Process

Kingdom Stone INC.

SLAB INSPECTION:

All slabs should be inspected prior to fabrication in sufficient lighting conditions.

* Slabs should be checked for the following:

  • Shade Variation
  • Sheen Variation
  • Surface Imperfections
  • Slab Damage§ Flatness

TEMPLATE PROCESS:

Templating Countertops

After getting your approval, we will request to deposit 60% of the amount to further proceed to template stage. Once the cabinets are installed, our professional ‘templators’ will visit your place to move further with your project. The location of seam and faucet is determined during the templating session. It is strongly recommended to check the sink size before placing an order for new sink. You can ask our sales team if you have any doubt about the size.

Before Templating:

All the crucial elements of the kitchen such as sinks, RO filters, hot water dispensers, stove, cook top etc. must be available before templating process.

New Kitchen

You must notify your kitchen contractor about cabinet installation date to avoid any delay in the scheduling. Make sure all the cabinetry and other elements of the countertops must be leveled and properly installed.

Existing Kitchen

Clear the countertops of appliances and decor. Kingdom Stone Inc employees will not be held responsible for any damage of articles or surface.

CUTING THE STONE:

The stone is then cut using either a water jet or a bridge saw. Historically, the bridge saw has been the favored tool, however in recent years the “saw jet” which is a combination of a water jet and saw has come into play.

The bridge saw cuts with a diamond segmented blade, and cuts at a feed rate of approximately 7 feet per minute. The water jet cuts with high pressure water with garnet particulate suspended in the water at a feed rate of 1 foot per minute. You are probably asking, who would cut with a water jet? The benefit of the water jet is that it can cut circles, radius’, or any intricate pattern, where the bridge saw cuts only straight lines.

Recently, a more specialized tool has come to the marketplace. A saw jet, which has a saw head and a water jet built into it. You program the saw jet with the parts you need cut, it then determines where to use the water jet and where to use the saw, giving you the best productivity of both worlds.

Once the pieces are cut from the large slab, those pieces are forwarded to a CNC machine and with the help of a vacuum lifting system, the granite countertop pieces are then fabricated.

FABRICATING:

In this phase of the stone fabrication, the cutouts for your undermount sink, cooktop, or holes for faucets are all made. The first step is cutting the stone to approximately 1/16 of an inch of its final size. Then, the CNC (Computer Numerically Controlled) machine is programmed to know the size of the stone or stones on the table. You can put multiple pieces of stone on the table and work on them together. The CNC machine is then programmed to know where the stones are located and what to do to each of those pieces. Since every stone has different working characteristics, it is key to have an experienced and knowledgeable CNC machine operator. It is truly a job where artistry and technology meet to produce the optimal finished product. Some stone materials require the CNC machine to move more slowly, some require stone to be entered in a certain way. Without this industry experience, the fabricating process may not produce the best end result we are looking for as consumers.

Once the holes are cut in the granite the edge is shaped by the CNC machine before the countertop is taken to final polish. There are a variety of stone edges to choose from, but the versatile CNC machine can produce any edge you select. For more information on the variety of edges, please see our article.

POLISHING:

We are approaching the end of the process here, polishing the stone. When the granite arrives to the fabricator from our suppliers, the face of slab is already polished. Typically the granite face is not polished or changed at the fabricator’s shop. What does need polished, however, is the edge. Recall during the fabricating step the CNC machine created the countertop edge you selected for your project.

Regardless of the edge, it will now go through a 7 step polishing process. The industry standard is to use diamond polishing pads of increasing grit from 50 to 3,000 to polish the edge. Think of sandpaper in increasing grit to visualize how this process works. The CNC machine first starts with a diamond polishing pad of 50, then 100, 200, 400, 800, 1500, ending at 3,000. The CNC shapes and polishes at the same time, leaving the edge shaped and polished. Similarly, if your granite is ever scratched or damaged, this process is used to repair it.

QUALITY CONTROL & HAND FINISHING:

The final step in the process is inspection of the stones. The stone fabricator will ensure the edges are uniform around all sides of the stone(s). Then they will be reviewed from multiple angles to make sure the light is bouncing of the edges uniformly, and the color of the top of the stone and the edges match perfectly. At this point, we have a finished product ready to be installed in your home.

Stone is truly a piece of natural art, and following this extensive process ensures that your finished product is a beautiful focal point of your project. Mixing experience, technology, tools and artistry is key to a stunning end result.

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