Lost technology statues cast from granite marble. Stone block casting - chispa1707 - LJ
Granicoat is universal modern material... It is aesthetically beautiful, practical and durable. The technology for manufacturing products from Granicoat is so economical and simple that production can be organized both within the framework of a small business and on the scale of a large furniture enterprise. The advantageous advantage of Granicoat is the virtually waste-free production.
The simple process of making products from artificial stone Granicoat and liquid granite allows it to be used in a wide variety of construction and decoration fields. It is used to create elements of external and internal decor, manufacture of furniture, plumbing parts, various components and much more.
Granicoat technology for the production of liquid stone products is different from other polymers. Granicoat is not glued or poured into the mold, but is applied to the workpiece using special spraying equipment under high pressure. This is one of the factors that ensure the high strength of Granicoat products.
There are supporters and there are opponents of the stone block casting version. Many facts cannot be explained by mechanical processing of rocks, blanks, except for the molding of a liquid or pasty mass, including hard types of stone, crystalline, like granite, basalt. Add fuel to the fire or shift the weight towards the cast technology version.
Previous articles on this topic:
Casting of granite. Here are examples from Egypt:
The vertical conjugation of blocks is curvilinear. This cannot be achieved by mechanical processing. And what are these strange notches of material on the blocks? More like traces of poorly installed formwork. In principle, accuracy was not needed here.
Basalt. Sagging on the edges of the block. It can be seen that they were chipped
Row of basalt cubes with beads
What is the point of treating basalt like this and leaving such a "visor"?
It seems that the plastic mass was held by flat boards with supports. But their area was less than the area of the resulting block.
Vertically mate blocks
Horizontal and vertical fillet curvilinear
Like running dough out of a saucepan.
Here something was pressed down from above
Granite cladding of the Menkaure pyramid
How can granite blocks of this size be mechanically adjusted?
The edges of the masonry are not brought out to the plane to the end over the entire area
This is where the granite flakes
I believe that the outer cladding (surviving) of the pyramid at Giza is filled in block-by-block
Facing the pyramid at Giza
Concrete granite and basalt floor in Giza
How did these stones get into the granite mass? What will the skeptics say?
Another option is that the basalt blocks were laid on a plastic base
Are there any doubts that this is not a block-filled mass? Or will skeptics argue that such a lower curved surface can be rubbed against the unevenness of the base?
What kind of grasshoppers are building something?
Although, there are many questions about the basalt floor, and most likely it was made through mechanical processing of blocks. More about this
But let's continue the topic:
Comparison of rocks under a microscope
***
But how can all this be explained in terms of casting? In light of the many factors that can be seen in the photographs, some are of the opinion of granite casting. But granite is not concrete, there is no binder and filler. There is one filler (crystals of minerals), which are arranged like puzzles - fitted to each other without voids. Those. it is a polycrystal. Considering that there was a technology that made it possible to knead a solution under granite with a filler and a binder, which in a short time also turned into a crystalline structure, then this opens up huge open spaces for using this technology. But how does the binder crystallize? In nature, this happens under pressure and at high temperatures.
For those who misunderstood. In concrete, the binder is cement. After reaction with water, it polymerizes into a single monolith. But, depending on the chemical formula in it, it has different strength and abrasion resistance. To save cement and to make concrete more resistant to abrasion, a filler (sand, ASG, granite chips, etc.) is added to the cement.
And granite is a rock where each crystalline grain of a filler is connected to another in a single puzzle. No voids. Quartz in granite has greater strength than cement and fills in the rock as a binder in concrete. But quartz is a crystal, not a cementitious polymer.
Those. in order to say with confidence that there was liquid (or plastic) granite, it is necessary to resolve the issue of crystallization, petrification. Or softening granite. And this is generally incomprehensible.
But the traces, the contenders for the casting technology, can be viewed further:
Columns can now only be made from segments. PetroMramor plant
Turkey. Peace. Columns. There is a hole in the base of the granite columns with rust from a metal part.
Baalbek. Inside - concrete (crushed stone on a solution)
Cyprus. Inside the stones are in solution
The joint between sandstone blocks. How could they stick together grains of sand?
Kazan Cathedral. Venetian plaster under granite
A separate topic is poking in blocks, and even more so in granite and other rocks:
After what I saw in the photographs, I no longer have any doubts that many granite massifs in ancient structures (in particular throughout Egypt) are casting or molding of masses (mixed or softened). Yes, fantastic. But I see no other logic in this.
***
Thanks to the readers who in the comments showed a well-forgotten technology that they tried to implement on an industrial scale in the USSR:
Silicalcite is made from 90% sand of almost any natural quality and 10% lime. The main method of dramatically increasing the physical and mechanical properties of autoclave-hardened silicalcite products is undoubtedly fine grinding of lime and sand by the method of free high-load impact using a special grinder - disintegrator:
Disintegrator series HORS
Disintegrator basket with grinding fingers.
A pilot plant, which produced over 35 thousand cubic meters, began operating in the city of Tallinn in the early 50s of the last century using this technology. a wide variety of products, ranging from cellular wall blocks, load-bearing floor panels to roof tiles and sewer pipes... As a result, from lime and simple sand, this plant began to produce products with a grade of M3000 in mass production, and up to M5000 in pilot production. (And this is half a century ago! Today, concrete grade M600 is considered almost the pinnacle of applied concrete science).
Silicalcite is of higher quality than concrete for all construction and technical parameters. In silicalcite, sand and lime particles are combined in much the same way as soda and sand particles in glass. It is impossible to separate them from one another by conventional research methods. In concrete, the grains of sand and gravel practically do not take part in the formation of the internal structure of the artificial stone, they are simply glued together with cement.
Doesn't this structure remind you of granite? There, too, feldspar particles with quartz particles are firmly bonded like a polycrystal.
Read more about silicalcite
There were such thoughts as to make masses of artificial stone, and even granite:
They took a mixture of sand and lime crushed into powder (nanopowder) and rammed it with granite chips or the same sand. Then they were heated in ovens. There is an opinion on silicalcite that it is not even necessary to heat it, it will gain the necessary strength over the years, extracting carbon dioxide from the atmosphere and becoming more and more stone. Perhaps, it was on this technology that buildings were built in Egypt, St. Petersburg?
There are supporters and there are opponents of the stone block casting version. Many facts cannot be explained by mechanical processing of rocks, blanks, except for the molding of a liquid or pasty mass, including hard types of stone, crystalline, like granite, basalt. Add fuel to the fire or shift the weight towards the cast technology version.
Previous articles on this topic:
Casting of granite. Here are examples from Egypt:
The vertical conjugation of blocks is curvilinear. This cannot be achieved by mechanical processing. And what are these strange notches of material on the blocks? More like traces of poorly installed formwork. In principle, accuracy was not needed here.
Basalt. Sagging on the edges of the block. It can be seen that they were chipped
Row of basalt cubes with beads
What is the point of treating basalt like this and leaving such a "visor"?
It seems that the plastic mass was held by flat boards with supports. But their area was less than the area of the resulting block.
Vertically mate blocks
Horizontal and vertical fillet curvilinear
Like running dough out of a saucepan.
Here something was pressed down from above
Granite cladding of the Menkaure pyramid
How can granite blocks of this size be mechanically adjusted?
The edges of the masonry are not brought out to the plane to the end over the entire area
This is where the granite flakes
I believe that the outer cladding (surviving) of the pyramid at Giza is filled in block-by-block
Facing the pyramid at Giza
Concrete granite and basalt floor in Giza
How did these stones get into the granite mass? What will the skeptics say?
Another option is that the basalt blocks were laid on a plastic base
Are there any doubts that this is not a block-filled mass? Or will skeptics argue that such a lower curved surface can be rubbed against the unevenness of the base?
What kind of grasshoppers are building something?
Although, there are many questions about the basalt floor, and most likely it was made through mechanical processing of blocks. More about this
But let's continue the topic:
Comparison of rocks under a microscope
***
But how can all this be explained in terms of casting? In light of the many factors that can be seen in the photographs, some are of the opinion of granite casting. But granite is not concrete, there is no binder and filler. There is one filler (crystals of minerals), which are arranged like puzzles - fitted to each other without voids. Those. it is a polycrystal. Considering that there was a technology that made it possible to knead a solution under granite with a filler and a binder, which in a short time also turned into a crystalline structure, then this opens up huge open spaces for the use of this technology. But how does the binder crystallize? In nature, this happens under pressure and at high temperatures.
For those who misunderstood. In concrete, the binder is cement. After reaction with water, it polymerizes into a single monolith. But, depending on the chemical formula in it, it has different strength and abrasion resistance. To save cement and to make concrete more resistant to abrasion, a filler (sand, ASG, granite chips, etc.) is added to the cement.
And granite is a rock where each crystalline grain of a filler is connected to another in a single puzzle. No voids. Quartz in granite has greater strength than cement and fills in the rock as a binder in concrete. But quartz is a crystal, not a cementitious polymer.
Those. in order to say with confidence that there was liquid (or plastic) granite, it is necessary to resolve the issue of crystallization, petrification. Or softening granite. And this is generally incomprehensible.
But the traces, the contenders for the casting technology, can be viewed further:
Columns can now only be made from segments. PetroMramor plant
Turkey. Peace. Columns. There is a hole in the base of the granite columns with rust from a metal part.
Baalbek. Inside - concrete (crushed stone on a solution)
Cyprus. Inside the stones are in solution
The joint between sandstone blocks. How could they stick together grains of sand?
Kazan Cathedral. Venetian granite plaster
A separate topic is poking in blocks, and even more so in granite and other rocks:
After what I saw in the photographs, I no longer have any doubts that many granite massifs in ancient structures (in particular throughout Egypt) are casting or molding of masses (mixed or softened). Yes, fantastic. But I see no other logic in this.
***
Thanks to the readers who in the comments showed a well-forgotten technology that they tried to implement on an industrial scale in the USSR:
Silicalcite is made from 90% sand of almost any natural quality and 10% lime. The main method of dramatically increasing the physical and mechanical properties of autoclave-hardened silicalcite products is undoubtedly fine grinding of lime and sand by the method of free high-load impact using a special grinder - disintegrator:
Disintegrator series HORS
Disintegrator basket with grinding fingers.
A pilot plant, which produced over 35 thousand cubic meters, began operating in the city of Tallinn in the early 50s of the last century using this technology. a wide variety of products, ranging from cellular wall blocks, load-bearing floor panels to tiles and sewer pipes. As a result, from lime and simple sand, this plant began to produce products with a grade of M3000 in mass production, and up to M5000 in pilot production. (And this is half a century ago! Today, concrete grade M600 is considered almost the pinnacle of applied concrete science).
Silicalcite is of higher quality than concrete for all construction and technical parameters. In silicalcite, sand and lime particles are combined in much the same way as soda and sand particles in glass. It is impossible to separate them from one another by conventional research methods. In concrete, the grains of sand and gravel practically do not take part in the formation of the internal structure of the artificial stone, they are simply glued together with cement.
Doesn't this structure of granite remind you? There, too, feldspar particles with quartz particles are firmly bonded like a polycrystal.
Read more about silicalcite
Interesting comment pavell743 in repost:
In chemical analysis, feldspar consists of sodium (potassium) oxides, aluminum oxide, and silicon oxide. The pH of spar is close to 9-10. It is an alkaline structure. The structure consists of 4 oxides. sodium oxide, silicon oxide, aluminum oxide and hydrogen oxide (water). We have a classic hydro-sodium aluminosicate.
If you look at modern Portland cement, it has replaced potassium with calcium. And the first of the brothers responsible for strength is three calcium aluminosilicate. When hydrated, it forms a water-insoluble crystal. PH of concrete 12-14.
What happens to concrete if caustic soda or potassium is added to it?
And the following will happen. The PH will shift to 14. And the formation reaction will begin, following the example of feldspar (sodium, silicon, aluminum and water).
Now let's look at the chemical composition of simple ash from coal or firewood.
Silicon about 30%, aluminum up to 50%, calcium 2-10%, potassium and sodium up to 1-2%.
Doesn't it remind you of anything? The composition is almost finished with feldspar. Only in the ash are the particles melted and they are round under the microscope.
With the combined grinding of ash and caustic sodium in a ratio of 1/10, a dry reaction begins by activation of silicon and aluminum with sodium. When water is added, hydrolysis occurs and the pH tends to 16, causing the formation of sodium hydroaluminates of silicon.
The temperature for firing and obtaining clinker is not required. We need grinding and activation as at the final stage of obtaining Portland cement.
This is called alkaline concrete.
Well, a video about industrial production geopolymer cement in Chelyabinsk:
Take a look at the tanker from the 70s of the last century.
Read the books of Glukhovsky. And you will understand that you can get an almost transparent binder.
Regarding silitcalcite, there is one minus activation is needed and that the pH is constantly shifted to the alkaline side, the stronger the better. It is difficult to obtain a long-playing alkaline pH on lime; for this reason, silitcalcite requires autoclaving and sand activation (knocking off the husk from the quartz grain).
In the modern construction industry, there are many ways to obtain stone. This and the technology of hard concrete is when the water-cement ratio is low and the strength is high, but the mixture is difficult to install. And with a large w / c ratio of the code, pour it like sour cream.
There is a lot of technology. There are self-creeping and self-compacting mixtures. It is difficult to move with low shrinkage of the cone. But when vibrating, current.
The problem of modern cement is that it is just a glue and does not react with the aggregate, while in alkaline binders, the aggregate reacts to form a spatially rigid structure with a constant growth of bonds, until all potassium or sodium with water.
The strength of slag mixed with water without binders is in the range of 20-30 kg / cm squared. With only 1% active alkaline part. And that carbonated one. When heated or fired, the carbon dioxide part leaves and we get clinker, if we grind and seal it, we get a binder.
If we just add caustic sodium to the ash and grind it, we will also get an astringent.
Alkali knits quartz and clay. The basis of ceramics.
The acid fluffs up the clay, the alkali knits.
The basis of ceramics.
Alkaline concrete, when calcined, recrystallizes and obtain heat-resistant systems. Since there is almost no free water, it is consumed by caustic liquor, then there are no problems with steam-gas ruptures of the structure.
***
There were such thoughts as to make masses of artificial stone, and even granite:
They took a mixture of sand and lime crushed into powder (nanopowder) and rammed it with granite chips or the same sand. Then they were heated in ovens. There is an opinion on silicalcite that it is not even necessary to heat it, it will gain the necessary strength over the years, extracting carbon dioxide from the atmosphere and becoming more and more stone. Perhaps, it was on this technology that buildings were built in Egypt, St. Petersburg?
Marble is considered one of the most attractive materials in terms of aesthetic and technical and operational qualities. However, the use of this stone is accompanied by difficulties in handling and transportation. And this is not to mention the high cost of a natural mineral. Actually, the same situation is observed with a number of other rocks, including granite. To get rid of such shortcomings, the technologies for the production of artificial analogs allow. In particular, cast marble is more affordable price and allows you to get the desired shape of the final product even at the manufacturing stage. It can be a piece of furniture, a purely decorative element of garden decoration, or a panel for cladding. Of course, there is no need to talk about the complete similarity with the natural prototype in the case of composite materials, but according to the main characteristics, the imitation justifies itself.
What is cast marble?
This is a material that is created on a polymer basis with the inclusion of fillers. The production technology itself implies ample opportunities for changing the aesthetic properties of this stone. Compared to natural marble, the composite analogue makes it possible to use any color shades, not being limited by the size of the product. It should also be noted that it differs from the classic production technology. artificial stones... Unlike materials created using cement, cast marble involves the use of polymers as a binder. It is thanks to this technological features high performance properties are achieved. Among them are noted: solidity, moisture resistance, optimal thermal conductivity, etc.
Manufacturing technology
Despite providing a wide range of positive qualities, the technological process of making marble is quite simple. For this purpose, enterprises use special matrix forms, in which a previously prepared raw material base is placed. The final product is formed by casting - the container is filled with a mixture with filler and additives, which further solidifies. At the same time, there are several methods by which cast marble is produced. The technology in the standard scheme involves the use of polyester resins. Due to the introduction of this component, the output is a product that can be used in the design of home furnishings. It is using this technology that parts and full-fledged interior objects are produced. In practice, the peculiarity of cast marble is felt even with ordinary touch - the material gives off heat. This quality distinguishes the stone from natural marble and granite.
Forms for products
Much in the quality of the implementation of the technological process depends on the equipment used, the main element of which is the aforementioned form, that is, the matrix. There is ready-made equipment on the market, but in most cases manufacturers purchase matrices on special order. The fact is that the molds for cast marble determine what the final product will be like. Therefore, we are not talking about the performance standards of such equipment - each manufacturer strives to make their products unique, therefore the matrix sketches are developed as copyright ones with unique sizes and textures. Another thing is that in each case high requirements to the material for making molds. Usually, a composite material is used, similar in characteristics to plastic, but, of course, much stronger and more durable.
Raw materials for cast marble
In addition to the shape, such products also differ in composition. The standard set of components includes the addition of filler, polyester resin and gelcoat. The basis is the filler, which, by the way, is the most affordable component of the raw material set. Usually this component of the mixture is stone or concrete waste. As for the gelcoat, it belongs to specialized additives. Thanks to this element, high strength and moisture resistance are achieved - properties that high-quality cast marble has. The production of the material also involves the introduction of polyester resins. This is an important component due to which the product acquires the durability of the structure and optimal viscosity indicators. 
Products based on cast marble
The flexibility of the manufacturing process allows you to diversify the shapes and sizes of the resulting products. For this feature, the material is appreciated by lovers of original design solutions... Experts identify three main areas in which the manufacturers of these products work. The first group includes materials intended for cladding: tiles, facade panels, stone boards, etc. The second group is represented by articles made of cast marble in the form of items of interior accessories and furniture. These can be countertops, flowerpots, candlesticks, kitchen surfaces, and other objects. However, the greatest interest among true connoisseurs of cast marble is caused by the products that are used to decorate staircase structures. Manufacturers form whole series in which you can find steps, handrails, balustrades and other accessories.
Features of industrial cast marble
This type of artificial marble is also called polymer concrete. Its peculiarity lies in the absence of decorative qualities and increased properties of vibration and chemical resistance. These characteristics determined the scope of use of the material. Usually it is used in structures requiring protection from physical influences. In particular, cast marble for industrial use is used in the manufacture of platforms for machine tools and equipment, containers for chemical compositions, breakwaters, drainage structures, etc. I must say that in terms of durability and shock resistance, this material is much superior to traditional concrete structures.
Manufacturers
Domestic enterprises are still only mastering this technology, relying on the experience of foreign companies. Nevertheless, on the market you can find products of quite solid quality. The high level of technical and operational indicators of their products is demonstrated by such cast marble manufacturers as Sanola, Avstrom and Decorlit. Also, a rich assortment is offered by the Royal Cream Stone company, which has its own enterprises in Kazakhstan and Europe. A feature of the proposals from these manufacturers is the possibility of cooperation on individual orders, which allows you to purchase products made of cast marble that are unique in shape and texture.
It is also worth noting that the production of marble using casting technology is also available to private craftsmen. The purchase of raw materials is a minimum fraction of the total cost of the product. According to some calculations, standard sizes the countertop has a cost price of 500-600 rubles. Of course, for its manufacture, in addition to raw materials, it will also be required special equipment in the form of the same matrix. Therefore, you should count on such an enterprise only if the technology is used regularly.
And now they know how to cast Granite and marble, and easily. Look around!
And then it was only in this way it was possible to technologically solve this problem and the granite column - the highest in the world was cast on Palace Square - the largest monolithic column in the world - the Alexandria Pillar.
And now balls are being cast on the Neva and vases at the Moscow railway station
It is very pleasant to know that what I have been explaining for five years now is gradually reaching everyone!
Here's a repost: the person also realized that it was all cast ... and if the opinions coincide, it will soon look like the truth. but how to prove it all - that is the question.
I just know it.
Monolithic steps of the Monument to Nicholas I. This monument could not be disassembled and left.
Writes koparev (koparev) http://koparev.livejournal.com/232491.html
2016-05-24 23:59:00
People in the Middle Ages successfully produced artificial granite and marble, or Megaliths.
The sculpture of this girl is in the Vorontsov Palace (South Coast of Crimea). What technology was used to create this sculpture? Is it really made from a single piece of marble? How did you get the curls on her head? 
Here is a column in Palmyra. It is larger in size than the columns of St. Isaac's Cathedral. How did the ancients create this miracle? 
This is the base of this column. How did the sandstone rod end up inside the granite column? Is it possible that the rocks were so deposited on the site of the quarry? The sandstone is seemingly covered with granite, like plaster that has been carefully polished after it has hardened ... Is it possible to make a material like granite soft? 
Is this sculpture created with a chisel and a hammer? This sculpture HAS BEEN PASTED. 
Do you believe that the sphinx was carved from solid rock? Then why is his head darker than the body? Could it have been cast from concrete?
Of course, it is cast from geopolymer concrete. Several centuries ago, our ancestors already knew what a concrete solution was. Moreover, in the days of "Antiquity" they could create artificial granite and marble.
About the fact that in the Middle Ages (and in "Antiquity") artificial granite and marble could be successfully obtained, G. Brodersen's book "Handbook" and A. Job's work "On the importance of chemical research" were written. It is very important to remind that artificial granite DOESN'T DIFFER IN ANYTHING FROM NATURAL GRANITE. The same can be said for marble. No geochemist, having carried out chemical research, can distinguish artificial marble from natural, since they have the SAME COMPONENTS.
Artificial granite was obtained in "Antiquity" as follows:
C 42. kn. G. Brodersen. Directory.
Artificial marble according to Ostermeier was obtained in this way:
S. 42. kn. G. Brodersen.
P. 41. G. Brodersen.
Download book. Brodersen G.G. Handicraft handbook. Recipes. M., Glagol, 1992. - Reprint ed. Brodersen G. Handbook. - M., GI, 1932.: https://yadi.sk/i/XEg0GnAjrwm7d
Download the book of A. Jobsky On the importance of chemical research. M., AN, 1832 .-- P. 9.
https://yadi.sk/i/NINR5kZarxojo 
Moreover, silt from the bottom of the sea was used as a building material, which, as a result of a natural disaster, was thrown out onto the coast. It has a high content of silica and calcium oxides. With the passage of time, this silt, like concrete mortar, TURNED TO GRANITE. From this "solution", the Barabar caves were created.
The seam between the layers of "mortar" is visible.
The crumbling and flaking of the "concrete" at the top of the structure can be seen. The builders left traces of some kind of mechanism.
http://s.fishki.net/upload/post/201505/16/1534238/15.jpg
I would like to note from myself that the walls of Peter and Paulivka and kilometers of round borders on the Neva and, in general, granite embankments on the Neva are naturally cast from Granite. as a designer then going. I even saw blast furnaces near Petropavlovka on the Kartina. And in Ruskol there is a factory for smelting marble sculptures. You will not say that they were made by hand in every Museum of the World.
And why are all the streets dressed in natural granite now, I can't put my mind to it ... 
Probably just sawing the Budget, Or really do not know ??
then for them this post!