Reasons for the birth LIGHTWEIGHT MARBLE and earlier solutions

Traditional stone slabs are achieved from sawing into slices of blocks stone. Stone slabs having dimensions of a few square meters and usually are characterized by a commercial standard thickness of 2 cm and a general weight of 54 kg per sqm. Commercial stone slabs are cut in smaller pieces in order to adapt them to be installed on walls, facades, coatings and floor. Marble, used since antiquity as a natural decoration, it’s a heavy material with a low resistance to mechanical stress; the largest the slab is, the easiest will be damaged.

An ideal solution would be the installation of some large, lightweight and tenacious stone slabs:
  • large because the largest the slab is the easiest would be to appreciate its beauty,
  • lightweight because the whole marble slab would be greatly facilitated its installation,
  • tenacious because it would extend the applications types.

From the need of working pieces of stone slabs characterized by a thinner thickness, addressing the problem of their fragility gluing to the stone slab some support lightweight and tough (honeycomb), is started first solution of lightweight marble. However this solution, which is now a few decades old, had a poor evolution. The stone business has always devoted time and money to research and machines evolution in order to make the stone working easier with less time and costs. However by doing this, marble remains “alone”, working and evolving itself into that “dogmatic sarcophagus” that characterized its use through centuries.

Since decades lightweight marble has been produced coupling honeycomb and stone slab reducing the thickness of the stone itself. But what’s honeycomb? The honeycomb is a coated aluminum structure with two glass fiber mats impregnated with resin. Honeycomb panels are used in all areas where there’s the need of high tensile strength to compression and impact, having the shape of a thin and resistant panel. The panel can be use with a great variety of finishes such as ceramic, acrylics, silicones, mosaics, aluminum, wood, stones, etc.. Honeycomb panels can be also used to create flat surfaces to allow the application of such traditional polymer-based plasters, exterior isolation and acrylic systems.

So here's a lightweight and strong support that addresses the drawbacks of the marble. But we must have attention to a very real important fact: the honeycomb panel is just a generic support for various materials. So the need to study which kind of honeycomb panel and which type of his raw materials are indispensable to guaranteeing and securing the performance of the lightweight marble over time, and understand which processes are more appropriate to join together indissolubly the different components.

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Print | Development and typologies of LIGHTWEIGHT MARBLE by FFPROCESS®
Lightweight Marble • Technical-scientific resources on LIGHTWEIGHT MARBLE by FFPROCESS®

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