How to Cut Corian Countertops

Corian, a type of solid surface material produced by DuPont, is becoming an increasingly popular countertop material.

Though professional installation is still most common (and almost always produces a better cut), many homeowners with a DIY eye prefer to install their new Corian countertops themselves.

Most of the time, your Corian slab will arrive precut according to your measurements, but additional cuts are sometimes still needed during the installation process.

Although it might seem intimidating at first, cutting Corian countertops is actually quite easy with just a few simple tools.

Here’s how to cut Corian countertops for your bathroom or kitchen.

Why Choose Corian Countertops?

A huge benefit of Corian countertops is how easy they are to work with.

Not only is it relatively simple to cut them to your desired dimensions, but they’re also easier to install than many other materials.

On top of this benefit, Corian is also notable for its seamless appearance, extreme durability, and simple maintenance.

Although it’s not composed real stone, like granite, Corian mimics the real thing relatively well.

The downside is price. Corian is still a relatively expensive countertop option. It’s actually comparable to granite countertops in terms of cost.

What You’ll Need

There are a lot of different ways to cut Corian countertops, but we’re going to focus on a simple, easy method that utilizes power tools most home DIYers already own.

Here’s what you’ll need:

Safety First

One of the major benefits of Corian is that it’s so easy to work with.

Unlike granite and similar materials, you can actually cut Corian with just about any tool that cuts through wood.

This makes it considerably less dangerous to cut Corian than countertops made with other materials.

You’ll still want to don, at the very least, a pair of safety goggles as you make your cuts.

Just as important is working with a partner to lift and move the Corian slab. You don’t want to risk it falling and breaking a corner while you're cutting or moving it around.

Step I: Prepare for the Cut

Don’t just rush into the cut – take the time to prepare, so you’re happy with the end results.

Start by measuring the area where the countertop will go then using these measurements to measure and mark the countertop itself.

Mark the cutline on the back of the Corian countertop. You must cut the slab from the backside to prevent chipping.

Lay the slab on two sawhorses, a workbench, or a similar sturdy area that allows for a full cut.

The last preparation step involves changing out the blade of your circular saw with a triple chip grind blade. A TCG blade utilizes rounded teeth to minimize chipping during your cut. 

Step II: Cut from the Back

As descibed above, lay the Corian countertop so that the backside is facing up.

Begin your cut by moving slowly and gently through the cut line with the circular saw equipped with a TCG blade.

You’ll likely be surprised at just how easy it is to cut Corian with a circular saw.

Remember to move slowly through the duration of the cut. If the blade starts to smoke, you’re moving too fast and must move more slowly.

Step III: Finish the Edges

There’s a good chance that your Corian countertop is ready to install right after the cut.

Those looking for a smoother finish on the edges, or even a rounded finish, can use sandpaper to accomplish this task.

Sand the edges to the desired smoothness or roundness. Finish up with 220-grit sandpaper to remove any sanding lines for a polished overall look.

Alternative Cutting Methods

One of the nicest characteristics of Corian is that it can be cut with just about any tool/method that will cut wood.

This means that a circular saw is far from the only method to cut a Corian countertop. Other options include a radial arm saw, beam saw, or router.

Just making small cuts? Then a belt sander might work. This power tool is extremely accurate and will help you shave off small portions at a time.

Despite the fact that you can use other power tools for this project, DuPont still recommends a circular saw above all else.

If you don’t own a circular saw yourself, remember that most home improvement store offer affordable rentals on power tools.

Final Thoughts

Learning how to cut Corian countertops is a lot simpler than you might think.

All that it requires is some basic know-how, a helpful partner (for lifting and carrying), and a circular saw equipped with the right blade.

Now that you’ve read this guide, you should feel confident completing your bathroom or kitchen countertop installation project.

About Gus Donaldson

I built houses for over 30 years and recently retired. I've made lots of mistakes and hopefully teach you not to make the same ones. I still love to build and have a garage workshop that I use for hobby projects like the walnut bookshelf I made for my wife. I like to write and let people know that working with your hands and tools does not need to be intimidating.

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