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How Shackerley's façade panels are made

There are many different manufacturing and prefabrication processes involved in the creation of a SureClad® ceramic granite ventilated façade panel.

Step 1 - Raw Materials

Pure raw materials are sourced from across the world - clays, fieldspars, minerals, pegamites and metal oxides. No resins, cements or other binders are used.

Step 2 - Grinding

These powders, rocks and minerals are amalgamated, wet ground to a fine powder, refined to remove impurities and turned into a perfectly homogenised slurry.

Step 3 - Spray drying

The slurry is injected at high pressure and nebulised inside a spray dryer. The contact with very hot air causes instant and even drying.

Step 4 - Mixing & pressing

Using a unique patented method, the dried materials are mixed and are then subjected to intense hydraulic pressure - typically over 12,000 tonnes.

Step 5 - Firing

The pressed slabs are fired at 1260°C until fully vitrified: impervious to water, dust or chemical attack. During the firing process the constituent parts become irreversibly fused without any need for bonding agents.

Step 6 - Surface finishes

At this stage the ceramic granite slabs can be left with a natural unpolished finish or can be given a semi-lustre or high sheen, diamond polished surface. No chemicals are involved in the polishing process.

Step 7 - Quality control

Every ceramic granite slab is checked electronically and by highly trained technicians for uniformity of colour, structural integrity and critical sizing.