How to Repair a Cracked Solid Surface Countertop

Solid surface countertops, like Corian, are popular options for kitchen and bathroom remodels thanks to their sleek, seamless look and durable nature. However, solid surfaces can become damaged over time, resulting in cracks, chips, and scratches. While more minor cosmetic damage can often be buffed out, deep cracks require a more intensive repair process. This article will provide a step-by-step guide on how to repair cracked solid surface countertops, allowing you to restore their flawless finish.

Assessing the Damage

Before determining the repair process, you’ll need to assess the specifics of the crack. Here are some key factors to consider:

  • Location – Note where the crack is situated on the countertop. Cracks along edges or near seams may require extra reinforcement.
  • Length and depth – Measure the length and depth of the crack. Minor surface cracks under 3 inches may be easier to repair than longer, deeper cracks.
  • Cleanliness – Check if the crack contains any debris or stains. This may require extra cleaning steps.
  • Cause of cracking – Understand how the crack occurred in the first place. Cracks from impact or excessive weight may need additional structural repair.
  • Accessibility – Can the crack be easily accessed, or is the area blocked by a sink, stove, etc? Limited access will make the repair process more difficult.

Once you’ve evaluated the details of the crack, you can determine the best repair approach.

Gathering Your Materials

Repairing solid surface cracks requires collecting the proper materials ahead of time. Here’s what you’ll need:

  • Sandpaper – Various grits like 220 and 400 for smoothing and blending.
  • Solid surface repair kit – Specifically designed epoxy to fill cracks.
  • Reinforcement tape – Fiberglass mesh tape for extra strength.
  • Router – For edging cracks wider than 3/8″.
  • Acetone – Used for cleaning and prepping the surface.
  • Stir sticks – To properly mix two-part epoxy.
  • Microfiber cloths – Lint-free cloths for applying epoxy.
  • Painter’s tape – To mask off crack repair area.
  • Safety gear – Gloves, goggles, mask to protect yourself.
  • Rags – For acetone cleanup.
  • Sanding blocks – Helps sand even and smooth.

Be sure to use repair products specifically designed for solid surfaces like Corian. Hardware stores carry kits with color-matched epoxy.

Cleaning and Prepping the Area

Before filling a crack, you need to clean and prep the solid surface area. Follow these steps:

Clearing Debris from the Crack

  • Use a razor blade to gently scrape out any hardened debris or gunk from the crack.
  • Flush out the crack with acetone and wipe clean using a lint-free rag.
  • Blow out any remaining particles using canned air. The crack needs to be completely clear.

Lightly Sanding the Surface

  • Lightly sand a 2 inch perimeter around the crack using 220 grit sandpaper.
  • Avoid aggressively sanding, which can damage the solid surface. Just scuff the area.
  • Carefully vacuum and wipe away all sanding dust with a dry cloth.

Masking Off the Area

  • Apply painter’s tape around the crack to mask off the repair zone.
  • This helps keep the epoxy contained to just the crack itself.
  • Press the tape firmly to prevent any seepage.

Final Cleaning with Acetone

  • Wipe the sanded surface and crack with an acetone-dampened cloth.
  • Acetone removes residues for better epoxy adhesion.
  • Let acetone fully evaporate before moving onto epoxy application.

Thorough cleaning and sanding provides the preparation needed for the epoxy to properly bond with the solid surface. Avoid skipping any prep steps.

Applying the Solid Surface Epoxy

With the area prepped, it’s time to apply the solid surface epoxy filler according to the manufacturer’s instructions:

Mixing the Two-Part Epoxy

  • Measure out equal parts of the resin and hardener as specified.
  • Thoroughly mix the two components together with a stir stick.
  • Mix for at least 60-90 seconds to fully incorporate the ingredients.

Filling the Crack

  • Use a disposable brush, stick, or spatula to apply epoxy directly into the crack.
  • Push the epoxy fully into the bottom and sides of the crack.
  • Overfill slightly to account for shrinkage as the epoxy dries.

Removing Excess Epoxy

  • Once crack is filled, slide a stiff plastic card across the surface.
  • This squeegees away any excess epoxy surrounding the crack.
  • Work quickly before epoxy begins curing and gets sticky.

Allowing Epoxy to Cure

  • Epoxy will need to fully cure based on manufacturer guidelines.
  • Cure times range from 30 minutes to several hours.
  • Avoid disturbing or wiping the area while curing.

Applying the right amount of epoxy filler ensures the crack is completely filled while minimizing excess.

Sanding and Blending the Repaired Area

Once the filler has fully cured, sanding and blending will help achieve an smooth, flush finish:

Sanding Down Excess Epoxy

  • Use 220 grit sandpaper to sand away any dried excess epoxy.
  • Sand using light, circular motions concentrating on the raised areas.
  • Be careful not to disturb epoxy within the crack itself.

Blending and Feathering the Edges

  • Switch to 400 grit sandpaper for final smoothing.
  • Blend and feather out the edges where the epoxy meets the solid surface.
  • This helps hide the transition between materials.

Polishing Surrounding Area

  • Polish about 2 inches around the repaired crack using acetone on a cloth.
  • This restores the solid surface sheen around the blended epoxy.
  • Avoid getting acetone directly on freshly sanded epoxy.

Proper sanding and feathering helps hide the crack repair and restore a flawless, uniform finish.

Applying Reinforcement Tape (For Larger Cracks)

If repairing a larger crack exceeding 3 inches or impact cracks, reinforcement tape provides extra strength and durability:

Cutting Tape to Size

  • Measure and cut fiberglass mesh tape so it extends 2 inches beyond each side of the crack.
  • Cut tapered edges to help blend the transition.

Applying Epoxy to Crack

  • Fill the crack with epoxy using a disposable stick or spatula.
  • Spread a thin layer also along the sanded countertop surface.

Pressing in Tape

  • Lay the fiberglass tape centered directly over the crack.
  • Use a plastic spreader to firmly press it into the epoxy.
  • Avoid creating air bubbles underneath the tape.

Allowing Epoxy to Cure

  • Give the epoxy several hours to fully harden and bond with the tape.
  • Once cured, you can sand and blend as normal.

The reinforcement tape provides long-term strength and helps prevent future cracking.

Routering Severely Damaged Areas

For cracks wider than 3/8” or sections broken into separate pieces, structural repair is needed:

Marking Damaged Area

  • Use painter’s tape to mark off the entire damaged section needing repair.
  • This helps guide the router to remove the right amount.

Setting Router Depth

  • Set router bit depth to 1/8” deeper than the bottom of the damage.
  • This ensures all compromised material gets removed.

Routing Out Damage

  • Using a spiral upcut router bit, begin removing the marked section.
  • Rout all the way through the countertop laminate and substrate.

Sanding and Cleaning Routed Area

  • Smooth router cut edges with 120 grit sandpaper.
  • Vacuum and wipe out all debris before applying epoxy.

Routing out extensive damage allows new epoxy filler to re-bond the countertop area.

Preventing Future Cracks

To help prevent cracks from forming again, follow these maintenance tips:

  • Use cutting boards to protect from knives and sharp objects.
  • Immediately wipe up spills to avoid prolonged moisture exposure.
  • Avoid exposing solid surface to extremely hot items straight from the oven.
  • Have countertop professionals perform minor filler repairs at the first sign of damage.
  • Consider applying a penetrating sealer to increase surface resilience.

With proper care, your solid surface countertops can continue looking pristine for years before needing crack repairs.

Tips for a Smooth Crack Repair Process

Repairing solid surface countertops takes patience, care, and the right techniques and tools. Here are some additional tips:

  • Work in a clean, dust-free area to avoid contaminating epoxy.
  • Tape off any nearby walls, backsplashes, even sink bowls when working around edges.
  • Apply release tape along the crack itself to avoid bonding two sides.
  • Avoid wiping or disturbing epoxy once applied until fully cured.
  • Sand and blend edges into the countertop seamlessly to disguise the repair.
  • Use a heat gun to warm epoxy that is too viscous or hard to apply smoothly.
  • Let countertop cure 72 hours before regular use after routing extensive repairs.
  • Hire a pro for complex repairs like seam separation or cracks near appliances.

Questions and Answers About Repairing Cracked Solid Surfaces

Still have some questions about repairing solid surface countertop cracks? Here are answers to some common FAQs:

Is every solid surface brand repairable?

Most major brands like Corian, Gibraltar, Avonite, Swanstone, and Wilsonart can be repaired using their color-matched kits. Lesser known brands may lack repair products. Always check manufacturer guidelines.

Can I use epoxy from the hardware store?

For best results, use solid surface specific repair epoxy. Hardware epoxy won’t provide accurate color-matching or the same performance. Investing in the right kit prevents do-overs.

What if the crack is near a sink or seam?

Cracks near edges and seams make repair more complex. You may need to remove sinks or cooktops to access the crack. Longer reinforcement tape anchored to adjoining areas can also help stabilize these cracks. Consider hiring a pro.

Will the repair be noticeable?

In most cases, repairs blended well become nearly invisible. But certain heavily damaged or poorly matched areas may still show some signs of repair on close inspection. Thankfully solid surfaces can be refinished.

How do I avoid cracking in the future?

Use trivets for hot pans, wipe spills quickly, don’t stand on countertops, install reinforcements behind sink and stove cutouts, and reseal surfaces annually. Immediately repairing chips and scratches can also prevent larger cracks.

When should I call in a professional?

If a crack is widely separated, repaired areas keep cracking, repairs require seam work or plumbing disassembly, or color-matching is proving difficult, call a countertop pro. They have the specialized tools and expertise.


Repairing cracked solid surface countertops requires careful prep work, the right materials, and finesse sanding and blending. But with some time and effort, you can successfully restore solid surfaces to a flawless, crack-free condition. Paying attention to maintenance can help prevent most cracks in the first place. And should damage occur, these repair techniques will have your countertops looking brand new again.