THE BASICS

INTRODUCTION TO TUBLINERS:

A tubliner is a new bathtub custom-made to fit perfectly over an existing tub. It is manufactured using a sheet of co-extruded DR/ABS (Durable Rubber Acrylic/Acrylanytril Butadiene Styrene). The acrylic portion of the product, the DR is the top 10% of the sheet. It is pigmented a solid color then modified for a high-impact surface. The ABS is the bottom 90% of the sheet. Like the DR, it is also pigmented. ABS is used because it is rigid, yet capable of flexibility.

Using a process called co-extrusion, a single sheet is manufactured by combining both materials simultaneously. It is not like laminating, which is heat-bonding two pieces together. Laminated goods may separate or peel especially in the hot humidity found in the bathroom. With different length capacity, assorted solid colors, and the variety of molds ready at the manufacturing facility, there are thousands of tubs styles available. Every tubliner has an NAHB approved, integral slip-resistant bottom.

With its durable surface, DR/ABS will not chip, crack, scratch easily or peel. It is also easy to clean; with proper care, it will retain its gloss for many years. DR/ABS is a non-organic compound and is not affected by most acidic drain cleaners. A list of recommended cleansers can be found on this web-site. If improper cleansers are used, damage can occur and void the manufacturer's warranty. Keep in mind, the less effort expended on scrubbing the bath area, the better the DR/ABS acrylic will look!

A BRIEF "PLASTICS" HISTORY:

Plastic is a term applied to organic polymeric materials (those consisting of giant organic molecules) that are plastic- that is, they can be formed into desired shapes by extruding, molding, casting or spinning. The molecules can be either natural: cellulose, wax, or natural rubber or synthetic: polyethylene or nylon. The starting materials are resins in the form of pellets; from these are formed the finished plastics.

Plastics are characterized by high strength-to-density ratios, excellent thermal and electrical insulation properties, and good resistance to acids, alkalies and solvents. The giant molecules structuring the plastic is linear or branched which are called thermoplastic; the plastic will soften when heated.

The development of plastics began about 1860, after Phelan and Collander, a U.S. firm manufacturing billiard and pool balls, offered a prize of $10,000 for a substitute for natural ivory. One of those who tried to win was an inventor John Wesley Hyatt. He developed a method of pressure-working pyroxylin, a cellulose nitrate of low nitration, that had been plasticized with camphor and a minimum of alcohol solvent. This product was patented under the trademark Celluloid. This was used to manufacture objects ranging from dental plates to men's collars. Unfortunately it was highly flammable and liable to deteriorate when exposed to light. Other plastics were introduced such as rayon (modified natural polymers) and Bakelite (totally synthetic plastic).

In 1920 a German chemist, Hermann Staudinger, hypothesized that plastics were truly giant molecules. The subsequent efforts to prove/disprove this claim resulted in major breakthroughs in the chemistry of plastics. Contributed were materials such as: cellulose acetate (for molding resins and fibers), polyvinyl chloride (for plastic pipe, vinyl coatings, and wire insulation), urea-formaldehyde resins (for tableware and electrical applications), acrylic resin (for a binder for laminated glass) and of course polymerized methyl methacrylate, which beginning in 1937, was marketed as Lucite and Plexiglass.
The basic polymerization process for producing the resin is addition reaction. Addition reaction produces only specific chain lengths of molecules with no by-products generated. Addition polymers include polyethylene, polypropylene, polyvinyl chloride, and polystyrene. The manufacture of the acrylic product involves procuring the raw materials, synthesizing the basic polymer, compounding the polymer into a material useful for fabrication, and molding the acrylic into raw sheet in preparation for the final forming.

Most acrylic raw material today is derived from petrochemicals. Coal gasification is also being explored due to the possible exhaustion of the world supply of oil in the 21st century. As the polymer is to be compounded chemical additives are often used to produce some desired characteristic. In our acrylic you can expect: ultraviolet stabilizers to protect against discoloration due to florescent or natural light, plasticizers to make the polymer more flexible, and the pigment is added for the color. Many plastics are manufactured as composites. This involves a system where reinforcements are added to a plastic resin matrix. Composites have strength and stability comparable to that of metals but with much less weight.

The technique used for shaping and finishing plastic depends on three factors: time, temperature, and flow (or deformation). Our acrylic is fabricated by extrusion. This allows for consistent and exacting standards for the finished product. The extruder is a device that pumps the flowable acrylic through the desired shape (flat sheet) which creates a regularly shaped cross section. It is then sheared at the length desired and palletized for shipping. The next manufacturing step is at Liners Direct to a tubliner, shower liner, window kit, soap dish, tower caddy, etc.

To the majority of homeowners, the idea of covering the tub up rather than throwing it away and starting over makes sense on a number of levels:

• It's faster and more efficient
• It's much less disruptive
• It's cheaper
• It's environmentally friendly- we're not cramming overloaded landfills with bulky, corroded bathtubs.

In summary, this is a win-win product and LDI provides a very high quality product. At .270, it is the thickest tubliner material available. The basis for pre-installation measurements, shipping in modules (or pieces) which conform to exact measurements, and doing a professional installation makes imminent sense. These procedures work because:

• The molds at the factory really do conform to the requirements of each customer
• Our acrylic material really is mildew resistant and so easy to maintain
• The adhesive seal during installation really is airtight and waterproof, when done correctly.
• The silicone used really is mildew-resistant and won't stain if cleaned regularly, and won't crack or corrode like traditional latex caulks.

Who should have acrylic?

• Single family homes: the time not needed to scrub away lime stains or re-grout speaks for itself. Also, the acrylic will not harbor mold- a terrible health allergy for children which gets worse (not better!) with time.
• Empty-nesters: now that the kids are gone, it's your turn for a beautiful, timeless bath that will remain clean while you're off to Arizona or Aruba.
• Neighborhoods 8 years or older: most of these homes have bathrooms in pretty good shape, they're just not pretty. Don't wait for the bathroom to be condemned before you do a facelift!
• Homes with pets: (especially dogs) Acrylic can take a beating so don't worry about tossing Prince into the tub for a shower!
  

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