On Site Fabrication

Stone Fabrication Process

The natural stones are cut and taken from the quarry in blocks. These blocks are then cut into 1 1/4" slabs. The slabs are then shipped to Shaker Hill Granite Company for fabrication. The cut slabs are shaped, polished and installed by our installation team. This sequence has been changed over the years. In the fabrication process, three basic types of machines have been used. They are saws, polishers and routers.

Diamond wire saws are used to cut the stone slab into proper shape for its application. Circular metal blades studded with diamonds are used and water is sprayed on the blade to cool it during the cutting process.

Routers are used to create edge profiles on slab and sink/cooktop cutouts. For countertops and tables standard edges are available from simple to highly decorative edges.

Polisher will grind down the natural rough surface to complete as per consumer desire. Stones like marble and granite can be polished to give a mirror finish. It consists of rotating pads which are surfaced with an abrasive substance. Most polishers produce variety of finishes the smooth, shiny mirror finish and decorative finishes like flamed, tumbled, or hammered.

Then the series of saws and routers will cut the slab into correct dimension, appropriate holes and shapes of the edges. The computer will control the entire aspect of the shaping process. After the performance of the saws and routers the countertop will move on to polishing machine, to grind the surface of the slab to the desired finish. The machines having laser eyes will ensure that the finish is perfect across the entire countertop. To finish the edge profiles, Edge polishing machines are used. Its contribution is significant in reduction of the cost of natural stone countertops, tables, sinks, tiles, and fireplaces, and continues to bring the costs down. It has increased the quality of the finished product.