Process of Making Synterra Surfaces
Ever wondered how our Synterra Surfaces are created?
Synterra Surfaces are crafted differently from traditional engineered stone or porcelain. Made from natural clay and fired at low temperatures, each slab is created through a controlled, gentle manufacturing process that prioritises durability, stability, and beautiful design.
Here’s an inside look at how Synterra claystone slabs are made — step by step.
1. Creating the Product: Refining the Raw Clay
The journey begins with raw clay.
The clay is carefully
refined, filtered, and processed into a fine clay powder, removing impurities and preparing it for transformation.
Once refined,
colour pigments are blended into the clay, allowing us to create the full range of Synterra Surface colour collections.
Every shade is designed to replicate the organic beauty of natural stone — without the silica or stress of traditional materials.
2. Manufacturing the Slab: Forming the Claystone Base
After the pigments and clay have been combined, the mixture becomes the base of our Synterra claystone.
From here, the coloured claystone is:
- Poured and moulded into slab form
- Shaped and refined using both specialised machinery and detailed hand‑work
- Designed individually, giving every slab its own natural character and veining
This blend of technology and craftsmanship ensures each slab is consistent in performance while still having unique visual depth.
3. Curing the Slabs: Slow, Gentle, and Controlled
Once shaped, the slabs enter the curing stage — the key to Synterra’s strength.
Unlike materials that are flash‑heated at extremely high temperatures, Synterra Surfaces are:
- Baked slowly at low temperatures (105–110°C)
- Compacted at up to 1700°C during manufacture, then
- Cured for 12–24 hours to prevent internal stress
- Cooled for a similar period to avoid cracking or tension
This gentle curing cycle is essential.
By heating the slabs slowly and cooling them just as gradually, the claystone develops durability and structural stability without brittleness.
4. Final Finishes: Polished, Protected, and Ready for Installers
When fully cured, each slab undergoes its finishing stages:
- Quality checking for any imperfections
- Polishing to the correct finish (matte, textured, or soft sheen depending on the collection)
- Cleaning and sealing
- Wrapped with a protective coating for safe transport and storage
Once complete, the slabs are ready for fabrication — cut, shaped, and installed by stone professionals around Queensland.
A Better Way to Build With Stone
Synterra Surfaces are created with performance, sustainability, and installer safety in mind.
From raw clay to final slab, every step is designed to deliver a strong, 0% silica surface that looks and feels like natural stone — without the limitations of traditional materials.
