To produce high-quality products, it requires perfect process management, quality control system, excellent talents, and advanced equipment. We have been perfecting and upgrading our equipment to improve the precision of production. The thickness can be controlled within 0.5mm according to the requirements, the polishing degree can reach more than 90 degrees, and the length and width accuracy is 100% ...
In our previous articles weve already talked about how marble and granite had been formed by nature, now wed like to explain how natural stone is processed and the important role of Marmi Rossi in the manufacturing process.
We personally choose all the blocks in various quarries and therefore, we travel to all corners of the globe during the entire year, always in search of new material. Mostly, we visit quarries in Brazil, India, Scandinavia, Spain and Africa.
The block selection is a very important part of our job and it takes a lot of expertise and care. It is essential to recognize fractures, infiltrations and mineral inclusions inside the block, otherwise one runs the risk to obtain fragile, stained or defective slabs after the cutting. Obviously, each natural stone has its own characteristic and each block requires to be valued according to different criteria.
In our block storage you can find about 500 blocks of random material types, which are stored on our stockyard according to their origin and colour. When necessary, the blocks are carried to the factory where they are cut into slabs.
The diamond wire saw is used upon request to cut sections or to align and adjust a block before it is cut into slabs. A block can be divided or cut in several parts before being cut into slabs, in order to check the colour, quality and defectiveness of a block.
Besides the multi wire saws, that are cutting continually blocks into slabs, our company has got other machines that polish and hone raw slabs to produce different surface finishing for our customers.
Each slab is calibrated after the cutting to obtain a homogenous thickness, then, depending on the type of material and the customers request, the surface is finished to emphasise the beautiful features of the slab.
The most sought after surface finishing are polished, honed, satined and flamed surfaces, but there are several other solutions, either the above mentioned are combined with each other or new techniques are used, e.g. water jet. If you like to learn more about surface finishing, come visit us.
A polished surface should only be used in interior spaces, whereas a honed surface and similar alternatives are suited for outdoor areas. Then again, there is no reason why you should not use flamed surfaces for interior design, particularly if in contrast to other finished surfaces.
The sequence of events which brings natural stone from the quarry to the home has not changed much since stone entered the homes of the ancient Greeks. First, large blocks of stone are cut from the quarry. From those blocks, thin pieces of stone are cut, called slabs. The slabs are then shaped and polished and shipped for installation.
What has changed dramatically over the years is the type of machinery used in this age-old sequence. Three basic types of machines are involved in the fabrication process: saws, polishers, and routers.
Saws perform several functions during fabrication. A block saw, or gang saw, cuts the massive stone blocks into slabs. These days, diamond wire saws make short work of this task. A metal wire is studded with industrial-grade or synthetic diamonds, and this wire quickly cuts through stone as hard as granite. A bridge saw is then used to cut the stone slab into the proper shape for its application, whether it be a countertop or a sink. These saws typically use circular metal blades studded with diamonds, and water is sprayed onto the blade to cool it during the cutting process. Modern technology has produced a new type of saw utilizing water jets combined with an abrasive material, which cuts edges and holes quickly and smoothly, and many fabricators are upgrading to these machines.
Polishers grind down the naturally rough surface of the stone to whatever finish the consumer desires. Hard stones like marble and granite can be polished all the way to a mirror finish. The polisher consists of rotating padswhich are surfaced with an abrasive substance. The finer and smaller the abrasive grits are, the higher the polish. Most modern polisherscan produce a variety of finishes, from the smooth, soft look of a honed finish to a slick, shiny mirror finish even decorative finishes like flamed tumbled or hammered.
Routers create edge profiles on a slab, and cut designs on larger pieces like fireplace mantles and hearths. There are dozens of standard edges for countertops and tables, from simple to highly decorative. Routers have a spinning blade covered with diamonds which is water-cooled. It travels along the edge of the slab to shape it.
In the past, these machines were either operated by hand, or had some limited automatic function. The time needed to create a finished countertop was significant. A countertop with a complex edge profile might take three weeks or longer.
With the introduction of CNC technology, however, that time has been dramatically decreased. CNC, or computer numeric control, utilizes digital technology to precisely control all three types of fabrication machines: saws, polishers, and routers. CNC has cut production time down to a single afternoon for a countertop, even with a very complex edge. CNC also makes the shaping of intricately-designed pieces like stone fireplaces fast and simple. What would normally take a sculptor many weeks to carve may now take as little as a few hours.
Today, a countertop begins its journey through the CNC fabrication process in the home, where a wooden or plastic template is cut from the existing countertop to ensure that the new countertop is a perfect fit. In the fabrication shop, the template is placed on a digitizing table, where its exact dimensions are recorded and exported to a Computer Assisted Design (CAD) program. The designer's modifications to the countertop (if any) can now be made, as well as the specification of the desired edge profile, and the location of holes for sinks, faucets, and cooktops.
Then the action begins. A massive stone block is placed on the block or gang saw, and the computer tells the saw how thick to cut the slab. Once the slab is cut, it is picked up by computerized arms and moved to the CNC machine. Here, a series of bridge saws (or water jets) and routers cut the slab to the correct dimensions, cut appropriate holes, and shape the edges. The computer controls every aspect of the shaping process, and the operator doesn't even have to remain at the machine for the entire duration. The countertop is then moved to the polishing machine, where polishing pads grind the surface of the slab to the desired finish. Some machines have laser eyes which ensure that the finish is perfect and even across the entire countertop. Edge polishing machines are then used to finish the edge profiles.
CNC has doubled (or more) the productivity of most fabrication shops that have acquired it. It has contributed significantly to the reduction in the cost of natural stone countertops, tables, sinks, tiles, and fireplaces, and will continue to bring these costs down. It has dramatically increased the quality of the finished product. And the best news of all is that it will only get better!
From the quarry and until they are loaded onto containers ready for shipment, marble slabs go through different transformation phases. Depending on the needs, each block of marble is cut in slabs or as per the required measures in order to build staircases or to be used in flooring, wall tiling, etc.
Extraction methods and the resulting marble block sizes will depend on the quarry in question. Marble quarrying is usually done in vertical cuts. However, there are also cases where it is also done in horizontal cuts. This shall depend on the areas morphology.
The resulting block comprises 6 parallel sides. Each of these sides weighs between 6 and 15 tonnes. In regards to dimension, it can be between 2.2 and 3 metres. Width can also be 1.2 to 1.5 metres, with 0.9 to 1.2 metres in height.
Once the blocks have been extracted from the quarry, these are transported by HGV lorries to the manufacturers for processing. At each production centre, the blocks are unloaded and classified in the blocks yard prior to being sawed.
Marble is cut usingmultiwire or block cutters. Depending on their dimensions, blocks may be cut using different methods, i.e., large blocks will be processed in the multi wire cutter, while smaller, irregular blocks will be cut using block cutters. The aim is to make the most of the blocks measurements by reducing any waste as much as possible.
They comprise diamond wires that can cut the block in a vertical direction. In this manner, they are able to obtain as many slabs as the number of wires they are equipped with. A Crema Marfilblock will usually take around 8 hours to cut.
If the marble slabs are being shipped abroad, a series of wooden bundles will be prepared in order to introduce them into containers. While if your slabs are being shipped within Spain, these are transported using iron a frames to hold them in place.
Marble attracts a great deal of interest worldwide. For that reason, you can easily find it anywhere in the world. As previously mentioned, we will use different shipment methods depending on the destination.
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