The Process for Obtaining Natural Stone - Blog Post on Northstar Surfaces Webpage

From Ground to Grand Design

Few materials can even come close to rivaling the beauty, durability, and versatility of stone. From granite and marble to quartzite and soapstone, nature offers a wealth of attractive options that truly stand the test of time.?

How does rock, formed over the course of centuries or even millenia, go from quarry to countertop (or fireplace surround, flooring, backsplash… the list goes on and on!)???

The Process for Obtaining Natural Stone?

Part science, part art, the process for obtaining natural stone starts with… well, location, location, location. Rocks are everywhere – but sourcing stones like granite, marble, and quartzite requires careful planning, which includes geological surveys. Quarries must be located where the stones naturally occur, of course, and ideally, they are near efficient routes for transport to manufacturers.??

Geological surveys, exploratory probes, and in-depth expertise into the terrain and the types of rocks ``born” in them are required when finding an optimal location. Before a quarry can be established, the owners must ensure that proper steps are taken and strategies implemented to minimize environmental and community impacts. There is also extensive permitting and regulatory processes.?

So that’s the first step – and it’s a big, complex one! The specific next steps depend largely on the type of stone being mined. We’ll cover two of the most popular and sought-after natural stones: marble and granite.?

How is Marble Mined???

During the Renaissance, wooden pegs were the key to freeing marble from quarries. Workers inserted these pegs into naturally occurring cracks in the rock and then poured water onto them. The pegs would swell and eventually split the rock.??

Science has advanced – fortunately! Today, in open-pit mines, a bench wall is created (i.e. a large section of marble along a vertical wall) using diamond cables, diamond-tipped drilling equipment, and torches. Specialized saws with blades up to 17 feet long create a clean vertical cut to separate the bench wall from the side of the quarry.?

Once separated, the stone is cut into uniform blocks weighing between 15,000 - 25,000 pounds. From there, it is transferred to a cutting and finishing facility, where the blocks are cut into slabs. This is what you will see when you go into a showroom.?

If you want to go deep down into marble mining, This Old House has a terrific video on the?Danby Quarry in Vermont. This is an underground quarry (with some mines up to a mile below ground) from which nine different types of marble are extracted – some of its quarries are as deep as one mile below ground. You will see a machine with a seven foot, diamond studded blade that creates clean cuts through the mountain. While it looks like a “glorified chainsaw,” this innovation vastly improves stone quality and, more importantly, the safety of workers.??

How Is Granite Mined??

Contrary to popular belief (and old mining techniques), you don’t set off some dynamite and hope for the best!?Granite?needs to be carefully extracted in large blocks. Quarry workers drill small holes to define the targeted block size. Explosives – strategically used to separate the block without damaging or wasting material – create a blast that is just strong enough to break the stone free. The blocks, weighing in excess of 40 tons, are extracted with cranes.?

Heavy duty trucks haul the blocks to cutting facilities, where they are shaped into 7-9 foot slabs. From there, they are polished and either sent to vendors or to fabricators who cut them into lengths that are suitable for residential and commercial use.?

With custom applications, you will see the polished slabs in supplier showrooms. After discussing your project needs, a fabricator will meticulously create the right fit for your unique specifications.??

Other stones are mined in generally the same way: big blocks are cut out of the quarry using diamond-studded, high-speed equipment. This has made the process of obtaining natural stone much more efficient, streamlined, and safe. Once extracted, they are sent off to cutting facilities, turned into slabs, and delivered to suppliers and fabricators who can turn these amazing rocks into stunning focal points for your home or business.?

Northstar Surfaces: Your Last Step In Obtaining Natural Stone?

The work of finding and extracting coveted materials like marble and granite is intensive and often complex. However, when it comes to our customers, the process of obtaining natural stone could not be easier.??

We specialize in unique stone that cannot be found anywhere else – and we personally inspect each and every slab to deliver the highest quality. As a distributor/wholesaler, we pride ourselves on building strong working relationships with fabricators to ensure your project is an unmitigated success. While we do not sell directly to homeowners, we welcome you into our showroom to view our stunning?natural stone inventory?and to discuss your goals.?