Granite Step Production Tour

Our Quarry

We begin by drilling or burning to free the granite ledge vertically from the quarry walls. Then, we utilize Pneumatic equipment to drill holes horizontally at the base of the ledge. These holes are then packed with dynamite charges, that, when detonated, lift the ledge free from the wall of the quarry. An average section of freed ledge is approximately +/- 30'-0" L x 5'-0" W x 17'-0" H. The ledge is then drilled and split into smaller blocks +/- 9'-0" L x 5'-0" W x 4'-0"H, which are taken from the quarry wall by large derricks and over-sized industrial lift trucks. The blocks are then loaded onto tractor-trailer trucks for delivery to our production facility for processing.

Our 100,000 Square Foot Production Facility Once inside the plant, each granite block is examined for proper usage, according to the list of orders waiting to be produced. Large (up to 11'-6" diameter) computer-guided diamond-tipped blades saw the blocks into slabs, traveling back and forth against the grain of the granite. Water is integral to this process, both to cool the blade while sawing and to effectively eliminate the granite dust created by sawing, making the air safe for the employees to breathe.

Next, the slabs make their way to a thermalling machine, which utilizes water and a high-temperature flame to expand part of the surface of the top layer of granite. This creates a slightly pebbled surface, similar to a coarse sandpaper texture, which is a non-slip surface for walking on.

Once the thermalling has been completed, the slab travels to the splitting machine. Rows of carbide teeth, driven by 6,000 psi of hydraulic pressure, which creates 600 tons of splitting force, cause the granite to split along the natural grain of the stone. This process is repeated on all four sides of the slab, creating a finished Split Face granite step. The edge of the Split Face step has a natural surface that alternates between a slightly concave and slightly convex finish.

For a more bold edge finish for your step, we split the step slightly larger than the finished size will be, and send it to our Rock Facing station. Our skilled craftsmen then use a hammer and chisel to remove the excess granite from the top and bottom edge on three sides, bringing the step to its finished size, and creating a heavy relief along those edges. A clean arris line is then applied to the front corners of the step.

Once your step is ready for shipment to our retail locations, we use radio-controlled overhead cranes, capable of lifting up to 35 tons each, to lift your step and transport it to a flatbed trailer in our loading dock.

Delivery to your home Once your steps reach our retail store, they will be loaded onto our ten-wheel flatbed crane truck for delivery to your home. On average, our cranes will reach up to 20 feet from the truck, and you should check with our sales associates to determine that we can reach where you need to have the steps installed, and that no obstacles exist.

On a properly prepared and level, concrete or compacted gravel pad (ask your sales associate for details), our delivery driver will install your granite steps in front of the door to your home. Granite steps are impervious to the effects of rock salt, and will weather beautifully over time. Your steps are maintenance free for your peace of mind.