Replace a Backsplash Section

A. Finished-Project Specification

Deliverable: one limited kitchen or vanity backsplash section removed and replaced with the approved tile, sheet, or panel system, installed over a sound and dry substrate, with correct coverage, joint spacing, grout or seam finish, and flexible sealant at every countertop and change-of-plane joint, with devices reinstalled and accessible.

B. Removal Limits and System Selection

Item	Recorded Value
Approved backsplash system	Tile / sheet / panel (state manufacturer, product, and size)
Removal boundary	Cabinet, corner, countertop, trim, or pattern-break location on each side
Adhesive or mortar system	State product and required notch size
Grout or seam-finish product	State product, color, and joint width
Flexible sealant	State product and color for countertop and change-of-plane joints
Devices in the work area	List each device and whether qualified de-energization is required

C. Acceptance Standards

Check	Standard
Substrate condition	Clean, dry, flat, sound, and within the selected system's tolerance before adhesive is applied
Layout	Level and plumb reference lines established independently of the countertop or cabinet edge
Coverage	Adhesive or mortar coverage and notch size match the manufacturer instructions for the material selected
Joint treatment	Fixed joints grouted or seam-finished per product instructions; every movement and countertop joint filled with flexible sealant, not rigid grout
Device access	Electrical boxes, device screws, and plumbing escutcheons remain accessible after installation
Finish integration	Plane, pattern, cuts, coverage, joints, sealant, and cleanliness accepted under normal viewing conditions

D. Preparation — System Selection and Protection (Steps 1–7)

1. Select the approved backsplash system: tile, sheet, panel, or other specified finish. Record the manufacturer, product, and size on the Removal and Reference Record before ordering material.
2. Review removal limits, substrate, countertop joint, cabinets, outlets, devices, plumbing, pattern, edge trim, adhesive or mortar, grout, sealant, finish, and cure requirements. Confirm every item is recorded in Section B before removal begins.
3. Confirm whether the location is a decorative splash area or part of a code-controlled wet-area or fire-protection assembly. Stop and obtain the approved wet-area design before proceeding if the location is code-controlled.
4. Complete hazardous-material assessment before disturbing old tile, mastic, adhesive, wallboard, texture, coating, or grout. Do not sand, grind, or dry-scrape suspect material until the assessment and required controls are in place.
5. Coordinate device de-energization, removal, box protection, extension, and reinstallation with a qualified person where required. Confirm de-energization with a non-contact voltage tester before any device is touched.
6. Protect countertop, sink, faucet, cabinets, appliances, floor, and adjacent finishes. Install protection sheeting over every surface that will remain in place.
7. Mark the exact demolition boundary at cabinet, corner, countertop, trim, or pattern breaks. Confirm the marked boundary matches the Removal and Reference Record before cutting begins.

E. Removal and Substrate Inspection (Steps 8–15)

1. Remove accessories, edge trim, and sealant in a controlled sequence. Score sealant and caulk lines at the boundary before releasing any trim piece.
2. Break or release existing material using methods that limit substrate damage and flying debris. Work from the marked boundary inward using protective blocks against the countertop edge.
3. Keep tools clear of concealed wires, plumbing, gas lines, and wall framing. Control cutting and prying depth to the known thickness of the existing finish and backing.
4. Remove adhesive, mortar, fasteners, or backing only to the approved depth. Stop removal at the point specified for the substrate-repair method to be used.
5. Inspect wallboard, plaster, backer, framing, moisture, mold, utilities, device boxes, and countertop-to-wall movement. Record findings and photograph the exposed wall before any repair begins.
6. Stop for wet or deteriorated substrate, unsafe electrical condition, active leak, major wall damage, or unapproved wet-area requirement. Issue a change notice and obtain approval before continuing if any of these conditions is found.
7. Repair the wall with a compatible approved substrate and allow required cure or drying. Use the drywall repair method from Chapter 5 or the manufacturer-specified backer-board method for the selected system.
8. Verify the surface is clean, dry, flat, sound, and within the selected system's tolerance. Measure moisture at the repaired area and confirm it meets the product's installation requirement before proceeding.

F. Layout and Installation (Steps 16–24)

1. Establish level and plumb reference lines independent of irregular countertop or cabinet edges where needed. Mark these lines directly on the prepared substrate using the level and layout gauge.
2. Dry-lay the pattern and center or balance cuts at visible boundaries. Confirm the dry layout matches the approved pattern before mixing any adhesive.
3. Plan outlets, corners, edge trim, inside corners, countertop joints, and termination pieces. Mark cutout locations on the dry-laid material before cutting.
4. Cut test pieces and verify blade, edge quality, fit, and material support. Confirm cut edges are clean and free of chipping before cutting the remaining pieces.
5. Mix or prepare adhesive, mortar, or panel bonding system according to product instructions. Mix only the quantity that can be applied within the stated working time.
6. Apply only an area that can be covered within the product's working time. Confirm the applied adhesive has not begun to skin over before setting material.
7. Set tile or panel material from the approved reference while maintaining alignment, coverage, joint width, movement joints, and edge support. Verify each piece against the reference lines as it is set.
8. Keep electrical boxes, device screws, plumbing escutcheons, and serviceable components accessible. Confirm cutouts align with each device before the adhesive sets.
9. Do not fill required movement or countertop joints with rigid grout. Mark every movement and countertop joint location for flexible sealant before grouting begins.

G. Joint Finish, Reinstallation, and Cure (Steps 25–29)

1. Allow the installation to set before grouting, finishing, or loading. Confirm the manufacturer's required set time has elapsed before continuing.
2. Apply grout, joint treatment, or panel seam finish using the specified product. Pack every fixed joint completely and consistently using the grout float or specified applicator.
3. Clean the surface without washing out joints, scratching finishes, or contaminating sealant surfaces. Use the product-specified sponge and water-change schedule during cleanup.
4. Install compatible flexible sealant at approved changes of plane, countertop joints, and material transitions. Tool the sealant bead to a smooth, consistent profile at every marked movement joint.
5. Reinstall edge trim, devices, plates, accessories, and plumbing trim after required cure and qualified inspection. Confirm the qualified person has approved device reinstallation before restoring power.

H. Inspection and Documentation (Steps 30–31)

1. Inspect plane, pattern, cuts, coverage, joints, movement accommodation, sealant, device fit, cleanability, surface damage, and finish integration. Complete the Inspection Checklist below before the project is considered complete.
2. Document substrate repair, products, lot information, cure conditions, electrical coordination, and care instructions. File the complete record with the project package.