Repair Plan Mends Cooktop Cracks

by WOHe

While surveys show that the majority of homeowners who have
purchased solid surface kitchen countertops are delighted with
their decision, a few consumers do experience problems. Responding
to their complaints effectively is a way to ensure the continuing
high reputation that solid surface materials enjoy.

One of the most difficult problems that needs to be addressed is
countertop cracking adjacent to a cooktop or a range. Many
complaints of cooktop cracks I’ve witnessed are repeat complaints
in other words, a previous repair attempt has been

The most important way to prevent this sort of problem is to
follow the manufacturer’s recommendations for machining and
preparing a cooktop cutout. Work from a checklist, and be sure that
every procedure has been carried out properly.

Even with good fabrication and installation techniques, however,
failures can still happen. It may not be possible to identify the
reason for a given failure with absolute certainty, but patterns do

Heat is the most important factor responsible for this problem,
since cracks at cooktop cutouts are far more common than those at
sink cutouts. Heavy cooktops also tend to cause problems more often
than lighter cooktops, as do cooktops with narrow flanges. Cooktops
with built-in downdraft fans also cause more problems. Cooking
styles such as prolonged, high-heat cooking, deep-fat frying,
candymaking and canning also increase risk, as does the use of high
BTU “power burners” and cooking without a ventilation fan.

The shortcoming of conventional repair techniques is that, in
many cases, the underlying cause of the problem is not addressed.
In order to have a high success rate in repairing cooktop cracks,
the repair procedure must accomplish two things: It must
effectively isolate the countertop material from the heat source,
and it must remove the weight of the appliance and items being
cooked from the countertop.

The right repair
The most effective repair procedure involves fabrication and
installation of a custom stainless steel ring or collar that
surrounds the appliance. This stainless steel surround allows for
the cutout in the countertop to be enlarged significantly, and for
a plywood support structure to be fabricated and installed, which
takes the weight of the appliance off the cooktop.

Consumers will, of course, be concerned about the appearance of
this stainless steel collar. It’s essential to present this repair
procedure tactfully, explaining that the item will be custom
fabricated to match the specific cooktop in question, and will
appear to be part of the original cooktop. If the cooktop has a
brushed stainless finish, that’s how the collar should be finished
as well. The collar can also be powder-coated to match any standard
appliance color.

A properly sized cooktop collar will extend 1/2″ past the flange
of the cooktop on all four sides. The visible outside corner radius
will complement the existing outside corner radius of the
appliance. For example, if the existing cooktop has a 1/4″ corner
radius, I have the collar fabricated with a 3/4″ corner radius.
Since the collar extends 1/2″ past, a radius 1/2″ larger will look
very natural and compatible.

The cooktop collar must be measured carefully, with cutout
dimensions being large enough to accommodate the cooktop. Check for
any irregularities or protrusions on the cooktop body, such as
screws, rivets or flanges, and be sure to allow for them.

The outside dimensions should be 1″ larger in both directions
than the overall dimensions of the cooktop. This will allow for
1/2″ of the stainless steel collar to show on all four sides. After
the stainless steel cooktop collar has been obtained, make a
matching collar out of good quality plywood the same thickness as
the countertop material, usually 1/2″. The cutout in the plywood
will be the same size as with the stainless collar, but the overall
dimensions will be 1/4″ to 3/8″ less, to allow the stainless steel
to overlap the plywood by at least 1/8″ on all four sides. Neatly
wrap this plywood collar with aluminum tape.’

When the repair begins, disconnect and remove the cooktop and
place the plywood collar on the countertop surface, aligned with
the existing cutout. Draw a pencil line around the plywood collar.
Using a router, enlarge the cooktop cutout in the countertop
slightly past this pencil line. At this point, your plywood collar
should fit loosely into the opening.

Now, repair the crack in the countertop, and reinforce the
repair wherever possible with a second layer of solid surface
material bonded beneath. Trim the finished repair back flush with
the enlarged cutout edge, and sand all edges of the cutout until
perfectly smooth. Round over the top and bottom edges, and be sure
that all irregularities have been eliminated.’

Next, fabricate and install a plywood support frame, connected
structurally to the cabinet and possibly the wall instead of the
countertop. The exact configuration of this support frame will vary
depending on jobsite conditions, but it must be stable and sturdy,
and its top surface must be flush with the underside of the
countertop material.

Place the plywood collar into the opening. It should sit flush
with the countertop surface. Using thin shims as needed between the
support frame and the plywood collar, ensure that the top surface
of the plywood collar sits just slightly higher than the countertop
surface about 1/32″ is right. Strips of plastic laminate work well
as shims. Finish the inside of the opening with aluminum tape or
insulating tape in accordance with the solid surface manufacturer’s

Place the stainless steel collar on top of the plywood collar,
and reinstall the cooktop.’
If the repair has been done properly, there will be a barely
visible gap between the stainless steel collar and the solid
surface material. This air gap is your assurance that heat transfer
has been dramatically reduced and that stress due to the weight of
the cooktop bearing on the countertop has been eliminated.

Some consumers may prefer a bead of caulk between the stainless
steel collar and the countertop. Others may want to be able to lift
the assembly for cleaning. Either technique is fine.

Stainless steel collars can be ordered through my Web site, At this site, you’ll also find a comprehensive
directory of solid surface industry Web sites, and copies of many
of my past columns.

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