Granite Countertops – Fabrication Process for Your Granite Countertops
Granite Countertops – Fabrication Process for Your Granite Countertops
Getting granite counter tops set up in your house is a fairly easy procedure when taken a look at from the point of view of exactly what you as the customer can see from starting to end. Basically, you call us, choose your pieces, & settle on the details, then a few weeks later on they are installed.There is nevertheless a
prolonged procedure associated with getting the stone from its natural state in the earth all the method to your kitchen area counter top. The procedure of turning stone into ornamental and practical structure products has actually been basically the exact same for centuries. On the other hand, the devices has actually altered drastically because time, and the production time significantly reduced.The procedure begins at the stone quarry where big blocks are cut from the earth frequently in a stair-step like pattern. Different kinds of sawing & cutting techniques are utilized. There are wire saws which are long steel cable televisions with diamond areas embedded in them. These cable televisions are gone through”core holes”which have actually been drilled horizontally and vertically to a conference point in the undetectable corner of the”bench” to be eliminated. Then the cable television is gone through a drive, constantly going deeper into the stone. Core drilling, as discussed above, combined with”blasting”is another technique of releasing big blocks of stone in this initial step of the procedure. Some quarries utilize broadening liquid instead of dynamites in the core holes-this is for the more delicate stone to avoid fracturing the blocks.This initial step of the procedure needs huge and heavy devices to obtain the granite obstructs from the earth and prepared for delivering to the “gang “saws. When the blocks reach the gang saw operation, the whole block is cut into some 40-60 pieces at the same time. These blocks are not a basic size, nevertheless a rough average would be 6 feet by 6 feet by 10 feet. This would yield 72 one inch thick pieces less the cutting blades, so around 60 pieces. The blades on a common gang saw are not truly blades, they are flat steel product 3” x 3/16 inch thick. They have no teeth or diamond in them. They are installed on a big rack 2cm or 3 cm apart depending upon the wanted piece density. The rack is larger than the 6 foot broad piece. This rack in turn is installed to an arm that is connected to the external side of a huge flywheel producing a backward and forward movement of the rack as the wheel is turned by effective motors.Once the block has actually been become pieces, the cart holding the 60 pieces is generated on its rail cart to the polishing line. The polishing line is
another huge device with several heads generating different grits of grinding and polishing wheels advancing from rough to polish. These heads generate horizontal mills as the rough piece goes on a horizontal airplane gradually through the device on a conveyor belt. When the pieces come out the other end of the polishing line, they have actually ended up being polished from their rough state. They are then packed onto A frames for delivering to the wholesale storage facilities throughout the world.At this point the pieces enter our world here at Alpha StoneWorks, and our turn in the procedure starts. We concern your house and make a precise design template of your counter top locations.
This can quickly be done on brand-new cabinets or on top of your existing counter tops without disrupting them. After we have actually made the design template, we want to consult with you at our look for a design evaluation so we can settle on which part of the different pieces will go on the various areas of your counters.Once we have actually settled on the design, we go to word cutting and polishing your counter tops. The surface area has actually currently been polished or refined, or brushed as the case might be. We cut the counters to match the design templates on exactly what is
referred to as a bridge saw. This is a big “upside down”table saw. The sawing motor with the diamond blade are suspended above the saw table on the “bridge”. This bridge in turn is resting on 2 rails some 18 feet apart with rack and pinion drive to move the whole bridge east and west. The motor with blade runs north and south on the bridge through another set of rack and pinion gears. This whole device enables the blade to be placed anywhere over the 6 foot by 12 foot piece of granite. The saw motor just relocates one straight line, so the table below that the piece is laying on rotates in order to enable cuts at any angle required. The turning table has favorable lock stops at 90, 45 and 135 degrees, and can be secured other degree for other cuts as required. The table on our saw tilts as much as almost vertical through hydraulic cylinders. This makes packing simple and safe for both our employees and for your product. When the counter top pieces have actually been cut to size, the edge polishing procedure begins.Depending on the setup of the piece and the preferred edge information, we have a number of various techniques of shaping and polishing them. If they are straight line edges with a flat, beveled, or bull nose shape, they go one our “Pro Edge “device. This is a device some 18 feet long, 6 feet broad and around 6 feet high.
It is enormously heavy and does the work of 2 to 3 guys in regards to its output abilities. You will see both the bridge saw and the Pro Edge in action in the video. If the edges are rounded or have jogs in them, these are formed with routers and mills. Ogee edge information and other complicated shapes of edges are finished with big routers.All through the procedure we have water spraying on the diamond tooling doing the cutting and grinding. When the cutting and grinding is done, we continue with the polishing procedure. This is finished with a series of polishing pads on hand polishing mills. There are 4 to 8 actions associated with the polishing procedure depending upon the stone type and surface wanted. The polishing grits begin around 50 grit and increase to 8000 or 10,000 grit. When it comes to antique surfaces, stiff brushes are utilized on the grinding devices in location of the polishing pads.Now that we have your counter tops produced, it is time to bring them into your house and install them in location. This needs a little strength and a little experience does not harm a thing! We have actually learnt how to work smarter, not always harder, to obtain the pieces into location. Granite counter tops are extremely heavy to generate. We utilize a mix of wheels, ramps
, tables and other gadgets depending upon the task. The pieces are test fitted then we adhere them to the cabinet tops with the suitable stone adhesives. Joints are assembled with epoxies developed for stone work. When the epoxy remedies, we spruce up the joints and other last information, leaving you with brand-new gleaming granite counter tops!