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ALPHA SURFACES

Fabrication & Installation Manual

Version 1.0

March 2026

© Alpha Surfaces

[Cover Image – Alpha Surfaces Kitchen Installation]

CONTENTS

• Introduction

• Product Overview

• Slab Information

• Product Inspection

• Storage & Handling

• Fabrication Equipment

• Safety Guidelines

• Templating

• Cabinet & Support Requirements

• Fabrication Procedures

• Edge Fabrication & Polishing

• Seaming

• Installation

• Wall Applications

• Care & Maintenance

1. INTRODUCTION

Alpha Surfaces represents the next generation of high-performance mineral surfaces. Developed using an advanced Zero Silica Formulation, Alpha Surfaces is engineered from premium minerals and recycled materials to deliver exceptional durability, enhanced translucency, and superior aesthetic performance - while prioritising fabrication safety and environmental responsibility.

2. PRODUCT OVERVIEW

The composition of Alpha Surfaces ensures high durability, structural stability and excellent resistance while completely eliminating crystalline silica.

Our surfaces offer classic engineered-stone aesthetics, including solid colours, natural stone tones, subtle patterns and mor dramatic veinng, produced using advanced moulding technology adapted from traditional quartz manufacturing but now reengineered for a silica-free formulation.

Aesthetic and functional performance

The zero-silica surfaces display remarkable depth and brightness, free from visible particulate grains and offering superior light reflection and colour clarity. Engineered to meet both residential and commercial requirements, the material delivers excellent hardness, stain resistance, low porosity and long-term durability.

These next-generation products redefine engineered stone by delivering full elimination of crystalline silica, high recycled content and advanced digital design technologies.

Alpha Surfaces are developed to provide a sustainable, high-performance surface suitable for residential and commercial applications.

Alpha Shield

Thanks to AlphaShield™ Technology, Alpha Surfaces provides a Lifetime Stain Resistance Guarantee on all surfaces when used in approved applications.

When properly installed and maintained according to the Alpha Surfaces Care & Maintenance Guidelines, Alpha Surfaces products will:

• Resist staining from common household substances

• Withstand exposure to substances with a pH range between 1 and 13

• Resist acid corrosion within this pH range

The warranty does not cover staining caused by substances exceeding pH13, harsh chemicals, misuse, or failure to follow the recommended care instructions.

• SLAB INFORMATION

SIZE

Slab dimensions: 3200 mm × 1600 mm usable surface

THICKNESS

Available in 20 mm thickness

FINISH AVAILABLE

• Polished

• Matte

BACK LIGHTING

Available in some surfaces (refer website)

Slab Image indicating nominal slab size of 3200 x 1600mm

COMPLETE INSPECTION OF PRODUCT

VISUAL INSPECTION OF SLABS

A complete visual inspection for defects and colour consistency is essential when working with engineered stone. This inspection must be carried out before any cutting or fabrication begins.

Follow the steps below:

• Remove the protective film before inspection.

• Inspect both the front and back of the slab.

• Check for hairline cracks or structural defects.

• Confirm accurate colour matching between slabs before fabrication.

• Verify dimensions, warping, irregular spots, or other defects that may make the slab unsuitable for fabrication.

• Check the pattern flow and orientation for veined materials.

Important:
Once a fabricator has deemed a slab acceptable and it has been cut or machined in any way; the slab cannot be exchanged or refunded. The fabricator is responsible for ensuring the slab is suitable for fabrication before modification.

Alpha Surfaces will not accept claims once the slab has been modified, cut, or fabricated.

Alpha Surfaces replicates marble and features veined patterns that are non-directional. Vein distribution may vary throughout the slab and along its edges. As slabs are not book matched, fabricators must carefully plan the layout to achieve the best aesthetic outcome.

Slight colour variation between batches or production cycles is normal due to the blending of natural minerals and raw materials.

When using multiple slabs:

• Check the batch and shade numbers on the slab labels.

• Remove the protective plastic film.

• Visually inspect all slabs for colour consistency and defects before cutting.

• When planning the layout, ensure backsplashes match the countertop colour and vein pattern.

Standard Alpha Surfaces Labels on Slabs

Each slab includes two to three labels:

• Safety sticker

• Slab detail sticker

• Alpha Shield label

Slab Sticker Information

• Item name

• Item number

• Production batch

• Shade number

The item number, batch number, and shade number are also printed on the edge of the slab.

Please note: These slabs contain less than 1% crystalline silica.

Image of all labels

RECOMMENDATIONS FOR SLAB STORAGE IN FABRICATION SHOPS

A-FRAMES

The best way to store Alpha Surfaces slabs for fabrication or transport is on A-frame racks constructed from wood or metal.

These frames should ideally include forklift receivers for safe loading and transport.

Frame Image

Double A-frames must have equal numbers of slabs on each side for proper balance and safety.

Typical A-frame sizes:

Basic A-Frame

• 1500 mm (L) × 1510 mm (W) × 1600 mm (H)

• Capacity: 3,900 kg

• Weight: 54 kg

Large A-Frame

• 1830 mm (L) × 1830 mm (W) × 1624 mm (H)

• Capacity: 5,500 kg

• Weight: 68 kg

Single-sided A-frames may also be used according to the manufacturer’s specified capacity.

When storing slabs:

• Always strap slabs to the frame.

• Store slabs flat with no gaps between them.

• Place slabs face-to-face or back-to-back to protect polished surfaces.

Alpha Surfaces slabs must always be securely strapped when transported, whether inside the fabrication shop or on vehicles.

A-frames are suitable for temporary storage only, not long-term storage.

Image

VERTICAL STORAGE RACKS FOR SLABS

Vertical storage racks are recommended for long-term slab storage.

Racks should:

• Be steel constructed

• Be capacity rated

• Be designed specifically for stone slab storage

Most systems come in 1.5 m or 3 m sections with 50 mm × 50 mm uprights. Rubber-tipped uprights are recommended to prevent slab damage.

Typical capacities:

3 m Rack Systems

• Usually include 16 uprights

• Approximate capacity: 10,750 kg between uprights

• Approximate load per upright: 5,400 kg

1.5 m Rack Systems

• Usually include 8 uprights

• Capacity between uprights: 3,100 – 4,100 kg

• Load per upright: 1,450 – 2,000 kg

Actual capacities vary by manufacturer. Values in this guide are based on heavy-duty racking systems.

Slabs should always be stored:

• Face-to-face or back-to-back

• With the protective plastic film intact

RECOMMENDED FABRICATION EQUIPMENT & BASIC SAFETY EQUIPMENT

PROPER MATERIAL HANDLING OF ALPHA SURFACES

Alpha Surfaces slabs must never be transported horizontally. Horizontal handling places excessive stress on the slab and may cause hairline cracks or breakage.

Recommended handling equipment:

• Heavy-duty slab carts or dollies

• Slab booms and clamps for cranes or forklifts

• Pneumatic vacuum suction cups with white rubber pads. We recommend that all suction cups be used with white rubber to prevent dark rings from appearing on the slabs.

All countertop cutouts should be supported with 2" × 4" × 8' support rails during transportation.

BASIC DIAMOND TOOLING & POWER TOOLS

Minimum tooling required for fabrication includes:

• Wet diamond polishing pads (grits: 50, 100, 200, 400, 600, 800, 1500, 3000)

• Honed finish pads (100–600 grit)

• Diamond cup wheels

• Diamond core bits

• Diamond contour blades (sink cutouts)

• Diamond turbo blades (5" and 6")

• Diamond r