The Definitive Interactive Guide to Sintered Stone Fabrication

Your essential digital tool for flawless fabrication and installation. Navigate to any section for immediate, task-specific instructions.

Material Properties: Sintered Stone vs. Alternatives

Understanding the unique properties of sintered stone is the first step to successful fabrication. Its extreme hardness is paired with high internal tension, making it behave like tempered glass. Unlike granite or quartz, its primary challenge is managing this internal stress to prevent fractures. This section provides a comparative analysis to highlight these critical differences.

Comparative Analysis: Key Metrics

Hover over the bars to see precise values. Note the significantly higher Modulus of Rupture (flexural strength) of Sintered Stone, which indicates its strength under ideal conditions, but also its brittleness when stress is localized.

Pre-Fabrication Protocol Checklist

The most costly errors happen before a blade ever touches the stone. Following this pre-fabrication protocol is not optional—it's the foundation for a successful project. Use this checklist to ensure every critical step is completed.

Safe Handling, Transport, and Storage

Sintered stone is most vulnerable when being moved. Improper handling can introduce micro-fractures that lead to failure later. Every movement must be deliberate and use specialized equipment to prevent flexion and impact. This section outlines the mandatory protocols.

Transport & Unloading

  • Vertical Orientation: Always handle and transport slabs in a near-vertical position.
  • Mechanical Lifting: Use forklifts with booms or gantry cranes. Manual lifting is prohibited.
  • A-Frames & Straps: Secure slabs to sturdy A-frames with wide webbing straps. No metal chains.
  • Rubber-Jawed Clamps: Use specialized clamps to prevent edge chipping.

Workshop Mobility

  • Vacuum Lifters: Use multi-cup vacuum lifters rated for the slab's weight. Inspect cups daily.
  • Support Cutouts: Handle pieces with cutouts with extreme care, keeping them vertical. Leave a "stiffening strip" in large cutouts until installation.
  • Flat Support: Ensure work tables are perfectly flat, clean, and fully support the material.

Storage & Racking

  • Certified Racks: Store slabs vertically on certified A-frames or heavy-duty slab racks.
  • Inspect Racks Regularly: Check for damage like cracked welds or bent members.
  • Full Support: Ensure slabs are fully supported. Thin slabs may need a solid backing.
  • Protect from Impact: Store in a low-traffic area to prevent accidental damage.

Interactive Cutting Guide

Cutting sintered stone is a precision operation. Success depends on using the right tool with the right parameters. Select your machine below to get specific, manufacturer-recommended settings. Remember the universal principles: the workpiece must be on a flat, solid, clean support (preferably with a rubber mat or wood board underneath), and an abundant, continuous flow of clean water for cooling is **mandatory** for all operations.

Bridge Saw Fabrication

Use high-performance diamond blades specifically engineered for ultra-compact surfaces. Miter cuts require significantly slower feed speeds. Reduce feed rate by 30-50% when entering or exiting a cut to prevent chipping.

Slab Thickness (mm) Blade Ø (mm) RPM Cut Type Feed Speed (m/min)
12 350 1900–2200 Straight 1.2–2.5
20 350 1900–2200 Straight 0.6–1.5
12 350 1900–2500 Miter (45°) 0.5–0.75
20 400 1500–2300 Miter (45°) 0.5–0.75

Waterjet Fabrication

The preferred method for curves and internal cutouts. The most critical step is the initial pierce. **Always use a low-pressure piercing cycle** (e.g., 700 bar / 10,000 psi) to avoid shattering the material before ramping up to full cutting pressure.

Slab Thickness (mm) Piercing Pressure Cutting Pressure Abrasive (g/min) Speed (mm/min)
≤ 6 700 bar 3500 bar 130 1500–1800
6-12 700 bar 3500 bar 160 1000–1500
>12 700 bar 3500 bar 190 800–1000

CNC Machining

CNC provides ultimate precision but requires specific tooling and programming. Use tools designed for hard ceramics. Program toolpaths with smooth, arcing entries and exits—never sharp 90-degree turns. Secure the workpiece with vacuum pods, especially under the drop-piece of a cutout.

Operation Tool Type RPM Feed (mm/min) Max Removal/Pass
Hole Drilling Thin-Wall Core Bit 7k–10k 80–120 N/A
Cutout Milling Finger Bit 7000 300–400 0.5–1.0 mm
Edge Profiling Profile Wheels 4.5k–5k 300 Varies
Surface Engraving PCD Engraving Bit 7.5k–10k 80–120 1.5 mm

Advanced Fabrication: Cutouts & Edges

Cutouts and edges are high-risk, high-value operations. An error here can lead to a complete failure of the piece. The principles of stress management are paramount. This section details the non-negotiable rules for creating durable, chip-free results.

The Golden Rule of Cutouts: RADIUS ALL CORNERS

A sharp 90-degree internal corner is a stress concentration point and is **strictly prohibited**. It creates a weak point where a crack will inevitably form. All internal corners must be machined with a smooth, continuous radius.

  • General Cutouts: Minimum 5 mm (3/16") radius.
  • Sinks & Cooktops: Minimum 10 mm (3/8") radius is strongly recommended.
CORRECT

Radiused Corner (≥10mm)

INCORRECT

Sharp 90° Corner

Cutout Fabrication Steps:

  1. Drill Corners First: Use a diamond core drill to create the relief holes for the corners.
  2. Connect the Dots: Make straight cuts connecting the tangent points of the drilled holes.
  3. Support Drop-Piece: The material being removed MUST be supported from below to prevent it from snapping off and cracking the main piece.
  4. Maintain Distances: Keep at least 50mm (2") of material between any two openings or an opening and the edge.

Edge Profiling & Reinforcement

A sharp edge is a fragile edge. Profiling the edge is not just for aesthetics; it's a critical step for long-term durability and chip resistance.

Chip-Resistant Edges:

All exposed edges should be finished with a minimum 2mm bevel or a 3-5mm pencil round profile on both top and bottom. A larger radius provides more impact resistance.

Reinforcement Strategies:

For pieces with large cutouts, long narrow sections, or significant overhangs, reinforcement is necessary.

  • Rodding: Embed fiberglass or carbon fiber rods in epoxy on the underside of the slab in high-stress areas. Avoid steel to prevent rust.
  • Surface Mesh: Laminate a fiberglass mesh to the entire back surface for overall strengthening, especially on thinner slabs.

Installation: Substrate, Adhesives, and Placement

A perfect fabrication can be ruined by improper installation. The substrate must be perfectly flat and level, the correct adhesive must be used for the application, and movement joints must be incorporated. Failure in any of these areas can lead to post-installation cracking.

Substrate Preparation

  • Perfectly Flat & Level: Maximum deviation of 2-3mm over the entire surface. Use self-leveling compound for floors and shims for cabinets.
  • Structurally Sound: Substrate must be clean, dry, and able to support the material's weight (up to 75 kg/m²).
  • Overhang Support: Any overhang exceeding 200mm (8") MUST be supported by steel brackets or a continuous sub-top.

Jointing: A Structural Necessity

  • Countertop Seams: Use color-matched epoxy and mechanical seam setters to create a tight, level, and invisible seam.
  • Floor/Wall Grout Joints: Minimum 2-3mm for indoor, 5mm for outdoor. Butt-jointing is prohibited.
  • Expansion Joints (Critical): Flexible expansion joints must be installed every 25m² indoors and every 9-16m² outdoors or in areas with sun exposure. They must run through the tile and adhesive down to the substrate and be filled with flexible sealant (silicone), not hard grout.

Adhesive Selection Guide

Using the wrong adhesive is a primary cause of failure. A rigid epoxy is for seams; a flexible mortar is for tiling. For all wall and floor installs, the **"back-buttering"** technique is mandatory to ensure 95-100% coverage and eliminate voids.

Application Recommended Adhesive Key Properties
Countertop Seaming Color-Matched Epoxy Rigid, High Strength, UV-Stable
Countertop to Cabinet Neutral Cure Silicone Flexible, Strong Bond
Wall/Floor Tiling C2S1 Polymer-Modified Mortar Flexible (S1 rating is critical), High Adhesion