This year we have been blessed…. Well, maybe not blessed but we’ve had the pleasure of having to produce some VERY awkward counters, I’d like to talk about 2 in particular which have one thing in common, the finish.
They are both covered with solid surface material, Solid surface is a man-made, non-porous material composed primarily of acrylic, polyester resins, and natural minerals. It’s designed to mimic the look of stone while being seamless, durable, and hygienic. Common brands include Corian, Hi-Macs, and Staron.
This material is ideal as it can be thermoformed into curves, joined invisibly, and easily repaired or refinished, making it ideal for, counters in healthcare and commercial spaces. The fact that it can be joined invisibly was the reason it was chosen for these applications.
Both desks were for want of a better word… Awkward! They were both a funny shape on all planes and tested our skills to the max. I’ll describe each counter individually for you and you may be pleased to read that I have pictures….
The first desk we undertook was for a hospital in Coventry, this desk had special requirements, it had to be a certain shape so it would allow the user to be able to view the length of all four corridors in the ward, it was also required to be built in a cantilever angled fashion so there was no way of anyone being able to climb over it. in short… ANGLES – SO MANY ANGLES!
To achieve the shape, we first visited site to take a precise template of the area, using it as a rod back in the workshop to build from (proper old skool!) Danny and I then drew up the counter ribs so they could be CNC-cut from plywood. Once those were ready, we set about constructing the desk. The whole team got involved, building a substantial ply framework which would later be clad with MDF.
Cladding the frame brought its own challenges, compound angles were running through the lads’ minds every minute of every day. The desk completely dominated Unit 5, swallowing up space and chewing through a serious amount of material. Once the cladding was complete, the team took the unit to site for a trial fit. We needed to be sure it was spot on, as once it was wrapped in solid surface, any alterations would be a whole different story!
We are lucky to work with some wonderful companies, we have some brilliant partners in many fields, Metalwork, Building, Glazing and in this case Solid Surface. In both these projects we worked seamlessly (no pun intended) with Ideal Surfaces in Hinckley. Once we were certain the desk fit, we took it down to Ideal Surfaces so they could work their magic. During the solid surface fabrication, Danny and Owen made regular visits to their factory to discuss progress, plan the installation, and iron out any issues as they arose.
Thankfully our templating and site check paid off as the unit fit perfectly in position.
The inevitable day arrived, the delivery and installation day for this colossal beast of a desk! It was a full team effort, with five lads from JFW Ltd and two from Ideal Surfaces making up the fitting crew, and we needed every one of them. This thing genuinely weighed a ton! Thankfully, all the careful templating and our on-site trial run paid off, as the unit slid perfectly into position without a hitch.
Now, the client has a stunning desk that fits the space flawlessly, both in size and style. It not only meets their functional needs but also makes a real statement in the room, combining craftsmanship, precision, and design in one impressive centrepiece.
That wraps up the first of our two solid-surface challenges. The second counter was every bit as intricate, but with its own unique twists and surprises.
Part 2 will be available to read next week, keep an eye out!
Have a great weekend.
Adam
