Engineered quartz countertops have become an increasingly popular option for kitchen and bathroom remodeling projects in recent years. But how exactly are these countertops fabricated? Here is an in-depth look at the manufacturing process behind engineered quartz.
What is Engineered Quartz?
Engineered quartz is a man-made material that combines ground natural quartz with resin binders and pigments. It is sometimes referred to by brand names like Silestone, Caesarstone, Cambria, or Zodiaq.
The quartz content typically makes up 90-94% of the material, while resins make up the remaining 6-10%. Pigments are added to achieve the desired colors and patterns. The end result is a material that has the look of natural stone but with enhanced performance qualities.
Raw Material Sourcing
The manufacturing process starts with sourcing high-purity quartz crystals and quartz powder. These are mined and processed from locations around the world, including the USA, Brazil, India, and China.
Polyester resins, polymers, and color pigments are also sourced from chemical suppliers. These additional ingredients are crucial for binding the quartz particles together and tinting the material.
Mixing the Quartz Blend
At the engineered quartz fabrication facility, the raw quartz crystals and powder are combined with the resins, polymers, and pigments using precise mixing equipment.
Getting the ratio of ingredients just right is critical for achieving the desired material performance and aesthetics. The mixing process results in a viscous quartz blend or slurry.
Pressing into Slabs
The quartz slurry then goes through a process called vibro-compression, where it is poured into molds and pressed under vacuum conditions.
Hydraulic presses apply up to 100 tons of pressure, compacting the slurry into a solid slab form. This is done in cycles, building up the engineered quartz slabs layer-by-layer to achieve the desired thickness.
Typical slab sizes are about 55-125 inches long and 30-65 inches wide. Thicknesses range from 0.5 inches for flooring up to 2 cm for countertops.
Curing and Polishing
After vibro-compression, the quartz slabs go through additional steps to cure, harden, and polish them into finished products.
The curing process involves putting the slabs in a kiln or heated chamber. This causes the resins to solidify fully, making the material hard and durable.
Polishing uses diamond-tipped blades, abrasives, and pads to grind and buff the slabs. This brings out the glossy, smooth surface finish characteristic of quartz countertops. More matte finishes are also possible.
Inspection and Quality Control
Throughout the engineered quartz manufacturing process, rigorous quality control and inspection measures are implemented.
This includes evaluating slab dimensions, shine, color consistency, and physical integrity. Technicians check for any cracks, pits, or imperfections that could affect structural performance.
Any slabs not meeting quality standards are rejected and recycled back into the manufacturing process. Only slabs passing inspection are crated for shipment.
Cutting, Shaping, and Installation
The finished quartz slabs are transported from the manufacturing facility to stone yards and showrooms. There they can be cut, edged, and polished into the final countertop shape.
Expert fabricators use advanced cutting tools, CNC machines, water jets, and lathes to achieve precise sizing and cutouts for sinks, faucets, and cooktops per customer specifications.
The shaped countertops are then installed by experienced technicians. They seam edges together for a smooth appearance, and securely fasten the countertops in place.
Benefits of Engineered Quartz
Engineered quartz offers distinct advantages over natural stone countertops:
- More consistent patterning and colors
- Stain, scratch, and heat resistance
- Minimal maintenance requirements
- Molding capabilities for seamless edges and built-in designs
- Greater flexibility for plumbing and cooking surface cutouts
So while the manufacturing process is quite complex, it produces a versatile and durable countertop material perfect for today’s kitchens and baths. The technology and quality control behind engineered quartz gives it reliable performance for years after installation.
Frequently Asked Questions
What makes engineered quartz different than natural quarried stone?
Engineered quartz is manufactured, while natural stone is quarried and cut. The manufacturing process allows quartz to be blended with resins and polymers to improve performance. Natural stone is 100% quarried material without additives.
Is engineered quartz fragile?
No, engineered quartz is actually exceptionally hard and durable due to the vibro-compression process used during manufacturing. It stands up well to heavy use.
Can engineered quartz get stained?
Engineered quartz resists stains far better than marble or granite. However, prolonged exposure to strong chemicals and dyes can cause discoloration over time.
Does engineered quartz need to be sealed?
No sealing or waxing is required for engineered quartz surfaces. The material is non-porous, so it does not need additional sealing to prevent staining or damage.
Can hot pots and pans be placed on engineered quartz?
Yes, engineered quartz stands up to brief contact with hot pots and pans. But prolonged direct heat exposure should be avoided by using trivets.
Conclusion
Engineered quartz has become a go-to material for countertops due to its visual appeal, durability, and low maintenance needs. Advanced manufacturing techniques allow quartz particles to be mixed with resins under heat and pressure to create a stone-like material with enhanced performance capabilities. Strict quality control and inspection of the manufacturing process results in reliable, consistent engineered quartz slabs ready for fabrication and installation in homes. With the right cutting and polishing, engineered quartz can transform into custom, durable countertops that will last for many years.