How headstone is made - material, manufacture, making, ...

Headstone

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Understanding the Background of Headstones

Headstones, also referred to as memorial stones, grave markers, gravestones, and tombstones, all serve the same purpose: to honor and remember the deceased. Initially, headstones were crafted from fieldstones or wooden pieces. In some areas, "wolf stones" were utilized to cover shallow graves and protect them from scavenging animals.

The Evolution and History of Headstones

Archaeologists have discovered Neanderthal graves dating back between 20,000 and 75,000 years. These graves, often found in caves, had large rock piles or boulders covering their entrances. It is believed these sites were accidentally created as the sick or injured were left behind, with rocks or boulders placed for protection from wild animals. For instance, the Sharindar Cave in Iraq revealed the remains of an individual surrounded by flowers, dating back to around 50,000 B.C.

Over time, various burial methods emerged. The Chinese pioneered the use of coffins around 30,000 B.C. In Egypt, mummification and embalming processes began around 3200 B.C. to preserve the bodies of pharaohs for the afterlife. These pharaohs were entombed with statues, gold, and luxuries to ensure their acceptance in the afterlife. Both cremation, which began around the same time, and traditional burials, continue to be popular. Presently, cremation accounts for 26% of the disposal methods in the U.S. and 45% in Canada.

Religious developments often frowned upon cremation, associating it with pagan rituals. Burials became the preferred method, with bodies sometimes laid out for days at home for friends and family to pay their respects. The European Plague in 1348 necessitated quick burials away from cities to control the spread of the disease. This led to regulations regarding grave depth and smaller funerals. Overcrowded cemeteries remained an issue until the establishment of garden-style cemeteries, like Paris's Pèere-Lachaise in 1804, where headstones became elaborate status symbols.

Materials Used in Headstone Creation

Early headstones were crafted from slate, particularly in New England due to its availability. Marble later gained popularity, but it was prone to erosion, making inscriptions difficult to read. By 1850, granite emerged as the preferred material due to its durability and availability. Today, granite is the most commonly used material for memorials.

Granite is an igneous rock consisting mainly of quartz, feldspar, and plagioclase feldspar, with other minerals mixed in. It can appear in various colors such as white, pink, light gray, or dark gray, formed from slowly cooled magma. This magma is brought to the surface through geological movements and soil erosion.

Custom Headstone Designs

Headstones can be highly customized with epitaphs ranging from scripture quotes to humorous statements. Statuettes may adorn the stones, either carved into, placed atop, or positioned beside them. The size and shape of headstones also differ widely. Typically, all stones are machine-polished and carved before being finely detailed by hand.

The Detailed Process of Manufacturing Headstones

1. The first step involves selecting the stone type (usually marble or granite) and its color. The granite block is then quarried from the bedrock using one of three methods. Drilling is the traditional method, where a pneumatic drill creates vertical holes. Jet piercing, a faster method, uses a high-speed flame to cut the rock. Water jet piercing, a quieter and more efficient process, employs high-pressure water streams to cut the granite.
2. The block is then detached from the quarry bed using blasting charges placed in horizontally drilled holes. This results in a clean break from the remaining rock.
3. Granite blocks, typically 3 feet wide, 3 feet high, and 10 feet long, are lifted and transported to the headstone manufacturer. The blocks weigh around 20,250 pounds. Some quarries are independently owned, while others are part of larger companies.
4. Arriving at the manufacturing facility, the granite slabs are cut into smaller sections with a rotary diamond saw, ranging from 6 to 12 inches thick.
5. The slabs are polished by passing under several rotating heads with varying grit levels to achieve a smooth, polished finish.
6. Next, the polished slab is moved to the hydraulic breaker, which uses carbide teeth to make a vertical cut through the stone.
7. The stone is then shaped, either by hand with chisels or more precisely with a multi-blade diamond saw. This machine can hold multiple blades to cut the stone into the desired shape.
8. The surfaces are further polished and smoothed.
9. Vertical edges are polished by an automated machine, while radial edges are ground and polished simultaneously using diamond grinding drums with differing grits.
10. For intricate shapes, a diamond wire saw, guided by computer software, etches the designs into the headstone. Fine details are completed by hand.
11. In the finishing stage, the outer edges of the stone might be hand-chiseled for a more personal and defined appearance.
12. For engraving, sandblasting is commonly used. A rubber stencil is applied over the stone, and the design is transferred onto the stencil. Sandblasting cuts the exposed design onto the stone. The process is done in a controlled environment to protect the worker from harmful particles.
13. Finally, the stone is cleaned with high-pressure steam, polished once more, and carefully inspected. It is then packaged and shipped to the customer or funeral director.

Ensuring Quality Control

Quality control is essential throughout the manufacturing process. Each granite slab is inspected for color consistency, and any stone showing signs of defects is removed from the production line.

Managing Byproducts and Waste

Waste production varies with the quarrying method. Drilling generates more waste, while the water jet method is quieter and more efficient, with minimal dust and noise pollution. Sandblasting waste is minimal as sand particles are often recycled. Any rejected granite is usually sold to other manufacturers or exported.

Future Developments in Headstone Production

Advancements in software allow for more intricate headstone designs, including laser etching, which can inscribe detailed pictures and designs using laser beams. This method makes the crystals on the granite surface pop, creating raised and light-colored etchings. Despite increasing granite quarrying, new sources continually emerge, and regulations limit export quantities. Changing burial practices, like the rise of cremation, might also influence headstone production trends. By 2015, cremation was expected to become the more prevalent choice over burials in Canada.

Where to Learn More

Other

Cold Spring Granite Brochure. 17 October 2001. <http://www.coldspringgranite.com>.

Elberton Granite Association, Inc. Elberton Granite: The Quarrying and Manufacturing Process. 19 October 2001. <http://www.egaonline.com/index.htm>.

The company is the world’s best lying angel marble statue services supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.

Monument Builders of North America. The Monument Industry Certification Manual. July 1993. <http://www.monumentbuilders.org>.

Rock of Ages Web Page. 17 October 2001. <http://www.rockofages.com>.

Deirdre S. Blanchfield

How Do You Make a Memorial Headstone?

For thousands of years, memorial headstones have been a way for people to honor their loved ones who have passed. In ancient times, stone grave markers were exclusive to the wealthy. Creating these markers required the effort of hundreds to cut, move, and engrave the stones, making them a luxury only few enjoyed.

As technology improved, headstones became more affordable. Machinery capable of cutting and transporting stone in large quantities reduced costs, making headstones increasingly accessible. Consequently, stone head markers or tombstones became more widespread.

Stones used to mark graves centuries ago remain today, providing solace to those who want their loved ones to be remembered for many generations. Yet, many wonder about the modern process of creating a headstone.

Beginning at the Quarry

The majority of today's headstones are made from granite, a material prized for its durability and relative ease of cutting and transportation. Granite can withstand extreme weather conditions, from hurricanes to floods, lasting for centuries. Typically, granite is extracted from a rock quarry where it is cut from the bedrock, generally by drilling.

A pneumatic drill drills vertical holes, usually around 20 feet deep, enabling miners to remove significant granite blocks approximately three feet wide, three feet high, and ten feet long. Weighing about 20,250 pounds each, these blocks are lifted onto flatbed trucks using a winch and transported to a granite manufacturer.

At the manufacturing site, these granite slabs are then cut into smaller, more manageable pieces using a diamond rotary saw. Depending on the specific order requirements, the slabs are cut between six to twelve inches thick.

Polishing Process

After cutting, each granite slab undergoes a polishing process. Multiple rotating heads with different grit levels polish the stone. Initial heads with rough diamond grit remove large imperfections. Subsequent heads hone the stone, while the final heads, equipped with felt buffer pads, impart a glossy finish using water mixed with aluminum or tin oxide powder.

Once polished, the slabs are cut to the desired shape and size based on customer specifications. This can involve industrial diamond blades or rock pitching, in which a stone mason manually chisels the edges to achieve a unique shape. The finished monument is then packaged and shipped to the monument builder.

At the monument builder's facility, often referred to as the stone mason's, the granite is transformed according to the customer's design. While waiting for the granite slabs, the stone mason collaborates with clients on the tombstone design, using drawings or computer models to visualize the final product. This ensures customer satisfaction before the carving begins, minimizing waste.

Final Production Stages

Once the design is approved, engravers use computer-generated models to create stencils that guide the engraving process. Information such as names, dates, and artwork is etched into the granite. Advances in technology now allow for more detailed designs, including artwork and portraits not previously possible.

Engravers use high-pressure air hoses to trace the stencil design onto the granite. Crevices can be filled with litho to make the lettering stand out against the stone's natural coloring. The stencil is then removed, leaving the engraved headstone ready for shipping.

This process, from cutting the granite to the final product, takes time. Transporting the stone from the quarry and cutting it can take several weeks. Although some granite manufacturers have pre-made slabs, custom pieces require a longer wait. The design stage can range from an hour to several months, while the engraving process itself can vary from a day to several weeks based on complexity.

It often takes several months from the initial order to the final headstone placement.

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