Kerrock Solid Surface

Solid Surface is a type of man-made stone, which is typically made of either acrylic or polyester resin combined with ATH (which is a derivate of aluminium mining).

Common uses for Solid Surface, in both commercial and residential applications include:

• kitchen worktops
• vanity tops
• shower surrounds
• shower trays
• reception desks
• teapoints
• wash troughs
• walling and flooring

Solid Surface is also well known for being durable, resistant to stains and heat, and repairable.

There are several brands of Solid Surface available within the UK market.

• Corian
• Hi Macs
• Staron
• Hanex
• Durasein
• Durasein
• Durat

We currently offer 13 different brands within our portfolio, this for more info take a look here.

Most of the brands are made in the same/similar way, with comparatively identical chemical compositions.

The biggest difference here is where the material is manufactured and who the material manufacturer and distributors are, the colour offering and the pricing structure. Each brand approaches the colours and designs differently, and there is no rule of thumb where colours are concerned.

Although Solid Surface itself is sold to the fabricator in sheets of material, which are a standard size and thickness, with a wide range of standard colours available, what we provide is very different.

The advantage of Solid Surface fabrication is that a skilled fabricator can take the raw sheet material and transform it into what the end client desires, as everything that is manufactured is custom-made and hand-crafted to order, meaning every single item made is unique and bespoke to the end user.

Solid Surface should be installed by a skilled, experienced, professional, as it is a process that typically involves carefully manoeuvring into place and securing the joints, using the specialist glue and techniques required, in order to obtain the best possible, inconspicuous seam attainable.

If it is something that can be placed in one piece and does not require joining, you can likely install it yourself. If it needs a join (which we call a seam) then it will need to be installed by one of our skilled, trained fitting team, as we use specialist techniques to ensure the seam is inconspicuous and maintain your warranty is secure.

Solid surface is relatively easy to clean and maintain. It can be cleaned with mild soap and water, and should be wiped dry to prevent water spots. For more stubborn stains, you can use Bar Keepers Friend or a mild kitchen bleach cleaner.

If you would like to know more about how easy it is to clean Solid Surface, take a peek at my article which gives more information, here, or download our guide here.

The short answer is yes, Solid Surface materials can be joined seamlessly.

The process of joining Solid Surface is known as seaming, which involves using the correct adhesive to bond two pieces together, to ensure the best joint possible.

The adhesive is applied to the edges of the two pieces and then pressed together, creating a smooth, seamless joint.

The quality of the seam depends on the skill of the installer and the quality of the adhesive used. A well-executed seam should be inconspicuous, creating the illusion of a single, solid piece.

The warranty is usually ten years from installation with the warranty covering the material, therefore, in the rare event of a material failure (clouding, colour etc) then the manufacturer will need to be involved.

It does not cover for wear and tear, abuse or accidental damage.

Solid Surface materials are generally resistant to germs and stains, as they are non-porous, which means that there are no tiny holes that can trap dirt and bacteria, making them easier to clean and less prone to staining. They are also water tight, meaning they are perfect for using as sinks, vanities and trough sinks.

Solid Surface materials can be repaired if they get damaged. Minor scratches, burns, and stains can often be repaired using a light sanding or a mild abrasive cleaner. More severe damage, such as deep scratches or chips, may require an experienced professional to undertake this type of work.

Most Solid Surfaces are not warranted to use with instant hot water taps, (Hanex being the exception as their sinks are warrantied for use with Qooker). This is due to the risk of cracking and thermal shock (where a sink can be damaged due to the extreme changes in temperature). To avoid any issues, we normally, material and project dependent, recommend the use of Axix 1810 sinks, which can be lined with any Solid Surface on all four side, leaving the base exposed. These are available in stainless steel, copper and gunmetal finish. Please talk to us for more information about these sinks.

Solid Surface can be heat treated (thermoformed) to 168 degrees C, in our multi therm platten oven, which makes it malleable to manipulation. We then create shapes, curves and sizes using custom-made formers, which are unmoveable once the material has cooled and been joined and finished.

A substrate is a term used for the support structure underneath the fabricated item – a worktop, or vanity unit etc, which is typically made from MDF or plywood.

When we use the phrase ladder substrate, this is when the substrate is created as a “ladder” underneath, providing strength and integrity to the unit, whilst enabling the Solid Surface and substrate to expand and contract, as all materials are prone to do, depending on the temperature setting they are in. The reason for this is that both materials contract and expand at different rates to each other, so it is important to allow for this movement to avoid any kind of cracking occurring.

No, unlike other materials such as marble, granite and stone, Solid Surface is completely non-porous, and therefore does not require any form or sealing once fabrication has concluded.

Solid Surface can be used anywhere, within reason, as it is very durable. It is often used outside, for cladding on the outside of building, as planters and outside BBQ kitchen areas. Most colours are UV stable so there is an element of comfort that the sun will not discolour it too dramatically, unlike other materials used.

Custom colours can be produced, within reason, for projects. There is normally a minimum order quantity and an extensive lead time to undertake this, this differs for each supplier, so if this if of interest, please do ask.

We use cleats, which are small pieces of Solid Surface, which are positioned underneath the site of a join, to ensure the strength and integrity of the join.

In very simple terms, Solid Surface is a man made stone, which can be curved and shaped; which can be joined together with inconspicuous joins. It can be made into larger, more quirky shapes and sizes, is incredible durable but also very attractive on the eye. For more info please read my previous article here.

We do not provide prices in m² for a number of reasons. As we can optimise the sheet material by seaming together, there is a risk that the price will actually be more expensive. We also need to take into consideration any drainer grooves, upstands, sinks, sink cutouts hob cutouts etc which cannot be included if providing an m² price.

We have made a lot of investment into machinery, as have most Solid Surface specialist fabricators. We have a Striebig wallsaw, which we use to achieve the very precise cuts which allow for “mirror jointing”. We also have a C Axis CNC, a 5 Axis CNC, Multi-therm platten oven, fifty tonne water cooled press, v groover as well as specialist festool sanders and routers.

These tools enable us to be exceptional craftsman and produce specialist items from Solid Surface.

There is no typical lead time for Solid Surface fabrication, as every item made is handcrafted, and custom-made to order, so there needs to be enough time to create the items that are required. Typically most fabricators state between 4-6 weeks, including ordering material, site survey, fabrication and installation, however, it is important to check with your chosen fabricator stock levels and lead times for manufacturing from their facility.

Getting a price for Solid Surface worktops

Not every fabricator uses the same process to price for projects. We use our in-house estimating database, which enables us to offer the most competitive prices possible.

Every item we make is hand-made to order, therefore, they are priced accordingly, consequently, there is no one set price for anything, as every item is evaluated when offering a quote.

We do not offer a price per M2 or linear metre, as this can be misleading due to the way in which the product can be used, which can reduce cost and also save on wastage.

Want to talk to me or one of my team?

We are based in Essex, the land of glitter and gold (shh don’t tell our chaps that), here is a little snippet of info about our factory.

We do work nationwide, and although this depends on the nature of your project, it is good to talk about what you need.

For a more in-depth look at how we work, it would be great if you took a look at my showcase article here.