Site Automation
STRATOLITH™
SYSTEM
Mobile. Autonomous. Modular. Revolutionising stone block extraction with automation
● Quarrying System Overview
Automated Quarrying System
● Metrics
System Metrics
Cutting Bed
3.6m x 3.6m
Machine Footprint
3.6m x 6.2m
Daily Output
12,400 bricks
Output Dimensions
215 x 102.5 x 65mm brick, 440 x 215 x 100mm block
Reconfigurable
Annual Output
3.72 million
16hrs for 300 days per year
Efficiency
Up to 95%
Geology dependent
Tolerances
± 2mm (BS EN 771-6)
24 Hr Automation
Capable of 24 Hr Automation
Scalable
Modular format
Parallel machine capable; suites a variety of site sizes
Electricity Cost
0.0313 kWh per brick*
Blade wear Cost
Est. 2 cents per brick**
CO₂ Reduction
99% lower than ceramic brick
Zero CO₂ if using renewable electricity source
● Components
● Functions
Mobile Stratolith™ System
A fully mobile robotic gantry with integrated control software. The system moves autonomously across the site, aligning to digital cutting planes for precise extraction.
Brick Palletisation
Raw stone converted into uniform structural bricks. Automatically cut, graded, stacked and palletised in a continuous process.
3.6 × 3.6m Grid Cell
The grid unit worked in the video above. The cutting bed works a 3.6 × 3.6 × 0.8m grid section at a time. This unit grid is designated within the digital twin control software.
● Sitemap
Quarrying Sitemap
Stratolith 1
First Stratolith unit. Cuts and extracts stone bricks directly from the quarry surface.
Stratolith 2
Second Stratolith unit operating in parallel, extending production capacity.
Stratolith 3
Third Stratolith unit operating in parallel, extending production capacity.
Forklifts — Block Moving
Forklifts moving palletised blocks between Stratolith output, stacking area, and dispatch.
Site Coordination Towers
Mast towers providing site-wide coordination, communications, and monitoring coverage.
Power & Water Delivery
Storage tanks and power distribution infrastructure supplying the entire site.
Solar Array
On-site solar panels generating renewable energy for Stratolith operations and site facilities.
Brick Stacking Area
Finished block stacking and storage zone. Palletised product cured and held before dispatch.
Control Warehouse
Site operations and control facility. Houses equipment, staff, and production management systems.
HGV Loading Area
Heavy goods vehicle loading bay. Finished blocks dispatched directly from site to customers.
Ramp into Quarry
Access ramp for forklifts, maintenance, etc.
Quarry Floor
Active extraction zone.
Pallet Store
Pallets ready for brick stacking.
The Successor to In-Situ Quarrying
An evolution of traditional quarrying. Building on systems used globally, Stratolith integrates extraction, processing, and formation through robotics and digital control, delivering uniform construction blocks in a continuous, automated flow.
● Stationary System Overview
Stationary Block Processing System
● Metrics
System Metrics
Stratolith can also operate in a stationary configuration. In this mode, quarry blocks are fed beneath the system, where they are cut directly into uniform bricks and automatically stacked. Using the same automation system for traditional large blocks as well as quarrying directly.
Cutting Bed
3.6m x 3.6m
Machine Footprint
3.6m x 6.2m
Daily Output
9,600 bricks
Output Dimensions
215 x 102.5 x 65mm brick
Future ability to reconfigure to 440 x 215 x 100mm block
Tolerances
± 2mm (BS EN 771-6)
24 Hr Automation
Capable of 24 Hr Automation
Electricity Cost
0.0313 kWh per brick*
Blade wear Cost
Est. 2 cents per brick**
● Components
● Functions
Rapid Deployment
Stratolith™ is containerised and designed for rapid setup, enabling deployment on site and operational readiness within approximately one day.
Block Scan & Optimisation
The system scans quarry blocks to optimise internal cutting layouts, maximising brick yield and aligning cuts with material structure before extraction.
Automated Stacking & Palletisation
Cut units are automatically graded, stacked and palletised, maintaining continuous output flow from extraction through to dispatch readiness.
● Sitemap
Block Processing Sitemap
Stationary Stratolith
Fixed Stratolith unit cutting and extracting stone bricks on site.
Stacking System
Automated system that stacks and grades bricks directly from the Stratolith output.
Pallet Store
Organised pallet storage area holding finished product ready for dispatch.
Block Stockpiles
Large open-air stockpiles of raw or finished blocks awaiting processing or dispatch.
Power Delivery / Solar Panels
On-site solar array providing renewable power delivery to the facility and equipment.
HGV Dispatch Area
Heavy goods vehicle loading and dispatch zone for outbound product deliveries.
Wheel Loader — Block Moving
Heavy wheel loader handling bulk block movement across the yard between stockpile zones.
Water Delivery / Store
On-site water storage tanks supplying the production process and site facilities.
Forklifts
Forklifts moving palletised product between the production line, store, and dispatch areas.
Site Control Building
Site coordination office. Interioir Storage space.
System Summary
Full-Site Automation
A single integrated workflow automates cutting, separation, extraction, sorting, waste removal, grading, stacking and pallet preparation directly at the quarry face.
Workflow
24 Hr Automation
OPEX
Significantly Reduced
Labour & Safety
Reduced
High Output Density
Each 3.6 × 6.2 m unit delivers up to 12,400 bricks per day. At 70% efficiency, a 100 × 100 m quarry site supports sustained high-volume production within required tolerances.
Daily Output
12,400
Footprint (MAX)
3.6 × 6.2m
Tolerances
± 2mm (BS EN 771-6)
Higher Recovery
By reducing heavy machinery use, we maximise the geological recovery per m³ of ground use. The system can unlock substantially more usable stone than conventional extraction methods.
Recovery
Up to 90%
Typical
~30%
Gain
Up to 2.6×
Lower Operating Cost
The system is fully automated, relies less on other machinery chains, and reduces labour dependency. The main operating costs are electricity and blade wear only.
Electrical Cost
0.0313 kWh per brick*
Blade Cost
Est. 2 cents per brick*
OPEX
Significantly Reduced
Low-Carbon Production
By eliminating kiln firing, stone brick production can reduce embodied carbon by approximately 95–99% compared with conventional ceramic bricks.
Reduction
95–99%
Clay Brick
~500g CO₂
Stone Brick
~3.25g CO₂
Scalable Site Deployment
A modular, software-led architecture enables repeatable deployment across quarry sites with low disruption and consistent control.
Architecture
Modular
Control
Software-led
Scaling
Variety of site sizes
● Quarry Sites
Work with
Irkalla
We are looking for quarry operators and landowners interested in deploying and running our fully automated stone block extraction systems.
What this means
- Early discussions around quarry suitability, geology and operational goals
- Integration with new or existing quarry workflows rather than wholesale replacement
- Phased deployment of automated cutting, handling and dispatch systems
Typical process
- Initial conversation and site review
- Assessment of extraction conditions and infrastructure needs
- Planning, setup and progressive operational rollout
Typical site requirements
- Suitable stone beds and an accessible extraction zone
- Space for gantry rails, palletisation and finished goods staging
- Basic water, power and ancillary site infrastructure
● Enquiry
Register Interest
Tell us about your site, your company or your interest in working with Irkalla.