The process of fabrication of your countertop starts with measuring, template and drawing. At this time our professionals will discuss with you the details of your custom project, that includes seam position “if necessary” and proper direction of the counter top’s flow “if there is any”. Accurate measurement results in a perfectly installed countertop. The drawings and specifications of your job are then reviewed by our production manager to make sure they are complete.
Before the cutting and fabricating of the stone, customers are invited to see the layout of the job with templates on the stones. That helps the customers to better visualize how the project is going to look like and allow them to make any changes before it is cut and installed. After layout, stone is cut, sink cut outs are done and edges are polished.
Due to the limitations of the granite slab size, some of the kitchen countertops will have seams. One of the biggest concerns of home owners planning granite countertops is seams. We use ultimate heavy-duty seam setter for joining, leveling, and flattening stone.
With our flat polishing machine, we are able to make high quality flat polishing on all of the stone backsplashes or any smaller countertop pieces with straight edges.
After fabrication is completed, the countertops are placed on tables specially made for handling granite. Our highly skilled hand fabricator inspects the entire countertop and completes any further improvements needed. The improvements may include final polishing steps, taking care of any sharp edges, fixing any chips in the edge profiles, etc. Once satisfied with the final outcome, the pieces are thoroughly cleaned and sealed. At this point the granite countertops are ready to go.
The process is primary cutting or shaping of the material. This is typically accomplished using a diamond wire-saw. When operating a circular or diamond wire saw, a continuous stream of water over the saw is required in order to dissipate heat generated by the process. Elevated temperature can cause major machine and material damage.
Once the block has been shaped from the wire-saw, inspection is done to ensure that there are no cracks or breakage during the cutting process. The blades are set in the gang-saw machine according to the hardness of the rock and the thickness specification.
The tray housing the granite block is then moved into the gang-saw machine. A mixture of water, lime, and grit; referred to as the slurry is used in the cutting process that helps in cutting the block as it absorbs any heat dissipating from the cutting process. The viscosity of the slurry is vehemently monitored and adjusted for every material and also during the cutting process.
Every 2-3 hours the machine and the block is observed and re-adjusted, if needed to ensure a steady and straight cut for the blocks. Once the slabs are cut, they are inspected for any defects and then are marked individually for inventory tracking and moved for further processing.
The first step in quarrying is to gain access to the granite deposit. This is achieved by removing the layer of earth, vegetation, and rock unsuitable for product with heavy equipment and transferring to onsite storage for potential use in later reclamation of the site. After the face of the granite is exposed, the stone is removed from the quarry in benches, usually 8 to 12 feet square extending 20 feet or more using a variety of techniques suitable to the geology and characteristics of the granite deposit.
Quarrying operations typically include the drilling of holes along the perimeter of the bench, followed by either cutting the stone out of the deposit using saws equipped with diamond wire, or by splitting the stone using hydraulic splitters or small explosive charges. Once the bench is cut or split loose from the deposit, heavy equipment is used to lift the granite bench and transfer it to an inspection area for quality and size specifications.
Every block that meets the size requirement is then thoroughly checked for quality specifications. We have the most experience personnel including the directors, visiting the quarry and inspecting blocks that will be further processed. The blocks are checked for cracks, fissures, color pattern and other variations that help in ensuring the best blocks are selected and further moved to processing. After inspection, only 20% of a stone block is separated as premium first quality, then 40% standard and 40% commercial grade.
We want the installation to be as efficient as possible, but we also want you to feel comfortable with the process. If you have any questions, please ask them before our installers start bringing in the granite. They will of course be ready to answer any questions you have after the installation.
Installing stone countertops requires a lot of focus and precision. Keep in mind that a 3cm “1 ¼ “ stone weights in average 18 to 20 pounds per square feet and kitchen island are getting bigger by the day.
Once installers have made sure the space is ready, they will begin carrying in the individual pieces of granite. Most kitchens will have several sections of stone that will be expertly seamed together during the installation.
Once it is laid on a level surface sinks are installed and faucet holes are drilled.
Epoxy will be mixed and color blend onsite to carefully match your countertop color. As soon as the seams are dry, they will carefully skim off excess epoxy with a razor blade to ensure the seam is as smooth as possible. Then the granite will be secured to the cabinet with caulking or silicone.
If you have ordered full matching stone backsplash, the guys will probably need to make some minor adjustments to those pieces for a tight fit before installing them and setting the seams in the same way as the decks (the main, horizontal pieces of countertop).
if you have a cook top (as opposed to a slide in range), the installers may need to cut the hole for it out on-site.
Once all the stone is secured in place, the team will use acetone or denatured alcohol to remove any excess epoxy, caulk, and any dust leftover from the cook top or faucet hole cutting. We’ll clean and seal your counters, clean up the job site, give you instructions on how to clean and care for your counters, thank you for your business, request you to sign the job approval and leave you to admire your new countertops.