Ever wonder how a boring-looking mass of rock like granite or quartz becomes beautiful when fabricated into custom countertops? “Even after six years of installing custom marble countertops, I still wonder if it’s for 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 on the manufacture of custom countertops.

Inside out

The attractive features you see on countertop surfaces represent the inherent nature of natural stone. Polishing or honing 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

Rocks mined from the ground 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 the rocks into blocks.

Slabs on countertops and tiles

Based on clients’ requirements, the slabs are shaped into countertops or sinks with a bridge saw and given a final touch by polishing.

automated manufacturing machinery

Recently, it has been discovered that many companies use CNC routers and machineries to adjust the manufacturing process. In these processes, 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. Edging to customer specifications completes the manufacturing process.

The following are the stone making tips for best results:

• Avoid vibrations and prevent damage to the slab during the cutting process by holding it close to the line of cut.

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

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

• While cutting thick or deformed slabs, cut half its 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 tiles.

Solid surface manufacturing

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. It’s hard to find a natural quartzite countertop these days, as most of the varieties available are man-made.

Manufacturing granite countertops or any other natural surfaces and flooring surfaces is an art. Even a small carelessness can damage the product. Careful planning, labor, and attention to manufacturing basics prevent damage to your custom countertops.