By Paul Bianchina
If you're looking to do something different in your kitchen, you might want to consider the option of a solid-surface countertop such as Corian or Avonite. While more expensive than many other types of tops, they can make a bold and beautiful addition to any kitchen.
Solid surface tops are manufactured from specific polymer blends, chemically engineered to be resistant to stains and acids. Besides good looks, solid surface material offers a number of benefits when used as a kitchen countertop. The material is solid color throughout; the color and pattern go all the way through the countertop. This differs from a plastic laminate top, which only has a surface layer of material over a substrate of plywood or particleboard, and even ceramic tile, which has a glazed color layer over a white core.
This translates to a top that is extremely durable and easy to maintain and repair. The material is non-porous and naturally resistant to a number of stains, so routine maintenance typically involves only washing with a damp cloth. But should you stain, burn or scratch the surface, you can literally sand it off. Depending on the severity of the stain, you can use anything from abrasive household cleanser to fine sandpaper to remove the discoloration.
A Look at the Options
You will find solid surface tops in a variety of colors and patterns. There are solid colors ranging from white and almond to several different colors. There are also natural-looking patterns that duplicate the rich and fascinating colors of granite, marble and onyx in subtly blended shades ranging from tan and peach to greens, blues, grays and blacks. Where solid-surface materials such as Corian used to be associated only with white, there are now enough colors to match and compliment any type of kitchen.
Solid surface materials are typically available in 1/4", 1/2" and 3/4" thicknesses. The 1/4" material requires solid backing, and is typically used primarily for shower walls and similar applications. The 1/2" and 3/4" materials are best for countertops, with the 3/4" material being able to span greater distances unsupported. Refer to the manufacturer's specifications for specifics on span and weight-bearing capabilities.
In addition to the solid sheets, there are accessories such as pre-cast sinks and cutting boards to round out the installation. Sinks can be either top-mounted or mounted underneath the counter, and are available in several colors and patterns and in sizes ranging from approximately 14" x 16" (bar sink size) to standard 36" x 22" double-bowl configurations. Sinks come pre-cut with a bottom drain hole that fits all standard basket strainers and garbage disposals, and can be ordered with one to five holes for mounting faucets and accessories, or undrilled for more on-site placement flexibility.
Fabrication and Installation
For the experienced do-it-yourselfer, solid surface polymer materials can be cut and shaped with most types of standard woodworking tools, including table saws, jig saws, routers and drills. Carbide-tipped cutting tools are recommended. The material is hard and dense, and is somewhat similar to working with a hard, straight-grained wood such as maple. Fabrication takes care and patience, and you need to wear eye protection to guard against the possibility of flying chips.
Special seam kits, available from your material supplier, are used to join the pieces together at the corners and other areas. This is a two-part material similar to epoxy, and when done correctly, it produces a flawless seam that is virtually invisible. Read all manufacturers' instructions in advance, and follow them exactly for best results.
A better option is to have the tops professionally fabricated. After your cabinets have been installed, the fabricator will measure the exact size of each cabinet run, and will custom-make the counters to fit, including making cardboard templates of curves and complex areas as necessary. The tops are final trimmed on site, and backsplashes and other components are added to complete the installation.
Another advantage to having a pro do the work is the availability of a wider variety of custom edge treatments. You can choose from simple square or curved edges, or thicker and more complicated routed edges. You can also select from a wide variety of inlays to accent the front edge, ranging from simple color stripes to inlays of brass and other materials.
Solid surface countertops average 3-4 times the cost of a laminate top, and 1 1/2 to 2 times the cost of ceramic tile, depending on the complexity of the installation, the edge treatment chosen, and the number of custom features such as built-in sinks. You can find solid surface material suppliers and fabricators in the Yellow Pages under "Counter tops."
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