Quartz countertops and sinks have become increasingly popular in kitchen and bathroom remodels due to their durability, aesthetics, and ease of maintenance. But how exactly are these engineered stone products fabricated? Here is an overview of the quartz manufacturing process.
Raw Materials
Quartz countertops and sinks contain about 90-95% ground natural quartz combined with resins, pigments, and other compounds. The quartz is mined and then crushed into a fine powder. Polyester, epoxy, or acrylic resins are added as a binder. Pigments tint the material to achieve the desired colors. Other compounds like recycled glass or mirrored flakes may also be blended in for decorative effects.
Molding and Pressing
The quartz powder mixture gets poured into molds and compacted under intense vibration and vacuum pressure. This compacting fuses the materials together to form a solid slab. The slabs are then cured in ovens or heated rooms to harden the resins. Pressure and heat fuse the materials into an incredibly hard, non-porous surface.
Cutting and Polishing
Once cured, the slabs are trimmed to size and gauged to thickness using diamond-tipped saws. Computer-guided machines cut the slabs with extreme precision based on measurements taken of the raw mold. The edges are profiled and polished to achieve the desired edge details like bullnose or ogee.
Inspection and Quality Control
Each slab gets thoroughly inspected for any flaws or defects. Any cracks, pits, or color deviations result in the slab getting rejected. Approved slabs proceed to final polishing using a series of polishing heads from coarse to extra-fine grits. This achieves the signature glossy, glass-like surface finish. A final inspection ensures only quality slabs get crated for shipping.
Digital Template and Cutting
For custom projects, installers take precise digital measurements of the space. These measurements get used to program computer-guided cutting equipment. The fabricators expertly nest pieces to minimize slab waste. Water jet, diamond blade, or CNC machines cut the pieces to size.
Installation and Integration
The pre-cut pieces get installed and secured to the countertop base or sink frame. For seamless countertops, pieces are bonded together with adhesive. The installers may do additional trimming and final polishing on-site. The last steps integrate the countertop or sink such as attaching faucets, drainage, and other fixtures.
FAQ
What makes quartz better than natural stone?
Quartz is non-porous, stain-resistant, and less prone to damage compared to natural stone. It does not require sealing and is virtually maintenance free. The color and pattern consistency of engineered quartz also surpasses natural stone.
Is quartz healthier than granite?
Quartz lacks the natural radioactivity found in some granite. Quartz also has a non-porous surface that resists bacteria growth. However, both materials are considered food-safe and hygienic for kitchen use when properly cleaned.
How durable and heat-resistant is quartz?
Quartz is incredibly hard, durable, and resists scratches, dents, and heat up to 212°F. However, prolonged high heat can damage the resin binders. Quartz maintains its shine and appearance for years with normal use and care.
How often does quartz need to be resealed?
Unlike natural stone, quartz never requires sealing due to its non-porous composition. This makes maintenance much easier compared to granite or marble that need frequent sealing.
Is quartz affordable compared to other countertop materials?
Quartz is priced competitively with materials like granite and solid surface. While more premium than laminate, quartz provides an attractive upscale look for the cost. The durability and longevity also make it a sound investment.
How sustainable is quartz?
Many manufacturers use recycled materials like glass, mirrors, and plastic in their quartz blends. Quartz is also largely composed of natural quartz making it an eco-friendly material choice for green homes.
Conclusion
Quartz offers the best qualities of natural stone and engineered surfaces. Advanced manufacturing techniques allow quartz to be molded into remarkably strong and beautiful countertops and sinks. While the process involves precise machinery, quartz derives its beauty from natural quartz crystals. When blended with resins and polymers under heat and pressure, quartz becomes an ideal surface for kitchens and bathrooms. With routine care, quartz countertops and sinks maintain their radiant like-new appearance for years.