Marble and block reinforcement methods

Prepared by: Muharrem DEĞİRMENCİ – Alfa Line Marble and Block Reinforcement Products Sales Coordinator

Turkish natural stone sector was introduced to the block vacuum system in 2011 and 2012. With the vacuuming of the blocks before cutting, the marble blocks that could not be cut in the factories were brought into production and gained economic value. This expensive and arduous method first applied on blocks with high added value but today it can be applied to almost all stones. In order to apply the vacuum method, the block should be washed, cleaned of mud and dust and dried. We also need to make sure that the weather conditions are suitable since this process does not give the desired result below 10 degrees. It should be applied outdoors in summer and indoors in winter. It is very important that all the apparatus and epoxy chemicals applied at a time suitable for the stone and in suitable weather conditions. If the epoxy is applied in the summer, the cooling time should be long, if in winter, the cooling time should be normal with low viscosity. Optionally, epoxy can be colored in the color of the stone in order to obtain a decorative appearance. The stronger the vacuum pump and compressor used, the more blocks can be vacuumed at the same time. A tick flow mesh should be preferred in order to obtain a thick frame in the slabs cut from the blocks since flow mesh provides epoxy thickness in blocks.

Application methods in block reinforcement with epoxy

The most applied method in block reinforcement is the method that is done manually with block gel and 500-gr block mesh. However, there are some points to be noted here. While an economic application is desired, many blocks unfortunately break up in the gang saws during cutting. Once the clean block is cleared of mud and dust, it is cleaned with 1 kg of acetone or thinner. Following this, 1 kg of epoxy mixture is applied to block with a roller (since epoxy is liquid, it will absorb some of the stone and a better grip on the surface. The frame during cutting and after cutting will be minimum) After 20 min. the block gel prepared in the correct proportions is mixed with the help of a mixer. 500 gr mesh is applied on the block gel applied in one layer, another layer of block gel is applied and the process ends. If there are many cracks in the block structure, it is reinforced with additional mesh on its four corners. Thus, breaking occurs at a minimum level both in the gang saw cutting and during slab drying process in the epoxy oven.

Reinforcement in quarry faces and export blocks

As the block productivity increases in the factories, reinforcement of blocks in the quarry face and reinforcement of exported blocks gained importance. Reinforcement is done in two different ways in marble quarries. Currently, due to the situation in the formation of marble quarries with 3 meters face height and 7 meter and higher face height and the traditional methods in practice unfortunately, the works here are not at the desired speed in our country. The dismantling style, which is called potatoes in the stone structure of the quarry or where the structure is not fully formed, reduces the quarry productivity considerably. Productivity have increased considerably with the application of Alfa Line Quarry Gel to the faces. Before starting this application, the face is washed, cleaned and dried. A day after the application, the face is tipped down by cluttering soil at the bottom of it. This application, which is made with the help of a mesh on three sides of the face, is also done in many countries of the world. Reducing the face sizes also made a serious contribution to the reduction of waste in the quarries. Face sizes have started to be reduced as much as possible in the new levels.

Depending on the tonnage lifting power of the work machines in the quarries, the block that is cut from the smaller bedrock ensures that the heavy-duty machines in the quarries are used more efficiently and at a more economical fuel level.

The method of pulling small blocks from the face is now frequently used in marble quarries. With this application, the block is taken from the mirror with the help of a digger after the application of Quarry Gel on two faces. There are two methods to consider here. While the bottom of the face is being cut, the balloon sheet is placed to the bottom of it so that the blade of the digger can easily enter the bottom. This application, which seems to be expensive, is not done in all stages of marble quarries, the important thing here is to make sure that the commercial value of the stone is high by considering the colour on the face. Since making high production does not mean obtaining high amount of blocks, such applications started to become widespread.

Applications applied to export blocks

Our other application in marble quarries is the casualties occur during shipping, customs and breakages on blocks due to sudden movements on ships. Although wrapping the blocks with a spatzet or steel rope was believed to prevent this situation, the desired efficiency could not be obtained. The 20 cm wide 500-gr mesh made with Alfa Line Quarry Gel, allows the transportation of blocks to the farthest countries without any damage. With this application, the customer can see all the surfaces of the block and can easily perform vacuum or other strengthening operations. Such applications, which we try to pioneer, will of course be made more beneficial to the sector by being further developed by new technologies and new generations.

Who is Muharrem Değirmenci?

Muharrem Değirmenci who entered this sector as a marble Sw seller in Polmak Machinery Industry in 1996, has continued his carrier in Köksal Machinery, the representative of Italian Breton and Tenax Company in Turkey at that time, in 2002. Değirmenci, who assumed an important mission in the promotion of Tenax products to the Turkish market in this process, continued this duty as the company manager until his retirement in 2018, after Tenax decided to establish its own marketing system in the Turkish market in 2007. Değirmenci, who rested for a while after retirement, later became Enkatech Integrated Chemicals factory, which was established within the body of NGA Marble. He worked as the sales coordinator of ALFA LINE Marble and Block Reinforcement Materials, the brand of the company. Muharrem Değirmenci, who acted as one of the important actors in using epoxy systems and enabling its dissemination in Turkey, continues this duty.