05.10.2023 | High-tech material with outstanding properties

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By virtue of its special properties, DuroCast can be used to produce precise shapes with fine contours and radii, as illustrated here by the above-counter basins of the Vitrium range by Christian Werner. (Image source: Duravit AG)

• Mineral material produced from select raw materials
• Four variants available: DuroCast Plus, UltraResist, Smooth and Nature
• The material’s special properties make it ideal for bathroom objects
• Durability, high stability and slip resistance
• Broad variety of finishes, colors and textures

Duravit presented the first bathtubs produced in a mineral material in 2015. The development of the mineral casting process at the complete bathroom supplier goes back much further than this, however: For 20 years, materials experts, product developers and designers have been working hand in hand to examine how selected raw materials interact, in a quest to identify the ideal high-tech materials for the production of bathroom objects in particular. By virtue of its special properties, DuroCast can be used to produce precise shapes with fine contours and radii, textured surfaces, diverse colors and matt or glossy finishes. The material is also long-lasting, slip-resistant and extremely robust.

Duravit has continually developed this innovative material, which is now available in four variants: Alongside DuroCast, the mineral-cast range also includes DuroCast UltraResist with an additional lacquer finish and DuroCast Smooth featuring a gelcoat. Rounding off the range, DuroCast Nature is used in the recyclable Sustano shower tray range.


Material development meets design

By interlinking material development and design, Duravit is setting a new standard, as the interaction between the two components gives rise to innovative ideas. “Here at Duravit, materials research and design development work hand in hand like cogs in a finely tuned machine. This ensures that the original idea ultimately leads to a perfect end result,” explains Juri Wittich, who is responsible for Product Development Management – Wellness Technologies. With over 20 years of experience in mineral casting technology, the complete bathroom supplier has a wealth of knowledge and internal expertise at its disposal. In close cooperation with renowned designers, this gives rise to ground-breaking bathroom equipment and fittings


In-house technology and production

A design workshop with integrated technology center dedicated to the new mineral material DuraCast has been established between high-tech and manual work at the production plant in Bischwiller, Alsace. Here, as at the plant in Egypt, Duravit recently began manufacturing washbasins and paneling for toilets, in addition to its bathtub and shower tray production.
DuroCast Plus, UltraResist and Smooth consist primarily of natural minerals plus resin as a binder. In contrast, DuroCast Nature consists of polyurethane mixed with marble powder and is provided with a colored gelcoat finish, similarly to DuroCast Smooth. In the case of DuroCast Plus, the entire substrate is enriched with pigments, resulting in full-body coloring.
The raw materials are mixed in an automated process and prepared for casting. The resulting homogeneous casting mass is poured into the molds. Casting is followed by two drying stages: In the first step, the liquid casting mass hardens in a mold in the drying chamber. In the second step, the product is demolded and undergoes low-stress tempering in a kiln on a separate pivot bearing at temperatures of up to 80 °C. The final material hardness is achieved during this stage. The low drying temperature means that production of the material requires less CO2 compared to the energy-intensive production of ceramics.


Special features of the materials

DuroCast Plus – for robust bathroom classics
In a cooled state, the products receive their defining finish in the polishing booth. “This is where the fine finish which makes the product especially warm and gentle to the touch is applied,” notes Eric Mercier, director of the DuroCast production plant in France. DuroCast Plus is a homogenous material with full-body white coloring. It is durable, stable and furthermore allows any signs of wear to be touched up and kept, provided that the repair work is carried out in the correct manner. A further advantage of this material is its slip-resistant surface structure, which is particularly important in the bathroom.

DuroCast UltraResist – for extreme robustness
In contrast to the Plus variant, the demoulded bathtubs and washbasins in DuroCast UltraResist are provided with a lacquered finish to seal the surface. For this purpose the products are first of all cleaned and provided with a thin preparatory lacquer layer, to which the first lacquer coat is then applied. After the first drying process of 5 to 6 hours’ duration, the surface is gently ground before applying the second and final lacquer coating, which again dries for 5 to 6 hours.
The double lacquer coating provides DuroCast UltraResist with an immaculate finish and also endows the material with properties which are particularly advantageous in the bathroom area: The porous surface makes DuroCast UltraResist easy to clean and comparatively resistant to scratches and dirt.

DuroCast Smooth – for versatility and variety
For this material variant, a gelcoat is first of all applied to the molds. In the subsequent casting process, the casting compound of the substrate bonds with this gelcoat. The gelcoat provides DuroCast Smooth with a robust, easy-to-clean and UV-resistant surface which offers excellent material properties and a diverse range of finishing options. The gelcoat enables varied colour designs and unusual textures – with a choice of glossy or matt finishes, as demonstrated by the paneling for the Millio toilets, for example.

DuroCast Nature – for more sustainability
Here too, the gel coat is first of all applied to the molds. The casting process then takes place, in the course of which the casting compound bonds with the gelcoat. Duravit has set up a new production facility to manufacture shower trays made from this material. The molds are developed and produced in-house, guaranteeing precise shapes (and, where appropriate, geometries) with extremely minimal tolerances. DuroCast Nature is recyclable and boasts excellent properties, such as the robust and easy-to-clean gelcoat, which offers superlative slip resistance in the matt variants.
As well as being pleasant to the touch, the pore-free surface creates a fine finish which opens up diverse options in bathroom design in combination with modern colors.
Another advantage is the ease of handling: shower trays from the Sustano range can be easily modified during installation at the construction site, and up to 100 mm can be taken off the sides. In addition, the shower tray’s low weight facilitates handling at the construction site and reduces transport-related CO2 emissions. At the end of their useful lives, the products can be returned to Duravit or a local recycling center.