Corian countertops and hand-sinks are a popular choice among homeowners and home decorators. Corian comes in a wide variety of colors that will match just about any design in kitchens, bathrooms, laundry rooms or anywhere you have a sink. Corian has a longstanding reputation for being durable, long lasting and virtually maintenance free. Corian resists heat, stains and is generally a very strong material for both areas that require an extra measure of toughness or even those that receive gentle use.

Dupont makes Corian from a combination of polymers, resins and acrylics. After the plastics are heated to a thick and runny liquid, coloring is added and mixed in to create a solid surface with color throughout. Light surface scratches and nicks are hardly noticeable because of the color permeating throughout. Dupont offers Corian hand-sinks as the perfect blend of style, form and function. The sinks are manufactured as a hand-sink only that mounts to the underside of the countertop, mounts on top of the counter, as a one piece countertop that has the sink molded right in or as a hand-sink that stands alone.

Even though Corian is very strong and durable, it is not impervious to damage. A forceful impact can cause the sink to crack as well as repeated blows. If a Corian hand-sink cracks, many homeowners feel they have no choice, but to replace the sink. Replacing the hand-sink can be very costly when you factor in the cost of a new sink, an installer and maybe even a plumber. A much more economical way to regain a fully functioning hand-sink it to make repairs and seal the cracks in the sink.

Preparing to Repair a Corian hand-sink

Take everything out of the sink.

Pour white vinegar into a spray bottle and generously spray the insides of the sink. Scrub all of the surfaces of the hand-sink with a nylon scrubbing sponge. Do not use steel wool or scouring powders as they will scratch the sink and make the problem worse. White vinegar will remove any dirt, grease, oils and soap residue from the Corian surface.

Rinse the hand-sink with hot water.

Spray the sink a second time with white vinegar. Let the vinegar sit on the surface for two to three minutes and scrub it again.

Rinse the hand-sink with hot water to remove all residues.

Repairing the Corian Sink

Use 180-grit sandpaper to sand the edges of the crack smooth.

Vacuum up the sanding dust or wipe the inside of the sink with a tack rag.

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Wrap a rag around the end of a flat bladed screwdriver and dip the end into denatured alcohol.

Wipe the inside of the crack, edges of the crack and approximately ½ inch of the surface that surrounds the crack.

Deep or Shallow Crack Repair

Deep cracks go through the entire sink – these are the type that water will leak from. If the hand-sink is housed by a cabinet, open the doors so you can reach the underside of the sink. Put a piece of wax paper over the crack from the underside of the sink. Tape the wax paper firmly in place with masking tape.

If the crack does not go through the entire thickness of the hand-sink and does not allow water to leak out, you can skip adding wax paper to the underside of the sink. The wax paper is used to keep the epoxy putty or paste from dripping through the crack.

Move back to the inside of the hand-sink. Place blue painter’s masking tape on both sides of the crack. Make sure the tape is very close to the edges of the crack.

Open windows or set up a fan to provide adequate ventilation. Put on protective latex or rubber gloves.

Use a disposable plastic plate, small disposable plastic cup or a piece of clean scrap wood.

Add equal parts of two part epoxy repair putty or paste. Choose an epoxy repair kit made for swimming pools, bathtubs or hot tubs. The kits typically come with a coloring agent. Slowly add the coloring agent to epoxy until you achieve a color match. If the colors in the kits will not match your Corian sink, use white epoxy putty or paste. Mix as much epoxy as you will need to complete the repair. Mixed epoxy cannot be saved for later use.

Dip a thin plastic putty knife into lacquer thinner. Lacquer thinner will keep the epoxy from sticking to the putty knife.

Scoop up a small amount of mixed epoxy and press it into the crack as far as you can push it in. Continue to add the epoxy to the crack until you have filled the gap completely. Build the repair putty or paste up so it sits about an 1/8 inch above the surface of the sink.

Pull the wax paper off of the underside of the hand-sink.

Allow the repair to set up for five to six hours.

Sand the surface of the repair with 220-grit sandpaper until it is flush with the surrounding surface.

Wipe the inside of the sink with a tack rag to pick up the sanding dust.

Run water over a piece of 400-grit sandpaper and sand the repair making a small circular motion.

Wipe the hand-sink with a tack rag to remove the sanding dust.

Run water over a piece of 800-grit sandpaper and sand the repair again using a small circular motion.

Wipe the sink with a tack rag to remove the dust from sanding.

If you were unable to match the color of the epoxy putty or paste to the hand-sink, buy a matching color epoxy paint. Choose a paint that is made for swimming pools, hot tubs or bathtubs.

Use a thin paintbrush to add color to the repair patch. Apply the paint from the center of the patch creating brush strokes that move passed the outer edges of the epoxy patch.

Let the paint dry for four to six hours.

Dip a thin paintbrush into clear epoxy and paint a layer over the painted area.

Allow the clear epoxy to dry overnight before using the sink.