Countertops

Epoxy Resin

Epoxy resin, silica, fillers and a hardener are mixed as a viscous liquid. The liquid is poured into molds and cured in ovens. When removed from the molds the surface of the material in contact with the mold becomes the exposed work surface. The industry standard for the work surface thickness is generally 1". Material thinner than 1" may have a tendency to warp during curing process and over 1" is very heavy. Colors include black, gray, and beige. Molding allows for various raised edge and integral backsplash designs as well as integral drain grooves and raised ribs. Molding also provides "dished" fume hood work surfaces with special accommodations for containment and service routing. Surface is satin to high gloss and non-porous.

Solid Phenolics

Solid phenolic resin work surfaces are very similar in nature to high pressure plastic laminates with the exception that the phenolic resin saturated craft paper backers are built up to a finished thickness of ½" to 1". This material is not laminated to another substate material as is high pressure decorative laminate. The backer material and resins may be varied to better suit particular applications. The surface resins may also vary according to product - intended application or manufacturer. Varying performance for specific applications will also vary. Surface appearance can vary from textured or dull gloss to polished (edges included) as desired.

Plastic Laminate

High-pressure decorative laminates are traditionally used for work (horizontal) surfaces. High-pressure laminates are manufactured by saturating a decorative paper with resin (usually melamine or polyester). Heavy brown craft papers are saturated with phenolic resin and stacked with the saturated decorative paper on top. Under elevated temperature and pressure the stack is pressed to form a "plastic" laminate. The thickness of the laminate is dependent on the thickness/number of craft paper backers. The decorative surface does not vary with laminate thickness. The back side of the laminate sheet is sanded to provide a rough surface to facilitate gluing to a substrate of plywood or particle board. Additional formulations of resins may be introduced to the surface of the material to enhance specific surface characteristics such as chemical or abrasion resistant characteristics. Other specialized variations of the basic material are available such as a plastic laminate with a conductive layer under the surface for electrostatic dissipative applications. Plastic laminate thickness (for horizontal surfaces) is generally 0.028" to 0.050". The substrate material may be ¾" to 1 ½" thick and may have built-up thickness at the edges. Balancing of the substrate material (lamination of the opposite face with a material of similar characteristics) and proper edging of work surfaces are imperative for use in laboratory applications. Edging may be high pressure laminate, PVC tape (of thickness ranging from ½ mm to 3 mm) or wood strips. High pressure plastic laminate counter tops are available in hundreds of patterns and colors. Surface appearance can vary from textured to extremely high gloss and is a function of the surface of the press plates.

Stainless Steel

This is usually one of the most specialized application work surfaces. Field modification is difficult so exact field conditions and dimensions are necessary prior to fabrication. The material is usually type 304 or 316 stainless steel. Material determination must be made according to application. The steel is cut, joined, welded, ground and polished. Steel work surfaces include integral sink basins, raised edges, back and side splashes. The bottom of the work surfaces are reinforced with welded hat channels or wood framing and are usually coated with a mastic to deaden sound and minimize sweating. This type of work surface may be free standing on tubular legs or fitted to laboratory casework. Drain boards and sink basins may be sloped

Natural Stone

Resin-impregnated sandstone is a unique sandstone that is quarried in large blocks. The blocks are then "sliced" into slabs which are immersed into a bath of resin. After the resin soaks into the surface of the stone the slab is coated with additional layers of special surface resin. The slab is baked to cure the resins and add structural stability to the stone. The composition of this material varies from the baked-on surface to a natural sandstone center. Thickness is generally 1" to 1 ¼" and colors are black, green, beige, and gray. Surface is high gloss and non-porous.

Others

A large portion of the use and abuse of laboratory operations impacts the work surfaces. The proper selection of materials and configurations is very important in first cost as well as long-term suitability and performance. Although no material is impervious to everything and suitable for every application, there are a number of special materials suited for unique applications.
Contact us to discuss your special requirements and how non-traditional materials such as ceramic, plastics and other composites can help.

Ceramic Is manufactured by pouring a ceramic slurry into a mold. The mold is then inserted into an oven for curing of the worktop. After removal from the mold the top is coated with a borosilicate glaze which is fired in an oven for curing. The surface of the worktop has the properties of glass but the substrate remains a relatively porous ceramic. Color is a function of the surface glaze and six to ten neutral colors (brown, gray, beige, white, and off-white are common). Thickness is generally from ¾" to 1 ½". Molding allows for various raised edge and integral worktops. The manufacturing process imposes limitations regarding size and thickness tolerances. Variations can occur during the firing process. The surface is a high gloss and the material is usually fabricated in modular sizes.

Modified Plastic Composites Marketed under various trade names and proprietary specifications these materials are compositions of natural mineral fillers and various forms of modified resins such as polyester or acrylic. The materials are usually manufactured in ¼" to ¾" thickness and applied to a substrate material with an adhesive. The material can be laminated into greater thickness for dimensional or decorative effects such as contrasting edges. Joints, splash and sink basin joints can be filled and sanded to be undetectable. The surface of the material usually appears to be low to medium gloss and a wide range of colors is available. Various stone-like patterns are also available.

Hardwood Generally a tight grain hardwood (such as maple) but other species (such as oak or ash) may be used. The wood is cut into strips and glued to adjacent pieces to form a larger surface. The finished product is sanded and finished with an oil or synthetic sealer. The oil finish will have a dull appearance while synthetic finishes may vary from low luster to high gloss. The finished thickness of the work surface is usually between 1" and 2" but thicker material is possible if required. Color is usually a light natural woodgrain but stains may be added to darken the appearance.

Coated Medium Density Fiberboard The work surface is fabricated of medium density fiberboard. After cutting and edging the board is sprayed with several coats of resin finish which is baked and sanded between coats. Thickness is generally 1" to 1 ¼" but build-ups are possible for additional thickness. Colors are black, gray, beige and green. The finished product has a high gloss appearance. The surface is relatively easy to damage which allows infiltration of moisture and chemicals to the substrate.

Fiber-Cement Composite Cement is reinforced with fiberglass or other inert fibers and formed into sheets. Curing is accelerated by autoclaving. The composition is homogenous. Thickness is generally 1" to 1 ¼" and color is usually dull gray. Surface is very low gloss and porous.