| The
Manufacturing Process
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The manufacturing process begins by sawing the rough
granite blocks into slabs that are 6 to 12 inches thick. This is
accomplished by utilizing diamond rotary saws with blades up to 11 feet in
diameter and containing 140 or more industrial diamond segments. These saws,
using tons of water as a coolant cut the Elberton granite at an average rate
of 25 square feet per hour. The saws contain micro computer controls which
can be programmed to operate around the clock by presetting the block size,
and desired thickness of the pieces. |
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Finishing cuts and intricate designs can be made with
a computer controlled diamond wire saw - a small 1/4" steel wire containing
diamond segments can cut the granite into any desired shape.
The geometric pattern is first scanned, then entered into the saws computer.
The wire will follow the programmed shape exactly as it completes the
cutting process automatically.
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The next step in processing the granite into many
finished monuments is giving it a glossy finish under high speed polishing
mills. The operator guides a heavy wheel over the piece and different grades
of abrasive together with water gradually grinds the surface of the stone
smooth. |
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The final step is the heavy buffing wheel which is
guided over the entire piece until a brilliant mirror like finish has been
achieved. This entire polishing operation normally takes about 45 minutes.
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The
granite is now broken into smaller pieces that will become the actual
monuments and markers. The initial cuts are made by a massive gullitine.
This machine uses hydralic pressure and its carbide tipped teeth to cut
pieces up to 22 inches thick. |
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After the
granite is broken to the specified size, highly skilled craftsmen use their
hammers, pneumatic tools and razor sharp carbide tipped chisels to shape the
monument to the final dimensions using old world artistry to transform the
granite pieces into beautiful memorials. |
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Large
cranes are used to move the monuments to the sandblast department where the
process of carving and lettering takes place. The drafting department has
already prepared a unique design based on the customers specific order. |
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Today,
computer graphics offer an infinite array of design possibilities. The final
design is transferred directly to the rubber stencil be the computer. A
razor sharp knife automatically cuts the tiny lines in the stencil that will
expose the surface for sandblasting. |
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A liquid
glue is brushed on the polished surface of the monument so the rubber like
stencil will bond to the granite securely, while the glue is drying the
stencil is carefully spread and pulled tightly over the polished surface.
Once the stone is ready for engraving, all areas are patched with stencil to
protect them from abrasive overspray. |
