The Quarry
A quarry is a type of open-pit mine from which rock or minerals are extracted. Quarries are generally used for extracting building materials, such as dimension stone. Quarries are usually shallower than other types of open-pit mines. The sequence of events, which brings natural stone from the quarry to the home, has not changed much since stone entered the homes of the ancient Greeks.
Stone comes from around the world. Various types of stone, in myriad colors and textures, are found in different countries. Much of our granite comes from Brazilian, Indian, US and Chinese quarries. Marble is mostly from Italy, Spain and Mexico. Slate is imported from Brazil, India and China, while travertine and limestone come from Spain, Portugal and Mexico.
All stone is taken from the earth in the form of raw blocks. Explosives, large saws and specialized equipment are used to extract the stone from the earth. It is cut out of the mountains (quarries) in huge blocks weighing up to 20 tons.
Some blocks are transported to Italy, which is where most of the worlds supply of granite and marble is processed.
Others are processed at on site processing areas. The stone blocks are cut into thinner, more easily handled pieces called slabs. Slabs may be cut into slabs 2 and 3 centimeters (3/4" or 1-1/4") thickness. The process can take up to six days to complete. The minimum average sizes of granite slabs is approximately 105" x 54". Slabs can weigh approximately 600 to 700 pounds each. A 3/4" thick slab can weigh an average of 12.8 lbs. sq. ft. and a 1-1/4" thick slab can weigh an average of 18 lbs sq. ft.
The slab itself is then processed, depending on the intended use of the stone. It may be given a high shine and shipped to a stone fabricator, who will ultimately turn it into a table, vanity top or whatever; or it may be transformed by some very expensive and sophisticated equipment into tiles for installation on floors or walls.
The deep shine we see on polished stone is achieved by rubbing the stone with a series of abrasive materials. The process is very similar to sanding a piece of wood. The stone is rubbed with coarse abrasive grit, followed by finer and finer grits until the stone becomes smooth. The scratches, that may have been left behind from one grit, are removed by the next creating finer and finer scratches.
The process continues until the scratches are microscopic. The shine on the stone is achieved by abrading the surface to the point at which it becomes extremely smooth and starts to develop some reflectivity. The shine on the stone is thus a product of optics. This same optical property can be observed on a pond. When the wind is blowing and the surface of the pond is wavy, it becomes difficult to see a reflection; when the air is still and the pond is calm, a deep reflection can be observed. So in order to achieve a deep shine on your stone, all that really needs to be done is to smooth it until it shines.
The Fabricator
Once the customer picks the color of their stone, then the countertop begins its journey through the fabrication process. A template is made from the existing countertop to ensure that the new countertop is a perfect fit.
In the fabrication shop, the slab that was selected by the customer is placed on the cutting table and the templates are placed on the slab utilizing as much of the slab as possible. A bridge saw is then used to cut the stone slab into the proper shape for its application. These saws typically use circular metal blades studded with diamonds, and water is sprayed onto the blade to cool it during the cutting process. Modern technology has produced a new type of saws that utilize water jets.
The cut pieces are then taken to the polishing area. Polishers grind down the naturally rough sides of the stone to whatever finish the consumer desires. Hard stones like marble and granite can be polished all the way to a mirror finish. The polisher uses a combination of rotating pads, which are surfaced with an abrasive substance. The finer and smaller the abrasive grits are, the higher the polish. Most modern polishers can produce a variety of finishes, from the smooth, soft look of a honed finish to a slick, shiny mirror finish.
Routers are used to create edge profiles on a slab, and cut designs on larger pieces like fireplace mantles and hearths. There are dozens of edges for countertops and tables, from simple to highly decorative. Routers have a spinning blade covered with diamonds, which is water-cooled. It travels along the edge of the slab to shape it.
The countertop is sealed and then taken to the home for installation where a new kitchen is born.