Category Archives: Featured Solid Surface Projects

Tips for Successfully Seaming Corian® & Other Solid Surface Brands

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Integra Adhesives

Integra Adhesives

Have you ever spent hours correctly measuring, cutting and fitting pieces of Corian® or other solid surface material together, only to have your seams fail? If you have, then you know how frustrating this can be!

How do you avoid this? The key is to keep your solid surface adhesive live and performing throughout the fabrication process. Here are some highly effective strategies for storing and applying adhesive to ensure the best possible performance and seaming success:

Adhesive Care

  • Store adhesive upright in a cool dry place that is away from direct sunlight.
  • Store adhesive in an air-conditioned room or a refrigerator designed for the storage of flammable products to extend its shelf life. (NOTE: Do not store adhesive alongside food.)
  • Store upright to allow any trapped air bubbles to reach the top (outlet) of the cartridge and be eliminated during the initial purge. To purge, hold the cartridge at an upward angle, mixing tip NOT attached, and dispense approximately a tablespoon into a disposable container like a paper cup. Make sure you see adhesive dispensing from both sides of the cartridge.
  • Do not use the adhesive if it has been exposed for an extended period to high temperatures during transport or storage. In this situation, the activator (catalyst) may break down and lose strength.
  • High temperature decomposition of the activator can also release gasses into the activator component, which may impact the consistency of the cure, leaving uncured spots.

If stored correctly the adhesive can last for a year. However, the activator portion will slowly lose reactivity over time. If in doubt, run a test by dispensing a ¼” bead on cardboard and if a slow, uneven or incomplete cure results, discard the adhesive.

In addition to properly caring for your adhesive, following these eight performance guidelines will help ensure successful seaming during your fabrication process:

Performance

  • Allow both the adhesive and solid surface sheet material being joined to reach a room temperature of at least 60 degrees Fahrenheit (18 degrees Celsius) before assembling.  Bringing material into a warm humid room after being cold can cause moisture to condense on the surface, which can interfere with bonding.
  • Fabricating cold sheets in a warm room will cause the adhesive on the edge of the joint to cure faster than the adhesive deep in the joint. This is because cold solid surface materials absorb a significant portion of the energy from the chemical reaction, resulting in less than optimal curing conditions. This can ultimately cause a weakening of the seams in those areas. It is best practice to let the sheets reach room temperature.
  • Another reason to allow cold adhesive to return to room temperature before use is that some adhesive components become thicker at low temperatures. This creates higher pressure that may flex the cartridge wall and throw off the mix ratio.
  • If you re-warm adhesive, make sure the cartridge outlet plug is in place rather than the mixing tip. Adhesive left in the tip will warm faster and may expand back into the activator chamber where the two components will harden and result in a plugged cartridge.
  • Never expose adhesive to high heat. Warming adhesive above 110 degrees Fahrenheit can damage the activator component.
  • When gluing pieces together, run two small beads (one over the other) instead of a larger single bead. Overlapping adhesive streams will greatly reduce the possibility of under cured areas caused by air bubbles, from the activator side of the cartridge, mixing in with the base component in place of activator.
  • Use the full stroke of the trigger to maintain a smooth and constant feed pressure. Quickly re-trigger the gun and continue this technique until dispensing is complete. This application technique will help to prevent adhesive from seeping out of the tip between strokes. Using a dripless adhesive gun is also beneficial.
  • Apply as little pressure as possible to dispense the adhesive and maintain a constant forward motion of the cartridge pistons to minimize off-ratio dispensing. We recommend an 18:1 thrust ratio on the gun for smooth dispensing.

Here’s to Your Seaming Success!

Using a quality dispensing gun and quality adhesives, storing them correctly and following the simple procedures outlined above will result in a flawless seam most every time. If the viability of your adhesive is ever in doubt, simply run a ¼” diameter test bead on some scrap cardboard for a couple of feet and look for slow, uneven or incomplete cure results. Once you are certain you have live and performing adhesive, you’re fabrication process should go seamlessly!

Visit our Working With Solid Surface guide to learn more great fabrication techniques.

10 Qualities of a Great Solid Surface Adhesive Dispensing Gun

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Solid surface adhesive dispensing guns have evolved to become an easy to use and essential part of fabricating solid surface. A few years ago the adhesive came in two separate containers. You then had to mix it together in a paper cup with a wooden stick, similar to a doctor’s tongue depressor.

After that you could spread the adhesive mixture onto the solid surface joint with a stick. It was a tedious, time consuming and messy process with plenty of opportunity for mixing ratio errors. If the correct amount of catalyst was added to the base component in the ratio of 10 base to one catalyst, and the temperature in the facility was right, then the adhesive would set (harden) in 20-30 minutes. In this case, the project could move along as planned.

If too much catalyst was added, then the set time would be shorter. However, the challenge in this case is that  you wouldn’t be aware of this until it started to set, making it too late to position the components. This would leave you with an excess of gelled adhesive that would have to be removed before the job could go forward.

If too little catalyst was added, the set time would be extended. In this instance you wouldn’t know it until the pieces were in place, forcing you to wait until the adhesive had set. This process could take hours, once again resulting in a project delay.

Adhesive guns have come a long way!

Today, almost every adhesive brand comes in a two cylinder cartridge. The larger cylinder holds 10 times more base component than the smaller cylinder that contains the catalyst. This is where the terminology 10:1 adhesive comes from. [See Photo 1]


Photo 1: Integra Adhesive 10:1 ratio adhesive cartridge and mixing tips.

This delivery design allows for the same ratio of adhesive to be dispensed, cartridge after cartridge. When you pull the adhesive gun trigger, the adhesive in the cartridge is applied directly to the solid surfaces to be joined. This results in a lower risk of project delays due to improper component ratios.

The Top 10 Qualities of New Solid Surface Adhesive Dispensing Guns

Now, let’s consider the top evolutionary qualities of the new solid surface adhesive guns and how they can positively impact the success of your project:

  1. Possesses a “dripless” feature so when you release the trigger (in order to squeeze the trigger again) the adhesive doesn’t run out.
  2. Fits 250ml adhesive cartridges from Integra, Sta-Put (Plexus), HI-MACS, Avonite®, Formica®, and Wilsonart® (Gibraltar) and others.
  3. Has a comfortable padded grip to help prevent hand fatigue.
  4. Possesses an 18:1 thrust ratio so you can use a moderate controlled hand pressure to make sure the adhesive flows evenly from the tip.
  5. Has twin precision gripping plates that carefully control the advancement of the pistons.
  6. Contains a “wear adjustment” screw to keep the gripping plates configured properly.
  7. Capable of dispensing high-viscosity solid surface adhesive.
  8. Has a thumb-activated rear lever to instantly stop dispensing when completed.
  9. Contains extra durable, heat-treated piston push-rods that resist wear and misuse.
  10. The durable cartridge cage is made of steel for long life.

How do these top 10 qualities fit into the task of seaming solid surface?

Lets take a look at the actual steps that promote a good bond and successful project:

  • First, cut and position the solid surface components so they are ready for the application of adhesive. (It also helps if the material is allowed to reach the temperature of 60 degrees or warmer.) [See Photo 2]


    Photo 2: Prepare the material and tooling.

  • Place the cartridge in the gun and pull the trigger to position the gun pistons correctly behind the cartridge.
  • Open the cartridge, and hold the gun at an upward slant with a paper cup under the cartridge openings. Pull the trigger so a small amount of materials are dispensed from both cylinders of the cartridge. (Make sure you see material flowing from both cylinders.)
  • Place the mixing tip in place and tighten the retaining nut to hold it there.
  • Pull the trigger so that adhesive flows through the mixing tip and onto a scrap piece of cardboard or into the cup. Dispense a blob about the size of a quarter to make sure it is flowing properly. [See Photo 3]


    Photo 3: Purge a small amount of adhesive to ensure a good mix.

  • Apply the adhesive to the materials to be joined. Lay down the bead of adhesive by pulling the gun tip toward you. [See Photo 4]


    Photo 4: Apply a 1/4″ bead of adhesive.

  • Infrequently, an air bubble that is trapped in the catalyst part of the adhesive is released into the mixing tube and the air (instead of catalyst) mixes in with the base component. As a result, this portion of the bead will lack the catalyst and will not cure or set. To prevent this from happening, add a second bead of adhesive to ensure that catalyst is available to all areas of the adhesive bead. It’s unlikely that air bubbles will occur at exactly the same point twice.   (TIP: storing the cartridge in an upright position allows air bubbles to rise to the top and be expelled during the initial dispensing of material from the cartridge that is mentioned above)
  • Clamp the pieces together, let the adhesive set, and move on to the next steps for completing your project. [See Photo 5]


    Photo 5: Clamp the pieces together.

As you can see, the new adhesive guns have been optimized to make your solid surface projects easier and more effective. Here’s wishing you every success(!) and be sure to also visit our instructional guides for working with solid surface for more in-depth instruction.

 

How to Choose a Sink For Solid Surface Countertops

Karran Seamless Undermount Stainless Steel - Dual Single Bowls

Karran Seamless Undermount Stainless Steel – Dual Single Bowls

Feeling overwhelmed by all of the sink options available? Well, it’s time to take a deep breath and relax. We’re here to help you focus your decision and hone in on the sink material and style that will fit your needs best for your Corian® or other brand of solid surface countertop.

To start, take a moment to consider what’s most important to you with regard to the new sink you are going to install in conjunction with your solid surface countertops. Where is your sink going to be placed—in a kitchen, bathroom, wet bar, laundry or even laboratory? Is your decision driven by design and aesthetics? Is it based on the fact that you want a new sink that is going to be durable and stand the test of time? Or perhaps an antiseptic environment and ease of cleaning are your prime outcomes?

It’s important to focus on what benefits are most important to you and what takes priority as you design your parameters.

We’ve identified three key considerations when choosing your new sink: the type of sink, whether or not to top mount or undermount it, and if undermounting it, whether or not to do a seamless undermount.

Time to pick your basin!

Type of Sinks Available

There are currently four types of materials that sinks are constructed from: solid surface, stainless steel, granite or quartz composite and cast iron. Pros and cons arise with each option available, such as cost, durability, aesthetics and antiseptic properties. Consider the pros and cons of each type.

Solid Surface (Acrylic) Sinks

Karran Seamless Undermount Solid Surface

Karran Seamless Undermount Solid Surface

Solid surface sinks offer a wide range of benefits. According to the U.S. Department of Commerce (2000), they (along with other composite sinks) are rising in popularity and use. They are molded from an acrylic resin with added fillers and colors and are the same color throughout. Because of this, any chips or scratches can be sanded out without causing any permanent damage or marks. Similarly, although solid surface sinks can discolor after extended use, this discoloration can be easily removed by scouring the basin with a cleanser, like Comet.

From a décor standpoint, standard solid surface sinks are currently offered in a handful of colors, like white, off-white and bone, to name a few. If color is a factor in your sink choice, then you might consider quartz. For the more design-adventurous, solid surface sink basins can also be creatively developed through thermoforming at the manufacturer.

Solid surface sinks, undermounted to your solid surface countertop using a seamless undermount approach (see below), are one of the most hygienic sink options available; meeting NSF 51 food equipment sanitation certification standard for “Splash Zone” and “Food Zone” applications. While this approach is not technically “seamless”, it is a bonding process that causes the two surfaces to come together so there is no support for the growth of bacteria and mold and no water penetration.

Lastly, if high heat is a factor in your sink usage, you might want to consider a stainless steel or cast iron option.

Granite or Quartz Composite Sinks

Karran Quartz Undermount Sink

Karran Quartz Undermount Sink

Also a composite, granite sinks are molded using ground up quartz pieces, quartz dust and acrylic resins and is the same color throughout. Similar to solid surface sinks, granite can also discolor with extended use. Although you can scour the surface and remove minor stains, excessive abrasion can lead to non-removable scratches.

Granite composite sinks are offered in a wide range of color options, with unique design features. This allows you to choose from a wide range of color contrasts, grains and patterns.

Cast Iron (Porcelain Enamel) Sinks

Cast iron sinks have a glass (also called porcelain enamel) surface, which is applied to the cast iron or steel basin and then fired at high temperatures. The glass color layer sits on top of the cast iron or steel. This glass layer is offered in a wide range of colors—such as black, brown, blue, gray, red and white, etc—based on the manufacturer’s options. It’s also important to note, the porcelain enamel surface can scratch and chip, which is non-repairable.

Stainless Steel Sinks

Karran Stainless Steel Seamless Undermount Double Kitchen Sink

Karran Stainless Steel Seamless Undermount Double Kitchen Sink


 Stainless is made from different thicknesses of stainless steel (usually 18 gauge but can range from 16 to 23 gauge) Remember, the lower the gauge (thickness), the more durable the sink will be. Scratches can be removed or masked by using abrasives such as sand paper or steel wool. Always be mindful to go “with the grain.” All previous styles (solid surface, granite and cast iron) can chip, whereas stainless will dent permanently.

In general, stainless steel is a rugged, durable material. And, when it comes to antiseptic properties, stainless steel can also meet NSF 51 certification.

Top Mount (Drop-In) or Undermount?

Karran Stainless Steel Seamless Undermount Vanity Bowl

Karran Stainless Steel Seamless Undermount Vanity Bowl

Ease of Use – Top mounted sinks create a lip or edge, which prevents the easy sweeping of countertop debris into the sink while undermounted do not. Installing a top mounted sink will require caulking around the edge between the lip of the sink and the countertop. This prevents water from running under the rim.

Food Safety and Hygiene – Because of the caulking requirement, top mounted sinks provide a location for bacteria and mold to reside. Undermounted sinks also produce a seam that needs to be caulked and cleaned regularly.

Undermount Sinks – Standard or Seamless?

Karran Undermount Stainless Steel Sinks

Karran Stainless Steel Seamless Undermount

There are two types of undermount sinks—seamless, and one where the edge of the countertop extends beyond the inner edge of the sink, creating a visible joint.

In the typical undermount installation where the seam is visible, the sink can be glued or mechanically fastened under the countertop or both. The weight of the sink will dictate the method of installation, based upon the manufacturers recommendation. The joint between the top and bowl (on the sink bowl side) is typically sealed with silicone or caulk. Keep in mind that this area will need to be routinely cleaned to prevent the growth of bacteria and mold.

Karran Stainless Steel Seamless Undermount

Karran Stainless Steel Seamless Undermount

A seamless undermount is where the bond between the sink and the countertop is completed using an acrylic-based adhesive that hardens into a non-porous surface. The area of the seam is then routed and sanded so the countertop surface flows together with the sink surface. When the countertop and sink are the same color this joint is virtually invisible.

Solid surface and Karran stainless steel sinks can both be undermounted seamlessly. All types (granite and cast iron included) can all be undermounted in a non-seamless fashion.

Ease of Use & Hygiene – Seamless undermount sinks are easier to maintain and keep the most hygienic since there is not a caulk line to trap debris, bacteria and mold. This is an important consideration for sinks being placed in food preparation areas, dental and medical offices and other areas where an antiseptic environment is desired.

Learn how to install the various types of sinks in our Countertop Fundamentals instructional guides.  Sinks, sink adhesives, mounting kits and other sink accessories can all be purchased at SolidSurface.com.

4 Tips to Sanding Corian®: Guidelines for a Perfect Finish

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5" Sanding Kit at SolidSurface.com

5″ Sanding Kit by SolidSurface.com

Sanding is often considered one of the most dreaded parts of most DIY or professional projects. However, perhaps a little shift in perspective is called for here. Instead, imagine this… immediately being able to take something from a lifeless finish to a matte or gloss finish, creating a thing of beauty right before your eyes, in a matter of steps!

The Correct Finish for Corian®* is the One You or Your Client or Customer Prefer

Although you should always go with the finish that either you or your client or customer desires, here are some good rules of thumb to choosing an effective finish:  High use areas call for light colors and a matte finish, as this combination is the least likely to show wear and tear. On the contrary, dark colors with a high gloss finish show wear and tear more readily and are best placed in lower use areas. Whatever finish is chosen, no additional sealers or coatings of any kind are required.

Use Random Orbit Sanding

Using a random orbit sander can provide you with an almost undetectable “scratch pattern.” The random orbit-sanding pad oscillates in a 3/32” circle while rotating at a variable rate, in a circle the width of the sander. The resulting sanding pattern is described as being a “random orbit scratch pattern” that is very difficult to detect compared to scratches left when sanding in a straight line or a circle.

To achieve an even sanding pattern over a large area, move the sander itself, front-to-back, over an area of about 2’ x 2’ and then cover the same area side to side. Repeat this pattern over the area two or three times. Wipe the area thoroughly with water to remove the sanding grit and dust and repeat the process with the next finer grit. Each new pass of the sander (front to back or side-to-side) should overlap the previous pass by 1/3 the diameter of the sanded path.

TIP: we recommend using a 5” or 6” diameter random orbit sander with a hook and loop disc and the ability to collect its dust.

Corian® is the Same Color Throughout, So—Sand Away

Many of the color options for Corian®, as well as other brands of solid surface, arrive from the factory with a matte finish, so sanding with a 280-grit disc will produce a similar matte finish. Before you change to the next finer grit make sure that the sanding scratches from the previous grit are completely removed and you’ll have less work to do. See the section below for how to achieve higher gloss levels.

If necessary, deep cuts or scratches can be removed using 120-grit, followed by 180-grit. When you are sanding out a deep scratch or cut, be aware that you may leave a noticeable indentation if you only sand the immediate area of the cut. Instead, feather sand the area away from the cut. Start by using 120-grit paper to sand away the cut in a tight circular pattern and then increase the sanding radius out to about 12”, spending more time toward the center. Next, sand the entire area with 180-grit paper, feathering out another 8” or more. Remember the color goes all the way through.

TIP: the larger the sanding grit number, the smaller the grit. The reverse is true if you are talking about grit size in microns. Also, positioning a light beyond the area you are sanding will help you see the sanding pattern.

Level of Gloss

In a situation where the countertop surface is completely covered by sanding scratches, the less depth that the scratches have, the higher level of gloss. Or stated differently, if light rays bounce off a surface without being deflected by sanding scratches, then you would see a mirror like reflection. As scratches on the surface become deeper, the light is deflected at greater angles. The resulting images become less distinct and less polished or mirror-like. Ultimately this results in a semi-gloss or blurred image, to even a matte finish where no image is reflected.  For a more in-depth article on finishes, see How to Clean and Refinish Corian® and Other Brands of Solid Surface Countertops.

Using non-woven pads (available in our sanding kits) with a random orbit sander adds an interesting touch to the desired finish that is hard to describe. Sand the surface one final time with 280-grit paper if a matte finish is desired. Making another pass with a maroon colored 320-grit non-woven pad, will give the surface an additional touch of “richness” that is different than if you had used a sanding disc with 320-grit.

The Sanding Sequence

Use 120-grit and 180-grit discs to remove heavy scratches and return the surface a flat finish, similar to the flat finish provided by some sheet manufacturers.

    • Matte finish: Use 280-grit and then the maroon non-woven pad.

    • Satin finish: Use 280-grit, 400-grit, and gray non-woven pad

    • Gloss finish: The degree of gloss appearance desired will depend in part on the material color and particulate composition. Use 280-grit, 400-grit, 600-grit and the gold non-woven pad for a moderate gloss. Then for a higher gloss use the 1000-grit in place of the gold pad and the 2000-grit polishing compound with the white non-abrasive non-woven pad. For the gloss-purest you can buff the surface with an automotive polisher and foam polishing pad glaze. This will yield the ultimate shine!

  • Surface Maintenance: Surface maintenance procedures are dependent on the type of damage and the degree of shine on the finish. Sand out cuts and scratches with 120-grit, 180-grit, and then 280-grit, which will approximate the matte finish of the original piece. Then use the procedures above to match the final finish.

Tip: if a small surface area with a matte finish needs touch-up, experiment with a damp sponge and cleansing powder like Comet®. If there is more sheen than a matte finish then use a cleansing powder and a maroon, grey, or gold non-woven pad.

Grit to Micron Conversion: 120-grit (125 micron), 180-grit (82 micron), 280-grit (52 micron), 400-grit (35 micron), 600-grit (26 micron), 1000-grit (18 micron).

*Corian® (by DuPont™) was invented in 1964 and has become the term used by many to refer to solid surface materials. Since then, several brands have been developed that are all similar in how they look, wear, and are fabricated. Other manufacturers and brands include:  LG Hausys HI-MACS®, LOTTE Staron®, Wilsonart® Solid Surface, Formica® Solid Surface, Hyundai L&C Hanex, Aristech® Avonite Surfaces®, Aristech® STUDIO Collection, Meganite®, and Mystera®, to name a few.

Information in this communication is provided as possible ways among many to accomplish the goals expressed and there are no warranties implied. SurfaceNet LLC dba SolidSurface.com is not liable or responsible for any actions taken.