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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]
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See also
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References
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January 10, 2023
According to MyHome Designers, homeowners frequently indulge in the perfect countertop material for both the kitchen and bathroom and have progressively done so. To help you with your countertop decisions, we asked our remodeling consultants, project managers, and designers to tell us which is their favorite countertop material. The clear winner was engineered quartz.
What is Engineered Quartz?
Engineered quartz is a man-made material that is ninety percent ground quartz mineral and a ten percent mixture of pigments, polymers, and resins depending on the manufacturer. The quartz mineral is grounded along with the other materials and resin and then pressed together to form slabs. Engineered quartz recently gained popularity because it is less expensive.
The cost depends on who manufactured the material as well as installation costs. You can expect to pay anywhere between $60 to $120 per square foot for engineered quartz and another $180 to $350 per square foot for the installation. The cost may vary depending on whether you’re installing a builder, premium, or designer-grade engineered quartz counter. The most well-known manufacturers of engineered quartz are Caesarstone, Silestone, and Deckon.
The Advantages of Engineered Quartz
#1: Finishes
Engineered quartz comes in a variety of finishes and colors, making it stress-free to decide what works best for your taste and palette. You can pick from a variety of options such as speckles or veining that mimic natural stone countertop or a solid color. Several engineered quartz selections look so similar to authentic stone that it is hard to tell them apart. Whites and grays are among the more conventional color choices for a quartz countertop. But if you want to be more adventurous and add a pop of color to your furniture, you will see that quartz counters can come in shades of blue, green, black, purple, and even gold. There’s no shortage of style when it comes to natural quartz in the form of an engineered stone.
#2: Durability
Engineered quartz is exceptionally durable. Unlike marble kitchen countertops, quartz countertops are much more resilient to damage as they are a stronger stone. This is particularly important in the kitchen and bathroom since they are usually the most used rooms in your home. Engineered quartz can withstand coming into contact with an acidic substance, where most other materials would normally stain. It does share many of the same qualities as granite countertops, including its lifespan, but it is, by far, a more forgiving option than a granite countertop. It is resilient against cracking, chipping, etching, and scratching. This makes quartz countertops perfect in the kitchen as they are resistant to knife damages. It would require extreme pressure to even make a small dent on a quartz countertop.
Most manufacturers offer an unusually long warranty, but if you maintain your engineered quartz properly, it should last a lifetime.
#3: Low cost
Engineered quartz is usually easier to install than natural stone. Considering its durability and quality, engineered quartz countertops cost less is relatively cost-effective compared to other options. What’s more, quartz is one of the most common minerals on the planet, making it less expensive to mine. If you’re on a budget but want something stylish and durable, then engineered quartz is a great choice.
The price depends on the color, finish, or veining you choose. Bold and rare color choices can also impact the price range, as these are considered designer-grade engineered quartz countertops. Depending on the veining, the cost can be as much as natural stone, but nevertheless engineered quartz is still a great choice because of its value. Price is often determined by size and manufacturer. However, some engineered quartz countertops are further cost-divided by type, like tile or slab quartz counter.
#4: Nonporous
Engineered quartz is hard to stain because of its nonporous quality. This effect is achieved during the manufacturing process when the natural quartz is smoothed out and cleared of all its pores. The nonporous quality also does not allow viral or bacterial growth, which is extremely important in areas such as your bathroom. It can easily handle being drenched in wine, coffee, juice, or oil, unlike marble countertops. This aspect of engineered quartz means there’s no need for standard sterilization when cleaning. All you need to clean engineered quartz is soap and water. You can avoid abrasive scrubbers or harsh chemicals.
The Disadvantages of Engineered Quartz
#1: Visible Seams
Engineered quartz can be rendered as a rip-off of a natural stone. The method used to create an engineered stone countertop means that the differences between it and natural stone granite, marble, or even wood are very noticeable. This is true when the veining appears too symmetrical or perfect. If you need to use numerous slabs of engineered quartz, you will most likely see the seams. Light-colored quartz countertops in shades of white and gray and with fewer patterns should have the least visible seams. This is not an issue for bathrooms because the countertops are typically smaller.
#2: Heat Damage
Engineered quartz can and will be damaged if you set hot instruments such as curling irons on it with no protection. The resins and polymers that cause the engineered stone to be more durable, ironically, make it more susceptible to heat. To avoid heat damage, you will need to use a trivet for hot items. Keeping hot pads and coasters near the stove will greatly help in protecting your quartz countertop. It may be stronger than marble, but engineered quartz is not indestructible. At most, engineered quartz countertops can successfully manage to withstand temperatures as high as 300 degrees Fahrenheit.
All-purpose household cleaners that contain bleach or acidic elements will damage your engineered quartz. Before using any cleansers, first, check the manufacturer’s cleaning recommendations. Some engineered quartz is less stain-proof than others. High-grade natural quartz, particularly Petrosstone, is one of the more stain-resistant ones. If you’re looking into this as an option for your renovation or remodel, you must do due diligence and research the choices for your lifestyle.
Engineered quartz is a popular countertop material for bathrooms and kitchens alike. Therefore, a quartz counter is a solid choice for sprucing up your kitchen due to its resilience and clean finish–not to mention these countertops cost less than some natural stone options! Use our list of advantages and disadvantages to see if it is right for your next renovation project.
MyHome’s design consultants are ready to recommend the best material for your family and home renovation goals. Contact the MyHome Team to see how we can help you here!
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We hope you found this bit of information helpful, inspiring, and motivating in renovating your kitchen and bathroom.
Are you interested in learning more about Custom Artificial Quartz Stone? Contact us today to secure an expert consultation!