Chloe Zhang
Plastic laminate countertops, such as Formica, are a popular choice for those looking for an affordable, lightweight, and easy-to-install option. Formica is a well-known brand of household laminate that comes in a variety of colours, textures, and patterns. In this guide, we will walk you through the steps of installing plastic Formica countertops, from preparing the surface and measuring the space to cutting, gluing, and sealing the laminate. We will also offer tips on choosing the right type of laminate for your project and provide care instructions to ensure your new countertops stay beautiful for years to come.
| Characteristics | Values |
|---|---|
| Installation | Measure the length and width of the area, scribe the Formica if walls are not at right angles, use a tape measure, place Formica on a flat surface, mark measurements on the back of the Formica sheet, apply masking tape along the lines, cut using ordinary saws |
| Adhesive | Apply contact cement to the edge strip and surface, allow to set until tacky, follow manufacturer's directions, use a brush or roller |
| End caps | Iron onto the end of the countertop with a back-and-forth motion, tap carefully with a rubber mallet, finish trimming with a fine file, use non-pre-glued end caps with contact adhesive, follow manufacturer's guidelines, roll laminate with a J-roller |
| Edge pieces | Cut from laminate, apply contact cement, align the edge strip carefully, press it to the surface, use a roller |
| Angled edges | Install using miter bolts and sealant, use precut angles of 45º or 22.5º for L-shaped countertops, apply a bead of sealant, tighten fasteners enough to hold in place, tap surfaces to align, tighten securely |
| Backsplash | A vertical section of material above the countertop to protect the wall from stains, consider installing a laminate backsplash |
| Maintenance | Clean with a damp cloth and mild soap or detergent, avoid abrasive pads and cleaners, use hot pads or trivets for hot objects, use a cutting board to avoid surface damage, use self-cleaning wax to minimize staining |
| Material | Plastic laminate is durable, lightweight, easy to work with, and reasonably priced, comes in various patterns and colors, hide decorative edge treatments with different patterns or materials |
| Thickness | Typically about 1/16-inch thick |
| Transport | Roll the plastic laminate in a minimum 24-inch roll and tie with string |
| Installation surface | If keeping the same countertop shape, apply plastic laminate over the old countertop, fill in any deep gouges, use 3/4-inch-high density particleboard for a new shape, repair any blemishes, cut with a circular saw and jigsaw |
| Gluing | Clamp a straight edge over the laminate, use a scoring tool to mark, flex to break, glue laminate to particleboard with water-based cement, use a heat gun to bend around ends, glue on the edge piece |
| Cost | Formica laminate costs $14 to $38 per square foot, compared to installed granite at $120 per square foot |
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What You'll Learn
Planning and preparation
Firstly, decide on the shape and style of your countertop. You can use your old countertop as a template or create a unique shape. If you opt for an L-shaped or U-shaped countertop, you will need to join pre-cut mitres during installation. Consider the colour, pattern, and finish of the Formica to match your house's colour scheme and design style. Formica comes in a variety of options, including solid colours, graphic patterns, and natural stone looks. You can also choose between a matte or glossy finish, keeping in mind that matte finishes hide wear and tear better.
Next, carefully measure the length, width, and dimensions of the area where you will install the Formica. Proper measurement is crucial, especially if you are having your Formica pre-cut. Ask your countertop supplier for specific measuring instructions. If your walls are not at perfect right angles, you should scribe the Formica accordingly.
Prepare a flat, stable surface larger than the Formica sheet to keep it steady while cutting. Use scrap plywood or similar material. Mark your measurements on the back of the Formica sheet, adding an extra inch to each measurement to avoid wasting material. Draw cut lines along the increased measurements and apply masking tape along these lines.
If you are installing a full countertop, plan for end caps at each appliance and wherever the countertop ends. You can use pre-glued end caps or apply contact adhesive to both the substrate and the laminate, following the manufacturer's guidelines. If you are installing laminate on a countertop with edges, begin by applying contact cement to the edge strip and the surface it will attach to.
Before gluing the Formica, clamp a straight edge over it and use a scoring tool to mark it. Then, flex the sheet up and down to break it. You can use water-based cement, which is safer to work with, or solvent-based contact cement, which dries faster.
Finally, gather the necessary tools and materials, including a saw, sander or block plane, J-roller, rubber mallet, and laminate trimmer (optional). If you are installing a sink, have the necessary plumbing fittings ready.
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Cutting the Formica
Cutting Formica or any other brand of household laminate does not require special tools. You can use ordinary saws to cut the laminate to size.
Before cutting, measure the length and width of the areas where you will install the Formica. Use a tape measure to get an accurate measurement of each dimension of the area. Place the Formica on a flat, stable surface, like scrap plywood or a similar material. Avoid concrete or another surface that will damage the saw blade.
Mark the measurements on the back of the Formica sheet, adding 1 inch (2.5 cm) to each measurement. Draw your cut lines onto the laminate at the increased measurement, which ensures you don't waste material by cutting too small a piece. Apply masking tape along the lines.
If you are installing an L-shaped countertop, Formica typically comes precut with angles of either 45º or 22.5º. If you are cutting the angles yourself, attach the diagonal pieces together with miter bolts after aligning their front edge. Do not over-tighten the miter bolts. Only tighten enough to keep the pieces in place. Tap down one piece of laminate with a rubber mallet or shoe heel if the surface is not level across the diagonal.
If you are installing a sink, you may find it more convenient to install the sink faucets, supply tubing, and basket drain before dropping the sink into place.
If you are cutting the laminate yourself, apply contact cement with a brush or roller to both the laminate and the edge surface it will attach to. Allow it to set until it feels tacky, according to the manufacturer's directions. If you are using pre-glued end caps, heat a clothes iron and place the laminate against the edge, ironing back and forth. Let it sit for one minute and gently tap it along its length with a rubber mallet or shoe heel.
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Applying contact cement
When applying contact cement, follow the manufacturer's instructions. If you are installing laminate on a countertop with edges, start with the edge pieces. Cut them from the laminate and apply the contact cement with a brush or roller to both surfaces. Let the cement set until it feels tacky, following the manufacturer's directions. If you are using pre-glued end caps, heat an iron and place the laminate against the edge, ironing it back and forth. Allow it to sit for a minute and then tap it carefully with a rubber mallet or your shoe heel.
If you are using non-pre-glued end caps, apply contact adhesive to both the substrate and the laminate, following the manufacturer's guidelines for bonding readiness. Roll the laminate with a J-roller. Finish by trimming with a fine file, applying pressure only on the upstrokes. If you are using a laminate trimmer with a flush trim carbide router bit, remove the excess laminate and file smooth, again applying pressure only on the upstrokes.
If you are gluing the laminate to particleboard, as recommended by James Dulley, a mechanical engineer, use water-based contact cement for safety, despite it drying slower than the solvent-based variety. Use a heat gun to bend the laminate around the ends and then glue on the edge piece.
When adhering the laminate to an MDF top, roll it firmly in place with a laminate roller after applying the contact cement. Trim the sheet laminate to be about 1 to 2 inches larger than the MDF substrate.
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Trimming the edges
First, measure the length and width of the areas where the Formica will be installed. Use a tape measure to get accurate dimensions. Mark these measurements on the back of the Formica sheet, adding an extra inch to each measurement to ensure you don't cut too much. Draw your cut lines onto the laminate at these increased measurements. Apply masking tape along the lines to protect the surface.
Place the Formica on a flat, stable surface, such as scrap plywood, that can accommodate the cutting process without damaging your tools. Clamp the Formica securely to this surface to ensure stability during cutting. Use a circular saw to cut the basic rectangular shape of the countertop, following the marked lines.
Now, you can focus on the edges. If your countertop has angled edges, such as for an L-shaped or U-shaped configuration, Formica typically comes with precut angles of 45 degrees or 22.5 degrees. Attach these diagonal pieces together using miter bolts and apply a bead of sealant or laminate caulk to ensure a waterproof corner. Tap the surfaces with a rubber mallet or wood blocks to align them properly before tightening the fasteners securely.
For the final touches, use a fine file to finish trimming the edges. Apply pressure only on the upstrokes to smooth out any rough spots and create a clean, straight edge. If you are using a laminate trimmer with a flush trim carbide router bit, remove any excess laminate and file it smooth, again, applying pressure only in the upstrokes.
By carefully following these steps, you will achieve a precise and attractive edge trim on your plastic Formica countertops.
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Caring for your new countertop
Now that you've installed your new plastic laminate countertop, you'll want to keep it looking its best. Here are some tips to care for and maintain your new countertop:
Cleaning
- Plastic laminate countertops are easy to clean and maintain. Simply wipe off any spills or messes with a clean, non-abrasive, damp cotton cloth.
- Use mild soap or detergent and warm water to address any stubborn stains. Avoid using harsh or abrasive cleaners, pads, or powders as these can damage the surface.
- Rinse the countertop with clean water after cleaning and dry it with a soft cloth or towel.
Heat Protection
- Plastic laminate countertops can melt if exposed to excessive heat. Always use hot pads or trivets when placing hot items on the countertop to avoid damaging the surface.
- Ensure temperatures do not exceed 275°F (135°C) when in contact with the countertop.
Cutting and Knives
Do not cut directly on the countertop as knives and sharp objects can damage the surface. Always use a cutting board when preparing food or chopping.
Sealing
While not necessary, you can use self-cleaning wax to help minimize staining and enhance the durability of your countertop.
Plumbing
- If you have a sink installed in your countertop, ensure that all areas around the sink are properly sealed to avoid water damage to the base material.
- Use a suitable sealant and remove any excess sealant from the sink area.
By following these simple care instructions, your new plastic laminate countertop will remain beautiful and functional for many years to come.
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Frequently asked questions
Use a tape measure to get an accurate measurement of the length, width and depth of the area. If your walls are not at right angles, you should scribe the Formica first.
Place the Formica on a flat, stable surface, like plywood. Mark the measurements on the back of the Formica sheet, adding 1 inch (2.5 cm) to each measurement. Draw your cut lines onto the laminate, then apply masking tape along the lines.
Apply contact cement to the edge strip and the surface it will attach to. Allow it to set until it feels tacky, then carefully align the edge strip to the surface and press it down.
If you are installing an L- or U-shaped top, precut mitres should be joined at this point. Apply a bead of sealant to each mitered edge, then tighten fasteners and tap surfaces to align.
Clean with a damp, non-abrasive cloth or sponge, using mild soap or detergent. Avoid placing hot items directly on the countertop. Use a trivet or hot pad, and always use a cutting board to avoid damaging the surface.
