Which Resin Countertops Are Best For A Lab?

Resin countertops can serve as an attractive addition to a laboratory, blending aesthetics with functionality. Yet it’s important to know that in harsh environments, not all resin countertops are created equal. 

As a lab manager, you face the dilemma of choosing among the resin countertop options available, from the durable epoxy and phenolic resin to the attractive polyester and versatile acrylic. Here’s what you need to know about each type of laboratory work surface and whether it can meet the demands of your lab.

Epoxy Resin Countertops

Epoxy resin countertops are commonly used in laboratories due to their exceptional chemical resistance, durability and other beneficial properties. Epoxy resin countertops are typically made using a combination of epoxy resin, hardeners and fillers. The choice of materials may vary slightly among manufacturers, but the primary component is the epoxy resin.

To create epoxy resin countertops, multiple layers of epoxy resin and filler materials are poured and bonded together. The layers can vary in thickness, typically ranging from 1/4 inch to 1 inch or more, depending on the specific requirements.

Once the layers are poured, they go through a curing process. The curing process involves a chemical reaction, heat or both, depending on the manufacturer's process. This curing process ensures that the epoxy resin becomes a solid, durable surface.

Benefits in Laboratory Environments:

• Chemical Resistance: Epoxy resin countertops are highly resistant to a wide range of chemicals, including acids, bases, solvents and reagents. This resistance protects the surface from damage and staining, making it ideal for environments where chemical experiments and tests are conducted.
• Durability: An epoxy countertop is extremely durable and can withstand heavy use, including the impact of laboratory equipment, glassware and tools. This type of countertop is also resistant to chipping and cracking.
• Non-Porous Surface: Epoxy resin countertops have a non-porous surface, which means they do not absorb liquids or contaminants. This makes them easy to clean and maintain, and it prevents the growth of bacteria, making them suitable for environments that require high levels of hygiene.
• Heat Resistance: Tolerant to high temperatures, epoxy resin is suitable for applications involving hot materials or equipment. However, it's essential to avoid placing extremely hot items directly on the surface to prevent potential damage.
• Customization: Epoxy resin countertops can be customized to fit the specific needs of the lab. This includes options for integrated sinks, backsplashes and various shapes and sizes.
• Longevity: Epoxy resin countertops have a long lifespan and can withstand the rigors of a lab environment for many years.

Overall, epoxy resin countertops are an excellent choice for laboratories, cleanrooms and other environments where chemical resistance, durability and hygiene are critical. They provide a reliable, long-lasting and low-maintenance surface that contributes to the safety and efficiency of the workspace.

Phenolic Resin Countertops

Phenolic resin countertops are another popular choice for laboratory and industrial environments due to their exceptional chemical resistance, durability and hygienic properties. 

A phenolic resin countertop is made from layers of kraft paper impregnated with phenolic resin and other additives. The specific formulation may vary by manufacturer, but the key ingredient is phenolic resin.

Several layers of the resin-impregnated kraft paper are stacked together. During this process, additional materials, such as decorative layers and a clear melamine surface, may be added to enhance the appearance and protect the core layers.

The stacked layers are then subjected to high pressure and heat. This process compacts the layers and cures the phenolic resin, transforming it into a solid, dense and durable surface. The heat and pressure also bond the layers together.

Once cured, the phenolic resin sheets are cut and shaped into countertops according to the specific requirements of the laboratory. This can include cutting sink openings and forming edges.

Benefits in Laboratory Environments:

• Chemical Resistance: Phenolic resin countertops are renowned for their exceptional resistance to a wide range of chemicals, including acids, bases, solvents and reagents. This chemical resistance makes them ideal for laboratories where chemical experiments and tests are common.
• Durability: These countertops are highly durable and can withstand the rigors of a laboratory setting, including heavy equipment, glassware and tools. They are resistant to scratching and impact.
• Non-Porous Surface: Like epoxy resin, phenolic resin countertops have a non-porous surface, making them easy to clean and maintain. They do not absorb liquids or contaminants, which prevents the growth of bacteria and maintains a high level of hygiene in the laboratory.
• Heat Resistance: Phenolic resin countertops can tolerate high temperatures, which is important in laboratories where high-temperature processes and hot equipment may be used.
• Customization: Phenolic resin countertops can be customized to fit the specific needs of the lab.
• Longevity: Phenolic resin countertops have a long lifespan and can withstand the challenges of a laboratory.

Phenolic resin countertops are another excellent choice for laboratories and other environments that require high levels of chemical resistance, durability and hygiene. They are reliable and require low-maintenance while maintaining a safe and efficient workspace in laboratory settings.

Polyester Resin Countertops

Polyester resin countertops are a type of solid surface countertop material that is constructed using a combination of polyester resin and various filler materials. These countertops are often used in both residential and commercial settings and are known for their durability, versatility and aesthetic appeal. 

Polyester resin countertops are typically made by blending polyester resin with a variety of minerals and pigments. These filler materials can include materials like crushed stone, quartz or glass particles. The specific combination of materials can vary by manufacturer and product line.

Polyester resin countertops are available in a wide range of colors and patterns, and they can mimic the look of natural stone or other materials. They offer a seamless appearance without visible seams or grout lines, making them popular for modern and minimalist kitchen and bathroom designs.

These countertops are known for their durability and resistance to stains, scratches and impact. They are also less porous than natural stone, which means they are less prone to staining and are relatively easy to clean.

While polyester resin countertops are generally heat-resistant, they are not entirely immune to heat damage. It's advisable to use trivets or hot pads when placing hot cookware on the surface to avoid potential damage.

Benefits in Laboratory Environments:

• Customization: Polyester resin countertops can be custom-made to fit specific dimensions. They can also be molded into various shapes and designs, including integrated sinks and backsplashes.
• Repairability: These countertops are typically repairable if they become damaged or scratched. A skilled professional can sand and polish the surface to remove minor imperfections.
• Hygienic: Polyester resin countertops are non-porous, which makes them resistant to the growth of bacteria and mold. This is an advantage in areas like labs or medical facilities where hygiene is essential.
• Cost: The cost of polyester resin countertops can vary depending on factors such as thickness, color and design complexity. However, they are often considered more affordable than natural stone surfaces like granite or marble.

Despite these benefits, polyester resin countertops are generally not the first choice for lab or manufacturing environments where specific requirements for chemical resistance, durability and cleanliness are required. While polyester resin countertops have several advantages, they may not meet the stringent demands of these specialized environments. 

For example, polyester resin countertops are not highly resistant to corrosive chemicals and may be vulnerable to damage or staining when exposed to strong acids, bases or solvents. Polyester resin countertops may not be as durable as other materials like epoxy resin or phenolic resin countertops that are designed specifically for these environments.

While polyester resin countertops are relatively easy to clean and maintain, they may not meet the highest hygiene standards required in certain lab and cleanroom settings. In manufacturing environments, there may be extreme temperature variations as well. Polyester resin countertops can be damaged by prolonged exposure to high heat, which makes them less suitable for processes that generate heat or involve hot materials.

Acrylic Resin Countertops

Acrylic resin countertops are constructed using a combination of acrylic polymers, natural minerals (such as aluminum trihydrate) and pigments. They are made through a process that involves blending, casting and curing the materials. 

When manufacturers construct acrylic resin countertops, they mix together acrylic polymers, natural minerals and pigments to form a homogenous material. The specific ratios and additives may vary by manufacturer, but the resulting mixture should have a smooth consistency.

The blended material is then poured into molds to create sheets or slabs of the desired thickness and dimensions. During this process, the material can also be pigmented to create the desired color and pattern.

The cast material is then cured or polymerized, often using heat. This step helps the acrylic resin solidify and become a durable, solid surface. Finally, once cured, the acrylic resin sheets are cut and shaped to fit the specific requirements of countertops, including the creation of seams, sinks and other integrated features.

As for their suitability in a laboratory setting, acrylic resin countertops have some advantages but also certain limitations.

Benefits in Laboratory Environments:

• Chemical Resistance: Acrylic resin countertops offer moderate chemical resistance and can withstand exposure to common laboratory chemicals. However, they are not as chemically resistant as epoxy resin or phenolic resin countertops.
• Durability: These countertops are durable and resistant to scratching and impact, making them suitable for daily lab activities.
• Non-Porous: Acrylic resin countertops are non-porous, which means they are easy to clean, maintain and do not harbor bacteria or contaminants.
• Customization: Acrylic resin countertops can be customized to fit the specific needs of the lab, including the integration of sinks and backsplashes.

While acrylic resin countertops are more chemically resistant than some other materials, they are not as chemically resistant as epoxy resin or phenolic resin countertops. This means they may not be suitable for certain specialized lab applications that require higher levels of chemical resistance.

Acrylic resin countertops are also sensitive to high heat, and prolonged exposure to temperatures exceeding 200°F can cause damage. In labs where high-temperature processes are common, this may be an important limitation to consider.

Which Resin Countertops Are Best For A Lab?

In laboratory and industrial settings, selecting the right countertop material is crucial to ensuring safety, functionality and longevity. Two of the best options for these demanding environments are epoxy resin and phenolic resin countertops. These materials offer exceptional chemical resistance, durability and hygiene, making them well-suited for the challenges of laboratories, cleanrooms and industrial workspaces.

Of these two, which is better? Epoxy resin countertops or phenolic resin countertops?

Your decision boils down to two key areas: Continuous heat tolerance and budget. 

Epoxy resin offers protection against continuous high heat exposure for extended periods of time. On the other hand, phenolic resin countertops still offer excellent resistance to heat, but can only withstand continuous heat exposure up to 350°F.

Another important consideration is the cost. Epoxy resin countertops are generally more expensive than phenolic resin countertops. In fact, pricing for phenolic resin averages $15 to $18 per square foot and increases based on modifications specific to a lab’s needs. 

The cost of epoxy resin typically runs $100 to $200 per square foot. Epoxy resin is also a heavy product, which can impact shipping costs.

The choice among resin countertops for laboratory settings depends on the specific needs of the lab. In laboratories with harsh working conditions, epoxy resin and phenolic resin offer outstanding protections. However, phenolic resin may be the preferred choice when cost is a primary concern and heat resistance is not a key requirement. 

Careful consideration of these factors, along with consulting experts in laboratory design, is crucial to make the right choice for your laboratory or industrial workspace.