Technical Process
Our marble extraction methods are of high precision technology, which have evolved from rudimentary methods. With these newer processes, we extract intact blocks to minimize wastage.
Probing and Pickling
Before extraction, we probe the area and then drill strategic holes with Diamond Core drills to inspect the quality of our stone. Following, we remove the “cap” (earth and stone of lesser quality) to expose the Marble worktop.
The Primary Cut
We start with a Diamond wire saw, where we make two holes (one vertical and another horizontal) that cross. A steel wire with industrial Diamond pearls goes through those holes, creating a lasso that, rotating at high speeds cut giant slices of the rock.
Drilling and Wedging
To separate the base of the block or subdivide it, we use a pneumatic driller to create a line of holes and insert hydraulic wedges that create pressure to crack the stone in a controlled method.
The Fall
A classic technique where the cut block is tipped to the quarry floor. To avoid the Marble from breaking on impact, we create a “bed” of debris and soft earth (Shock absorber).
Squaring and Extraction
The block is then cut into square or rectangular blocks. After that its hoisted from the depths of the quarry by one of our 30-ton Tower Cranes.
Cleaning and Cutting
The blocks are then watered down to detect any natural cracks. We then use our multi-wire cutter to correct the format of the blocks and make them uniform.
Sustainability and Eco-Friendliness
Sustainability in Marble Extraction and especially in Pardais, focus in transforming the old concept of “wastage” into a circular economy. Nowadays, around 80 to 90% of the extracted material does not become quality blocks, making us look at creative and industrial ways to recycle.
Wastage and Reuse
Unusable and cracked marble is reused for the following:
Crushed are used for pavements, construction, and agriculture.
Marble Powder are used for chemicals, paints, tooth paste, paper and plastic industries.
Reconstructed Marble is another issue we are looking into. Where small fragmented Marble stones are mixed with resins to create Reconstituted / Engineered Marble.
During the cutting process, white mud is created. We are looking to improve and find solutions for reusable purposes. There are tests being made on these muds to fabricate bricks, ceramics, and mortars.
Upcycling are small leftover pieces used by designers to create furniture and decorative objects.
All these waste and usage processes are
already being done or are on the verge of being done.
Water Management
Our quarries have an internal water cycle renewal and filtration system. We use decanting and pressing filters where the water used on the cut is filtered, the “mud” is removed, and the water is reusable almost in its entirety. Minimizing consumption.
Energy Efficiency
The substitution of old extraction methods with newer extraction methods has helped reduce the energy consumption drastically and cut times. Making the transformation process more efficient per square meter.
Safety
We are highly focused on safety for our workers and the environment. The stability of the vertical walls is monitored rigorously and all our equipment are maintained in order to guarantee safety measures. PPE and safety training are given every three months to our workers to minimize and control risks.