(Written in July, 1999)
by Jim Heaphy
Most homeowners prefer a
countertop with a coved backsplash, and for good reason. There is little doubt that
a coved backsplash is more sanitary and easier to keep clean than a loose backsplash
installed separately and caulked with silicone. Coved splashes are common with plastic
laminate countertops, where mass production techniques allow this feature to be offered
at a negligible price. Matters are different, though, with solid surface countertops.
Creating a coved backsplash has always been an expensive and labor intensive proposition
when working with solid surface materials.
However, there are a growing number
of methods, both new and old, to create coved backsplashes. The choice of methods
depends on fabricator preference and is influenced by the volume of coved splash
work that a given company does or plans to do in the future.
When I first
got involved with countertop fabrication about sixteen years ago, use of a portable
coving router was the accepted technique, and this remains a good choice for many
fabricators. These machines have been improved over the years, resulting in more
reliable performance, and at least one model now incorporates dust control. Before
using the router, the countertop and splash must be glued up accurately with a filler
block creating a stair step detail where the splash meets the deck. Sources for this
type of tool, which costs approximately $800.00, include Art Betterley Enterprises
at 800-871-7516 and Specialtytools.com through the Internet at www.specialtytools.com
or at 800-669-5519.
The next major development in coving was the introduction
about ten years ago of the mass-produced coved backsplash molding by TFI Corporation.
Distributed through the Dupont CORIAN network, this molding is consistent and predictable,
and allows a cove to be created with a single glue line, as opposed to the double
glue line common with many other methods. It is not necessary to purchase any special
equipment other than a specific router bit and some inexpensive clamping clips to
fabricate a cove by this method. For more information, contact your CORIAN distributor,
or TFI Corporation at 800-422-8746 or through the Internet at www.tficorp.com.
Fabricators have sometimes tried to create coves using joint adhesives or other
liquid resin products. Such experiments usually prove to be complete failures, as
it is almost impossible to maintain a consistent cove shape without unacceptable
bubbles, voids and slumping. One company has made progress toward eliminating these
problems. The Align-Rite Tool Company has developed its Liquid Coving System that
applies a thick liquid epoxy with a caulking gun, which is then smoothed with special
tools. The system can match a wide variety of particulate colors, and has been described
in literature that Dupont publishes for CORIAN fabricators. A kit that will do 40
to 50 feet of coving sells for $65.00. Contact Align-Rite through the Internet at
www.alignritetool.com or call 520-624-4438.
A variation on the theme of the coved backsplash molding is offered by Great
Lakes Kitchen & Bath, manufacturers of the Quick Cove Moulding. Rather than a
molding that consists of the entire backsplash, this smaller molding takes care of
just the coved area, and a rectangular piece of conventional solid surface makes
up the balance of the splash. The countertop deck is rabbeted to accept the molding,
and the edge of the backsplash receives a beveled dado that corresponds with the
angled top edge of the cove molding. This arrangement forces the face and the top
edge of the cove into precise alignment as the splash is clamped into position. The
company claims a 70% reduction in labor as compared to other methods, and the only
special tool required is a router bit. Call Great Lakes Kitchen & Bath at 517-846-9211
for more information.
Now, a dedicated cove manufacturing system is available
for production oriented shops. The Machining Center by Merlin Systems, Inc. can machine
200 feet of coved backsplash per hour, according to the company. Total productivity,
including gluing and sanding, is estimated at between 5 to 7 feet per man hour on
residential jobs and 10 to 12 feet per man hour on straight run commercial jobs.,
As well as producing standard straight splashes, the system can also cove curved
splashes and both inside and outside corners at any angle, not just 90§. The machine
is in the $30,000.00 price range, and is available on a 5 year lease plan. For more
information, call 800-805-9545 or e-mail to merlin sys@aol.com.
Automatic V-grooving machines have grown in popularity with larger solid surface
fabrication shops in recent years because of their ability to automate the fabrication
of countertop front edges. However, by changing a cutter head, or using a double
head machine, V-groovers can also be used to produce coved splashes. This type of
equipment, which was pioneered by Auto V-Grooving of Toronto, is in the $100,000.00
price range. For more information, contact Auto V-Grooving at 800-387-5819 or through
the Internet at www.vgrooving.com.
The choice
in coving techniques, then, is a function of the inclination and experience of the
fabricator, the company's current and projected sales volume, and the company's ability
to finance capital equipment. What is clear is that quality backsplash coving technology
is available to fabricators of every size. Unfortunately, it is also clear that,
though costs may be declining, the solid surface coved backsplash remains much more
expensive than the same detail in a plastic laminate countertop.
NOTE: Here
are links to two additional companies that sell technology to help with coved backsplashes:
The
Pinske Edge
Norford Industries