Splitface 3x6 orange Marble wall office

Production Process & Machinery

Block Selection & Preparation

Process: Raw marble blocks are inspected for consistent veining, color, and structural integrity.

Machinery: Gantry cranes, diamond wire saws (for trimming blocks into slabs).

Slab Cutting

Process: Blocks sliced into 3cm-thick slabs.

Machinery: Gang saws (multi-blade) or diamond wire saws for precision.

Tile Sizing (3x6 Format)

Process: Slabs cut into 3"x6" (or 6"x3") tiles.

Machinery: Bridge saws with diamond blades, CNC waterjet cutters (for complex edges).

Splitface Texturing

Process: Tiles split along natural grain to create rugged, 3D surfaces.

Machinery: Hydraulic splitters or guillotine-style machines. Critical: Angle/pressure calibration to avoid over-cracking.

Surface Finishing

Process: Brushing to smooth sharp edges while retaining texture. No polishing (splitface relies on raw beauty).

Machinery: Automated brushing machines with abrasive nylon brushes.

Calibration & Backing

Process: Tiles ground to uniform thickness (±0.5mm tolerance); mesh/fiberglass backing added for stability.

Machinery: Calibrating machines, automated mesh applicators.

Quality Control & Packaging

Process: Sorting by color/texture; sealing (optional); foam-lined crates.

Machinery: Spectrophotometers (color matching), automated sorting systems.

Key Quality Control Essentials

Material Consistency

Vein/Color Matching: Use digital imaging to ensure tiles from the same block are grouped.

Defect Screening: Reject tiles with micro-cracks, excessive fillers, or color bleeding.

Precision Engineering

Thickness Uniformity: Calibrate all tiles to prevent installation lippage.

Edge Safety: Brush edges to eliminate sharp points (critical for high-traffic lobbies).

Structural Integrity

Mesh Adhesion: Test bonding strength to prevent delamination during installation.

Moisture Resistance: Apply penetrating sealers (if specified) to prevent staining.

Batch Traceability

Document block origin, production date, and QC checks per batch for accountability.

Critical Success Factors

Natural Texture Preservation: Avoid over-processing; retain the stone's organic character.

Commercial-Grade Durability: Test tiles for impact resistance (ASTM C1353) and abrasion (ASTM C241).

Installation Readiness: Ensure tiles are flat-backed and interlock seamlessly for large-scale lobby walls.

Pre-Shipping Mockups: Provide a 3x6ft panel sample for client approval of color/texture flow.

Pro Tip: Partner with factories using ISO 9001-certified processes and request third-party inspection reports. For office lobbies, prioritize low-maintenance finishes-specify fluoropolymer sealers for stain resistance without altering the natural matte look.