Quartz countertops have become incredibly popular in kitchens and bathrooms thanks to their durability, visual appeal, and easy maintenance. But how exactly are these engineered stone countertops made? The manufacturing process involves several steps to transform raw quartz crystals into beautiful, functional slabs.
An Overview of Quartz Countertop Manufacturing
The main ingredients in a quartz countertop are ground quartz crystals combined with polyester resins and pigments. The manufacturing process combines around 90% ground quartz with about 10% resins and pigments. The resin binds the quartz particles together while the pigments add color.
The basic steps to make a quartz countertop are:
- Mining and crushing quartz crystals
- Mixing the quartz particles with resins and pigments
- Pressing the quartz mixture into slabs
- Curing the slabs
- Polishing and finishing the slabs
Now let’s look at each step in more detail.
Mining and Crushing the Quartz
Natural quartz crystals are mined from the earth. Quartz is a very common mineral found all over the world. The mined quartz contains impurities so it first goes through a cleaning process. Once cleaned, the quartz crystals are crushed into smaller particles.
This crushing process typically uses a VSI crusher (vertical shaft impact crusher). VSI crushers break the quartz down into tiny granules between sand and fine powder in consistency. The crushed quartz particles provide the strength, durability and look of real stone or granite.
Mixing with Resins and Pigments
The crushed quartz granules get mixed with coloring pigments and a small amount of polyester resins in a large mixing machine. The resin binds the crushed quartz particles together. Different colored pigments create the unique look and aesthetic of the quartz slabs.
The ratio is usually around 90% crushed quartz to about 10% polyester resins and pigments. The mixture creates a durable material that can be formed into countertop slabs.
Pressing into Slabs
The quartz mixture gets pressed into thick slabs using a vacuum and vibration under intense pressure. This compaction process removes air pockets and compresses the quartz and resin material into a solid, dense slab.
The slabs are typically pressed to be 1.2 to 2 cm (0.5 to 1 inch) thick. The pressing machines impart tons of pressure to squeeze out excess resins and create an even consistency. This helps achieve the signature look and feel of quartz countertops.
Curing the Slabs
After pressing, the slabs go through a curing process. The quartz slabs get placed inside a curing oven or kiln. The heat helps to solidify the resins and cure the slab.
Curing occurs at 150 to 160°C (300 to 325°F). This heating process makes the slabs more temperature resistant as well. The curing time depends on the thickness but is usually around 45 minutes.
Polishing and Finishing
Once cured, the slabs get polished to achieve the desired smoothness and shine. This involves running the slabs through polishing heads containing diamond abrasives. The polishing heads spin at high speeds to grind and polish the surface.
Finer and finer grits remove any marks left behind and create an ultra-smooth finish. Some manufacturers further enhance the polish using diamond pads. This polishing process transforms the stone into beautiful, functional countertops.
The edges also get finished, cut or profiled as needed. Holes may get drilled for sinks and faucets. After polishing, the slabs are complete, ready for shipping to fabricators and installation.
Pros and Cons of Quartz Countertops
Understanding the manufacturing process helps appreciate the pros and cons of quartz:
Pros:
- Extremely durable and scratch resistant
- Stain resistant
- Easy to clean and maintain
- Consistent color and patterns
- Resists heat and scorching
- Won’t harbor bacteria growth
- Endless design options
Cons:
- Not as resistant to direct heat as granite
- Seams more noticeable than natural stone
- Less custom fabrication options
- Can chip if subjected to hard impact
- Manmade rather than natural material
FAQs About Quartz Countertop Manufacturing
Here are answers to some frequently asked questions about how quartz countertops are made:
Where does the quartz come from?
The quartz is mined from quarries, usually overseas. Major sources are Brazil, India, Turkey, and Madagascar. Quartz is an abundant mineral found all over the world.
Is the manufacturing process sustainable?
Quartz countertop manufacturing uses almost entirely natural ingredients. The resins are petroleum-based but make up a small percentage. Manufacturers are working on more sustainable and eco-friendly resins.
How thick are quartz countertops?
Quartz slabs are typically 1.2 cm to 2 cm (0.5 to 1 inch) thick. Thicker slabs of 3 cm (1.25 inches) are also available for kitchen islands and heavily used surfaces.
Can quartz be recycled?
It is possible to crush and reuse scrap quartz material in new slabs. However, recycling quartz is limited since factories require specific mixes. The resins also limit recyclability.
Does quartz need to be sealed?
No, quartz does not require sealing. The resins make quartz non-porous so it will not absorb stains. Sealing is not needed.
Can you repair chips or cracks in quartz?
Minor chips and cracks can be repaired by a professional fabricator filling them with color-matched epoxy resin. However, repair options are limited compared to natural stone like granite.
Conclusion
Quartz offers the look of natural stone with excellent durability and low maintenance. Understanding the manufacturing process gives insight into the pros and cons of quartz countertops. While making quartz countertops is a multi-step industrial process, the results are high-performance countertops that provide beauty and everyday functionality for today’s kitchens and baths.