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Last updated 7 November, 2011

Cabinets on-Demand: General Construction details:

All cabinetry is supplied as flat-pack, meaning that the cabinet is supplied unassembled. A typical carcass-only cabinet flat-pack contains the two end panels (referred also as gables in some states), a bottom shelf, a middle shelf and a top rail (if it is a base cabinet) and a back all made from 16mm High Moisture Resistant (HMR)white melamine particle board.

The kit form cabinet also includes a front Door often in a specified colour finish or Drawers Fronts where applicable, as well as Adjustable Legs and all Hardware for assembly (plus some spare screws and cams in case you drop some).

The cabinet components are supplied pre-drilled (machined) and pre-edged, ready for assembly. All required assembly hardware, door hinges, drawer sides and runners and adjustable legs are included. The components are typically grouped together and packaged as one pack, however sometimes parts of another cabinet are bundled into the same package for packing optimisation.

All our cabinetry is manufactured to meet or exceed the Building Code of Australia (BCA) as described in: "Guide to KITCHEN & BATHROOM CONSTRUCTION - edition 2 September 2007" of the Housing Industry Association Ltd (HIA).

Our Board Products meet the specification of Australian Environmental Labelling Association (AELA 28 – Furniture and Fittings). (be wary of High Formaldehyde on imported products - see AELA Report 28

The various Standards and Recommendations are referenced in the text that follows. The publication is available from the HIA via their website hia.com.au.

The discourse here is based on the expectation that the person that is assembling these flat-pack cabinets has some basic Cabinet Making experience, because they are custom manufactured to the size that you specify and are not a modular, pre-set size. A general, detailed "Assembly Guide" will be distributed on CD-ROM with the delivered components - all of whom are individually labeled..

Any competent DIY'er should find the assembly process easy enough to follow. You will need the basic Cabinet Making tools, such as a drill, battery drill, hammer, etc to assemble the cabinets are further details are provided in the Construction Page of this Web Site.

Inclusions and Exclusions
Wall based units include a TOP, but Floor based units are EXCLUSIVE of a Benchtop and Kick Boards. These components normally cover more than one cabinet and should be ordered separately.

Bench tops are not included (unless ordered specifically)because:

(1) they normally cover more than one cabinet at the time and
(2) often these are typically either a Granite or a Man-made material (like Ceasa Stone, SileStone, RockSolid, etc.) which require a Stone Mason to cut & polish the bench top (often on-site).

Cabinets on-Demand does supply also High pressure Laminate (Laminex, Wilson Art) Benchtops that can be ordered separately. Other benchtop materials, such as Granite, Engineered stone, Corian, Stainless steel etc. will need to sourced from a local Supplier and we suggest that you either contact your local HIA (Housing Industry Association) who can provide you with a list of suppliers or browse through the Yellow Pages.

Kickboards and Fascias are not included as normally these are ordered to cover more than one Cabinet and are shaped on site to fit the cabinet configuration.

Shelving: All cabinets have at least one shelf standard, which are shaped and edged with 1mm PVC tape. Base cabinets have shelves set-in 80mm as a default, Upper cabinets shelves have a 15mm set-in, Walkin pantries have a 120mm set-in, these values can be overwritten to suit the user's need.

Door Handles are optional but: - handle screw holes are NOT pre-dilled as placement is better identified once cabinets are in place, and again depend on personal preference (For some doors you may have the handles centered and horizontal, for others (e.g. wall units) at the bottom and vertical).

Mounting screws or wall anchors required to fix a cabinet to the wall are NOT included either, because everyone has different fixing methods and it is also dependant upon the wall surface you are fixing the cabinet to (timber frame, steel frame, brick or concrete).

All the parts are supplied clearly labeled, so unpacking and sorting at the final destination is simple. The hardware to build the cabinets are supplied in the hardware box, this is typically a separate box with all the hardware for all cabinets in it. The smaller items (such as screws and cam fittings) will be grouped in bags & labeled, while the larger items (such as hinges and drawer runners) will often be supplied in separate smaller boxes. and all the hardware to build that cabinet (screws, cams, hinges, drawer runners).

Cabinets are constructed in accordance with the dimensions are specified by the user - this is our great strength - but of course can be made to conform to general standard measurements as shown below:

In general the standard floor based cabinets produced by most suppliers are 720mm high, with a kickboard of 130 - 150mm and a benchtop of 34 - 40mm, giving a bench height of 900mm. However current generations are taller than in the past, and many new granite benchtops are of 20mm, thus a cabinet height of at least 750mm is recommended.

There is no general recommended height for Upper (Wall) cabinets but the 'standard' heights provided here are 572mm, 720mm and 912mm.

Base cabinet Depth including Door width is recommended to not exceed 580mm, allowing for a 20mm overlap of the standard 600mm benchtops.
Upper(Wall) cabinet standard Depth is 320mm and not to exceed 350mm normally, but can be specified up to 500mm.

A side elevation suggests:

All cabinet construction is typical "butt joint" construction and follows the Euro method of construction (frame less method), which is typically used throughout kitchen manufacturers in Australia.

The internal cabinet material (carcass) is made from 16mm white H.M.R (high moisture resistant) melamine particleboard board, which is again typically used by kitchen manufacturers in Australia.

Hinges and Drawer Sides and Slides are supplied by Hettich for high quality fitting and easy adjustments.

All straight edging on the carcasses is 1mm white PVC edging (impact resistant) -for durability and longevity, but Melamine is used when PVC is not supplied, while 2mm PVC can be chosen at a small additonal cost per cabinet.

Door and Drawer Gaps are set to 1.5mm for both LH and RH sides. Other dimensions can be specified in the "Special Instructions" boxes. (See Below).

The ends (gables) run the full height of the cabinet, with the bottom shelf, top shelf or rail 'butting' into the ends.
The back is generally 'planted' on the rear of the cabinet (the back is full height and full width of the cabinet), however some of the manufactures have the back inside the cabinet. There is no right or wrong with this method, it is purely up to the individual manufacturer and how their factory is set up.

Cabinet components are typically all screw fixed together, using a range of self-tapping pozi-drive screws, with some other components requiring the knock-in cam & dowel type construction. In either case, the total required number of screws and/or cam & dowels are supplied with each order.

Some Cabinetmakers prefer to nail or staple the components together initially, before screwing them. Some also pre-drill the components with a pilot hole, to avoid the possibility of the material splitting when the screw goes in (more typical if the product they are screwing is of MDF construction). Others also use glue on the joints to assist in the strength of the butt joint. These are all optional additional construction methods and can be preformed if you wish, but things like the nails, staples, etc are not supplied with the kit.

The bottom of the Floor cabinets, Pantries & Wall Ovens are supplied pre-drilled, ready to ‘knock-in’ the Plastic legs. If you prefer to use the solid ladder style kick board construction, then you can just ignore the leg drilling and build your kick as you normally do.

Any curved parts with exposed edges that require edging will be typically finished in a 'T-mould' (as conventional edge-banders can only edge straight edges). If the colour of the curved part for is not a standard “T-mould” colour, then the traditional thinner melamine edge tape may have to be applied.

As each cabinet is custom manufactured to your specific size, there is no 'one all' step-by-step instruction manual that can cover the endless array of possibilities available, this is where your basic knowledge of cabinet making is required. We suggest that you carefully layout each part of the cabinet you are assembling and 'dry' assemble it if unsure. Even though the parts are clearly labeled and the supplied hardware sheet outlines the location of the hardware (with a brief description of its function/location), care needs to be taken to avoid using the wrong screw or assembling the cabinet incorrectly.

Before assembly of each individual cabinet, it is recommended that you layout the cabinet parts out and sort out hardware - before you start (as it may save you time in the long run and avoid mistakes).

Tools and Hardware required to assemble custom sized Flat-packs. As a minimum, you will need a battery drill with a pozi-drive bit, a hammer (to knock in the plastic feet), a tape measure and a drill.

Screw cover caps (dress caps) are an optional accessory and are not included in the standard Flat-pack, it's use is an individual choice for Cabinetmakers.

All parts are individually labeled and there is specific information on each of the labels relating to the individual parts name, sizes & unique cabinet number, to name just a few. You will find this very helpful in the construction phase and it makes the construction process very simple to follow & understand.
Note: the labels do vary from manufacturer to manufacturer. The example below is from the Canberra based manufacturer.

The following schematic shows a sample of "standard" cabinets used in the industry:

Sample Labeling

Cabinet components (parts) are individually labeled.

Details include Room & Cabinet Number, your Business Name, Job Number, Reference, Dimensions and an image of the part containing both the edge banding sides and the machining (drilling) details.

This is produced in conjunction with our own customised software and the state-of-art QuickCam & CABCODE systems, which form an integral part of our CAD/CAM method of operation.


Ordering Information.

For each Cabinet that you select in a particular Size /Price class you must specify as a minimum the EXTERNAL Height, Width and Depth - we work out the the rest from this.

Special Instructions.

This "Comments" type box, shown for each separate Cabinet can be used for additional machining instructions such as:

Left Hand (LH) Door/Drawer Gap e.g. =2mm
Right Hand (RH) Door/Drawer Gap e.g. = 1mm.

Material / Colour required for an Open Box (e.g.Microwave Box)

Size dimensions if these are outside the Pre-Priced ranges.


For Long Haul shipping the cabinets components are stored in a specially sized box, to be shipped as one or more "skids" - to ensure it can withstand the rigours of transhipments and rough handling by carriers. The skid, which can be 100 - 900 kg is loaded by fork lift in the factory and is easily opened at the Delivery Address by opening the top and removing the contents as required.

Unfortunately for outlying areas it is not always possible to provide door-to-door delivery for heavy skids - it those cases the customer may have to unpack his skid at a Depot or arrange local transport at a convenient time.
For City delivery to residential addresses we rely on the carrier or courier to ring in advance to ensure someone is home to accept delivery.

This web site is targeted at the competent handyperson (who already has a good knowledge of general cabinet construction) and primarily at the Kitchen Trade Professional, if you are not familiar with general cabinet construction or are not particularly handy, then you may require the services of a Tradesperson to assist in the assembly these cabinets, as there is no detailed step-by-step assembly drawings/instructions supplied. The assembly process is not complicated one and any competent Cabinetmaker will find this system a breeze.

For any DIY clients that feel that this may be beyond them, we can supply technical information, support, design advice and construction advice –Please refer to the ‘Support’ Tab at the top of this site for more information and a schedule of rates.

Additional Specific Cabinet category information.

Floor (Base) Cabinet:

Typically includes a solid back, bottom, left & right ends (gables), a top rail and typically a shelf. The bottom shelf is typically pre-drilled to accept the knock-in style plastic legs. This cabinet has no solid top, as it is not required (it has a rail instead)

Floor Drawers (Base) Cabinet:

Typically includes a solid back, bottom, left & right ends (gables), a top rail. The bottom shelf is typically pre-drilled to accept the knock-in style plastic legs. This cabinet has no solid top, as it is not required (it has a rail instead). The drawers are set as default to Hettich’s Multi-Tech M4 Steel sided drawer system and include the Drawer bottoms, backs, runners, front clips –Everything you need.

The Drawer base is made of a 18 mm HMR White melamine bottom (4) plus a Back panel (5).

The Metal sides and slide come in sets, two for each drawer and consist of a Slide (1) that is to be screwed to the cabinet wall, the Drawer Metal side (2) that is affixed to the Front panel with the mount (3).
The Hettich M4 series comes in a range of sizes:

Wall (Upper) Cabinet:

Typically includes a solid back, bottom, top, left & right ends (gables) and shelf(s). ALL parts are made from 16mm HMR allowing Upper Cabinets to be screwed easily to the wall without needing additional strengthening like some.

Floor Corner (Base) Cabinet:

Typically includes a solid left & right back, bottom, left & right ends (gables), two top rails and a shelf. The bottom shelf is typically pre-drilled to accept the knock-in style plastic legs. The shaped bottom shelf and any other shaped shelves have there exposed edges finished in a white “T-mould” or melamine style edge.

Wall Corner (Upper) Cabinet :

Typically includes a solid left & right back, bottom, top, left & right ends (gables) and shelf(s). The shaped bottom & top shelf and any other shaped shelves have there exposed edges finished in a white T-mould or melamine style edge.
ALL parts are made from 16mm HMR allowing Upper Cabinets to be screwed easily to the wall without needing additional strengthening like some.

Pantry Cabinet:

Typically includes a solid back, bottom, top, left & right ends (gables) and shelf(s). The bottom shelf is typically pre-drilled to accept the knock-in style plastic legs.

Under Bench Oven Cabinet:

Typically includes a bottom, horizontal shelf (for oven to sit on) left & right ends (gables), top front rail and a rear to rail. There is no backing on this cabinet, to allow for deeper style ovens to fit without modification to the cabinet. The bottom shelf is typically pre-drilled to accept the knock-in style plastic legs. Oven cabinets have the option of having a diamond shaped ventilation hole in both the Ovens horizontal shelf and the bottom shelf, as different ovens have different specifications with regards to ventilation requirements. Just tick if you want the ventilation holes. If the under bench oven cabinet is required to have a shallow tray drawer included, then automatically included in the flat pack is all the drawer hardware for this.

NOTE: If you require some type of specific machining or something non-standard, make a note on the products "Special Requests" prompt box and we will advise you on if it can be done and what the cost will be for it.

Last updated 7 November, 2011


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