CLASSIFICATION OF NATURAL STONES SUCH AS PORCELAIN, MARBLE, AND QUARTZ PART 2

Man Made Materials

As you may have concluded, what we refer to as "man-made" materials are formed in a way other than that of the "natural materials" previously mentioned. These materials are brought about through the efforts of very skilled, talented, and intelligent humans that have created processes through which materials are produced. What are the characteristics of these kinds of materials?

Characteristics of Man-Made Materials

As we mentioned earlier, natural stone material has some attributes that make it what it is. Porosity is one of those attributes. But man-made materials do not, for the most part, have these properties. Nearly all of the man-made materials we will mention here are non-porous.

This trait of man-made material means that it will not absorb moisture like natural stone. Water and other liquids that come into contact with man-made materials simplstayys on the surface until they evaporate and are cleaned up, or chemical bonds the material.

Another trait that is found in man-made materials is that they are made to be relatively hard. Natural stone occurs with varying hardness depending on its type. On the other hand, man-made material is specifically fashioned to be hard so it will hold up under normal wear and tear and then some.

Examples of Man Made Materials

There are not as many variations of material from the man-made group as there are from the natural stone class, but there is a nice selection from which to choose. The following list includes some of the man-made materials that are popular for use as hard surfaces.

• Quartz
• Solid
• Surface
• Porcelain
• Sintered Stone

Like the list from the natural stone materials, the man-made materials vary from one another. So, the natural question that comes up then is which is better, natural or man-made materials?

The importance of having adequate equipment to cut dekton and porcelain

Dekton, among other alternative stone materials, continues to grow in popularity for applications such as countertops, flooring, and both interior and exterior wall cladding. Being a hard dense product, it is crucial to use appropriate tooling during the fabrication process. Carlos Sustaita, production director for STA Granite, provides several important tips of advice for those working with compact sintered stone.

Why do products such as Dekton need special/different tools than those that are used for cutting granite and marble?

Material hardness is the key to understanding why you need different tools to fabricate Dekton. The material has a

very high density (ultra-compact), which means that if you don’t use proper tools, you can either break the tool or the material or even worse, damage the machinery.

The cutting process requires trimming the edges to release tensions. Then you have to follow cutting recommendations, which include using plenty of water, the proper speed, feed rate, etc. Once you follow the rules, it’s a piece of cake.

When doing edging on Dekton, What is the difference in the process compared to a natural stone?

In this sense, Dekton’s edge is very easy to work with since the material is very homogeneous, and it is easy to get very good results. Any fabricator can do it well on the first attempt.

What are some common mistakes that fabricators are making when it comes to cutting this material? And, what are some common mistakes with doing edging or doing sinkholes or something?

The main mistake is trying to fabricate Dekton as if it was a granite or quartz composite. You will fail if you use the same tools, speed rates, and so on. Another common mistake is trying to cut Dekton in uneven support. It is a common source of problems too.

Sometimes people ask about what machine is best to cut Dekton. I believe the key is not the machine but the tools and proper maintenance. I have seen people with very modest equipment doing amazing things and the other way around.

7 Keys for Cutting Ultra-Compact and Sintered Dekton and Porcelain Materials

1. Water

It may seem too simple or too intuitive to matter, but less than adequate water AND hoses positioned incorrectly is the most common error causing headaches among cutting these materials.

2. Check your table level

One of the more overlooked aspects of successful cutting is, to the degree that your table is not level in the horizontal plane, vibrations will occur. This unevenness can result in chipping and likely breaking the edge of your slab.

3. Buy the right blade

As cliche, as it may sound, choosing the right blade for the material you are processing, is critical.

4. Removing tensioning strips

While each manufacturer of ultra-compact and sintered porcelain materials may, or may not have tensioning strips built into the perimeters of each slab, if they are not removed before cutting, the slab is at higher risk of cracking or breaking.

5. Feed rate and RPMs

Using the same feed rate and RPMs you may be accustomed to when cutting other materials can be a recipe for trouble. Unlike fabricating more common materials such as marble and granite, we’ve seen the most success cutting ultra-compact and sintered porcelain materials when following a systemized approach is used.

6. Avoiding Plunging

While plunge cutting tends to be of little concern for most sawyers when cutting ultra-compact and sintered porcelain materials it can pose big problems resulting in cracking or breaking your slab.

7. Cutting Sinks

Projects requiring a sink cut-out can be an obstacle many fabricators dread. Since we already know plunging is not the ideal way to go about this, what are your options? When preparing a sink cut-out, it is advised to drill each of the four corners with a 1/2” core bit before to start initiating cutting.