General-purpose and vertical-grade laminates are available, but only general-purpose laminate should be used for countertops. Vertical grade is designed for cabinets and doors. Use laminates with a matte or fine-matte finish for countertops. High-gloss laminates, or those that are heavily embossed, aren’t suitable because they can’t stand up to the heavy wear and tear that countertops are subjected to.
Plastic laminate is commonly sold in 4-by-8-foot sheets, but larger sheets up to 5 feet wide and 12 feet long are also available. Large sheets of plastic laminate can be hard to find, but most laminate manufacturers will help you search for a local dealer when you visit their websites. You can also try stores that cater to cabinetmakers. At the time of publication, plastic laminate prices ranged from $1.50 to $2.50 per square foot, depending on the color and pattern.
Several tools can cut plastic laminate, including a circular saw, saber saw, backsaw and a utility knife with a special blade for cutting laminate. Use a fine-tooth blade and place a strip of masking tape on the cut line to prevent chipping. Cut from the back side when using a saber saw or power circular saw. Cut from the front side when using a handsaw. If cutting with a utility knife, use a straightedge to guide the knife. This will ensure an even cut. Always cut sheets slightly larger than you need to allow for trimming. Trimming can be done with a hand-held router.
A hand slitter is a special tool that can make cuts on countertop edges. The tool can be adjusted to accommodate the thickness and width of your laminate and makes clean cuts and seams. At the time of publication, this hand tool cost from $130 to $150. It’s a good tool if you do a lot of resurfacing. However, if you don’t want to spend the money for a one-time use, you can also cut edges with a table saw or a pair of hand snips, although they won’t give you as clean a cut.