Solid surface

Solid Surface is a man-made material usually composed of bauxite, acrylic or polyester resins and pigments. It is most frequently used for seamless countertop installations.

Performance Characteristics

Solid surface is a non-porous, renewable, low-maintenance countertop surface. A man-made product, it has the ability to mimic the appearance of stone, wood and other naturally occurring materials, yet can be joined nearly invisibly by a trained craftsman. Typically manufactured in sheet form for fabrication into finished countertops, solid surface can also be cast into a variety of shapes, including sinks, shower pans and even bathtubs. Sheet goods can also be heated and bent into three-dimensional shapes using a process called thermoforming, which greatly adds to the flexibility and versatility of the product.

In a residential setting, solid surface can be used with excellent results as kitchen countertops, bathroom vanity tops and shower and tub surrounds. Countertop professionals, known as “fabricators,” typically seam solid surface sheets into desired shapes using a two-part adhesive, after which the cured joint is machined perfectly flat. The same technology is used to create extra thick edges, which can be machined using similar tools and techniques as those used to work with hardwoods.

A major appeal of solid surface is its seamless nature. Solid surface sinks can be joined to the countertop surface with no gaps, which eliminates areas for water to collect and bacteria to grow. Integral backsplashes can also be created that follow the contours of the wall “seamlessly” and without gaps.

Should the material become scratched or broken, solid surface can, in most cases, be repaired quickly by a trained fabricator to make the product look and perform “good as new.” Most manufactures offer a minimum 10-year installed warranty, but The Onyx Collection guarantees their products forever. Because solid surface is solid throughout, a countertop that has undergone years of wear and tear can be refinished to look as fresh and clean as the day it was installed. The installed product is available in a variety of finishes, ranging from matte to high-gloss, although most manufacturers recommend a matte or satin finish for ease of maintenance.

Solid surface is available in hundreds of colors and visual textures, ranging from solid colors to marbleized, granite effect or wood grain. Newly developed fillers and production techniques make it possible to create solid surface colors and patterns that transcend the natural, to mimic the technoculture of the 21st Century. Dozens of multi-national companies manufacture solid surface sheet goods and sinks for the world market; and hundreds of smaller, regional manufacturers produce for local markets with good results.

Although solid surface faces stiff competition from natural stone and quartz surfacing in the U.S. and in certain European markets, the material is wildly popular in Asia, particularly in residential new construction. An emerging market for solid surface is in commercial and industrial settings, where its non-porous characteristics, combined with exceptional durability, renew-ability and form-ability make it the material of choice for many designers and architects. Also appealing, is the wide range of colors and textures, as well as the ability to custom-color the material for large projects. Hospitals, in particular, employ massive amounts of solid surface for sinks, showers, nursing stations and wall cladding, because its seamless properties eliminate gaps and crevices that harbor harmful bacteria.

Fabrication

Solid Surface is manufactured by mixing Acrylic or Polyester resin with Stone (Bauxite) and pigments. Then, a chemical cure is operated, bringing the material up to 60°C or more. The material is then cut in sheets or shapes and sanded on one or both sides depending the brand used.

A additional step can be sometimes done: HI-MACS is also operating a thermal cure, bringing the material to 160°C and therefore improving the heat resistance. Marlan® is also operating a thermal cure. Acrylic-modified polyester solid surface can be mixed one sheet at a time using different formulations, affects and appearances. Quarrystone brand solid surface incorporates unique micromanufacturing techniques to achieve different affects.

Applications

Solid surfaces is used in the following environment:

• Kitchen/Bathroom: kitchen worktops with integrated sink, vanity countertop, bath tub etc.
• Hospitality/Catering: bars, tables, reception desks etc.
• Shop Fitting: displays, counters, wall cladding etc.
• Airports: check-in counters
• Public buildings: displays in museums, facades, meeting tables etc.
• Hospitals: laboratory countertops, decontamination sinks, endoscopy etc.

Advantages / Drawbacks

Recommendations. Anyone interested in a versatile, durable and renewable countertop product should consider solid surface as a viable decorative surfacing alternative. It is priced competitively to natural stone or quartz surfacing, is available in virtually any color or pattern and is backed by a 10-year minimum warranty. The material can be formed to practically any three-dimensional shape, which makes it particularly appealing to commercial and industrial designers. Because the industry is 40-plus years old, there exists a worldwide network of qualified fabricators that possess the skills and knowledge necessary to provide expert advice and customer service. It is a low-maintenance surface that does not harbor bacteria, and performs exceptionally well in high-use and/or constantly wet environments.

Limitations. Certain high-heat applications (anything above 400 degrees) are discouraged, due to the increased danger of cracking. Also, because scratches in solid surface appear white to the human eye, most dark colors are not recommended for high use areas.fr:Solid surface