The Case for Solid Surface

Solid surface, such as this bathroom fabricated in Hanex Grenicio color, can be used in numerous applications both horizontal and vertical and is particularly well suited for projects where hygiene is an important factor. PHOTO COURTESY OF HYUNDAI L & C

Solid surface has been around for more than 50 years now and is increasingly becoming the choice for healthcare, restaurant and hospitality applications because of its hygienic properties. Cleanliness and good hygiene are on pretty much everyone’s minds these days, but before getting into why solid surface is an intelligent choice for sanitary applications, just what is it?

Even with more than 50 years of development and refinement under its belt, many typical home or business owners, or even architects and designers, really have little idea of what solid surface is.

Solid surface, first invented in 1964 by Don

Slocum of Dupont ™ and released in 1967

under the brand name Corian ® , solid surface is a manmade material generally composed of

alumina trihydrate (ATH), which is a derivative of natural bauxite, and is mixed with acrylic or polyester resin binders (or some combination of the two) and pigments. It is then heated to typically between 140 and 160 degrees F and poured, most typically, into continuous sheets that are cut to a standard size. The sheets, which have the same color throughout (hence solid), are most commonly ½ in., but can be other thicknesses depending on the application and manufacturer (of which there are now many around the world).

Once the sheets are sized, most commonly 30 by 144 in. (although there are several manufacturers that offer alternative and custom sizes), they are sanded and then sent out through various distribution methods. Fabricators then purchase the sheets and use tools similar to woodworking equipment, to cut, route, sand and form them into countertops, wall cladding, furniture, signs and a variety of other products for use in residential, commercial and OEM applications.

In addition to being workable similar to wood, solid surface can be heated and thermoformed into curved and molded shapes. It can also be printed on using dye-sublimation techniques that deposit the ink just below the surface so the image becomes permanent. If it can be imagined, it can likely be created from solid surface.

One key quality of solid surface is that it is nonporous. This quality alone carries a lot of weight. It means that it does not need to be sealed and repels waters and most substances, such as wine, mustard, grease, “permanent” markers, hair dye, shoe polish, blood and other damaging materials that might potentially stain other surfaces, fabrics or any number of items. As such it is very low maintenance, easy to clean and does not harbor bacteria, mold or other fungus.

The fact that it is nonporous also makes it resistant to a variety of chemicals. Solid surface

is not impacted by chemicals like ammonia,

mild acids and trisodium phosphates, which are found in numerous household cleaners. It can

also be safely cleaned with a bleach solution, per

guidelines set forth by the Centers for Disease

Control (CDC) to kill viruses. While some highly

This leads to another common quality of solid surface — it is renewable and repairable. While durable and scratch-resistant, it can be scratched or broken with heavy or improper use. However, because of the homogenous color, in almost all cases scratches can be polished out by trained fabricators and even if broken, it can be repaired so that it looks and performs just like new. Most manufacturers even offer a minimum 10-year installed warranty.

Another quality of solid surface is that it comes in hundreds if not thousands of color and pattern options. It can be made to look like granite, quartz, solid colors, wood grains, veined stones, translucent colors and many others. Many manufacturers also will create custom colors for particular applications or to match logos, etc.

Solid surface can be joined nearly invisibly by a trained craftsman. That allows long stretches of material to appear as one piece and also unlocks the potential for integral sinks as well as coves. Coved solid surface means the material, even when in a butt seam, can be made so that there is a continuous flow with no cracks, crevices or seam visibility. The material can even be designed to perfectly follow the contours of a wall “seamlessly” and without gaps.

Typically manufactured in sheet form, solid surface can also be cast into a variety of shapes, including sinks, shower pans and even bathtubs. Sheet goods can also be thermoformed, which is when it is heated to a certain temperature and bent into 3-D shapes. When the material cools, the shape is retained

(Middle photo) Solid surface, like the Glacier White Corian used in this bathroom, are suitable for numerous uses. Not only can integral sinks be a great hygienic use, but it can be used for cabinetry, wall cladding, tubs, shower caddies and even ceilings and floors.

(Bottom photo) This operating room at University Hospital in A Coruña, Spain, is one of 18 at the facility clad in KRION K-Life solid surface designed by Casa Solo Architecture. The architects, which specialize exclusively in the healthcare industry, chose solid surface because of its durability, easy cleaning, antibacterial properties, chemical resistance and seamless joints. PHOTO BY ARUME PHOTOGRAPHY

(Above) Solid surface, such as Aristech’s Avonite, can be thermoformed for near limitless design capability, while also retaining its hygienic and seamless properties.

(Left) These beautiful shower walls with striking intricate patterns produced by MR Walls allow for seamless, coved corners for easy maintenance and even a shower bench and matching integral shower caddy.

permanently, which greatly adds to the flexibility and versatility of the product, both in terms of application and design.

While countertops are the most common use for solid surface, because of its aforementioned properties, it can be used in many ways.

When it comes to horizontal applications, countertops are just the tip of the iceberg. Tables, benches, furniture, commercial food prep areas, desktops, window sills, bar tops and even flooring are all potential uses for this material.

It is also suitable for numerous vertical applications. Among these are bathroom partitions, shower/wet walls, interior wall cladding, wainscoting, signs and even exterior cladding.

Another area for use of this material is OEM, custom or unique creations. Custom sinks, bathtubs, shower pans, switch plates, shelving, unique furniture, lighting applications, cabinetry, door pulls and both functional based and aesthetically pleasing art are all possible, as well as many things beyond. The possibilities are pretty much limited only to the imagination and skill set of the craftsman working with the material.

With at least a basic understanding of the material, its properties, fabrication techniques and popular uses, it begins to be easily seen why solid surface is highly suitable and growing in usage for healthcare, commercial kitchens and other places that can be potentially risky in terms of exposure to

This nurses’ station at Bryn Mawr Hospital in Pennsylvania uses two colors of LivingStone solid surface - Mink on the top and Nutmeg in the completer-assisted carved design on the front. LivingStone, like many brands of solid surface, is LEED, NSF and GREENGUARD certified.

PHOTO BY LIVINGSTONE ®

This waiting room designed by Casa Mata Architecture at the São Paulo Health Clinic in Brazil is fabricated from Durasein solid surface. Designed not only for hygiene, this project includes soft, warm lighting that pairs with the warmth of solid surface to be an inviting space. PHOTO BY PAULO SETUBAL VAN DEURSEN

This bathroom at Inova Louden Hospital in Virginia, was fabricated by ASST from LG HI-MACS Moon Haze colored solid surface. It shows the both the versatility and innovation inherent in the material.

harmful, illness causing agents and must be able to stand up against heavy use.

Antimicrobial – Solid surface is antimicrobial, in that it will not support the growth of bacteria, mold or other fungus, which makes it highly suitable for healthcare settings like hospitals, doctors’ offices, hospices and retirement homes. This also makes it desirable for commercial kitchens and bathrooms, which commonly come in contact with germs, and it goes without saying that these qualities are also great for household kitchens and baths.

Seamless – A major appeal of solid surface is its seamless nature. Because it can be joined with no gaps and coved connections, surgical room walls, ceilings and floors, showers/wet walls, coved backsplashes and integral sinks eliminate cracks, crevices and other areas for dirt, water, humidity, pathogens and other contaminants that build up and allow for bacterial growth.

NSF/ANSI Standard 51 Certified – Many, if not most, solid surface brands carry a certification that means it has been tested and is safe for food contact for all types of food. This is another reason why it is considered a safe product for use in commercial or residential kitchens.

– Another healthy certification that most solid surface brands have earned, this one means that it does not emit any of 300 gases that are considered harmful by Greenguard and does not pollute indoor air quality. This is just another of the factors that make solid surface a safe choice.

Once a solid understanding of the product is achieved that includes the numerous hygienic benefits, it becomes easy to see why the product continues to grow in popularity in the healthcare industry. It also shows what a great fit it is for restaurants and commercial kitchens, as well as any other application subject to high traffic or potentially harmful contaminants.

With growing fears regarding cleanliness, it can help to provide peace of mind to clients, but with good reason. However, because of the vast amount of color options and near-endless design possibilities, they don’t have to sacrifice looks for good hygiene.

Looking forward, with an aging Baby Boomer population, healthcare demands are expected to continue to grow, further driving growth of solid surface. As such, manufacturers, distributors, fabricators, architects, designers and all of the various entities involved in the creation and use of the product should make sure the potential of the material is understood. As always, this starts with educating the customer at all levels.

By doing this, the case for solid surface as a clean, durable, renewable and aesthetically pleasing option pretty much makes itself.

The International Surface Fabricators Association (ISFA) represents professionals in the premium surfaces industry. ISFA exists to help members increase profitability, quality, safety, and professionalism by facilitating education, standards, and camaraderie within the premium surfaces industry. For more information contact info@ isfanow.org.

Sometimes the best way to understand and deal with unforeseeable problems such as the COVID-19 pandemic, is to learn from peers and find out how others are responding. As such, ISFA reached out to several fabricator members to find out how they have been impacted and what they are doing to work through it. The following are responses from five of them:

markets do you serve? We fabricate laminate, solid surface, quartz, granite, marble and compact surfaces. We serve all markets from big box stores and residential to commercial work and new construction.

COVID-19? Initially we were most impacted on the big box retail front. I expect new construction to fall off (hopefully temporarily) as we move through summer, and most commercial work to be in a down trend through 2021. I think retail will improve as we enter the summer, and anticipate residential construction improving in the fourth quarter.

thrive” through the pandemic? We evaluated all positions within the organization to ensure they add value to the business, and made several adjustments. We also eliminated all overtime, which has been beneficial to our margins and bottom line. Additionally, we are updating our website to increase our online and retail presence.

markets do you serve? We fabricate granite, quartz, porcelain, solid surface and laminate. We work within the residential home builder, commercial, rehabilitation and some big box store markets.

COVID-19? It has been a challenge. Business has dipped, but we are working through it.

thrive” through the pandemic? We have taken some improvement steps to ensure we are lean in both our processes and our team.

markets do you serve? We fabricate laminate, solid surface, quartz, sintered stone and natural stone. The residential market is the biggest part of our business, with sales driven from a wholesale model to dealers and direct sales from our selection center. We also sell direct to builders, provide millworkers commercial work and have some direct general contractor sales.

COVID-19? The immediate impact was that many of our wholesale customers were shut down, so our sales were dramatically affected. We had recently hired on several employees who were training for what we expected to be a busy summer that we had to release. Commercial work deliveries were suspended until mid-May. Managers shifted attention to PPP loan applications and staff management with remote workers.

thrive” through the pandemic? We created split shifts in each work area with three- to fourpeople crews working 12-hour days Monday through Wednesday, and a second group Thursday through Saturday (paying them for 40 hours). We designated an area for installers only, and stagger shifts so only one crew is loading up at a time. It’s inefficient, but necessary to try to prevent one positive test from shutting down the entire business. It was survival mode in production, trying to keep money flowing in while keeping everyone as safe as possible. Administratively we worked to have equipment available for our office staff to work from home. This worked well and more efficiently than expected. Our selection center is “by appointment,” which also works well. Customers have been very good with distancing policy at both measure and installation, as everyone wants to remain safe. We created scripts for our staff member who sets up all field appointments as well as our crews who call ahead to ensure everyone is on the same page before arriving at the jobsite. Commercial business appears to be the most affected. We were pressed to maintain delivery schedules early on, then were told to cancel deliveries until further notice. We’ve restarted shipments on current projects, but are concerned with longterm issues within education and healthcare business that have been our consistent commercial segments. We strive to communicate consistently with business partners, customers and suppliers. We’re diligent in following up on all proposals/ quotes and candid with customers – their projects are important to us and we need their business. The biggest challenge is communicating with staff working different shifts or from home. We provide email updates, sharing what our sales trends look like, our key benchmarks for returning to normal schedule and policy regarding cleaning, social distancing and mask use. We are evaluating new opportunities, realizing there are going to be lasting economic impacts to work through for some time. There is a tremendous effort being put forth by many professionals to help all businesses increase their odds of surviving this mess. We take advantage of these learning opportunities that might help us during this crucial time. Most importantly, we try to remember the old adage — when a door closes, a window opens, and keep looking for the window!

markets do you serve? We fabricate granite, marble, soapstone, onyx, limestone, quartzite, and semi-precious stones, as well as Dekton, Neolith and Lapitec compact surfaces. We provide fabrication and installation for residential and commercial building, with a focus on sustainability, eco-friendly technologies and a dust-free workplace.

COVID-19? During this unique situation we

continuously look at the impact it might have on our clients, team members and industry, covering everything from how the virus affects jobs to what the future outlook is among homeowners and contractors. Our team serves in subcontractor roles to many area general contractors whose work is considered “essential” under our state and local government restrictions. The health and safety of our clients and staff is top priority. Some of the areas we have been confronted with are homeowners concerned about money/finances; homeowners who do not feel comfortable for contractors to be in their homes; and contractor’s ability to pay for services rendered.

& thrive” through the pandemic? We established protocols to ensure team members in our showroom, workshop and on jobsites are healthy. We immediately enforced daily temperature monitoring. We created a COVID-19 Safety Precaution Certification for our teams regarding entry into jobsites. Name and signatures of our team members and a short questionnaire are submitted to our general contractor clients. With the situation still developing and having local and global impact, we are continuously monitoring and making adjustments to our operating plan, as appropriate. We are surviving and being cautious. We made the following decisions: We trust science, not politics; we put employee health first – no one is safe until we are all safe; we work to strengthen trust – team members need to trust leaders, so we show them empathy and engage them in the decision process; we are equitable, treating everyone equally with fairness; we redesigned the workplace to practice social distancing and require anyone ill to stay home; and we mandated protective equipment, providing masks, gloves and hand sanitizer, along with encouraging frequent hand washing and giving each individual a zone in the shop they are responsible to keep clean.

markets do you serve? We fabricate laminate and Thinscape. We serve the commercial, residential, big box store, builder and multifamily residence markets.

COVID-19? Although we have been impacted like much of the rest of the country with decreased sales, they have been coming back and we feel very fortunate to have been an essential business and allowed to keep running throughout this time period. We have been consistently following our governor’s orders and CDC guidelines to keep employees healthy and safe.

thrive” through the pandemic? We frequently update our employees and customers as to best practices for health and safety, the positive flow of our raw materials and consistent delivery of our products. We have also distributed a plan in response to our governor’s orders to keep employees, customers and suppliers healthy and safe.

We’re all in this together, and ISFA is here to help. Check out both our Maker Meeting Mondays online conferencing to discuss ideas with your peers every Monday at 2 p.m. EST and the COVID-19 resources page on our website at www.isfanow.org.