The global marble market production value is expected to reach USD 64 Billion in 2023, which was USD 52 Billion in 2016. Marble production is growing with the increase in urbanization and its utilization in every sector.
There are various classifications of marble products, and recently marble plinth has gained popularity. They symbolize elegance and luxury that are widely used in homes or commercial places for multiple purposes.
Have you ever thought about the process of manufacturing marble plinths? Let’s reflect on the process of producing a marble plinth.
Classification of Marble Plinths
Marble plinths are manufactured in multiple shapes and designs. Here we are talking about the primary manufacturing of plinths irrespective of their design. They are classified into two categories when it comes to manufacturing:
- Solid marble plinth
A solid marble plinth means a solid block of marble is used to make the plinth.
- Hollow marble plinth
A hollow marble plinth is also named an assembled marble plinth. It does not use a solid block of marble; instead, marble slabs are joined to make a plinth, and the inside is usually empty.
We have described the top 10 popular materials for marble plinths in another article.
Processing of Solid Marble Plinth
Marble processing is a fascinating procedure. From mining to cutting to shipping, it goes through various phases. Let’s take a view of the main steps of producing a solid marble plinth:
1. Extraction of marble
Marble is a natural stone, mainly comprised of calcium carbonate. Nature is responsible for giving shape and color to the marble. Therefore, it is a beautiful exotic stone. Large blocks of marble are extracted from the quarries. A quarry is a vast pit, an open mine from where the natural stones are mined.
Depending upon the quarry, the size of the marble block and extraction method varies. Primarily, large blocks of marble are mined using vertical cuts. Sometimes, horizontal cuts are also used depending on the quarry’s morphology. The extracted block has six parallel sides. It can be as big as 8 meters high and 6 meters wide. It is just a rough estimate; as we said, it varies from quarry to quarry.
2. Loading the marble
Once the marble is extracted from the quarry using heavy machinery, it is loaded to move to the processing factory. Marble manufacturers prefer having their factories near the quarries to avoid damage and high transportation costs. Due to their heavy weight and large size, they are moved using cranes and other specific machines during loading and unloading.
Even during the processing, machines are used to move marble. Before the processing starts, the blocks are grouped according to color tone, streaks, size, cracks, and cleanliness. All these factors decide the price of the marble.
3. Cutting marble blocks
Cutting the marble blocks is the foremost step in producing the marble plinths. First of all, the most suitable block is selected according to the consumer’s requirements. Check the stone’s color, veining pattern, quality, size, Etc. The second step is covering the marble block surface with fiber mesh and glue. This mesh covering will strengthen the block and make it safer for cutting.
The third step is to cut the marble block with the multi-wire cutter or block cutter. Depending on the purpose of the block, a suitable blade is used. The multi-wire edge blade is used for cutting slabs. A Block cutter is used for cutting big chunks or blocks. Sawing blocks is a time taking process. It takes hours to cut one large block.
Plinths are cut with block cutters. A block cutter has a large round diamond saw with water constantly falling, so the saw doesn’t wear down quickly. A smooth cut is obtained for the plinth. The bottom line is to reduce wastage and maximize a block’s usage. If little side pieces are left, they are used to make tiles.
4. Marble Plinth Finishing
A solid block of marble is shaped like a plinth. Plinths vary in size, so different sizes are cut. The edges of the block are sharp at this stage. A skilled mason smoothens the edges using a hand grinder. This task needs expertise for safety and precision.
Now is the time to finish the marble plinth. The marble block goes through an abrasion process to achieve the required finishing. There are multiple types of finishing.
The polished finish is achieved by polishing the plinth with fine abrasives. The final look is glossy. The surface is so smooth that it reflects light. The abrasives remove any scratches that slow down the bouncing of light. Polished marble is slightly darker in color as compared to honed marble of the same type.
The honed marble surface looks matte and shine-free, feels velvety, and is scratch-resistant. This finish removes all the cutting marks from the surface. Honed marble plinths have a warm natural look. Travertine, limestone, or sandstone are always shown on such surfaces.
For the aging finish, the stone goes through a mechanical process that involves water and sand. After that, it looks as if the stone has lived through decades. The aging finish provides a rugged, shine-free, natural-wear feel.
- Split Surface
The machine will beat with a good rough shape, then the workers slowly knock off the outside pieces with a hammer, and then finally roll it round in the roller, so that it namely maintains this style, but also does not scratch people. Here is a detailed description of an Arabescato round plinth with a split face.
5. Packaging and shipment
While processing is finished, we have a strict inner inspection for quality control. After that, they are appropriately packed in wooden crates wrapped in foam to avoid damage and shipped to the destination.
Processing of Hollow Marble Plinth
The hollow marble plinths do not use solid blocks. They are made with marble slabs. These plinths are further segregated into two categories based on their manufacturing:
- Marble slabs only
- Marble aluminum honeycomb composite panel
Hollow marble plinth with marble slab
Half of the process of manufacturing hollow marble plinth is the same as the solid marble plinth. The first and second steps of extracting marble blocks and loading them into the factory are the same. Now comes the part where it is different from the solid marble plinth. Here we have another article to introduce the top 10 popular marble plinths.
A hollow marble plinth is made with marble slabs. The large blocks of marble are cut using the multi-wire cutter. This cutter has multiple diamond wire cutters that cut the large block vertically in equal slabs. Usually, the thickness of slabs ranges from 1.5cm to 3cm.
There are various marble plinths in the shop of MenuDesign, and you can view them here. Beautiful marble with perfect design shows the charm of natural materials.
The slabs are polished for a glossy finish or honed for a matte shine-free finish. Then the slabs are laminated together to form the shape of a plinth. Skilled artisans miter the edges. The hollow marble plinth is comparatively lightweight, easy to move, and less costly. Each piece is manufactured and polished by hand.
We can completely customize the order to befit customers’ preferences. After finishing, the hollow plinth is available for use. It is packed and shipped to the destination.
Hollow marble plinth with aluminum honeycomb panel
It is the other type of hollow marble plinth. It is made with a marble aluminum honeycomb composite panel. A marble slab is attached with a layer of aluminum honeycomb with a tenacious adhesive to form the composite board. These marble aluminum honeycomb panels are joined together to form the plinth. The edges are smoothened, and the surface is finished in one of numerous ways.
Here is a new design from The Gold Boutique, The inverted pyramid coffee table, standing on its end looks like it seems to balance on its smallest point, which defies the laws of physics.
The marble aluminum honeycomb plinth looks as beautiful as the solid marble plinth. A marble slab attached to an aluminum honeycomb board is highly durable, resistant, and long-lasting. It makes the plinth lightweight and durable. It combines the benefits of the solid and hollow plinth. The pitted marble plinth is ready to take up space in any home. No one can tell the difference by looking at it.
The process of producing a marble plinth is very intriguing and engaging. It can turn a mere rock into an art piece. With the process of extracting, cutting, and polishing, a large block of marble is transformed into a stunning plinth. If you are confused about where should I put the marble plinth, please check here to read another article.
These plinths can be made with solid marble blocks, marble slabs, or aluminum honeycomb composite boards. All of them require expertise and accuracy. You can order a plinth from the wide variety of our captivating and resilient marble plinths. We cater to customized orders and honor our customer’s demands.