Quartz countertops have become increasingly popular in kitchens due to their durability, low maintenance, and stylish appearance. Understanding how these countertops are made provides insight into why they are such a great option for busy kitchens. Here is an overview of the quartz countertop fabrication process.
What is Quartz?
Quartz is a manufactured blend of around 90% natural quartz aggregates and crystals combined with approximately 10% polymer resins and pigments. The resins bind the quartz particles together to form a durable, non-porous slab. The pigments introduce color and pattern.
Quartz Countertop Manufacturing Process
1. Sourcing and Crushing Quartz
The manufacturing process starts by mining and crushing quartz crystals and aggregates from quarries. The quartz is crushed into different sizes to achieve the desired smooth or textured aesthetic in the final product.
2. Mixing with Resins and Pigments
The crushed quartz granules are combined with polyester or epoxy resins and pigments in precise ratios. The resin binds the materials together while the pigments add color and pattern. Popular quartz patterns mimic natural stone like marble or granite.
3. Molding into Slabs
The quartz resin mixture is molded into large slabs using one of two methods:
- Bretonstone System – This vibro-compression vacuum process compacts the materials under pressure to form slabs.
- Pressing System – Hydraulic presses squeeze the quartz mixture into slabs between two plates.
The slabs are molded to a thickness between 2 to 3 cm. This allows for sufficient thickness once the countertop is fabricated and installed.
4. Curing and Polishing
The molded slabs go through an accelerated curing oven to harden the resins fully. Once cured, the slabs are polished on both sides to achieve the desired smooth, shiny finish. This polishing enhances stain resistance and makes the countertops sparkle.
5. Quality Control and Shipping
The manufacturer inspects the slabs closely for any defects before packaging them for shipping. Quartz slabs are heavy, weighing hundreds of pounds, so they require proper steel or wood crating. The crated slabs are shipped globally to distributors and fabricators.
6. Fabrication and Installation
Fabricators purchase the slabs and customize them for each project. The countertops are cut to the exact size and shape needed, edges are finished, holes are cut for sinks, and any other customizations are completed. The installer then fits the fabricated quartz countertop pieces seamlessly onsite and securely affixes them to the kitchen cabinets.
Why Choose Quartz?
Understanding how quartz countertops are engineered gives insight into their best features and benefits:
- Extremely durable – Quartz is resilient and able to withstand heavy usage in busy kitchens.
- Hygienic – The nonporous surface resists bacteria and stains.
- Heat resistant – Quartz holds up to heat better than many other countertop materials.
- Low maintenance – Routines cleaning is all that is needed to keep quartz looking like new.
- Stylish – Quartz offers an array of colors and patterns that mimic high-end natural stone.
- Customizable – Quartz can be fabricated into any shape and size.
With the right fabrication and installation, a quartz countertop will stay beautiful in a kitchen for many years. Understanding the manufacturing process helps homeowners appreciate the technology and effort that goes into creating these durable and stylish countertops.
Frequently Asked Questions About Quartz Countertops
How durable is quartz?
Quartz is extremely durable and resistant to scratches, cracks, and heat. The resin binds the quartz particles to form a hard, non-porous surface. Properly installed quartz countertops can last for decades.
What colors and patterns are available?
Quartz comes in a wide array of colors and patterns. Popular options mimic expensive natural stone like marble and granite. There are also solid colors and abstract patterns to suit any style.
Does quartz need to be sealed?
No, quartz does not require any sealing. The non-porous surface prevents moisture from penetrating into the countertop. This makes maintenance easy.
Can you cut on a quartz countertop?
Yes, quartz stands up well to being cut on as long as sharp knives are used. The surface resists scratches and damage from everyday kitchen tasks. Using a cutting board is still recommended to keep the counters looking their best.
Is quartz resistant to stains?
Quartz is highly stain resistant and non-porous. It will not absorb stains from spills like juice, wine, oil, etc. Simple wiping is all that is needed to clean up spills.
Is quartz heat resistant?
Quartz has relatively good heat resistance compared to other natural stone. However, prolonged direct heat exposure from pots and pans can potentially damage the surface over time. Using trivets is recommended.
Conclusion
Quartz kitchen countertops offer unparalleled performance, beauty, and value. Understanding the manufacturing process provides insight into why quartz makes an excellent choice for kitchen countertops of all styles. With the right fabrication and installation, quartz countertops will stand up beautifully in kitchens for many decades to come. Discuss your vision with a professional to determine if durable, low-maintenance quartz is the right material for your next kitchen countertop project.