Q.
What is the best way to fasten a laminated particle board countertop to a cabinet?
Forum Responses
I pre-drill and use a heavy thread screw (like a #12 woodscrew). Just don't over-torque the drill and strip out the hole.
Brian Personett, forum technical advisor
Expansion of the plywood has never happened to us in the 15 years we have been building kitchens. However, we have had problems with particleboard and MDF, with swelling at joints or from steam from a dishwasher.
I use 5x12 sheets to avoid seams whenever possible. I do not encourage post formed counters and although the look is nice, my customers prefer the plywood base and not having 45 degree seams in the corners.
We have two separate shops here, one which builds cabinets and one which builds tops. Although there are sometimes tops that go with cabinets, we rarely sell to the same customers. We sell tops to dealers, kitchen and bath retailers, Lowes, etc. Shuffling scrap back and forth is not a particularly good option.
Here in the Midwest US, I had never heard of 5x12 plywood. It can be had, custom order 1 unit min. I also checked on pricing for 5/8" 4x8's. My price is 789/M. I currently pay 428/M for 3/4" PB. Depending on which brand laminate, I pay anywhere from 1.02 sq ft to 1.27 sq ft, for this illustration I'll use an average of 1.145. PB price of 1.145+.428=1.57 per sq ft for materials less glue. VC price of .789+1.145=1.934 per sq ft for materials less glue. My material cost has gone up a smidge over 23%. There is no way I can compete in the market using VC. It is simply too competitive. We feel like we have built a good relationship with our dealers, providing a quality product, good service, and a fair price. But I don't think the first two are going to overcome a substantial price increase to cover the additional expense of using VC.
Every laminate company that I know of recommends the use of PB for a substrate. We also feel like it is the best solution. VC is not without it's problems as well, telegraphing, voids, delamination of the plys.
No matter what you do, if you have a top that is over 5x12, there will be seams, because that's the largest size the laminate companies make. We too make seamless tops up to 5x12, if the customer requests it. I'm not certain how practical it is in most cases.
The downside of all of this is it seems that PB gets a bum rap for a leaking sink, or a bad gasket on the DW. The plain simple truth is, it's only the symptom of the problem. Sinks should be properly caulked, plumbing should not leak, DW's should not leak steam as they are working, and that puddle of water should not be left to stand on a seam in the plastic. I have two small children and I assure you no ones DW gets opened and closed during the cycle more than mine, yet I have not had a problem with the PB swelling. We also have more than our fair share of water/pop/Kool-Aid standing around, yet no problems. Even if you don't follow all of the rules, the rate at which PB fails is fairly small and in extreme cases, where I'm quite certain that eventually VC would fail as well.
Brian Personett, forum technical advisor
