Method for manufacturing articles in the form of thin slabs of composite stone and resultant articles

A method for manufacturing a thin slab, the thin slab being between 10-30 mm in thickness, the method comprising the steps of:

• (a) mixing cement, water, fluidizer and latex to form a cement paste, mixing being performed using mixing blades shaped to exert a cutting action on items being mixed;
• (b) coating a first plurality of coarse aggregate with the cement paste and a hydrophilic additive to form a first intermediate mix, each granulate of the coarse aggregate being a greater than 0.8 mm, the hydrophilic additive is dry carboxymethyl cellulose of the type which is fast-dissolving and resistant in a basic environment;
• (c) adding a second plurality of coarse aggregate to the first intermediate mix to obtain a second intermediate mix and homogenizing the second intermediate mix;
• (d) lining a temporary support or mould with a first sheet of plastic impermeable to water vapor;
• (e) distributing the second intermediate mix to form a material layer of predetermined size and thickness on the temporary support or in the mould;
• (f) applying onto the material layer a second sheet of plastic impermeable to water vapor;
• (g) vacuum compressing with an accompanying vibrating action the material layer thus enclosed by the first and second sheets to form a molded article;
• (h) sealing the first and second sheets of plastic along their perimeter to form an encased molded article;
• (i) transferring the encased molded article onto a rigid and flat hardening support;
• (j) permitting setting of the encased molded article until the encased molded article is suitably hardened for handling;
• and
• (k) curing for at least 7 days the encased molded article to form the thin slab.