Repairing Chips and Filling Fissures

It is very common to have some chipping of corners and edges of panels during installation. This is more often found in softer stones such as marble and limestone, but can also be found in granite. It is most often caused by handling (or mishandling) the panels. Obviously, it is best to handle the stone very gently to avoid these problems all together. While it is not possible to completely hide them, small chips can easily be filled.

Another common problem found in stone is small fishers or cracks in the surface. These are most likely natural fishers in the stone from its formation, but they will often need some attention to make them less obvious.

The following procedures are used to repair chips at corners or edges or fill small surface cracks or holes that have occurred in the face of Ultra-Lite Stone Panels.

MATERIALS

Most of these materials are readily available from your local stone and tile supply store.

• KNIFE GRADE RESIN - used to fill voids or fissures as well as to repair chipped or broken corners. Coloring pigments are used to color the resin to match the stone.
  
• HARDENER, FOR RESINS - resins are mixed with coloring pigments prior to adding hardener. Hardener should be added to the resin at a 3% hardener-to- resin ratio. Increasing the percentage of hardener speeds curing time, however the hardener ratio should not exceed 10%.
• WATERCLEAR FLOWING RESIN - used primarily on fissures or voids being less than 1/32" in width or depth Coloring pigments are generally not used with the clear flowing resin. Clear fingernail polish can be used for this same purpose on polished marble on interior applications. This helpful with in-place vertical applications adjacent to caulked joints.
• METHYL-ETHYL-KEYTONE (M-E-K) - used to remove dust and dirt prior to filling, and to clean up excess resin after filling.
• Razor Blades
• Masking Tape
• Clear Packing Tape
• Small Paper or Plastic Cups
• Stir Stick
• Sandpaper of Various grits from 120 to 600 grit

Instructions:

Note: It is advisable to make a trial application on a piece of scrap material to test / practice the below procedure.

Stones, like sponges, absorb water. If the stone is wet, the surface may be easily dried with a small blow torch or heat gun. Always remember to keep the flame outlet or direct heat source moving while heating the area. Concentrated heat will crack the surface of the stone.

Clean area to be repaired with Methyl-Ethyl-Keytone (M-E-K) to remove dust and dirt from the void. Allow the MEK to completely evaporate prior to applying the patch.

When filling edge chips or chipped corners, it is often helpful to use the masking tape to tape along the edge or corner to create a dam to put the resin into. Be sure to keep the top edge of the tape flush with the top of the stone, or it will be difficult to work the resin down into the hole you just created.

After the area has been cleaned and dried, prepare enough resin to fill the area to be patched. Small paper cups and wood craft sticks or tongue depressors are recommended for mixing the resin and hardener together in the ratio shown above.

Note: If repairing a deep gouge or break, you may want to prepare several fills, layering one on top of the other until the desired height is reached. An accurate color match will not be necessary until the last two layers are mixed.

Scoop out some of the resin into a small cup and mix in pigments to color match to the stone. When working with color pigments, start with a minute amount. A little bit will go a long way. You may mix colors together to form new colors if you wish.

In dealing with Granites that have large crystal clusters of various colors, you may want to mix more than one patch for the same area. It is recommended that you get each patch mixed and ready before applying any catalyst. When you are ready, put the catalyst into each mixture and apply all of the prepared mixtures at the same time. For example, if you are repairing Diamond Pink where you have large clusters of black and pink, mix a black patch and a pink patch. Place the black on one side of the repair and the pink on the other. When they harden, they will naturally connect together. The whole patch may then be worked to match the surface.

Mix in the catalyst (hardener - usually in a white tube) at about 7 parts resin to one part hardener, or about a 1/2" bead of harder to a ¾ dixie cup of resin. Stir very well with a stir stick, it is very important that all of the resin is mixed with the hardener. If it starts getting lumpy, you have added to much hardener or taken too much time, throw it out and start over. The more catalyst that you put into the patch mixture, the faster it will set up. Temperature and stone dryness will also affect reaction time.

Apply blended resin to the area being repaired, you are trying to get the resin to be flush with the stone surface and extend slightly wider than the area to be patched. However, the resin will recess a little when it dries, so leave a little extra on the area, or come back and fill it a second time after the first has dried. Use the razor blade to scrape off the excess resin. If the resin starts getting lumpy or very sticky, stop working it with the razor blade. To aid in keeping the patch flush with the adjacent stone surface a piece of clear packing tape can be applied over the patch after it is in place. Smooth over the tape over the patch with your finger to give a more polished appearance to your patch.

After the resin is fully cured use M-E-K and "00" steel wool to clean excess resin from adjacent stone. If surface of patch is low repeat the process.

Note: Always be careful when working on a marble or limestone surface. It is easily scratched and cannot withstand vigorous rubbing with abrasive materials.

Removing excess Patch material will dull the finish, but may be restored by polishing the patch with sandpaper starting at 120 grit up to about 600 grit. Take care not to damage the polish on the stone around the patch. Reapply epoxy as required to fill voids.

Other materials that may be used to restore a polish when polishing is not possible are liquid super glue or clear nail polish. Both will last for several years under normal conditions.

Please contact our Technical Services Staff if you have any additional questions not answered by this document.

Disclaimer

Stone Panels, Inc. does not manufacture installation products or stone cleaning/maintenance products. Stone Panels, Inc. provides the information contained herein to its customers as an information source only. The products identified in this website may have chemicals that cause reactions in certain individuals. Stone Panels, Inc. strongly recommends the use of safety glasses, respirators (masks) and gloves in handling any materials that contain chemicals. Stone Panels, Inc. recommends the proper disposal of any scrap stone/stone, installation and/or maintenance products discussed herein. Please contact the manufacturer directly, PRIOR to usage, to obtain proper handling instructions, application instructions and warning concerning potential health hazards for any product contemplated for use. Stone Panels, Inc. also strongly recommends that you ALWAYS test a small area PRIOR to usage of any installation/stone/cleaning/maintenance product to determine whether the product you are about to apply serves its intended purpose.

By writing these instructions, Stone Panels, Inc. in no way makes any warranty nor takes any responsibility for cleaning of the stone, stain removal or any other work. Further, these instructions are merely our suggestions on how to maintain the stone. Use at your own risk. Any warranty, representation, statement or undertaking whatsoever that may be expressed or implied by statute, custom or otherwise is hereby expressly excluded. Under no circumstances shall Stone Panels, Inc. be liable for any costs, losses, expenses or damages (whether direct or indirect, consequential, special, economic or financial including any losses of profits) whatsoever that may be incurred through the use of any information contained in the Stone Panels, Inc. website or in any other website. This website may contain inaccurate information. Stone Panels, Inc. is under no responsibility to update or correct any such information or to even maintain this website.

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