Pohaku Fabrication is pleased to provide full-service stone template, fabrication and installation services. At each stage of your project, you can expect expert and professional service where quality and your satisfaction is our goal. Our professionals are trained in the most current techniques and utilize the latest technologies. Click the steps of the process below to learn more about each service and step of the process…
Once we have firmed up the details of your project and we have a signed contract, our general manager will schedule a template to be made of your project. Please ensure you have read, signed and complied with the items on the Pre-Template Checklist, as this will ensure that we make the most accurate template for your project.
When our professional arrives at your location, they will walk through every detail with you and/or your contractor/project manager to ensure you get exactly what you have envisioned. If changes need to be made to the cabinets, sink, stove, outlets, etc., you will be notified by our template master. Our team is known for being meticulous so as to ensure your complete satisfaction with the finished product. We use low profile plastic strips in the template process that reduce waste and increase accuracy enabling us to outline any cabinet, sub top, fireplace, vanity, shower or other feature.
We also provide full support for every project; this means if you have a question or need some advice, give us a call! We are always willing to share our professional experience with you to help better your project, and the best thing about it………we offer it completely FREE! Email us if you have any questions on our process, need advice or if you’re ready, come down right now to pick out your dream kitchen!
After your template has been created, your project is then put into the production schedule. The template is laid on the slab of stone, then our lead fabricator will position the template so the color as well as the veining match as closely as possible. This is a crucial step as a well matched seam will make your surface flow seamlessly.
After your stone is carefully cut with our Gantry Saw, our fabricators will begin to put the edge detail on each individual counter. A laminated edge is the standard and and the best way to achieve a perfect lamination is to grind the bottom of the stone smooth and custom tint our industrial strength glue to a perfect color match with the stone. After the glue is cured, it moves to our Pro-Edge where it receives a perfectly carved custom edge detail with a sheen that matches the entire counter top. We are capable of creating any edge detail that you can envision!
Seams & Final Fit
After the edge detail is finished, each piece is put on a table and the template is placed back on the top to double check and trim each piece to ensure a smooth installation. The seams then go through our special 3-step process to ensure an outstanding fit. The entire project is then put together using specialty tables that allow us to physically put your project together in the shop to double check everything before installation.
Sink Cut Outs & Finishing Touches
After your kitchen is put together in our shop, each sink is laid out to the exact location specified on the template. Our professional sink cutters have years of experience and have cut thousands of sinks of all shapes, styles and sizes. This is a precise cut that is rough cut, carefully ground to shape, then finished to match the surface of your counter top no matter if it is polished, honed, brushed, leather or even flamed! Once the sink is cut, each piece is compared to the template and the details are checked yet again to ensure a smooth installation. After we are all satisfied that your project is something we will be exceptionally proud of, it receives an impregnating sealer in the shop to help protect your counter surface.
The project is ready for installation! Our scheduler will contact you or your project manager to set up a day and time for installation!
OK! So now your project is ready for installation! We will give you notification of an installation time at least 1 day in advance. We take pride in being punctual, our installation crew does its best to reach your job site at or before your scheduled time. We ask for your kokua in helping our installation go smoothly by having all areas to receive stone be clear off prior to our arrival and a clear path be make so our installers can safely do their job. These are heavy pieces of stone and we want your house as well as our crew to end the day safely!
Our highly trained installers go to great lengths to treat you and your house with the professionalism and respect it deserves. If there is any concern or question you have, don’t hesitate to ask one of our professionals. Installation will usually take 4 to 8 hours; some times our installation crew will work a little late as they are dedicated to getting your project done and done right. On some rare occasions, our installers may return the next day to finish or do touch up work. Faucet holes are usually drilled on site and we ask that you or a representative (i.e. contractor, plumber) be present to lay out the position of the holes and confirm the size of the holes needed. This extra step is to ensure the plumber will have the room to install the fixtures and you get the custom finish that you had envisioned.
After everything is completed, we will cover your finished project with blue protective plastic to help protect your investment until your entire project is completed. If you do not wish to have this plastic installed, let the installers know and they will more than happy to accommodate you. We do ask that you try not to bump, push, stand or put any pressure on the counter tops for at least 24 hours to give our adhesives time to harden and cure.
Congratulations! Your stone surfaces are now in place! We will send you a thank you letter, an invoice as well as a brochure on how to maintain and care for your new counter tops or you can visit our Care & Maintenance page for more information.
Pohaku Fabrication is proud to announce the ability to precision cut any material, a unique service offered on Kauai! We offer custom cutting for that unique project or help you create that hard to find part. You can bring in your own design, or we can work with you to design exactly what you need for custom individual pieces or high volume production! Visit us for a free consultation.