I have to modify some existing lab cabinets at a local college. I need to make a cross cut on the existing counters in place. These counters are phenolic or composite, whatever they make these things from.

I have no experience working with this type of counter. What do I need to make a cross cut on this type of material? I need to make a cost allowance if I have to purchase any special blades or tooling.

Also, I will need to add an end splash at my cut point. Does anyone know who sells this sort of material in the Carolina/Georgia area?

Thanks for any help

Ronnie,

I have been working with lab tobs for over 20 years. There are really two types. One is a Phenolic (also known as Composite Resin), the other is Epoxy resin if they are not too old (1980's and later). If your tops are much older, from 60's-70's, they could have asbestos and you should not cut. The Phenolic and Epoxy resin are very different from each other when it comes to cutting or drilling. To find out for certain which type you have you can take a regular drill bit for drilling metal and drill the underside of the top in an inconspicuous area. If shavings come off and the material drills similar to a very dense plastic then you have Phenolic tops and they can be cut with a standard carbide blade, it cuts like a very hard wood. If it seems to drill similar to concrete instead then your tops are Epoxy resin. Cutting Epoxy resin is best done with a diamond blade for cutting concrete (prices range from $30-$100 and all work fine, just let the blade do the work). Blades are available for a skil-saw, and hand grinder. Be aware, cutting epoxy resin will release a massive cloud of epoxy dust. Wear a good respirator, cover everything in sight with plastic, and use a large shop vac holding the nozzle at point of cut to minimize the cloud (the filter will clog quickly). As far as purchasing a backsplash, only two manufacturers in the US I am aware of. Durcon in Taylor, Texas and Kewaunee Scientific in North Carolina. Durcon usually has a shorter lead time and I believe Kewaunee only sells through dealers. Good Luck, feel free to email me if you have any further questions.

Ronnie,

I should clarify, the two companies I listed are the only ones in the US I know of that do Epoxy Resin, they also do the Phenolic. There are other companies which only handle the Phenolic such as AGRFabricators in Florida, Chemtops, Trespa, FormaSpace to name a few.

adding to the previous, excellent comment:
Use diamond tips and blades for epoxy. Shallow passes with a saw, low speed with rotary tools - it is a plastic, and heat is the enemy. sand edges to 120 grit and buffing compound or edge sealer to match sheen of tops, if required.
American Epoxy Scientific is another epoxy top manufacturer you might check out.
with phenolic, there is always a substrate, some times paper, (used to be asbestos, as mentioned), but always an obnoxious mess to cut. Bring your sharpest blades, or better yet, advise the client that custom tops are not as expensive they might think, and cheaper than wrapping up a lab, buying new blades, and paying the fire department for false alarms at a hazardous chemical listed address.