Care and Maintenance Tips for Solid Surface

• Regular cleaning is easy using a non-abrasive cleaner and a damp cloth or sponge. If the product has a factory matte finish, then abrasive cleaners may be used. Follow the manufacturer's recommendations.
  
  
• Prompt clean up of spills will minimize even stubborn stains such as food dye, tea, fruit drinks, and some juices. For stubborn stains on polished surfaces, use full strength bleach for two to five minutes followed by a general cleaner, then flushed with water. On a matte finish, follow the same procedure or use a bleaching abrasive cleaner.
  
  
• Cigarette burns on the surface are usually a nicotine stain or scorch that can be easily removed by cleaning with an abrasive cleaner or buffing with a plastic (not metal), abrasive household sponge.
  
  
• Never set hot pans directly on a solid surface. Use a trivet or potholder to protect the top. Using your countertop for a cutting board will result in unnecessary damage that may require professional repair.
  
  
• Repairing superficial scratches is a breeze on solid surface products. Sand lightly with 350 grit sandpaper or buff with a plastic (not metal) household sponge. Deep scratches or chips should always be removed professionally.

Article Source: ICPA

Solid Surface Countertops

Solid surface countertops have been available for over 25 years. They are a product of the plastics industry. Plastics, in one form or another, dominate the kitchen and bath countertop industry. The vast majority of plastic countertops are made from thin sheets of plastic laminated to wood or wood by-product substrates. Solid surface countertops are simply that, they are solid plastic.

The solid nature of these materials offers distinct advantages. Colors and patterns are solid throughout the material. These solid surface materials have many of the same properties of wood, which allows them to be shaped and molded into countless shapes and figures. Because the material is plastic, special adhesives allow separate pieces of the material to be welded to one another to make one solid piece. These adhesives actually cause the plastic molecules of one piece to interlock with the molecules of the other piece.

Solid surface countertops do have distinct differences. Different materials are made from different plastics. Some materials are primarily acrylic while others are a blend of acrylic and polyester plastics. Those solid surface materials which have a high content of acrylic plastic seem to have higher performance standards.

Your concerns about durability are, for the most part, groundless. These materials have excellent characteristics. They have great impact resistance. Virtually all of them are nonporous, so they are unaffected by food and liquid stains. These nonporous surfaces also inhibit the growth of bacteria, mold, and germs.

A unique property of these solid surface materials is their ability to be easily repaired. Scratches can be buffed out by hand. Cigarette burns can be sanded away. Severe damage to the surfaces can also be repaired in virtually all instances. To the best of my knowledge, no other countertop material can make similar claims.

Solid surface countertops do have a slight drawback. Excessive, concentrated heat can damage the surfaces. However, this problem is frequently overcome with the use of decorative trivets made from the scrap material from the sink and cooktop cutouts.

You do have other alternatives, however, no single one seems to have as many advantages as solid surface materials. Natural stone products, such as marble and granite, can be difficult to repair. Solid color laminate plastics offer fewer advantages, yet cost virtually the same as solid surface materials.

Artificial stone products, because of their composition, do not seem to perform as well as the plastics. Remember, as with many other things, you get what you pay for!

Article Source:Ask the Builder

What is solid surface?

Solid surface is an acrylic material manufactured into flat sheet panels and designed for use in interior and exterior applications. It is suitable for a wide variety of residential and commercial applications including kitchen counter tops and bathroom vanities, restaurant table-tops and work surfaces, hospitality areas, healthcare, banks and other corporate environments.

Solid surface sheets may be bonded to each other to create a continuous, seamless surface that is suitable for both horizontal and vertical use. Most solid surface materials combine two main ingredients: a natural mineral, which serves as the filler, and a resin, which serves as the binder. These are combined and then cast in a curing process that results in a sheet or a shape.

The most common mineral is alumina tri-hydrate, or ATH. ATH is a refined form of bauxite ore and can comprise up to 75 percent of a sheet of solid surface. Bauxite is a form of clay.

ATH is chemical and stain resistant, water-resistant, fire resistant, translucent and is hard enough to give impact-resistance, but soft enough to be machinable.

Other materials have been used as fillers for solid surface. Calcium carbonate glass fibers and even recycled newsprint have all at one time been used as fillers.

Two main resins used in the manufacturing of solid surface are acrylic and polyester. A purely acrylic-based resin yields a sheet that is thermoformable. It can be heated, bent into a new shape and cooled without any loss of performance characteristics.

Polyester resins, including those that are mixed with acrylic, are used in demanding or high strength applications. With the addition of a catalyst, usually peroxide, the sheets are then cast and cured.

Casting of solid surface consists of mixing the resin with fillers and additives. The mix is poured into an open mold. Occasionally, molds are closed for products with shape. In casting, air bubbles should be avoided by either adjusting the viscosity of the mix or vibrating the casting table. Air bubbles in the material cause voids once the material is cured.

Some solid surfaces cure in the open air. Steam or ovens are sometimes used for curing. Many polyester resins require a heating-cooling cycle after curing, which increases the degree of cure. An improperly controlled cure can cause air bubbles appearing in the material, which effectively ruin it as a solid surface. Carefully controlling temperatures during curing is an effective way of reducing this risk.

Features and Benefits
• Durable: resists chipping and cracking and retains its beauty
• Renewable: scratches, cuts and burns can be sanded away
• Available in classic solid colors and versatile patterns
• Homogeneous composition for color and pattern retention throughout the thickness of the sheet
• Offers seamless, one-piece appearance
• Stain-resistant and easy-to-clean
• Nonporous and hygienic: dirt can’t be trapped, liquids won’t penetrate, bacteria and fungi won’t grow

Article Source: Moden Woodworking

Solid Surface Installation Guidelines

When working with solid surface products, it is important to remember that the fabrication techniques used will affect the appearance and performance of the finished installation. Training, which specifically addresses solid surface fabrication and installation, is recommended.

Proper conditioning of the solid surface sheets, along with other materials being used in the assembly, will minimize shrinking or expansion of the final installation. Ideally, all components should be conditioned at 70° to 75°F and relative humidity at or below 45% for 48 hours prior to installation.

Corner joints should be made square rather than mitered. This minimizes material usage and facilitates installation. To prevent stress cracking, seams should be placed at least 3” (76.2 mm) away from any corner or cutout.

All joints should be reinforced with a 4” (101.6 mm) wide strip of solid surface material and supported by framing. Joint edges should be straight, smooth and clean. To minimize the potential for stress cracking, exposed edges of the reinforcing strip should be chamfered.

For cutouts, use a router equipped with a sharp 3/8” (9.5 mm) diameter (minimum) carbide bit. The corners of a cutout must be rounded to a 3/16” (5 mm) radius and smoothed on both top and bottom. Inside corners require a smooth 1/2” (13 mm) radius. Larger radii are recommended whenever possible.

Solid surface is compatible with many commercially available caulks and sealants; however, a specially-formulated solid surface adhesive is required for making joints, repairs or custom edges.

Install countertops on perimeter framing support (without added substrate), using small amounts of silicone sealant.

Sheets of solid surface may be installed vertically over suitable substrates such as marine-grade plywood, water-resistant gypsum board and ceramic tile. Neoprene-based panel adhesive or white or clear silicone may be used. DO NOT USE WATERBASED ADHESIVES.

The recommended expansion clearance with uncaulked solid surface sheets is 1/32” (.8 mm) for every 8’ length. Joints to be caulked should be approximately 1/8” (3 mm) wide to allow for caulk penetration and expansion.

Article Source: Modern Woodworking

Solid Surface Tops Make Great Kitchen Countertops

If you're looking to do something different in your kitchen, you might want to consider the option of a solid-surface countertop.

Solid surface tops are manufactured from specific polymer blends, chemically engineered to be resistant to stains and acids. Besides good looks, solid surface material offers a number of benefits when used as a kitchen countertop. The material is solid color throughout; the color and pattern go all the way through the countertop. This differs from a plastic laminate top, which only has a surface layer of material over a substrate of plywood or particleboard, and even ceramic tile, which has a glazed color layer over a white core.

This translates to a top that is extremely durable and easy to maintain and repair. The material is non-porous and naturally resistant to a number of stains, so routine maintenance typically involves only washing with a damp cloth. But should you stain, burn or scratch the surface, you can literally sand it off. Depending on the severity of the stain, you can use anything from abrasive household cleanser to fine sandpaper to remove the discoloration.

A Look at the Options
You will find solid surface tops in a variety of colors and patterns. There are solid colors ranging from white and almond to several different colors. Solid surface materials are typically available in 1/2", and 3CM thicknesses. The 3CM materials are best for countertops, with the 3CM material being able to span greater distances unsupported. Refer to the manufacturer's specifications for specifics on span and weight-bearing capabilities.

Fabrication and Installation
For the experienced do-it-yourselfer, solid surface polymer materials can be cut and shaped with most types of standard woodworking tools, including table saws, jig saws, routers and drills. Carbide-tipped cutting tools are recommended. The material is hard and dense, and is somewhat similar to working with a hard, straight-grained wood such as maple. Fabrication takes care and patience, and you need to wear eye protection to guard against the possibility of flying chips.

Special seam kits, available from your material supplier, are used to join the pieces together at the corners and other areas. This is a two-part material similar to epoxy, and when done correctly, it produces a flawless seam that is virtually invisible. Read all manufacturers' instructions in advance, and follow them exactly for best results.

A better option is to have the tops professionally fabricated. After your cabinets have been installed, the fabricator will measure the exact size of each cabinet run, and will custom-make the counters to fit, including making cardboard templates of curves and complex areas as necessary. The tops are final trimmed on site, and backsplashes and other components are added to complete the installation.

Another advantage to having a pro do the work is the availability of a wider variety of custom edge treatments. You can choose from simple square or curved edges, or thicker and more complicated routed edges. You can also select from a wide variety of inlays to accent the front edge, ranging from simple color stripes to inlays of brass and other materials.

Article Source: Doityourself.com

Benefits of Solid Surface

Solid surface is a 100 percent manmade product, which means great diversity when it comes to color and texture variations. It is made of resin, an acrylic or modified polyester; alumina trihydrate, a filler which allows for a Class 1 Fire Rating; color pigments; and added particles that give a mottled, veined, or textured look to the surface. Solid surface is machinable and can be cut into about any shape imaginable. It also can be heated and molded. Solid surface is the only material that features molded sinks seamed directly to the countertop with no gaps or caulks. Built-in coved backsplashes can be fused to the countertop to create a water-tight transition.

Various additives allow for the creation of hundreds of looks, from speckles of granite particles to the swirls of a marble vein. Surfaces are available in finishes from dull matte to high gloss.

Solid-Surface Benefits
Solid-surface kitchen countertops offer homeowners the benefits of a warm-to-the-touch surface with low maintenance requirements. Normal wear and tear requires only soap and water cleanup.

Solid-surface products offer these benefits:

• Stain and chemical resistance
• Scratch resistance
• Easy cleanup
• Durability—The product is "homogenous" meaning the color and pattern are consistent throughout. There are no veneers to chip, crack, peel, or wear out.
• Long warranty. Solid-surface products generally come with a 10-year warranty.

Solid surface is manufactured to be stain, chemical, and scratch resistant, but it is not impervious to harm. It can be scorched and may crack if incorrectly installed too close to a high-heat producing appliance or if hot pans are placed on it. To prevent damage, homeowners are encouraged to use trivets or hot pads.

Wine, mustards, and other high stain producers could leave a mark if not quickly wiped up. Solid surface can be scratched and cut so homeowners are advised to use cutting boards. Damage can be repaired and the product restored often by using a non-woven scrubbing pad—such as Scotch Brite—or an or abrasive liquid cleanser followed by the pad to maintain the same appearance as the rest of the countertop. Always check with the manufacturer for their specific care instructions since care and repair options vary depending on the finish and the degree of repair needed. Deep scratches will probably require professional services, but repairs for cracks or chips can be practically invisible.