Site Automation
STRATOLITH™ SYSTEM
Revolutionising stone block extraction with automation
Explore Our System →Site Automation
STRATOLITH™ SYSTEM
REVOLUTIONISING stone BLOCK EXTRACTION with automation
Explore Our System →What our system delivers
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 10 × 10 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)
10 × 10m
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. This compresses the operating cost structure of stone extraction.
Electrical Cost
0.0313 kWh per brick*
Blade Cost
1 cent 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
Suited to a variety of site sizes
Site Automation
The Stratolith™ System
Stratolith is Irkalla’s integrated quarry automation platform, combining control software with robotic hardware.
The robotic gantry operates within a defined footprint of 10x10m. This gantry moves autonomously around the quarry site, aligning cutting planes to digital planes after the initial site scan and setup.
The platform coordinates cutting paths, movement of the gantry system, geological adaptation, water systems, quality control, stacking, palletisation, storage and parallel machine operations across the site.
The entire site is controlled by our all-in-one software management tool.
The system is adaptable across multiple quarrying applications, including the production of structural stone bricks, extraction of block dimension stone and automated stone mining operations such as calcium carbonate extraction.
Key System Functions
Rail-system positioning and full gantry movement control
Automated cutting paths and adaptive extraction sequencing
Geology-responsive processing and quality grading
Waste management system for failed blocks
Automated sorting, stacking and pallet preparation
Water management, blade servicing and machine upkeep
Fleet coordination across multiple parallel operating units
System Metrics
Daily Output
12,400 bricks
Annual Output
3.75 million (at 300 days)
$ Yield per m³
Up to 4x (OPEX down, Yield up)
Efficiency
Up to 90% (average geology ~70%)
Coordination
Fully software-led
Operation
Machines can run in parallel
Software
01 Digital Plane Alignment
Establishes the digital control grid and quarry reference planes to which the Stratolith gantry system aligns itself, forming the positional framework for accurate and repeatable extraction across the active site.
Includes
Site model
Digital surface and geometry capture
Control planes
Reference grid definition across the quarry face
Calibration
Positional alignment of system to site geometry
Accuracy basis
Repeatable cutting coordinates for downstream operations
Provides the spatial basis for precise automated extraction
Software
01 Digital Plane Alignment
Establishes the digital control grid and quarry reference planes to which the Stratolith gantry system aligns itself, forming the positional framework for accurate and repeatable extraction across the active site.
Includes
Site model
Digital surface and geometry capture
Control planes
Reference grid definition across the quarry face
Calibration
Positional alignment of system to site geometry
Accuracy basis
Repeatable cutting coordinates for downstream operations
Provides the spatial basis for precise automated extraction
Software
02 Software Setup & Machine Control
Initialises the operating environment for each machine, loading cut logic, workflow parameters and positional data so the system can coordinate movement, cutting and handling operations across the site.
Includes
Path planning
Cut sequencing and operational logic
Workflow control
Task coordination across machine subsystems
Monitoring
Status visibility for active quarry operations
Machine instructions
Live control data for movement and execution
Converts site geometry into live machine operations
Software
02 Software Setup & Machine Control
Initialises the operating environment for each machine, loading cut logic, workflow parameters and positional data so the system can coordinate movement, cutting and handling operations across the site.
Includes
Path planning
Cut sequencing and operational logic
Workflow control
Task coordination across machine subsystems
Monitoring
Status visibility for active quarry operations
Machine instructions
Live control data for movement and execution
Converts site geometry into live machine operations
Hardware
03 Site Preparation & Gantry Setup
Deploys the rail-mounted gantry system onto the prepared working zone, establishing the physical operating footprint, movement boundaries and machine access required for continuous quarry-face production.
Includes
Rails
Installation across the designated extraction area
Gantry position
Machine placement within active working bounds
Utilities
Integration of power, water and control systems
Calibration
Operational setup prior to extraction
Establishes the physical platform for automated quarry production
Hardware
03 Site Preparation & Gantry Setup
Deploys the rail-mounted gantry system onto the prepared working zone, establishing the physical operating footprint, movement boundaries and machine access required for continuous quarry-face production.
Includes
Rails
Installation across the designated extraction area
Gantry position
Machine placement within active working bounds
Utilities
Integration of power, water and control systems
Calibration
Operational setup prior to extraction
Establishes the physical platform for automated quarry production
Hardware
04 Cutting
Executes the programmed cutting sequence directly into the quarry surface, producing dimensionally controlled stone bricks or blocks through automated saw movement, depth control and feed-rate adjustment.
Includes
Cut sequence
Automated linear and cross-cut operations
Depth control
Consistent material engagement and cut depth
Dimensional accuracy
Formation of repeatable brick and block geometry
Output basis
Prepared units ready for separation and handling
Converts quarry surface directly into defined stone units
Hardware
04 Cutting
Executes the programmed cutting sequence directly into the quarry surface, producing dimensionally controlled stone bricks or blocks through automated saw movement, depth control and feed-rate adjustment.
Includes
Cut sequence
Automated linear and cross-cut operations
Depth control
Consistent material engagement and cut depth
Dimensional accuracy
Formation of repeatable brick and block geometry
Output basis
Prepared units ready for separation and handling
Converts quarry surface directly into defined stone units
Hardware
05 Extraction & Handling
Separates and removes cut material from the quarry surface using robotic or mechanised handling systems, transferring units from the extraction zone without disrupting surrounding production areas.
Includes
Separation
Release of cut units from the quarry bed
Lift and transfer
Movement away from the cutting area
Handling logic
Load-aware transfer and placement operations
Flow continuity
Clearance for ongoing automated production
Removes finished units cleanly from the active extraction zone
Hardware
05 Extraction & Handling
Separates and removes cut material from the quarry surface using robotic or mechanised handling systems, transferring units from the extraction zone without disrupting surrounding production areas.
Includes
Separation
Release of cut units from the quarry bed
Lift and transfer
Movement away from the cutting area
Handling logic
Load-aware transfer and placement operations
Flow continuity
Clearance for ongoing automated production
Removes finished units cleanly from the active extraction zone
Operations
06 Stacking & Palletisation
Organises extracted material into ordered stacks or pallets ready for storage, quality grading or onward movement, reducing manual handling and preparing output for immediate dispatch.
Includes
Stacking
Ordered arrangement of extracted units
Pallet formation
Preparation of dispatch-ready loads
Handling reduction
Less manual intervention after extraction
Output organisation
Grading, storage and stacking
Turns raw machine output into organised dispatch-ready stock
Operations
06 Stacking & Palletisation
Organises extracted material into ordered stacks or pallets ready for storage, quality grading or onward movement, reducing manual handling and preparing output for immediate dispatch.
Includes
Stacking
Ordered arrangement of extracted units
Pallet formation
Preparation of dispatch-ready loads
Handling reduction
Less manual intervention after extraction
Output organisation
Grading, storage and stacking
Turns raw machine output into organised dispatch-ready stock
Operations
07 HGV Dispatch
Transfers palletised stone products into the outbound logistics flow, enabling direct loading for road transport and reducing delays between extraction, handling and delivery.
Includes
Dispatch flow
Continuous movement from pallet area to loading
Road transport
Integration with HGV collection and delivery
Site logistics
Reduced lag between production and shipment
Commercial output
Finished stone leaves the site ready for sale
Connects automated production directly to outbound delivery
Operations
07 HGV Dispatch
Transfers palletised stone products into the outbound logistics flow, enabling direct loading for road transport and reducing delays between extraction, handling and delivery.
Includes
Dispatch flow
Continuous movement from pallet area to loading
Road transport
Integration with HGV collection and delivery
Site logistics
Reduced lag between production and shipment
Commercial output
Finished stone leaves the site ready for sale
Connects automated production directly to outbound delivery
Work with Irkalla
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
Register Interest
Tell us about your site, your company or your interest in working with Irkalla.
Learn More About the System
Explore the technology behind automated quarry extraction and the production of structural stone bricks.