How Stone is Quarried & Processed

Quarrying natural stone and installing it in someones home is an incredibly long and
arduous process. Removing a 40,000-pound block of stone from the earth and turning it into
a handcrafted countertop or gleaming marble floor is not easy. There are many steps and
intricate details which cannot be overlooked in order for a piece of stone to find the perfect
setting where it will look beautiful for years to come.

Quarrying
The first step to finding the perfect slab is finding an optimal deposit of material with
desirable color, pattern, and composition. This requires geologists to look for stone outcrops
which are more easily examined since the bedrock is exposed. Samples are then obtained by
boring into the earth to take core samples with expensive diamond-tipped drill bits. These
samples are then tested to determine if the stone is suitable for use as dimensional building
stone. Later they are polished so that their color and pattern can be examined to determine
marketability.

Once this is done, the owner applies for a concession for the quarry area. After the concession
is purchased, the next step is to apply for all of the correct licenses from the local, state and
federal government. This is a lengthy process in the United States and an even longer process
in third world countries where corruption can exist on every level of the application process.
Sometimes it can take years for the necessary approvals to be authorized. All of the
paperwork must be submitted before the actual quarrying process can begin.

Clearing the way to reach the best material allows a quarry to reach its full potential. Each
quarry presents a unique challenge for the extraction of blocks. There may be months of
removing overburden, or dirt, before the stone is accessible. Many times innovative
construction, such as building roads or digging tunnels, is necessary to access the quarry. At
other times, the quarry faces the complex challenges of being in the middle of a war zone, or
the extremes of glacial temperatures.

It takes lots of experience, vision and hard work to bring a quarry into full production. A good
quarry manager is able to control how to material is removed based on the veining and
coloration within the deposit. The manager must have the vision to see how the stone "flows"
through the quarry. The same stone can take on many different looks just based on how the
block is cut from the wall and later processed. If it is cut with the flow of the source stone, it
is called Vein Cut. Vein Cut highlights the movement in the rock. Alternately if the block is
cut against the vein, Cross-Cut, it creates a more uniform look for the stone.

After the quarry manager decides how to extract the blocks, the drilling can begin. The
process starts by taking down a bench wall, a large dimensional chunk of rock that is then
cut into smaller blocks which will eventually be sent to the factory for processing. The bench
walls are cut using a combination of diamond wire cables, drills and even high temperature
torches that will melt the stone. Dirt is pushed up against the base of the wall to cushion the
fall, and small dynamite charges jar the wall loose to bring it down to a horizontal position.
The blocks can then be drilled from the bench wall. Blocks of a given type of stone usually
have a fairly uniform size, due to the size of the processing equipment used. Granite blocks
usually weigh between 38-42,000 pounds, while lighter marble and travertine blocks weigh
between 15-25,000 pounds.

Once the blocks have been extracted, the journey to the processing facility can begin. For
blocks processed in the same country, the trip is short in distance, but long in duration. The
blocks could be high in the mountains of Brazil or off the beaten paths of India. Others are
bought by overseas processors with skilled speculative buyers who combine geological science
with an eye for color to select the best blocks for processing.

Processing

Once blocks of stone reach the processing facility, they are cut down into smaller more
manageable pieces. For tile, this means cutting the stone into billets before polishing. For
slab materials, this typically means a trip to the gang saw. A gang saw works just like a giant
bread slicer, with many adjustable blades that allow for the thickness of the slabs to be
adjusted. The gang saw can cut the entire block of stone into slabs at one time. More delicate
materials may require the use of a diamond wire saw to gently cut one slab at a time with
less trauma to the stone. The most recent technology involves multi-wire gang saws which
have the potential speed production on exotic materials exponentially.

After slabs are cut on the gang saw, they are moved one at a time to the polishing line, where
they are laid horizontally on a large conveyer type line called a polishing line. There, they
pass under polishing heads which begin with very coarse diamond abrasives, and then move
to finer and finer grit abrasives, just like sanding wood. Travertine slabs and some marbles,
will receive a cementicous or epoxy compound to fill the natural voids of the stone. Part of
the way through this line, slabs of granite, marble, and onyx will receive a coating of a resin
treatment which will fill in any pits or micro fissures which are inherent to the stone in order
to make the final surface easier to clean. Most of the excess resin is removed by further
polishing, with only 1% remaining on the finished surface. For materials where the final
surface is to be honed, the process will stop with a lower grit abrasive than materials with a
polished surface.

At this point the materials are checked for quality and carefully packaged for their long
journey. Tiles are packed into boxes and tightly fit into wooden crates that will protect them
from bumps along the way. Slabs are bundled together and braced with a wooden framework,
custom built to ensure the slabs stay upright during the shipping process. All materials are
loaded into standard 20 foot shipping containers and braced to prevent any shifting or
movement which could cause damage to the material. Due to the immense weight of stone,
many containers are not fully packed, but are loaded to maximum weight limit of 42,000
pounds, or 20 tons.

The journey begins when the container is loaded by massive cranes onto a large ocean vessel.
After about four or five weeks at sea, they arrive at US ports. Here the containers are
offloaded with cranes, passed through customs, and transferred to rail cars for the trip to the
Midwest. The last leg of the journey is a quick trip via tractor trailer from the rail depot to
Global Granite & Marbles door.

Care & Maintenance

Stone's durability has been tested throughout the agesin homes, commercial buildings, cathedrals,
and even pyramids. Use the following care tips to ensure that your stone will not only last, but will
stay beautiful. Global Granite & Marble carries a full line of stone care products manufactured by
Miracle Sealants. These are our general recommendations, and we invite you to call us regarding any
specific stone care questions. Always test cleaners and sealers on a small, inconspicuous area in order
to achieve desired results.
Sealing Natural Stone

Sealing natural stone is a simple process that prevents staining and maintains stone's
beauty. We recommend an impregnating sealer which penetrates the stones surface to
protect it against moisture, dirt, and stains. Before sealing, a thorough cleaning is
recommended to avoid sealing dirt and grease into the stone.

The life of the sealer will depend upon the type and finish of the stone, the area of application,
and its exposure to wear. A piece of stone which is sealed with an impregnating sealer and
put in a closet will stay sealed indefinitely. Impregnating sealers are preferred to topical
sealers because they increase both the longevity and quality of the protection. Although
sealer makes the stone less susceptible to staining, applying when it is unnecessary just
wastes time, effort, and money. A simple test to determine if your stone needs to be resealed
is to sprinkle it with water. If the water beads up tightly, then the stone has maintained its
seal. If the water soaks in or darkens the stone, then allow the water to evaporate and reseal.
Granite sealers can last up to 15 years, depending porousity and type of granite. General
recommendations for residential flooring is to seal once every 5-10 years.

Prior to sealing, clean your natural stone thoroughly with warm water and Mira Clean. Let
the stone dry, and then begin working in sections. Apply the impregnating sealer using a
clean towel, wiping on a thin coat on your stone evenly covering the entire surface with sealer.
Allow the sealer to stand for approximately three to five minutes. Remove excess sealer by
buffing with a clean dry towel. If the sealer actually dries on the surface, rewet with more
sealer, and wipe dry with a clean terry cloth. Upon completion, wait 24 hours and repeat the
water test. If the water beads up, you are finished sealing. If the water does not bead up,
apply another coat of sealer.

The process of sealing stone is straightforward and can usually be handled by a homeowner
as part of normal home maintenance. Sealing a kitchen countertop will take about 30
minutes, but a large area of flooring can take considerably more time. If you prefer,
contractors and restoration companies can take care of cleaning and sealing for you.

The "Water test": Here you see unsealed granite on the left where the water is soaking in and
darkening the stone. The stone on the left needs to be sealed. Compare this to the sealed
granite on the right where the water droplets create beads which sit on top on the stone. The
stone on the right is already sealed.
Cleaning Natural Stone

At Global Granite & Marble we recommend Miracle Counter Kleen for countertops and
Miracle Mira Clean for regular cleaning. A pH neutral cleaner will work for any type of
natural stone. Be careful not to use bleach or abrasive products on any natural stone
installation to prevent damage to the stone. Many name brand household cleaners are highly
acidic and can cause damage to calcareous stones like marble, limestone, travertine and onyx,
as well as the sealers protecting them. We will be happy to help make more specific
recommendations for your home, or help you to determine what type of cleaning regimen
needs to be established for a commercial project.

For those applications which require a disinfectant, Miracle Sealants Company created
Disinfecting Wipes and Disinfecting Spray that is specially formulated to kill viruses, fungi,
bacteria, mold, and mildew. These disinfecting products are safe for use on any type of
natural stone in any area of the home, including showers and baths.

Granite

Granite is a versatile natural stone product that can be used almost anywhere. It stands up
well indoors and outdoors. Studies show that granite does not host bacteria due to its high
density. Combined with the fact that it does not respond to acid, this makes granite among
the most sanitary countertop materials available.

A penetrating sealer should be applied directly after installation to prevent staining. When
your countertops are newly installed, perform the following test to determine if they need to
be sealed: Sprinkle some water on your granite. If it beads up, it is sealed. If the water does
not create round beads, follow these instructions, and repeat if necessary.

Sealing: Polished granite should be sealed using Miracle 511 Impregnator. Honed or textured
granite should be sealed using Miracle 511 Porous Plus.
Daily Countertop Cleaning: We recommend Miracle Counter Kleen for daily cleaning of granite
counters, vanities or table tops. This neutral cleaner can be used anytime and as frequently as
you like.
Stain Removal: Granite is very resistant to staining. However, if a stain does occur it may be
removed using Miracle Sealants Poultice Plus powder or Liquid Poultice. These products can
help draw the stain out. Follow product directions carefully. Once the stain is removed, clean
the entire area and reseal as directed above.
Polish: Miracle Stone Polish is a light wax that gives a nice finishing touch to your granite
countertops. It washes off with several cleanings, so wax buildup is not a problem. Apply a
thin coat, allow it to dry, and then wipe off.
Granite Floors: Floors and countertops are handled in much the same way, but stone polish is
not recommended on granite floors. To clean floors or any large expanse of natural stone,
concentrates are the most economical. Use Mira Clean for polished stone and Mira Soap for
honed and textured surfaces. Both are excellent heavy duty cleaners.

Marble, Travertine, Limestone, & Onyx

Marble, travertine, limestone and onyx are beautiful natural stones that offer unique
patterns and colors found in no other materials. Because of their chemical composition, the
basic care for these stones is the same.

Marble, travertine and limestone are practical for bathrooms, fireplaces and most flooring.
Onyx is the jewel and the most fragile of these, and should therefore be used only in low
traffic areas. It is important to use good judgment on where to use these calcium based stones
because they are susceptible to acid etching. Etching occurs when acids microscopically eat
away at the surface of the stone, and are characterized by dull spots in the surface of the
material. This effect can be visually minimized by using a honed surface instead of a polished
surface. Any spills that occur should be wiped up immediately. For centuries marble
countertops have epitomized elegance and the patina that is created with time tells stories
of meals enjoyed with family and friends.

Sealing: The proper sealant for these materials is Miracles 511 Porous Plus. The stones should
be sealed immediately after installation. See the sealing application for additional details.
Daily Countertop Cleaning: Miracles Counter Kleen and Mira Clean are wonderful cleaners
for all tops. Clean all spills quickly, especially acidic liquid, because they can etch into the
stones surface. Place all hot cooking pans on trivets or placemats.
Stain Removal: A well- sealed stone is very stain resistant. However, if a stain does occur, it
may be removed using Miracle Sealants Poultice Plus powder or Liquid Poultice.

Slate & Quartzite

Slate has a unique look, and is an extraordinary and versatile material. Slate has very low
porosity that makes it stain resistant and easy to maintain. However, the natural clefts of
slate does make its care slightly different than a smooth surface. At Global Granite &
Marble, we strongly encourage sealing naturally cleft slate both pre- and post-grouting to
make removal of excess grout easier.

Quartzite can be clefted like slate, or can be smooth and more similar to marble and granite
in appearance. The major difference between slate and quartzite is quartzites ability to
withstand many freeze-thaw cycles. While quartzite that looks like slate is also cleaned like
slate, polished quartzite that looks like marble or granite is cleaned and treated like granite.

Slate and Quartzite are sealed and cleaned in the same manner.

Sealing: The proper sealant for these materials is Miracles 511 Porous Plus. The water test
will determine if your stone needs to be sealed.
Daily Countertop Cleaning: Miracles Counter Kleen is recommended for slate and quartzite
tops.
Cleaning of Floors and Walls: We recommend Mira Soap to clean slate and quartzite walls or
floors.

Soapstone

Maintaining a soapstone countertop is simple. Oil your countertops to guarantee the stone
will darken evenly. Traditionally, mineral oil is used because it is easily available and non-
toxic. Because soapstone is non-porous, it does not need to be sealed. If you choose not to oil
your soapstone, it will not harm the stone. However, you will soon notice darkened areas from
use and spills. You cannot oil your soapstone too much or too little. Simply use a paper towel
to remove the excess oil. It will require several coats of oil to bring your stone to its final color,
and the countertop will hold each coat of oil longer than the previous coat. Regular soap and
water is advisable for cleaning because harsher solvents may remove the mineral oil
treatment.

Due to soapstones soft characteristics, it is prone to scratches. The advantage is that most
scratches can be obscured. A light coat of mineral oil will hide a shallow mark, and a deeper
cut can be sanded away. Using 120-grit sandpaper, sand in a circular motion until the scratch
is nearly invisible. Then repeat the sanding process using 220-grit sandpaper, and
incorporating water. Sanding will remove the mineral oil from the surface. Once the scratch
is removed, reapply mineral oil in the sanded area to bring the color back to the desired
shade.