We love natural stone. And there’s a lot to love – durability, beauty, refinement. The finished project, whether it’s a countertop or shower surround, never disappoints. Stone is a durable crafting material that always produces a unique, exquisite surface that can last a lifetime. But while many of us are familiar with the finished product, we know less about its origin. The process begins in a natural stone quarry, where transforming raw stone into architectural and design elements is complex.
The first step is to identify a suitable quarry site, which is a place where stone is mined. They are usually built right atop a deposit of the desired material, like marble. A lot of different equipment is used in the process of mining natural stone, too. Excavators, diamond-wire saws, wheel loaders, dump trucks, and cranes are just a few.
Finding a suitable site for a quarry is a challenging task. It involves geological surveys, environmental impact assessments, and careful consideration of the stone’s quality and accessibility. Once a site is selected, the process of uncovering the stone begins.
The quarry is a fascinating space, too. It’s a geological wonder all on its own. The quarry walls, sculpted by millions of years of geological activity, often reveal ancient and intricate patterns. The quarry itself is just as gorgeous as the end result.
Modern Quarrying Techniques
Traditional quarrying techniques have often involved manual labor and explosives, a process that could be both dangerous and inefficient.
Technological advancements in mining have come a long way, but the tried-and-true method (and also the oldest) involves driving a wedge into the natural stone along a pattern. Miners will then use a ‘feather,’ which is a small contraption set into a drilled hole in the stone. The wedge is then hammered into the feather, creating and expanding a rift in the stone that results in its eventual separation.
Explosives are also used, though this is not common today. This involves drilling a pattern into a natural stone surface, filling the holes with explosives, and blowing a chunk of stone loose. This method, however, is considered inefficient because the stone itself can be damaged in the process.
While these methods can still be used today, advancements in technology are transforming the industry. Diamond-wire saws, capable of slicing through even the hardest granite with remarkable accuracy, have largely replaced explosives. These saws consist of long wires, usually steel, that are beaded with diamonds. They are attached to an engine that spins the wire around a select stone, sawing through it to create more manageable chunks.
The saws we use to produce our custom designs here at Stone Central are a bit smaller and more traditional. The saws used in quarries, however, are often hundreds of feet long. They are guided along predetermined cutting paths and capable of creating massive blocks of stone ready for extraction. These diamond-based saws are also useful for grinding, polishing, and drilling.
And because stone dust can be hazardous to workers’ health, water is used to ‘dampen’ the dust. This makes it too heavy to go airborne. Years of innovation have made stone mining fast, efficient, and safe.
Stone Extraction and Processing
Once freed from the quarry face, these colossal blocks, sometimes weighing several tons, are carefully transported to a staging area. Here, they undergo further processing, including cutting, shaping, and polishing.
At this stage, the stone is usually turned into slabs that are convenient for transportation. This is also why natural stone is sold by the slab. We get it straight from the quarry in this shape.
Because of the particularity of each stone, slabs themselves may differ in shape and thickness among the different types natural stone. Working with an industry professional such as ourselves can help you find a slab that meets your specific requirements.
Once you’ve selected your stone, it can be shaped with precision to meet any form you need. Once cut, the stone is installed with special adhesives that ensure it stays in place.
Making Natural Stone a Part of Your Home
Making natural stone a part of your home integrates beauty into your everyday life. It turns the mundane into something marvelous. Even something as simple as a backsplash can take on a regal air when made from this ornate material.
This is because the beauty of natural stone isn’t just visual; the effort that goes into creating each slab is awe-inspiring. Extracted with care and precision, a freshly installed piece of granite, quartz, or marble is a testament to the beautiful things our natural world can make.