Fabricating Cabinets Learner Guide
Fabricating Cabinets Learner Guide
Fabricating Cabinets Learner Guide
Supporting:
LMFKB3005A
Fabricate cabinets for
the built-in environment
Learner guide
Learner Guide
This unit is also available in an e-learning format, which contains additional photos,
interactive exercises and a voice-over narration of the text. It can be viewed on CD-
ROM, or live on the web at:
http://www.kbcabinetmaking.com.au/
www.workspacetraining.com.au
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Questions about the design and content of the resource itself should be addressed to the project
manager:
David McElvenny
Workspace Training
PO Box 1954 Strawberry Hills, NSW, 2012
Email: david@workspacetraining.com.au
E-learning version
All of these units are also available in an e-learning format, which contains additional
photos, interactive exercises and a voice-over narration of the text. The
e-learning version can be viewed live on the web at:
http://www.kbcabinetmaking.com.au/
The web version can also be purchased on a CD at a cost-recovery price from the
project developer:
ACT
Martin Jud – Canberra Institute of Technology
Victoria
Bryon Stanley – Furnishing Teacher's Advisory Group (VIC, SA, TAS)
Richard Brooks – Cabinet Makers Association
Simon Hampton – Wodonga TAFE
John Simpson – Holmesglen TAFE
Tasmania
Stephen Kirkman – Skills Institute Tasmania
Queensland
Rob McAdam – Skills TECH Australia
Brad Buhse – Skills TECH Australia
Roberto Viola – Gold Coast Institute of TAFE
South Australia
John Holst – Marleston TAFE
Dean Hart – Mt Gambier TAFE
Martin Videon – Furnishing Industry Association of Australia
Western Australia
Garry Michels – Polytechnic West
Keith Campbell – Polytechnic West
Adrian Boyling – Polytechnic West
David Boaden – Polytechnic West
Lorenzo Procopio – South West Institute of Technology
National
Laurie Kruize – Housing Industry Association
Financial contributions
This resource was largely funded by the Workplace English
Language and Literacy Program, through the Department of
Education, Employment and Workplace Relations. However, due
to the scale of the project and the provision of print-based and
website resources, additional financial assistance was provided
by the following organisations:
Disclaimer
The content of this learner guide is provided for educational purposes only. No claim
is made as to the accuracy or authenticity of the content. The views expressed in this
publication do not necessarily represent the view of the Minister for Education or the
Australian Government. The Australian Government does not give any warranty nor
accept any liability in relation to the contents of this work.
Introduction............................................................................................................... 1
Introduction
You will cover the actual operation of different types of machines and tools in other
competencies from your trade course. There’s a wide range of competencies
available, and your trainer will help you to choose the most appropriate ones for the
type of work you do.
Your choice is likely to include some or all of the competencies shown below.
LMFFM3023B Set up, operate and maintain planing and finishing machines
LMFFM3025B Set up, operate and maintain routing and shaping machines
LMFFM3027B Set up, operate and maintain automated edge banding machines
LMFFM3031B Set up, operate and maintain CNC machining and processing centres
Each section contains an Overview, an Assignment and Lessons which cover the
content material. Your trainer may ask you to submit the assignments as part of your
assessment evidence for the unit. You will find hard-copy templates for these
assignments in the separate Workbook.
Electronic ‘Word’ templates of the assignments are available on the website for this
resource, at: http://www.kbcabinetmaking.com.au/
The electronic versions can be completed on-screen and sent to the trainer either as:
• a printed hard copy, mailed through the post
• an electronic file, emailed as an attachment.
Practical demonstration
Your final assessment of competency in this unit will include various practical
demonstrations. Their purpose is to assess your ability to fabricate kitchen or
bathroom cabinets in a workshop. To help you get ready for these hands-on
assessment activities, there is a Practical demonstration checklist at the back of this
Learner guide.
The checklist sets out the sorts of things your trainer will be looking for when you
undertake the practical demonstrations. Make sure you talk to your trainer or
supervisor about any of the details that you don’t understand, or aren’t ready to
demonstrate, before the assessment event is organised. This will give you time to get
the hang of the tasks you will need to perform, so that you’ll feel more confident when
the time comes to be assessed.
Section 1
Manufactured
boards
Overview
The choice of which board product you should use for a particular job will depend on
a range of factors. These include how strong it needs to be, what fasteners will be
used, how much moisture it will be exposed to, and of course, the level of quality that
the client is prepared to pay for.
In this section, we’ll examine four common board products used in cabinet
construction. We’ll discuss their properties, typical end uses and main advantages
and disadvantages.
• Plywood
• Hardboard
• Surface treatments
• Manual handling.
These lessons will provide you with background information relevant to the
assignment.
Particleboard
Various additives are included in particular grades, depending on the properties the
board needs to have. For example, paraffin wax is used to increase the board’s
resistance to water and to reduce the swelling that occurs if it gets wet. Fire
retardants, insecticides and fungicides are also used to improve the board’s durability
and performance.
Advantages
Particleboard is easy to re-saw and machine. Nails and screws have reasonable
holding power when used properly, and joints can be glued for extra strength.
It is a very cost-effective substrate for plastic laminates and timber veneers, and it
does not swell or shrink, as long as it’s kept dry. Melamine-faced moisture-resistant
particleboard is particularly suitable for cabinet carcases and shelves.
Disadvantages
The biggest weakness of particleboard is its inability to resist moisture. Once it gets
wet and ‘blows up’, it doesn’t shrink back to its original thickness. Instead, the board
loses strength and becomes crumbly where it has swollen. Although moisture-
resistant board performs much better than standard board, it still needs to be
protected from direct wetting.
Another disadvantage is its rough edge, and inability to hold fasteners tightly when
fixed into the edge. ‘Helical’ nails and ‘chipboard’ screws help to overcome this
problem by providing more grip with their coarse threads.
Learning activity
Moisture resistant particleboard generally has a green tinge to
it, especially on the edge of the board. If you haven’t noticed
this before, go out to your workshop storage area or local
building supply company and compare the colour of a sheet of
standard grade board with a moisture resistant board.
While you’re looking closely at the edge, check out the three different layers. Why do
you think it’s useful to have a fine texture on the top and bottom faces and a coarser
layer in the middle? Share your answer with your trainer and other learners in your
group.
The end result is a sheet with a higher density than particleboard and an even
consistency right through to the centre. This allows MDF to be machined or routered
to a profile on the face and edge without the fibres pulling out or chipping. It can also
be sanded and painted to give a smooth finish.
Advantages
Disadvantages
Like particleboard, MDF does not tolerate wet conditions. Moisture-resistant boards
are able to cope with areas of high humidity and occasional wetting, but they still
need to be protected from prolonged contact with moisture.
MDF will also swell and shrink in response to changes in humidity. In locations where
dimensions are critical, MDF should be acclimatised for up to 48 hours prior to use
to make sure that its moisture content is in balance with the surrounding atmosphere.
Learning activity
Have you heard the term ‘acclimatise’ before? It’s the process
of bringing the board’s moisture content in line with the
surrounding atmosphere – or ‘climate’ – by letting the board
naturally take up or give off moisture into the air over a period
of time.
How would you do this if you had several large sheets? That is, how would you stack
the sheets to ensure that the air could circulate around all surfaces?
Write down your answer and share it with your trainer and other learners in your
group. If you have examples in your own workplace of methods used to acclimatise
board products, take some digital photos to include with your answer.
Plywood
The glues used in plywood vary depending on the strength and durability required.
They range from Type A, the strongest and most weather resistant bond, to Type D,
the weakest and least durable bond.
Type A bonds are used in most plywoods these days, because the benefits generally
outweigh the extra cost involved. However, Type C and D are sometimes still used in
interior ply with light-coloured veneers that might be discoloured by the heavy brown
Type A glues.
There are also four grades of veneer quality. These range from A Grade, which has a
high quality appearance designed for clear finishing or staining, to D Grade, which
contains various defects and is designed to be covered. Some manufacturers use the
term S Grade to refer to a high quality sliced veneer.
Advantages
Plywood is very strong and very stable. This is because the alternating veneers
maximise the natural strength of timber along its grain and minimise its tendency to
shrink across the grain. It also allows the sheets to be nailed or screwed close to the
edge without splitting. Panels that use Type A glue bonds are highly durable and
suitable for use in wet areas.
Disadvantages
Because the layers of veneer are bonded at right angles to each other, there can be
some tear-out on the edge if it is machined. The edge can also split when screws are
used unless pilot holes are drilled first. Another disadvantage is its cost – plywood is
more expensive than most other board products.
Learning activity
The second major difference is the joins that occur in sliced veneers where the
individual ‘leaves’ are laid side by side across the face of the sheet. You can see
these joins in any sliced-cut face veneers, both in plywood sheets and other timber
veneered boards.
See if you can find an example of each of these types of face veneers – rotary cut
and sliced. If you have a digital camera or mobile phone, take a photo of each one.
Send the photo to your trainer and other learners in your group. Try to name the
species of timber in each case.
Hardboard
Hardboard is often referred to by the trade name ‘Masonite’, which comes from the
Mason gun used to produce the wood fibres. In this process, the wood chips are
steam heated in a high-pressure cylinder and then released into a cyclone, which
causes the chips to explode into fibres.
Types of Hardboards
Advantages
Hardboard can be nailed or screwed close to the edge, and does not split, chip-out or
produce splinters. The board is also flexible and easy to bend into curved shapes.
Because of its strength and smooth surface it is ideal for cabinet backs and drawer
bottoms. It is also widely used in templates and jigs.
Disadvantages
Hardboard is a high-density material and tends to blunt cutters more quickly than
other board products. It tends to be only available in thin sheets – the standard
thicknesses are 3.2 mm and 4.8 mm.
Learning activity
Hardboard was once commonly used in kitchen and bathroom
cabinet backs and drawer bottoms. However, it is much less
popular now and has largely been replaced by melamine-faced
particleboard or MDF.
Do you use hardboard in any of your cabinets or other furniture items? If so, where
do you use it and why is it considered the best choice for that application? Share
your answers with your trainer and other learners in your group.
Surface treatments
Timber veneers
Learning activity
You’ve no doubt seen all of these surface treatments in various
kitchens, bathrooms and items of furniture. You may have also
seen combinations of treatments in a single panel, such as:
• particleboard sheets with a timber veneer face and white
melamine back
• MDF with a laminated face and a painted edge
(machined to a profile).
See if you can give an example where each of these surface treatments might be
used in a panel or component in a kitchen or bathroom installation. You may take
digital photos if you wish to help illustrate your answers. Share your findings with
your trainer and other learners in your group.
Manual handling
For more information on good manual handling techniques you should refer back to
the 'Manual handling' lesson in the Working safely unit.
Mechanical aids
There are various mechanical aids you can use to reduce the manual handling
involved in moving sheets around the workshop. Here are some examples.
Learning activity
Assignment
1. There are two main methods used to produce timber veneers. Name each one
and briefly describe the process.
2. What is MDF? How is its structure different from particleboard? What does its
structure allow you to do with the board that you couldn’t do with particleboard?
3. What is a ‘substrate’? Name the two most common substrate board products in
kitchen and bathroom cabinets?
4. What is the difference between a high pressure and low pressure laminate?
Include an example (such as a name brand) for each one.
5. Name four types of surface finishes commonly used on cabinet doors. For each
one state how the surface finish is applied and briefly describe its main
advantages and disadvantages.
6. Describe two methods you use in your own workplace to reduce the strain on
your body when moving large sheets of material around.
Section 2
Cutting and
edging
Overview
The assignment for this section will ask you questions about
the machinery and processes involved in cutting and
preparing components. Have a look at the Assignment on
page 34 to see what you’ll need to do to complete it.
Panel saws
Panel saws that are designed to cut laminated boards often have a scribing blade
(also called a ‘scorer’) in front of the main saw blade. It cuts slightly into the
underside of the panel before the main blade cuts through the full thickness. This
helps to stop the problem of ‘break-out’ occurring on the underside of the board,
where the surface chips out as the teeth pull through the material.
Types of saws
Types of blades
Kitchen and bathroom manufacturers generally use tungsten carbide tipped (TCT)
blades, because they are very hard wearing and suitable for cutting boards that
contain glues and laminated veneers. The tooth profiles can vary, depending on the
types of boards being cut. Below are the three most common profiles.
Square top teeth are ground square. They cut both sides of the
‘kerf’, or saw cut, at the same time, so they are fast and efficient.
However, they tend to tear out the grain or chip out surface
laminates at their exit point.
Learning activity
Have a look at the main blade used on the panel saw (or saws)
at your workplace. What type of teeth are they? Take a close-up
photo of the teeth, or alternatively do a line drawing of the
profile. Name the type of teeth, and share your answer with
your trainer and other learners in your group.
Cutting lists
If you were to draw up a cutting pattern by hand, you would start with the largest
panels and then use the offcuts to recover the smaller panels and components. You
need to take into account the direction of the grain if the panels are timber veneered,
so that they all match when they’re cut. The same applies to patterned laminates.
You also need to make allowance for the saw cut thickness – generally 3 to 4 mm –
between the boards. On a CNC (computer numerically controlled) machine, the
thickness will be greater because it uses a cutter rather than a saw blade.
Learning activity
1. Name the type of job that the cutting list relates to (e.g. kitchen cabinets
carcases, etc.)
2. What type of saw will be used to cut up the materials shown on the list?
3. Is the list printed out in hard copy or displayed on a computer screen (or
both)?
4. Write down each of the column headings shown in the list and describe the
purpose of each column.
Quality checks
If you don't, you may end up with twisted or bowed panels, which can play havoc
later when the time comes to assemble the carcase.
You should also check the edges of boards for damage when you’re taking them out
of the storage racks. Boards can sometimes have crushed or chipped edges if
they’ve been dropped on the floor or bumped with a forklift truck.
Once the boards have been cut to-size, the edges should be checked again for any
problems that might have been caused by incorrect saw settings or malfunctioning
machinery.
Set out on the following page are some of the problems that can occur. If you see
any of these issues in a board that’s just be re-cut, it's important that you tell the saw
operator straight away, because it may mean that the saw needs to be re-adjusted or
a part needs replacing.
Scorer kerf doesn’t align to main kerf Scorer is out of line with the main blade
Saw cut is not at 900 to the face of Main blade is not running plumb and
the board true.
Learning activity
Edge treatments
The process is either carried out in a static post forming machine or an automated
continuous machine. The simplest method is to glue the laminate to the flat area of
the bench top first, with an overhang where the rounded edge will be formed. The
bench top is then loaded into the machine and the area to be formed is heated to the
correct temperature.
The edging is usually done in an edge banding machine, which applies the glue as it
rolls the edging onto the board using pressure rollers. The machine also trims the
edges and snips the ends.
Boards with a timber veneer can be edged in the same way. At its simplest, a pre-
glued edge strip can be applied with a household iron, and then trimmed and sanded
by hand.
Note that the thickness of the edging will affect the gap
between doors and drawers, so it’s important to
establish this thickness before these components are
cut to size.
Painted finishes
Learning activity
Share your answer with your trainer and other learners in your group. You may
include digital photos of the machine and the process of rolling the laminate if you
wish.
Controlling dust
There are various problems with exposure to these dusts. Firstly, in some people it
may trigger an asthmatic attack or some other form of allergic reaction. But more
seriously, workers who breathe in these dusts over a long period of time run the risk
of developing cancer in their nose, lungs or other parts of their respiratory system.
Here are some general hints on how to keep the level of dust down in the workshop:
1. Keep machines, work benches and floor areas clear of dust. Use an industrial
vacuum cleaner rather than a broom to pick up dry dust. Place sweepings in a
suitable bin with a covering to stop the dust from blowing out.
2. Make sure the dust extraction system is working properly on all machines. Check
that the collection hoods are fitted correctly and there are no blockages in the
system.
3. Empty the extraction system bags or hoppers regularly, so the dust can’t build up
and overflow.
4. For jobs where you will be generating dust that can’t easily be collected, wear a
dust mask.
Learning activity
There will be separate MSDSs for all of the manufactured board products you use,
including particleboard and MDF. Choose one of these products and have a look at
the MSDS produced by the manufacturer.
If you don’t know where these documents are kept in your workplace, ask your
supervisor for help. Alternatively, you could simply find it on the internet - just enter
the brand name and ‘MSDS’ into your search engine and you’ll get a link directly to it.
Write down your answer and share it with your trainer and other learners in your
group.
Assignment
1. Name the parts labelled on the saw diagram below, and provide a brief
explanation of their purpose.
2. You need to cut the components shown below from a single sheet of 2400 x
1200 x 16 MDF. Once the components are cut to size they will be sprayed with a
high gloss polyurethane lacquer.
(a) Draw up a cutting pattern to show how you will recover these components
from the sheet.
(b) Just say the customer decided to use a sliced-cut timber veneer finish instead
of polyurethane lacquer. Could you use the same cutting pattern? Why or why
not?
3. Describe one potential quality problem that you should look out for at each of the
following stages of the production process. For each problem, describe the most
likely cause (or causes), and provide a possible solution.
(a) When the board is picked up off a stack held in storage.
(b) When the board is cut to size on a panel saw.
(c) When the board is edged on an edge bander.
Section 3
Assembling
the cabinet
Overview
In this section, we’ll look at the principles of constructing modular frameless cabinets.
They are ‘modular’ in the sense that they’re prefabricated in the workshop in
separate ‘modules’, and then transported to the site for installation as a set of
cabinets, often lined up in a row.
We’ll also cover the various aspects of workshop construction, including making
bases, assembling carcases, hanging doors and installing drawers.
The assignment for this section will ask you questions about
the assembly process for different carcases and components,
and the quality checks you should make to ensure that the job
has been done properly. Have a look at the Assignment on
page 52 to see what you’ll need to do to complete it.
Set out below are the main types of joints and fasteners used in pre-fabricated
cabinets.
Joints
Variations on the standard butt joint include the rebated butt joint and the mitre joint.
Conventional fasteners
Knock-down fittings
There are lots of different knockdown fittings on the market, many of which have
patented designs. They can be divided into three main groups.
System 32 construction
The holes are designed to house the hardware items used in the construction of the
unit, including drawer runners, catches, hinges and adjustable shelf supports.
Learning activity
You may use System 32 components at your workshop in
particular cabinets or other units. Even if you don’t, you will
have seen them used everywhere in flat-pack furniture
products, such as those sold by Ikea.
Take digital photos of your examples and share them with your trainer and other
learners in your group. If you don’t have a camera or mobile phone to take the
photos, do a line drawing of each one and label it with the correct name.
Bases
This type of base can either be prefabricated in the workshop or built piece by piece
on-site. For more information about on-site methods, go to the ‘Installing the base’
page in the unit: Installing cabinets on-site.
Adjustable legs are commonly used in bathrooms and other areas where moisture
could be a problem at floor level. They are quick to adjust and allow all boards and
timber to be kept clear of the floor.
Learning activity
Carcases
The rails are used to fix the underside of the bench top to
the carcase.
Learning activity
The most common method for fixing the back panel in kitchen
and bathroom cabinets is to use an external back.
Is this the method you use? Do you ever use other techniques
for particular jobs? If so, what are they, and what sorts of
cabinets are they used on? Share your answer with your trainer
and other learners in your group.
Assembly
Using screws
Be careful not to over-tighten the screws. There are several problems that might
occur if you did – the screw head could burr, the thread might chew out the fibres and
loosen the screw’s grip, or the veneered surface might de-laminate around the screw
head.
If the pressure is too low, the head of the fastener will sit
proud of the surface and need to be tapped in with a
hammer. If the pressure is too high, the head will
countersink too far below the surface and may damage
or split the board.
Remember to wear safety glasses when using air-powered tools. This will protect
your eyes from any fragments that might break off and fly out, as well as from dust
and other particles that will blow around each time a blast of air comes out of the
gun. You should also wear ear plugs or ear muffs while handling the gun.
Learning activity
Share your answers with your trainer and other learners in your group. You may want
to include digital photos with your answers.
Doors
B: adjustable cabinet screws – fix the mounting block to the inside of the cabinet, and
allow the doors to be adjusted vertically (up and down).
C: locking screw – used to lock the arm in place once any sideways adjustments
have been made (note that it needs to be loosened before screw D can be turned)
D: adjusting screw – used to adjust the door horizontally (from side to side).
Learning activity
Share your answer with your trainer and other learners in your group. You may take
digital photos to help illustrate your answer.
Drawers
Pre-finished drawers
There are various types of pre-finished drawers available. The main types are as
follows.
You'll find more details on drawer fronts and runners in the lesson 'Drawers' from the
unit Adjusting cabinets on-site. This includes simple installation and adjustment
procedures.
Learning activity
Share your answers with your trainer and other learners in your
group. You may wish to take digital photos to include with your
answers.
Assignment
2. Choose one type of concealed hinge that you use at work and provide the
following details:
(a) State the name of the manufacturer and product name of the hinge.
(b) List the items of equipment needed to install the hinge, including hand
tools.
(c) Briefly describe the process used to install the hinge.
(d) Name one quality check you need to make to ensure that the hinge has
been installed correctly and is working properly.
3. Choose one style of carcase you manufacture and provide the following
details:
(a) Name the materials used in the carcase.
(b) List all hand tools and fasteners used. If there is more than one type of
fastener, name each one and state where it is used.
(c) Describe the method you use to fix the back panel in position.
(d) Name one potential problem you need to look out for while carrying out
the assembly process and describe how you would deal with it.
4. Choose one drawer design you use in your drawer cabinets and provide the
following details:
(a) State the manufacturer and product name, if it is a patented drawer
system. If not, state the manufacturer and product name of the drawer
slides (and any other items of specialist hardware).
(b) List the different materials or components used in the sides, back, front
and base.
(c) Briefly describe the method used to fix the base into position.
(d) Briefly describe the method used to fix the drawer front into position.
(e) Briefly describe the method used to install the runners into the cabinet
carcase.
(f) List the main quality checks you should carry out to make sure the
drawer is installed correctly and running properly.
Practical demonstration
The checklist below sets out the sorts of things your trainer will be looking for when
you undertake the practical demonstrations for this unit. Make sure you talk to your
trainer or supervisor about any of the details that you don’t understand, or aren’t
ready to demonstrate, before the assessment event is organised. This will give you
time to get the hang of the tasks you will need to perform, so that you’ll feel more
confident when the time comes to be assessed.
When you are able to tick all of the YES boxes below you will be ready to carry out
the practical demonstration component of this unit.