24x24 penny black Quartzite wall corridor/Aisle

The Production Process & Required Machinery

1. Block Selection & Slab Production

Process: A suitable block of Flowing Rocks Quartzite is selected for its color consistency and structural integrity. The block is cut into slabs. The thickness is crucial; for penny tiles, the slab is typically cut to the desired final thickness of the pebble (e.g., 10-20mm).

Machinery: Block Saw (gang saw or wire saw) with diamond tips.

2. Resin Impregnation (Highly Recommended for Quartzite)

Process: The slabs are placed in a vacuum chamber. A catalytic resin is infused into the stone under pressure, which is then hardened. This is critical for quartzite due to its potential micro-fissures.

Why it's important: It drastically strengthens the fragile pebbles, prevents breakage, enhances color, and seals the stone against staining-a must for a floor application.

Machinery: Vacuum Resin Impregnation Line.

3. Cutting the Pebbles ("Pennies")

Process: This is the core of the operation. The resin-treated slab is fed into a specialized machine that punches out the small, round discs. The spacing of the cuts on the slab is optimized to minimize waste.

Machinery: CNC-Controlled Hydraulic Punch Press or a CNC Waterjet Cutter.

Punch Press: Uses a hardened steel die to punch out the circles like a cookie cutter. This is faster for high-volume production.

Waterjet: A high-pressure abrasive jet cuts the circles. This offers more flexibility for size changes and creates less mechanical stress on the stone, potentially reducing micro-cracks.

4. Tumbling (Edge Finishing)

Process: The freshly cut penny rounds have sharp, brittle edges. They are loaded into a large, rotating drum (a tumbler) along with abrasive grit and water.

Goal: The tumbling process rounds off all the sharp edges, gives the pennies a smooth, worn, natural-river-pebble feel, and provides a uniform, matte finish.

Machinery: Stone Tumbling Machine (a large rotating barrel).

5. Sorting, Blending, and Mounting

Process:

Sorting: The tumbled pennies are sorted by size and color to ensure consistency.

Blending: Pennies from different production batches are blended to create a harmonious mix of shades and veining, preventing "banding" in the final installation.

Mounting: The pennies are carefully laid out face-down in the desired pattern (often a tight honeycomb or offset pattern). A flexible, strong mesh backing is applied with adhesive to hold them together in sheets (typically 12"x12" or 24"x24").

Machinery: Sorting conveyors, manual sorting tables, custom jigs for sheet layout, adhesive applicators.

6. Quality Control and Packaging

Process: Each sheet is inspected. The sheets are then stacked face-to-face and back-to-back to protect the surface, packed in sturdy boxes, and often palletized for stability.

Machinery: Packing stations.

What is Important for Achieving a Good Quality Product?

1. Premium Resin Impregnation:

This is the single most important factor for durability. Without it, the pennies are highly susceptible to

cracking during transport, installation (from being walked on or tapped into place), and from point-load pressure in use. It also guarantees long-term stain resistance.

2. Consistent Pebble Size and Thickness:

Diameter: All pennies must be perfectly uniform in diameter. Inconsistency will create uneven grout lines and a messy appearance.

Thickness: This is critical for installability. Every pebble in a sheet must be the same thickness. Variations will cause lippage and make it impossible to create a flat, safe floor surface, especially in a high-traffic corridor.

3. Complete and Uniform Edge Finishing:

The tumbling process must be long enough to ensure every single pebble has completely smooth, rounded edges. Incomplete tumbling will leave sharp, dangerous edges that can also chip easily.

4. Secure and Flexible Mounting:

Mesh Backing: The adhesive must be strong enough to hold every penny securely during handling and installation. A poor bond will cause pennies to fall out of the sheet before they are set.

Flexibility: The mesh must be flexible enough to allow the sheet to conform to slight curves or irregularities in the corridor floor substrate.

5. Color and Veining Blend:

Since the product is made from natural stone, the pennies must be thoroughly blended from multiple slabs before being mounted. This ensures a natural, random distribution of color and veining across the entire corridor, avoiding obvious patches of light or dark tiles.

6. Packaging that Preents Breakage:

The sheets are fragile. Packaging must prevent the pennies from being crushed or from flexing, which could crack the stone or break the mesh bonding. Rigid boxing and secure palletizing are essential.