Selecting a new countertop is no doubt an exciting experience. Countertops are the centerpiece of any kitchen or bathroom renovation. When it comes to choosing a new countertop, many consumers focus on selecting the right material to work with their home design. But, what you may not be familiar with is the fabrication process — which will significantly impact the look and feel of your final product.
It’s about making and kitchen countertops.
Fabrication refers to all of the processes that take place after you have selected your countertop material. This includes creating a design template, cutting the stone, sealing it, and more, to prepare it for installation in your home. The fabrication process is important because it ensures your countertop will be sturdy, long-lasting, and look beautiful in your space.
This article is an overview of the fabrication process and questions to review with your fabricator.
What is the process of countertop fabrication?
Choosing the countertop material
Nowadays, consumers have a wide variety of choices when it comes to stone type and color. Stone type should be considered carefully because it will impact the long-term wear and maintenance of the countertop.
Harder stones, such as granite and quartz, have higher durability. For example, granite is scratch resistant and highly heat resistant, making it one of the most popular choices for kitchens. These types of harder stones are generally excellent choices for high-traffic areas, like countertops where a family cooks regularly.
Stone type is one of the great materials of countertops.
In contrast, softer stones like limestone and marble are easier to damage and require more care over time. Marble has been used in homes for centuries and tends to gather scratches and patinas with age, which can contribute to the historic feel of a home. However, it is susceptible to stains if not sealed regularly. It may not be the right selection for a countertop that endures lots of use, spills, and splashes if the owner wants it to maintain a showroom look.
Next, you should consider the look of the stone and how it fits into your home design. Different types of stone naturally have unique designs through their color, veining, mineral patterns, and speckling. Quartz, which is an engineered surface, can be designed to mimic the look of other types of stone. Consider how the colors of your stone will fit into your other design elements, including wall color, furniture materials, and lighting, to create the most cohesive space
Consider how the color of the stone on the countertop affects other design elements such as furniture and lighting.
Inspection of the selected slab
Once you have selected the slab material for your countertop, you will then begin working with your fabricator. First, you and your fabricator will inspect the slab. As stone is a natural material, it will contain characteristics like directional veining, dry seams, black spots, knots, and more. You will work with your fabricator to determine any areas of the slab that you don’t want included in your final countertop design. Your fabricator will also identify any irregularities that should be removed.
During inspection, you will also want to talk with your fabricator about the final design of the countertop. For example, you may want the most beautiful area of the slab to be the kitchen island, while a section of the stone with natural fissures will go in a less visible area of the kitchen.
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Countertop slab template layout
The bullnose edge is a classic and elegant choice. It features a rounded edge on both the top and bottom corners, creating a smooth, curved profile. This profile is not only visually pleasing but also safe, making it a suitable option for high-traffic areas and homes with children. Bullnose edges work well with various countertop materials and design styles . Once you complete the inspection, your fabricator will create a template for your countertop design. The template reflects the logistical and technical use cases for the countertop, as well as your requested design considerations. The templates are arranged on the slab to check for the best flow for your design.
For example, for an L-shaped countertop, your fabricator will work to ensure that the stone’s natural patterning looks smooth. This is particularly important for stones with highly visible color variations or veining, like marble. This step in the process is a mix of technical expertise and artistry.
Cutting the stone
Once your fabricator has identified the best template for your slab, they will then cut the stone to fit the measurements of your space.
Fabricators cut stone using one of two methods: a bridge saw or a water jet. A bridge saw cuts straight lines into stone using a diamond segmented blade. A water jet is a newer tool that uses a garnet particulate suspended in water to cut stone. It can be programmed to cut in any intricate pattern needed. A water jet often achieves increased productivity and quality.
Once the stone pieces are cut from the original slab, the stone pieces are sent to a computer numerical control (CNC) machine using a vacuum lifting system for fabrication.
Fabricating the stone
At this stage, the CNC machine will create the cutouts for your countertop design. These can include a sink, cooktop, or faucet cutout.
The CNC machine is programmed to read the size of the stones and where they are located. It then cuts the desired shapes into the stones, moving at varied rates as needed for different materials. It also shapes the edges of the final cuts before the stone moves on to polishing.
Once the fabricator is done with the CNC machine, the stone is polished to ensure its surface is smooth. If needed, your fabricator may even strengthen the stone by adding rot slots and epoxy to minimize cracking.
Your fabricator will then apply a sealer to your countertop. This protects the natural stone from damage by keeping out liquids and spills. It’s especially important for stain-prone stone types, like quartzite. Sealers do not degrade in indoor settings, but some stone materials may need to be resealed every year to protect the countertop.
Finishing the stone
Finally, your fabricator will inspect the stones. They are looking to see if the edges are uniform, if the light bounces evenly across the surface, and if the color and patterns of the stones match one another. Once inspection is complete, your countertop is ready to be installed in your home.
Now, after all the verification, the countertop is ready to be installed.
Factors to consider when finding a countertop fabricator
How long has the fabricator been in the industry?
Working with a skilled fabricator is essential to ensuring the success of your project. Fabricators have both a mastery of the technical processes needed to create your countertop, including knowledge of materials and machinery, as well as the artistic eye needed to create a beautiful final product. When searching for fabricators, look for professionals who have many years of experience in the industry and several similar projects under their belt.
Find and get started with experts who have experienced a lot of projects in the industry.
What is not included in the quote?
The fabricator that you work with and the specifications of your project will directly impact your quote. First, stone materials typically have different costs. The more exotic your stone is, the more expensive it will be. In addition, the work required to fabricate your countertop will affect pricing, such as the number of cutouts, finishes, types of edging, and need for strengthening.
In general, you should request that your fabricator include the entire price of services in your quote. Some fabricators will attract customers with low initial quotes, but then add on services à la carte. In the end, you may end up paying more through this quote structure.
Questions to ask countertop fabricators
How long will the countertop fabrication process take
A typical countertop fabrication can take a few days to a week to complete. However, this will vary based on a few factors. Working with a local fabricator can reduce time spent on shipping and transportation of materials. Unique or less common stones can also take additional time to order, fabricate, and install.
Which countertop material is easiest to fabricate
In general, popular types of stone will be an easier fabrication process. The most common slab materials include quartz, granite, quartzite, and marble. However, each of these can require different levels of labor. For example, granite tends to have unique patterns that may require creative templating depending on the customer’s preference.
Which factors of countertop fabrication affect remodeling cost
Other factors can also impact the overall remodeling cost. These can include the measurements of your kitchen and countertop area, or unique features you would like to add, like a kitchen backsplash
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Contact us
LX Hausys experts can help you select the ideal material for your countertop and discuss the specific needs of your renovation project. Contact us today to get the conversation started.
