The production of artificial stone is a truly successful business plan. Equipment for the production of artificial stone

For many millennia, decorative stone remained the best construction and finishing material. Decorative stone is expensive, so many craftsmen have mastered making stone at home, for example, light gypsum stone or heavier and inexpensive concrete-based stone.

What is decorative stone made from?

In the 60s of the twentieth century, artificial stone began to be actively used in the West - the walls and foundation look organically in the concrete jungle of the metropolis. The idea of ​​producing decorative stone and decorating buildings was picked up by architects and interior designers, pushing an entire segment of entrepreneurship to the development. A forgotten building material is popular again.

Ancient craftsmen long ago learned how to process stone; they distinguished it by type of use, such as:

• construction or hewn;
• finishing or decorative;
• ornamental for jewelry work.

In previous centuries, sand and stone chips, grated pumice and shells, lime and chalk were mixed into the hardening gypsum. Natural dyes were used:

• soot;
• colored clay;
• metal oxides.

Nowadays, stone and its analogue have come into modern construction and arrangement of rock gardens, and today it is difficult to imagine a modern house without them. The decorative stone, a photo of which is presented in the article, clearly demonstrates the capabilities of this building material.

Do-it-yourself decorative stone today is made on different bases, and there are technologies available at home. The molds are prepared independently or purchased from factory models. Recipes, technologies and components are also known - they are offered by specialized companies.

Simple mixtures are based on water, cement and fine, pigment is added. The material turns out to be quite durable, similar to natural stone, and has excellent decorative properties. An option close to ancient methods is made from gypsum, and today polymer materials are used as a binder.

The texture of wild stone has a different surface:

• fine-grained and smooth,
• layered and lumpy,
• chopped and ribbed.

Natural stone crumbles and delaminates upon contact with a tool, while artificial stone does not require treatment. It is immediately given the required shape. The most common varieties:

• rubble, similar to a natural boulder;
• chipped, uneven, resembles chips from an impact;
• sawn, with smooth and even edges;
• wild stone, natural form;
• decorative of any shape, with sagging, folds or bumps, reflects any designer’s imagination.

Advantages and disadvantages of artificial stone.

Advantages:

• Possibility of on-site casting to reduce transportation costs and scrap generated during delivery;
• made in small thin plates to reduce the weight of the finished structure;
• its strength does not depend on the size and shape of the tile;
• the pigment added to the mixture gives the desired shade;
• it is possible to obtain a stone of straight and arbitrary shape;
• allows you to make tile sizes that correspond to the installation location, even taking into account curvature and unevenness;
• manufactured ready-made forms make it possible to obtain a coarse-grained and smooth texture, almost polished;
• it is easy to make material of any irregular shape and broken front surface;
• some technologies make it possible to obtain a more durable analogue of fragile natural stone;
• polymers provide plasticity, and even after manufacturing, you can give a new shape or think over the edge for a seamless connection;
• artificial material often has better decorative properties;
• differs from natural stone in ease of installation, thanks to the smooth back side;
• an indispensable fire-resistant building material for decorating stoves, barbecues, fireplaces and fireplaces;
• quite moisture resistant, suitable for wet areas such as a swimming pool or wine cellar;
• the price of artificial decorative stone is less than its natural counterpart, which requires technological cutting and processing;
• does not require special care, serves for a long time and reliably;
• Various options for shape, shade and texture allow artificial stone to fit into interiors of any style.

Flaws:

• some decorative types have complex manufacturing technology, which increases the cost of the material;
• not every wall is suitable for finishing with wild stone due to its high specific gravity, with the exception of gypsum analogues;
• sometimes requires additional costs for transportation and high-tech installation;
• It is not always possible to ensure an impeccable joint between individual fantasy-shaped blocks; gaps must be designed.

To guarantee quality, finishing building materials are made in strict accordance with the recipe and production technology. The components and production technology make it possible to obtain decorative stone of different names and properties.

1. Reinforced concrete stone, the so-called monumental stone, is a free-forming material; it is made piece by piece by hand where it is installed. This is a technology for cobblestones, boulders and artificial granite slabs.

The basis for the mold batch is cement-sand mortar:

• for 3 parts cement in proportion - 1 dry sand;
• 2-6% pigment by weight of the solution;
• add polymer additives.

2. A similar material is shaped stone from the same cement-sand mixture. Suitable for construction and finishing. It is characterized by increased strength and frost resistance. It is made in hangars, workshops and garages in the cool season.

3. Ceramic is the most expensive material, requiring firing or hardening at a certain temperature. Its production requires high energy consumption and the presence of a large free heated area. In addition, trained workers are needed.

4. Gypsum cast decorative stone is the simplest technology and minimum equipment. They do it at room temperature, but it is only suitable for interior finishing work; it does not like temperature changes. The mixture quickly becomes viscous.

It is made in small portions and immediately poured into the prepared form, but no later than 3-4 minutes from the start of the batch. You need citric acid up to 1.3% by weight of dry gypsum, it will slow down hardening, pigment - 2-6% by weight of gypsum plus water. It is better to make several test samples to adjust the proportions.

5. Decorative polyester synthetic material. It is made by hot hardening with the addition of mineral fillers. It is superior to many natural analogues, but the hardening technology requires a vacuum and is done in workshop conditions.

6. Liquid stone on gelcoat. It is inferior in hardness to cast stone; the gel takes less mineral fillers. The mixture is suitable for producing products with complex configurations, such as stone puzzles, but gel-acrylic-based stone is more expensive.

There are 2 compositions - primer and front, they differ in the percentage of filler and composition. Primer composition: gelcoat – 20%, microcalcite – 73%, hardener – 1% and accelerator – 6%. Front composition: gelcoat - 40% accelerator and hardener - as in the 1st composition, back composition - filler plus pigment up to 6% by weight of the solution. The composition sets in about half an hour, after a day the stone can be laid.

7. Cold hardening cast acrylic stone based on acrylic resin. Easy to manufacture, requires strict adherence to instructions and additional equipment, such as a vibration stand. It is superior to other artificial materials in many properties. At high temperatures up to +210°C, you can change its shape without changing quality.

Advice: The absence of pores and resistance to chemical reagents of acrylic stone in finishing ensure impeccable hygiene, so it is suitable for rooms where frequent contamination and cleaning of surfaces is possible - hallway, kitchen, veranda and covered terrace. The material is also known for its low thermal conductivity and gives a feeling of warmth - this is the best choice for a bathtub, toilet or swimming pool.

There are many methods for making stone molds yourself using your chosen method, but it’s easier to buy ready-made ones.

There are about a dozen types of molds for making artificial stone with your own hands, but most often 3 types are used:

1. Ready-made polyurethane, for small-scale production, they are offered by companies producing equipment and selling wild stone technologies, they are convenient and durable, but they cost a lot.

2. Clay molds on a lost wax model, suitable for sculpting and artistic casting.

3. Silicone molds are suitable for making tiles individually at home; they are enough for dozens of castings; they become deformed over time.

Advice: A sand cushion is required for silicone molds; vibration and heating cause them to burst. Before casting, the mold is deepened into sand in a tray up to 3/4 of the height to reduce deformation, and the horizontalness of the immersion is checked with a water level.

Additional materials.

1. Pigment for building mixtures is offered in catalogs and stores for building materials in various forms: liquid, paste and powder. The synthetic pigment powder is evenly introduced into plaster or other dry filler, the pigment paste is introduced into the prepared batch. By the way, thanks to the pigment paste it is easier to get uneven coloring - layered or spotty; it is injected with a syringe directly into the batch at the end of mixing.

2. There are different types of separators:

• for cast acrylic;
• for concrete mortar;
• for gypsum composition;
• for liquid stone.

They are sold with ready-made instructions and a detailed recipe. You can also use high-quality lubricant - cyatim, fiol.

3. A heat gun is a device like a small hair dryer with a strong jet of heated air.

4. A vibration stand is the main machine for making stone with your own hands, guaranteeing high quality of the final product and ensuring the uniformity of the hardening mixture.

Advice: You can make such a stand yourself - there are detailed instructions and videos on the Internet, for example, on making decorative stone on a cement base using a homemade vibration stand.

The simplest technology.

1. Sand is mixed with cement for the first layer 3:1 until smooth, for coloring a suitable dye is added about 2-3% relative to cement, mixed with water until sour cream thick, the liquid pigment is pre-diluted with water.

2. The finished mixture is evenly poured halfway into the mold, compacted and distributed by shaking and tapping. To reinforce the stone, a metal mesh is placed on the 1st layer, the 2nd layer is poured without pigment and cross-shaped grooves are struck with a nail for adhesion during installation.

3. After 10-12 hours, the finished stone can be removed from the mold and laid to dry completely. The mold must then be cleaned and rinsed with Fairy after each pour.

4. In the process of monumental molding of a large block, the base is formed on a blank covered with reinforcing mesh and wire, onto which thick cakes without dye are laid out in layers. When the base has set a little, prepare a solution with the addition of pigment of the desired consistency and make the final shape. When artificial boulders harden, they are covered with a film from rain for about a month.

At home, decorative stone is made in several ways. Let us dwell on the description of what has been proven in practice.

2. 1 liter of silicone sealant based on acetic acid is evenly squeezed into it, the layer is lubricated with grease or another separator so that the finished stone does not stick.

3. The sample stone is pressed into a box with silicone until it is completely sunk in it, right up to the back surface, the excess silicone must be cleaned off, and the mold dries for a couple of days.

4. After complete drying, the sample is carefully removed from the mold box. The finished silicone is soft and elastic.

5. The gypsum mixture according to the recipe is kneaded until it becomes thick with sour cream and pigment, and poured into a mold greased with grease. After the first layer, it is advisable to reinforce the tile with a fine metal mesh, pour in a second layer without dye, shake to achieve leveling and leave to dry. If the gypsum sets quickly, interfering with the reinforcement process, the mixture is diluted with milk - then it takes longer to thicken.

6. It is better to drown the mold in sand on a pallet to preserve the silicone mold, and press the plaster with corrugated glass on top so that the uneven back surface is better attached to the wall.

Advice: There are labor-intensive methods for making stone, such as quartz, that make it possible to obtain the highest quality and durable building material for cladding. Having mastered some techniques, you can open your own business.

1. The finished decorative stone is attached to any dry surface with additional sheathing. Installation, with or without jointing, is done using cement mortar, construction adhesive, the stone is cut with a grinder at low speed with a concrete disc.

2. Before starting installation, it is better to make a sketch of the finished work or use a picture with similar material. The stones are laid out according to the pattern on the surface for the most beautiful placement and fit of the fragments.

Additional decoration.

For a long time, stone was not only widely used in architecture, the Japanese decorated Tobiishi gardens with it. Today, for special design purposes, the stone is additionally painted or primed on part of its surface, so that green growth will form in the rock garden more quickly. They rub it with ocher and soot, making it old, and the protuberances on the south side are rubbed with red lead to obtain the appearance of tanning and weathering.

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.

Recently, artificial stone has been used for cladding buildings and interior decoration much more often than natural material. The reason for this is the low price, high strength, as well as a variety of colors and textures. The production of artificial stone as a business brings good profits. We will discuss how to open such an enterprise in this article.

Scope of application and properties

Despite the fact that natural stone has many undeniable advantages, many consumers prefer its artificial counterpart, which is presented on the market in a huge variety of colors and shades.

In addition, it has the following properties:

• Resistant to chemicals and ultraviolet radiation;
• Unique decorative capabilities;
• Light weight;
• Easy installation;
• Environmentally friendly;
• Moisture resistance;
• Durability.

Typically, decorative stone is used for cladding external surfaces in residential and public buildings, as well as for making window sills, countertops, fireplace portals, columns and other things. Using this material, you can create an interior design in any style. If you can competently organize the production of artificial stone as a business, the enterprise will bring you a decent, stable income, since there has been an increased demand for such products recently.

Material advantages

The main advantage of decorative stone is its thermal conductivity properties. It is warm to the touch, so it does not make the room cold. In addition, this material is resistant to mechanical stress. It does not prick or break. There are no microcracks or pores on the surface of the artificial stone, so bacteria and harmful organisms do not multiply on it.

The only drawback of acrylic stone is that it scratches easily. This is especially true for dark-colored glossy surfaces. But such defects can be eliminated right on the spot. It is enough to polish the surface well and it will regain its original appearance. The service for restoration of decorative stone is offered by many companies that produce such products.

Raw materials and technology

To produce decorative stone you will need cement, fillers, multi-colored mineral pigments, hardening accelerators and special plasticizers.

Since the technology for producing decorative stone is quite simple, anyone can set up the production of such products. You do not need any special education or experience to do this. To make artificial stone, you can use one of two technologies - vibration pressing or vibration casting.

Advantages of vibration casting:

• Cheap equipment;
• High surface quality;
• Rich colors;
• Large range of products.

Advantages of vibrocompression:

• Low production costs;
• Fully mechanized production.

Before you start work, find a video of artificial stone production on the Internet. This will help you choose the technology that suits your conditions.

Room

Before purchasing equipment, you need to select a suitable production facility. It is desirable that it be located on the outskirts of the city. In this case, you will pay less for rent.

The workshop area must be at least 100 square meters. meters. In addition, you need to allocate separate rooms for storage, drying and a staff room. There are no special requirements for production space. The most important thing is that the building is not in disrepair and is located away from residential buildings.

Equipment

In any manufacturing business, the largest expense is spent on equipment. To produce decorative stone at home you will need:

1. Vibrating table or vibrating conveyor;
2. Vibrating sieve;
3. Concrete mixer;
4. Forms;
5. Drying chamber.

There is no need to use complex equipment for the production of decorative stone. You will spend about 40 thousand rubles on a vibrating table and a concrete mixer. In addition, for work you need to buy an electric drill, spatulas, hammers, buckets, shovels, etc.

Another major expense is forms. To start, you will need 6 pieces. One polyurethane matrix costs approximately 8 thousand rubles. Some manufacturers make molds for the production of decorative stone in-house. Thanks to this, they significantly reduce costs and can also move on to releasing new models at any time.

Staff

To work in production you need to hire two workers. One person will do the physical work - bring materials, make mortar and load finished products. The second employee must understand the technological process, monitor the equipment and the quality of the products. You can hire a former foreman or builder for such a position.

If you also want to set up the production of foam concrete at home as a business, in order to receive additional income, you will also have to hire an experienced technologist. He will develop a recipe, set up a technological process, and also monitor all important technological aspects.

Where to begin?

Before opening an enterprise, first of all you need to draw up a business plan for the production of artificial stone. This is the document on the basis of which you will build all your future activities.

Preliminary planning allows you to consider all possible options, calculate risks and assess the feasibility of the project. In addition, you will be able to accurately determine the size of the initial investment, outline ways to sell finished products, and also approximately calculate the amount of future profit. You can develop a business plan for the production of decorative stone yourself, but it is best to entrust this matter to specialists who have experience in this field.

Financial calculations

To understand whether a business producing artificial stone is profitable, you need to calculate all costs and future profits. For the production of 1 sq. meter of product you will need:

• Cement – ​​35 rub. (6 kg);
• Sand – 15 rub. (19 kg);
• Plasticizer – 2.5 rub. (0.06 kg);
• Pigments – 9 r. (0.15 kg);
• Depreciation of forms - 6 rubles;
• Electricity – 0.2 rubles;
• Transport costs – 5 rubles.

Total for the production of 1 sq. meter of stone you will spend 72.7 rubles. The average market price of this material is 650 rubles. for 1 sq. meter. To increase the profitability of the enterprise, you can open it in parallel. In addition, offer material installation services to customers.

Now let’s roughly calculate the costs of producing decorative stone from gypsum for a medium-sized enterprise:

• Rent of premises – 10–20 thousand rubles (monthly);
• Vibrating table – 30–70 thousand rubles;
• Electric drill – 3–5 thousand rubles;
• Desk – 7–10 thousand rubles;
• Manual equipment – ​​8–12 thousand rubles.

To offer customers an assortment of products, you need to purchase at least 10 different forms at the start, costing 4–7 thousand rubles. In general, to open such a production, you will need 300 thousand rubles. Such a project pays for itself in about 1 year.

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Sales and advertising

In order for the production and sale of decorative stone to bring good profits, it is necessary to conduct an effective advertising campaign. To do this, you should place advertisements in the media and on the Internet. You can also hand out flyers on busy streets or mail them to mailboxes. It is advisable to sell your products at retail prices, bypassing intermediaries who want to purchase goods in order to resell them at a higher cost.

Decorative stone is mainly purchased by architects, designers, as well as various organizations involved in repairs and construction. If you get it right

Stone for decorating premises, the so-called decorative stone, has been used since ancient times. Even in the 21st century, the century of new construction technologies, stone does not lose its position. Even in ancient Greece, stone was highly valued as a decorative element. The first artificial decorative stones appeared there. Currently, the production of decorative stone has been put on stream and is available to everyone due to minimal investments in this business.

Decorative stone is used for finishing and cladding various surfaces of walls, ceilings, portals for fireplaces, columns and other things that the interior designer has enough imagination for. Artificial stone can be used both outside and inside. Depending on the area of ​​application, the technologies for manufacturing decorative stone differ. Today we will talk about the production of gypsum decorative stones for mainly indoor use.

What is gypsum decorative stone?

Gypsum decorative stone is made from a mixture of powdered gypsum, filler (sand, marble cat, etc.), modifiers, dyes, surfactants (surfactants) and water. Each manufacturer has its own recipe for production, however, the basis of all recipes is gypsum and water.

The advantages of gypsum stones are obvious:

• ease,
• ease of installation,
• hypoallergenic,
• naturalness,
• high strength and performance characteristics,
• the cost of gypsum stone is an order of magnitude lower than the cost of natural stone.

Modifiers and surfactants used in production are designed to improve these characteristics of natural gypsum.

Production of decorative gypsum stone

The technological process of making stone from gypsum is distinguished by its simplicity and speed. One person can cope with the task. Production does not require complex mechanical or special devices. The basis of production is matrices or initial forms.

For gypsum work, matrices made of soft materials are usually used - polyurethane, silicone. Less commonly used are forms made of hard plastic, wood or metal. This is due to the fact that it is easier to “shake out” a plaster product from a soft mold than a hard one. In addition, the soft form boasts depth and variety of relief for molding the finished product. A solid matrix cannot be distinguished by the rich texture of the finished gypsum stone. Matrices are used repeatedly, however, soft matrices wear out faster due to their lower density than hard ones.

Molds for the production of artificial stones are the only special devices.

The production process itself is quite simple:

• The molds are lubricated with a special lubricant (composition for pre-treatment of molds) to facilitate the removal of finished products;
• Inside the mold, paint is applied with a brush to the required areas (2-3 colors);
• A mixture of gypsum (alabaster), sand and water is prepared with the addition of plasticizers and modifiers. To color the stone throughout its entire volume, a dye is added to the mixture. The volume of the finished mixture must be calculated so that it completely fits into the matrix. The gypsum solution sets quickly and its excess cannot be reused.
• The finished mixture is poured into matrices. Each form of solution must be gently shaken with a sifting motion. This is necessary so that the solution spreads more densely and evenly across the molds, and air bubbles are removed.
• As the mortar sets in the matrix, you can use a notched trowel to apply horizontal or vertical stripes on the back of the tile. Such strips simplify the installation of finished tiles and make it more reliable.
• After 30-40 minutes, when the gypsum has completely hardened, the artificial stone can be removed from the matrix for final drying. There is no need to do any additional actions for drying. Typically the “stone” dries within 36 hours. To speed up this process, many craftsmen use special devices. The simplest: a sealed box (made of plywood, chipboard, laminate) with holes for ventilation at the top and an electric heating device at the bottom. Finished products with a gap of several cm from each other are placed in this chamber. The heater turns on. It is important to maintain a temperature of 30-50 degrees. Higher temperatures will dry out the products and make them brittle. The drying process in such chambers takes from 2 to 8 hours. The time depends on the number of products and their weight (thickness). After which the product can also be painted or coated with a protective layer of a special primer.

Business payback

Despite the fact that there are many offers on the market, the demand for gypsum decorative stone is stable and constantly growing. The average cost of 1 m² of gypsum stone is 7...150 rubles (depending on the material used). The cost of artificial decorative stone at retail is from 150 to 1000 rubles per 1 m². The cost of matrix molds for making stone is from 5 to 25 thousand rubles.

Additional profit is obtained if you provide services for the delivery and laying of stone.

For several thousand years, natural stones have been used to decorate buildings and structures. Today this is a fairly expensive material, but it has an alternative - making artificial stone with your own hands at home. If all actions are performed correctly, it will look attractive, and its cost will be significantly lower.

Using stone in interior decoration can achieve unexpected results. It is perfect for decorating the entire room or its individual elements, such as columns. Making artificial stone with your own hands is not difficult, but you need to correctly follow the entire sequence of procedures.

In terms of mechanical resistance or other qualities, artificial stone is in no way inferior to natural stone. In addition, it has several important advantages:

• At home, artificial products can be made in thin tiles. This will reduce the weight of objects, but at the same time maintain strength;
• When working independently, it becomes possible to make a stone of the required shape for a specific place;
• Its production can occur at the point of use, so transportation waste is eliminated;
• It is possible to obtain a smooth stone. This eliminates polishing costs;
• Artificial stone at home can be created in irregular shapes. This allows you to imitate the household stone variety.

Making molds for artificial stone

Molds for making artificial stone can be purchased at a specialized store, but it is recommended to make them yourself. You need to start by choosing one of the samples. A stone is selected that matches not only its size, but also its shape.

Silicone is used for the main material. To make the mold you will need to take a box of suitable dimensions. It should be larger in shape than the stone taken as a sample. The box will act as formwork.

Afterwards, you need to apply a thick layer of grease to both the box and the selected sample. Then carefully place the stone at the bottom of the formwork. To increase productivity, it is recommended to create several boxes at once along with forms.

The next step is to pour silicone into the formwork. For subsequent compaction, you need to use a simple paint brush, previously soaked in a soap solution. After the final filling of the form, it is recommended to carefully level the entire surface using a spatula. It is also best to soak it in a soap solution.

The poured mold will dry for 15 days, and only after this period can the box be disassembled and the sample stone removed.

The result is ready-made silicone molds necessary for making artificial stone yourself. If small cracks or defects are found on the surface, it is recommended to additionally fill them with silicone.

Advice: Instead of soap, you can use a few drops of Fairy detergent to create a solution.

Making a mold, video:

Creation of artificial stone from gypsum

Materials

The technology for making artificial stone from gypsum is the most popular. At the preliminary stage, to create it, you need to prepare the following materials with tools:

• plaster in white;
• anhydride;
• warm water;
• river sand;
• a plastic container necessary for mixing all the elements together;
• pallet;
• matrix;
• electric drill;
• corrugated glass;
• water-based dyes.

To produce artificial stone from gypsum you do not need a large area. A few squares will be considered quite sufficient. To begin with, you should carefully consider the arrangement of your workplace; all racks and necessary shelves should be at hand. The next step of the work is preparing the gypsum solution.

Manufacturing technology

After preparing the workplace and creating silicone molds, you can begin creating it. To do this, below are instructions:

• To save money, you need to prepare an amount of solution that is equal to the number of forms. The gypsum dough cannot be left for use next time, as it quickly hardens and becomes unusable.
• You need to determine the proportions of water with gypsum yourself.
• After adding water, you need to pour plaster into a container specially prepared for this. You need to add it in small portions. This will allow you to obtain gypsum dough with normal thickness. The consistency of the solution should be thick. The liquid mixture takes longer to dry and has low strength.
• You can get a harder material by adding 10% sand to the mixture.
• The next step is to lubricate the working forms and their surfaces. In this case, wax and turpentine are used. This procedure is necessary; without it, it is difficult to remove the frozen stone from the mold.
• The preparation of this mixture is carried out in a water bath. This allows the wax to dissolve. Afterwards the substance is applied in a thin layer to the surface of the mold.
• When drying, shells may form on the stone. To protect against them, it is recommended to apply liquid plaster to the workplace. It is best to place stones on a pallet.
• To obtain a stone of a certain color, you need to mix paint with gypsum. This is recommended to be done at the stage of mixing the gypsum dough. To achieve this goal, it is best to use separate containers.
• Afterwards, you need to fill the main part of the stone into a special form. Using a spatula, carefully smooth out the mixture.
• The forms are covered with long corrugated glass, then vibration is carried out. This is a necessary stage of work for uniform installation. This process will take about two minutes.
• Hardening of the plaster takes about twenty minutes. The glass is easily separated from the mold, so there will be no difficulties with this activity. We take out the resulting product and let it dry completely in the open air. Heat treatment is not recommended, as it greatly spoils the performance properties of gypsum.
• Upon completion of the process, the stone must be painted. It is necessary to prepare a brush along with special paint. To paint, you need to remove dust and similar dirt from the surface of the stone, then evenly distribute the coloring composition. After final drying, it is recommended to apply several more layers, this will allow you to obtain the desired shade.

Artificial stone made of cement

Artificial stone made of cement, video:

Manufacturing process

After completing the preparation of the form, the following several stages of work are carried out.

• The first step is to mix sand and cement.. This is necessary for the first layer. It must be applied to a silicone mold. The ratio of cement to sand will look like this: 1:3.
• Next you need to add a certain amount of water. The mass should be similar to the consistency of thick sour cream.
• If you intend to paint a ready-made artificial stone, you will not need to add any components. If it is already necessary to give a shade to the future product, then it is recommended to add dyes at this stage in an amount of 2.5% of the total volume of the solution. The amount of dye should vary depending on the desired color and its brightness.
• As a result, the resulting mixture should be laid out in the finished form, but only up to half.
• Next, the mesh is cut out from the outer mold. It is necessary to harden the stone. The mesh needs to be placed on the mixture, then topped with silicone.
• At the end of the pouring process, you need to draw a sharp element on the top layer to form a groove.. This will allow you to get excellent grip on the surface.

Apparently, the technology is simple and does not require the use of additional equipment. It is recommended to remove the stone from the mold only after 12 hours, and then leave it to dry again for two weeks. During this period, the material will finally gain the necessary strength. After completion of work, the mold must be thoroughly rinsed.

If no coloring components were added to the composition during the manufacturing process, then coloring can be completed during the manufacture of the stone.

To do this, you need to clean its surface from dust and dirt. Apply paint evenly using a brush. To create shades, it is recommended to use paint with a darker base.