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Bretonstone, also known as vibro-compression under vacuum, is a formerly-patented technology [2] [3] invented in the early-1970s[ citation needed ] by Breton S.p.A. [4]
Nowadays most manufacturers of engineered stone use similar technology, typically involving quartz and a resin binder combined under vacuum, and compressed under heat into a desired form such as a contertop slab. [5]
In the early-1970s Marcello Toncelli, [6] founder of Breton, started developing the Bretonstone system, which allows to produce a solid surface similar to granite, using small stone aggregates and stone-like materials. The composite material is manufactured in slabs, which can be worked as natural stone, instead of blocks that should have been cut.
Basically the vibro-compression vacuum technology, [7] [8] used by Bretonstone system, consists of blending the natural aggregate of stone with a polymer mix (usually unsaturated polyester resin), [9] taking away air with a vacuum, and catalyzing the molded product whilst vibrating and applying pressure to this mix. Then the mixture is heated, and the output is a slab of non-porous and quite stable engineered stone.
The following improvements led the agglomerated stone to obtain the same hardness as granite, when siliceous stone or quartz were added in the mix.
The agglomerate produced with the Bretonstone system looks like natural stone and varies in look according to the types of stone aggregates and stone-like materials used in the process. [10] Some types of agglomerate are:
Fiberglass or fibreglass is a common type of fiber-reinforced plastic using glass fiber. The fibers may be randomly arranged, flattened into a sheet called a chopped strand mat, or woven into glass cloth. The plastic matrix may be a thermoset polymer matrix—most often based on thermosetting polymers such as epoxy, polyester resin, or vinyl ester resin—or a thermoplastic.
A quarry is a type of open-pit mine in which dimension stone, rock, construction aggregate, riprap, sand, gravel, or slate is excavated from the ground. The operation of quarries is regulated in some jurisdictions to manage their safety risks and reduce their environmental impact.
Epoxy is the family of basic components or cured end products of epoxy resins. Epoxy resins, also known as polyepoxides, are a class of reactive prepolymers and polymers which contain epoxide groups. The epoxide functional group is also collectively called epoxy. The IUPAC name for an epoxide group is an oxirane.
Terrazzo is a composite material, poured in place or precast, which is used for floor and wall treatments. It consists of chips of marble, quartz, granite, glass, or other suitable material, poured with a cementitious binder, polymeric, or a combination of both. Metal strips often divide sections, or changes in color or material in a pattern. Additional chips may be sprinkled atop the mix before it sets. After it is cured it is ground and polished smooth or otherwise finished to produce a uniformly textured surface. "Terrazzo" is also often used to describe any pattern similar to the original terrazzo floors.
Fibre-reinforced plastic is a composite material made of a polymer matrix reinforced with fibres. The fibres are usually glass, carbon, aramid, or basalt. Rarely, other fibres such as paper, wood, boron, or asbestos have been used. The polymer is usually an epoxy, vinyl ester, or polyester thermosetting plastic, though phenol formaldehyde resins are still in use.
A binder or binding agent is any material or substance that holds or draws other materials together to form a cohesive whole mechanically, chemically, by adhesion or cohesion.
Dimension stone is natural stone or rock that has been selected and finished to specific sizes or shapes. Color, texture and pattern, and surface finish of the stone are also normal requirements. Another important selection criterion is durability: the time measure of the ability of dimension stone to endure and to maintain its essential and distinctive characteristics of strength, resistance to decay, and appearance.
A countertop, also counter top, counter, benchtop, worktop or kitchen bench, bunker is a raised, firm, flat, and horizontal surface. They are built for work in kitchens or other food preparation areas, bathrooms or lavatories, and workrooms in general. The surface is frequently installed upon and supported by cabinets, positioned at an ergonomic height for the user and the particular task for which it is designed. A countertop may be constructed of various materials with different attributes of functionality, durability and aesthetics, and may have built-in appliances, or accessory items relative to the intended application.
Engineered stone is a composite material made of crushed stone bound together by an adhesive to create a solid surface. The adhesive is most commonly polymer resin, with some newer versions using cement mix. This category includes engineered quartz (SiO2), polymer concrete and engineered marble stone. The application of these products depends on the original stone used. For engineered marbles the most common application is indoor flooring and walls, while the quartz based product is used primarily for kitchen countertops as an alternative to laminate or granite. Related materials include geopolymers and cast stone. Unlike terrazzo, the material is factory made in either blocks or slabs, cut and polished by fabricators, and assembled at the worksite.
Polyester resins are synthetic resins formed by the reaction of dibasic organic acids and polyhydric alcohols. Maleic anhydride is a commonly used raw material with diacid functionality in unsaturated polyester resins. Unsaturated polyester resins are used in sheet moulding compound, bulk moulding compound and the toner of laser printers. Wall panels fabricated from polyester resins reinforced with fiberglass—so-called fiberglass reinforced plastic (FRP)—are typically used in restaurants, kitchens, restrooms and other areas that require washable low-maintenance walls. They are also used extensively in cured-in-place pipe applications. Departments of Transportation in the USA also specify them for use as overlays on roads and bridges. In this application they are known AS Polyester Concrete Overlays (PCO). These are usually based on isophthalic acid and cut with styrene at high levels—usually up to 50%. Polyesters are also used in anchor bolt adhesives though epoxy based materials are also used. Many companies have and continue to introduce styrene free systems mainly due to odor issues, but also over concerns that styrene is a potential carcinogen. Drinking water applications also prefer styrene free. Most polyester resins are viscous, pale coloured liquids consisting of a solution of a polyester in a reactive diluent which is usually styrene, but can also include vinyl toluene and various acrylates.
Artificial stone is a name for various synthetic stone products produced from the 18th century onward. Uses include statuary, architectural details, fencing and rails, building construction, civil engineering work, and industrial applications such as grindstones.
A climbing hold is a shaped grip that is usually attached to a climbing wall so that climbers can grab or step on it. On most walls, climbing holds are arranged in paths, called routes, by specially trained route setters. Climbing holds come in a large array of sizes and shapes to provide different levels of challenge to a climber. Climbing holds are either bolted to a wall via hex-head bolts and existing t-nuts or they are screwed on with several small screws. In extreme cases, concrete anchors may be used.
Epoxy granite, also known as synthetic granite, is a polymer matrix composite and is a mixture of epoxy and granite commonly used as an alternative material for machine tool bases. Epoxy granite is used instead of cast iron and steel for improved vibration damping, longer tool life, and lower assembly cost, and thus better properties for stabilizing and housing machines.
Solid surface is a man-made material usually composed of a combination of alumina trihydrate (ATH), acrylic, epoxy or polyester resins and pigments. It is most frequently used for seamless countertop installations.
Polished concrete is a multi-step process where a concrete floor is mechanically ground, honed and polished with bonded abrasives in order to cut a concrete floor's surface. It is then refined with each cut in order to achieve a specified level of appearance.
A thermoset polymer matrix is a synthetic polymer reinforcement where polymers act as binder or matrix to secure in place incorporated particulates, fibres or other reinforcements. They were first developed for structural applications, such as glass-reinforced plastic radar domes on aircraft and graphite-epoxy payload bay doors on the Space Shuttle.
Out of autoclave composite manufacturing is an alternative to the traditional high pressure autoclave (industrial) curing process commonly used by the aerospace manufacturers for manufacturing composite material. Out of autoclave (OOA) is a process that achieves the same quality as an autoclave but through a different process. OOA curing achieves the desired fiber content and elimination of voids by placing the layup within a closed mold and applying vacuum, pressure, and heat by means other than an autoclave. An RTM press is the typical method of applying heat and pressure to the closed mold. There are several out of autoclave technologies in current use including resin transfer molding (RTM), Same Qualified Resin Transfer Molding (SQRTM), vacuum-assisted resin transfer molding (VARTM), and balanced pressure fluid molding. The most advanced of these processes can produce high-tech net shape aircraft components.
Flexible stone veneer is a veneer with a layer of stone 1 to 5 mm thick. Flexible stone veneers should not be confused with traditional stone veneers. It is used for both interior and exterior and especially where bending to a curved surface is required. Flexible stone veneers are made from various types of slate, schist, or marble.
Breton S.p.A. is an Italian, privately held company established in 1963 that produces machines and plants for engineered stone and metalworking. Machines and plants by Breton can be used in diverse sectors such as die-making, aerospace, automotive, racing cars, energy, gears, general mechanics, stone processing and kitchen top manufacturing.
Akemi GmbH is a company in the chemical industry which is active worldwide. Its headquarters are in Nuremberg in Germany and its core competence is the manufacturing of two-component adhesive systems. The chemical-technical specialist factory manufactures adhesives, fillers as well as cleaning and care products for the natural stone sector. In addition, it produces fillers and repair materials, sealants, protective coatings, varnishes as well as cleaning and car care products for the automotive branch.