COMPACT LAMINATE

As installers explore kitchen surfaces which are not only hardwearing, but are also easy to fit and maintain, compact laminate has emerged as a viable alternative to a natural stone countertop. Here, Paul Graham, technical expert at Bushboard, takes a closer look at how straightforward the versatile material is to work with.

While the home improvement boom may have started to slow, many kitchen installers will still be keen to explore products that are more cost effective and help them to reduce project lead times. One such material, compact laminate, offers an aesthetic comparable to natural stone, but with a surface that is much more straightforward to work with.

Historically seen as a 'value' alternative for worktops, continual research and development has ensured the surfaces available today not only replicate the look and feel of stone but are just as hardwearing. →

Created by compressing layers of decorative paper and resin to form a non-porous core, the surfaces are then sealed for a watertight and non-abrasive finish. Surfaces such as Bushboard’s Zenith range are among the most economical options for kitchen worktops that offer greater design freedom than their stone counterparts.

Compact laminate, offers an aesthetic comparable to natural stone, but with a surface that is much more straightforward to work with.

Tooling and planning

While stone or marble worktops require specialist tools, no specialist tools are needed to cut and fit a compact laminate worksurface to a high standard needn’t be quite so specialist. One piece of technical advice that is always worth considering, however, is that if your plunge saw with router has a speed regulator, it is always advisable to reduce it to half speed when working with compact laminate.

Before cutting to size, it is vital to ensure no joints in the laminate surface extend across any oven or sink cut-out areas and joints should always be supported from below. When cutting, it's best to have the blade at speed to avoid burning the product and plunge in three sets of 4-5mm increments to complete the cut. Finally, allow for 2-3mm for the final skim to size. Once scribed to the walls with a circular saw, you can sand the front edge. Top and bottom edges should be sanded with 240 grit sandpaper to remove any chipping or sharp edge that has occurred during the scribing and cutting process.

Creating the perfect bond

To bond two worktops together, you'll need a 2-part epoxy resin adhesive. Bushboard also supplies its own patented colour-matched adhesive called Complete – a liquid polyurethane-based formula adopted from the marine and aerospace industries, offering gap filling properties and strong grab adhesion to create a water-tight seal. Joints can be formed either as a mason mitre or butt joint.

Make a dry-fit of the joint before using your chosen adhesive to adhere the two parts together. Suction cups should be used to keep the edges tight and once these edges have been pulled up tight you should see adhesive squeeze out. This surplus adhesive must be removed at this point using a cleaning wipe and not left to cure as that will negatively impact the finish. Finally, edges can be shaped using a router and template to the desired radius or shape then using grit sandpapers to create a smooth front edge and remove any router marks. As they are supplied with a finished surface with a semi-finished front edge that must be sanded to remove any visible manufacturing saw marks. No oiling or polishing is required to complete the installation.

Zenith Boston with 10mm upstand

Final finishes

With its waterproof core and nonporous surface, the compact laminate Zenith range is ideal for installing under-mounted sinks and inset drainage grooves. Both inset sinks and drainage grooves can be installed with relative ease, ensuring the functionality of the kitchen appeals as strongly as its looks.

Complementing any kitchen design, the Zenith range comes with matching breakfast bars, upstands and splashbacks, which are as easy to install as the worksurfaces, meaning there are opportunities for further hassle-free work.

As homeowners look for maximum value from their investment in home improvements, compact laminate can help any time-pressed installers with its straightforward installation process, further attracting clients with striking design possibilities, rivalling stone worktops not just in cost but versatility.

www.bushboard.co.uk.