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Taj Mahal Mitered Edge Cutting Wastage

7 years ago

Hi,

Love these forums and this is my first post…


We are renovating our kitchen with Taj Mahal quartzite countertops (fell in love with this stone). Slabs already selected (had to have them due to unique veining) are 2cm thick x 120” x 74” with mesh on backside. Countertop on Island in kitchen will be 114” long x 44” wide. My fabricator is telling me a couple of things.


Firstly that due to the mesh on backside that creating a laminated flat butt joint for a 1.5” high flat edge profile will not look good. They say they would have to grind off the mesh/glue along the edges which will leave some chipping so that when the two pieces are joined there will be a noticeable seam even after polishing (basically due to removal of mesh process we may never get a good near-invisible tight seam). They also said mesh is there because the stone is brittle and can flake apart as you cut it possibly. Which confused me as I thought Taj Mahal was one of the strongest quartzite stones even stronger/harder than granite. So another question is even though it may be hard like granite is it brittle at the same time and tricky to work with?


Secondly, because of the above concerns they say a mitered 1.5” edge profile is the best way to go (which I frankly do not have any problems with). But they are also saying that because of the way the miter has to get cut (saw issues and or quartzite cutting concerns) there is always around 4” or so of wasted stone between the two cuts. Meaning you just can’t slice the stone, miter the two edges and rejoin them to have a nice 1.5” waterfall edge. They say we would lose 4” or so of stone “meat” between the two pieces. So it would never have perfect waterfall veining match up since the 4” between the pieces is discarded. I have searched online for info/videos showing the exact process (start to finish) for creating a mitered waterfall edge profile in quartzite (or any stone for that matter) and I see some showing the cutting part or the end part when they are glued together but never showing how much if any waste of stone there is between these pieces to be joined back up. So I’m questioning the validity of their statements regarding “miter cutting creates a lot of waste” as I just don’t understand why and can’t find info to educate myself on it. I am seeing online pics of beautifully made Taj waterfalls that look perfectly continued from horizontal to vertical sides. Another way to ask all this is… if I want a 114” x 44” countertop with 1.5” mitered edge. What are the overall minimum stone dimensions needed?


Any thoughts or help on both the butt edge joint with mesh issue, or miter cuts waste info are greatly appreciated. Thanks in advance.

Comments (18)

  • PRO
    7 years ago

    Find a high end fabricator with the proper set ups, tools, glues that match your stone, experience, and proven work you can either see or talk to folks he/she did work for. It is very tricky, but it can be done. Be prepared to pay a good price for this fabrication. I have Taj Mahal quartzite in my kitchen 2cm, with glued, curved edge to look 3cm. Straight edges, with very slight eased edges. The previous owners had this done and I can see the seam but it isn't too bad. There is a small chip on one edge which is not unusual with this stone. I'm not sure it is worth the cost, but of course, that is your choice. Just have to find the right fabricator. This person doesn't sound like the right one.

    PSC Services thanked Flo Mangan
  • PRO
    7 years ago

    When you take your business to another fabricator, you're actually doing this guy a favor. When he loses enough work to a fabricator who can do the job without as much waste and who charges more, he'll have to pick up his game.


    I've had customers tell me they've had other fabricators tell them "It can't be done" and then I do it for them. It is sweet.

    PSC Services thanked Joseph Corlett, LLC
  • 7 years ago
    last modified: 7 years ago

    Taj Mahal quartzite countertops (fell in love with this stone)

    Who hasn't? It's lovely stuff.

    due to the mesh on backside ... there will be a noticeable seam even after polishing

    I'm not sure I follow. Are you saying this seam would be on the backside? I know some people do have the underside of island overhangs finished. If the seam is on the backside, I wouldn't care a bit ... if it's going to be "noticeable" on the top side, it's a solid no from me. For what this costs, it'd better be right.

    Meaning you just can’t slice the stone, miter the two edges and rejoin them to have a nice 1.5” waterfall edge.

    Again, I'm a little lost. How sold are you on the waterfall edge? If you skip the waterfall thing, would this problem disappear? If so, that's my vote. Personally, I'm not into the waterfall thing anyway.

    Find a high end fabricator with the proper set ups, tools, glues that match your stone, experience, and proven work you can either see or talk to folks he/she did work for. It is very tricky, but it can be done. Be prepared to pay a good price for this fabrication.

    I was going to say the same thing. A second opinion is a good idea ... but, yes, if your stone and your goals require expertise, be prepared to pay for that person's skill.

    PSC Services thanked Mrs Pete
  • 7 years ago

    I used three slabs of TM for my kitchen with pattern matched straight dropped sides. It looks fine. You do need extra to accomplish this. Depending on your slabs, it may not be essential to pattern match it and you wouldn't need as much product. TM is brittle and takes much longer to cut than most stone; and it does chip on the edges. I don't understand the mesh.

    PSC Services thanked suzyq53
  • PRO
    7 years ago

    Insist that the mesh be ground away at an undermounted sink, please. I've seen when it's not and it's gross.

  • PRO
    7 years ago

    Excellent point Joseph. Will do for sure thanks!

  • PRO
    7 years ago

    Oldryder. Your comments are great and help a lot thanks. Your comments about the miter that may need to get re-cut if too chippy makes sense and that was what I was kind of thinking their explanation meant. I would think that if they could make the 2 miter pieces as close as possible they certainly would. But perhaps they are doing exactly that, under promising with aim to over deliver. I certainly hope so.

  • PRO
    7 years ago

    To Mrs Pete & susyq53


    The mesh is on the backside meaning underside of the 2cm slab (only one side polished). I'm guessing quarry put it on to add some strength during transport just in case. I'm not fully sure why mesh is put on and shy only some slabs. But I'm guessing it's probably for the thinner cut slabs and to manage risks during handling. I have attached pics of a sample piece from my stone supplier. You can see the mesh on the backside. It would not be visible when stone is installed but a couple inches of it would have to be removed from edge if they were to make the laminated butt seamed edge profile (to get stone touching stone without mesh in between). Oldryder explained it well how it may chip a bit while grinding this stuff off making that edge seam not super tight and thereby not as invisible.


    And Mrs Pete the waterfall is in regards to the 1.5" edge (with veining water-falling over along edge to match. I was considering a full 36" wall waterfall at the viewing end of this long island but not sure I have enough material and trying to avoid a 3rd slab. WRT waterfall mitered edges, I think it would be nice but may not be critical. I would hope a stone like this is pretty forgiving with it's coloration and veining that an edge piece taken from another part of the slab would still blend in pretty well along the edge. To the point of not jumping out at you as a mismatched edge unless you really studied it.


    Top/Front of TM sample


    Underside/Back of TM sample showing mesh






  • PRO
    7 years ago

    Regarding suggestions to look at other fabricators... I may still do that to hear what they have to say and understand their methods of working with this stone. I'm not locked in with this particular fabricator. But they are the preferred vendor for my kitchen cabinets vendor of choice. Who has an excellent reputation with loads of awesome reviews on various sites. So if this Stone vendor has been making the majority of the Kitchen vendor's client's CTs for many many years. They must be doing something right, I figure. The CT Fabricator let me tour their shop and it was full of CNC machines and all workers looked very professional. I was not disappointing and my Spidey Senses were not tingling from that visit (always a good thing).


    But glad I reached out out to you all here as this feedback is already helping me understand things a bit more. Thanks again! :)

  • 7 years ago

    So I thought I'd post a picture of my TM miter edge for you. You can see how the pattern continues, but in some places it doesn't matter because the pattern there is more subdued.




    PSC Services thanked suzyq53
  • PRO
    7 years ago

    Those pics speak volumes suzyq53. Exactly what I am struggling with. In that fist pic we can see that your fabricator had literally no waste or space between the two cuts to form the edge. You have that waterfall look with the veining flowing over the edge and down. As i suspected it clearly is possible! I may need to show this pic to my fabricator to get to the bottom of what they were telling me.

    I also appreciate that second pic which also proves with this stone you don't necessarily need the cuts to be from exactly the same location in the slab as pattern is forgiving enough. Another great pic for my piece of mind.

    Thanks!

  • 7 years ago

    I also have TM and did a laminated edge (I think that is the proper term). It matches in some spots and not in other. It really becomes a non issue when you look at the whole kitchen ... like only seeing the tree in front of you and not the whole forest around you.

    I also have a seam to the right of my sink where 2 slabs had to come together ( I needed 3 for my kitchen). When it first went in, I hated the difference and wished we had matched up some other part, etc. When I look at it now, the color of the two sections looks the same. Maybe some dirt and wear evened things out or once the backsplash was added it tied the color difference together. Point is, the things we obsess about, do become non issues when viewed as a whole when the project is complete.

    PSC Services thanked chispa
  • PRO
    7 years ago

    All counters TM, mitered due to leathered finish.

    2018-19 El Dorado Hills Ridgeview Village · More Info


  • PRO
    7 years ago

    Wow stunning work Jeffrey!

    Can I ask why it had to be mitered due to leathered finish?

  • PRO
    7 years ago

    To continue the leather finish onto the front edge, otherwise it would be polished ... at client option. Another client using 3cm leathered granite and was perfectly happy with a polished edge, saving the cost of miter.

  • PRO
    7 years ago
    Jeffery. Outstanding work! That’s what I mean. True craftsman. Among best work I have ever seen.
  • 5 years ago

    Chispa- May I see an up close pic of the laminated seams? I found 3 slabs I live but it’s only 2cm thick