing wheels, preferably wool.  Be careful to remove any items within the room or area in which you are working that may react with the wax.  The wax, as on a car, will protect the film which is below the wax from damage.  It will more or less protect the finish from light surface scratching since the wax is much more easily repaired that the polyester.

Reparability

A polyester repair kit is available from KP Manufacturers.  The kit will repair most light dents reasonably well.  Keep in mind that any repair will always look like a repair if you look close enough.  Any repair on the face of a large expansive table is extremely difficult, if not impossible, to repair.  The greater the fill, sheen, and hardness the more difficult the material is to repair.

Limitations

While we are confident that polyester offers the best protection for your top surface, we cannot assure every client that they will not experience some form of surface scratching or indentations over time depending on the type of individual use.

While the product as shipped from the factory is relatively cured to 99.5% of its total hardness, the nature of the product is that over time it becomes exponentially more durable.  For the first thirty days it is recommended that the product be used with a certain amount of discretion so that the finish may achieve optimum results.

Prepared by KP Manufacturers