Quartz countertops have become an increasingly popular option for kitchen and bathroom remodels in recent years. But where exactly are these engineered stone countertops made? The manufacturing process of quartz countertops is quite extensive and involves mining raw materials, formulating slabs, and fabricating/installing the finished product. Let’s take a closer look at the origins and production of quartz countertops.
Mining the Raw Materials
The key ingredients that go into making a quartz countertop are ground quartz crystals, resins, and pigments.
Quartz Crystals
Quartz is one of the most abundant minerals found in the Earth’s crust. Natural quartz slabs are mined from quarries located around the world. The largest quartz deposits are found in Brazil, China, India, Spain, Portugal, Romania, and Turkey. Quartz crystals are mined from deep within the earth, cleaned, and processed into a fine powder.
Resins
The resins used in quartz countertops act as a binder to hold the quartz particles together. The most commonly used resins are polyester, polyurethane, epoxy, and acrylic. These resins are derived from petroleum and are sourced from resin manufacturers.
Pigments
Pigments are added to quartz slabs during production to achieve the desired color and pattern. Common pigments used include iron oxide for red, yellow, and brown tones, titanium dioxide for whites, and chromium oxide for greens. These color pigments are sourced from specialty chemical companies.
Formulating the Slabs
With the key ingredients gathered, quartz countertop manufacturers blend them together according to proprietary recipes to create quartz slabs. The manufacturing process generally follows these key steps:
Mixing
The mined quartz crystals are crushed into a fine powder. This quartz powder is combined with resins, pigments, and other proprietary additives in precise ratios and mixed thoroughly.
Compacting
The blended quartz mixture is then compacted into molds under intense vibration and vacuum pressure. This compacting process removes air pockets and compresses the materials into a solid slab form.
Curing
The pressed slabs are then cured in ovens or exposed to ultraviolet light. Curing hardens the resins to produce a durable, non-porous slab.
Polishing
Once cured, the slabs are polished to achieve a smooth, glossy finish. This involves grinding and polishing with diamond-tipped tools.
Inspection
Finished slabs are inspected for any defects prior to being packaged for shipping. Approved slabs will be vacuum sealed in plastic for protection during transport to fabricators.
Major Quartz Countertop Brands
While quartz slabs are made using the same basic ingredients and processes, the leading manufacturers have their own unique quartz formulations, technologies, and facilities.
Caesarstone
The pioneer of engineered quartz surfaces, Caesarstone was founded in Israel in 1987. Their state-of-the-art factory in Bar Lev Industrial Park produces over 6 million square feet of slabs per year. Caesarstone has over 50 colors and patterns to choose from.
Cambria
Based in Minnesota, Cambria’s manufacturing facility opened in 2000. Cambria has over 100 unique quartz designs. Their BrittaniccaTM collection features striking metallic patterns.
Silestone
Part of the Spanish company Cosentino, Silestone opened its first U.S. manufacturing site in Top, Georgia in 2008. With over 90 colors and textures, Silestone offers integrated sinks and unique designs like Eternal Collection Calacatta Gold.
MSI
Headquartered in Orange, California, MSI imports their pre-fabricated Q Premium Natural Quartz slabs from factories in India and China. Their collection includes popular white quartz options like Statuario White Venatino.
Other major brands:
- Pental Quartz
- Viatera
- Hanstone
- LG Viatera
- DuPont Zodiaq
- Wilsonart Quartz
- Cambria Quartz
Fabricating and Installing
Once the quartz slabs arrive from the manufacturing facilities, trained fabricators cut, shape, and polish the materials into custom countertops. Using advanced tools like CNC machines, waterjets, and laser technology, the slabs are fabricated to precisely fit each customer’s kitchen or bath dimensions.
The fabricated quartz countertop is then installed by skilled professionals. Countertops are secured to the cabinetry or base structure using adhesive, brackets, and other fasteners. The installers also seam together the edges of the countertop slabs to create a smooth, continuous surface.
Many quartz manufacturers partner with local fabricators and installers to bring their products directly to consumers. Large home improvement chains like Home Depot and Lowe’s also offer quartz countertop installation services.
Quality Control and Certifications
To ensure durability and safety, leading quartz brands adhere to quality control standards and pursue third-party certifications.
Quality Control
Manufacturers follow rigorous testing protocols checking for:
- Color consistency
- Stain resistance
- Heat and scratch resistance
- Resistance to chemicals, acids, and liquids
- Strength – ability to withstand weight and pressure
- Abrasion resistance
Any slabs not meeting quality benchmarks will be rejected.
Certifications
- NSF/ANSI 51 – Certifies food safety for use in commercial kitchens
- Greenguard Gold – Certifies low chemical emissions for indoor air quality
- UL GREENGUARD – Additional measure of environmental safety
- **Bre ** – Certifies low VOC emissions
- LEED – Verifies sustainability credits for green building
- Kosher – Complies with Jewish dietary laws
These certifications provide consumers with assurance that quartz countertops meet the highest standards for health, environmental safety, and durability. Brands will often display the logos of organizations they are certified by.
The Benefits of Quartz Countertops
Understanding the manufacturing process gives insight into why quartz makes an excellent countertop material. Benefits include:
- Hardness and durability – Quartz is one of the hardest minerals, making countertops highly scratch and chip resistant. They can withstand heavy daily use.
- Non-porous – Resins fill the space between quartz particles, creating a waterproof surface that resists stains. Quartz does not require sealing.
- Heat resistant – Engineered quartz is more heat tolerant than natural stone. However, hot pans should still be used with trivets.
- Low maintenance – Routine cleaning with soap and water keeps quartz countertops looking like new for years. No special cleaners needed.
- Color and pattern consistency – Slabs used on a project will have uniform coloring and patterning since they are factory produced.
- Cleaner production – Manufactured in controlled factory settings instead of dusty work sites. Workers are protected from lung hazards.
- Stylish options – From glittering aggregates to veined marble looks, quartz offers extreme versatility in colors and patterns. New styles are frequently released.
FAQs about Quartz Countertop Manufacturing
Where are quartz slabs made?
Quartz slabs are engineered in manufacturing facilities generally located near the sources of raw materials. Major plants exist in the United States, Spain, Italy, Israel, India, China, and other countries.
Does quartz come from natural stone?
Natural mined quartz crystals provide 90-94% of the material in a quartz countertop. A small portion comes from synthetic polymers. Pigments can also be natural or synthetic.
What is engineered vs natural quartz?
Engineered quartz slabs are made by blending ground quartz with resins and pigments under pressure. Natural quartz exists as solid mineral deposits and lacks the color patterns of engineered quartz.
Why is quartz cheaper than granite?
Quartz fabrication requires less time and labor compared to natural stone. Quartz is mined and produced in high volumes allowing manufacturers to take advantage of economies of scale.
Are quartz countertops sustainable?
Leading brands tout their green practices including recycling water, reusing waste, and pursuing certifications. Quartz contains high amounts of recycled content. New bio-based resins are also being developed.
How thick are quartz slabs?
Quartz slabs are typically 0.5 to 1.25 inches thick. Thicker edges add durability. 3 cm (1.25 inch) thick edges are recommended for floor installations or commercial projects seeing heavy use.
How much do quartz countertops cost?
Quartz countertops range from $80-150 per square foot installed. Factors affecting price include color/pattern, thickness, and edge treatments. Highly intricate designs cost more. White quartz is often the most affordable option.
Conclusion
Understanding where quartz countertops originate gives you an appreciation for the meticulous engineering and processing required to create these beautiful and functional surfaces. Quartz offers the allure of natural stone with enhanced durability and maintenance ease. Leading manufacturers have invested heavily in technology and quality control to ensure consumers get a top-notch product backed by warranties. While quartz fabrication remains centered near raw material deposits, globalization allows these quality engineered slabs to make their way into homes across the world.