To introduce you to the most popular materials and construction methods used to manufacture fixtures, here is a list of the widely used materials. The is an ever-changing collection of special materials available for unique, one-of-a-kind fixtures today- notable for the bathroom. Unique bathing pools/bathtubs are also available. Here are just a few of the more common ones.
CAST IRON
You may have heard the term "cast iron" but never actually knew what the term really means. "Cast iron" actually describes a manufacturing process used for more than a century to produce bathtubs and kitchen sinks. The molten iron is "cast" in a sand mold. Sand is used to shape the cavity of the mold. The reclaimed molten iron, at 27-- F is poured into a channel, filling the cavity. After the molten iron has cooled and solidified, the sand cast is removed (the sand is recycled) and the exposed product is ready for finishing. The exterior surface must be smoothed to a uniform finish. Once this is done, the final enamel finish coat is added. The finish is a combination of clay, frit, color oxides and opacifers. IT is applied to the exposed surfaces of the fixture in powder form, and then fired at 1250 F which melts the powder uniformly into a smooth coating which fuses to the cast iron base material.
The enamel coating on iron is much thicker, and the cast iron more resistant to movement than is the case with an enameled steel fixture
Heat transference
Cast iron fixtures are cool to the touch and therefore, may be momentarily uncomfortable for the bather as he/she reclines against the backrest above the water line. Because the cast iron is a conductor of heat, the bath water will cool more rapidly in a cast iron bathtub than it will in one made out of a plastic material, which has better insulating properties.
Weight Factor
Kitchen sinks and bathroom lavatories are heavy , but can be carried by one person. Cast iron bathtubs are heavy and therefore generally limited to sizes up to 72"x36" and 60"x 42". Attention to this weight factor is important if you are designing a bathroom that is accessible only up a long flight of stairs. It can easily require four strong men to wrestle a cast iron bathtub up to a second floor location!
COMPOSITE
The use of composite kitchen sinks is growing rapidly. However, because there are many types of composite sinks, there is much confusion in differentiating one from another. In general the main types are acrylic/polyster, granite-based and quartz composite.
Acrylic/Polyster.
Of all the types of composite sinks available, acrylic/polyster are the lowest performing in terms of scratch and stain resitance, because they are made from soft materials that can cut and nick easily. On the positive side, acrylic/polyster-based composites tend to have a "shiny" look that appeals to many homeowners because they brighten the kitchen. They are also popular because the come in a variety of colors.
Granite Based.
The most scratch resistant sink material on the market today is a "granite" composite. These sinks offer stain, chemical, and scratch resistance. They also offer the highest level of durability because of the extremely high density of rock particles at the sink's surface. Granite based sinks are available only in matte finishes; therefor, the consumer is not offered the "glossy" of other options.
Quartz Composite
With a combination of 70% quartz and 30% resin filler, quartz composite sinks provide a durable surface. These sinks can resist everyday cuts, scuffs, and dents and can easily stand up to harsh cleaning materials or liquids that might stain other sinks. Quartz composite sinks are available in a variety of colors. Because the color is uniform throughout, the material never loses its original color. Once again, quartz sinks are available in a matter finish only, rather than the glossy look of a cast iron sink.
Enamel Steel
Bathtubs and lavatories can be constructed out of enameled steel. This material is fabricated by forming steel in a cold state, then applying a coat of enamel, and finally firing the finished piece in an oven.
To fabricate an enameled steel fixture, a sheet of metal is pressed in a die so it forms the desired shape. This process is called "drawing" because the process results in creating a shape that has depth. The fixture is also subject to mechanical operations, called "stamping" to cut or form the individual parts of the fixture. Some enameled steel fixtures also require sections to be welded together.
FIRE CLAY
Fire Clay is a compound ceramic material that includes pre-fired clay particles mixed with ball and china clays. The pre-fired clay particles are ground into small grains and added to the liquid casting slip, giving it a unique and distinct appearance. Fire clay colors- notably white- are typically more brilliant than the colors of cast iron products. The porosity also makes the fire clay more resistant to shock than vitreous ware; therefore, its durability characteristics are similar to cast iron.
Lastly, fire clay products are distinctly different from cast iron in that they are lighter in weight. One of the advantages of the lighter weight material and less shrinkage in fire clay is that considerably larger pieces cab be manufactured with less warpage and crisper design details. However, the porosity makes fire clay products non-code compliant for toilets and urinals - all surfaces containing water must be glazed.
There are several other materials used in sinks and fixtures such as acrylic, fiberglass, and even injection molding, but this list will get you started with learning about some of the materials used in these type of fixtures.
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