sintered stone

Sintered stone differs from other artificial stone materials not only in its composition, but also in characteristics and production process. Because sintered stone slabs can be very thin, the items produced from this material have modern, lightweight and minimalistic look. Sintered stone hardness and durability is superior to that of natural stone, such as marble or granite. This 100% natural material is the latest high-tech fad. Sounds like a green choice! Have you heard of its low maintenance? Sintered stone doesn't need to be sealed, waxed or coated with any kind of varnish.

It is hard to imagine what the raw mixture of ground rocks undergoes before it becomes a sintered stone slab from which your worktop can be fabricated. Crushed stone dust, sand and clay mass withstands terrifying pressure. Just imagine the raw slab pressed by the weight of two Eiffel Towers! The densely compressed slabs are then baked in a special oven at a temperature of 1200 ºC degrees or even hotter. This technology naturally melts and fuses the minerals together, giving the new material exceptional physical and mechanical properties. 

Sintered stone is very hard, durable and 100% natural material used in interior and exterior projects. It is resistant to scratching and extreme temperatures. Sintered surfaces are hard to damage by burning, stomping or mechanical scratching. This artificial stone material is great for wall cladding, terrace flooring and house facades. Thin sintered slabs can be used to make furniture fronts, fireplace surrounds. Some sintered stone brands are paint-resistant, which means that graffiti paintings can be easily wiped from them. Because of this feature, sintered panels are often used to clad facades of schools and other educational institutions.

It is important to have in mind that sintered stone slabs can reveal their durability and shock-resistance when glued onto a hard solid base. E.g. after the piece of furniture is fixed in place and stable, or after concrete floor has been leveled. However, if the bed is not even-leveled, thin sintered slabs may crack under pressure, while being slightly bent or under shock-impact. The standard thickness of a sintered stone slab is 12 mm. The thinnest sintered panels can be as thin as 3 mm, 4 mm or 6 mm. This amazing material does not require special maintenance or sealing. It is non-porous and can hardly be stained. 

Most often, patterns and textures of sintered stone slabs are only visible on the surface. The colour of the cut normally is even, which means that the veins and dots seen on the surface do not have volume as the veins and dots of natural stones. In other words, the simple sintered stone slab pattern is not 3D. However, manufacturers are constantly improving their technologies and release some sintered stone collections with 3D patterns, where veins run through entire thickness. Full bodied sintered stone slabs are more expensive. Manufacturers do not disclose their secret technologies, therefore the properties of different brand slabs may vary.

Cutting and working sintered stone requires special diamond saws, special tools and very advanced skills. Sintered slabs are very hard and rigid, their lack of flexibility makes them easy to crack if handled improperly. The edges of sintered slabs often chip when cut with ordinary stone cutting saws. Cracks can also occur if the final products are transported carelessly. Therefore it is important to attach the final products fifirmly to special support in order to eliminate shock when the car is shaken.

Sintered stone countertops and floor panels need a firm and rigid base, especially if they are fabricated from thin 6 mm thick slabs. Only then sintered stone products can reveal their exceptional hardness. Sintered stone flooring can only be laid on well levelled concrete, and this should be all the more important if heavy furniture is to be placed upon it. Just remember that most sintered stone slabs are 3 m long and 1,5 m wide!

Sintered stone is 100% natural and hygienic material based on granite minerals, glass minerals and natural oxides. It is manufactured using recent technological advancements which mimic the processes that form natural stone deep beneath the earth's surface. Granite materials, such as quartz and feldspar, give sintered stone its exceptional hardness and strength. Glass minerals like silica, ensure the material's chemical stability. Natural oxides are added to give the slabs different colors.

In the first manufacturing phase, the raw materials (minerals and stone dust) are carefully selected. The mixture is then subjected to extreme heat and pressure (approximately 400 bars). In the second phase, the slabs go through a special kiln where they are baked at a temperature of more than 1200ºC. When the process is finished, the particles are bonded together permanently, without the need for resins or binding agents. This process of ultra-compaction creates full-body surfaces with unique technical features. In the last stage, a very high quality print is added to the slab surface. The result is the material of exceptional hardness and other great qualities.

The properties of sintered stone slabs can differ depending on the brand. Different manufacturers use different technologies and different recipes for making sintered stone, which they tend to keep secret. Slabs produced by different manufacturers vary mainly due to different raw materials used and their proportions. E.g. a slab baked from pure crushed quartz dust at extreme temperature and pressure will be harder, stronger and more resistant than a slab produced from lime or clay particles at lower temperatures and pressures.

The colour pattern of sintered stone slabs is generally visible only on the surface, the sides and the cut remaining evenly coloured (the pattern does not go through the entire slab depth like in natural stones). Some manufacturers also produce slabs with textures and patterns that run through entire edge thickness. Some manufacturers' slabs are more resistant to impact, others are less fragile, others have distinctive patterns and textures. Neolith, Lapitec, Dekton sintered stone is particularly strong and scratch resistant.

The brands strive to manufacture surfaces as true to the original source material as possible, but with the enhanced resistance and characteristics of sintered stone. Therefore the process is very precise, it goes slow and the experiments are very costly. E.g. Neolith recently created full body veining for its thicker slabs. Full body technologies ensure the continuity and visibility of the superficial pattern and elements through the entire edge of sintered slab, regardless of where it is cut. Thus full body technologies enable architects and designers to create more visually appealing works.

Sintered stone surfaces are low maintenance, strong and wear resistant. Countertops made from this material are hygienic, as the surface is non-porous, therefore liquids cannot penetrate or accumulate in them. Grease and dirt can be easily removed from such countertops with dishwashing detergent or kitchen surface cleaner.

The major advantage of sintered surfaces is that they can handle a wide range of more potent cleaners. Non-glossy sintered surfaces generally tolerate cleaning with bleach, alcohol, acetone or other agents. Being a stain resistant surface, sintered countertop can be cleaned without worrying about wearing away its finish or causing any unsightly color changes. However, glossy surfaces might be sensitive to abrasive cleaners, creams, strong detergents, bleach and hydrofluoric acid.

A big advantage of sintered stone is that food can be prepared directly on such countertops without fear of staining or mechanically damaging them. Even if so, spills and dirt from sintered work tops are best cleaned up with hot water and mild soap. It is usually sufficient for quick cleaning. If a continuous use of soap builds up soap residue on the surface, a more thorough scrubbing with a worktop cleaner will do the job. Sintered surfaces are very resistant to external impacts, but it is always better to handle them soft.

Although traditional ceramics may share some similar properties with sintered stone, it does not possess the performance qualities of sintered surface. Sintered stone combines stain, scratch, chemical and heat resistance in one single material. 

Sintered stone is manufactured from similar raw materials as ceramics and porcelain. However, there are a few key differences regarding manufacturing process: the additional components, the pressure applied, the time of manufacturing.

• Raw materials used in the production of sintered stone  are far finer and purer, guaranteeing a more uniform structure than in traditional ceramics. In addition to raw materials that ceramics and porcelain contain, sintered stone also contains componients used to manufacture quartz and glass. This makes sintered surfaces stronger and more durable than porcelain and ceramics.

• Extreme pressure and temperature is used to compress and fuse the components together when manufacturing sintered stone.  In other words, raw materials are pressed at a significantly higher pressure than in ceramic production to obtain a denser, stronger final product.

• The pressed materials are fired in kiln substantially longer than traditional ceramics. Ceramics have much shorter firing cycles. These longer firing cycles create a product with a highly resistant, non-absorbent surface.

The conditions in which sintered stone is manufactured resembles those deep inside the earth needed for rocks to be formed naturally. Today's high technologies simulate these processes and speed up the process. While it takes millions of years for the rock to form in the ground, modern technology reduces the time to one or two days.