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Manufacturing Marble Kitchen Countertops

Evan Zgonis of Olympia Marble and Granite gives Bob a tour of the facility where the kitchen countertops are being manufactured. The marble slabs are brought in from the yard by crane. Once the slabs are brought in, the majority of the process is then automated. The first step in the countertop fabrication process is to square off the edges of the slab with a water saw. After that, the marble is brought to a CNC (Computer Numerically Controlled) machine. The machine's cutting head is controlled by a computer that has been programmed with the dimensions for the countertop design. The designs were created from a template made on site. The key points are marked on the slab, and using a CAD program, they are then fed into the computer. The machine can make complex cuts by utilizing different blades and manipulating the slab, all automatically.

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Manufacturing Marble Kitchen Countertops

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Kitchen Cabinet Installation

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Installing the Marble Kitchen Countertop

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Kitchen Cabinet Design

Clip Transcript For:

Manufacturing Marble Kitchen Countertops

computer-generated transcript - may not be 100% accurate

" We're looking at racks of granite and marble here at Olympia marble and granite in Needham Massachusetts and you'll find. Shops like this throughout the country where you can order your kitchen countertops now in Carrara Italy which has been the center of the marble industry for nearly five centuries as the place where Michelangelo went to. Choose out a block of stone for his -- This is the center of the stone business in the world stone from all over the world even Brazil and Africa will go to Carrara where gang saws -- cut it into slabs like this. And they in turn are shipped all over the world here in Massachusetts we're just looking at one facility one of the top state of the art facilities where our kitchen counters are being kind -- go inside we'll meet. Evans a -- with one of the proprietors here. Now once these slabs of stone come in from the yard into the workshop everything becomes relatively automated."

" Right correct at this point the the forklift has brought it here these suction machine vacuum device will grab the stone at a vertical position. Turn it to the horizontal so this is a little a little so the suction cups except they're very strong and very very very they're hanging by cable off of crane system that can travel around the workshop. Kevin how much does when -- way. About eighteen pounds a square foot so we're looking at about. 800 pounds. A vacuum machine like this allows us to deal worked with the happy slash. Just set a position properly."

" And so the first. The first order -- business is to square the sheet off right right."

" So it is a classic water saw. The classic water -- all the water is recycled water. Heavy use some water to prevent the diamond from burning -- And running to a field with the."

" It's all been cut this to decide that we need for the island. Well these -- this is the stone who's gonna be our island countertop right. Now it assumptions just. Do their magic and lift up this heavy stone and right up."

" And they've got a look around us. Right it's being picked up by the polished side. So it's going to be brought over to the Dolly and looked around set up ready for the CFC issue. Finality. The slab that's been cut for the island will be picked up. I'm afraid set up on the job table. It'll slide to designated points that it is already. Set it set up with the program right now Evan we had Ricardo out at the job site making templates for these. Stone countertops how does how does the template interface with the computer here. Thanks -- do Bob is that we take the template that. The settlement weapon -- and then key points. A mock. On the back of -- which brought into the cab program. Do. At that point for the flooring is made of the template. And the computer now understands what it -- had to write down the scale. This setup can be customized to any shape any shape any design in this particular capability when not. Yeah we'll look at that the piece on the reverse right because Paula if you want the out the vacuum to hold the policyholder -- there was no movement. Once the milling gets done. The casinos -- We program. Fresh positions you know. We'll now thoughts of the mill blade and will position itself. Begin the point. Where are we sorry I hope all of so there's different cutting heads involved and it just changes."

" Bob it's a slow it is -- profit for the right. My -- for site. -- The beautiful part about this is that. A -- IC NC machine can produce two to three kitchens a -- on the on the wall followed."

" Why haven't you. It's equipment like doesn't really make this. They're very complicated."

" Quite the village -- it or how little homework thank through."

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Kitchen Countertop Options by Price

Here s another great tip from BobVila.com. Countertops are such a big part of any major kitchen remodel and there are so many new options, deciding on the best choice can seem a little daunting. Starting with the budget can make the decision easier. Countertop materials range widely in price, anywhere from $11 to $200 per square foot installed. Generally speaking, while high-end countertops can boost your kitchen s look, you don t want them too far out of sync with the price point of your cabinets and appliances. Heavier materials like concrete and natural stone can also require added support, so cabinet and countertop quality should be consistent. Once you ve decided what you can spend, you can narrow your countertop options. For smaller budgets, get creative with ceramic tile at $11 to $30 per square foot. Or, check out some of the new high-tech options in laminate, which can be fabricated and installed at $36 to $45 per linear foot. Solid surface countertops offer lots of creative color options from $40 to $60 per square foot installed, and an integral solid surface sink is a great easy-care feature. In the $50 to $100 range, there are many choices. Among them are wood and butcher block with its warm beauty and natural antimicrobial properties; natural stone like slate, soapstone, marble, travertine and granite with all the quirks of nature built in; and engineered quartz countertops with a wide color range and more consistent patterns. Stainless-steel and concrete countertops are generally the most expensive at around $100 on up per square foot. But they can also be fabricated with integral sinks and they re great if you re going for that restaurant or industrial look. Find out more at BobVila.com: the ultimate home improvement web site! 2008 BobVila.com

Installation of the Marble Kitchen Countertop

Bob and Chris Vila enter the penthouse apartment to look at the installation of the kitchen countertops. This particular kind of Italian marble-like stone is a schist called Pietra Cardosa, from the area of Cardosa, Italy. It is fairly porous, with great abrasive resistance, but may require a bit more care than the average countertop as it cannot be polished to a shine. Nick Tagios from Tagios Tile and Marble explains the attachment of the countertops to the Cherry Craftline island cabinet. First a bead of silicone caulk is laid down to adhere the stone to the wood. Tagios and crew level the top with shims. To install the bridge that will become the kitchen�s island sink surround, steel bars are added between the slabs by sawing out a line and then sealing the bars inside with the stone-colored epoxy. Supports are attached to the sidepieces of stone and the bridge is laid between. To eliminate the line and space between the two stone slabs a dyed two-part epoxy is added. After the epoxy dries the counter top is sanded to remove any excess epoxy.

Installing Quartz Kitchen Countertops

Dupont has provided a new product for the solid surface kitchen counters called Zodiaq, which is made of natural silica, quartz, and about eight percent polymer. Zodiaq quartz surfaces are made of a naturally refractive material that gives it a subtle sparkle. It is extremely hard making it resistant to scratches, chips, cracks or dulling and not porous making it hard to stain. The man-made stone countertops are easier to care for than 100% natural stone and are installed in the same manner. In our kitchen the installer used a technique called a mason�s mitre that gives the joint between the pieces additional surface area for the polyester epoxy to bond. The epoxies from Dupont are specially formulated to match the countertops color. David Miller from Desavino and Sons is on hand to explain the countertop installation. One of the unique things about a Simplex house is the exacting consistency of measurements. A digital image is sent from Simplex to the countertop fabricator and they either create a template from the image, or cut the countertop directly from the image provided by Simplex.

Installing Corian Countertops and Sink

Bob is with Andrea Johnson from Corain as Scott Lawyer of Solid Surfacetops arrives to install the shop-fabricated Corian countertops in the Punta Gorda kitchen. This counter features an integral sink that is attached to the counter by the fabricator in his shop. The seam between the sink and counter is made with liquid Corian that forms an impermeable and invisible seam between the sink and the counter. These integral sinks have no edge or grunge line, which makes for easy cleaning and a sleek look. The Canyon color chosen by the homeowners is dark, like the Porcelanosa metallic-look tile. Johnson remarks what a good job the homeowners have done matching the counter color to the tile. Bob adds that the cool, dark colors bring a soothing, cooling presence to the interior spaces of this hot-climate home. Bob then watches as the crew from Solid Surfacetops installs the counter pieces and creates an invisible seam. The two sections of Corian are fitted with wood blocks that will hold the clamps as the sections are glued with liquid Corian that matches the countertop and clamped tight to set. Once the glue has set and dried for about 25 minutes, the clamps are removed and the seam is sanded to give a seamless look to this two-piece installation.