Classy Counters

Granite Lite — a material that is manufactured using natural stone and said to be stronger, lighter, and more flexible than traditional granite — has entered the RV marketplace.

By George Myers, L2014S

If you have been looking into kitchen remodeling or watching home-improvement shows such as "This Old House," you know that the top-of-the-line kitchen countertop material is real granite. Not a composite made up of plastic and stone dust, but the real thing sliced off a block taken out of the ground. It is considered the best, because it is almost impervious to scratches and burns. Until now, however, granite counters have not been practical in motorhomes, even the largest, because granite is too heavy and too brittle. The traditional granite used for countertops is an inch or more thick to give it the strength to withstand the handling needed between the quarry and the kitchen. Even with that thickness, it might not be able to withstand the flexing encountered in a moving coach.

Granite Lite, a new product made of real granite, is suitable for use in an RV. It is the real thing. However, it is only 3/8-inch thick. This cuts the weight to a fraction of a full-thickness slab. Granite Lite has been available in Europe for a few years and is now being introduced to the RV market in the United States by FlexStone Inc. It is being used in both traditional-style kitchens and in very modern ones, and it is available as an aftermarket installation or from many motorhome manufacturers and conversion companies.

The stones selected for Granite Lite are sliced by diamond-tipped saws into slabs less than 1/2-inch thick. To give Granite Lite the necessary strength, the material is heated to approximately 200 degrees Fahrenheit, which opens the pores in the stone so that plastic resins can be forced into the fissures. A saturated layer of heavy cross-woven fiberglass is bonded onto the back of the countertop material and coated with another layer of resin. This yields a material that is said to be five times stronger and 70 percent lighter than typical granite countertops.

Weight
The traditional granite countertop weighs about 15 pounds per square foot. Granite Lite weighs only about 5 to 6 pounds per square foot, depending on the stone’s density. This compares to solid-surface materials that weigh 4 to 5 pounds per square foot, or formed high-pressure laminate counters that average approximately 4 pounds per square foot (the weight with these counters is in their particleboard foundations).

A typical 2-foot-by-8-foot coach counter of 16 square feet will weigh approximately 90 pounds when made of Granite Lite. The area for the sink and stove cutouts should be subtracted and the material for the edge treatment and the backsplash added to find the true weight. However, the total weight for even a large counter should be less than 100 pounds.

How Flexible?
I think the accompanying photo says it all. This piece of Granite Lite is flexing far more than any counter will in a coach. The granite can bend in this manner because it is so thin. It holds together because of the layer of fiberglass bonded on the back. This material is called woven roving in the fiberglass industry, where it is used for high-impact and high-strength applications.

Edge Treatment
Most of FlexStone’s customers want a simple square front edge so that it looks like a standard 1-1/2-inch-thick granite counter. This traditional look is easily made by bonding another piece of Granite Lite to the edge. While this produces a seam about the thickness of a sheet of paper, it is almost invisible. One layer of Granite Lite with a polished top edge usually is used for the backsplash.

There are other ways of treating the front edge of the countertop using pieces of Granite Lite. The same color granite can be used, or a contrasting accent color can be incorporated. Strips of other materials can also be added to decorate the front edge. These can be plain or fancy. However, my personal choice would be to stick with the elegance of a plain granite edge.

Shapes
Any shape that can be cut out of a flat sheet or built up from bonded layers can be made of Granite Lite. Obviously, the more complex the shape, the more it will cost. If the sink or stove is recess-mounted (up against the bottom of the counter), the hole can be cut to the exact dimensions, the corners smoothed, and the edges polished. A lay-in cutting board to cover the sink is usually made to provide a larger work area and to hide the sink.

Colors
Granite Lite currently comes in nine standard colors. It is very difficult to take photos of the material, because it is so shiny that it reflects whatever is on the other side. High-quality scanned photos that show the actual colors are available from FlexStone. Do remember that this is a natural product and there are some minor variations between samples.

Other Uses
In addition to countertops, Granite Lite can be adapted for many other uses. FlexStone has fabricated shower stalls, entrance stairs, tables, coffee tables, windowsills, edging on cornice boards and between windows, nightstands, wine cabinets, armrests, dashboards, and floors. Because of the cost, it's likely that only the very top-dollar, custom-built coaches will be outfitted with the material throughout. However, a growing number of manufacturers are offering Granite Lite counters in the kitchen and bath.

The beauty of the polished granite certainly makes it ideal for general decorating. One coach reportedly contains 42 separate pieces of Granite Lite. Having the same exceptional material in many places throughout a coach certainly makes for a very stunning interior.

Cost
I’m sure most of you are expecting the old phrase, “If you have to ask the price, you can’t afford it.” Granite Lite is definitely not the economy countertop. However, in a new high-end motorhome, Granite Lite counters would add only about one percent to the total cost of the coach. A simple counter with a drop-in sink and stove would probably be in the $5,000 to $7,000 range. The 42 separate pieces of Granite Lite in the coach mentioned above cost about $30,000. But other materials are not inexpensive, either. For a simple counter, Granite Lite is priced competitively with other quality materials.

An Installation Example
My wife and I drove our motorhome to Decatur, Indiana, to watch the installation of Granite Lite counters in a coach belonging to our friends, Charles and Eileen Martin, F168599. They were well into the process of building a lovely interior in their MCI 102C3 bus conversion. However, their varnished pine plywood countertops appeared out of place with the classic custom-made oak cabinets. They had been planning to install solid-surface countertops, but the companies they contacted were not willing to put them in a coach. One installer said an RV was a rolling earthquake that measured a 7 on the Richter scale. When the Martins saw Granite Lite material, they fell in love with it. Plus, they found that FlexStone is not only willing to install it in a coach, but the company is specifically trying to serve the RV customer. The Martins decided to have counters made for the kitchen and the bath, as well as two end tables.

Our friends have had their granite counters for about a year. They are still in love with them. Eileen said, “I enjoy cooking and usually cook two meals a day in our coach. The Granite Lite is beautiful and easy to keep shining. I use my toaster, coffeemaker, electric fry pan, and George Foreman grill and never worry about heat damaging the counter. I accidentally dropped a soup can and a 10-ounce bean can and neither one made a mark. After washing the dishes, I wipe off and dry the counter with a towel, and it shines like new.”

Care
Granite Lite counters should be cared for the same as any quality granite counter. The stone must be sealed, which takes place at the factory prior to installation. It must be resealed periodically if it changes color when it gets wet. If the stone does change color, it will change back when it dries. Special cleaners are available from any dealer that sells granite counters.

Retrofitting
If you want to install new counters in your current coach, a two-step process is involved. First, a template is made to the exact shape of the final counter. This template must be absolutely correct and include the locations of openings for each appliance, faucet, hold-down screw, etc. The counter is then made to the exact shape of the template. Because the shape is literally cut in stone, an accurate template is critical. The second step is to remove the old counter and install the new one.

Some Background
Granite Lite was first developed to cover the sides of commercial buildings. Using blocks of granite that are many inches thick, as our ancestors did, is too expensive today. In addition, slabs of granite hanging on the side are too fragile and dangerous. When the morning sun hits dark granite that has been cold soaked overnight, the granite can crack and fall away. Because of how thin it is, Granite Lite can flex a bit to relieve the stress. If it should crack, the fiberglass layer will hold it in place.

Closing Thoughts
Many motorhomers want only the very best materials in their coaches. Thanks to Granite Lite, real granite is now available in a reasonable form. Solid-surface materials have been the countertop materials of choice in high-dollar coaches and likely will continue to be used, primarily because they are so easy for the manufacturer to work with. However, they are easily cut or burned. Granite Lite is real stone and can’t be worked with standard wood-working tools. Counters fabricated from this material must be custom made by a company that has the tools to cut and polish the stone.

Because Granite Lite is so strong and reasonably light, the counters can be made at the facility in Indiana and shipped anywhere. FlexStone is developing a network of dealers to install the material and, as noted above, a number of manufacturers are now offering Granite Lite as an option.

FlexStone Inc., 1337 Village Green Drive, Decatur, IN 46733; (877) 656-6680, (206) 610-5772; www.flexstone.com.