Cement-based artificial granite is widely used in interior decoration, flooring, and wall cladding for its cost-effectiveness and natural stone-like appearance. However, traditional production methods face critical challenges: poor aggregate dispersion, high void ratio, color mixing during molding, and warping after hardening—all of which reduce product quality and production efficiency. The addition of a thermally crosslinkable melamine resin solves these pain points.
This article details how melamine additives optimize artificial granite production, including mechanism, process steps, performance improvements, and industrial value—essential for stone manufacturers aiming to upgrade products.
Traditional processes struggle to meet high-quality standards due to inherent flaws:
Thermally crosslinkable melamine resins (e.g., methylol melamine, dimethoxylated melamine) act as multifunctional additives, optimizing mortar properties and production workflows:
Dual-Rheological Behavior: Mortar with melamine additives has high viscosity under static conditions (similar to rice cake) to prevent color mixing; under vibration, fluidity increases significantly to fill aggregate gaps and ensure uniform dispersion.
Thermal Crosslinking Hardening: During autoclaving (150℃×3h), melamine resin undergoes crosslinking and polymerization, forming a chain-like network around aggregates and cement particles. This enhances bonding strength and reduces shrinkage.
Water Reduction: Melamine additives lower mortar water demand, minimizing shrinkage and warping while improving compactness.
Type: Thermally crosslinkable melamine resin (hydroxymethyl melamine or dimethoxylated melamine).
Dosage: 6 parts by mass per 100 parts of cement (see Table 1 for standard mix ratio).
Compatibility: Works with natural stone aggregates (0.3–5mm particle size) and common cement-based mortars.
The new method integrates melamine additives into existing workflows, requiring no major equipment modifications.
Step 1: Prepare Colored Mortars
Mix aggregates (0.3–5mm natural stone particles, 100–450 parts per 100 parts mortar) with cement, sand, blast furnace slag, water, and melamine additive.
Add pigments to prepare multiple batches of mortar in different colors (no mixing under static conditions due to the mortar’s high viscosity).
Step 2: Mold Filling with Segmented Color Injection
Inject different colored mortars into molds in segments. The high static viscosity of melamine-modified mortar prevents cross-color mixing.
Step 3: Vibrational Compaction
Vibrate the mold (or use internal vibrators) to increase mortar fluidity. The mortar easily penetrates fine gaps between aggregates, ensuring dense packing and uniform dispersion.
Step 4: Initial Hardening & Demolding
Allow the mortar to harden to demolding strength at room temperature.
Step 5: Autoclaving Curing
Transfer demolded slabs to an autoclave for curing at 150℃ under pressure for 3 hours. Melamine resin crosslinks and polymerizes, while cement hydrates fully—forming a strong, compact matrix.
Step 6: Surface Polishing
Polish the hardened slab to expose aggregates. The dense, void-free surface and distinct color textures mimic natural granite.
No need for new equipment—compatible with existing production lines.
Low additive dosage (6 parts per 100 parts cement) with significant performance returns.
Suitable for various aggregates (natural stone, synthetic resin particles, metal particles) and color systems.
Adjustable mix ratios for different product requirements (flooring, wall cladding, countertops).
Melamine resin is non-toxic and stable after curing, meeting global environmental standards for building materials.
Reduces material waste and energy consumption (shorter grinding time, lower scrap rate).
Melamine additives address the core pain points of traditional cement-based artificial granite production by enabling dual rheological behavior and thermal crosslinking. By improving aggregate packing density, preventing color mixing, and reducing warpage, they enable the production of high-quality, natural-stone-like products with greater efficiency and lower costs.
For stone manufacturers, this technology is a low-investment, high-return upgrade that expands product portfolios, enhances market competitiveness, and meets growing demand for premium decorative materials. As the building materials industry shifts toward sustainability and aesthetics, melamine additives will become a standard component in the production of high-grade cement-based artificial granite.
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