How Premium Custom Countertops Are Made
Ever wonder how a dull looking rock mass like granite or quartz turns beautiful when made into custom countertops? “Even after six years of installing custom marble countertops, I still wonder if it’s real!” says Jonathan, the proud owner of your marble countertop. A perfectly finished countertop can easily transform the look of your home into modern or rustic. In this article we will have a perspective on the manufacture of custom countertops.
The attractive features you see on countertop surfaces represent the inherent nature of natural stones. Polishing or honing simply smoothes the surface and makes its characteristics visible. The reason for this effect is “quartz”, the transparent mineral whose surface scatters light when uneven and lets it in when polished, thus revealing opaque minerals and their colors.
Initial manufacturing process: cutting blocks into slabs
The rocks extracted from the ground are divided into blocks and transported to the manufacturing centers. There, the blocks are cut into slabs with a block saw. Industrial grade diamonds studded on metal wire saws are also used to cut rocks into blocks.
Slabs on countertops and tiles.
According to customer requirements, the slabs are molded into countertops or sinks with a bridge saw and given a finishing touch by polishing.
Automated manufacturing machines
Recently, it has been discovered that many companies use routers and CNC machineries to support the manufacturing process. In these processes, the robots handle everything from block movements, slab cutting, to countertops and finished natural stone surfaces needed for the home and office.
A water cooling system helps prevent heating of the stone during the cutting and polishing process. Edges to customer specifications complete the manufacturing process.
Following are stone making tips for best results:
• Avoid vibrations and prevent damage to the slab during the cutting process by holding it close to the cutting line
• Since the slab already comes with the proper polish and finish, redoing it may damage the surface.
• Cut long slabs lengthwise first, then widthwise, not the other way around
• When cutting thick or warped slabs, cut half their thickness from opposite sides
• Follow a standard of 1.5mm radius for outside corners and 6mm for inside corners
• L-shaped countertops do not need rounding
• Avoid seams or cut edges near corners, as they are vulnerable
• Use enough water to avoid dust and heat when cutting or polishing tiles.
Solid Surface Fabrication
In contrast to all of these manufacturing methods, quartz and solid surfaces have different manufacturing processes that involve mixing marble, limestone or sandstone dust with resin and acrylic. These days, finding a natural quartzite countertop is difficult, as most of the varieties available are man-made.
Fabrication of granite countertops or any other natural surface and floor surfaces is an art. Even a little carelessness can damage the product. Careful planning, labor, and attention to manufacturing basics prevent damage to your custom countertops.