Method of Surfacing a Substrate

Abstract

A method is provided of resurfacing a substrate with a natural stone the substrate having a top surface and an edge, the method including placing a plurality of templating strips on the top surface to form a template defining an outside dimension, cutting out a top piece for resurfacing the top surface based on the outside dimension of the template, cutting out an edge band for resurfacing the edge of the substrate, bonding the edge band and the top piece together to form a replacement top and adhesively joining the replacement top to the substrate. A plurality of templating jigs may be used for forming a template. Pieces of natural stone may have respective bevel cuts made in their respective edges for adjoining with other pieces to form a replacement top of natural stone. Inside edges may be reinforced with a fiberglass cloth coated with a polyester resin. A plurality of natural stone pieces may be adjoined to form a segmented radius of curvature for covering a corresponding radius of curvature of an edge of the existing substrate.

1 ) A method of resurfacing a substrate having a surface and an edge, the method comprising: 
 placing at least one templating strip on the substrate surface to form a template defining an outside dimension of the substrate surface;    removing the template from the substrate surface;    overlaying the template on a sheet of resurfacing material;    determining an amount of overhang for a substrate surface replacement piece to extend beyond the outside dimension of the substrate surface;    cutting the substrate surface replacement piece from the sheet of resurfacing material based on the outside dimension of the template and the determined amount of overhang, the substrate surface replacement piece used for resurfacing the substrate surface;    cutting an edge band from the sheet of resurfacing material for resurfacing the edge of the substrate, the edge band having a thickness that is substantially the same as the determined amount of overhang;    bonding the edge band and the substrate surface replacement piece together to form a replacement structure; and    adhesively joining the replacement structure to the substrate.    
   
   
       2 ) The method of  claim 1  further comprising: 
 the resurfacing material comprising a natural stone; and    cutting the substrate surface replacement piece and the edge band from a slab of the natural stone having a thickness of about 5 millimeters to 19 millimeters.    
   
   
       3 ) The method of  claim 2 , the bonding step comprising: 
 cutting a bevel of about 45° to 47° along a length of the outside dimension of the substrate surface replacement piece;    cutting a bevel of about 45° to 47° along a length of the edge band;    laying the substrate surface replacement piece and the edge band on a piece of adhesive material so their respective bevel cuts are parallel and adjacent;    applying an adhesive to a respective surface of each bevel cut; and    forming an approximately 90° angle between the substrate surface replacement piece and the edge band to form an inside edge.    
   
   
       4 ) The method of  claim 3 , the bonding step further comprising: 
 positioning a block in the inside edge against which the substrate surface replacement piece and the edge band may each be braced; and    compressing the edge band toward the substrate surface replacement piece to maintain the approximately 90° angle there between.    
   
   
       5 ) The method of  claim 3  further comprising: 
 applying a reinforcing fiberglass cloth along the inside edge; and    applying a liquid resin over the reinforcing fiberglass cloth.    
   
   
       6 ) The method of  claim 1  further comprising: 
 cutting the substrate surface replacement piece to include a first radius of curvature portion; and    bonding the edge band to the substrate surface replacement piece so the edge band is aligned with the first radius of curvature portion when the replacement structure is adhesively joined to the substrate.    
   
   
       7 ) The method of  claim 1  further comprising wherein the determined amount of overhang is greater than a maximum thickness of the edge band.  
   
   
       8 ) The method of  claim 7  further: 
 leveling a top surface of the substrate; and    adhesively joining the substrate surface replacement piece to the top surface using a first adhesive having a first setting time and a second adhesive having a second setting time where the first setting time is longer than the second setting time.    
   
   
       9 ) A method of resurfacing a substrate with a resurfacing material the method comprising: 
 placing a plurality of templating strips on a top surface of the substrate to form a template sized to cut a first piece of the resurfacing material for resurfacing the top surface of the substrate;    removing the template from the top surface of the substrate;    overlaying the template on the resurfacing material;    cutting the first piece of the resurfacing material based on an outside dimension of the template;    cutting an edge band of the resurfacing material sized to resurface an edge of the substrate;    cutting a bevel in an edge along a length of the first piece of the resurfacing material;    cutting a bevel in an edge along a length of the edge band of the resurfacing material;    adjoining the first piece of the resurfacing material and the edge band of the resurfacing material to form a replacement piece, the first piece of the resurfacing material and the edge band of the resurfacing material adjoined along their respective beveled edges to form a substantially right angle there between having an inside edge;    applying a fiberglass cloth to the inside edge; and    adhesively joining the replacement piece to the top surface and the edge of the substrate.    
   
   
       10 ) The method of  claim 9  further comprising: 
 placing the plurality of templating strips on the top surface of the substrate so the outside dimension of the template is substantially the same as an outside dimension of the top surface of the substrate;    determining an amount of overhang the first piece of the resurfacing material will extend beyond the edge of the substrate; and    cutting the first piece of the resurfacing material based on the outside dimension of the template plus the determined amount of overhang.    
   
   
       11 ) The method of  claim 10  wherein the determined amount of overhang is greater than a thickness of the edge band of the resurfacing material.  
   
   
       12 ) The method of  claim 9  further comprising: 
 cutting a plurality of resurfacing material pieces of substantially the same dimensions, each piece comprising a respective top edge and respective lateral edges;    cutting a radius of curvature along an edge of the first piece of the resurfacing material;    cutting a bevel of approximately 10° in the respective lateral edges of the plurality of resurfacing material pieces;    cutting a bevel of approximately 45° to 47° in the respective top edges of the plurality of resurfacing material pieces;    cutting a bevel of approximately 45° to 47° in the edge of the first piece of the resurfacing material having the radius of curvature;    adjoining the plurality of resurfacing material pieces along their respective lateral edges to form a segmented radius of curvature; and    adjoining the segmented radius of curvature to the edge of the first piece of the resurfacing material having the radius of curvature.    
   
   
       13 ) A method of resurfacing a substrate with a natural stone having a thickness of about 5 millimeters to 19 millimeters, the substrate comprising a top surface and an edge extending downwardly from at least a portion of the top surface, the method comprising: 
 cutting a top piece of the natural stone sized to cover at least a portion of the substrate's top surface and defining an edge having a radius of curvature overhanging a corresponding radius of curvature of the substrate's edge;    cutting a plurality of natural stone pieces of substantially the same dimensions, each piece comprising a respective top edge and respective lateral edges;    cutting a bevel in the respective lateral edges of the plurality of natural stone pieces;    adjoining the plurality of natural stone pieces along their respective lateral edges to form a segmented radius of curvature;    adjoining the segmented radius of curvature to the radius of curvature of the top piece to form a replacement top; and    adhering the replacement top to the substrate so that the segmented radius of curvature covers the radius of curvature of the substrate's edge.    
   
   
       14 ) The method of  claim 13  further comprising: 
 cutting a bevel in the edge of the top piece having the radius of curvature;    cutting a bevel in the respective top edges of the plurality of natural stone pieces; and    adjoining the segmented radius of curvature to the radius of curvature of the top piece along their respective beveled edges.    
   
   
       15 ) The method of  claim 13  further comprising: 
 cutting the top piece to define a linear edge overhanging a corresponding linear portion of the substrate's edge;    cutting an edge band of the natural stone sized to cover a surface of the corresponding linear portion of the substrate's edge;    cutting a bevel in the linear edge of the top piece;    cutting a bevel in an edge of the edge band;    adjoining the top piece and the edge band along their respective beveled edges to form the replacement top; and    adhering the replacement top to the substrate so that the segmented radius of curvature covers the radius of curvature of the substrate's edge and the edge band covers the linear portion of the substrate's edge.    
   
   
       16 ) A method of fabricating and installing a structure on an existing substrate, the method comprising: 
 providing a sheet of resurfacing material;    cutting a first piece from the sheet of resurfacing material for resurfacing a surface of the existing substrate, the first piece of the resurfacing material sized to include an expansion gap that will overhang an edge of the existing substrate when the first piece of the resurfacing material is placed over the surface of the existing substrate;    cutting a second piece from the sheet of resurfacing material for resurfacing the edge of the existing substrate, the second piece of the resurfacing material having a thickness that is less than a width of the expansion gap;    adhesively joining the first piece of the resurfacing material and the second piece of the resurfacing material to form the structure; and    adhesively joining the structure to the surface of the existing substrate.    
   
   
       17 ) The method of  claim 16  further comprising: 
 sizing the expansion gap to be greater than a maximum thickness of the second piece of the resurfacing material.    
   
   
       18 ) The method of  claim 16  further comprising: 
 placing a plurality of templating strips on the surface of the existing substrate to form a template having an outside dimension that is substantially the same as an outside dimension of the surface of the existing substrate;    removing the template from the surface of the existing substrate;    overlaying the template on the sheet of resurfacing material;    sizing the expansion gap to be greater than a maximum thickness of the second piece of the resurfacing material; and    cutting the first piece of resurfacing material based on the outside dimension of the template and the size of the expansion gap.