Introduction to Quartz Countertops
Quartz countertops have become an increasingly popular option for kitchen and bathroom remodeling projects over the past couple of decades. Made from engineered stone, quartz counters offer a stylish, durable, and low-maintenance alternative to natural stone and other materials. But what exactly is a quartz countertop and how is it made?
Quartz counters are composed of ground natural quartz crystals combined with polyresin and pigments. The quartz provides strength and durability, while the resins allow flexibility in color and patterning. Quartz counters are made by blending roughly 90% ground quartz with 10% polymer resins and pigments, then compacting the mixture under extreme vibration, pressure, and vacuum. This forms solid, non-porous slabs which can then be fabricated into countertops.
Compared to natural stone like granite or marble, quartz offers distinct advantages:
- Durability – Quartz is extremely hard and resistant to scratches, chips, cracks, and heat. It can withstand heavy daily use.
- Low Maintenance – Quartz requires no sealing and is easy to clean. Non-porous so resists staining.
- Consistent Coloring – Pattern and color run through the entire slab for consistency.
- Flexibility – Available in wide array of colors/patterns to suit any style. Customizable edge profiles.
- Non-Toxic – Contains no hazardous materials like radon or asbestos.
Yet despite being an engineered product, the best quartz counters look remarkably similar to natural stone when fabricated well. Advanced manufacturing techniques now allow very convincing stone-like patterns. This article will explore exactly how quartz countertops are made and what goes into their production.
How Quartz Countertops Are Manufactured
Quartz slab production involves a multi-step process with exacting controls to ensure optimal quality:
1. Sourcing Quartz and Other Ingredients
- Quartz – Mined from quartz quarries, then crushed and ground into a fine crystal powder. Provides strength, hardness, and translucency.
- Pigments – Added to achieve desired colors. Can mimic natural stone colors or create bright solid colors.
- Polymer resins – Act as binder to hold everything together. Provide flexibility and workability.
- Other ingredients – Extra compounds like glass, mirrors, pebbles, etc. can be added for special effects.
2. Mixing the Ingredients
- All ingredients are carefully measured and mixed together in precise proportions.
- Pigments added to create specific colors/patterns. Different formulations for different looks.
- Mixing done in large vats to ensure thorough blending and consistency.
3. Compacting into Slabs
- The blended mixture is poured into molds then compacted under extreme pressure.
- Hydraulic presses apply up to 100 tons of pressure per square inch.
- This compacts the quartz composite into a solid slab and creates bonding.
- Additional vibration and vacuum cycling removes all air pockets.
- Result is a fully non-porous, densified slab.
4. Curing and Finishing
- Once pressed, slabs cure in climate-controlled environments.
- Curing times vary from 10-20 minutes to over an hour depending on manufacturing process.
- The cured slabs are then polished on both sides to achieve a smooth, consistent surface.
- Edge profiles may be shaped, special cuts made, holes drilled, etc.
- Final quality control checks look for any defects before slabs shipped out.
Popular Brands of Quartz Countertops
Although relatively new on the scene, quartz counters are now offered by many major manufacturers. Some of the most popular quartz countertop brands include:
- Caesarstone – The original quartz countertop maker, founded in 1987. Known for natural stone looks.
- Silestone – Another early quartz brand, part of global company Cosentino. Wide range of bold colors.
- Cambria – Made in the USA brand with extensive style and color options. Natural quartz look.
- LG Viatera – High-end brand offering unique stone styles and large slab sizes.
- QuartzMaster – Budget-friendly quartz counters available at big box stores. More limited colors.
- HanStone – South Korean company focusing on technology and unique patterns.
- Vicostone – Vietnam-based company specializing in affordable quartz counters.
- ** MSI** – Major supplier to home centers with very competitive pricing. Value-oriented.
The best brands engineer their quartz to optimize performance while providing the latest styling trends. Higher priced quartz tends to offer more unique finishes.
Pros and Cons of Quartz Countertops
Quartz counters have risen in popularity for many good reasons, but also have some downsides to consider:
Pros of Quartz Countertops
- Extremely durable and scratch/chip/crack resistant
- Requires no sealing or frequent polishing
- Resists stains, spills, burns, and daily wear-and-tear
- Non-porous so inhibits microbial growth
- Available in wide range of colors, finishes, patterns
- Consistent coloring through the slab
- Easy to clean and maintain
- Does not need frequent re-sanding or refinishing
- Heat and fire resistant
Cons of Quartz Countertops
- More expensive than laminate; competitive with granite/marble
- Limited number of slab sizes and thicknesses
- Fewer dramatic unique patterns than natural stone
- Minimal maintenance still required
- Can chip if subject to heavy impact
- Requires professional fabrication and installation
- Seams more visible than with natural materials
- Resins can yellow slightly over time
On the whole, quartz offers an excellent balance of aesthetics, performance, and value. But natural stone counters still retain unique allure and prestige.
Quartz vs. Granite Countertops
Granite remains the most popular natural stone counter material, so how does quartz compare?
Similarities:
- Offer stylish high-end look for kitchens and baths
- Available in wide range of colors and patterns
- Offer good durability and longevity
- Require professional fabrication and installation
- Comparable pricing – granite and quartz both premium materials
Differences:
- Maintenance – Quartz requires almost none while granite needs annual sealing. Quartz resists staining that can occur with porous granite.
- Durability – Quartz is harder than granite so more scratch and heat resistant. But granite unlikely to chip.
- Appearance – Granite has more dramatic, unique natural patterning. Quartz looks more uniform.
- Fabrication – Quartz only comes in slab form. Granite can have custom edge details.
- Sustainability – Granite is a natural material while quartz is engineered.
- Cost – Material prices are similar, but quartz doesn’t need yearly sealing.
For most buyers, the decision between granite vs quartz comes down to personal preference on appearance and maintenance. Both offer quality and beauty.
Quartz Countertop Colors, Finishes and Patterns
One area where engineered quartz excels is the diversity of available styles. Through use of pigments and add-ins, quartz can exhibit an endless array of colors, finishes, and patterns.
Solid Colors
- Vibrant solid colors like red, blue, and green create a bold modern look.
- Softer hues like cream, gray, or tan work well in traditional kitchens.
- Interesting mottled solid color slabs can appear like a natural material.
Granite-look Finishes
- Many quartz slabs mimic popular natural granites. For example, Ubatuba, Taj Mahal, Calacatta Gold.
- Careful placement of colored pigments results in a similar visual texture.
- Quartz granite-look counters maintain the performance benefits.
Marble Appearance
- Delicate veining and swirls recreate the beauty of marble.
- Improved durability and stain resistance versus real marble.
- White marbling on gray or black base slabs is a popular quartz marble-look.
Other Natural Stone Styles
- Quartz can also imitate soapstone, onyx, travertine, limestone, sandstone textures.
- Natural stone elegance without all the maintenance needs.
Metallic/Glass Accents
- Mica, metal flakes, ground glass create sparkling countertops.
- Mirrored surfaces or metal mesh layers add dramatic effects.
Thanks to modern manufacturing processes, quartz can realistically imitate natural materials while offering improved performance. This broadens stylistic possibilities for kitchen and bath design.
How Thick Should a Quartz Countertop Be?
Quartz countertops are available in thicknesses ranging from 3/4″ to 2″ plus. So what thickness should you choose?
- 3/4″ – Best suited for low-use backsplashes and vertical surfaces. Too thin for heavy duty.
- 1 1/4″ – The minimum thickness for horizontal countertops. Works well in low traffic areas.
- 1 1/2″ – The most common quartz thickness. Provides adequate durability for most kitchen counters.
- 2″ – Extra thickness adds stiffness and durability for heavy usage. Good for commercial projects.
- 2 1/4″ – 3″ – Only required in certain situations like large spans or overhangs. Significantly increases cost.
Most quartz fabricators recommend a 1 1/4″ or 1 1/2″ thickness for residential kitchen countertops. Go thicker if planning an overhang for seating or worried about cracking.
How to Choose the Right Thickness
Consider the following when selecting quartz thickness:
- Intended usage – backsplashes, low traffic areas, daily cooking, etc. Thicker for heavy wear.
- Cabinet base depth – thicker counters may not fit standard cabinet boxes
- Desired aesthetic – thicker has more visual mass
- Spans between supports – longer spans need thicker material to prevent sagging
- Budget – thicker slabs cost exponentially more due to material costs
A good rule of thumb is 1 1/4″ thick for walls and backsplashes, 1 1/2″ for most countertops, and 2″ for heavy commercial use or substantial overhangs.
How Thick are Standard Quartz Slabs?
Quartz slab thickness can vary slightly by manufacturer and region. But these are typical thicknesses:
- 3/4″ – Used for wall applications like backsplashes
- 1 1/4″ – Thinner residential thickness to reduce cost
- 1 1/2″ – Standard thickness for most countertops
- 1 3/4″ – Sometimes used instead of 1 1/2″
- 2″ – Typical thick commercial grade material
- 2 1/4″ – 3+” – Made-to-order extra-thick slabs
Not all brands offer all thicknesses. 3/4″, 1 1/4″, 1 1/2″ are widely available. Thicker commercial grades harder to source. Talk to your fabricator about lead times for thicker slabs.
How Much Do Thicker Quartz Countertops Cost?
As a rule of thumb, each 1/4″ increase in quartz thickness increases the material cost by about 25%. Here are rough estimates:
- 3/4″ – $40-$65 per sq.ft. material only
- 1 1/4″ – $55-$75 per sq.ft. material only
- 1 1/2″ – $65-$90 per sq.ft. material only
- 2″ – $90-$110 per sq.ft. material only
- 3″ – $130-$170 per sq.ft. material only
Keep in mind that material costs make up only about 40% of the total installed price. Fabrication, transportation, installation are also major expenses. But thickness has a very large impact on the budget.
How to Choose Quartz Thickness by Application
Follow these guidelines on quartz thickness selection:
Walls and Backsplashes
- 3/4″ thickness usually recommended
- Provides cost savings versus thicker counters
- Adequate durability for limited use backsplashes
Bathroom Vanity Tops
- Can be 1 1/4″ thick if use is light
- 1 1/2″ better for bathrooms with sinks seeing high usage
- Match thickness to rest of counters for consistency
Kitchen Countertops
- 1 1/4″ only if on a tight budget or limited kitchen use
- 1 1/2″ optimal for majority of residential kitchens
- 2″ for heavy prep/cooking use or significant overhangs
Bars and Islands
- At least 1 1/2″ since these see more use and abuse typically
- 2″ better for overhangs or commercial bar use
- Islands benefit from thicker material due to spans
Cutting Boards and Prep Areas
- Should be 2″ thickness minimum
- Reinforces strength where knives will be used
Match quartz thickness to the application based on expected usage. Thicker quartz costs more but prevents cracks and damage in high traffic zones.
How Much Does Quartz Countertop Installation Cost?
For a typical 30 sq.ft. residential kitchen, total installed costs break down as follows:
- Quartz Material – $2000-$4000
- Fabrication – $800-$1500
- Installation – $300-$800
- Total Estimate – $3100-$6300
Quartz costs $80-$150 per sq.ft. installed on average. Higher prices for premium brands, more complex projects, and thicker material.
Cost Breakdown:
- Materials – Make up about 40% of total budget
- Fabrication – 30-40% of budget. Includes transportation, sinks, edges, seams, cutouts.
- Installation – Around 15% of overall cost
Get itemized quotes from at least 3 fabricators. Be sure the quote covers all necessary services.
Factors That Increase Quartz Countertop Costs
Several variables can significantly increase your quartz installation budget:
- Premium brand selection (Caesarstone, Silestone, Cambria, etc.)
- Thicker 2″ quartz material rather than standard 1 1/2″
- Large surface area over 50 sq.ft.
- Complex multi-level island designs
- Special edge profiles like double edge or full bullnose
- Incorporated sinks, hotspots, electrical cutouts
- Remote location increasing fabrication and installation fees
- High-demand color choices that increase material lead times
- Rush fabrication and installation fees
How to Get the Best Price on Quartz Counters
Here are some tips to get your dream quartz countertops while sticking to your budget:
- Shop around for sales or remnants for major savings on materials.
- Select a more affordable quartz brand like MSI over premium Caesarstone.
- Stick with standard 1 1/2″ thickness unless you need thicker for durability.
- Choose an edge profile in the fabricator’s pre-set options, avoiding custom edges.
- Get quotes from 3-4 highly reviewed local countertop shops.
- Provide accurate measurements and template to minimize fabrication errors.
- Be flexible on timing – longer lead times can mean lower pricing.
- Avoid complicated multi-level island designs requiring extra fabrication time.
- Consider DIY installation if skilled at tilework, avoiding labor fees.
Discuss your budget upfront with your selected quartz fabricator. Being flexible on certain specifications and timing while shopping around is key to quartz countertop savings.
Should I Install Quartz Countertops Myself?
Installing quartz counters involves adhering the fabricated slabs to properly prepared cabinets. While DIY-friendly materials like laminate countertops can often be self-installed, quartz has some unique challenges:
Considerations for Self-Installing Quartz:
- Requires careful transportation of fragile slabs – ideally have helpers
- Proper support framing must be installed and level
- Slabs are heavy, with seam placement precision critical
- Bonding to substrates requires specific adhesive mastery
- Cutouts for sinks/fixtures demand special skills
- Finishing edges and seams very technique-sensitive
- Errors in install show and require replacing slab
For most homeowners, professional installation is highly recommended for quartz counters. The few thousand dollars in labor fees provides experience securing seams, cutouts, proper bonding, and finishing. Damaging slabs by DIYing is an expensive risk. But self-installation can be successful with sufficient preparation.
Hiring a Quartz Fabricator vs Installer
Two key professionals are involved in your quartz project:
Fabricators
- Specialize in precision cutting and shaping of slab materials like quartz.
- Fabricate counters to exact dimensions provided, including necessary cutouts.
- Will transport counters to site once fabrication complete.
- Do not typically handle installation.
Installers
- Specialize in adhering fabricated counters to cabinetry onsite.
- Prepare cabinets for installation, making any needed adjustments.
- Adhere slabs using specialized tools and bonding agents.
- Seam and finish countertops.
Fabricators and installers work closely together, but most don’t offer both services. Reputable quartz fabricators have partner installers they work with regularly and will arrange installation as part of the overall bid.
Key Questions When Choosing a Quartz Fabricator
To select the right pro for your quartz project, ask fabricators the following:
- Are you certified in fabricating the quartz brand we selected? Uncertified shops risk errors.
- Can you provide examples and references from past quartz jobs? Check their quality.
- What specific adhesives do you use for bonding quartz