In the ornamental rock industry (e.g., granite, marble), a huge amount of rock is wasted during extraction, cutting, and polishing. Up to 70% of the material can be lost due to block breakage and crumbling. This not only increases costs but also causes environmental issues like soil loss and water pollution. Traditional methods to reinforce rocks are time-consuming, expensive, and often unreliable, requiring up to 10 days of curing time and prone to detachment during processing.
Core Features of the Invention
This invention introduces a fast, durable, and standardized process for wrapping ornamental rock blocks before cutting. The process involves four layers:
- A deep-penetrating epoxy sealant,
- A layer of expanding rigid foam,
- A strong mesh layer bonded with resin,
- A final layer of expanding foam.
Each layer strengthens the block and prepares it for safe sawing and polishing.
Inventive Step
Unlike older techniques that rely on slow-curing epoxy mortars and manual application, this new method uses quick-setting materials and automated tools to apply the layers. This cuts curing time from over a week to just one day—while also improving strength and reducing material loss.
Tangible Benefits
- Reduces waste and breakage during rock extraction
- Cuts production time dramatically
- Lowers environmental damage by minimizing discarded rock and reducing noise pollution from machinery
- Decreases costs by improving efficiency and material usage
Broader Impact
This process could significantly improve sustainability in the ornamental rock industry. With millions of tons of waste produced annually, this invention can help reduce environmental harm, improve productivity, and add economic value by converting more raw stone into finished slabs for use in homes, buildings, and decorative applications.