Modern finishing materials must satisfy not only aesthetic and functional needs, but also have practical properties, such as protection from pollution, mechanical and climatic influences. Artificial facing stone is one of the most popular materials for both internal and external construction of buildings. To create a unique design project, it is possible to produce this facing material yourself.
Advantages of artificial material
Making decorative stone with your own hands has a number of advantages. Similar creative process is not very difficult provided you have the right tools, materials and specific skills.
The advantages of artificial stone are as follows:
In order to figure out how to make an artificial stone, it is necessary to determine the initial components. For interior facing work, stone based on gypsum, acrylic or alabaster is used. For outdoor use, materials that are resistant to weather conditions and mechanical damage are required, therefore, a cement base is the most suitable raw material.
To give the finished product a certain relief shape, sand, crushed gravel, and marble chips are added to the original components . To obtain different shades colors use either dry or diluted pigment dyes. This component is added to the main composition during the mixing process, which gives the finished product a uniform color. Or spread it over the bottom of the mold before pouring the prepared mixture. In this case, it is possible not to completely cover the form, but with selected fragments, which will give the resulting material a unique pattern with a reliable imitation of natural stone.
To increase the density of the finished product and reduce the amount of water in the solution, it is recommended to supplement the main composition with a special plasticizer. Fiber fiber is also used as an additive to prevent cracking of artificial stone.
Gypsum-based stone
Before you start working directly, it is very important to arrange a comfortable and functional workplace. Be sure to have a large table or workbench with an ideal horizontal surface, which will make it possible to produce tiles strictly fixed thickness. To dry a large amount of the resulting material, you need to allocate separate shelves or racks, since this process takes several days.
The next stage in obtaining a high-quality finished product is preparation for use of the necessary tools, related equipment, and raw materials:
- a container of a suitable size for mixing the components;
- electric drill with a special mixer attachment;
- mold for filling made of plastic material;
- spatulas and brushes;
- constituent components (gypsum, washed river sand, coloring pigments, water, additives);
- lubricants (turpentine, wax).
Before you start working with the mixture, you should consider several important nuances. Firstly, to obtain a homogeneous mass without lumps, you need to add gypsum to the water, but not vice versa. Secondly, gypsum dries very quickly, so to prolong the liquid state, citric acid is added to the solution at the rate of 0.8 g of crystalline powder per 1 kg of dry gypsum.
Citric acid should be dissolved in water, and only then added to the mixed solution. Thirdly, to give the gypsum tile additional strength and hardness, the working mixture is supplemented with fine sand. It is also recommended to add PVA glue as a plasticizer.
Making artificial stone at home as follows:
Giving a Unique Look
The resulting finished tiles can be additionally painted with liquid color if desired. You shouldn’t draw a specific drawing; it’s much more picturesque to create with chaotic strokes. Then “walk” over the fresh paint with a rag or a wide brush dipped in a solvent (acetone, turpentine, white spirit). In this case, the depressions on the surface of the artificial stone will be darker, and the protrusions, correspondingly, lighter.
This procedure will create an inimitable unique pattern and a believable imitation of the naturalness of the material. For additional protection from moisture and dust, it is possible to coat the gypsum tiles with a matte varnish. It is highly undesirable to use glossy varnish, because the effect of natural stone will disappear.
Cladding material made from gypsum-sand mixture is widely used when decorating interior walls, but it cannot be used for flooring, finishing of fireplaces and fountains.
DIY wild stone
It is not difficult to produce artificial stone, which will be used for finishing the basement floors of buildings, paving paths, framing a fountain or an alpine slide. A cement mixture is used for it. To prepare it you will need the same tools as for the gypsum base. It is worth noting that wild cement stone can be made not only with a flat base, as is the case with gypsum samples, but also in the form of cobblestones or large boulders. In this case, a silicone mold will not be needed at all.
Making decorative cobblestones yourself is quite simple. It is necessary to prepare raw materials and auxiliary equipment:
Description of working with the material
Working with the material requires the following steps:
Large artificial boulders can be used not only as a design decoration for a garden plot, but also as a disguise for necessary technical communications, for example, sewer hatches. Therefore, it is advisable to think in advance about the size and purpose of the future stone.
Making your own mold
To begin, prepare smooth, even, moisture-resistant plates that will be easily detached from the silicone. At a hardware store, purchase material for the form at your discretion. It can be one-component silicone (available in plastic buckets or tubes). Or a two-component polyurethane compound, products from which are characterized by high physical properties and wear resistance. As a sample texture, you can use natural stone, several ready-made tiles from the store, or cut the desired shape from a wooden blank.
Sequence of making a silicone mold:
After the specified period, the frozen silicone mold is removed and thoroughly washed to remove any remaining lubricant.
Beautiful appearance, environmental friendliness, excellent sound-absorbing and heat-insulating characteristics, as well as resistance to high and low temperatures - all these qualities are inherent in artificial stone, which has become widespread in the modern building materials market.
This is easily explained by the affordable cost of the products, the ease of finishing work, as well as the ability to implement any design solutions. Artificial stone can be given any color and texture you want, and it fits perfectly with almost all types of interior decoration.
Why is the production of decorative stone a highly profitable and in-demand type of business? The low level of competition in this niche, the demand for the product on the market, the low purchase cost of raw materials, minimal energy costs and the simplicity of organizing the work of the enterprise make this type of activity attractive to every person who wants to open a profitable business.
What is artificial stone?
It is very convenient to work with artificial stone when performing finishing work, which is why it is popular among craftsmen and customers. This material is used for decorating interiors and exteriors of buildings. It is a special tile for covering various surfaces, the texture of which completely imitates brick or natural stone.
The production of artificial stone is carried out by casting, for which various mixtures are used, which are placed in special molds. The composition of the solutions can be prepared on the basis of porcelain stoneware, gypsum, acrylic, quartz agglomerate, concrete and other compounds.
Important: for interior decoration, decorative stone made from gypsum, agglomerate or porcelain stoneware is used. For external wall cladding, concrete products are the best choice, since this material is highly resistant to external aggressive environments and retains an attractive appearance for a long time.
There are various methods for producing artificial stone, which make it possible to produce facing products that are in no way inferior in their characteristics to natural materials; moreover, the decor is much cheaper and lighter in weight.
To obtain high-quality artificial stone, manufacturers use dyes exclusively on a natural basis. During manufacturing, they give the products the desired color, which does not fade under the influence of sunlight for many years. Artificial products for cladding have not only different compositions, but also shapes, while the stone can be made in the form of decorative cobblestones, bricks or tiles, which allows you to create beautiful original masonry.
Kinds
Depending on the type of cladding, natural stone chips, hardeners and polymer resins can be used to prepare mixtures. Let's consider the types of artificial decor that are widely used in construction and interior decoration, which are usually distinguished by manufacturing methods and materials used:
- Agglomerates. This type of artificial stone is made from quartz sand, granite or marble chips, natural pigments and limestone. Polyester resins are used to bind these components. The main advantage of conglomerates (this is also the name of this type of cladding) is the high strength of the products and increased resistance to temperature changes. This material is widely used in decorating various surfaces; countertops, bathtubs and other products that require increased impact resistance are made from it. It is worth noting that agglomerates are not recommended for use in underfloor heating systems, since the resins that bind the stone and other additives are deformed during heating.
- Acrylic artificial stone. This material is usually classified as conglomerates. It has high strength, elasticity and allows you to get a product of any shape and size. Acrylic is used to make countertops, window sills and kitchen splashbacks. The material is highly moisture resistant, safe for human health, easy to maintain and can be easily restored in case of mechanical damage.
- Concrete molded. The material for the production of concrete stone is a cement-sand mixture. By adding natural pigments, the attractive appearance is maintained for a long time. Concrete stones are not afraid of frost and are used for walls and plinths outside buildings.
- Concrete monumental. This stone is made using the free-forming method with mandatory reinforcement of the product. As a rule, this method is used directly at the site of application of artificial decor. Cobblestones, boulders and stone slabs that have a natural appearance are produced individually from reinforced concrete.
- Gypsum cast. Finishing cast stone from gypsum is produced at minimal cost. It is made only for decorating the interiors of buildings, since it is afraid of moisture and is not resistant to low temperatures. The mold method is ideal for producing artificial stone at home.
- Porcelain tiles. The production of this type of artificial stone has certain difficulties, since it requires the use of specific equipment, large areas, and a significant amount of electricity is consumed for its production. The composition of porcelain stoneware includes certain types of clay, natural dyes, feldspar and all kinds of mineral additives. All components are thoroughly mixed, after which the composition is compacted in a vibropress and fired. Ceramic artificial stone is highly durable, and its texture can be very diverse. It is used for finishing various surfaces, making steps, floor coverings, sinks and other products.
- Hot curing polyester stone. The decor is made using fillers of a mineral nature. For this reason, the compound will harden exclusively at high temperatures, for which vacuum ovens are used. This method of making stone is not suitable at home due to the complexity of the technological process and financial costs. Polyester products are in no way inferior to their natural counterparts in strength and decorative qualities.
Products made from liquid granite are also widely used. Its preparation is carried out on the basis of a binding gel component, which is called gelcoat, and mineral fillers. This technology allows you to give the finished product complex shapes. You can use liquid stone for countertops, sinks, decorative elements or for making window sills, which are durable and original. In addition, liquid stone with your own hands allows you to make various products by casting, for which special molds are used. The finished composition is poured into them, then the “stone” hardens, after which it is removed from the matrix and subjected to mechanical processing.
Advantages and disadvantages
Above we have listed the advantages that artificial stone has. Here we should also add the excellent thermal conductivity of this material. If you decorate a room with such decor, it will be warm even in winter.
Artificial stone is resistant to mechanical stress, so products made from it do not break and they rarely chip. This material has no pores or microcracks, which completely eliminates the development of pathogenic microorganisms on its surface. The advantages also include:
- ease of product installation and transportation;
- the ability to carry out repair and construction work of any complexity;
- production of decorative elements and furniture of any configuration;
- ease of repair of damaged products.
Important: Please note that damaged surfaces are restored on site, so there is no need to take them to specialized workshops.
But like every material, artificial stone has some disadvantages:
- Products made from it have a significantly shorter service life compared to natural originals.
- If the customer wishes to make furniture elements from artificial stone, the cost of the sets will increase significantly. For example, a porcelain stoneware countertop costs more than the same element made from laminated boards or plywood.
- Acrylic “stone” surfaces look very beautiful, however, they are susceptible to scratches and are susceptible to exposure to high temperatures. Therefore, countertops made of this material are in less demand among buyers, since hot dishes cannot be placed on them and they quickly lose their attractiveness. For these purposes, it is better to use artificial agglomerated stone.
Artificial stone manufacturing technology
To make artificial stone yourself, no lengthy training is required. To produce decorative products, you need to prepare a cement mortar, as well as natural pigments of various colors, hardeners and plasticizers.
The technology for manufacturing artificial stone is quite simple, for this reason every novice entrepreneur can organize production. The most commonly used methods are vibrocasting or vibrocompression. If you use vibration casting technology, you will not need to purchase expensive equipment to start a business. This method allows you to obtain a wide variety of products, different colors, as well as excellent quality of the surfaces of the finished tiles. Preparation of the compound using a brick press is characterized by the low cost of artificial stone, and the entire production process is fully automated.
Important: There is a large amount of video material on the Internet dedicated to the production of artificial stone. It is necessary to first assess the conditions in which the production processes of the future enterprise will take place, which will allow you to decide on the choice of technology.
The production of artificial stone deserves special attention, the production of which will require plaster and polyurethane molds. This type of activity is considered highly profitable, since a 30-kilogram bag of raw materials costs about 340 rubles, while the price of the finished “stone” on the market fluctuates around 600-700 rubles per 1 m². From it you can make 8-10 “squares” of decorative cladding, which in monetary terms is about 6 thousand rubles. The benefit is obvious. The technological process is characterized by high speed and simplicity. The dry gypsum mixture is filled into the tank, after which it is diluted with water to such a state that the resulting solution itself spreads into the molds. Please note that liquid gypsum fills even the smallest depressions in the matrix, so no special equipment is required to prepare the solution. After a quarter of an hour, you can remove the “stone” from the mold, after which it should dry completely. After this, coloring of the finished product is allowed.
The good thing about gypsum “stone” is that it can be given color at the customer’s site, so there is no need to spend money on purchasing pigments. You can sell both unpainted plaster blanks and sell decorative elements, giving them a certain shade.
How to start the production of decorative stone?
Let's consider the main stages of starting the production of artificial stone.
Business registration
Entrepreneurs need to officially register their activities with the Federal Tax Service, for which they will have to register an individual entrepreneur (best). The following documents must be submitted to the tax office at your place of residence:
- passport of a citizen of the Russian Federation (copy);
- birth certificate (copy);
- application for opening an individual entrepreneur;
- receipt of payment of state duty.
Important: If you plan to organize a large production with the involvement of hired employees, it is recommended to form an LLC. To start activities, you will need to obtain permits from the fire inspectorate and sanitary and epidemiological station.
Since the production of artificial stone does not require businessmen to have certificates and licenses, this allows significant savings on obtaining permits. As for the choice of taxation system, entrepreneurs can opt for UTII or simplified tax system.
Search for premises
Before starting production, you will need to find appropriate premises. They will house the equipment. As practice shows, production space outside the city limits can be rented much cheaper.
It is necessary to find a building for the enterprise, which will have premises for production, a warehouse for finished products, drying of products, as well as a workers’ living room. The total area must be at least 100 m². It is advisable to provide production with a good lighting and ventilation system.
Equipment purchase
For obvious reasons, most of the costs are the purchase of production equipment. For equipment you will need:
- vibrating table;
- vibrating sieve;
- polyurethane molds;
- drying chamber;
- concrete mixer.
In addition, you will have to purchase shovels, an electric drill, buckets, and spatulas. The purchase of a concrete mixer and a vibrating table will cost about 70 thousand rubles. As for matrices, for 1 unit you need to pay about 8 thousand rubles. At the initial stage of production, 5-6 pieces will be required. You can make matrices yourself, which will save you money. This will also make it possible to come up with new models of facing materials and expand the range of finished products.
Purchasing materials
Depending on the type of technology chosen, you should purchase raw materials for the production of artificial stone. If you plan to produce gypsum products, you will need gypsum in bags, citric acid powder (0.3% of the total mass), which slows down the hardening of the composition, and pigment. It needs about 5-6% of the total volume of the prepared mixture.
Artificial concrete stone requires the preparation of a cement-sand base. This requires cement and sand in a ratio of 3:1 (not to be confused with preparing a building mixture!). You will need the same amount of dye as in the case of making gypsum mortar.
If you plan to produce cast acrylic decorative stone, you need a hardener and resin. To prepare the compound, you should add a mineral filler. Its share, including the dye, is 3 parts of the finished mixture. The pigment in the mixture should not exceed 6% (standard ratio: 71% filler, 20% acrylic resin; 5% hardener, 4% natural dye).
Recruitment of working personnel
To start production, you will need to hire two people, one of whom will be a handyman. This employee supplies the necessary materials, prepares solutions, and also loads the finished stone. Another employee is required to fully master the technology of the production process, maintain the equipment, and also monitor the quality characteristics of the finished stone. If a large production is planned, in this case it will be necessary to invite a technologist who will be able to develop a unique recipe for the preparation of decorative stone, establish production technology and keep all processes of the enterprise under control.
Conducting an advertising campaign
An advertising campaign should be carried out when the exact range of finished products has been determined, selling prices have been established and possible production volumes have been determined. Initially, you need to create a business card website, where you should place high-quality photographs of images of the finished stone, a price list, delivery conditions and contact information.
It wouldn't hurt to make business cards to hand out to all potential customers. It is recommended to produce and show samples of finished stones to customers, which will allow them to evaluate the quality of the products. It is important to know the range of your enterprise and the technical characteristics of all types of stone offered.
The work of your enterprise must be announced in the media (print, television, radio). Also, to promote your business, it is worth creating thematic communities on social networks, which will quickly attract the target audience (people interested in purchasing artificial stone). As an option, you can offer wholesalers individual terms of cooperation, which imply some discount, short production and delivery times.
Search for sales channels for finished products
How and to whom to sell the finished artificial stone? First of all, it is a specific product that is aimed at construction and repair organizations, as well as retail outlets for the sale of finishing materials.
Despite the demand for decorative stone in the construction market, many entrepreneurs do not know how to properly present their products and set up sales channels. The main task of every businessman is to establish relationships with the leaders of the above-mentioned organizations, personal communication with them about upcoming cooperation and the presentation of favorable partnership conditions.
It is mandatory to take part in various events and exhibitions that are dedicated to popularizing the construction business. This will allow a large number of potential clients to learn about the work and products of your enterprise. You should also establish collaborations with design firms, companies that offer architectural services, and building materials markets.
Production of artificial stone - financial plan
Before starting an enterprise, it is necessary to calculate the expenses and possible income in the future. This is not difficult to do. For example, let’s take the calculation of the profitability of products made from a cement-sand mixture.
To prepare 1 m² of artificial stone, you need 6 kg of cement (35 rubles), 19 kg of sand (15 rubles) and 60 g of plasticizer (2.5 rubles). You will also need to consider:
- electricity costs;
- fare;
- depreciation of the matrices used.
It turns out that the cost of 1 “square” of stone tile is about 73 rubles, and its market value can exceed 700 rubles. It is imperative that as production capacity increases, you should have your own team of builders and finishers and offer their services to your customers. This will allow you to earn additional profit.
As for production costs, we note that the most expensive purchase will be the purchase of a vibrating table, which will cost 50-70 thousand rubles. You will also need to take into account the costs of:
- rental of production space – up to 20 thousand rubles per month;
- desktop – 10 thousand rubles;
- equipment and electric drill – 15 thousand rubles.
To open a medium-sized manufacturing enterprise, at the initial stage you will need about 350 thousand rubles. As practice shows, a business pays off by the end of the first year of operation.
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To summarize, we note that the production of artificial decorative stone is a highly profitable and low-cost type of business activity. It is worth considering combined production options, where, along with the facing material, countertops, sinks and other decorative elements for finishing the premises will be produced. Only the production of high quality products guarantees the success of the enterprise.
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Finishing materials in various forms are available in incredibly large quantities on the modern construction market. The assortment can satisfy any, even the most sophisticated, needs of a fastidious designer. In all the variety of finishing materials, artificial stone occupies far from the last place.
Few people can distinguish artificial stone from natural stone, but at the same time it is more convenient to work with, since its underside is completely smooth.
The appearance of artificial stone is very aesthetic, it is quite light and is a universal material in the finishing field. And, what is very important, its price is quite reasonable.
It is very rarely possible to distinguish an artificial stone from a natural one. It has the same front side as its brother, but the back is made smooth for ease of finishing work with its use. At the same time, it weighs several times less than the natural one, and its installation does not require any special tricks; such a decorative element can simply be placed on glue, like the most ordinary tile, and it can also be attached with bolts.
Its composition can be quite different. It depends on the effects that the user needs and on the area of application. This can be gypsum, asbestos, acrylic resins, Portland cement, ordinary cement and other materials. Artificial stone is used not only in interior decoration. It is also used to decorate external walls; tiles are made from it for outdoor use, for example, for paths. They cover flower beds or simply place large stones for aesthetic purposes. These artificial elements are used in the arrangement of large and small aquariums, for design solutions for the arrangement of personal plots, fountains and much more.
In each case, special properties are needed to protect against various external influences.
An artificial decorative element made of cement can have a structure that is lightweight with expanded clay additives of the desired grain size. This does not change the quality in any way, but it lightens the material very significantly. There are additives designed to increase strength or to give it anti-corrosion properties, which are so necessary in wet operating conditions. To create the required shade, various coloring pigments are used. The color of a stone that is made with one’s own hands can be given after its manufacture using special paints that allow any imitation of natural stone to be made.
Advantages of artificial stone: light weight, can be laid on any surface, good appearance, relatively low cost, versatility.
Artificial stone has many more positive qualities than negative ones. It actually weighs little, can be easily and easily mounted on any surface, looks great for aesthetic reasons, is inexpensive and is universal in use, as mentioned above. In addition, structures made from hand-made artificial stone, provided they are properly manufactured, are very resistant to certain conditions of use, do not fade, do not crumble, and are easy to clean and easy to clean. Each condition of use requires its own manufacturing methods, special fillers and final surface treatment.
But with all its positive qualities, it can in no way be said that artificial stone is an ideal finishing option for all occasions. Some versions of the stone are not resistant to strong impacts from sharp objects, that is, the abrasive effect will spoil the appearance of such a finish.
Fake diamond
Artificial stone can have all sorts of shapes and sizes.
Not all finishing materials can be made with your own hands. But artificial stone is not one of them, and there are enough descriptions for making it yourself. Creating this artificial material with your own hands is not a very difficult task, and with careful adherence to technology and a certain amount of effort, this task is feasible for any person. No special conditions are required for its manufacture; it can be done even in an apartment. The composition for making stone is selected based on materials already available at hand, or specially purchased.
As already noted, the basic materials for artificial stone can be different, but in any case, making an artificial stone with your own hands begins with choosing an initial sample and creating a certain shape, with the help of which the future artificial stone will be cast. If you make several model molds, then the required amount of this material can be produced quickly enough.
If you wish, you can find a stone for the model yourself or purchase a model stone in a store. You can buy ready-made silicone molds for making artificial stone yourself.
Materials for work
If you decide to make a structure from cement, then we collect the following necessary materials:
- cement or Portland cement;
- pure water;
- staple;
- a container suitable for preparing cement mortar;
- fine-grained sifted sand;
- special release agent;
- brushes of different sizes;
- paint of various shades;
- polyurethane forms for pouring mortar;
- fine mesh to strengthen artificial stone.
A mold for artificial stone can be purchased at any hardware store.
Before you start making a mold with your own hands, you select a suitable stone in size and shape. A box is selected that will serve as formwork for the silicone; it should be larger than the stone. Next, both the box itself and the stone are coated with grease or something similar. For greater productivity, you need to take several such boxes and suitable stones.
The stone is laid out on the bottom of the box and this entire structure is filled with silicone. In order to make the silicone denser, it needs to be compacted with a regular paint brush, which should be moistened in a soap solution. You can also use dishwashing detergent. I leave the filled forms to dry for 2-3 weeks. Then the formwork is disassembled, the form is carefully cut in half and the sample stone is removed. If there are minor defects on the mold, they need to be repaired with silicone.
Further actions with cement
Artificial stone can be given any color; to do this, you need to add a dye when making the cement mixture.
The further stage is performed in several steps. Sand and cement are mixed for the first layer of the artificial element, which will be applied to the silicone mold. The required ratio of material in this case is: 3 parts cement and 1 part sand. You need to add enough water to make the mixture look like thick sour cream. If you intend to paint an artificial stone with paints, after preparing it, nothing else is added to the mixture. If you need the original shade of the future stone, then dyes are added to the mixture in an amount of 2-3% of the volume of cement. The more saturated the shade is needed, the more dye should be added.
The mixture obtained with your own hands is laid out halfway into the finished mold, then a mesh of the desired shape is cut out to strengthen the stone, placed on the mixture and topped with silicone to the very edges. To save paint, the second layer may not contain it.
After pouring, small grooves should be made on the top layer with a nail or something similar, so that during installation you get better adhesion to the surface to be decorated.
As you can see, the described technology is quite simple and allows you to make stone with your own hands without special equipment. The stone can be removed from the mold after 12 hours and left for another two weeks to gain final strength. After removing the stone, the mold for making it yourself must be washed with Fairy detergent, and this procedure is mandatory after each pouring and removal.
Stone coloring
No one will deny that to completely imitate natural stone, artificial stone must have a similar color. There are several painting methods:
- adding dyes directly to the concrete mass;
- applying paint to the inside of the mold before pouring it with cement mortar;
- painting the finished stone in several layers to achieve the greatest plausibility.
Before painting artificial stone, it must be cleaned of dust and possible sand, apply an even layer of paint using a brush; for shades, paints darker or lighter than the main one are used and applied with thinner brushes, but only on the last applied layer. And at the same time you will need at least minimal drawing skills.
The technique of making large artificial decorative stones with your own hands differs in many ways from this technology and is more complex. But if necessary, its description can also be found in special articles.
Natural stones have been used for finishing the interiors and facades of buildings for a long time. The use of stone in interior decoration allows you to achieve the most unexpected results. With its help, you can design your home and garden in the style of a knight's castle; columns trimmed with stone look elegant, and a fireplace framed with slate is attractive. It should be noted that natural stone is a very heavy material, so not every wall can withstand such a load. The large weight of the material also increases the cost of its transportation. In addition, natural stone is quite expensive.
Thanks to artificial stone, you can achieve very interesting results when decorating interiors and exteriors.
But there is a way out. In order to make it possible to use stone in interior decoration, cladding the facade of a house, garden design and to overcome all the shortcomings, it was developed. You can make artificial stone with your own hands, and it will practically not differ from natural stone. The price of material made at home will be much lower than that of natural material. Outwardly, they hardly differ from each other, while artificial stone is devoid of all the disadvantages of natural stone. Read more about how to make artificial stone at home.
Artificial stone can be made to imitate any type of natural rock, repeating its texture. It can have the following types of surface: chipped with an uneven surface and edges, sawn with smooth, even edges, rubble (looking like ordinary natural boulders) and random. Certain design tasks may require different types of surfaces. During manufacturing, you can obtain a material suitable for finishing a specific room. The most popular type of artificial stone is slate.
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What is artificial stone made from at home?
To make this material with your own hands, several different technologies are used. One technology involves making it from cement, fine sand and water, the other from gypsum or alabaster. There is also an option for making stone with your own hands, in which polymers are used to bind all the components. Therefore, the composition of the mixture for the production of this building material at home is determined based on the available ingredients and capabilities.
The procedure for manufacturing this material is simple; you can do it yourself if you carefully follow the technology.
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The process of making stone with your own hands
The main components in the manufacture of this material are cement and gypsum (alabaster).
In any case, making artificial stone with your own hands must begin by selecting an initial sample and creating a mold with which the products will be cast. Having several of these molds, you can quickly make the required number of products. As a model, you can purchase in the store a sample of suitable size and shape, or ready-made silicone molds, which are ready-made kits for the manufacture of this building material.
In order to make artificial stone at home, you will need the following materials and tools:
- cement;
- sand;
- alabaster;
- silicone;
- box;
- grease;
- paint brush;
- putty knife;
- coloring matter;
- dishwashing liquid.
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Mold making
For gypsum stone, silicone molds are most often used.
The production of artificial stone begins with making a mold. To do this, select a sample, which is a stone of suitable size and shape. Silicone is used to make the mold. Then you need to make a box of the appropriate size, which should be slightly larger than the sample. It will serve as formwork. The box and sample must be thickly coated with grease or some other lubricant. The stone is placed at the bottom of the box, after which silicone is poured into the formwork. It must be compacted with a brush dipped in a soapy solution, for which you can use regular dishwashing detergent. After pouring the silicone, the surface must be leveled with a spatula moistened with soapy water.
The poured forms must dry for 2-3 weeks, after which the formwork is disassembled, the sample is removed and ready-made forms for the manufacture of artificial stone are obtained. Small defects on the surface are sealed with silicone.
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Manufacturing from cement
With this method, work is performed in several stages. First you need to mix sand and cement for the first layer in a ratio of 1:3, mixing the components until one mixture is formed. The desired color is obtained by adding a dye, the amount of which is determined experimentally. After this, add water to the mixture and stir everything until sour cream thickens.
The resulting mass should be poured into the mold to about half its volume and compacted by shaking and tapping for about a minute. A metal mesh is placed on top of the mortar to give the stone additional strength and a second layer of mortar is poured. There is no need to add dye to the second part of the solution.
On the top layer of concrete after pouring it, you need to make small grooves using a nail for better adhesion to the surface during installation. Judging by the description, this technology is quite simple; the material can be produced in this way without the use of special equipment. After 12 hours, the finished product is removed from the mold and left to dry for 2 weeks. The mold must then be washed, doing this after each pour.
Artificial stone is a good alternative to natural stone. It is used both for interior decoration and for exterior cladding of building facades, fountains, paths, etc. It is lightweight and easy to cut, making installation easier. Today, a large number of ready-made kits for making artificial stone are sold, which greatly simplifies the process of creating it yourself. But you can do all the work yourself, choosing as a sample the stone you need in terms of texture and shape.
Artificial stone - what is it?
The materials for making artificial stone are different and depend on the place where the finished stones are used. So, for exterior work they are made on the basis of cement mortar, and for interior finishing, gypsum is used.
In addition, sand, stone chips or fine gravel can be added to gypsum and cement mortar to add texture. You can also immediately add a coloring pigment, which will not affect the physical properties of the finished product.
The price of artificial stone is low, but it is even more profitable to make it yourself. In this case, the final cost will be significantly lower than the market price, which will make it possible to decorate large areas with them at low financial costs. Making artificial stone at home is a very simple process that even a child can handle. The key to success in this work is good form. It’s better not to save money and not buy a plastic one, which will break after several fills. The most reliable and durable forms are made of polyurethane and silicone.
Mold making
First, formwork is made, which should be 1 cm wider and 3 cm higher than the original sample. It is made from plywood, boards or plastic panels. If you need a small shape, just use a juice box.
It is more convenient when a separate formwork is made for each stone. It must be connected carefully so that there are no gaps left. Then any lubricant, such as grease, is generously applied to the bottom and walls. Next, a natural stone is placed into it, from which the shape is taken, and also generously covered with lubricant. A ready-made gypsum stone, coated with several layers of drying oil or varnish and thoroughly dried, is suitable as a sample. If you need efficient formwork, you need a small one, you can use a juice box. eln
Polyurethane or silicone sealant is used to make the mold. It is evenly squeezed into the mold and compacted with a wide brush, which is constantly wetted in a diluted soap solution. This is done in order to remove all air bubbles and make it more durable. After the entire mold is tightly filled to the brim, its surface is leveled with a spatula. This stage is very important, since during further pouring any unevenness will lead to distortion and uneven distribution of the mixture. Then the form along with the formwork is left to dry, which takes at least 2 months. After this period, the formwork is removed and the resulting form is washed from grease.
Advice: cracks formed on the surface of the mold must be immediately sealed with sealant and leveled.
But if you don’t want to do it yourself, you can always buy ready-made molds for making artificial stone. If you need to make a small quantity, an economical option is suitable, consisting of a set for pouring 3-4 stones.
How to make artificial stone from gypsum
In addition to the fact that artificial stone is much cheaper than natural stone, it is also much lighter. This is especially important when large areas are finished with it.
For ease of manufacture, it is necessary to prepare the working area. You will need a flat surface on which to place the molds for filling. It should not have the slightest distortion, otherwise the stone will turn out thicker and stronger at one end, and thin and fragile at the other. The gypsum hardens very quickly in its form, but for further work it is advisable to dry it for several days. Therefore, you will need racks with a large number of shelves. In addition, you need a place where plaster, paint, mixing container, etc. will be placed.
Important! When making a gypsum solution, gypsum is added to the water, and not vice versa.
Gypsum hardens very quickly, so it must be diluted to pour 1-2 stones at a time. The ratio of water and dry mixture is selected individually, depending on the brand of gypsum. But it should be remembered that the thicker the composition, the stronger the stone. Ideally, the consistency of the mixture should resemble thick sour cream, but at the same time, it should be easy to pour and not thicken ahead of time. If it didn’t work out quickly and mounds formed on the surface, they can be easily removed from the finished stone using a utility knife. Strength can be further enhanced by adding approximately 10% sand to the solution.
To speed up the work, a plasticizer, such as PVA glue or citric acid, is added to the gypsum composition. It will prevent the plaster from hardening quickly, and will allow the mixture to be diluted onto a larger number of stones.
When using a polyurethane mold, there is no need to lubricate it before pouring. The gypsum stone will be easy to remove from it. But if a plastic or silicone mold is used, for better separation after hardening, special compounds based on wax and turpentine are used.
When pouring gypsum, air bubbles form, most of them disappear on their own after a while, but it is better to be on the safe side and shake the mold slightly. After 20-30 minutes, the stones are taken out and placed on shelves to dry.
To do this, the colors of the required colors are diluted in a large amount of water and applied with a brush. You don’t have to be an artist and draw out the nuances; it’s enough to apply strokes randomly, resulting in a natural color.
Finally, the stones can be varnished, but use matte rather than glossy. The latter will make them look plastic and unnatural. If the room has normal humidity, then it is not necessary to cover them with a protective compound.
The artificial stone produced in this way received a lot of positive feedback and became the most common modern finishing material.
Making artificial stone from cement
Inexpensive artificial stone for outdoor use is made from more durable cement. A solution of one part sand and three parts cement is mixed. The required coloring pigment is added to it; the required amount can only be determined experimentally. Water is added to the resulting dry mixture until the solution has the consistency of thick sour cream.
Then the mold is half filled with the resulting mixture and shaken well to compact it. After which, to increase strength, a reinforcing mesh is placed on top, and the form is filled with mortar to the top. Grooves are made along the top with a stick or nail - this will provide better adhesion to the wall during installation.
At least 12 hours are allotted for its hardening, then the stone is removed from the mold and left for final drying for 2 weeks.
Important! After each pour, the mold should be washed with detergent or soap.
Laying artificial stone
Methods for laying artificial stone will differ depending on the material used. Artificial stone masonry is washed with a detergent or soap composition and left for final drying using steam.
You can make the surface more consistent with natural stone by making it monolithic and homogeneous. This is done using a seamless installation method. It is important that it has smooth edges and a clear geometric shape, in which case each tile will fit perfectly together.
When simulating brickwork or cobblestones, the stones are attached with seams between them, which are subsequently filled with grout of the desired color. It is worth noting that such seams do not have to be made even; for a natural effect, they must differ in width.
Rectangular stones, when installed, can be fastened with a change in direction. Some of them are installed horizontally, and the other part vertically. This method creates an abstract surface that looks equally good in both classical and modern styles.
- To lay artificial stone indoors, ceramic tile adhesive, liquid nails or acrylic sealant are used. If the stone needs to be fixed outside the house, then cement moisture-resistant and frost-resistant glue or liquid nails are used.
- The first row of rectangular stones is laid out using a level, since it will be decisive for all subsequent rows.
- When attaching a stone over an opening, spacers are installed to secure it during gluing.
- When installing artificial stone, you need to pay attention to the texture and color of the tiles. They should not be repeated on neighboring stones.
Artificial stone in the interior
In recent years, it has become fashionable to use natural materials for interior decoration. Stone is suitable for all areas of interior design, but the cost of natural material is very high, and therefore not available to everyone. The artificial analogue, which appeared not so long ago, became instantly popular due to its complete resemblance to the natural one, as well as its low price. When using stone in the interior, the room becomes refined, beautiful and cozy.
It goes well with antique luxury furniture, which adds solidity and charm.
And it looks harmonious in houses filled with modern technologies.
To create a unique design, it is not necessary to decorate entire walls with stone. It is enough to cover shelves, window sills, corners, door or window openings with it.