We recently received a query from one of our readers looking for more information on Caesarstone’s manufacturing process. We decided to create an article that will help answer any questions when it comes to how Caesarstone is made.
What is Caesarstone?
Caesarstone is an international brand of engineered stone (sometimes also referred to as composite stone) that is predominately made of Natural Quartz. The end result is an almost completely non-porous surface that offers a cost effective substitute to natural stone.
Being an engineered material, the product does not require regular sealing and is much less prone to staining or cracking when compared to natural stone benchtops such as granite or marble.
What Materials are used to make Caesarstone?
Caesarstone benchtops are made of a unique blend of up to 93% Natural Quartz combined with pigments and polymers to create different styles, patterns and colours. Caesarstone benchtops are mostly available in a smooth, semi-sheen finish with some colours (such as their Rugged Concrete for example) feature a textured or matte finish to mimic the look and feel of a concrete benchtop.
How is Caesarstone made?
Each step in creating Caesarstone’s spectacular benchtops is outlined below:
Feeding & Mixing
After all raw materials are thoroughly inspected, they are combined and mixed together.
Moulding & Pressing
The mixture is then poured into a mold to form a slab size of 3050 x 1440mm.
After being compacted in a special vacuum, the slabs are then vibrated at a pressure of 1000 tonnes to remove any inconsistencies and air pockets.
Once the slab is formed it is then gauged, calibrated and polished up to Caesarstone’s popular and highly durable semi-sheen finish.
Each slab is thorouhgly inspected to ensure a quality product.
Finally, each Caesarstone slab is labelled and marked with all relevant information.
The video below offers a snapshot into Caesarstone’s factory, providing an excellent summary of the manufacturing process of this amazing product.
A lot of care is taken to ensure Caesarstone’s manufacturing and distribution procedures have a minimal effect on the environment: 95% of all water used throughout the process is actually recycled and stone dust is not only kept to a minimum, but is also cleaned at every step of the way to ensure both worker and customer health and safety.
The next step of course, is fabrication! When you select a Caesarstone product for your home, you should always ensure it is installed by a qualified Stonemason – Proper installation of the product is crucial to avoid any cracks in your benchtop later on! Not only that, but your warranty will be voided if the work has not been carried out by a qualified Stonemason!
You can find out more about the fabrication process in this excellent video from Form-Rite.