اخبار الصناعة

1. Process Flow

1) Surveying and Marking:

Before the stone installation for the scenic wall and retaining wall, survey along the centerline (or boundary) of the wall based on the designed elevation, setting a control point every 5 - 10 meters. Measurements must be carried out according to the design layout or construction drawings, marking the centerline, horizontal level lines, and grid lines.

2) Base Leveling:

According to the measured position and elevation, level the base. If the base has defects, use cement mortar (for walls) or crushed stone concrete (for the top surface) to level and treat the base.

3) Stone Pre-assembly and Selection:

All stones used in the project should be processed in the factory as per the layout drawing and numbered and packed. After the stones arrive on-site and are unpacked, each piece should be checked individually. Stones that are broken or have missing corners should be separated and reprocessed by the factory.

Once the stone selection is complete, pre-assemble on-site. Pre-assembly ensures that the colors, patterns, and textures align, and the seams match tightly. The pre-assembled stones should be numbered in two directions and stored in piles according to categories for future use.

4) Vertical Stone Installation:

(1) Small-sized Stones:

In a damp base, apply one coat of pure cement slurry (with 10% by weight of 108 glue mixed with water) and apply it while it's still wet.

For the base mortar, use a 1:3 cement-sand ratio, about 12mm thick, applied in two layers: the first layer about 5mm thick and the second layer about 7mm. After the base mortar is compacted and smoothed, scratch the surface of the mortar.

Once the base mortar is set, mark the lines for each stone section. Apply a 2-3mm thick cement slurry (with 20% by weight of 108 glue) to the back of the pre-wet stones and install them (alternatively, adhesive powder can be used). Tap with a wooden hammer to ensure alignment and use a level tool to check for flatness and straightness.

(2) Large-sized Stones:

For stones larger than 40mm on any side, or if the installation height exceeds 1m, the following installation method is used:

A. Drilling and Chiseling:

Before installation, use a drilling machine to drill holes according to design requirements. Secure a wooden frame to align the drill bit with the upper edge of the stone. Drill holes at 1/4 of the stone width from each end. For each surface, drill two holes with a diameter of 5mm and a depth of 12mm. The hole's center should be about 8mm from the back of the stone.

If granite is used and the stone width is large, increase the number of holes. After drilling, lightly chisel a 5mm deep groove around the holes to form an "elephant trunk" shape for embedding copper or galvanized wire.

For larger stones, especially prefabricated granite, if it's difficult to tie the galvanized lead wire or copper wire at the lower end, use a portable small thin grinder (4 - 5mm) to create grooves (approximately 3-4mm long and 12mm deep) at the 1/4 height of the stone on both the upper and lower surfaces.

B. Threading Steel Wire or Galvanized Lead Wire:

Cut the prepared copper wire or galvanized lead wire to a length of approximately 20cm. Fix one end into the drilled hole with epoxy resin and a wooden wedge, securing it firmly. The other end should be bent and placed in the groove, ensuring the wire doesn't protrude from the stone's top or bottom to allow a tight seam with adjacent stones.

C. Tying Steel Mesh:

First, remove the embedded steel bars from the wall and clean the installation area. Begin by tying vertical steel rebar (φ6) and securing it to the wall using the embedded steel bars.

For horizontal steel, use it to tie the polished granite slabs. For example, for a slab with a height of 60cm, the first horizontal bar is tied 10cm above the ground and used to secure the lower copper or galvanized wire of the first stone layer. The second horizontal bar is tied at the 50cm level, 2 - 3cm below the upper edge of the stone, to secure the copper or galvanized wire at the top of the first layer. Continue every 60cm with additional horizontal bars.

D. Line Marking:

Use a plumb bob to determine the vertical alignment of the polished granite wall from top to bottom. Consider the thickness of the granite slabs, the mortar gap, and the steel mesh. The gap between the granite skin and the structural surface should be 5 - 7cm.

After vertical alignment, mark the outline of the stone installation on the ground. This outline serves as the reference line for the first layer of stone. Place the marble or prefabricated terrazzo slabs along the marked reference line with a 1mm gap between each stone (if specified, adjust the gap according to the design).

E. Stone Installation:

Select the stone pieces, align the copper or galvanized wire, and install the stones. The top edge of the stone should be slightly tilted outward. Insert your hand behind the stone to tie the copper or galvanized wire at the bottom of the stone to the horizontal rebar.

Do not tighten the wire too much; leave some slack. The stone will be anchored once the grout is applied. Place the stone upright and secure the top copper or galvanized wire. Use wooden wedges to stabilize the stone and leave a gap of 30 - 50mm between the stone and the base for grouting.

Use a level tool to check for vertical alignment and flatness. If there is any gap or irregularity, use lead foil to pad and ensure uniform spacing. Ensure the top edge of the first layer of stones remains straight.

After confirming alignment, prepare gypsum in a bowl and apply it as a paste between the two stone layers to bond them together. Wood wedges may also be used to stabilize the stones. After the gypsum hardens, the grouting can proceed (if required, insert plastic tubes before grouting).

F. Grouting:

Prepare a 1:2.5 cement-sand mix and add water to create a slurry with a consistency of 8 - 12cm. Slowly pour the grout in while using a rubber mallet to gently tap the stones to expel air and ensure proper adhesion. 

The first layer of grout should not exceed 1/3 of the stone height, generally about 15cm. It is critical to ensure the grout does not cause displacement of the stones. If any stones shift, immediately dismantle and reinstall them.

After 1 - 2 hours, check for movement before applying the second layer of grout, which should be around 20 - 30cm high. After initial setting, continue grouting until the height is within 5 - 10cm of the top of the stone.

5) Laying Top Surface Stones:

Clean the stones and wait until the vertical stone mortar reaches sufficient strength. Then, apply a dry mortar layer (1:3 cement mix) on the top surface, ensuring it is compressed and extends 3mm above the vertical stone surface and 100 - 300mm beyond the stone's edge. Sprinkle pure cement slurry on top, place the top stones, and gently tap with a rubber mallet to expel air.

6) Joint Cleaning:

After the installation of all stones, clean off any residual grout, using a cloth to wipe the surface. Prepare grout of matching color and fill the joints, cleaning as you go to ensure a uniform, tight, and clean seam.

2. Quality Standards:

1) The stone installation must be flat and stable.

2) The texture should be consistent and smooth.

3) Appearance inspection: No lifting should occur, and the grouting (joint filling) should be complete.

4) Measured items: