Producing your memorial is, within its' realm, an art. Once the design has been confirmed, an order is placed for the material at a quarrying center. These centers are worldwide and the particular center being used would depend on the granite, or marble, selected by the client. A normal lead time to expect when ordering a special shaped stone would be about 90 to 120 days for arrival. Occasionally, when ordering foreign granites, this lead time can be extended due to government regulations at the port of entry.
Since the beginning of time, man has recorded history by engraving in stone. The durability of this process can be seen from the discovery of cave art and the Egyptian Pyramids. Engraving has evolved into a mechanized process, for the most part, in the memorialization industry.
To give a simplified overview of how a memorial is produced, using the sandblast process, is as follows: a stencil of the design is prepared using the information provided by the client. The stencil is then applied to the stone of choice. The areas of the stencil that are to be sandblasted will have the masking removed to allow the sand to enter and cut the stone surface, creating the lettering and pattern selected. Once the stencil is completed and information verified, the unit goes to the actual sandblast process. An experienced craftsman controls and monitors this phase of production continuously, as this is a critical stage of the production process. Once the unit completes this stage of the process, it then moves into the shaping room where floral carvings are hand shaped to become three dimensional. Upon completion, the unit is washed and placed in the delivery department.
Modern technology has opened a new realm in memorialization by introducing etching, either by hand, or laser. Generally this is done on black granite. It offers clients much greater detail in design as well as a greater variety of designs in comparison to sandblast carving. Scenes of hunting and fishing, vehicles, and portraits are favorites when using this process.
Sears Monument Company installs memorials in over 800 cemeteries each year. Many of the cemeteries are located in rural areas which require the use of a four wheel drive vehicle. Quite frequently, and in addition to the four wheel drive vehicle, we have to use a "power buggy" to assist us . This is a result of the hilly terrain of our region. We do our best to assess the information provided by our clients to determine what equipment is needed for each installation. Many times the purchasers are, themselves, not familiar with what is needed to accomplish the task. As a result of these situations, our normal delivery time of 6 weeks is often lengthened. One of our most common problems we face when getting to the site is finding we need a "dutchman" to make a proper installation. A "dutchman" is an additional piece of granite, placed on top of the concrete foundation, used to make the memorial level. A photo of a unit which has a "dutchman" used is shown to the left. The size of a dutchman and the quantity needed will vary for each size of the base of the memorial and the amount of slope at a site. Some people use "formed-up" concrete for this function. Exposed concrete will erode in our "freeze/thaw" climate creating a problem down the road with a leaning, or, fallen memorial. Utilizing granite solves the problem ahead of time.
Additionally, we can supply a concrete foundation for the memorial. We guarantee the memorial to remain level for future generations. Some families prefer to do this foundation work themselves. We will deliver the memorial upon notification from the client and place on their foundation, however, the warranty to remain level would not apply.