Quartz countertops have become increasingly popular in recent years due to their durability, aesthetics, and ease of maintenance. But how exactly are these countertops made? The manufacturing process of quartz countertops involves several key steps.
Sourcing the Raw Materials
The main raw materials used to create quartz countertops are:
- Quartz – This makes up 90-94% of a quartz countertop. Quartz is an engineered stone made from crushed quartz bound together with resin. The quartz provides strength, hardness, and scratch resistance.
- Resins – Epoxy or polyester resins make up around 6-10% of a quartz countertop. The resins bind the quartz particles together. Resins impact the countertop’s strength, flexibility, and resistance to stains.
- Pigments – Pigments are added to achieve the desired colors and patterns. Common pigments include iron oxide for red hues, chrome oxide for greens, and titanium dioxide for whites.
- Recycled materials – Some manufacturers incorporate recycled glass, mirrors, porcelain, etc. This reduces waste and creates an eco-friendly product.
The raw quartz is mined and then crushed into a fine powder. Polymer resins are combined with the quartz chips along with pigments. These raw materials are precisely measured, tested, and mixed together to achieve the desired technical specifications and visual effects.
Mixing the Quartz Slurry
The raw materials are blended together with water to create a viscous slurry. This quartz slurry contains around 15% water which allows the materials to flow and be molded.
Powerful mixing machines thoroughly blend the quartz, resins, pigments, and water together into a homogeneous mixture. Getting consistent dispersion ensures there won’t be color variations in the finished product.
This mixing process removes air pockets and creates a smooth, lump-free quartz slurry ready for the next manufacturing phases.
Molding and Pressing
The quartz slurry is poured into molds and pressed under vacuum conditions. This compacts the slurry into a dense, solid surface.
There are a few methods used to mold and press quartz countertops:
Vibration and Compression
The molds vibrate at high frequencies to evenly distribute and settle the quartz slurry. Hydraulic presses then apply pressure up to 100 tons to compress the material. The combination of vibration and compression removes air bubbles and compacts the slurry into a thin, uniform slab.
Vacuum and Pressure
With vacuum pressing, the quartz slurry is poured into a mold enclosed in a vacuum bag. A powerful vacuum is pulled within the bag to remove any trapped air bubbles. The vacuum bags are then moved into a press where up to 100 tons of pressure is applied. This binds the materials together into a condensed slab.
Vacuum and Membrane
This method involves covering the mold with a flexible membrane material. The mold is placed inside a chamber where a vacuum is created. The outside air pressure then forces the membrane to press down on the slurry. This compacts the material into a solid slab with minimal air pockets.
The type of molding process impacts the density, consistency, and performance qualities of the engineered quartz material. Most manufacturers use a combination of vibration, vacuum, and high pressure in their molding operations.
Curing and Hardening
Once molded and pressed, the quartz slabs go through a curing process to harden the resins and complete the chemical bonding.
The pressed slabs are first moved to a curing room or oven. Here the engineered quartz is baked at temperatures ranging from 180-450°F. This heat energy speeds up the exothermic reaction between the polymer resins and quartz particles.
Over 6-12 hours the resins transition from a liquid to solid state. The slabs leave the curing room/oven fully hardened and transformed into a durable engineered quartz material.
Cutting and Polishing
The cured slabs are trimmed down to size using cutting machines with diamond-tipped blades. Computer-controlled machines precisely cut the quartz into standard or custom sized countertop pieces.
Edge profiles can also be cut at this stage. Common edge styles include straight polished edges, beveled edges, and bullnose edges with rounded corners.
Once cut to specifications, the slab pieces move on to polishing wheels. A series of polishing heads with incrementally finer grits grind and buff the quartz surfaces. This brings out the high gloss, smooth finish signature to quartz countertops.
Some manufacturers incorporate additional surface treatments during this stage. For example, nano-glazing sprays on an extra layer of glassy resin. This enhances scratch and scuff resistance.
Flamed or textured finishes can also be applied to the surface for varied appearances.
Quality Control and Final Inspection
Throughout the manufacturing process, the engineered quartz surface is closely monitored to ensure it meets quality standards. But before slabs are packaged and shipped the finished pieces undergo final multi-point inspections.
Inspection teams check for any defects in appearance, dimensions, surface polish, edging, etc. High-tech instruments measure slab tolerances down to a fraction of a millimeter. Any pieces that don’t pass the strict checkpoints are rejected or recycled.
Quartz slabs that pass quality control are prepared for shipment to fabricators or retailers. Each slab is barcode labeled for inventory tracking. The finished quartz pieces are packaged in protective crates or wraps.
Key Takeaways
That covers the major steps involved in engineering and fabricating quartz countertops:
- Quartz slabs are made by blending quartz chips and resins with pigments and other additives.
- The quartz slurry mixture is molded in presses using vibration, vacuum, and pressure.
- Curing and heating hardens the resins to transform the slurry into a solid surface.
- Cutting machines mill the quartz into countertop sizes which are then polished.
- Throughout the process, quality control teams ensure the specifications and appearance meet standards before shipping.
Understanding how quartz countertops are manufactured gives greater appreciation for the engineering and craftsmanship behind these beautiful and functional surfaces. With quality quartz, homeowners can enjoy long-lasting countertops that stand up to years of use and still look brand new.
FAQ About Manufacturing Quartz Countertops
Here are answers to some frequently asked questions about the manufacturing process for quartz countertops:
Where is quartz for countertops mined?
The natural quartz used in engineered quartz countertops is mined globally from quarries in Brazil, India, Turkey, Italy, and a few other countries. Quartz is an abundant mineral found in many parts of the world.
Does engineered quartz contain radon or radiation?
No. Manufactured quartz is made from crushed natural quartz which does not have harmful radiation. Granite contains trace amounts of natural uranium that can emit radon. But quartz countertops are radon-free and perfectly safe.
What makes a quartz countertop non-porous?
It is the resin binders that make quartz non-porous. Polymer resins fill the spaces between the ground quartz particles to create a tight, impervious surface. The resins cure to form a waterproof barrier that prevents stains from penetrating the material.
Can you include recycled glass in quartz?
Yes. Some quartz contains up to 75% recycled content such as glass, porcelain, mirrors, and processing waste. This reduces environmental impact. However, too much recycled material can compromise performance, so there is a limit.
How thick are quartz countertops?
Most quartz slabs range from 2 to 3 cm thick (about 0.75 to 1.25 inches). Some thinner 1.2 cm slabs are made for vertical applications. Thicker slabs of 3 cm or more provide greater strength for heavily used counters.
Why does quartz have a glossy finish?
Polishing with diamond abrasives is what makes the quartz surface shiny. The material’s resin binder also gives it a glassy appearance. Quartz can be dulled with a honed or textured finish, but the standard finish is finely polished for a glossy look.
Can you cut quartz countertops at home?
It’s not recommended. Quartz is very dense and tough on cutting blades. The crushed quartz dulls blades very quickly. Cutting also produces dangerous silica dust. It’s best to have a professional fabricator cut and install quartz countertops.
Conclusion
Engineered quartz has grown into one of the most popular countertop options due to its superior durability, aesthetic potential, stain resistance, and easy maintenance. Advancements in manufacturing technology have allowed quartz surfaces to mimic high-end natural stone while avoiding drawbacks like cracking and porosity. Understanding the manufacturing process gives homeowners and designers deeper insight into this innovative material. From sourcing raw quartz to molding, curing, cutting, and polishing, today’s quartz countertops represent a fusion of nature and human engineering. With proper fabrication and installation, quartz is able to enhance kitchens and bathrooms with beautiful, worry-free surfaces that endure for many years.