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Engineered stone is a composite material made of crushed stone bound together by an adhesive to create a solid surface. The adhesive is most commonly polymer resin, with some newer versions using cement mix. This category includes engineered quartz (SiO2), polymer concrete and engineered marble stone.[1] The application of these products depends on the original stone used. For engineered marbles the most common application is indoor flooring and walls, while the quartz based product is used primarily for kitchen countertops[2] as an alternative to laminate or granite.[3] Related materials include geopolymers and cast stone. Unlike terrazzo, the material is factory made in either blocks or slabs, cut and polished by fabricators, and assembled at the worksite.
Engineered stone kitchen countertops with undermount sink and cooktop installed. Tops are cut and polished at the fabricator's shop.Engineered stone is also commonly referred to as agglomerate or agglomerated stone, the last term being that recognised by European Standards (EN 14618), although to add to the terminological confusion, this standard also includes materials manufactured with a cementitious binder.[citation needed] The quartz version (which end consumers are much more likely to directly deal with) is commonly known as 'quartz surface' or just 'quartz'.[4]
Manufacturing equipment
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Breton S.P.A., a privately held company of Treviso, Italy, that developed the large-scale Breton method in 1960s,[1] is the dominant supplier of equipment for making engineered stone.[citation needed] Although Breton was the original manufacturer of moulding equipment and still holds multiple international patents on the process, there are now several other companies producing similar machinery.
Composition
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99.9% pure silica in grits and powder form constitutes 90–93% of the body by weight dispersed in a matrix of unsaturated polyester resin (7–10%) mixed with peroxide catalyst and cobalt accelerator which facilitates the curing of the thermoset at ambient temperature. The cured material is normally kept for 24–48 hours before polishing and finishing absorbers are also dosed into the chemical mix to inhibit the discoloration as a result of reaction of unsaturated polyester resin with UV light. Engineered quartz stones manufactured by using unsaturated polyester resins are characterized by low water absorption, superior chemical durability, high hardness, flexural strength and good thermal shock resistance compared to granite and marble.[5]
Process
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Compaction by vibrocompression vacuum process uses elastomeric molds in which a crushed stone/resin mix is cast on a moving belt. The mixture of approximately 93% stone aggregates and 7% polyester resin by weight (66% quartz and 34% resin by volume) is heated and compressed under vacuum in a large press. The vibration helps compact the mixture and results in an isotropic slab with virtually no porosity.[1] Engineered stone is then processed in basically the same manner as its natural counterpart.
Some companies import boulders themselves to crush into agglomerates (stone powders) of various grain size for their products, others simply buy already-crushed stone powders.
Properties
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Engineered stone is typically worked in the same way as natural stone using a water jet cutter or a diamond blade. This is in contrast with solid surface materials which can be cut with regular saws.[6]
The material can be produced in either 12 mm, 20 mm or 30 mm thicknesses. The most common slab format is 3040 mm x 1440 mm for Quartz and 3050 mm x 1240 mm for Breton-based marbles, but other sizes like 3040 mm x 1650 mm are produced according to market demand.
Engineered stone is non porous,[7] more flexible, and harder than many types of natural stone. Since it has a uniform internal structure, it does not have hidden cracks or flaws that may exist in natural stone and also has a color/pattern consistency from slab to slab.[8] Polyester resin binding agents allow some flexibility, preventing cracking under flexural pressure. But, the binding agents often continue to harden, leading to a loss of flexural strength over time. The polyester resins are not completely UV stable and engineered stone should not be used in outdoor applications.[9] Continuous exposure to UV can cause discoloration of the stone, and breakdown of the resin binder.
The material is sometimes damaged by direct application of heat. Quartz engineered stone is less heat resistant than other stone surfaces including most granite, marble and limestone; but is not affected by temperatures lower than 150 °C (300 °F). Quartz engineered stone can be damaged by sudden temperature changes. Manufacturers recommend that hot pots and pans never be placed directly on the surface, and that a hot pad or trivet is used under portable cooking units.
When used as floor tiles, care is required in ensuring compatibility with the adhesive used. Reaction resin adhesives and rapid drying cementitious adhesives are generally successful, but bond failure or discoloration can occur with other cementitious adhesives. Additionally, agglomerate stone tiles are more sensitive to both thermal expansion and contraction and to dampness from underlying screeds, necessitating the inclusion of movement joints at a higher frequency than for stone or ceramic floor tiles (see for example British Standard BS 5385-5: 2011) and verification by testing of the dryness of underlying layers.
Difference between marble and quartz
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Although both the marble- and quartz-based engineered stones are created through a similar process, and multiple companies produce both at the same time, there are distinct differences in their properties and applications.
Marble is a relatively soft material which is prone to scratching, but simple to maintain. Typically it can be repeatedly polished until it becomes too thin. Marble is much more common and accessible around the world, and comes in a wider variety, which gives its engineered counterpart a significant edge in pricing, and more variety in pattern and colors. Engineered marble is typically used as flooring materials for large commercial projects such as hotels, shopping centers, business lobbies, where it combines the attractive appearance of marble with budget-friendly cost and reliable delivery time.
Quartz is a much harder material. The Mohs scale hardness of marble is roughly 3, whereas that of quartz is around 7. This makes it much more resistant to scratching, however it also makes re-polishing and general processing a more difficult task, which is why it is most commonly used for kitchen counter tops, where the value added through processing can offset its considerably higher cost.
There is also a difference between quartz and quartzite, which may be confused because of the similarities in the name. Quartz countertops are man-made even though quartz is a natural material. Quartzite countertops on the other hand are natural and they are considered to be a high end countertop material.[7]
Market development
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Italy was the most dominant country in the supply of engineered stone products from the 1980s until the early 2000s, especially in engineered marble. The growth of the Chinese economy has changed the market drastically as China now has the most producers and largest overall quantity produced. There are estimated to be more than 100 engineered stone suppliers in China alone. India also has roughly 40 slab producing units as of December 2012. The original companies that operate Breton machines such as the Italian companies, Quarella, Santa Margherita and the Taiwanese company Romastone remain the most recognizable brands for marble. The private Spanish company Cosentino brand Silestone and the public Israeli company Caesarstone are the most recognizable brands for quartz, as well as Totem Quartz, an Iranian company which has a huge market in the middle east and Central Asia. Gulfstone, an Oman-based company, is the only producer of engineered quartz stone in the GCC. China is now probably the largest market for engineered marble due to new construction projects, while engineered quartz is primarily sold in North America and Europe as high end residential kitchen counter tops. [citation needed]
Health issues
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As with any silica-containing stone, silicosis can result from breathing dust produced when cutting or processing engineered stone made with quartz. The risk of inhaling quartz dust can be mitigated by taking appropriate safety precautions.[10][11] Risk of silicosis is high when little or no safety precautions or protective equipment are used. This may occur in small shops or in countries where the industry is not regulated or monitored.[12][13]
In Australia, a National Dust Diseases Taskforce was established in July 2019.[14] In Western Australia, legislation was introduced to support the early detection of silicosis caused by engineered stone.[15] Medical practitioners in Western Australia are advised to follow strict guidelines for the health surveillance of at risk workers.[16] In February 2023 Australian trade unions called for banning the importation of engineered stone into Australia.[17] In December of the same year, Australia became the first country to ban engineered stone in response to workers developing silicosis.[18]
In California, 77 workers at quartz countertop fabrication shops have been diagnosed with silicosis as of July, 2023. Inspections by safety officials in 2019 and 2020 showed that 72% of these shops were out of compliance with federal silica dust exposure standards. The state's Occupational Safety & Health Standards Board approved emergency regulations in December, 2023.[19]
See also
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References
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Photo provided by James St. John under the Creative Commons 2.0 license.
Blue Pearl is one of the names of granite you will find in our gallery. This is one of many different types of natural granite that people use for kitchen countertops and other surfaces. As with most granite, there are some specific features that Blue Pearl possesses. Additionally, there are some traits that make this granite unique. In this article, we won't go into too much detail about the unique qualities of Blue Pearl. We will mention some brief comments about the composition or the visual appearance or both, but the majority of this article will talk about working with Blue Pearl and how to take of it.
One of the first things to contemplate when considering any granite surface is why people choose it. There are many reasons people select natural granite for kitchen countertops. Blue Pearl Granite has many of the benefits that virtually all natural granite offers. It does however, have some characteristics that make it what it is. And like many other stone surfaces knowing a bit about the composition can be helpful. The following quote was taken from the description of a photo written by a geologist about Blue Pearl.
Larvikite is dominated by large crystals of spectacularly bluish-iridescent (schillerescent) perthitic feldspar (closely intergrown potassium feldspar and plagioclase feldspar). The play of colors is the result of light being dispersed along the plagioclase and K-feldspar crystal boundaries. The smaller black crystals are pyroxene. Varieties of larvikite are popular decorative/ornamental stones known commercially as "Blue Pearl Granite", "Emerald Pearl Granite", and other names.
In addition to those basic comments, many other important facts about Blue Pearl are helpful to be aware of. We'll consider some additional helpful information about this remarkable natural stone.
As with most natural granite, Blue Pearl is a composition of primarily natural quartz and/or feldspar. It can contain other materials, but the main minerals are those in most cases.
The minerals that make up a Blue Pearl Granite slab give it some qualities that people are drawn to. Some of these qualities translate into practical properties for daily use and care.
One of the big advantages of natural granite over other hard countertop surface materials is that it is very hard. Materials such as Blue Pearl Granite are scratch resistant because of the hardness of the material. Blue Pearl is also heat resistant. Unlike some engineered stone, granite can resist heat and does not burn or discolor.
Blue Pearl natural granite is also very unique. Not just unique from other stone, but it is also distinct from other Blue Pearl slabs. Choosing your specific slab is encouraged since each stone can vary one from another.
What goes into working with and fabricating Blue Pearl Granite? Well, for most of us the project is bigger than we are equipped to take on. This is because Blue Pearl is such a hard material that ordinary tools aren't the best suited for working with it. For example, just drilling a hole in a Blue Pearl kitchen countertop slab will take a diamond core bit designed to cut through rock. Stone fabrication professionals have all this equipment. Therefore, the project is not only easier for them, but they have more experience actually working with granite. So, cutting, drilling, and installing Blue Pearl is much easier for them than it would be for a novice.
Even transporting Blue Pearl natural granite can be a challenge for the average person. Even handy individuals and do-it-yourselfers could find moving a piece of Blue Pearl Granite form point A to point B. Since Blue Pearl is heavy, it requires more than one person to move, lift, and adjust it. That doesn't even take into consideration the material handling equipment that one needs to transport it. Additionally, installing Blue Pearl will require a specific formulated and colored granite glue. These are all supplies that fabricators are familiar with and even already have.
There are some basic care requirements involved with owning a Blue Pearl kitchen countertop. It is a natural surface and it is very durable. And although it is very durable, keeping it looking its best takes a bit of regular care. This care comes trough a couple of channels. Each of the following plays an important role in caring for your Blue Pearl Granite surface.
Even before your surface arrived in your home it was being given treatments to prepare it for the "day in, day out" wear and tear that comes from normal household use. One of the treatments the surface underwent was an initial sealing. Granite slabs get sealed to make them less absorbent. Natural granite is porous. And some Blue Pearl Granite slabs are more porous than others. So slabs get an initial sealing to help them be more resistant to water-based and oil-based liquids that can penetrate the pores and stain them.
One of the parts of caring for your Blue Pearl surface includes periodically sealing the stone using a natural stone sealer. In the case of a Blue Pearl Granite kitchen countertop, you may want to choose a food safe granite sealer designed especially for eating surfaces. Treating the surface when the stone begins losing its repellent nature is the first part of the two-pronged care process.
Another aspect of caring for your granite surface is to use a cleaner formulated for use on natural stone. Blue Pearl countertops and other surfaces are natural stone and sealing them is only one part. Not every household cleaner is made for use on natural stone. In reality, some cleaners actually break down natural stone sealers. So to maintain the seal that you are replenishing every-so-often, be sure to use a natural stone cleaner that will not degrade sealers. This is true of all sorts of natural stone cleaners. Let's look at some basic ones now.
One type of natural stone cleaner is the daily cleaner that is designed to remove the spots, smudges, and food residue that inevitably ends up on your Blue Pearl kitchen countertop. Another type of cleaner that is not as frequently needed is a stain remover. If your sealer breaks down and and an oil based liquid or a water based liquid gets into the pores of the granite, you may need this type of cleaning agent. These products are formulated to draw the stain out of the stone. But once again, keeping the sealer replenished on the stone reduces the need for these types of stone cleaners.
It really just boils down to putting together a regular routine of cleaning and sealing your natural Blue Pearl Granite surface. Once you get the routine into full swing, it just becomes second nature. A good routine for maintaining natural granite, including Blue Pearl, basically involves the following:
Blue Pearl Granite is a unique natural stone that will result in your design being truly unique. Your kitchen or other area will not only be appealing, but it will also be functional. Additionally, how you care for your Blue Pearl surface will play a role in how long it looks its best. However, for the best results, the install will most likely need to be handled by a professional fabrication company.
* A thirsty granite stone is one that quickly absorbs water resting on its surface. Simply put a tablespoon of water on the surface of the stone. The faster the water is absorbed, the "thirstier" the stone is.
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