Fabrication

fabrication
Once we have templated your worktops, the next stage in their journey to become worktops is fabrication in the factory. For those interested in the manufacturing process, below is a description of what happens. You can also watch our video “From granite slab to kitchen worktop – see how its done”

Cutting the slabs

  • Firstly, the slab edges are cut to straighten them, particularly if they are granite slabs.
  • When cut, the worktops which are to be seamed together are checked for correct colour match
  • Any straight lines are cut with a flat diamond disk on a bridge saw
  • Any curved lines are manually cut with a router with a diamond finger
  • Holes are machine cut with a drilling machine and diamond cup drill

Inside Corners

  • L or U shaped worktops are always fabricated with a join on the inside corner between the slab pieces, never a diagonal cut.
  • A join is created for every change in direction of the surface.
  • We always template for the fewest number of joints possible. This is determined by the size of the slabs available.

Cut-outs

All kitchens require installation of accessories, such as sinks and hobs.

  • Cut-outs can be polished for undermount sinks or unpolished for inset sinks and hobs.
  • Drainer grooves are cut with diamond tipped flutting wheel and can be applied to one or both sides of the sink.

Undermount sink installation

  • The sink is positioned flush underneath the surface of the worktop
  • The cut-out is fabricated slightly smaller than the sink leaving a small overhang, so that the join between the sink and the worktop surface is not visible.
  • The edges are bevelled and the inside of the cut-out polished.

Over-mount or inset sink installation

  • The lip of the sink or hob extends above the surface and rests on top. The edge of the cut-out is smoothed with a grinding wheel and remains unpolished
  • A space is left between the sink wall and the surface

Polishing Edges

  • Edges are always polished to the same surface polish of the slab.
  • Only the edge of the slab is polished, never the surface.
  • Water cooled tips are used for polishing as dry polishing can overheat and damage the area
  • Diamond polishing pads are used with water, working with 6 pads through grit sizes from coarse down to fine.
  • Each stage of the polishing removes the marks from the previous stage and only when a uniform finish is achieved is the next pad moved onto.
  • We never polish edges in excess of the factory surface polish of the slabs.

Types of Polished Finishes

  • Polished finishes are smooth and shiny.
  • These are created by using Diamond Polishing Pads in a progressive manner through all the grit pads.

Honed Finishes

  • Sometimes a slab may have a non-polished surface, often referred to as Honed or Matt.
  • The honed surfaces are smooth, but not shiny.
  • Regular polishing brushes are used with a honed finish with plenty of water to prevent overheating.
  • 4 progressive stages work through the brush sizes starting at grit size 120 completing with 500.

Textured/Viento Finishes

  • These are slightly coarse and have a low gloss finish
  • To create a textured edge, diamond polishing pads and diamond brushes are used with plenty of water.

L-shaped Edges

  • L-shaped edges or a downstand is where a strip of quartz or granite is glued along the edge of the work surface in order to create the illusion of a thicker slab.
  • This process is more complex and time consuming than single thickness edges. It does produce however a rich aesthetic appearance.
  • L-shaped edges can be fabricated to any height, shape and depth.
  • The height of the edge is independent on the thickness of the slab. So for example a 13mm slab could be used with an L shaped edge of 40mm, or larger.
  • The L-shaped edge allows the continuation of a design around an edge.
After fabricatation the worktops are ready for fitting or installation. Read the next section Installation to learn more.

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  1. You bring in a sample of your cabinet door & kitchen plan
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