Precision metal processing (with bars and V-matrixes) as an invisible foundation for the creation of authentic artificial rocks.
When guests step onto your floating platform, the first thing they notice is its stunning aesthetics. The edges that faithfully mimic natural Dalmatian rocks create the feeling of an authentic island. But behind this beautiful visual illusion and the texture of quartz sand lies an invisible, indestructible “skeleton”.
For artificial rocks to withstand decades of ravaging waves, docked workboats, and extreme weather conditions, they must have a flawless mechanical foundation. That foundation is a highly engineered stainless steel frame. In this article, we reveal the metalworking process that ensures your platform’s beauty is built on industrial strength.
1. Inox 316: The only choice for the maritime industry
Forget about galvanized steel or standard alloys – sea salt, humidity and constant sun exposure would destroy them in just a few seasons.
To create the supporting framework of our thematization, we use exclusively stainless steel grade 316 (Inox 316). This specific molybdenum-enriched alloy offers superior resistance to corrosion and pitting in chloride and saline environments. Inox 316 forms the perfect backbone around which the volume of the rock itself is later built.
2. Precision of press brakes and V-die
The metal frame does not consist only of straight tubes. In order to achieve the irregular, organic shape of the rock while maintaining maximum load-bearing capacity, sheets and profiles must be precisely bent into complex geometric shapes. This process is performed on high-precision hydraulic press brakes.
This is where true engineering expertise comes into play. For example, when bending 3 mm thick steel sheets, our engineers use precisely selected tools, such as 30 mm V-groove dies. Using such a matrix, the required tonnage of bending force is accurately calculated to achieve the ideal inner radius.
This level of mathematical and mechanical precision ensures that there is no material thinning or microcracking at the point of bending. The steel retains 100% of its structural strength, which is critical for the parts of the frame that will experience the greatest hydrodynamic loads.
3. Welding and creating a 3D mesh
Once the elements are precisely cut and bent, assembly begins. Using TIG (Tungsten Inert Gas) welding, we connect the stainless steel components into a complex 3D mesh surrounding the HDPE platform base.
This mesh is deliberately shaped with irregular corners and protrusions. Masters in the production plant already at this stage of mechanical work define the future lines, cuts and "ridge" shapes of the rocks, following the exact drawings generated from our 3D CAD SolidWorks models.
4. Synergy of steel, foam and polyurea
Once the indestructible stainless steel frame is completed and attached to the hull, it becomes the support for the remaining layers:
- Volume and buoyancy: High-density 2K polyurethane foam (60 kg/m³) is injected inside and around the stainless steel mesh. The foam envelops the steel, fixing it and giving the platform enormous additional buoyancy.
- Protective armor: Polyurea enriched with pigments and quartz sand is applied over the shaped foam, creating a hard, waterproof and anti-slip crust.
In this synergy, polyurea protects against wear, polyurethane foam gives shape and unsinkability, while The precisely machined stainless steel frame takes on all stress forces., preventing the outer layer from cracking.
The invisible power of your investment
The most important parts of any marine facility are the ones the client never sees. By investing in top-notch precious metal processing and precision engineering, we guarantee that our theming is not just an empty shell, but a reinforced shield that protects your platform.
Are you interested in a more detailed specification of the materials we use in production? Our team will be happy to present you with the technical aspects of our production process.
