General Information on Granite Work Surface Fabrication
While not manmade, the process from extraction of natural stone to placement as a kitchen
Work surface is very intense. The natural stone industry goes largely unregulated so each stone
distribution company and fabricator is free to use their own terminology for grade and colour as well
as price, adding to the confusion for the average work surface consumer. However, with granite there are some
universal materials that share the same name, such as Ubatuba, Baltic brown,
Absolute black, black galaxy, Santa Cecilia, etc.
After the initial quarrying of the rock, it is cut into manageable blocks. These
blocks are cut, inspected and sorted into three or four tiers depending on the mineral composition.
The crystalline minerals of granite range in size creating various degrees of porousness, color
and movement (pattern and grain). Top tier stone from one manufacturer can vary from another.
The stone is then cut to a thickness ranging from 2 cm to 4 cm with the
standard in most places in the UK typically being 3 cm. The standard length
and width of a granite slab is 2.8 meters x 1.6 meters although slab sizes vary because of the
nature of the material. Slab cutting is typically done now with high technology machinery, which
may use high-pressure water streams and diamond-bladed saws as used by Cargo Granite suppliers in Italy. When this cutting is complete, the
granite is polished, resined with epoxy or polyester and conditioned in heated ovens. More and
more, resining is becoming standard practice for any grade of granite as it increases durability.
More fragile slabs may also have a fibrous backing material put on them to keep them from
breaking during shipping and storage.
The slabs are then shipped to various stone distributors around the world, ready to be selected by
fabricators or individual consumers.
Some types of granite and other natural stones are referred
to as “exotics” because of their limited availability.(See 'Just Arrived section on the site) That is, in the quarrying process, sometimes a
unique section of stone, with an exotic make-up and look, is run across. These highly sought after
segments are harvested separately and their rare nature is reflected in their availability and price.
After selecting the type of natural stone to be used in a worktop , before it can be made, a
worktop fabricator will visit the installation site and take exacting field measurements of the
area to covered, furniture and leveling of surrounding walls. This process
may use everything from tape measurers and strips of thin wood or plastic to more advanced
means such as photo telemetry or laser measuring(Cargo Granite use both tradtional wooden templates and the latest laser technology). Once the very exact measurements are taken,
a template is created for each granite or quartz worktop either in a hard form (6mm MDF) or in
digital form (computer drawings), from which the creation of the actual granite work surface will be based on.
Natural stone supports a wide variety of edging, cornering and backsplash options. The straight
edge, bullnose, full bullnose and ogee edges remain the most popular, but custom profiles can
be accommodated by stone (although they may also dramatically affect the price). Backsplashes
must also be specified. Upstands 100mm high of the same thickness are the
most popular, as a full height backsplash may require the use of an additional slab, increasing the
price and the chances that color and veining will vary.
Sink styles will also have to be known before final cutting. overmount and
undermount sinks are used more frequently, but use of a Butler/Belfast style sink is also possible.
The undermount design may require auxiliary framing to support the weight. Typical stone
Work surfaces are heavy (up to 300 kg.) and will require several installers to deliver and fit. The
final installation can generally be done in 2 to 4 hours