Natural stones such as marble and granite have long been used in residential and commercial buildings to enhance their appearance. However, there are a number of drawbacks to using these stones that make factory-made quartz a better alternative to these stones.
Some of the main disadvantages include natural stones are susceptible to stains, they have natural features in the form of cracks; they are not as smooth; they are not elastic enough; they are not seamless, so it is difficult to have length accuracy.
Natural stone has been used for many years for its durability, strength and other strong properties, but quartz stone offers a better alternative to these stones because it is stronger and does not possess the poor qualities of natural stone.
Overview of Quartz Minerals
Quartz is a mineral that forms crystals due to extreme pressure. As a compound, it consists of one part silicon and two parts oxygen. It is considered to be the most abundant mineral that can be found on the Earth's surface. Through its unique properties, it is one of the most useful minerals.
At the same time, this mineral comes in different colors, transparency and varieties. Amethyst, rose quartz, agate and tiger eye quartz are some of the popular quartz varieties. It is abundant in sedimentary, metamorphic and igneous rocks. It is known for its high chemical and mechanical weather resistance.
In terms of use, quartz's color, transparency and luster make it ideal for gemstone and glass making. This mineral is useful in electronics due to its heat resistance and electrical properties.
Engineered Quartz
Unlike granite, quartz does not form any boulders and exists naturally in clusters. While some people are interested in this mineral as part of their kitchen design, quartz in its natural state is considered unsuitable for countertops and any other large slab applications.
However, in order to make quartz suitable for slab applications, it can be converted into other forms such as open-air engineered stone. Engineered quartz is also commonly referred to as reconstituted or reconstituted stone. The manufacturing process involves a mixture of quartz aggregated chip pigments, additives and resin binders.
Engineered quartz stone for floor and countertop applications comes in a variety of colors, textures and patterns. Depending on the manufacturing process, the texture can be rough or fine. It can then be combined with glass and any other reflective material to achieve a sparkling finish. When the non-porosity of quartz is combined with the durability of granite, high-end and rugged applications are possible.
Quartz Stone Manufacturing Process
As we learn about the quartz stone manufacturing process, we will also introduce the quartz raw material manufacturing process and see how quartz raw materials are manufactured before being supplied to the quartz stone manufacturing industry.
Manufactured From Raw Quartz
Due to its usefulness and fundamental properties, quartz is one of the top B2B products extracted and processed, supplied and exported. As part of the manufacturing process, the mineral goes through the extraction process all the way up to the actual manufacturing process.
1) Quartz Extraction
Quartz can be extracted by open pit mining. On rare occasions, miners have to use explosives when they need to expose deep seams of minerals. But it rarely does because, regardless of its hardness, it is easily damaged when exposed to sudden changes in temperature.
In mining operations, it is common to use excavators and bulldozers to effectively remove clay and soil around minerals. After that, the crystal veins of quartz will be exposed in the rock. Once exposed to the surface, the team will use picks and chisels and other small hand tools to extract the quartz directly from the quarry.
Quartz Stone Manufacturing
1) Raw Materials
When it comes to the manufacturing process of engineered quartz stone, the process begins with the selection of the quartz material for manufacture. It can be any quartz product such as quartz sand or quartz particles.
2) Mix
The selected raw quartz is pulverized and then mixed with other additives in a binder at a ratio of 93% quartz aggregate to 7% res.
3) Slab Pressing
In addition, the mixture will be compacted to form slabs for about 100 seconds using vacuum and vibration methods at 100 tons of pressure. Using this process, it minimizes porosity while reducing water absorption.
4) Heating
After that, the slabs will be cured using an 85-degree kiln for about half an hour. That's all the necessary properties to get stain and impact resistance. To speed up the curing process, steam or an oven can be used. Once this process is complete, the produced slabs are measured, calibrated, polished and then prepared for the packaging process.
5) Cool Down
After curing, hold the slab upright and cool for 24-36 hours with the help of jigs.
6) Trim
The sides are trimmed and leveled.
7) Quality Verification
Shading and size will be consistent and uniform with the help of engineered quartz manufacturing processes. Therefore, it can save time during construction. While the engineered version resembles the pattern of natural stone, it provides a more consistent color, pattern and texture, as well as a uniform appearance. Also, since they are man-made, they can be easily made in large sizes, which can lead to better aesthetics and fewer joints.
In Conclusion
The market for quartz minerals is growing, so it's no surprise why mining and manufacturing processes are also advancing. The beauty of quartz is that it is so flexible that it can be used in different applications, from interior design to jewelry pieces to larger industries. Therefore, everyone can expect high-end use, as well as individual benefits, as quartz goes through a thorough and careful manufacturing process.
