The following instructions are intended to save you time, effort, and money when it comes to installing Formica or plastic laminate countertops.
Laminated plastics are available at many hardware and home improvement stores in a wide variety of colors, designs, and patterns, and have many applications such as countertops, tabletops, flooring, and more. Laminate plastic sheets are available in a gloss or opaque finish, so you have options when preparing for a project. Laminated plastic is made from layers of paper that are injected with resin and bonded together under high pressure and high temperature to form a strong, rigid sheet.
When preparing the surface: 1/16″ thick plastic sheeting is generally recommended when working on a flat surface. On vertical surfaces, you should use 1/32″ thick sheeting. Sand and thoroughly clean the surface where the plastic laminate is to be applied, removing any paint, varnish, dirt or surface imperfections. Although many manufactured countertops use high-density particleboard for their surfaces, regular particleboard or plywood may be more ideal bases for plastic laminates.
When cutting plastic laminates: You can use a circular saw, saber saw, backsaw, or utility knife to cut plastic laminate. If you plan to use a saw, make sure the saw blade is a fine tooth blade. Using a strip of masking tape along the cutting line will help prevent splintering and make the line much easier to see while cutting. If you are using an electric circular saw or table saw, cut into the back of the laminate to prevent splintering. Cut at a low angle from the front if you’re using a handsaw to cut the plastic sheeting. To allow for trimming, be sure to cut the sheet of laminated plastic slightly larger than you’ll need. You may also consider using a steel ruler or square to create a smoother, more even cut. You can use a utility knife to score the laminate plastic, then lift the shorter end and apply light pressure to break the scored line. Be sure to choose the proper cutting attachment for the size of the job.
When applying laminate plastics: You can usually use contact cement to apply laminate plastic. Epoxy adhesives can also be used, but contact cements are generally recommended. You should first roughen the surface with coarse grit sandpaper, but be sure to clean off any sanding residue with compressed air or a light brush to ensure the surface is as clean as possible. Next, you’ll want to brush on the contact cement, applying it to both the counter surface and the back of the clean laminate sheet. After both surfaces have dried, you can lay the laminate sheets.
To finish the job: Use a roller to apply pressure to the newly applied plastic laminate sheets. Be sure to roll the entire surface well to remove any trapped air pockets and ensure the plastic is firmly attached at all points. You can also use a wood block and mallet to ensure proper bonding on the newly laid surface, removing any trapped bubbles and pressing both layers of contact cement in as far as possible. If there is any leftover contact cement where it shouldn’t be, you can remove it with a special solvent, or nail polish remover.