I. Mining Stage: The transformation from the mine to the raw material
Mine exploration and stripping
Before mining, the soil layer, weathered layer and broken stone covering the ore body need to be stripped off to expose the complete marble ore body. Miners in the Apuan Mountains of Italy use traditional methods combined with modern blasting techniques to remove impurities and enhance mining efficiency.
Cutting technology
Wire saw cutting: The core tool is a diamond string of beads. Three holes (1 vertical +2 horizontal) need to be drilled in the stone, and the wire saw should be inserted for cutting. The hydraulic motor drives the rope saw to rotate at high speed, and with the help of water cooling for temperature reduction, it can almost cut out complete blocks without any damage.
Large cutting machine: The saw blade is up to 5 meters long, inlaid with diamond particles, and has a longer lifespan than traditional cutting machines. Continuous water supply is required during cutting to suppress dust and lower the temperature of the saw blade.
Raw material transportation
The cut raw materials weigh several tons and need to be pushed over to the soil pile by an excavator for buffering to prevent breakage. Forklifts load the raw materials into heavy-duty trucks and transport them to the processing plant. The raw materials from the Carrara mining area in Italy are scored based on their patterns and broken lines. Some are exported to New York for skyscraper decoration, while others are carved into artworks by local artists.
Ii. Processing Stage: Fine processing from raw materials to finished products
Shaping and sawing of raw materials
Shaping: The irregular blocks are cut into rectangular prisms, with their dimensions restricted by transportation costs (height ≤2.3 meters) and the width of the container.
Sawing: Use a frame saw or circular saw to cut the raw material into rough boards 2-2.5 cm thick, or semi-finished products in the form of strips or blocks. The equipment includes large diamond saws, single-blade bidirectional cutting machines, etc.
Grinding and polishing
Rough grinding and leveling: Remove sawing marks to make the board surface smooth.
Semi-fine grinding, fine grinding, and fine grinding: Gradually enhance the surface finish.
Polishing: By using ten-head automatic continuous grinding and polishing machines, bridge grinding machines and other equipment, and in combination with abrasives such as corundum and silicon carbide, the natural texture and luster of the marble are presented.
Cutting and shaping
Shaping and cutting: Using longitudinal multi-saw blade cutting machines, bridge cutting machines and other equipment, the rough board or polished board is cut into the required finished size as needed.
Irregular shape processing: Through water jet cutting (computer-controlled high-pressure water jet) or profiling milling machines, complex shapes such as curves and inlaid patterns are created.
Auxiliary processing
Edge grinding and chamfering: Use an automatic edge grinding and chamfering machine to process the edges to prevent bumps and knocks.
Drilling holes: Reserve holes for installation requirements.
Milling grooves and edges: Enhance decorative effects or functionality.
Inspection and repair
Cleaning and inspection: Remove defective boards such as cracks and holes.
Bonding repair: For minor defects, fill them with resin combined with stone debris. After repair, the color should be consistent with the original material.
Protective treatment
Six-sided protection: Spray fluorosilicone penetrating protective agent to form a waterproof and oil-resistant film, reduce surface tension and prevent disease.
Back mesh reinforcement: Fiber mesh is pasted on the back of thin plates to enhance toughness and prevent detachment when wet pasting.
Iii. Packaging and Transportation: Safe arrival of finished products
Protective packing
Spray protective water on all six sides and lay protective film to prevent transportation friction.
Long or brittle plates need to be reinforced with reinforcing bars on the back.
Packed and dispatched
The items inside the box are neatly arranged, accompanied by a layout diagram, a packing list, a copy of the driver's license and a transportation agreement.
The finished marble from the Carrara mining area in Italy, with 2-centimeter-thick slabs, is often used for both indoor and outdoor decoration, and some are exported to the global high-end market.
Iv. Technical Challenges and Industry Pain Points
Mining risk
Wire saw cutting requires precise drilling; errors may cause the stone to break.
Blasting stripping requires controlling the amount of TNT used (the Italian government mandates that it be used up each time) to avoid waste of resources.
Processing hazard
Cutting dust can easily cause pneumoconiosis. Workers need to wear protective equipment and have regular physical examinations.
Grinding and polishing require multiple processes and have high labor costs.
Resource scarcity
The more unique the color and texture of natural marble are, the more expensive it is.
Miners in the Apuan Mountains of Italy, who have decades of experience, still need to bypass mountain defects to reduce the risk of rupture.