How to fabricate engineered stone worktops
Engineered stone is a man-made composite material which is made up of 90 – 95% crushed natural stone, most commonly quartz, combined with resins and pigments to create the durable slabs we use today.
Quartz has for many years been the go-to surface for kitchens across the UK and Europe – for a good reason. It is notoriously hard-wearing and durable, making it a great choice for a sturdy, beautiful worktop with low-maintenance, and a stunning look. When it comes to fabricating quartz, it’s not as simple as putting it on the saw and getting started. This material can be quite hard and rather unforgiving. You need the right tools and processes to do it – and we are here to advise you on both.
Our technical team of trained fabricators with decades of years of on-the-tools experience, who are provide round-the-clock to support our customers and help them overcome their challenges. As such, they are able to provide us with unique insight into the correct tooling, processes and parameters needed to deliver excellent finished work. This feedback is fed into our NPD process. We have a dedicated New Product Development team, who work tirelessly to provide solutions for each unique challenge faced by our customers. Once these products have passed through extensive scope and screening, our technical experts rigorously test every tool that we sell, to ensure it guarantees performance and lifespan. We don’t just develop tools that do the job, but ones that transform process – saving time, improving finish and giving your team the confidence to cut engineered stone with precision, every time.
Templating – the beginning of precision
The journey begins with precise measurements and templating of the kitchen where the engineered stone worktops will be installed. Many fabricators and fitters use traditional methods of templating such as Correx, others use slightly more advanced machines such as the Proliner, the Leica, or the LT – 2D3D. Those who are looking for that extra versatility along with the ability to take on more complex projects such as waterfall islands, media walls, and other intricate kitchen features, often choose the Flexijet 3D. This device also provides excellent accuracy for standard sinks, hobs and other applications and is a true standout digital device in the world of kitchen measuring. Templating is the first critical step to ensure a perfect fit and seamless install of the finished granite or engineered stone kitchen worktop.
A blade that is a cut above the rest
Quartz can be a rather hard material to deal with. That’s why it requires stone tooling that’s up to the job. The Tempest bridge saw blade isn’t just another diamond blade, it’s the result of precision engineering, years of field testing, and direct feedback from fabricators. Here’s what sets it apart:
It’s this combination of speed, life and quality of cut that makes the Tempest blade a firm favourite in workshops looking to increase productivity without compromising on finish. You spend 50% less, and cut 4x more – it’s that good! A vital part of best practice when cutting quartz worktops is understanding the correct parameters of the tooling, to deliver the best performance without compromising on tool lifespan.
We tested the Tempest blade against a popular alternative currently available and discovered that while other blades may appear more cost-effective upfront, and provide an adequate cut, the Tempest delivers better performance, longer life, and cost savings. You can cut 416 granite or engineered stone kitchens with the Tempest compared to just 107 with a popular alternative blade currently available.
We know that every fabricator has specific needs when it comes to cutting materials. That’s why we hold a wide range of Stonegate exclusive granite and engineered stone blades in stock such as the Vortex, Conqueror and Speedmaster – consistent, reliable and a great solution to various respective challenges. They’ve been trusted favourites in factories across the UK and Ireland for years – standing the test of time and delivering excellence with every cut.
And remember, safety is just as important as process. In the workshop, it’s crucial that all cutting is done with a constant flow of clean water to keep the material cool and prevent silica dust. To find out more visit our Safe in Stone campaign.
Tap holes, drainer grooves, and sinks?
Sink, drainer groove or tap hole cut outs are predominantly created using the CNC, with specific tooling.
Quartz is a dense material, meaning not all core drills are up to the task of working with it on multiple projects. That’s why we offer a full range of quartz-specific core drills, from thin-wall electroplated, to heavy-duty segmented options. Each one has been tested to destruction, guaranteeing longevity, speed and consistency every time you use it. Whether you’re coring for taps, sockets, or sink cut-outs, you’ll achieve clean, precise holes with minimal effort.
Keep chipping to a minimum when cutting larger shapes like sinks, with our Status Routers – a range designed specifically for granite and engineered stone. You can expect impressive speeds and longevity from Status Routers, and they’re reinforced with an end segment for plunging and rebating – two functions in one!
Edging and polishing: the final steps to perfection
Once all the cutting is done, the edges of the engineered stone now need to be polished to create the perfect profile. Whether you go for a straight edge, bullnose, bevel or ogee, this step involves the use of our specially designed edge profiling tools, resulting in a smooth finished surface to match the face of the slab. To create those beautiful edges on any material, we developed a range exclusive to Stonegate –Infinity. Designed to maximise efficiency, and save you time and money, this range of profile tools comes in nearly every shape imaginable. Paired with our Optimo tooling precalibration service, you can’t go wrong.
To create a consistent edge on your engineered stone worktop, you need a consistent edge polisher. Marmo Meccanica machines are designed to work in any factory, and are fully configurable to suit your requirements.
If you prefer to finish your jobs by hand to create a smooth flat finish, our Trimax pads simplify traditional 6 or 8-step processes to just 3 – delivering unbeatable shine in no time. The key differentiators of Trimax pads include their intricate pattern designed for effective water dispersal and efficient cooling, high diamond concentration for controlled polishing, and optional position 0 to buff out heavy saw marks before polishing up. We would also advise on wet polishing, as it will making working quicker, with better results but, more importantly, it aids in dust suppression. With Trimax, you’ll discover that the water is evenly spread across the pad, resulting in an even polish and no burn marks! Talk to us on the tools and processes needed to speed up hand polishing whilst still delivering the finish your client expects.
Install: Bring the vision to life
The final step is installation. Skilfully placing and securing the countertop accurately is no simple task.
Investing in sturdy lifting and handling equipment can ensure your brand-new engineered stone worktop will reach your clients in one piece, as well as providing additional safety for your fabricators and fitters, all the way from the slab storage to your clients kitchen! Check out our range of solutions online.
During installation, use a high-quality adhesive to create seamless joints and ensure your engineered stone worktop stays securely in place – for life. Our knife-grade polyester resin, Bondex, is ideal for vertical joints, as it doesn’t sag or drip after applying. For mitred edges, Invisabond is the perfect seaming adhesive, specifically formulated for that purpose. Both adhesives are colour-matched to hundreds of different stone types and brands. Use our online Colour Match Tool to find the perfect match for your material before starting any job!
Once installed, seal your edges with a smooth quality silicone. Our Colour Range offers fantastic resistance to water, moisture and cleaning products. A well-sealed joint puts the finishing touch in a brand-new kitchen! All of our silicones are pre-matched to hundreds of different brands of stone. You can find these matches online on by visiting our Colour Match Tool.
Simple template, faster cuts, cleaner edges: a better workflow
From the initial templating to the final installation, the fabrication of engineered stone incorporates the blend of traditional craftsmanship and modern technology.
Every minute saved cutting, profiling and finishing quartz is money back in your pocket. With the right tooling and processes in hand, you can eliminate on-site corrections, reduce wasted materials, and ultimately boost output. Imagine being able to cut faster without sacrificing edge quality and polish in half the time!
Interested in seeing the full process?
At Stonegate House, we have a live fabrication workshop, the Innovation Hub, where all our testing and demonstrations take place. This is also available for you to book in for a day of training with our expert technicians – they’ll run live demonstrations on granite and engineered stone, and run through all any processes you’d like to see in action! To book your visit, contact us on +44 (0) 1482 620400, or email [email protected].
