Solid Surface vs Cultured Marble. What are the differences?
Posted: Saturday, May 06, 2006
by D Kaufman
Sunrise International Company
I get many inquiries from people who want to establish a solid surface' factory but soon realize they were using the term solid surface' when they were actually referring to what I call cultured marble'.
I'm hoping this article can explain the differences between Solid Surface and Cultured Marble, to both the end users as well as potential manufacturers. This will explain their applications and what is required to produce each.
Cultured marble is a mixture of polyester resin and crushed limestone. This matrix' mixture is poured over molds (forms) that have been sprayed with a clear gel coat. This clear gel coat is what seals the cultured marble product and gives it, its the stain resistant qualities. For example, to make a shower pan (shower tray), you would wax and spray gel coat on the shower pan mold and pour your matrix mix into the mold. It is the mold which gives your cultured marble (or onyx or granite) the shape of the product. The same process is applied to manufacturing bathtubs, wall paneling, vanity tops, pedestal sinks, window sills, trim moldings, etc. Simply put, the mold is what produces the shape and size of your products, and the gel coat is what gives your products the protection from any stains that may otherwise penetrate a stone product.
Solid surface requires a different formula and technique. Unlike Cultured Marble, Solid surface is generally poured in flat sheets and fabricated' (cut, seamed together, routed) to fit each particular project. A solid surface fabricator will work with Solid Surface similar to how they would work with a piece of wood, cutting the flat solid surface sheets, seaming them together, and routing various styles of edges on them. These are qualities you would not have in your cultured marble products, which are made out of crushed limestone or marble dust and simply poured into the molds. One can be very creative using Solid Surface but would require fabrication' skills. Fabricating the solid surface requires fewer molds, but would require more small hand tools and installation skills than installing cultured marble products.
Solid Surface does not require gel coat since the stain resistant qualities are in the matrix mix formula. Also, gel coat would not allow you to bond them together and achieve an indistinguishable seam or allow the customer to sand it to achieve a new finish. The hardness of your Solid Surface will be enhanced by post curing your Solid Surface products in a post curing oven.
Since you will be cutting the solid surface during fabrication, you will want a truly dense' part with no air bubbles in your solid surface sheets. A vacuum blender would be required to remove these air bubbles from the matrix mix prior to pouring the matrix on the mold. It does not matter that there are air bubbles inside your cultured marble products since you will be producing made-to-fit items on molds that will not require cutting, seaming, and routing.
The 36" (these come in various widths) belt sander should be used to sand your flat Solid Surface sheets to a uniform thickness. This is crucial when you are fabricating your solid surface products.
Facts: Cultured Marble: (1) Cultured Marble does not require a special vacuum blender. A standard matrix blender is sufficient.
(2) Cultured Marble does not require any post curing equipment. (3) Cultured Marble does not require the 36" belt sander which is required for Solid Surface. (4) Crushed limestone to produce cultured marble is are going to be available almost anywhere in the worldwide, whereas the raw materials to produce solid surface may not be as readily available in some areas, making less competitive.
(5) Cultured Marble does requires more molds since you will be forming' a wide variety of cultured marble, onyx, and granite products. If your customer requires a 36" X 72" Bathtub, you will require a 36" X 72" Bathtub Mold. If they require a 42" X 42" Shower Pan, you will require a 42" X 42" Shower Pan mold, etc.
(6) Cultured Marble is more simple to deliver to your customer since most of the work is done by the molds. You pour your matrix in the molds, let it cure, sand around the edges, buff it if required, and it is ready to send to market. No additional fabrication is required.
Fact: Solid Surface: (1) Solid Surface is more versatile in that you can fabricate' many creative counter tops from the flat sheets you produce. You are not limited to only manufacturing items in the shape of a particular mold.
(2) Solid Surface requires more expensive raw materials which may not be available in some places. (3) Solid Surface requires more equipment: vacuum blender, post curing ovens, large belt sander. (4) Solid Surface requires more installation tools and fabrication skills.
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More commentsMore than usefull article
Very helpful background info
I would like to know the difference in cultured marble and real marble, not manufactured marble. Pretaining to staining and scratching.Cultured marble has a gel coat finish so it is more stain resistant than natural marble. It is easier to maintain a glossy finish on cultured marble though it is more susceptible to scratches. You choice of materials, cultured marble, natural marble, or solid surface may depend on where you intend to install it. Some places I would prefer cultured marble, some places I would prefer solid surface, and for flooring I might prefer natural marble.
Thanks for the clear & simple explanation of these two material which is commonly mistaken by people. You're good!!!
Is Cultured Marble the same as Synthetic products? Is it made with the same material? Who can you call or is there a web-site to go to?These products are sometimes referred to as synthetic marble, cast polymer, artificial marble, plastic cement, etc., but Cultured Marble is the most commonly used name used here in the U.S. You can learn more about manufacturing Cultured Marble if you click on Sunrise International Company at the top of the article. It will take you directly to our website.
In additional to Cultured Marble, I've read about Cultured Granite and Cultured Onyx. Is there a difference in the underlying material (e.g., the use of crushed granite/onyx instead of crushed limestone or marble dust), or is it really only a difference in how the pigment is used?Cultured marble is produced using crushed limestone and adding pigments for the veining. Cultured granite, onyx, and solid surface require different fillers.
There are so many products to refinish cultured marble. What is the best? Does epoxy work well? Thanks.Would you please send answer to may email.Click on the company name, under my name, which is a link to our website. You'll find our contact info there. I'll be glad to respond through that avenue.
Thanks a lot for your explanations and information.It is really helpful for us Newbies getting simple and clear cut information helping us understand .JMTaiwan
how can I tell of my table is made of crushed marble/granite or not crushed one?Look on the bottom side of the marble and if you see little craters/pockets/pin holes, it's probably cultured marble or cultured granite. If you don't see any there's a good chance it's natural stone.
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