As proud homeowners, we love stepping into our kitchen in the morning and admiring the gleaming surface of our granite countertops. The rich colour and unique pattern add a touch of timeless elegance to the space.
But have you ever wondered about the fascinating journey your granite took to reach your home? This journey, from granite production deep within the Earth to the intricate quarrying process, is a testament to nature's artistry and human ingenuity.
So, let’s find out how the granite reaches your countertop from the queries.
The Formation of Granite
Granite is considered one of the hardest natural rocks, and a lot of it has to do with its formation process. Millions of years ago, molten rock deep within the Earth's crust began to cool and solidify under immense pressure. This slow and fiery process eventually gave birth to granite.
Unlike volcanic rock that cools rapidly above ground, granite's formation happens miles below the surface, allowing for the formation of large, coarse crystals of minerals like quartz, feldspar, and mica. The different minerals cool at varying rates, leading to the formation of visible crystals within the rock. These crystals, combined with natural variations in mineral concentration, make each granite slab unique.
These minerals combine to create incredible strength, durability, and the vast array of colours and patterns we see in finished granite products. So, it is fair to say that the breathtaking beauty of granite countertops starts long before the quarrying process even begins.
The Quarry
Even though granite production originally began under the earth’s crust, for us, it starts at the queries. The quarrying process starts with carefully choosing a location where a vast deposit of this stone may lie underneath. In this process, help is usually obtained from geologists who use different techniques to pinpoint promising areas where manufacturers can find both quality and quantity of granite reserve.
The next step in the quarrying process is the extraction, which is a combination of precision and power. Controlled blasting, strategically placed by experts, breaks the granite into manageable chunks. Specialised heavy machinery then takes centre stage. Powerful excavators with clawing buckets carefully remove the loosened rock while massive haul trucks transport the granite blocks to the processing facility.
However, the quarrying process doesn’t end here. As much as it is important to find the right quarry, it is also important to implement sustainable quarrying practices.
This includes minimising waste during the extraction process, implementing dust suppression techniques, carefully reclaiming the land after the quarry reaches its operational lifespan and so on. After extracting the rough granite boulders from the quarries, the next stage of granite processing is turning them into slabs.
From Rough Block to Slab
The granite blocks go a long way before reaching your kitchen countertops. The next stage of granite production and making it suitable for use is shaping it up. Here’s how the process looks from end to end.
Transporting the blocks
The granite blocks are massive when they are taken out fresh out of the queries. Sometimes, they can even weigh several tons. They can't exactly be loaded into a regular pickup truck! Instead, special heavy-duty trucks with super-strong cranes carefully lift the blocks and transport them to factories where they'll be transformed.
Slicing and dicing
Transforming the rough blocks into usable slabs involves some serious slicing and dicing. However, since granite’s hardness is between 6 and 7, it is not possible to cut them with metal saws. Usually diamond saws are used to slice granite as diamond has higher hardness than granite.
These are powerful saws embedded with industrial-grade diamonds. The "diamond teeth" allow the saws to slice through the granite with incredible precision, ensuring the slabs are all the same thickness.
But cutting isn't the only story here. The process can generate a lot of heat and dust. To keep things cool and minimise dust, water jets are used. These jets act like high-pressure assistants, spraying cool water on the blade and the granite as it's being cut.
Polishing
The slabs you see at the store aren't quite ready for prime time yet. While the cutting process reveals the natural beauty of the granite's patterns and colours, the surface is still a bit rough. A meticulous polishing process is followed to unlock the stone's full potential.
For this granite processing, industrial polishing machines are used, which are equipped with special pads that are kind of like super-powered sandpaper. As the slabs move through the machine, these pads gently buff the surface, removing any remaining roughness and revealing the granite’s patterns.
This last step is like an artist pouring varnish on an oil canvas to enhance the beauty of the picture.
Fabrication and Installation
Now that you have beautiful granite slabs, it's time to create the perfect countertop for your space. This is where fabrication comes in. Skilled craftspeople use templates of your countertop design to precisely cut and shape the slabs. They may also create cutouts for sinks or cooktops and choose an edge profile that complements your kitchen style.
Finally, the installation happens when experienced professionals carefully manoeuvre the granite countertops into place, ensuring a seamless fit and proper support. They'll secure the countertops and add finishing touches like caulking, leaving you with a stunning and functional centrepiece for your kitchen.
