Most of what makes granite so unique is the story behind the stone. In the G & L Marble lounges, where granite slabs are neatly stacked in bunches for viewing, it is easy to lose sight of the long process of granite production in the kitchen. So how does a stone become a tabletop?
First, you need to discover granite. Natural stone quarries are located around the world. Each continent has its own different rock types and colors. In the process of searching and studying geological surveys, objects are selected according to their structure, color and marketability. These sites can be located in extremely remote locations, such as Madagascar, the Amazon region in Brazil, or in the desert region of Namibia, located on the African continent. As soon as the site is selected, and mineral extraction licenses are obtained according to strict environmental recommendations, a career begins.
Then the granite must be removed from the ground. Extraction is the process of drilling and cutting the wire to release huge stone benches. Then the benches are drilled and divided into blocks. The finished blocks average 10 x 6 inches and can weigh up to 40 tons. Blocks are checked for cracks, major defects and color range.
Transportation from a quarry to a processing plant varies depending on the location of the quarry. From our desert quarries in Namibia, many of the blocks transported 1,200 miles to our plant in South Africa. Other units are shipped by truck to the port of Walvis Bay, Namibia, and then transported by ship to Italy for processing. Upon arrival at the processing plant, the blocks are selected for cutting. Using 40-ton gantry cranes, the blocks are placed on large carriages and are folded under the saws for cutting. Banking saws are terrible cars. The massive blades are aligned and located on a large trolley up to 18 inches wide. Driven by electric motors, the carriage is pushed and folded back and forth. While the blades are moving, the cutting slurry consisting of steel grain and water is distributed in blocks to provide abrasion for cutting.
Completion of cutting blocks takes from 2 to 7 days (depending on the hardness of the stone). The quality of cutting depends on the skills of the gang masters who are responsible for cutting. Due to varying stone hardness, density, slurry, blade tension and cutting speed, the sawing process requires constant monitoring by the craftsmen. Then, the rough plates are thoroughly cleaned with water and prepared for the next processing phase.
The next phase is determined by the specific type of stone. Many of the granites listed today undergo an epoxy process to improve the quality of the stone. For example, large quartz crystals found in some granites have cracks or crazes. The fact is that if there were no cracks, it would not be quartz. These characteristics are inherent in this mineral. These cracks are not defects, as we say in the stone industry: "Mother nature does not make mistakes." However, with today's epoxy technology, more exotic granites can be processed for countertops.
The epoxy resin process begins with the slab loading into the kiln to completely dry the stone and bring it to a uniform temperature before applying the epoxy. Epoxy resin is loved, and then it is found in a thin layer over the entire surface of the plate. The slabs are then rolled into a vacuum chamber, drawing out any air pockets so that the epoxy resin penetrates deep into the slabs. Then the epoxy resin is vulcanized into an extremely hard coating.
The polishing process is the same regardless of whether the epoxy board was. The polishing line is a long machine with a conveyor feed, which directs the plates under 21 separate grinding, and then polishing heads. Polishing is achieved by a series of pellets on rotating grinding heads, starting with a very coarse diamond diamond diamond grinding machine to 1800 granulating bricks. When epoxy boards are polished, all epoxy is ground from the surface. Epoxy resin remains and penetrates below any surface into any cracks, pits or voids. After checking the quality of the plates are ready for packaging, loaded into a container and shipped. After the plates have been packed in bundles (think pieces of bread in a loaf), they are loaded into shipping containers. These containers are then loaded onto a cargo vessel destined for different destinations. Our containers (shipped from all over the world) are brought to the port of Savannah or Charleston. Delivery time varies depending on the port of discharge, but 4-6 weeks is a typical journey time from any factory to our warehouse.
Upon arrival at the port of entry, customs clearance is carried out along with random inspection by the USDA. After being cleared from the port, the containers are then loaded onto a truck bound for our warehouse in Winston, GA.
In stock, containers are unloaded by bridge cranes and then delivered for quality control. During quality control, each individual slab is checked for defects in processing, cracks, polishing quality, etc. From our basic warehouse sets, we go to our exhibition centers in Alpharette, Atlanta, Birmingham, Destin, High Point, Jacksonville, Knoxville and Roles Slabs (weighing more than 1,200 pounds) are treated using bridge cranes or mechanical loading beams. In our showrooms, plates are fully displayed for customers to make their choice. Our showrooms are equipped to assemble a set of selected material so that the client can actually select their individual plates. When choosing and approving concrete slabs, the client then contracts with the manufacturer to cut and install their countertops. Manufacturers place an order for a customer's order using G & L, and we send them to the store within 2-3 days from the time an order is placed.
When you look at a granite countertop, it’s hard to imagine how extensive and time-consuming the process it went through before arriving at your home. Thousands of miles were transported, and hundreds of hands were extracted, ground, delivered, shipped, received, measured, cut and installed this piece of stone. Natural stone has a history in relation to its formation, but just to get from the earth to your home is history itself. This story explains why people who enjoy their granite countertops appreciate natural stone. Every detail is as unique as the homeowners themselves. This evaluation of natural stone separates granite from "just one building material." However, despite the many processes involved in this, natural stone remains very competitive. In many cases, it is rated lower than solid surface products, although a solid surface is obtained for a small fraction of the cost. Natural stone is in the same class. The only natural choice is natural stone.
