How do Solid Surface Bathtubs Compare to Other Materials?

Are you interested in transforming your bathing experience by bringing a modern-day oasis to the comfort of your home? Discover a luxurious freestanding solid-surface bathtub. While the use of bathtubs dates back to the Indus Valley civilization (3300-1300 BCE), its modern form was first commercially made available by the Mott Iron Works Company in 1842. The industry has come a long way from high-maintenance cast iron to convenient solid-surface bathtubs.

This blog post concerns solid surface bathtubs compared to other alternate materials. From medieval times to contemporary interior designs, bathtubs evolved in shape and material technology. If you want to buy a solid surface bathtub but still have questions about the right material choice, this blog post is for you. First, we will analyze the common problems with bathtubs to better judge material characteristics. Later, explore bathtubs with solid surfaces like copper, cast iron, fiberglass, stone resin, and more!

Common Material-Associated Problems in Bathtubs

Everyone wants to own a house that can be a place to relax and recharge their energy. However, an unforeseen bathroom repair or maintenance requirement can cause little free time from our busy lives to become tragic. To make well-informed decisions on bathtub materials, here are common problems associated with various bathtub materials:

● Mold: Fungi that Loves Humidity

Mold is a fungus that develops in a humid environment with oxygen. Bathtubs provide the ideal conditions for spreading mold by tiny reproductive cells called spores. Mold needs a surface to cling to, as it is naturally present in the air. Some bathtub materials enhance mold production, while others prevent it altogether.

● Bathtub Cracks: Blame the Installer?

Typically, bathtubs crack when the plumber does not correctly install them during construction. The uneven support can lead to cracking. Some materials are more susceptible to cracking than others. However, some materials have enough thickness to prevent cracks from developing.

● Hardwater: Stains that Don't Go!

The minerals in hard water can deposit a layer over your bathtub. It can disrupt the color scheme and cause the bathtub's surface to dull. Non-porous bathtubs are less likely to form the layer, but prolonged use can lead to hardwater stains.

● Chipping: Direct Damage

Any hard and heavy material can cause the bathtub material to chip away, which is a material that breaks away from the bathtub's surface. For example, a full shampoo bottle falling from a height can cause chipping on some bathtub material.

● Rough Texture

As time passes, the bathtub surface can become rough. Usually, bathtubs with thin finish layers can become bumpy. It can also result from using incompatible chemicals on the bathtub surface. We will discuss chemical compatibility later in the material sections.

Solid Surface Bathtubs: Modern Luxury with Convenience

Solid-surface bathtubs are the staple of modern, contemporary looks. They add elegance and sophistication to the interior design and provide diverse options catering to any body type. Acrylic solid surface bathtubs have the best price-to-performance and feature ratio.

♦ Solid Surface Bathtub Basics

The term solid surface is primarily associated with solid bathtubs inside and out. A typical solid surface tub can weigh around 135-230Kg. They consist of 100% acrylic or a combination of acrylic, shards of stones, binding agents, and pigments. The acrylic solid surface bathtub is also known as a stone resin bathtub. Every manufacturer has their own technique and resin mixture.

♦ Manufacturing Process of Solid Surface Bathtubs

Industries manufacture solid surface bathtubs using various techniques. The process involves multiple operations to achieve a solid body and a premium finish. Here is the manufacturing process of a solid surface or stone resin bathtub:

1. The manufacturer first prepares the base material using premium acrylic resin (a PMMA and MMA compound) mixed with quartz, limestone, aluminum, bauxite, or marble dust. At this stage, the material is in liquid form.

2. The liquid mixture then goes into molds with gaps that match the thickness and shape of the final bathtub product.

3. Now, the pre-designed mold is closed and allowed to cool and cure in suitable temperature and humidity conditions.

4. Removing the mold results in a roughly shaped free-standing bathtub.

5. The bathtub then undergoes cutting, grinding, and sanding operations to achieve the desired shape.

6. A high-quality gel coat is applied to the stone resin bathtub (solid surface) to protect and produce a high-quality finish.

♦ Material Characteristics of Solid Surface Bathtubs

Solid-surface bathtubs have a solid construction without any joints or patches. The acrylic mixed with minerals provides a solid shape that does not easily chip away. According to the 2015 International Plumbing Code, adopted by New York State, the maximum temperature flowing out of a faucet should not be above 49C, which is below the heat distortion temperature of solid-surface bathtubs.

Here are the key characteristics of a solid surface freestanding bathtub made with ISO resin with 1000-grit aluminum hydroxide and LR brand pigments the material:

- Tensile Strength: 50 Mpa

- Tensile Modulus of Elasticity: 2900 Mpa

- Elongation at Break: 5%

- Bending Strength 80 Mpa

- Impact Strength 12 KJ/m2

- Heat Distortion Temperature 50 ºC

Pros and Cons of Solid Surface Bathtubs

   Alternate Bathtub Materials: A Range of Options

Let's dive into other material options for bathtubs. There are tons of low-budget and premium material options. However, we are in search of the perfect material that will enhance your household aesthetics and keep your bathroom low-maintenance. Here are some alternate bathtub materials to solid surface bathtubs:

1. Porcelain-Enameled Steel

These are some of the most common designs in rental houses and budget hotels. Due to their multiple design options, such as a corner, double-ended, fitted, drop-in, alcove, and free-standing, porcelain-enameled steel, they make an ideal budget chemical-resistant bathtub option. In comparison to solid surface tubs, porcelain-enameled steel bathtubs are hollow.

▪ Manufacturing & Characteristics: Steel Sheet and Porcelain

These bathtubs typically start with steel sheets. A large steel sheet is pressed using a machine to get its final shape. Manufacturers coat it with porcelain to protect the steel from corrosion and ensure the product's longevity. After the coating, it is heat treated to allow the porcelain to stick to the steel surface.

   ▪ Pros and Cons of Porcelain-Enameled Steel

2. Fiberglass: Lightweight and Affordable

It is the lightest material available for bathtub manufacturing. It is also the most convenient installation and affordable option in the bathtub category. A typical fiberglass bathtub weighs around 32kg (70lb).

▪ Manufacturing & Characteristics: Fibers and Polymer Resin

The process starts by using a mold. Then, a production worker sprays a gel coat onto the mold, and the layering of fiberglass starts. Multiple fiberglass layers are applied and impregnated with resin to provide strength. The whole assembly is allowed to cure. The manufacturer performs the sanding, polishing, and necessary finishing, which results in the final product.

   ▪ Pros and Cons of Fiberglass Bathtub

PROS	CONS
✔ Easy to Install	‒ Breaks Easily
✔ Repairable	‒ Improper Installation Can Cause Failure
✔ Color Variations	‒ Lower Heat Retention

3. Copper: Premium Medieval Material

Copper is a well-known material in conductors like wires and circuits. It is soft by nature and has high conductivity. Intricate carvings and exquisite designs are a niche use of copper. Even though it has excellent characteristics, it costs a fortune to own one. The medicinal properties of copper and its antimicrobial capabilities have been well-known for ages.

▪ Manufacturing & Characteristics: Pure Copper

Copper is a soft, malleable metal that is easy to bend and carve. Skilled copper artisans can form premium designs. A large sheet of copper is either pressed into the shape of a bathtub, or an artisan can use special tools and techniques to create the shape. Unlike the solid surface bathtub, copper bathtubs may require welding and finishing jobs.

▪ Pros and Cons of Copper Bathtub

4. Cast Iron: Heavy Duty Material

Iron is directly affected by the percentage of carbon. Cast iron consists of more than 2% carbon, resulting in durability and hardness. It is relatively affordable compared to copper but costs more than a solid surface bathtub. The malleable property of cast iron makes it susceptible to damage in tensile stress.

▪ Manufacturing & Characteristics: Tough Under Compression

The cast iron process is similar to that of solid-surface bathtubs. It starts by pouring melted iron into a mold, allowing it to cure. Hammering Iron into shape is impossible, so it requires careful cutting, grinding, and finishing. Due to its high hardness, cast iron is difficult to handle and can break under stress.

▪ Pros and Cons of Cast Iron Bathtub

Final Verdict

Considering all other alternatives of solid surface bathtubs, solid surface bathtubs top the chart in all aspects. No wonder their popularity is ever-growing. Here are the key points why solid surface bathtubs are superior to other materials:

● A non-porous surface prevents the formation of mold or stains from hard water.

● Retains heat, unlike copper or cast iron bathtubs.

● Easy to clean using a mild detergent.

● It is ideal for some quiet time as there is minimum impact noise

● Resists cracking, chipping, and breaking.

● The solid surface bathtub is an ideal lightweight alternative to heavy metal bathtubs.

● Ease of installation and longevity.