New Shop Setup Checklist for Countertop Fabricators
What Does New Shop Setup Involve?
Setting up a new countertop fabrication shop requires planning across facilities, equipment, licensing, staffing, and operations. The typical startup investment ranges from $150,000 to $500,000+ depending on equipment choices and shop size. This checklist walks through every step from facility selection to your first completed installation, helping new owners avoid the expensive oversights that plague first-year operations.
TL;DR: New Shop Setup Priorities
- Facility needs: 2,500-5,000 SF minimum with water access, power, and overhead crane capacity
- Core equipment costs: $80,000-$250,000 for CNC, bridge saw, and edge polisher
- Licensing and insurance: $3,000-$8,000 annually depending on state requirements
- First-year revenue target for viability: $300,000-$500,000 (roughly 8-15 jobs/month)
- Time from lease signing to first job: typically 60-120 days
- Top reason new shops fail: undercapitalization -- plan for 6 months of operating expenses
- Average US fab shop serves a 30-60 mile radius
Complete New Shop Setup Checklist
Section 1: Business Foundation
- Business entity formed (LLC or S-Corp recommended)
- EIN obtained from IRS
- State business license obtained
- Contractor's license obtained (required in most states for installation work)
- General liability insurance secured ($1M minimum recommended)
- Workers' compensation insurance in place
- Commercial auto insurance for delivery vehicles
- Business bank account opened
- Accounting system set up (QuickBooks or equivalent)
- Business plan completed with 3-year financial projections
- Startup capital secured (minimum 6 months operating expenses + equipment)
- CPA or accountant retained
Section 2: Facility Selection
- Minimum 2,500 SF shop floor (3,500-5,000 SF preferred)
- Ceiling height minimum 14 feet for overhead crane installation
- Floor rated for heavy equipment loads (6" concrete minimum)
- Adequate electrical service (200A minimum, 400A preferred for CNC)
- 3-phase power available or cost to install confirmed
- Water supply adequate for wet cutting operations
- Floor drains or water management system feasible
- Exterior slab storage area (500-1,500 SF, A-frame accessible)
- Loading dock or grade-level access for deliveries
- Zoning confirmed for light manufacturing use
- Lease terms reviewed by attorney (minimum 5-year term recommended)
- Proximity to customer base (30-60 mile service radius)
- Office space for 1-3 administrative staff
- Customer-facing area or showroom space (optional but valuable)
Section 3: Equipment Procurement
- CNC machine selected and ordered (lead time: 4-12 weeks)
- Bridge saw selected (manual or automated based on budget)
- Edge polisher/profiler (inline or standalone)
- Overhead crane installed (1-2 ton capacity minimum)
- A-frame slab storage racks (shop interior and exterior)
- Forklift or boom truck for slab handling
- Digital templating system (laser or photogrammetry)
- Water filtration/recycling system (environmental compliance)
- Dust collection system
- Air compressor (for tools and cleaning)
- Hand tools: routers, grinders, polishers, clamps
- Diamond tooling inventory (blades, bits, pads)
- Installation truck with A-frame rack
- Suction cups and carrying clamps
- Safety equipment: glasses, gloves, ear protection, respirators
Section 4: Software and Technology
- Fabrication management software selected (job tracking, scheduling)
- CAD/CAM software for CNC programming
- Accounting software integration
- Customer portal or communication system
- Quoting/estimating tool
- Slab inventory management system
- Phone system with business line
- Email hosting with professional domain
- Cloud backup for all business data
- Template processing software (compatible with templating hardware)
Section 5: Regulatory Compliance
- Building permits obtained for facility modifications
- Environmental permits for water discharge (wet cutting)
- OSHA compliance review completed
- Silica dust exposure plan documented (OSHA Table 1 compliance)
- Fire suppression system adequate for shop operations
- Emergency exits clearly marked
- First aid station set up
- Safety Data Sheets (SDS) binder for all chemicals
- Waste disposal contract for slurry and offcuts
- Air quality permits (if required by local jurisdiction)
Section 6: Staffing
- Shop manager/lead fabricator hired (experience critical)
- CNC operator hired or trained
- Installer(s) hired (minimum 2-person crew)
- Templater hired or outsourced
- Office/sales staff hired
- Payroll system set up
- Employee handbook drafted
- Training plan established for each role
- Safety training completed for all staff
- Silica exposure training documented
Section 7: Supplier Relationships
- Primary slab suppliers identified (2-3 minimum)
- Supplier accounts opened with credit terms established
- Initial slab inventory purchased (15-30 slabs to start)
- Tooling supplier identified (diamond blades, pads, bits)
- Adhesive and caulk supplier established
- Hardware supplier (sink clips, supports, brackets)
- Plumbing parts supplier (for installation needs)
Section 8: Sales and Marketing
- Website launched with portfolio and contact form
- Google Business Profile claimed and optimized
- Yelp business page created
- Houzz profile created with project photos
- Business cards and brochures printed
- Vehicle signage/wrap installed
- Builder/contractor referral program designed
- Designer/architect outreach list created
- Grand opening event planned
- First 3 months of marketing budget allocated
Typical Startup Cost Breakdown
| Category | Budget Range | Notes |
|---|---|---|
| Equipment (CNC, saw, polisher) | $80,000-$250,000 | New vs. used significantly affects cost |
| Facility (lease, buildout, utilities) | $20,000-$60,000 | First/last month + buildout |
| Initial slab inventory | $15,000-$50,000 | 15-30 slabs at $500-$1,500 each |
| Tooling and consumables | $5,000-$15,000 | Diamond tooling, adhesives, hardware |
| Software and technology | $3,000-$10,000 | Annual subscriptions + hardware |
| Vehicle(s) | $15,000-$45,000 | Used truck with A-frame build-out |
| Insurance and licensing | $3,000-$8,000 | Annual costs |
| Marketing | $3,000-$10,000 | Website, signage, initial advertising |
| Working capital (6 months) | $30,000-$80,000 | Payroll, rent, utilities before revenue |
| Total | $174,000-$528,000 | -- |
Common Mistakes New Shop Owners Make
- Undercapitalization -- Running out of cash before reaching profitability. Plan for 6 months of zero revenue.
- Buying too much equipment -- Start with the essentials and add capacity as demand proves itself.
- Hiring too fast -- Owner-operators should run lean until monthly job count consistently exceeds 10.
- Ignoring water management -- EPA and local environmental fines for improper discharge can reach $10,000+.
- No written processes -- Without checklists and documented workflows, quality is inconsistent and training new employees takes 3x longer.
FAQ
How much does it cost to start a countertop fabrication shop? Total startup costs range from $150,000-$500,000+ depending on equipment choices (new vs. used), facility location, and initial inventory. Budget $30,000-$80,000 for working capital on top of equipment and facility costs.
How long until a new fab shop is profitable? Most new shops reach break-even at 8-12 jobs per month, which typically takes 6-18 months depending on market conditions and the owner's sales ability.
Do I need a contractor's license to install countertops? In most states, yes. Countertop installation is classified as contracting work. Requirements vary by state -- check your state contractor licensing board.
What is the minimum shop size for countertop fabrication? 2,500 square feet is the practical minimum for a CNC-based shop. This is tight. 3,500-5,000 square feet provides room for growth and better workflow.
Should I buy new or used equipment? Used CNC machines and bridge saws can save 40-60% over new. The trade-off is older technology, potentially higher maintenance, and no manufacturer warranty. For a startup, a well-maintained used CNC at $40,000-$80,000 is often the right call.
How many employees does a new shop need? Minimum viable team is 4-5 people: shop manager/CNC operator, one fabrication assistant, two installers, and one office/sales person. Many owners fill the sales role themselves initially.
What insurance do I need for a countertop shop? General liability ($1M minimum), workers' compensation (required in almost all states), commercial auto, and professional liability. Budget $3,000-$8,000 annually.
How do I find my first customers? Builder and contractor relationships are the fastest path to consistent work. Attend local builder association meetings, visit construction sites, and offer competitive pricing to build your portfolio.
Get Your New Shop Running on the Right Software
SlabWise helps new fabrication shops look professional from day one. Quick Quote generates accurate estimates in 3 minutes, the Customer Portal impresses homeowners, and Slab Nesting reduces waste by 10-15%. Plans start at $199/month. Start your 14-day free trial at slabwise.com.
Sources
- Natural Stone Institute -- New Business Startup Resources
- Small Business Administration -- Manufacturing business guides
- OSHA -- Respirable Crystalline Silica Standard for Construction
- Stone World Magazine -- Annual industry survey and startup profiles
- ISFA -- Fabrication shop planning guidelines
- EPA -- Stormwater and wastewater management for stone fabrication