Marble Acrylic Laminated PVC Foam Board combines a rigid extruded PVC foam core (celuka or free-foam) with a high-definition marble-patterned acrylic (PMMA) film. Lamination utilizes PUR (Polyurethane Reactive) hot-melt adhesive systems on continuous roller lines, finished with a UV-cured protective topcoat.
This material replaces natural stone and heavy ceramic tiles in vertical interior applications. Standard production sizes are 1220 x 2440 mm (4 ft x 8 ft) with thicknesses scaled from 3 mm to 18 mm.
Technical Specifications
| Parameter | Test Standard | Specification Value |
| Core Substrate | ASTM D1505 | Extruded Rigid PVC Closed-Cell Foam |
| Surface Layer | ISO 2813 | High-Gloss / Matte PMMA Acrylic Film (0.15 - 0.35 mm) |
| Adhesive System | Internal Method | Moisture-Reactive PUR Hot-Melt |
| Standard Thicknesses | ISO 4593 | 3, 5, 9, 12, 15, 18 mm (tolerance: +/- 0.2 mm) |
| Standard Dimensions | ISO 2768-m | 1220 x 2440 mm, 1220 x 3050 mm |
| Standard Density | ISO 1183 | 0.55 - 0.70 g/cm3 |
| Lamination Peel Strength | ASTM D903 | >= 45 N/25mm (Substrate failure threshold) |
| Surface Hardness | ASTM D3363 | 2H (Pencil Hardness Test) |
| Water Absorption | ASTM D570 | < 0.5% (24-hour immersion) |
| Fire Retardancy | UL94 / EN 13501 | UL94 V-0 / Class B s2 d0 |
Key Features
Moisture Immunity: Closed-cell PVC matrix prevents water migration, eliminating panel swelling, rot, and delamination in humid environments.
Dead-Load Reduction: Panel weight averages 6 kg/m2 (9 mm thickness), decreasing structural support requirements and shipping freight penalties compared to stone tiles.
Surface Resilience: PMMA cap-layer provides resistance to dilute acids, alkalis, household disinfectants, and surface scratching.
Machinability: Compatible with standard woodworking machinery (CNC routers, table saws, edge banders) without chipping or fracturing the decorative veneer.
Visual Continuity: Multi-pass rotogravure printing yields high-definition marble veining with regulated pattern repeat intervals across production batches.
Applications
Wall Panelling: Interior cladding for hotel corridors, commercial reception areas, and elevator cabins.
Casework & Cabinetry: Door panels, interior shelving, and partition inserts for high-end retail display fixtures.
Wet-Area Surrounds: Waterproof vertical paneling for commercial washrooms and healthcare interiors.
Visual Communication: Structural display backdrops and exhibition booth construction requiring rigid, high-gloss stone aesthetics.
Surface & Finish Options
High-Gloss Finish: Mirror-like reflection (> 85 gloss units at 60 deg) via UV acrylic topcoats.
Anti-Fingerprint Matte: Low-reflectivity surface (10 - 20 gloss units) designed to minimize grease smudges in high-touch environments.
Embossed Textures: Synchronized embossing aligned with marble veining to replicate tactile stone grooves.
Pattern Library: Over 120 stock patterns (Carrara, Calacatta, Statuario, Emperador) alongside custom digital color matching via physical client swatches.
OEM & ODM Customization
Density Tuning: Foam extrusion profiles adjustable from 0.50 g/cm3 (lightweight signage) to 0.80 g/cm3 (high screw-withdrawal strength for hardware mounting).
Backer Balancing: Application of a functional balancing primer or secondary film to the rear face to maintain panel equilibrium during thermal fluctuations.
Custom Dimensions: Non-standard widths up to 1520 mm and lengths up to 3050 mm subject to minimum batch runs.
Film Development: Custom acrylic film extrusion matching specific architectural color palettes (Minimum order: 500 sheets per pattern).
Quality Control
Incoming Material Audit: Virgin PVC suspension resin, calcium carbonate fillers, and imported PMMA films are tested for Melt Flow Index (MFI) and color delta-E limits prior to processing.
Peel Adhesion Testing: Destructive T-peel tests conducted every 2 hours on line samples to verify PUR bond integrity.
Accelerated Weathering: QUV-A chambers test color-fastness and gloss retention per ASTM G154 (1,000-hour threshold).
Dimensional Inspection: Automated optical sensors verify diagonal squareness, length, and thickness tolerances on every manufactured sheet.
Supply Chain & Logistics Capacity
Manufacturing Output: 6 automated extrusion lines with a combined monthly output of 350,000 m2.
Packaging Protocol:
PE protective masking film on the decorative face.
Low-friction polyethylene foam sheets placed between panels.
Corner edge protectors applied to all four sides.
Fumigation-free plywood pallets secured with steel banding and waterproof stretch-wrapping.
Container Utilization: Optimized loading patterns (e.g., approx. 850 sheets of 9 mm panels per 20GP container).
Standard Lead Times: 15 - 20 days for catalog finishes; 25 - 30 days for custom OEM runs.
Manufacturing & Processing Facility
Extrusion Systems: Conical twin-screw extruders combined with vacuum calibration dies ensure uniform foam cell distribution and consistent core density.
Lamination Cleanroom: PUR hot-melt roll application takes place within a temperature-controlled, filtered environment to eliminate particulate trapping beneath the acrylic veneer.
Post-Processing Cell: In-house automated panel saws, multi-head CNC routing centers, and edge-trimming machinery support custom cut-to-size deliveries.
FAQ