What Are the Materials and Construction of Stone Bath Mats?
GAIA ECO
Tired of soggy, slippery bathroom floors? Discover how stone bath mats can solve these issues with their innovative materials and construction.
Stone bath mats, primarily made from diatomaceous earth, quartz sand, and plant fibers, offer exceptional absorbency, durability, and eco-friendliness. Their unique construction ensures quick drying and long-lasting performance.
Let’s explore the materials and manufacturing processes that make stone bath mats so effective.
For example, GAIAECO’s stone bath mats utilize high-purity diatomaceous earth and rigorous quality control to deliver superior performance and reliability.
This chart focuses on each key factor contributing to superior absorption performance, with performance scores displayed.
High Porosity (90%): Provides excellent water absorption capability.
Absorption Rate (90%): Highly efficient in absorbing large amounts of water.
Low Swelling Rate (95%): Minimal volume change after water absorption, showcasing stability.
Structural Stability (85%): Retains shape and durability even after water absorption.
Quick Evaporation (80%): Rapid evaporation of absorbed water, ensuring dryness.
Understanding the materials is crucial for gaining a better insight into the quality and functionality of stone bath mats.
Stone bath mats are crafted from a blend of diatomaceous earth, quartz sand, plant fibers, and inorganic color pigments, each contributing to the mat’s superior performance.
Diatomaceous Earth (DE): The core material responsible for high absorbency, DE is a naturally occurring sedimentary rock formed from fossilized diatoms. Its porous structure allows it to absorb 2-4 times its own volume in water. Diatomaceous earth is characterized by its very high porosity, light texture, and low density. With a porosity rate of up to 90%, DE has far greater water absorption capacity compared to many other materials. The material’s surface area ranges from 40 to 65 m²/g, making it highly effective at quickly absorbing moisture. The density of diatomaceous earth is between 1.9 to 2.3 g/cm³, while its pore volume is 0.45 to 0.98 cm³/g. It can absorb 2-4 times its own volume in water, which is essential for quick-drying bath mats.
Property
Value
Porosity
90%
Density
1.9–2.3 g/cm³
Bulk Density
0.34–0.65 g/cm³
Surface Area
40–65 m²/g
Pore Volume
0.45–0.98 cm³/g
Water Absorption Rate
2–4 times its own volume
Quartz Sand: Enhances the structural integrity and durability of the mat, preventing cracking and maintaining shape over time.
Property
Description
Chemical Composition
It is primarily composed of silicon dioxide (SiO₂), which is highly stable and does not easily react with other substances.
Particle Shape and Size
Its particles are generally regular in shape, which ensures good flowability and stability when mixed with other materials.
Specific Gravity and Hardness
It has a specific gravity of 2.65 g/cm³, making it a relatively heavy mineral that enhances the overall stability and durability of the stone bath mat.
Compressive Strength and Heat Resistance
It has a high hardness (Mohs scale 7) and maintains stability at high temperatures, making it resistant to damage and wear.
Plant Fiber: Adds flexibility and eco-friendliness, increasing the mat’s resistance to wear and tear.
Inorganic Color Powder: Provide vibrant, long-lasting colors without compromising the mat’s natural properties.
GAIAECO sources premium diatomaceous earth certified by SGS standards, ensuring antibacterial and quick-drying properties. The inclusion of quartz sand and plant fibers guarantees durability and environmental sustainability.
2. What Are the Construction of Stone Bath Mats?
The construction process is crucial for ensuring the mat’s effectiveness and longevity.
Stone bath mats are manufactured through a high-pressure compression process, followed by steam and final curing to achieve optimal texture and durability.
Layering Process: Approximately 25 layers of diatomaceous earth, quartz sand, plant fiber, and color pigments are stacked to ensure even material distribution.
High-Pressure Compression: Materials are compressed under 5000 tons of pressure, binding them together without compromising absorbency.
Steam Curing: Mats are heated in a steam pressure chamber at 200°C and 10 atmospheres for 48 hours to solidify the structure and eliminate moisture.
Final Curing: An additional 30-minute baking step ensures the mat reaches a controlled moisture content, thus improving water absorption properties.
GAIAECO’s factory, equipped with two production lines, employs advanced machinery to maintain consistent quality and efficiency. Each mat undergoes rigorous testing for absorbency and durability before being shipped internationally.
Manufacturing Process Table:
Step
Description
Layering Process
25 layers of materials are stacked to ensure even distribution.
High-Pressure Compression
Materials are compressed under 5000 tons of pressure for durability and stability.
Steam Curing
The mat is placed in a steam chamber at 200°C for 48 hours to solidify and remove moisture.
Final Curing
The mat is baked for 30 minutes to improve water absorption properties.
3. How Well Do Stone Bath Mats Absorb Water?
Stone bath mats provide an effective solution with outstanding water absorption and quick-drying capabilities.
Stone bath mats can absorb up to 1-2 times their own weight in water, ensuring a dry surface after every use. This is due to the high porosity of diatomaceous earth.
Comprehensive Absorption Performance:
Stone bath mats maintain a water content of ≤15%, preventing dampness and mildew. Their moisture swelling rate is ≤0.25% and thermal shrinkage rate is ≤0.50%, ensuring they retain their shape and functionality even in humid environments. With a density of approximately 0.7 times that of water and a porosity rate exceeding 99.9%, these mats outperform traditional fabric mats by quickly drawing water into their fine pore structure, thereby avoiding unwanted moisture accumulation on the surface.
Water Absorption Performance Visual:
This visual chart compares the water absorption performance of stone bath mats and traditional cotton bath mats. It highlights five main test categories: water absorption rate, moisture content, wet expansion rate, thermal shrinkage rate, and moisture retention rate.
The results demonstrate the advantages of stone bath mats, particularly regarding water absorption speed, wet expansion rate, and thermal shrinkage rate.
4. How Are Water Absorption And Swelling Tests Performed?
Objective: Measure how much material changes in weight and size (swells) after absorbing water.
Steps:
1. Prepare the Sample:
Measure the dry dimensions (length, width, and thickness) and weight of the sample.
Record the initial values.
2. Submerge in Water:
Place the sample in a water bath at room temperature (25°C) for 2 hours.
3. Post-Absorption Measurements:
Remove the sample, wipe off the surface water, and measure the new dimensions and weight.
4. Calculate the Swelling Rate:
Use the formula:
5. Water Absorption Rate Calculation:
Use the formula:
Performance Category
Good Standard
Acceptable Standard
Poor Performance
Swelling Rate (SR)
≤0.25%
≤0.50%
>0.50%
Water Absorption Rate (WR)
1–2 times its weight
≤2.5 times its weight
>2.5 times its weight
Each step in the legend clearly explains the testing process and reference standards. A high-quality stone bath mat should meet the requirements of a wet expansion rate ≤0.25% and a water absorption rate of 1–2 times its own weight.
Summary
Stone bath mats, made from diatomaceous earth, quartz sand, plant fiber, and inorganic color powder, provide superior absorption, durability, and eco-friendliness. The use of these high-quality materials ensures that stone bath mats are not only effective at keeping your bathroom dry but also long-lasting and sustainable.
