Laminating and Solid Surfacing

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1/4" Corian over plywood

Leland Thomasset


I am doing a desk or 5 with 1/4" corian laminated to a substrate of which I can choose. I will be mitering all corners, front,sides,top and back edges. Miter fold actually. The units are 5'x3'x2.5'. I would like to use contact cement to adhere to the substrate. This could be plywood arch. Choice or mdf my thought as it is more stable and consistent. Any thoughts on this. I was thinking contact would have a little flexibility. I will be seaming miters with seam kit.

12/18/12       #2: 1/4" Corian over plywood ...
Marty Member

G'day Mate
I'd glue up all the corian first then drop over my substrate using silicone. Over time the contact glue will harden up more than you expect.

Merry Christmas


12/18/12       #3: 1/4" Corian over plywood ...
Dave Edgerton  Member

No contact cement for corian. You have to use either the 2 part epoxy for seaming or silicone. The silicone would give you a bond only where it contacts and will not be structural if this is what you are looking for. I would get some documentation on how to do this from the manufacturer.

12/19/12       #4: 1/4" Corian over plywood ...

I second the idea by Marty.
Have done lots of similar stuff using silicone.

12/19/12       #5: 1/4" Corian over plywood ...
Leland Thomasset


So you would build the structure and then fit the mitered corian then set silicone bead then corian seam kit the miters. Ok this is something I considered but I was thinking the silicone would be too thick and it would not allow the proper fit.

12/19/12       #6: 1/4" Corian over plywood ...
Ken Dolph  Member



I would not do it at all. There are reasons that the back side of 1/4" Corian says "Vertical Use Only". In the 90s the motor home industry tried this and had many failures over the years.

The wood substrate will expand/contract with humidity changes. The Corian will expand/contract with temperatures. On any given day the total of the changes will be twice as great as those you need to take into account with wood construction alone. The Corian alone can change 1/16" over 6' in normal home temperature changes.

1/4" Corian is, in most cases, no less expensive than 1/2" and it does not need a substrate. In fact, it is not recommended. So you would be going through more work and expense to have an inferior product.

12/19/12       #8: 1/4" Corian over plywood ...
Marty Member

Cut, glue and fold your corian using their correct adhesive. Use your finger to smooth the adhesive around the inside but leaving a nice "cove" as a backing and added strength.
Under cut your substrate about 1.5mm all sides and chamfer where required to clear your "cove". Seal your subtrate (MDF) both sides and all edges.
When applying your silicone to the flat surface do so in blobs, so as not to create "air locks" or sealed sections.
Now carefully caulk the under side again leaving small sections clear so as not to trap any air.

Cheers Marty

12/19/12       #9: 1/4" Corian over plywood ...
Leland Thomasset  Member


Thank you Marty,

This makes sense to me

12/19/12       #10: 1/4" Corian over plywood ...
Marty Member

Not a problem mate.
Just remember lots of smaller blobs are better than a few bigger ones and don't create any air pockets.

You'll be fine.

Cheers Marty

12/23/12       #11: 1/4" Corian over plywood ...

Just use 1/2" corian. I don't think your saving any money by using 1/4" material. I just took a look at my price list, and the 1/2" glacier white actually costs less, than the 1/4" material.

Gluing solid surface to plywood with contact cement is a no go. Backing with plywood, is not entirely recommended either. If you do go this route use coin sized dabs of silicone. This will allow movement in the substrate, and or solid surface material.

By the nature of your question, I would recommend that you take a look at the corian fab guide. There is allot of information that would answer your question.

If your getting the corian on the "grey" market, you can generally get the corian adhesives, and guns via ebay.

12/23/12       #12: 1/4" Corian over plywood ...
Leland Thomasset  Member


No grey market corian, this is all above board it is at the design of architect that we are going this route. I know 1/2 is the same or less expesive. The weight would be out of control on these units. Site fabrication would be a bad idea. So I want to see what others have done and get the great feed back that you and all the other contributers have provided.


12/29/12       #14: 1/4" Corian over plywood ...

just a note- If you are expecting to get the corian 10yr warranty then just about everything you are doing is a no-no. Correct way would be 1/2" corian over perimeter only support w/ dabs of silicone.

1/13/13       #15: 1/4" Corian over plywood ...
Terry LaFond Member


No need to miter solid surface. A good joint is invisible or very near that.

2/3/13       #16: 1/4" Corian over plywood ...

What was your reason for using the 1/4 inch would be my question. Personally I found it to be quite brittle and not easy to work with like the 1/2..

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