Solid surfacing materials are composed of polymerized monomers, resins, mineral fillers and additive pigments. The polymerized monomers and resins are made up of acrylics (PMMA – Polymethylmethacrylat) or polyester resin. Aluminium-(tri)hydroxide (ATH) is the primary mineral filler. The fact that acrylid solid surfacing materials are approximately two parts inorganic matter and one part pure acrylic resin (PMMA) contributes substantially to their favourable material properties. This material is homogeneous, solid, does not flake, and boasts a high degree of brilliance and colour fastness. Different manufacturers carry acrylid solid surfacing materials in board format and in varying sizes and thicknesses. In addition, modelled forms (sinks and washbasins) are available in different sizes and colours. Acrylid solid surfacing materials can be processed mechanically (milling, water-jet cutting, grinding, etc.Aided by CNC milling technology, three-dimensional forms, and intricate patterns and details can also be achieved. With sanders and polishing machines, the surfaces can be made semi-glossy or matt, or can be given a rough texture. Two- and three-dimensional thermoforming is another common way to work the material. The boards are placed between heating plates, heated to a temperature of 165 °C, and then transferred to wooden or metal forms to be shaped. The material can be curved in two dimensions to an inner radius of as little as 25 mm.
The surfaces of acrylid solid surfacing materials have great potential for variety. Boards which have received surface treatment as, for example, sublimation (see ill. 11), imprinting, and mechanical structuring, can be thermoformed afterward. Imprinted effects are achieved with bas relief techniques. To arrive at a texture, the board is heated to 160 °C and then “stamped” with the desired pattern. The stamp can be made of off-the-shelf perforated metal, checquer plate or even barbed wire. In addition, the surface can be engraved with the standard carbide tools or sandblasted. Stamping is well-suited, e.g., to wall cladding or signage. Inlays in different colours or materials are also possible, but metal content should be avoided due to its high thermal expansion.
Because its surface is non-porous, this low-maintenance material is well suited to use in areas in which hygiene is crucial, because neither bacteria nor mould can penetrate it. The surface may be vulnerable to some chemicals, such as powerful acids, ketones, chlorinated solvents, powerful mixture of solvents or powerful disinfectants. These could soil or damage the surface. In applications in which these agents might be present, thorough consultation with the manufacturer or subcontractor is recommended.
Acrylid solid surfacing materials are long-lasting and sustainable. By cleaning and/or sanding the material, the original surface can be restored. This applies not only to small cuts, scratches and spots (e.g. burn marks), which can be removed without professional assistance, but also to marks caused by chemicals, graffiti, vandalism or exposure to high temperatures. Partial replacement of material can also be advantageous. Acrylid solid surfacing materials and the adhesives used to work it should be low VOC (Volatile Organic Compound). Corian’s colours are all food-safe and free of heavy metals. The material is non-toxic, and under normal temperature conditions degassing does not occur. If incinerated, it releases primarily carbon dioxide.
Acrylid solid surfacing materials are suited to both interior and exterior use: for use in kitchens and bathrooms, as well as for reception counters and bars in hotels and restaurants; for presentation surfaces in museums and exhibitions; shop designs; furniture-making; lighting concepts; and in art and design. Outdoor applications – for street signs, benches, storefronts and building envelopes – have also recently been introduced.
Acrylid solid surfacing materials are hard and free of pores, lightfast, hygienic, flame retardant, easy to clean and reparable. The individual boards and elements can be adhesively joined to appear to have no seams, so that large-scale objects give the impression of being monolithic. In interior use, Corian expands about 1 mm/m (at a temperature difference of 30 °C). Accordingly, expansion joints corresponding to the length of the board must be provided for.
Frost-resistant to -40° Celsius, acrylid solid surface materials also have favourable load-bearing capacity and impact strength, are (air)pollutant resistant and easy to clean. The panels must be mounted on the load-bearing surface or support structure in a manner that allows the material to expand and contract. For calculating minimal expansion joints in facade cladding, the following formula applies: 35 ≈ 10-6 ≈ L (length of the element) ≈ ∆ (greatest expected temperature difference in C°) in mm. Joints requiring sealing should be about 5 mm wide in order to allow for expansion and the amount of sealing material required to be effective. Materials such as silicone or polyurethane are well suited because they retain their elasticity.
The degree of translucence is determined by the material’s colour and the thickness. Light-toned mono-colours such as white and beige are highly permeable to light, dark shades are less so. Translucence can also be achieved by reducing the thickness: the thinner the material, the more light shines through it. This could be done by milling or engraving. CNC milling makes almost any imaginable pattern and design possible. Varying the depth of the milling gives the material a three-dimensional effect.
