Quartz countertops have become increasingly popular in kitchens and bathrooms thanks to their durability, aesthetics, and ease of maintenance. When properly installed, a quartz countertop can last for decades with minimal upkeep required. However, before a quartz countertop can be installed, it must first be cut and fabricated to fit the desired space. The cutting and fabrication process is crucial for a perfect fit and flawless functionality. This article will provide a comprehensive guide on how quartz countertops are cut and fabricated for residential and commercial installations.
How to Measure for Quartz Countertops
The first step in any countertop installation is proper measurement of the space. Accurate measurements are critical to ensure a quartz countertop will fit perfectly with tight seams and proper support. Here are some best practices for measuring for a quartz countertop installation:
- Use a laser level or straight edge to determine level and plumb surfaces. Mark any out-of-level surfaces.
- Measure the length and width of the overall countertop space. For sections with walls at right angles, simply measure wall-to-wall. For angled sections, measure the distance along the wall.
- For island countertops or peninsulas, measure the circumference of the entire shape. Allow an overhang of 1-2 inches beyond the cabinet face.
- Measure any corners and angled surfaces independently to account for the proper shapes needed.
- Measure sinks, cooktops, and other cutouts independently from the overall surface measurements.
- Measure thickness of existing countertop and cabinet to ensure proper quartz thickness is selected.
- Take photos of the full space and any tricky areas to share with fabricator.
Accurate measurements are the key to proper quartz countertop sizing and minimal fabrication flaws. Invest time upfront to measure correctly.
How to Select a Quartz Slab
Once measurements are taken, select the specific quartz slabs to be used. Factors to consider:
- Color/Pattern – Browse quartz supplier catalogs to select preferred colors and patterns. Natural stone-like patterns are popular.
- Thickness – Select thickness based on cabinet/countertop dimensions. Standard is 3cm, thicknesses up to 5cm available.
- Square Footage – Estimate square footage needed based on measurements. Most slabs are 30 square feet. Allow 10-15% extra.
- Veining Run – Look at veining direction. Request veining runs horizontally for smoother look.
- Uniformity – Review actual slabs to avoid variation or flaws grouped together. Reject non-uniform slabs.
Pro tip: Lighting conditions in the supplier warehouse can alter quartz colors. Examine slabs in different lights to prevent surprises.
How Are Quartz Countertops Cut?
Once slabs are selected, the fabrication process begins by cutting the material to the measurements needed. Quartz is most commonly cut in two ways:
Water Jet Cutter
A water jet cutter directs an extremely high-pressure stream of water mixed with abrasive materials at the quartz slab. This gradually cuts through the material along precise computer-controlled paths.
Benefits:
- Extremely accurate with cuts to 1/1000 of an inch
- Minimal quartz dust/debris
- Ability to cut complex curved shapes
- No blade marks or chipping
Drawbacks:
- Slower than sawing
- Potential for laminate damage if settings not calibrated
- Water mixing and filtration requirements
Bridge Saw
A bridge saw is a large mechanical saw designed to cut heavy slabs. The quartz slab is moved under a motorized saw on a bridge frame to make straight cuts. Diamond-tipped blades specially designed for quartz minimize chipping.
Benefits:
- Fast and efficient for straight cuts
- Clean edges with minimal debris
- Ability to make mitered edges
- Wide selection of diamond blades
Drawbacks:
- Less accurate than water jet
- Higher maintenance of saw and blades
- Potential for small chips and roughness on cuts
Pros often use a combination of the water jet and bridge saw cutting methods to capitalize on the unique strengths of each.
How Are Cutouts Made in Quartz?
Cutouts for sinks, faucets, soap dispensers and other features need to be made with care to avoid cracking or chipping the quartz. Here are some tips:
Outline the Cutout – Use a marker to outline the shape and dimensions per the manufacturer specs. Allow a 1/8″ clearance on all sides.
Drill Holes – Drill a hole inside the cutout area with a diamond-grit hole saw. This prevents cracking.
Cut Out Shape – Use an angle grinder or router to carefully cut out the shape keeping within the outline. Go slowly and keep cool with water.
Smooth Edges – File, sand and polish the cutout edges for a smooth finish. Inspect for any small chips needing repair.
Reinforce – Apply fiberglass mesh tape around the underside edges of sink cutouts to prevent cracking over time.
Clean Area – Carefully clean the cutout area with a shop vacuum and/or damp microfiber cloths.
Patience and the proper cutting tools are critical for flawless cutouts in quartz countertops. Rushing can lead to permanent damage.
How are Seams Created in Quartz?
Long countertop runs will require seamed sections where two quartz pieces meet. The seaming process includes:
- Planning – Fabricators plan the layout to minimize seams and place them in inconspicuous areas.
- Cutting – Slabs are cut with precision to create tight-fitting seams when joined.
- Edging – The edges along the seams are polished smooth.
- Clamping – Sections are aligned and tightly clamped together.
- Adhering – Special adhesives designed for quartz are applied seam areas.
- Curing – Clamped seams are allowed to fully cure per adhesive specifications.
- Polishing – Once cured, the seams are carefully sanded and polished to create an imperceptible finish.
When done properly, quartz countertop seams should be undetectable. They should be completely smooth with no gaps or lippage between sections.
How are Quartz Countertops Installed?
Once fabricated, the quartz pieces are ready for installation. Here is the basic installation process:
- Remove old countertop if existing and prep the surface.
- Inspect base cabinets for level and make any adjustments.
- Dry fit the quartz pieces and test alignments.
- Apply thin bead of silicone adhesive to cabinets.
- Carefully lower quartz pieces into place. Apply clamps across seams.
- Allow adhesive to cure fully per manufacturer recommendations.
- Use color-matched caulk if needed for small seams or gaps.
- Clean area thoroughly and inspect final installation.
- Install backsplash and complete final details.
Proper installation is crucial to prevent slipping, cracking, or misalignment issues over time. Hire experienced professionals for a quality quartz countertop installation.
How to Care for Quartz Countertops
With proper care, quartz countertops can maintain their beauty and function for decades. Here are some quartz care tips:
- For day-to-day cleaning, use a mild soap and water. Avoid abrasive cleaners.
- Disinfect surfaces with diluted bleach or isopropyl alcohol if needed.
- Use trivets or mats under hot pans to prevent scorching.
- Clean up spills immediately to prevent stains, especially oils.
- Avoid cutting directly on the quartz. Always use a cutting board.
- Reseal seams and edges every 1-2 years with a flexible sealant.
- Don’t expose to strong chemicals like paint removers or oven cleaners.
- Use coasters under glasses and ceramic items to prevent etching.
With regular care and maintenance, quartz countertops will stay looking like new for an extremely long time.
FAQs about Cutting Quartz Countertops
How thick should a quartz countertop be?
The standard thickness for a quartz countertop is 3cm (1.25 inches). Thicker options from 3-5cm are also available for a heavier, more durable surface. The thickness should align with cabinet and existing countertop depth.
What tools are used to cut quartz?
Quartz fabricators primarily use water jet machines and bridge saws with diamond-tipped blades designed for cutting stone. Angle grinders, routers, and hole saws are used for specialty cuts.
Does quartz get cut to size on site?
Quartz slabs are cut to precise measurements at the fabricator’s workshop. Only minor trimming and fittings are done during on-site installation. Pre-cutting minimizes mess and ensures proper fabrication.
Can you cut quartz countertops yourself?
It is not recommended for DIYers to cut their own quartz. The specialized tools and risk of cracking make professional fabrication the prudent choice. Only simple trimming should be done on site by a skilled installer.
Is it cheaper to fabricate quartz yourself?
No, attempting to cut quartz without professional tools and training will likely result in damage and require replacement. The highly-skilled fabrication process is factored into the material and installation pricing from reputable vendors.
How long does it take to cut a quartz countertop?
The cutting time can range from 1-3 weeks depending on the fabrication schedule. The water jet and bridge saw cutting can often be done in a day or two. Additional fabrication time is required for edge treatments, polishing, inspection, and staging for installation.
Conclusion
Installing a custom-cut quartz countertop gives a kitchen or bath an incredibly durable yet beautiful accent. With the proper measurements, slab selection, cutting tools, fabrication process, experienced installers, and ongoing maintenance, quartz countertops will withstand decades of wear while remaining visually pristine. Pay particular attention to using the right cutting techniques to avoid any damage or flaws. And take care to keep quartz looking like new with regular cleaning and avoidance of excessive heat or chemicals. With the help of this guide on how quartz countertops are measured, cut, installed and cared for, your new quartz surfaces are sure to impress for years on end.