How to Prevent your Sheetrock from Being Crushed

In instances where a large counter extension or bar is being supported by countertop support brackets there can be heavy weights involved that will create great force down the flanges of the supporting brackets. The force created by the carrying of this heavy weight will cause the end of the down flange of the countertop support bracket to exert pressure on the supporting structure of the application. This supporting structure can be made up of all types of materials including solid wood, metal, plaster, cinder block or other composite building materials.

This blog entry will deal with solutions to compression on sheetrock material when it is the finished surface on a countertop support structure.

Regardless of the material used as the finishing surface on the support structure you will want to make sure that the supporting brackets are tied directly into a substantial (at least 3/4" thick)structure made of solid materials like wood. Fastening a countertop support bracket to material that will easily fail (such as thin chip board or thin fascia on the back of a cabinet) is sure to promote application failure. So when fastening your countertop brackets in place make sure that you hit the studs or use a thick plyboard to tie into for maximum stability.

When the finished surface of a support structure is composed of sheetrock (such as a stud half wall cover in sheetrock) the pressure exerted by the countertop and support bracket can cause compression of the sheetrock. The sheetrock will be imprinted or even get crushed by the pressure placed on it from the bracket down flange with the weight of the granite or solid surface material of the countertop.

The solution to resolve this compression is to use a material that will resist compression between the bracket flange and the sheetrock wall. This material would be in the form of a board or panel and it has to be of a density so that it will not compress under the weight of the countertop and bracket. Examples of this appropriate materials are wood, metal and densely packed composite materials such as fiber board (MDF and HDF). All of these have a higher density than the particles in sheetrock, which easily makes way for impression, crushing, and breakage under heavy weight. Dense materials will resist the compression and disperse the force of the weight along the length of the board thus protecting the sheetrock from impressions and crushing. These are commonly called backer boards.

Federal Brace has developed a new economical product that employs this idea of a force absorber called the Bracket Backer (tm). The use of Federal Brace's Bracket Backers (tm) will protect your sheetrock finish while enhancing the look of your support brackets and countertop. The Bracket Backer (tm) is made of high density fiber board and is specially designed in shape an appearance to match your support brackets with a variety of styles from which to choose. Just insert the backer between the sheetrock and the bracket or brace and stop any potential of crushing on your sheetrock.

In order to apply the Bracket Backer (TM) you will need to identify where the studs are behind your sheetrock. Then use a self drilling woodscrew or a drill and screw to fasten the Bracket Backer (TM) through the sheetrock and into the stud Make sure that the stud is securely gripping the screw. Then place the bracket or brace on top of the Bracket Backer (TM) and drill it through the backer, the sheetrock and into the stud, ensuring that it is also securely applied.

The Bracket Backer (tm) are excellent solutions in renovations or upfits when your sheetrock is already finished. However, do not use Bracket Backers or any other backing material as a sole support solution. Backers should not be consider a reenforcement of the support structure but rather a solution that prevent crushing on weaker materials.

Check out the Federal Brace Website for details on Bracket Backers and other countertop support products. Click Here for Federal Brace website.

How To Not Get Stuck Without Supports

Plan Ahead, Don’t Compromise

Charlotte, NC – July 6, 2010

One of the great influences for compromise in kitchen design and construction is lack of time. Countless homeowners have been forced to go with solutions that only barely meet their satisfaction because they either did not know what was required or procrastinated until it was too late to get the perfect solution to meet their design and functionality needs.

One area where this “no time – got to compromise” principle shows up is in the support of countertops. After investing thousands of dollars in their countertops most owners are never told that they need support for countertop overhangs. Well, they are likely told but not until the countertop fabricator shows up to run the templates or possibly when the installer shows up to put in the counters. This seriously limits the homeowner’s ability to select a desirable solution for supporting their countertops.

Countertop support brackets are more than just shelf brackets or standard decorative wood corbels. A countertop overhang is no small matter and true countertop brackets are designed to handle the load of the overhang. These types of brackets really constitute hardware in the kitchen and should be selected as such. You cannot pick up them up at the local hardware store or from large box stores because they are not carried. The countertop support brackets used to hold up stone counters are specifically designed for that purpose and are often made to order or when in stock require shipping to the customer’s construction site.

Cathy Morgan knows about the significance of delaying selection of countertop supports. The general manager of Federal Brace, a designer and producer of custom countertop support brackets says, “We hear daily from people looking for countertop supports having just learned that they need them for their countertop installation scheduled for the next day. Unfortunately, that leaves the customer limited to those supports that are stock and bearing overnight shipping costs in order to fill the need.” The additional costs associated with shipping overnight are one thing. But more unfortunate is the customer’s inability to take advantage of the full line of designer countertop supports available or the possibility of using the customization service provided by the company.

Bottom line - time is needed to select the right countertop support bracket. Homeowners are asked, months before they are needed, what type of knobs and handles they want on their cabinets. Why wait until the week before installation to ask what type of countertop support is desired? The answer is a bit simple. No one is sure whose job it is to specify the need for supports. The contractor will generally rely on the countertop fabricator. The fabricator may defer to the installer. Ultimately, they can all point to the problem with limited knowledge of the requirement standards.

Federal Brace is trying to eliminate this problem by educating the contractor and the customers. Their website boasts one of the most comprehensive resource areas on the topic of countertop support. Their customer service representatives are knowledgeable on solving the issue of timing as well. Cathy gives her pointers very concisely – “First, do not wait to hear that you need countertop supports. If you are planning a serving or seating area at your kitchen countertop you will likely need supports for the counters in that area. Be proactive and start your search early. 2. Do not compromise your desires because of timing. It is likely that whatever is put under your countertops will be there until they are removed. Make sure that it is a support that meets your needs visually and functionally.”


About Federal Brace
It all starts with helping people. Federal Brace designs and produces custom, designer countertop support products made specifically to solve the problem of countertop support. Federal Brace serves homeowners, interior designers, architects, builders (commercial and residential) as well as countertop installers and fabricators. Federal Brace supports the creation of U.S. based jobs by producing all its countertop support products right here in the USA.

How To Support My Overhang

Yesterday we talked about how to know when you need to support your countertop overhang. Today we are going to talk about how to support your countertop overhang and what type of support may be used.

There are many different ways that you can support your counter top overhang. Included in these ways are traditionally used methods as well as more contemporary methods. Below is a listing of a number of support terms and brief descriptions of what they represent:

• Corbels- corbels are generally wood, some are metal and some are even made in plastic. Corbels are decorative in nature and are limited as supporting members. A Key hole is used for attaching the corbel to the support structure. This method allows for no fastener to be seen from the face of the corbel but it also weakens the connection between the support structure and the corbel. In most cases the keyhole set up provides less fastening strength than a through hole.
• Brackets- brackets, also called braces or supports, are most commonly made out of metal but also may be made using wood. Brackets are true supporting members that provide a great degree of carrying capacity than corbels. Brackets use a through hole set up so that the full extent of their carrying capacity can be utilized. A metal bracket is stronger than a wood bracket of the same dimensions. However, wood brackets can be made thicker and bulkier in size to increase their strength. A thicker metal bracket is stronger than a thinner metal bracket.
• Legs or Columns- these are terms used to describe supports that extend from floor level to the base of the countertop. When installed with the base secured to the floor these types of supports with carry the most weight. Due to the size of legs and columns they tend to be the most expensive type of supports.
• Plywood Substructure - this describes the use of plywood board to "stiffen" and add additional support to a countertop overhang. However, it is important to understand that plywood board tends to be flexible overtime and may deteriorate over time in some environments. Plywood should not be relied upon as a supporting member for large countertop overhangs.
• Metal plates- metal plate are sometimes used as support for countertop overhangs. When using plate to support a granite overhang remember that it will act just like a non gusseted bracket (for information on non gusseted brackets click here). Under point load situations or in large overhang applications metal plate will be susceptible to deflection or bending.

Whatever support system that you choose for your countertop overhang application remember the importance of tying your supporting members into a strong support structure (stud wall, reinforced cabinet backs, etc.) In some application, such as a standard cabinet back, you will not find sufficient fastening material into which to anchor your support system. Make sure to make the most of your countertop support by setting it on a strong substructure. Also, at Federal Brace we recommend that the counter top support extend within 4 inches of edge of your countertop overhang to prevent compromise from point load events. Use fasteners that are substantial enough to hold your supports to the anchoring members. You can either use an adhesive or fasteners to attach your countertop to the supporting brackets and structure.

First and foremost plan ahead. Do not wait to the last minute to determine the need for your supports. It is best to know what you need to early and make preparations before the installation day. If we can help you please let us know -- www.federalbrace.com

How To Determine the Need for Countertop Overhang Support

A frequently asked question found on forums and other internet sites is, "Do I need to support my countertop overhang?"

Sources vary as to recommendations on what size countertop overhang requires supports and what constitutes sufficient bracing for a countertop overhang. While there appears to be few standards related to this topic the concensus established in the review of comments related to the topic show that a countertop overhang greater than 6 (or up to 10) inches needs to have additional support. It also appears to be common practice in the installation of stone
counters to allow a countertop overhang to be unsupport if not extending over 10 inches and/or if 2/3 of the total counter slab is supported by a cabinet or other sub support structure.

While not refuting the concensus, Federal Brace chooses to take a little more conserative approach to the need for countertop overhang support. We feel that there needs to be additional factors considered when determining countertop overhang support. The basic "standards" established take into account the static load of a countertop on its support structure. While static load is by far the most persistent of factors involved in carrying the load of a countertop, it is not the only factor. Some other factors may include:

• Point Load Occurances - where a heavy object or a significant force is placed on the counter at one point cause possible compromise within the stone slab itself or causing a deflection in the stone to point of cracking.
• Consistencies of Stone Character - Granite as an example has a variety of different classes (ratings) based on the individual characteristic of the granite itself including the presence of natural fissures that may cause the stone to react differently under force.
• Location and Environment - An indoor application in Kansas will be completely different from an outdoor location in California - not to mention the difference between a single family home and a frat house with table top dancing!

When considering all the possible factors involved, and thinking conservatively, Federal Brace has established a policy of recommending support on countertop overhangs of greater than 4 inches. Additionally, we recommend that the span between countertop braces does not exceed 30" in most instances when using a gussetted bracket (for more information on gussets view the Anatomy of a Countertop Bracket Here).

And one more thing to consider - though people often use supports under their countertop overhang they do not realize that their countertop braces need to have a sufficient supporting substructure and sufficient anchorage to that substructure. If this is overlooked it could be more of a problem than a solution. As an example, consider a project that uses 3 each 16" x 16" Brunswick Brackets (view here) to support a 20" overhang that extends 8 feet. If this application is entirely supported on a stud wall that is fastened to the floor than the total supporting structure incorporates the floor, studs and brackets. Now place that same application to a 3/4" thick plyboard back of a cabinet. Now the supporting structure consist of its weakest link - the plyboard - and the brackets are of little value. The board will bend and break over time and the whole application will fail.

When considering support for your countertop overhang always be conservative. It will never pay to limit your support and have a system that is either weak or will fail. The extra dollars that you spend on the support of your countertop overhang will save you some gray hair and the need to replace your kitchen countertop in the near future.

For more information on Countertop Overhang Support visit Federal Brace's Countertop Resources Area Here.