Corian is an artificial material made of acrylic and aluminum ore. It was introduced by DuPont in the 1960s and has been in demand ever since. It is a popular alternative to marble and granite. It is used as countertops in kitchens. It is available in the form of large slabs. You are supposed to buy the slab and cut it according to your requirements. So how to cut corian countertop?
How To Cut Corian Countertops- Step By Step Guide
In this article, we will learn about different steps on how to cut Corian Countertops.
Total Time: 1 Hour
The first step in cutting a Corian countertop is measurement. First, you should measure the area where you are going to install the Corian. Make sure to measure the length, breadth, width, depth, and height of the required area correctly. It is advisable to note down the measurements in a sheet of paper. You can use a retractable measuring tape for this job. However, you must check the measurements twice and be sure and accurate.
After being confirmed about the measurements, you need to mark the exact dimensions on the slab of the Corian. Again make sure that your measurements are final and refer to the numbers you have jotted down earlier while taking the measurements for accuracy. This is very important because you do not want to put the wrong marks on the Corian and waste the whole slab.
Now keep the Corian on the work table. Hold it steady in one place. Make sure to keep it upside-down.
For this job, you can use two sawhorses and a stable workbench or a cutting table. However, Corian is a pretty heavy material, so it is a wise decision to use a large surface to keep it. Also, if you are using a workbench, make sure to use clamps. Clamps will help in keeping these steady in one place.
After putting the Corian on the work surface properly, move on to the third step: Marking. Now mark the slab of Corian. You need to mark the slab according to the measurements of the area it is required to fit in. It is an essential step because if the markings are not on the accurate spot, the dimensions will alter. If you cut the slab according to the wrong dimensions, it will not fit in the required space. Thus, the whole endeavor will go to waste. So, be precise and careful.
You should use a grease marker for this task. Since you have put the slab upside down on the workbench, you will put the marks on the underside of the Corian. Marking the underside of the Corian is specifically essential to avoid staining the slab before installing it.
Now it is time to use the circular saw. First of all, before you start sawing, it is vital to attach the proper blade to the saw. Take a triple chip blade. Make sure it is made of tungsten carbide. Attach this blade to your saw.
You have the discretion to use any circular saw to cut the Corian. However, the blade must be a triple chip blade made up of tungsten carbide. It is essential to use this particular blade because you might risk the slab if you use any other blade. You might lose control of the saw and destroy the slab in seconds.
Moreover, you should also keep in mind that you should not use a ripping or combination blade to damage the slab permanently.
Before you start working with the saw, make sure that you have taken all the necessary precautions. Do not forget to wear protective goggles and a dust mask/respirator. Although the composition of Corian itself is not toxic, the fine dust that comes out of it while cutting possesses a threat to health. The dust particles are very minute and can be inhaled easily. These particles cause irritation and rashes in delicate areas like the eyes.
Moreover, if inhaled in large quantities, these can also damage your throat and lungs. So, it is essential to protect yourself while working. Never avoid wearing protective eyewear and a dust mask because safety comes first.
Now, you are all set to finally use the saw. So let us begin. Take the saw and make sure to put its straight edge next to the guiding line with clamps for better cuts. Clamp a leveler. Keep in mind to keep the leveler approximately 1.5 inches away from the spot which you have marked according to the dimensions you took earlier. Keep the leveler parallel to the guiding line. Now, put the base plate of the saw along the edge precisely where you want to cut. It is essential to do so to ensure that the guiding line on the saw and the marking on the slab are overlapping each other completely.
Put the circular saw precisely on the marked spot and once you are sure about the adjustments of the leveler and the guiding line, start sawing. Remember that you must set the depth of your blade. It is safe to adjust the blade’s range around 1 to 2 inches.
Once you have switched the saw on, you need to be very cautious. Hold the saw properly with both hands. Cut along with the marked spot. One thing you need to pay attention to while using the saw is to be patient. Let the saw start spinning at its full speed and only then start moving it forward. Do not put in a lot of pressure in pushing the saw further. Once it is at its optimum speed, give it a little push, and it will automatically start cutting through the slab without much force. When you are done, switch the saw off and wait for it to stop spinning altogether.
Sometimes, you may notice smoke coming out of your saw blade. Well, it happens because the saw blade and the Corian generates a lot of friction while being cut. The friction releases heat. Due to overheating, smoke starts coming out of the saw blade. If you notice anything of this sort, stop immediately. It generally can be solved by slowing down the speed of your saw blade. In cases like this, it is best to wait for a few minutes and allow the machine to cool down. Also, maintain a comparatively low speed.
Now it is time to give the finishing touch to the edges of the Corian. Check thoroughly to make sure that you have not left any of the edges. You might have missed some spots. If so, you would have to reconnect the saw and cut that portion. The Corian slab needs to be flat; otherwise, it will not fit in the area you want to install.
After making sure that you have flattened each edge of the Corian slab properly, move on to the next step. Now it is time to finish the edges. So, take a piece of sandpaper. You can use a 100-150 grit sandpaper for this task. Now attach the sandpaper to the sander. Once it is all set, you need to sand the edges of the Corian. Hold the sander carefully and press it on the surface of the edges of the Corian slab. Keep the sander in motion by sliding it back and forth. Keep on doing this until all the bumps on the surface of the edges of the Corian slab are smooth.
Repeat the process two to three times. But, if you are not getting a smooth finish, you can try using a higher grit ( 320-400 approximately).
Finally, give the last inspection to all the sides and make sure it is smooth and flat. If there are no more bumps, then you can install the Corian slab immediately. However, if there are still some unfinished edges, you can continue sanding till it’s all clean.
Thing You Need To Cut Corian Countertops
- Measuring Device
- Dust mask or respirator
- Protective goggles
- Grease marker
- Circular saw
- Triple-chip tungsten carbide saw blade
- Stable work surface / Workbench
1. I do not have the experience of working with a circular saw. Is there any other way to cut the Corian Countertops apart from a circular saw?
Yes, there are multiple ways and tools to cut a Corian slab. One of the most effective ones is a Router. However, make sure to use it along with a straight bit and a fence.
2. Which kind of sander will be better for the edges?
You can use either belt sander ( see three list top sanders)or disc sander. Both are equally effective for this purpose.
It might appear to be a tacky task but cutting Corian Slabs is not that difficult. If you take all precautions and follow the steps listed above, you will do it yourself. It will not take much effort or time. It will also save the extra amount you would have to pay to get it fitted.
Corian Countertops are beautiful, cheap, durable, and hygienic. It adds a charming aura to your home.