Countertops

When installed in a kitchen, countertops are usually about 25 1/2 inches (650 mm) from front to back and are designed to slightly-overhang standard kitchen base cabinets. This allows a convenient reach to objects at the back of the countertop. They often contain some sort of integrated backsplash to prevent spilled liquids from falling behind the cabinets and the face of the countertop may be decorated in ways ranging from plain to very elaborate. They may be cut away to accommodate the installation of sinks, stoves (cookers), ranges, and cooktops, or other accessories such as integrated drain boards and cutting boards.

Solid-surface plastic acrylic or polyester materials are usually prefabricated at the installer's shop and then assembled on site. The plastic material is readily glued and the glue joints are then sanded, leaving almost no visible trace of the joint. The edge treatment for solid-surface countertops can be very elaborate. The material itself is usually only about 12 mm (1/2 inch) thick so an edge is usually created by stacking up two or three layers of the material. The built-up edge then can be shaped to a rounded edge or an ogee. Fancier edge treatments are, of course, more expensive.

The most economical style is the "postformed" (or literally "formed after being laminated" to the substrate) high pressure laminate countertop, often referred to as "plastic laminate countertop", however, the surface material is more of a wood product, consisting of kraft and decorative papers, and resins, bonded through high heat and pressure. We often refer to the product as "Formica", but that is a trade name of a manufactured high pressure laminate. http://www.expol.com.pl

The postform countertop is typically a high volume factory-produced product, which accounts for the economy of the product. The material composition consists of a single thin sheet of laminate (typically .030" - .040" in thickness) that gets bonded to a 45# density particle board substrate (or other similar base material such as MDF - medium density fiberboard, or plywood), with a PVA adhesive (poly vinyl acetate - a water-based adhesive).

A typical system consists of the following:

1) An automated infeed system for sequencing the particle board into production. 2) The CorFab Machine, an automated feed-through machine that cuts to size, cuts and bonds build down sticks with a hot melt adhesive to the under side of the substrate, and shapes the edge detail, all in a single motion. 3) An automated laminating system that applies the adhesive to both the substrate and laminate. 4) An indexing unit that aligns the laminate to the substrate with the proper overhang. 5) A Pinch Roller that makes the bond between the laminate and substrate. 6) The Postforming Machine, that not only heats and forms the laminate around the substrate, but also cuts away the backsplash from the main deck, all in a feed-through motion machine. 7) The AutoCove Machine, which heats and forms the backsplash upward 90 degrees, locking it into place with what is referred to as a cove stick, utilizing hot melt adhesive technology to hold it all together. 8) The final stage of the system usually consists of a trim saw that cuts the countertops to rough lengths, typically 8', 10' and 12', ready for distribution.

Once manufactured and in the hands of a professional installer, the tops need only to be cut to length, mitered, fitted for assembly, and end capped (only if it is a visible finished end). Sink cut outs can be made either in the field or at the installers shop. A very specific machine for cutting the postform countertop is manufactured by only a few companies. This machine accurately cuts the countertop to field dimensions, making it easy for the installer to make the final scribe cuts on-site to complete the work.

A proper installation of a postform countertop will leave the home owner with a contemporary design element in their home, provide durability at a low cost, and allow for easy to no maintenance of their decorative surfaces for years to come. It is not only a wise choice for value, it is a smart choice for both function and esthetic.