HOW TO REINFORCE STONE COUNTERTOPS, PORCELAIN, DEKTON, QUARTZ, MARBLE, ETC. PT 1

During the countertop fabrication process, situations arise when some aspect of the project requires the stone to be reinforced. After all, you want the hard work you put into the surface to remain intact. A crack in the slab, a chip or break near a seam, or some other mar caused by a weakness in the material can quickly undo all the work you put into the project.

Stones that benefit from reinforcement

In stone fabrication and kitchen countertop work in general, reinforcing the countertop material is a practice used to ensure that the material is resistant to cracking that may arise from the settling of the house. Also, support brackets are used to reinforce overhangs so that the weight on one edge does not break the stone. What materials can be used for kitchen worktop surfaces and could benefit from reinforcement techniques?

• Granite
• Marble
• Dekton
• Quartz
• Onyx

Why Reinforcing Stone Countertops Is Needed

Why do stone countertops need to be reinforced if they are fashioned from solid rock? Stone slabs are durable, aren't they? The answer is yes. Natural stone is very durable. When you think about it, these materials have held up for millennia. However, there are a few things to keep in mind about stone surfaces and how they go from solid rock to become a countertop.

The first thing to remember is that the slabs are "sliced" off a block of solid rock, so the slab is not as thick as a solid chunk of stone. As a result, the slab is somewhat more vulnerable to its weight.

Another thing to remember is that every time a section of material is removed from the slab (e.g. sink cutouts), the narrow strips around the cutout are weaker since the slab on either side of the cutout is just as heavy as it was before the hole was cut, but afterward, there is less material to support it.

Finally, when laying out the countertop, you may need to cut the slab into multiple pieces to get the stone in the proper shape so it will line up correctly with the cabinetry in the kitchen. These seams can put stress on the stone's edge along the seam.

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.