HUB · CUT-TO-SIZE FABRICATION GUIDE
Cut-to-Size Turkish Marble Fabrication — 5 Stages, ±0.5 mm, Edge & Finish
Cut-to-size natural stone is a factory-fabricated product cut to the project's CAD file: slab size, edge profile and finish are completed under workshop conditions, and no site cutting is required. The Sipahi Marble workshop runs 5-axis CNC machining across marble, granite, travertine and onyx slabs to a ±0.5 mm dimensional tolerance and detailed undercut anchoring and curved geometries for cladding. This hub page summarizes the process stages, tolerances, edge profile and finish options, packaging and FCL/LCL logistics for architects, GCs and distributors.
30-SECOND SUMMARY
- 5-stage process: CAD intake → shop drawing → block/slab selection → 5-axis CNC fabrication → QC and packaging.
- Tolerance: Dimensional ±0.5 mm (below ANSI A137.3 and TS EN 12058 limits).
- Edge profiles: Straight, eased, bevel, bullnose, ogee, cove, waterfall/mitred — CAD-modelled per project.
- Finish types: Polished, honed, leathered, flamed, brushed — aligned with LEED HPD spec disclosure.
- Packaging & logistics: Wooden A-Frame, FCL 20'/40' container (25-27 tons), LCL consolidation.
- Lead time: 6-10 weeks (project scale dependent); Trade Program members prioritized.
1 · WHAT IS CUT-TO-SIZE
Factory-Cut Natural Stone — Why It Differs from Stock Slab
Cut-to-size natural stone is a product category where slabs are dimensioned in a workshop to the geometry of the project's CAD file and edge profile plus finish are completed before shipment. Buying a stock slab (standard 2400×1200 mm or 3200×1600 mm) forces on-site cutting — which reduces dimensional tolerance and increases breakage/waste.
Cut-to-size moves that risk to the factory: 5-axis CNC machines dimension the slab, drill undercut anchor holes, machine edge profiles, apply the finish and route through QC. The site team receives ready-to-install slabs — install time drops, dimensional errors decline.
Critical use cases: Facade cladding, interior flooring (especially large-format), countertops, bath paneling, stair treads and landscape stone. Cut-to-size is the standard preference in export markets and the most frequent request Sipahi encounters in US project spec sheets.
2 · 5-STAGE PROCESS
From CAD Intake to Container Loading — Workflow
STAGE 1
Project CAD Intake
We receive DWG/DXF, the slab schedule, edge profile spec, finish spec, seismic anchoring requirement (if any) and delivery date from the architect or GC. Sipahi's engineering team returns a pre-review and quotation within 2-3 business days.
STAGE 2
Shop Drawing Preparation
A dedicated shop drawing is produced for every slab: dimensions, undercut hole layout, vein-match plan (book-match, sequence-match, quad-match), edge profile detail and numbering. Fabrication starts after architect approval.
STAGE 3
Block / Slab Selection
Suitable slabs are selected from the quarry or from Sipahi stock veins. If vein-matching is requested, selection runs from a photographed stock catalogue with architect sign-off. The LEED Chain-of-Custody record begins at this stage.
STAGE 4
5-Axis CNC Fabrication
Cutting to size, undercut drilling, edge profile machining and finish application are completed in a single workshop. The 5-axis CNC holds a ±0.5 mm dimensional tolerance; typical machining time per slab is 20-45 minutes (geometry dependent).
STAGE 5
QC and Packaging
Pre-shipment, every slab runs through a photo-documented QC protocol: dimensional verification, surface homogeneity, edge integrity, vein-match check. Wooden A-Frame crating + pallet + banding; the packaging list is shared with the architect/GC prior to FCL/LCL container loading.
3 · TOLERANCES
±0.5 mm Dimensional Tolerance — Standard Compliance
Dimensional accuracy in the cut-to-size process directly drives the success of on-site installation. Tolerance targets applied at the Sipahi workshop:
- Length / width: ±0.5 mm. Below the ANSI A137.3 tile dimensional standard and TS EN 12058 limits.
- Thickness: Standard slab 20/30 mm, recommended cladding 30/40 mm. Thickness tolerance ±1.5 mm (TS EN 12058 limit is ±3 mm).
- Diagonal / squareness: ±0.5 mm. Corner angle accuracy on large-format slabs is calibrated to this value.
- Edge straightness: ±0.3 mm/m. Target for straight-edge profiles; bevel/bullnose profiles carry profile-specific tolerances.
- Undercut hole placement: ±0.5 mm radial and depth. Critical for AISI 316 anchor bushing form-fit.
4 · EDGE PROFILES
Edge Profile Options — Aligned to Project Character
Straight Edge
Flat edge. Modern minimalist applications, rain-screen facade systems, flooring. The most common cut-to-size choice.
Eased / Bevel
Light chamfer (1-2 mm 45°) or pronounced chamfer (3-10 mm 30-45°). Countertop edge, stair nosing safety.
Bullnose (R3/R5/R10)
Rounded edge. Bath/kitchen countertops, pool copings, safety in child-accessible zones.
Ogee / Cove
Classic decorative profile (S-shape). Ogee convex, cove concave. Restoration and classic interior projects.
Waterfall / Mitred (45°)
Two slabs joined at 45° for a seamless corner. Modern countertops and furniture cladding. Combined with book-match for vein continuity.
Custom / Project-Specific
Custom geometry to architect design. CAD-modelled, prototype tested on a sample slab, approved and released to production.
5 · FINISH TYPES
Surface Finish Options and ADA/LEED Alignment
Surface finish directly drives both the aesthetic character and technical performance (slip resistance, wear, cleanability) of a slab. In US projects, the ADA DCOF threshold (≥0.42 in wet condition) and finish disclosure in the LEED HPD spec are mandatory.
Polished
Glossy, high reflectance. Interior wall, countertop, decorative interior cladding. May fall below the ADA DCOF threshold — not recommended for public floors.
Honed
Matte flat surface. Interior floors, cladding, public areas. Meets ADA DCOF ≥0.42. Preferred finish for LEED submittal.
Leathered
Natural-textured satin surface. Kitchen countertops, landscape stone, wet zones (pool decks). Comfortably meets ADA DCOF ≥0.42.
Flamed
Granite standard. High heat spalls the surface for a textured, high slip-resistance finish. Exterior facade, paving, safety flooring.
6 · PACKAGING & LOGISTICS
A-Frame Crating and FCL/LCL Container Selection
To minimize breakage on long-distance export shipments of cut-to-size slabs, Sipahi uses two standard packaging options:
- Wooden A-Frame crate: Slabs held vertically in an A-shape crate with foam padding between each slab. The default for cladding and flooring slabs.
- Boxed packaging: For small format (countertop, bath panels), wooden boxes with foam inserts. Preferred for stair treads and landscape stone.
- Pallet + steel banding: Standard slab shipments — EU pallet + steel banding; forklift-friendly, cost-effective.
Container selection:
- FCL (Full Container Load): 20' container ~25 tons net, 40' container ~27 tons net (40' High Cube fits taller A-Frames). Standard choice for large projects.
- LCL (Less-than-Container-Load): 1-5 tons in a consolidation container. Preferred for sample kits, small batch orders and distributor introduction shipments.
- DDP / CIF / FOB: Sipahi offers three Incoterms® 2020 options. DDP (Delivered Duty Paid) is preferred by architects in US projects — the Sipahi team covers customs and inland transport coordination.
FREQUENTLY ASKED
6 Critical Questions for Architects and Distributors
What is the difference between cut-to-size and stock slab?
Cut-to-size is a natural stone product pre-fabricated to the project's CAD file — slab dimensions, cut geometry, edge profile and finish are completed in the workshop before shipment. A stock slab is sold at standard dimensions (typically 2400×1200 mm or 3200×1600 mm) and requires site cutting. Cut-to-size eliminates site cutting labor, guarantees a ±0.5 mm tolerance and delivers CNC-machined edge profiles from factory conditions (source: ANSI A137.3 dimension stone tile standard).
How many stages are there in the Sipahi cut-to-size workflow?
The standard workflow has five main stages: (1) Project CAD intake — DWG/DXF and spec sheet from the architect or GC, (2) Shop drawing preparation — Sipahi engineers detail every slab with its own drawing and numbering, (3) Block/slab selection — vein-match from the quarry or Sipahi stock, (4) 5-axis CNC fabrication — dimension, undercut, edge profile, finish, (5) QC and packaging — photo-documented pre-shipment inspection and pallet/container loading. Typical lead time is 6-10 weeks (project scale dependent).
How is the ±0.5 mm tolerance guaranteed?
The 5-axis CNC machines in the Sipahi workshop are calibrated to a target dimensional accuracy of ±0.5 mm. This is below the tolerance limits of ANSI A137.3 (dimension stone tile) and TS EN 12058 (natural stone products for flooring and stairs). Every slab is re-verified in the QC protocol with a CMM-equivalent dimensional check; any deviation triggers rework or rejection.
Which edge profile options are available?
Standard profile options: (1) Straight edge — modern rain-screen and interior applications, (2) Eased edge — 1-2 mm 45° chamfer for safety, (3) Bevel — 3-10 mm 30-45° chamfer, (4) Bullnose — R3 / R5 / R10 radius, typical for bath/kitchen countertops, (5) Ogee — classic S-shaped decorative profile, (6) Cove — concave inverse, stair nosing and countertops, (7) Waterfall / mitred (45° join) — 45° bevel for continuous corner. Every profile is CAD-modelled per project.
How to decide between finish types?
Polished: glossy, high reflectance, interior wall and countertop. ADA slip resistance may fall short — not recommended for public floors. Honed: matte/soft-satin, interior floor and cladding. Meets ADA DCOF ≥0.42. Leathered: satin-textured, kitchen countertops and landscape. Flamed: granite-typical, exterior facade, slip-resistant. Brushed: dedicated textural projects, disclosed in LEED HPD spec.
How are packaging and FCL/LCL logistics determined?
Sipahi offers two primary options based on shipment volume: FCL (Full Container Load) is typically 25-27 tons net in a 20' or 40' container — the standard choice for large projects; LCL (Less-than-Container-Load) is 1-5 tons of consolidated container, preferred for sample or small batch orders. Each slab is packed in a custom A-Frame wooden crate or box — breakage risk is minimized. QC photos and packaging list are shared with the architect/GC before container loading. Bill of Lading and customs documentation are prepared by Sipahi's export team.
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Turkish Marble Quarry Network
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Sipahi Trade Program
Architects, GCs, distributors — CAD and quote support
EVENT
Coverings 2027 Orlando
April 6-9, 2027 · physical sample kit meeting
Share Your CAD — Quote in 2-3 Business Days
Reach out with project name, scale (m² or slab count), edge profile, finish preference and delivery date. The Sipahi engineering team prepares the pre-review, pricing quotation and lead time schedule. Trade Program members receive slot prioritization.
Sipahi Mermer ve Granit San. ve Tic. Ltd. Şti. · İMİB Registry 336480 · Sakarya, Türkiye