One of the greatest features of natural stone countertop or a vanity top is, that there is very little processing required. The natural material itself makes a perfect surface for these types of applications. But at the same time, natural stone doesn't’t come ready-cut for your project – this work must be done at the fabrication shop and in some cases on installation job site.
Granite & Marble (natural stone) Fabrication Process.
There are three basic types of machines involved in the fabrication process: Saws (stone cutting), Routers (edge profiling) and Polishers.
CNC Stone Cutting Bridge Saw
Saws perform several functions during fabrication. A “block saw”, or “gang saw”, cuts the massive stone blocks, quarried from earth, into ¾" or 1 ¼" thick slabs. The stone blocks are cut with diamond wire saws. A metal wire is studded with industrial-grade or synthetic diamonds, and this wire (cable) quickly cuts through stone as hard as granite along with water which acts as a coolant.
A bridge saw or diamond bladed radial saw is then used to cut the stone slab into the needed shape, whether it is a countertop, vanity or a sink. These saws typically use circular metal blades studded with diamonds, and water is sprayed onto the blade to cool it during the cutting process.
More and more popular is becoming Water Jet cutting, which cuts edges and holes quickly and smoothly. Many countertop fabricators are upgrading to these machines.
Variable speed router. Ogee edge profile.
Depending on edge type, the next step after cutting maybe lamination. Why maybe? Because, if its going to be a common single edge profile, often it will be just cut and polished, there is no lamination involved.
After Natural Stone is laminated, next step is Routing. Routers create edge profiles, and cut designs on larger pieces like fireplace mantles and hearths. There are dozens of common (standard) and laminated edges to choose, from simple to highly decorative one's. Routers have a spinning routing bit covered with diamonds which is water-cooled. It travels along the edge of the stone piece and machines it to shape.
Common CNC routing and polishing bit's.
The last step in fabrications process is Polishing. Polishers grind down the naturally rough surface 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. An abrasive material is attached with the rotating pads to the polisher. The surface of the material varies according to purpose. The smoothness of the polishing increases with the fineness of the abrasive material. Most modern polishers can produce a variety of finishes, from the smooth, soft look of a honed finish to a slick, shiny mirror finish, even decorative finishes like flamed, tumbled, or hammered.
The next step after Natural Stone fabrication, is Installation.
