Ever wonder how a dull looking rock mass like granite or quartz becomes beautiful when it’s crafted 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 his marble countertop. A perfectly finished countertop can easily transform the look of your home from modern to rustic. In this article we will have a perspective of the manufacture of custom countertops.

Inside out

The attractive features you see on countertop surfaces represent the inherent nature of natural stones. Polishing or sharpening simply smoothes the surface and makes its features visible. The reason for this effect is “quartz”, the transparent mineral whose surface scatters light when uneven and lets it through when polished, thus revealing the opaque minerals and their colors.

Initial manufacturing process: cutting blocks into slabs

The rocks extracted from the earth are divided into blocks and transported to manufacturing centers. There, the blocks are cut into slabs with a block saw. Industrial-grade diamonds embedded in wire saws are also used to cut rocks into blocks.

Slabs on countertops and tiles

Based on customers’ requirements, slabs are shaped into countertops or sinks with a jigsaw and given a finishing touch by polishing.

automated manufacturing machinery

Recently, it has been discovered that many companies use CNC routers and machinery to adjust the manufacturing process. In these processes, robots handle everything from moving blocks, cutting into slabs, to finished natural stone countertops and surfaces needed for the home and office.

A water cooling system helps prevent the stone from heating up during the cutting and polishing process. Edging to customer specifications completes the manufacturing process.

Following are stone making tips for best results:

• Avoid vibration and prevent damage to the slab during the cutting process by bracing it close to the cut line

• Since the slab already comes with the correct polish and finish, redoing it can mar the surface.

• Cut long slabs lengthwise first, then widthwise, not the other way around.

• While cutting thick or warped slabs, cut half their thickness from opposite sides

• Follow a standard radius of 1.5mm for external corners and 6mm for internal 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 the 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 powder with resin and acrylic. These days it is difficult to find a natural quartzite countertop as most of the available varieties are artificial.

The manufacture of granite countertops or any other natural surface and flooring surfaces is an art. Even a little carelessness can damage the product. Careful planning, workmanship, and attention to manufacturing basics prevent damage to your custom countertops.