Engineered Stone Failure

6 years ago

last modified: 6 years ago

A former customer emailed me this picture of his estone top that was fabricated and installed by others. This was my response:

"Unfortunately, the crack from the inside corner is not cost effectively repairable. If it's any condolence, it was due to fabricator error, as all engineered stone manufacturers require a 3/8" minimum radius on inside corners:

https://www.thestonecollection.com/sites/default/files/CS_FabManual_0910.pdf (see page 10, please)

Note the inconsistency in the radius of the pictured edge profile please. Had the edge been more rounded, it would have been less likely to fail. This is also noncompliant with the manufacturer's 1/8" minimum edge profile. Page 10 again.

Look under your slabs and see the specific brand of your engineered stone please. Look up the manufacturer's fabrication and installation instructions and present these to your fabricator/installer. You've got a slam-dunk case for replacement with him, not the manufacturer.

I'll be happy to explain to your fabricator/installer his responsibilities in this matter free of charge. If I may be of any further assistance, please contact me at your convenience."

As Houzz readers know, I'll play fast and loose with some manufacturer's instructions, however, this is not one of them. If your fabricator/installer shows up with inside corners that look like this, don't even let them install the tops please. This took at least 3 years to fail. Granite should get a little radius too. If you've got to have square inside corners, use a French miter and stare at the extra seam.

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Comments (3)

PRO
Granite City Services
6 years ago
I am a fabricator. Joe is correct about both issues; the sharp inside corner creates a "stress riser" that invites a crack and the variation in the top round is just poor workmanship. The fabricator did a poor job.
Joseph Corlett, LLC thanked Granite City Services
PRO
Quartz - Stone Care, Cleaning & Repair Experts
6 years ago
Exactly
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PRO
Quartz - Stone Care, Cleaning & Repair Experts
6 years ago
Exactly, this is a major issue if you over cut the mitre to fit the drop front. But the major issue will be the support on the corner cupboard.

It causes the stone to flex and hence micro crack and break. We see this some times. If you look under the cabinet inside the corner cabinet the top rail on the carcass will be most likely flat.

It should be two things

1) of timber for extra strength - can be vinyl wrapped so it is still white. Though needs to be fitted on its edge for strength.

2) the span is too big for what is being used. If the span is over 2 feet then it should be steel or double timber rail.

This will stop the stone from flexing, would not have mattered if it was granite, marble, engineered stone., corian etc. The flex would have made them all fail.

This needs issue needs to be address if the tops are repaired or replaced. As it will cause it to fail again.

Whilst the photo above is for a cutout - it is standard practice for any cabinet rails for any stone to be this orientation, especially for spans of more than 400mm.