Production of cast marble
The more mineral filler in the mixture, the more solid and reliable the material turns out, the more the product acquires the properties of a stone. High-quality cast marble consists of 80% of minerals and only 20% of a binder (resin) and pigments. The size of the filler fraction also affects the strength of the finished product.
In the production of products with a complex shape, it is advisable to reduce the amount of filler and use fine fraction fillers. This reduces the viscosity of the mixture, improves and facilitates the casting of the product.
As a filler, materials that do not imitate natural marble, but perform a decorative function can also be used: quartz sand, pebbles, etc.
Outside, the entire surface of the product made of cast marble is covered with a layer of gelcoat up to 1 mm. Gelcoat is a special gel-like varnish that has increased resistance to moisture and ultraviolet radiation, provides additional protection against mechanical damage and gives the product a glossy sheen. When applying a transparent gelcoat, the surface of the product has the appearance of a natural stone, its texture is determined by the type of filler and the color of the pigment used to color the polyester resin. The casting stone itself is painted to the full depth and does not lose color over time. Depending on the type of filler, in addition to marble, it can imitate other natural stones: malachite, jasper, onyx, granite.
When using a colored gelcoat, multi-colored products with various patterns and patterns are obtained. This is the main difference between cast marble and natural marble - products made from it can have any shades: pink, purple, emerald and so on, with inclusions and veins.
In general terms, the manufacturing technology includes the following steps:
- preparation of the form (matrix);
- application to the form of gelcoat;
- preparation of a mixture of polyester resin filler;
- pouring the resulting mixture into a mold;
- curing the polyester resin in the presence of a catalyst;
- removing the finished product from the mold.
The main advantage of products made of cast marble, which they possess due to the polyester resin in their composition, is warmth. Unlike natural marble or the same granite, cast marble is always warm to the touch.
Typical products made of cast marble are various plumbing fixtures: sinks, bathtubs, as well as countertops, window sills, bar counters, etc.
