Solid Surface Installation Guidelines

When working with solid surface products, it is important to remember that the fabrication techniques used will affect the appearance and performance of the finished installation. Training, which specifically addresses solid surface fabrication and installation, is recommended.

Proper conditioning of the solid surface sheets, along with other materials being used in the assembly, will minimize shrinking or expansion of the final installation. Ideally, all components should be conditioned at 70° to 75°F and relative humidity at or below 45% for 48 hours prior to installation.

Corner joints should be made square rather than mitered. This minimizes material usage and facilitates installation. To prevent stress cracking, seams should be placed at least 3” (76.2 mm) away from any corner or cutout.

All joints should be reinforced with a 4” (101.6 mm) wide strip of solid surface material and supported by framing. Joint edges should be straight, smooth and clean. To minimize the potential for stress cracking, exposed edges of the reinforcing strip should be chamfered.

For cutouts, use a router equipped with a sharp 3/8” (9.5 mm) diameter (minimum) carbide bit. The corners of a cutout must be rounded to a 3/16” (5 mm) radius and smoothed on both top and bottom. Inside corners require a smooth 1/2” (13 mm) radius. Larger radii are recommended whenever possible.

Solid surface is compatible with many commercially available caulks and sealants; however, a specially-formulated solid surface adhesive is required for making joints, repairs or custom edges.

Install countertops on perimeter framing support (without added substrate), using small amounts of silicone sealant.

Sheets of solid surface may be installed vertically over suitable substrates such as marine-grade plywood, water-resistant gypsum board and ceramic tile. Neoprene-based panel adhesive or white or clear silicone may be used. DO NOT USE WATERBASED ADHESIVES.

The recommended expansion clearance with uncaulked solid surface sheets is 1/32” (.8 mm) for every 8’ length. Joints to be caulked should be approximately 1/8” (3 mm) wide to allow for caulk penetration and expansion.

Article Source: Modern Woodworking