3 Things You Must Know About Solid Surface Material

Transcription

1 3 Things You Must Know About Solid Surface Material Contents Part 1: Common Problems Part 2: What is Solid Surface Material? Part 3: Pros & Cons

2 Part 1: Common problems One of the most common problems we hear from architects is that there is little information about the basics of solid surface material available. Furthermore, to innovate and improve spaces, we need better materials, a greater understanding of the material, how craftsmen work with it, the problems they encounter and the solutions they discover. Only then can we truly maximise the benefits. Helen Kerr of Kerr & Company said If I was trying to do front edge, innovative work I would be met with resistance. It s better to meet resistance with deep knowledge. That makes you a better designer. This white paper looks to draw knowledge and experience from the experts and bring it all into one place for your benefit. In this White Paper we will explore: Durability and expected life Preparation required Application Sustainability Maintenance and cleaning requirements 2 3 THINGS YOU MUST KNOW ABOUT SOLID SURFACE MATERIAL

3 Part 2: What is Solid Surface Material? What is Solid Surface Material? In 1963, the concept of solid surface was arrived at by a group of engineers and researchers from the DuPont Chemical Company. The idea behind their invention was to have a surface that resembled natural stone, but unlike stone, was non-porous, thus promoting a cleaner and bacteria-free surface. Composition Solid Surface is a composite of 70% aluminium trihydrate (a natural mineral filler derived from bauxite) and 30% acrylic or polyester resin and add natural pigments for colour. Click here for a selection of brands Corian, Hi-Macs, Avonite, Staron & Krion. Each manufacturer brand has its own unique composition. Solid Surface material is supplied in sheets of varying thickness. 12mm is the most popular. Other grades are 4mm, 6mm, and 19mm. Preformed shapes are widely available. Manufacturing Journey 1. Bauxite Mined & Processed 2. Materials Mixed 3. Heated Up & Poured Into Sheets 4. Sheets Cut Into Pieces 5. Pieces Glued & Finished 6. Transported & Installed On-site 3 3 THINGS YOU MUST KNOW ABOUT SOLID SURFACE MATERIAL

4 Part 2: What is Solid Surface Material? Uses & Applications Kitchen Worktops Washroom Basins Exterior Cladding Reception Desks Furniture and Furnishings Interior Wall Surfaces Art Objects Laboratory Countertops Fixing Methods Solid Surface material can t be screwed into directly. The solution is Squirrel Fixings. One fixing can hold the equivalent weight of 5 people. (M8 Squirrel fixings are FIRA tested to 450kg each!) Seamless Solid Surface Finishing is the critical part and finishes can vary depending on the competence of the craftsman. Fabricators and installers should be certified. Finish will vary according to your requirements, however to achieve a finish which is easy to maintain in daily use, a matte or semi-gloss finish is recommended. Depending on the finish the product is taken through at least three sequences from coarse to fine (for example 80 grit sand paper to a paper towel). Substrate and Support All sheets must be supported on a strong perimeter frame that will keep the surface level for its useful life. Typically, MDF (Medium-density fibreboard) or plywood is used as a substrate, bonded with silicone, neoprene panel adhesive, or flexible polyurethane adhesive. At Lovair we use an adjustable metal frame and a unique rib cage system to prevent the use of materials that can be affected by moisture. Thermoforming Solid Surface sheets are warmed to approximately 180 degrees, on a heat bed. The heated sheet becomes floppy, and is then vacuum-formed over a mould for 120 minutes. Products can also be pressed. Talk to us to discuss radius and dimension parameters. Fabrication process Standard wood working tools such as CNC (Computer Numeric Control), saws, routers, sanders, clamps and templates are used to fabricate solid surface into virtually any design. 4 3 THINGS YOU MUST KNOW ABOUT SOLID SURFACE MATERIAL

5 Part 2: What is Solid Surface Material? Finishing and Polishing It starts with a perfect butt join. The join is pulled apart 3mm. Colour matched two part joint adhesive is added into join. Sheets are pushed together and clamped. Join is reinforced using a covering strip to the bottom of the join. Glue is left 45 minutes to cure. Once dry the seam is finished with a sander. This means the solid surface length constraint is only the site transport route. Reinforce all seams with 12mm joint reinforcement strip. Clean the seam with clear denatured alcohol and clean white cloth. Apply joint adhesive to the reinforcement strip. Push the sheets toward each other leaving a 2mm gap. Push sheets together to close the seam. Clamp up without over tightening Rough out excess glue. Sand. Internal and External Coved Corners Coving is created by inserting an additional piece in the seam between two right angles that is rounded to provide a seamless coved seam. 5 3 THINGS YOU MUST KNOW ABOUT SOLID SURFACE MATERIAL

6 Part 3: Pros & Cons Each material has its own pros and cons. Here s an overview of some of the key features and analysis to help you come to your own decision. PROS Seamless Materials such as natural stone, quartz stone or laminate require either an abut or silicone joint. Solid surface joins are inconspicuous. These joins can be both done in a workshop or on-site. The seamless look for integrated surfaces, sinks, objects means there are no crevices to trap dirt and bacteria. Weight 23 kg per m2 (12mm thick sheet). It is approximately half the weight of natural stone or manmade quartz stone. Colours Some brands offer up to 110 options ensuring an almost unlimited working palette. Please note dark colours are difficult to achieve inconspicuous joins. Please us and we will send you a sample. Cleaning and Maintenance The material is inherent therefore colours and patterns run through the entire thickness of the material and cannot wear away or delaminate. The ability to cove corners reduces dirt traps that are prevalent with square edge joints. Solid surface is non-porous so spills and stains remain on surface. The material is restorable with household mid-abrasive cleansers and a scouring pad (e.g. cigarette burns can be removed this way). Vandalism damage can usually be repaired on-site without the need to replace the whole installation. Unlike other materials damage can be fixed. There sometimes are light superficial visible marks under specific lighting conditions. Some chemicals can stain, discolour or damage surface e.g. Strong acids, solvents. Use soap and water or common detergents to remove most dirt and stains. Stubborn stains are removed using abrasive detergents (e.g. Jif) with abrasive sponges like Scotch Brite. If a piece is broken off or non-repairable damage is made the offending area can be routed out and a new piece stitched in seamlessly. If a cleaning regime is adhered to the product is kept like new. 6 3 THINGS YOU MUST KNOW ABOUT SOLID SURFACE MATERIAL

7 Part 3: Pros & Cons Sustainability Solid surface is durable and renewable; it has an extensive lifecycle and can be easily repaired and renewed. Because it is re-workable solid surface typically generates up to 1/3 less waste than stone in the fabrication process. Dupont Corian solid surface and cured adhesives are Greenguard indoor air quality certified for low VOC (Volatile Organic Compounds) content and emissions. It s a non-toxic and inert material that is nonallergenic to humans. LEED CRITERIA - POINTS MR & EQ Credit Description Performance Points 1.3: Building Re-use Maintain 50% of interior 50% 1 non structural elements. 3.1: Materials Re-use 5% 1 3.2: Materials Re-use 10% 1 4.1: Recycled content 10% post consumer + 10% 1 1/2 pre-consumer 4.2: Recycled Content 20% 1 5.1: Regional materials 10% extracted, processed and 10% 1 manufactured regionally 5.2 Regional materials 20% extracted, processed and 20% 1 manufactured regionally EQ Credit 4.1 Low emitting materials: Adhesives and sealants 20% 1 To learn more about points within SKA, LEED and BREEAM, please speak to us or book a face to face meeting with one of our experienced technical team. CONS Value & Tactile Perception Solid surface has a softer, warmer feel than stone which can be perceived as lower value than cold natural stone. Cost Cost per 3658mm x 760mm sheet white is approx It is one of the least expensive materials to fabricate into customised sizes and shapes. Note the general rule is the more pigment the higher the cost. White will always be the cheapest. Some brands have colour price brands from 0-4. Heat Although solid surface can withstand high temperatures it needs to be protected against direct heat. Quality of Finish The quality of finish is dependant on qualified fabricators and installers. Substrate When timber is bonded to solid surface material the product becomes very difficult to re-use or recycle. Timber substrates in wet areas have known to expand and contract opening up seams. 7 3 THINGS YOU MUST KNOW ABOUT SOLID SURFACE MATERIAL

8 Need Specific Advice for Your Project? If you want to have a chat with one of our technical team, click on the link below. Arrange a meeting 8 3 THINGS YOU MUST KNOW ABOUT SOLID SURFACE MATERIAL

9 Lovair & Solid Surface Material Lovair have been designing and manufacturing Solid Surface Material products for over 7 years. Design, testing, production and installation criteria are all approached in a deliberate and thoughtful manner, a way of working we believe is in the company s DNA. Corporate Slab Latherwash The scope of products are a fit for commercial, public, transport and education washrooms. How a Lovair Leatherwash is Made Corporate Slab Curewash Arrange a meeting 9 3 THINGS YOU MUST KNOW ABOUT SOLID SURFACE MATERIAL

10 Lovair s Purpose Washrooms dramatically affect the experience of a building, reinvigorating users and satisfying the senses. For far too long, though, washrooms have been an afterthought- often the last room in a building to be designed and the space given the least consideration. Lovair set out to change that, rethinking the washroom and revealing its potential. Manchester 27 Pavilion View, Newby Road, Newby Road Industrial Estate, Hazel Grove, SK7 5DA London 5th Floor, 22 Upper Ground London, SE1 9PD Los Angeles 5450 W. 83rd Street Los Angeles info@