The
Miracle of Stone
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| Quarrying
and Fabrication of Stone |
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In the quarrying
of stone dynamite is carefully placed in the natural crevasses
of the mountain. It is exploded causing large segments of the quarry
to separate. These separations are then drilled so that wire cutters
can be used to cut these blocks into more maneuverable block sizes.
Liquids, airbags and other preparations are used to separate the
block from the mountain. This process usually takes 2 days.
The separate
block is on average 8 feet wide by 4 1/2 feet high by 3 feet
deep. It is numbered and then transported to fabrication centers,
sometimes, many miles away. At the fabrication centers these blocks
are cut into slabs by gang saws and water. These slabs are usually
cut into multiple thickness from 3/4" and up depending on the
job. Cutting blocks into slabs can take anywhere from 7 hours for
limestone and marble and up to 2 days for some very dense granite.
These slabs
are then polishes, honed, flamed, bush hammered or sand blasted.
Slab uses include kitchen counters, vanity tops, tables, fireplaces,
fascias of buildings, walkways and so forth. These slabs are often
cut into smaller slabs called billets, which are used for tile.
These billets, usually 1 or 1 1/4" thick, are then split in
half thickness wise forming two 1/2" or 3/8" thick billets.
These pieces are then cut into tile, beveled, dried, packed, palletized
and shipped.
(This complete process takes one complete day)
It is indeed
a miracle that a piece of stone can be cut from quarry, trucked
or railed miles away to a fabrication center and be cut into slabs,
sliced, split and polished, packed, transported over the oceans
and reaches its final destination at such a remarkably low cost.
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| The
History of Stone |
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Stone
is a natural solid formation of many minerals. There are thousands
of stones quarried throughout the centuries from around the world.
The
minerals in stone were formed, as earth itself, from liquid
gasses, which cooled, hardened and formed a solid core. Through
pressure, the earth's crust began to form. As the earth's crust
began to expand and erode, heat and pressure pushed the solid materials
up to the earth's surface, which formed colossal rock beds. It took
up to 100 million years for some of these beds to form. Many of
these beds are now used for quarries.
Cancos
Tile imports stone from many of these quarries in Italy,
Spain, Brazil, India, Turkey, Mexico, China, Greece, Taiwan, France,
Tunisia, and Portugal for you, the customer.
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| Important
Facts You Should Know About Stone |
- Almost
all stone can stain.
- Almost
all stones can wear.
- Sand
plays havoc on all stones. (Stones should be protected from outside
debris, grit, rock salt, ice melt, and acid rain residue from
entering and eroding the stone.)
- All
stains should be wiped up immediately. The longer the stain stays
on top of the stone, the greater the damage of permanent stain.
- Some
stains can never be removed.
- Stones
can be ground and refinished and restored to their natural beauty.
- Almost
all stones should be sealed with penetrating sealant.
- Water
will darken stone whether sealed or not, however, it will return
to original color when dry.
Knowing
all these negatives about stone, then why stone? Why has the consumption
of stone in the United States doubled over the past 10 years?
The
answer is simple.
- Stone
is beauty.
- Stone
is sophistication.
- Stone
is tradition.
- Stone
enhances.
- Stone
is internationally accepted.
- Stone
is forever. (Like a diamond, the hardest of all stones is "forever".
Once stone is installed in your home it will remain there forever,
as the ancient palaces of Europe, so too, should your stone be
carefully selected, installed, maintained, and preserved.)
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| Stone
Definitions |
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Granite
Proportions of the chemical components of the continental crust
are such that, they were melted down, mixed thoroughly, and slowly
cooled, the result would be granite. Although a favorite for commercial
use, it has shown a resurgence recently for use in residential applications
due to it's superior hardness and durability.
Limestone
Composed wholly or part of calcium carbonate. Certain limestones,
when examined closely, are seen to consist almost entirely of fragments
of fossil shells. The size of the fragments and the method of cementation
can determine the porosity and the abrasion resistance and whether
the stone is suitable for commercial and/or residential applications.
In some markets, hone (matte finish) limestone paving has surpassed
marble in popularity.
Marble
A compact, granular, partially or wholly crystallized (metamorphosed)
limestone. Commonly produced with a polished finish, its decorative
and occasional vivid nature has made it the stone of choice for
centuries.
NOTE:
the boundary between crystalline marble and limestone is ill-defined.
A few characteristics make it possible to distinguish marble from
limestone which frequently appears similar to it.
Sandstone
A rock consisting primarily of quartz sand and cemented together
by silica rich waters seeping through its mass. Iron oxides give
the stone its yellow and rosy colors in some instances. Although
more commonly used as an exterior paving stone in cut shapes and
random (flagging), it is gaining acceptance for use as a interior
paving.
Quartzite
A compact, granular, partially or wholly crystallized (metamorphosed)
sandstone. Contains at least 95% silica (quartz sand) in its matrix
and often appears more textural with higher concentrations of mica
which gives it a shiny or platy appearance.
Slate
A primarily clay-based (argillaceous), fine grained rock that readily
splits into thin and even laminae. Many are formed in deep oceans,
or they may form in river beds, estuaries and deltas.
Travertine
A porous, crystalline calcium carbonate mud deposited layers from
ground or surface water. Trapped organics later dissolved give the
stone its characteristics pockets or holes.
Volcanic
Ash Stone
Known as canters, adoquin, Kirkstone, these stones are formed from
sedimentation and eventual consolidation of volcanic ash. In some
instances, metamorphic events recrystallize ash into harder, more
dense stones (Kirkstone).
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| Natural
Stone Characteristics |
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Natural
Color Variations
All stones (travertine, slate, marble, limestone, granite, etc.)
are from nature making it impossible to insure that every color
and marking in one piece will be present in the next piece. It is
this individuality of each piece gives a natural stone floor its
inherent natural beauty.
Finishes
Natural stones come in an array of finishes. These finishes can
add to the characteristics of the stone as well as dictate the type
of sealing that will be needed to protect the floor once it is installed.
Please refer to the care & maintenance section for sealing information.
Honed:
The surfaces is buffed to a smooth matte finish.
Polished:
The surface has been buffed to a smooth shiny finish.
Saw
cut/Flamed cut:
The surface has not been buffed. The rough saw cuts are left creating
an irregular rough matte finish.
Flame
cut:
Is hit with a torch creating a clefted finish.
Filled:
Natural stones that have a pitted surface are filled at the factory.
Unfilled
Natural stones that have a pitted surface are not filled at the
factory. This allows the customer the option to fill the pits with
a colored grout to add to the appearance of the stone.
Installation
The thickness of natural stone creates the need for a mud set installation
to insure stability and adhesion.
NOTE:
Green marble must be installed with a 100% solid epoxy to insure
that warpage will not occur.
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