From Raw Mineral To Stunning Surfaces. Discover the Art & Science Behind Quartz Countertops
As quartz countertops have continued to rise in popularity, manufacturers continue to upgrade the the manufacturing process to provide homeowners with an even greater selection of colors and patterns. But have you ever wondered how these gorgeous surfaces are made? Dive with us into the fascinating world of quartz manufacturing!
1. Starting with Raw Materials
While quartz is an engineered product, the journey begins with raw quartz, one of Earth’s hardest minerals. Nearly 90-95% of a quartz countertop is composed of pure, natural quartz. The rest consists of resins, polymers, and pigments, which give the countertop its color and endless design variations.
2. Purification and Enhancement
The raw quartz used for countertops comes from several regions around the world. The origin of the quartz often depends on the manufacturer and the specific quality or characteristics they’re seeking. Two popular sources are Brazil and India. Brazil has vast quartz mines, especially in the states of Minas Gerais and Bahia. The quality and colors of Brazilian quartz make it highly sought-after for countertop manufacturing. India has been an increasingly significant source of quartz, with Rajasthan being a primary mining state. Indian quartz is known for its variety in color and quality.
The extracted quartz is crushed into small particles. This ensures a uniform appearance and aids in the removal of any impurities. The purification process uses both physical and chemical techniques, ensuring a high-quality end product.
3. Blending with Resin and Pigments
Once the quartz is purified, it’s blended with polyester resins for binding. These resins help in making the countertop non-porous, stain-resistant, and ultra-durable. Pigments are also added at this stage to impart a variety of shades and designs to the mixture.
4. Molding and Pressing
The quartz-resin mix is then poured into molds, shaping them into slabs. These slabs are compressed under a vacuum and subjected to intense vibration. This process ensures air pockets are eliminated and the slab’s density is maintained.
5. High-Temperature Curing
Post pressing, the slabs are subjected to a curing process under high temperatures. This step solidifies the slab, ensuring the bond between quartz and resin is rock solid.
6. Polishing to Perfection
Once cured, the quartz slabs are polished using diamond-tipped blades. This imparts the glossy, reflective surface that quartz countertops are famous for. Moreover, different finishes like honed, leathered, or embossed can be achieved during this stage.
7. Quality Control
Before hitting the market, each quartz slab goes through stringent quality checks. Only those meeting the industry standards get approved for distribution.
The Final Steps
The manufacturing process of quartz countertops is a blend of art and science. It’s this meticulous process that in a countertop that’s not only stunning but also stands the test of time.
At All American Granite, we offer a stunning selection of premium quartz from the world’s top brands. Combined with our experienced design, fabrication and installation team, you can experience the world’s finest quartz surfaces in your home.