Solid Surface Manufacturers for Kitchen and Bath Countertops

Introduction

Kitchen and bathroom countertops are one of the most important elements that define the look and functionality of these important living spaces. With so many options on the market, it can be overwhelming trying to select the right countertop material that fits your needs, budget and style.

One popular countertop material that has been gaining popularity in recent years is solid surface. Solid surface countertops provide a seamless, non-porous surface that is easy to clean and maintain. They are made from a blend of natural minerals and high-quality acrylic resins to create a durable, resilient material perfect for kitchens and baths.

In this comprehensive guide, we will explore everything you need to know about solid surface manufacturers for kitchen and bath countertops. We will look at what solid surface is, its benefits and drawbacks, cost considerations, popular brand names, maintenance and care, and insights into working with professional solid surface manufacturers to select the perfect countertop for your next remodeling or new construction project.

What is Solid Surface?

Solid surface refers to a family of man-made countertop materials that are typically composed of a combination of natural minerals (such as bauxite, calcium carbonate and pigments) and acrylic resins. The natural mineral composition gives solid surface its durability, while the acrylic resins provide flexibility and workability.

Unlike natural stone surfaces, solid surface is non-porous, making it resistant to stains, mildew and bacteria growth. The material is molded into countertop slabs during production, resulting in visually seamless appearances once installed. The resin composition allows solid surface slabs to be seamlessly joined for a continuous appearance. Standard slab dimensions are 130 x 65 cm (51 x 26 inches). Custom fabrication can be done to create integrated sinks, drainboards, backsplashes, heat-resistant surfaces for ranges, and other specialized applications.

While solid surface was originally developed in the late 1960s, improvements in manufacturing techniques and performance in recent decades has led to a surge in popularity for kitchen and bathroom use. Today, solid surface offers homeowners a practical and stylish alternative to natural stone or laminate.

Benefits of Solid Surface Countertops

There are many reasons why solid surface has become a top choice for kitchen and bath countertops:

Seamless appearance – Solid surface slabs can be fabricated with inconspicuous seams for a continuous, streamlined look. This helps create a smooth, modern aesthetic compared to other countertop materials like granite or tile that have highly visible seaming.
Non-porous surface – Unlike natural stone and other porous materials, solid surface resists stains, moisture and bacterial growth. Spills and messes are easy to clean without risk of penetration into the material.
Heat and scratch resistant – Premium solid surface formulations are resistant to heat up to 180°C. They are also durable to withstand scratches, cuts and abrasions from everyday use. However, solid surface can be vulnerable to damage from extreme heat or force.
Easy maintenance – Routine cleaning only requires mild soap and water. Solid surface does not require sealing or polishing like natural stone. Repairs and resurfacing can be done for more significant damage.
Customizable – Solid surface can be fabricated into nearly any shape and configuration. Integrated sinks, drainboards, cooktop surrounds, curves and edge profiles can be created for a custom look.
Wide range of colors/patterns – From solid colors to simulated marble and quartz patterns, there are many options to match any design style. Custom digital print technology also allows for creative patterns.

Potential Drawbacks of Solid Surface

While solid surface countertops have many benefits, there are a few potential drawbacks to consider:

Susceptible to damage – Solid surface can be prone to scratches, cuts, dents and heat damage without proper care. However, minor damage can often be sanded and polished out.
Requires professional installation – Seaming and custom fabrication is best left to experienced professionals to ensure structural integrity and prevent cracks or separation. DIY installation is not recommended.
Higher cost than laminate – Solid surface is generally 2-3 times more expensive than laminate countertops, though it is comparable in cost to many natural stones.
Limited veining/patterns – The uniform patterning may not mimic the depth and complexities of natural materials like granite and marble. Custom digital printing provides more options.
Can stain from strongly pigmented liquids – Highly pigmented substances like wine, juice and mustard can temporarily or permanently stain if left on the surface.
Prone to damage from heat – Direct and prolonged heat exposure will damage the resin binders in solid surface. Trivets and hot pads should always be used.

While these factors should be considered, none are dealbreakers for most homeowners. With proper care and maintenance, solid surface performs exceptionally well in kitchens and bathrooms.

Popular Solid Surface Brands

The leading manufacturers of solid surface materials include well-known and trusted brands within the surfacing industry. Some of the most popular include:

Corian

Produced by DuPont, Corian was one of the first solid surface materials introduced to the market in 1967. Corian’s premium acrylic-polyester blend is available in over 100 colors and patterns. It remains one of the most recognized and specified brands of solid surface.

Avonite

Manufactured by Aristech Surfaces, Avonite offers one of the largest color collections with over 500 variations and patterns such as simulated granite, concrete, quartz and recycled glass.

Gibralter

Gibralter is a division of Wilsonart, another leading surfacing manufacturer. With a focus on high-performance and durability, Gibralter solid surfaces are GREENGUARD certified and contain antibacterial properties.

Meganite

Meganite has a premium cast acrylic formulation with integral fiberglass reinforcement for added structural capability. Their surfaces have high heat tolerance and are backed by a 15-year warranty.

Swanstone

The Swan brand from Swan Corporation features solid surface and quartz materials. Their maxi-sized 138 x 65 cm (54 x 26 inch) slabs minimize seaming. Swanstone is made in the USA.

Formica Solid Surfacing

Formica Solid Surfacing is part of the wider offering from long-standing laminate company Formica. Their Morro and Surell brands focus on budget-friendly options.

Samsung Radianz

As a global electronics leader, Samsung also manufactures Radianz Solid Surface for kitchen and bathroom applications. Radianz features acrylic and mineral-based designs.

Hanstone Quartz

Hanstone integrates natural quartz into its solid surface materials for enhanced durability and scratch resistance. Their signature Hanex material is backed by a limited lifetime warranty.

This covers some of the major brands available. Comparing warranties, designs, price points and reviews will help determine the right solid surface brand for your project. Many solid surface fabricators work with leading brands like DuPont Corian and Avonite.

Cost of Solid Surface Countertops

Solid surface countertops range in cost from $70 – $125 per square foot installed. This puts their price point below premium natural stones like granite and quartz, but higher than value-oriented options like laminate.

The total cost of your solid surface countertop project will depend on several factors:

Brand – There can be a range in price between brand names. Higher-end brands like Corian and Gibralter will be more costly than value lines from Aristech or Swanstone.
Material grade – Basic solid surface grades will cost less than premium or high-performance options with greater durability and heat resistance.
Color and pattern – More complex patterns and richer colors will typically cost more than basic solid colors.
Edge profiles – Decorative edges like ogee, bevel, bullnose and coordinating backsplashes will add cost over standard eased or square edge treatments.
Thickness – Standard thicknesses are 1/2” and 3/4″. Thicker material may provide greater structural capability and impact resistance.
Fabrication/installation – Highly customized projects and intricate seaming will have higher labor costs for fabrication and professional installation.
Market conditions – Pricing can vary regionally based on distributor availability, labor rates and material costs.

To maximize value, use price comparisons between local solid surface fabricators and negotiate complete installed costs rather than material price per square foot alone. Keep in mind total lifetime costs and benefits rather than focusing solely on initial price. Solid surface is a long-term investment that will last for decades with proper care.

Caring for Solid Surface Countertops

Caring for your solid surface countertops involves a few simple practices:

For routine cleaning, use a soft cloth or sponge with mild soap and warm water. Avoid abrasive cleaners.
Disinfect periodically with diluted bleach – 1 part bleach to 20 parts water.
Avoid exposing the surface to harsh chemicals like paint removers, oven cleaners, etc.
Use cutting boards and trivets/hot pads to prevent scratches and heat damage.
Re-apply surface sealers every 1-2 years per manufacturer guidelines.
Immediately wipe up spills, especially from pigmented liquids like wine, coffee and fruit juice.
Avoid leaving moisture sitting on joints/seams which can infiltrate over time.
Check manufacturer care guidelines for your specific brand and formulation.

Minor scratches, scuffs and stains can often be repaired yourself:

Light Scratches – Use a wet 400 grit sandpaper to gently smooth the area, then restore finish with a fine grit buffing pad.
Minor Cuts – Sand down lightly with 600 grit paper and restore surrounding finish.
Hard Water Marks/Stains – Use a green Scotch-Brite pad with diluted bleach, then rinse.
Discoloration – Try a white polishing compound or soft scrub cleanser.

For more significant damage, gouges or seam separation, contact your countertop fabricator to arrange professional repairs. Most quality installers provide repair services and warranties against defects and major damage.

Working with Solid Surface Manufacturers

Selecting the right solid surface brand, color, edges and customizations for your space is exciting – but the buying process can also be confusing. Working with an experienced local countertop fabricator is highly recommended to ensure you get the perfect counters for your needs and budget. Here are some tips:

Find retailers of leading solid surface brands like Corian or Avonite in your area. They will have a wide selection of materials, colors and edge profiles to choose from.
Look for an authorized fabricator of the brand you select. For warranties to apply, fabrication should be done through licensed distributors.
Discuss your needs – features like overhangs for bar seating, cut-outs for sinks, cooktop surrounds, etc. Experienced installers can advise you on the possibilities.
Request a quote for your complete project including materials, fabrication, delivery and professional installation services.
Ask about repair policies – many solid surface manufacturers stand behind their products with warranties and fabricated quartz tops should last a lifetime with proper care.
Inspect finished projects the fabricator has completed to evaluate their craftsmanship and project types.
Read reviews of local solid surface fabricators online to help select a reputable installer. Be wary of quotes that seem too low compared to other bids.

By partnering with a quality local solid surface manufacturer, you can feel confident you’ll end up with a beautiful, functional countertop installation built to last. With some smart shopping, you can get the high-end look and utility of solid surface within budget.

Commonly Asked Questions About Solid Surface Countertops

Is solid surface better than granite?

There is no definitive “better” material – both solid surface and granite have unique benefits. Granite is more heat, scratch and stain resistant. But solid surface offers seamless looks, non-porous easy-clean surfaces and extreme customization potential. Overall performance comes down to proper selection, fabrication and care for each material type.

How durable is solid surface?

Quality solid surface formulations like Corian are highly durable. They are impact, scratch and heat resistant when properly cared for. However, solid surface can be damaged by extreme force, abrasion or temperatures above 180°C. Minor damage is often repairable.Durability depends on the quality of the material chosen.

Can you cut on a solid surface countertop?

Solid surface scratches and cuts more readily than materials like granite. Using a cutting board is highly recommended to prevent damage over time. The exception would be specialty solid surface materials designed for food prep areas. Minor scratches from cutting can often be sanded and polished out through refinishing.

Are there seamless solid surface countertops?

Yes, a benefit of solid surface is the ability to create visually seamless countertops. Standard slab sizes limit seams, and professional fabricators use special adhesives and fabrication techniques to produce tight, inconspicuous seams. Larger customize pieces can further minimize visible seams.

Does solid surface stain easily?

Basic solid surface formulations can be prone to stains from highly pigmented substances like wine, coffee and fruit juices if not cleaned promptly. More advanced composites are formulated to be less porous and resist stains better. Stains are not absorbed and can often be removed with dilution, abrasives or refinishing.

Is solid surface environmentally friendly?

Many solid surface companies use recycled and sustainable materials in their manufacturing processes. Brands like Avonite offer surfaces made from recycled glass and shells. Solid surface does not require sealing or frequent replacement like some other materials, which reduces environmental impacts long-term.

How much does solid surface cost compared to quartz?

On average, solid surface runs $70 – $100 per square foot installed. Quartz countertops are typically $80 – $125 per square foot installed. So quartz is moderately more expensive in most cases. The specific type, brand, thickness and complexity of your project impact the final cost of either material.

Conclusion

Solid surface has proven performance and endless design potential making it an exceptional choice for kitchen and bath countertops. When selected and fabricated properly, solid surface offers unrivaled aesthetics, utility and longevity. Partnering with reputable solid surface manufacturers ensures access to premium materials, professional fabrication, warranties and service after sale. With some smart shopping, you can realize the benefits of solid surface within budget. Use this guide to feel fully informed, empowered and excited as you explore solid surface countertop options for your home improvement project!