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Engineered Stones: definition
• Engineered Stones: composite material comprising of rock and resin or cement. (Icestone from New Jersey produces slabs of cement).
• A man-made product
• Quartz and glass represent the main ingredient, a new addition is porcelain.
• Resin can be either epoxy or polyester
Engineered Stones: Manufacturing
Manufacturing technique for engineered surfaces:
1) vibrant-compression vacuum process aka the Breton System
2) vibration system aka the Trend System
3) extrusion system
4) block system
Engineered Stones: Manufacturing - vibrant-compression vacuum process
• The vibrant-compression vacuum process is the most used around the world (BRETON SYSTEM).
• 40 countries around the world. Over 200 different companies.
• produces between 12,000 to 32,000 sqf of slabs per day
• Today 99% of the manufacturer
Engineered Stones: Manufacturing - vibration system
• The Vibration System Trend Group.
• Developed over 30 years ago, this system allows for the production of thin and flexible slabs.
• WE ARE THE ONLY FACTORY IN THE WORLD TODAY.
• The "spreading of the natural agents" happens randomly while the mold vibrates horizontally and vertically.
• Then a nylon mesh is added to the material and finally in the last stage, before the curing process, a bed of calcareous stone is added, for calibration and to assure absorption of adhesive, especially for floors.
Curved countertop, leather inlaid and mosaic background. Funk it up!!!!!!
Engineered Stones: Manufacturing - extrusion system
• The extrusion system: from an area where the raw ingredient are mixed together, they are spread into a combination of belts that presses the material together, to create a composite slab, during the process the material is cured.
• The extrusion system is also used for the production of acrylic solid surfaces like: Corian and LG.
• For engineered stone, the use of an extrusion process limits the size of the aggregate to fine ( smaller than 1/8").
Engineered Stones: Manufacturing - Block System
• The block system, was the first manufacturing process used to produce engineered surfaces.
• The block system is the "father" of the vibrant-compression vacuum machine. It generates blocks, similar to a natural stone block, and with the same average size: 120"x55"x34"
• A block system, from Breton will allow a production of more or less 15,000 up to 80,000 sqf per day.
Modern residential kitchen!
Engineered Stones: Ingredients - natural minerals
• Quartz is the second most abundant mineral. In the Earth' continental crust, after feldspar.
• Variety of Quartz, semi-precious gemstones. Usually quartz: transparent or translucent.
• Quartzite: hard metamorphic rock, originally sandstone. Sandstone is converted into quartzite through heating and pressure. Usually white to grey.
• Granite is a igneous rock, the color of granite varies base on his mineralogy. It lacks of internal structures.
• Out of 10 blocks of granite, 7 are bad and 3 are OK.
Engineered Stones: Ingredients - glass and porcelain
• Glass is a non crystalline solid material. Made of up to 75% of silica.
• used in a variety of industries and application.
• We prefer to use post or pre consumer recycled glass.
• Porcelain is a ceramic material created through an heating process at temperatures of over 2000 degrees F. The main raw is kaolin. Kaolin is a clay mineral.
Engineered Stones: Ingredient - binding agent
• Polyester resin in its natural status is liquid. Then with the use of a catalyst and heat, the resin becomes the binding agent for the slabs.
• Epoxy resin: a copolymer formed by 2 different chemicals. One is the resin and the second is the hardener.
• Epoxy resin hardens at room temperature
• Acrylic resin is used in the production of acrylic solid surfaces. It is usually referred to as a thermosetting plastic, because it can be molded with heat.
So what?
• Low and easy maintenance is common for Engineered Surfaces.
• Heat, chemical, and scratch resistant (resistant does not mean proof), Common.
• With Trend System, it is easy to customize, and you have added flexibility.
• Does not require sealing, common to all.
• The polishing of an engineered surface is different compared to the polishing of a natural stone. Usually with engineered surfaces you achieve a lower luster. But in general the smaller the grain the higher the polishing of a slab. And it is a lot easier to polish a thick slab than a thin slab. 13 Heads VS 60 Heads.
Engineered Stones: Applications
• Countertops
• Vanity tops
• Floors
• Walls
• Special
Engineered Stones: Applications - exterior
• It is important to know that the resin, with time, will tend to become yellow. Resins, in general are not UV stable.
• For an exterior application to work, you must select the right color. A color that will not show the yellowing of the resin: use a dark color or a yellow/orange color. But We can do it and THEY CANNOT.
• Be sure that the sun hits the material in an homogeneous way, otherwise you will see darker and lighter areas.
• Engineered surfaces used for an exterior cladding project. Belgium 2004-05
Engineered Stones: Applications - tops
• One of the applications where engineered surfaces are used the most, it is without a doubt Tops.
• For tops, we consider residential and commercial tops.
SEGAFREDO l'originale, Lincoln road, South Beach. Red and black table with lights!
Engineered Stones: Applications - tops
• Better tech characteristics compared to a Natural Stone.
• Natural stone are beautiful and unique, but need maintenance
• The use of quartzite and quartz accompanied by pigments makes an ES usually more uniform than a Natural Stone. Granite can have shade variation, based on the natural changes in a stone. Hence, the shade variation that can exist between production lots.
• The use of other raw materials: glass, mirror chips, mother of pearl, avventurina, and porcelain, make an ES unique.
• The possibility of working with products that are light weight, makes the Trend productions even more unique. Today, still there are not many thin materials available.
Engineered Stones: Applications - specials
• The use of a light weight material is also crucial on those application where weight plays and important role like for RV boats and elevators
Countertops on a river boat. When light weight makes a difference!
Let's get funky. Light weight meets creativity – imagine the weight of these if they were done in Natural Stone or in a thick material. Ouch!!!!
Engineered Stones: Applications - floors
• Floor application are one of the most interesting area, where we can use ES.
• Not all the manufacturers produce tiles.
• A ES floor, brings back the timeless look of Terrazzo, without the inconvenience and time frame, of the installation of a terrazzo floor.
• A thin tile of ES, like Trend Q can be used on top of an existing floor, so you do not have to remove it. It saves in time and money.
Floor installation on top of an existing floor. The existing floor was 24x24 cross-cut travertine.!
A clever way to contribute to the achievement of MR credit 1.2!
Engineered Stones: Application - walls
• Natural Stone have been use as wall decorations for centuries.
• In the USA in the early 50' and 60', a lot of hotels displayed intricate solutions of wall coverings, most of the time by using large format slabs.
• Today with ES, if you can dream it, you can do it.
I am feeling blue!
Engineered Stones: thickness and weight
• ¼” only 2.87 lbs per square foot
• 3/8” is 5.10 lbs per square foot (76% heavier)
• ¾” is 12.8 lbs per square foot (3.5 times heavier)
• 1 ¼” is18.00 lbs per square foot (5.3 times heavier).
Engineered Stones: thickness and weight
• 3/4” and 1 1/4” slabs are sold in bundles
• 1 bundle = 10 slabs 3/4”
• 1 bundle = 6 slabs 1 1/4”
• avg. size 62”x112” for granite
• avg. size ES 55”x120”
Engineered Stones: thickness and weight
• 1 bundle, 10 slabs 3/4” NS is 6,476.8 lbs
• 1 bundle, 10 slabs of 3/4” ES is 5,836 lbs
• 1 crate 30 slabs US is 3,800 lbs
• 1 shipment is 58.67% lighter than NS and, 34.88% than ES.
Engineered Stones: thickness and weight
• 1 shipment is also more than double the surface. 1,259 sqf vs 506 sqf in NS and 456 for ES.
• Get more than double the area at less than half the weight
Engineered Stones: thickness and weight
• Double surface with half the weight means that US transportation costs, given 1 shipment are 4 times less.
• or them have to count 4 times the cost of shipment to get the same surface.
Water-jet design floor in a movie theater complex. It gets your color juices flowing!
Engineered Stones: thickness and weight
• At the arrival of a shipment, storage:
• 1 bundle of them requires the same space of 2 crates of US
• so NS 506 sqf, ES 456 sqf, US 2,518
• in the same space, US 4 times more SQF than NS and 4.5 times more than ES
Engineered Stones: thickness and weight
• Given the same volume you move monthly, US need at least 4 to 4.5 time less storage area then them, to say the least. The more you pile vertically, the higher the multiplier....
• An avg fabrication, them, shop is at least 10,000 sqf and they could go as high as 50,000 sqf.
• how many square feet do you have right now?
Volkswagen headquarter. !
Costs to set up a fabrication shop
• Do you want a fabrication shop able to get you 100 counter per month? Your set up cost in machineries will be between 400K-750K
• To move thick slabs you need a head crane that can cost at least $ 40K
• Fun fact, renting a forklift for thick stone: $ 150 per day
Costs to set up a fabrication shop
• Cutting and polishing is performed by machines that require knowledge of software and a specific maintenance. They also come with a hefty price tag.
• Start with a CNC machine: second hand, around 100K, a good new one is closed to 500k
New Brembana CNC machine, $ 550,000
Costs to set up a fabrication shop
• Few things: if you buy a machine like this, take into account the following:
• Will it require full attention or split attention?
• How much time for programming. If you produce in scale (same piece over and over) this time is low; if each piece is different...this time is long (up to 95% of total time).
Costs to set up a fabrication shop
• These are machines you need to know how to use.
• here some of the basics:
• http://www.mfgaa.com/fundamentals.html
• in the website you can find out much more
Disco any body???!
Machineries
• The machine produces revenue only when it operates, consider 2nd and 3rd shift per day.
• more info:http://stonecoldcnc.com/how-to-decide-which-cnc-machine-to-buy/
Machineries
• Extreme story:There are a ton of factors that go into costing a CNC, the monthly payment, the tool wear, the power consumption, the cost of the programmer, the cost of the user, if its wet, the cost of the water. A customer of mine just bought a brand new Northwood stone machine, he had a back log of quartz work waiting for the CNC to become active, the day his CNC got up and running, a contractor next door accidentally hit an underground power line killing the power to this guys machine! The neighbor came over to apologize and said his insurance would pay for any work lost due to the accident, just let him know what it costs; we did a full break down of costs, including CNC payment, operator down-time, schedule delays, etc, we covered everything and checked our calculations repeatedly, the cost of the CNC Not Running= $33.00 per minute!!!!
Machineries
• Because of high cost, of running a CNC machine you need to be competitive you need:
• 1) low material cost and large availability: you buy by containers 100 slabs at the time, and you have a large stock 500 slabs at least.
• 2) you need to turn volume at lower prices, so you work multiple shifts
• 3) concentrate on running the shop, They let other market for them.
No limits – Water-jet Design!
What is the cost of NS slabs? �(importer prices landed)
• The cost of NS varies greatly depending on your supplier and your purchasing power.
• in NS you grade a slab as: 1st Choice (FULL), 2nd Choice (Grade B) and Commercial (Cut to Size).
NS slabs cost
• A FULL slabs Landed in the USA may vary between: $ 325 and $ 1,191
• A Grade B landed may cost from $ 270 to $ 648
• A Cut to Size from $ 230 to $ 583.
Variables
• When fabricating a granite slab a shop will consider a waste from 20 to 30% in their prices
• Fabrication may cost between $ 10 to $ 15 per sqf
• Consumable around 3 to 5%
• Office space – get your juices flowing!
my top • Countertop 55.04 sqf, U shaped.
• Backsplash 28 sqf, L shaped
• Finished edge 29 lf
• Material: Viatera Antico Pearl
• European edge 1 1/4”, New sink, cook top cut out, 3 electrical outlet, faucet hole, removal of existing top......in zip code area 33139....how much?
my top • I got several quotes, this is Kitchen Panda: $ 6,974.
• cost of material $ 68.00 sqf.
• full backsplash
• not included: sink removal, plumbing, removal of electrical, removal of stove and refrigerator.
• 3 to 4 weeks to make it and up to 3 days with no kitchen.
my top
• the total square footage is 86.21
• US, 3 slabs
• Them, the same even if their slab is bigger (45.83x9 = 91.99)
Top
BackSplash
my top
• surface to cover 83.04 sqf
• US need 86.21sqf because of edge. But you can either order 1 slab in Grade B or you may have left overs. if you have left overs you can use 2 new slabs, since the backsplash can be slightly different.
• Them need 3 slabs (they told me).
my top
• Because they need 3 slabs now my quote is bumped up by half the price of 54 sqf
• 54x68 divided 2 = $ 1,836
• They offer to have more seams in my backsplash or use a different material.
my top
• Same quote with a granite called AZUL PLATINO @ 36.00 sqf is $ 4, 091.00 (more along the line of $ 49.26 sqf.
• Then, I am said that with a size of 63x115 per slab, I still need 3 slabs. This time, tough I am charged a flat fee of $ 500.00, because they say they use that granite quite often ($ 55.28 sqf total).
my top
• Avg price of material was between $ 65.00 and $ 70.00 sqf,
• they advertised lower prices, but in the end they have only few colors in each collection.
• They do not include a bunch of costs, and you may get, once there, a very different quote.
• Builddirect.com prefab DIY Counter. Not always ok based on your sizes. But you try.
• For my top the Total was $ 1,425.75
• 55.04 sqf + shipment + Adhesives and tolls
• Or Equal $ 25.90 sqf
• Simply Red – what a great 80’ group (also).!
And so.... • Them, offer a wider variety because they are
usually distributed by large organizations. In the same place you can find more materials.
• Thick materials have a higher exposure
• They are everywhere. Every Distributor in the US who promotes slabs, has capability to sell you: Cambria, Caesarstone, Silestone...
open up • US partner.....
• GT has an incredible network, but lower exposure in commercial arena
• Trend deals with Large distributors.
• Trend Experience 15-16th of May: 20 sales people of Daltile Florida. They are over 30 in Florida alone. Over 150 and these are not showroom sale people.
open up • We can train an ARMY of loyal customers who are
currently experiencing great customer service from TREND.
• Everything they need is an easy system to quote top and your support.
• Avg Trend Q order, above $ 40,000 only for floors. Every job needs a top. Condo projects need top
open up
• Hotels need tops
• Restaurants need tops
• And so it goes...
• Trend’s network of sales people attending the Experience learn about all of this.
