HOW TO INSTALL STONEWORK FOR PORCELAIN IN YOUR HOME

Porcelain installation requires some basic knowledge as well as the proper tools and equipment to perform the installation well. Having the right machines, blades, and bits makes a big difference in the outcome of the installation. In this article, we will take a look at some popular porcelain brands and what kinds of porcelain products these brands offer. Additionally, we will briefly look at some equipment that is needed to install porcelain.

Porcelain Brands to Install

Porcelain surfaces are not new. Porcelain has been used for design and decor for many many years. Porcelain tiles have been used for covering surfaces including floors, walls, and backsplashes. These surfaces were installed in kitchens and bathrooms of all shapes and sizes and a variety of price ranges.

In recent times though, new applications for porcelain surfaces have emerged on the scene. Since porcelain tile and other kinds of porcelain seem to be a staple of the design industry there is a good deal of porcelain brands available from which to choose. Some of the more popular brands of porcelain include the following:

Each porcelain brand offers a variety of surfaces including tile, panel, slab, and even countertops in some cases. This is because porcelain is so versatile that it is used for many applications. However, there are some important things to know and have when working with porcelain. Let's see some of them now.

Proper Tools for Installing Porcelain

Working with porcelain involves a specific set of skills. And if you're working with a large panel or porcelain countertops, there are a few extra practices to keep in mind. Even more than knowledge, the right tools are necessary if great results are to be achieved. Even the most skilled porcelain fitter can have a difficult time with a project if the equipment they are using is not working right.

Cutting Porcelain

Cutting porcelain surfaces, whether it is a tile, a panel, or even a countertop, is different from cutting other surfaces. Porcelain is an extremely hard material that must be cut using a diamond blade that is designed for the task. Other materials like natural and engineered stone are hard, but they are not as hard as porcelain. Porcelain is among the hardest materials used for countertops. Using a diamond blade for cutting porcelain is one of the key factors in getting great results when working with porcelain materials.

In addition to using the correct diamond, bridge saw blade, knowing how to use the blade is imperative. A good practice is to ease into and out of the cut when using a diamond blade. Cutting the material in this manner will help to avoid chips that can happen if the cut is started at full speed. There are other techniques for preventing chips when cutting porcelain. Depending on the type of porcelain, the size, and the thickness other techniques may be acceptable as well.

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.