What Is The Production Process Of Prefabricated Terrazzo Slabs? What Are The Things To Pay Attention To During The Production Process?

Manufacturing process of prefabricated terrazzo slabs
Prefabricated terrazzo slabs are decorative panels made by mixing materials such as cement and stones, and then undergoing processes such as molding, curing, and polishing. The production process mainly includes the following steps:

1. Raw material preparation
Cement: Usually, Portland cement, ordinary Portland cement, or slag Portland cement with a strength grade of not less than 42.5 is selected to ensure the strength and durability of the board.

Stones: Natural stone fragments such as marble and granite are generally used, with particle sizes selected according to design requirements. Common sizes include 3-6mm, 6-12mm, etc. Stones should have a hard, clean texture, no weathering, and no impurities.
Pigments: Inorganic pigments that are alkali resistant and light resistant should be used to mix the colors of terrazzo to ensure long-lasting stability.
Other materials, such as glass strips, copper strips, etc., are used to separate areas of different colors or patterns and increase the aesthetic appeal of the board.
2. Mold making
According to the design requirements, the mold should be made with accurate dimensions and a smooth surface to ensure the dimensional accuracy and appearance quality of the board.
Molds can be made of materials such as wood, steel, or plastic. Wooden molds have lower costs but are prone to deformation; Steel molds are sturdy and durable, but their cost is relatively high; Plastic molds are lightweight and easy to process, suitable for small-scale production.
3. Ingredients and Mixing
Accurately weigh the raw materials such as cement, stones, and pigments according to the design mix proportion, and put them into the mixer for mixing.
The mixing time should be determined according to the type of mixer and the properties of the raw materials, usually 2-3 minutes, to ensure that the raw materials are thoroughly mixed evenly.
4. Forming
Pour the mixed material into the mold and use a vibration table or manual vibration to compact it and eliminate any bubbles in the mixture.
Lay glass or copper strips on the surface of the mixture to form the desired pattern or dividing line.
Use a scraper to level the surface so that it is flush with the edge of the mold.
5. Maintenance
The formed board should be cured under suitable temperature and humidity conditions to ensure sufficient hydration reaction of cement and improve the strength of the board.
The maintenance method can be natural maintenance or steam maintenance. Natural maintenance is to place the board in a well ventilated and humid place, regularly water and maintain it, and the maintenance time is generally 7-14 days; Steam curing is to place the board in a steam curing room, control the temperature and humidity, and the curing time can be shortened to 3-5 days.

6. Demoulding
After the maintenance period is over, demolding can be carried out when the board reaches a certain strength.
Be careful during demolding to avoid damaging the edges and surfaces of the board.
7. Grinding and polishing
The surface of the demolded board may have defects such as unevenness and pores, which require polishing and grinding treatment.
Grinding and polishing are generally carried out using a water grinder, which sequentially uses grinding discs of different particle sizes for rough grinding, medium grinding, and fine grinding to make the surface of the board flat and smooth, achieving the required glossiness in the design.
During the polishing process, it is necessary to continuously rinse with water to remove debris and dust, while reducing the temperature of the grinding disc and extending its service life.
8. Apply protective agent
The surface of the polished board should be coated with a protective agent to prevent moisture, stains, and other contaminants from infiltrating the interior of the board, thereby improving its durability and stain resistance.
Protective agents can be made of organic silicon, fluorocarbon, etc., and should be applied evenly and comprehensively to ensure the formation of a dense protective film on the surface of the board.
9. Inspection and Packaging
Inspect the pre made terrazzo slabs to ensure that their size deviation, flatness, glossiness, color, etc. meet the design requirements.
Qualified boards should be packaged to prevent damage during transportation and storage. Packaging materials can be wooden boxes, plastic films, etc.
Points to note during the production process
1. Quality control of raw materials
Strictly control the quality of raw materials such as cement, stones, and pigments to ensure they meet design requirements and relevant standards.
Inspect and test raw materials, such as the strength and stability of cement, the particle size and mud content of stones, etc. Unqualified raw materials shall not be used.
2. Mix proportion design
A reasonable mix ratio is the key to ensuring the quality of prefabricated terrazzo slabs. The optimal mix ratio should be determined through experiments based on design requirements, raw material properties, and usage environment.
In mix design, attention should be paid to controlling parameters such as cement dosage, water cement ratio, and stone grading to ensure the strength, durability, and appearance quality of the board.

3. Molding process control
During the molding process, the vibration time and intensity of the mixture should be strictly controlled to ensure that the board is dense and free of defects such as honeycomb and rough surface.
When laying glass or copper strips, their positions should be accurate, firm, and evenly spaced to form beautiful patterns and separation lines.
4. Control of maintenance conditions
Curing is an important stage of cement hydration reaction, and the temperature, humidity, and time of curing should be strictly controlled.
The maintenance temperature should not be too high or too low, generally controlled between 15-25 ℃; The maintenance humidity should be kept above 90% to ensure sufficient hydration of cement and improve the strength of the board.

5. Grinding and polishing operation specifications
When polishing, different particle sizes of grinding discs should be used in order from coarse to fine to avoid skip polishing and affect the surface quality of the board.
Control the speed and pressure of the polishing machine to avoid defects such as scratches and dents on the surface of the board caused by excessive polishing.
During the polishing process, it is necessary to promptly clean up the debris and dust to maintain a clean working environment.
6. Quality of protective agent coating
The protective agent should be evenly and comprehensively applied to ensure the formation of a continuous and dense protective film on the surface of the board.
After applying the protective agent, it should be cured according to the requirements of the product manual to fully cure the protective agent and exert its protective effect.

7. Safety production
During the production process, safety production management should be strengthened, and operators should wear personal protective equipment such as safety helmets, gloves, goggles, etc.
Equipment such as mixers and water mills should be regularly inspected and maintained to ensure their safe operation.
Clear safety warning signs should be set up on the construction site to prevent safety accidents from occurring.