For centuries, marble has been used to decorate the interior and exterior of homes. This breed is a rare and expensive natural material that not everyone can afford. Latest developments in the field of construction, they created an unusual finishing product - concrete marble, which can be made even at home.
Properties of artificial stone
A number of undoubted advantages can make artificial stone the most popular material for interior and exterior decoration. The material imitates the shape and structure of a natural mineral. Thanks to the ability to use a wide range of colors for concrete staining, you can get concrete panels various shades.
Artificial marble has excellent physical and chemical qualities. It has strong properties. The material does not deform when exposed to high and low temperatures. It does not burn, so it is important to use it for finishing stoves and fireplaces.
The stone has a low thermal conductivity and can serve as additional thermal insulation for the facade. Also, an undoubted advantage is that it does not electricity. Often it is used to insulate and decorate ovens, radiators and other electrical devices.
The unique color and pattern will not fade under ultraviolet rays. The material is well resistant to moisture. Due to its durable properties, concrete objects can last for a long time. In the event of cracks, unnatural marble is easily restored and returns to its former appearance. In addition, it does not emit toxic substances into the atmosphere, which declares a high level of environmental friendliness. The production process leaves no waste, so the use of concrete stone is efficient and profitable.
When mixing all the components, the resulting mixture can take any form. The connection of its parts occurs according to the principle of puzzles. All joints are securely bonded to each other with adhesives and provide high strength of the entire surface.
Artificial stone has a small weight, unlike a natural mineral, so it is easier to process and install. Usually the material is created under the initially set parameters. Natural marble requires additional grinding and trimming before installation.
Application area
The material outwardly accurately imitates the pattern of natural rock, but unlike it has affordable price. It is cheaper by 8-10 times and in terms of its performance properties is not inferior to natural rock.
Finishing with this building product will add chic and sophistication to the interior and facades of the building. For arranging indoor surfaces, it is used as Alternative option ceramic tiles, as floor coverings, making sinks and countertops, fountains or decorative sculptures, bar counters, fireplaces and much more.
How to cook yourself
The production technology of the material is not difficult, so concrete marble can be easily prepared by yourself. Before proceeding with manufacturing, you should study the specifics of this process, then prepare all the necessary components.
To knead the panels, you will need the following materials:
- cement marked M400 or M500;
- form or matrix made of polyurethane (any plastic container will do);
- plasticizer C-3 - a special solution that increases the strength of concrete;
- water;
- fine sand;
- polyethylene film;
- a pigment that will not dissolve in water (oil paint will do);
- fine gravel, pebbles or ceramic chips as a filler;
- drill with mixer nozzle.
All components are mixed at home. With proper observance of all the nuances of production, the resulting material will be so similar to natural marble that at first glance it is difficult for an uninitiated passer-by to determine what the object is made of.
For the manufacture of stone will require plastic molds. You can purchase special products or make them yourself. To make a window sill, a regular tray of the right size is suitable.
If there is no suitable container, you can make them from plastic panels. To do this, the sheets are fastened together.
Production technology
After preparing all the necessary components, you should start preparing the mixture. All work is done in a clean container. The mixing solution has standard proportions of 1 to 3 parts. Fine sand is added to dry cement, which is pre-screened.
This must be done through a fine mesh so that the solution turns out to be homogeneous in its consistency. Then the filler is mixed. As it is most often used small pebbles or crushed stone. In addition, crushed expanded clay, pumice or ceramic chips can be used.
Color creation
According to the technology, a coloring pigment is added to the finished solution. It does not need to be thoroughly mixed. On the contrary, in order for the artificial stone to look more like a natural mineral, the composition should be made as heterogeneous as possible. Often several shades of paint are added to produce an unusual pattern on the cast object. Various bends, streaks, convolutions, dots or spots may appear on it. At this stage, you can give free rein to fantasy. A variety of color mixing can lead to unexpected results. By its quantity, the pigment should be 1% of the dry mass.
After introducing the pigment into the solution, it must be thoroughly shaken. Usually a vibrating table is used for this. For frequent use, you can do it yourself. But in the event that an artificial stone is made for the first and only time, then it is enough to shake the resulting mixture with your hands.
Next, water is added at the rate of one to two in relation to the dry component. First, about 80% of the solvent is poured in, everything is thoroughly mixed. Then a plasticizer is introduced, which serves to enhance the strength of the future object.
This element must be at least 1% of the total mass. Again, everything is mixed and left for a few minutes alone. The material becomes plastic and viscous. After that, the remaining 20% of water is poured in and distributed throughout the composition.
Then the prepared solution is poured into pre-prepared molds. It needs to be closed at the top. plastic wrap and leave until completely dry. To increase the strength of the material in liquid mixture a metal reinforcing mesh is placed.
After hardening, the finished panels are taken out of the molds and subjected to careful grinding. For this, special equipment with diamond discs can be used. After processing, the surface becomes even and smooth.
Manufacturing technology must be clearly maintained. If you skip any stage, the marble from concrete may not match the quality.
Before mounting the manufactured panels, it is necessary to prepare and clean the surface on which the installation will be carried out from climatic precipitation. This must be done with great care.
Various materials and products made from artificial marble made from concrete are considered to be as attractive, elegant, durable and strong as similar objects made from real natural rock. The production of this product in Russia first began more than 30 years ago, during which time it has been improved and reached a high level. It copies the appearance of the stone so accurately that an imitation cannot be distinguished by an inexperienced eye.
Long since for internal and exterior finish at home, our ancestors used only natural materials. This also applies natural stone especially marble. He, as a finishing material, has been known for a very long time, and still remains very popular. With the help of marble, you can give any interior an atmosphere of solemnity and celebration, emphasize the luxury and prosperity of the owners of the house. However, the cost of such material is far from accessible to everyone, so very often natural marble is replaced with an artificial analogue, which can even be made with my own hands. It is mainly used for countertops, window sills, columns, sinks, ceiling plinths, balustrades, pilasters, railings, bathrooms, sinks and much more. Marbled tiles are used for walls, floors, ceilings, stoves and fireplaces.
Marbled tiles are used for walls, floors, ceilings, stoves and fireplaces.
He, as a finishing material, has been known for a very long time, and still remains very popular. With the help of marble, you can give any interior an atmosphere of solemnity and celebration, emphasize the luxury and prosperity of the owners of the house. However, the cost of such a material is far from accessible to everyone, so very often natural marble is replaced with an artificial analogue, which can even be made with your own hands. It is mainly used for countertops, window sills, columns, sinks, ceiling plinths, balustrades, pilasters, railings, bathrooms, sinks and much more. Marbled tiles are used for walls, floors, ceilings, stoves and fireplaces. Michail RybakovArtificial marble is a finishing material that is obtained different ways. One of the simplest and most popular is artificial marble, obtained from gypsum, which is also called oselkovy marble. The natural pattern that is characteristic of natural stone, namely all kinds of stains, veins, cracks, can be imitated through the use of a special technology for uneven mixing of various dyes.
The natural pattern that is characteristic of natural stone, namely all kinds of stains, veins, cracks, can be imitated through the use of a special technology for uneven mixing of various dyes.
However, the cost of such a material is far from accessible to everyone, so very often natural marble is replaced with an artificial analogue, which can even be made with your own hands. It is mainly used for countertops, window sills, columns, sinks, ceiling plinths, balustrades, pilasters, railings, bathrooms, sinks and much more. Artificial marble is a finishing material, which is obtained in various ways. One of the simplest and most popular is artificial marble, obtained from gypsum, which is also called oselkovy marble. The natural pattern that is characteristic of natural stone, namely all kinds of stains, veins, cracks, can be imitated through the use of a special technology for uneven mixing of various dyes. Michail Rybakov Despite the fact that, it would seem, an artificial stone is only an analogue natural material, which means that it should be inferior to it in its qualitative characteristics, in fact, the opposite is true. Marble of artificial origin has a lot of advantages, among which high strength, wear resistance, durability, frost resistance, fire safety, its excellent sound and thermal insulation properties etc. It is an ideal material for creating an optimal microclimate in the house, as it has the ability to breathe. In addition, gypsum artificial marble is easy to daily care, since any detergents without abrasive, after which stains and stains do not remain on the surface. Artificial marble is resistant to contaminants such as gasoline, cigarette butts, acetone, shoe marks, etc.
Artificial marble is resistant to contaminants such as gasoline, cigarette butts, acetone, shoe marks, etc.
Despite the fact that, it would seem, an artificial stone is only an analogue of a natural material, which means that it must be inferior to it in its qualitative characteristics, in fact, the opposite is true. Marble of artificial origin has a lot of advantages, including high strength, wear resistance, durability, frost resistance, fire safety, its excellent sound and heat insulation properties, etc. This is an ideal material for creating an optimal microclimate in the house, as it has the ability to breathe. In addition, gypsum artificial marble is easy to maintain on a daily basis, as any detergent without abrasive is suitable for it, after which stains and stains do not remain on the surface. Artificial marble is resistant to contaminants such as gasoline, cigarette butts, acetone, shoe marks, etc. Michail Rybakov Products made of such material, if necessary, can be easily repaired by eliminating any defects, such as cracks, chips, etc. The production of artificial marble makes it possible to obtain, in contrast to natural stone, a wide color scheme and, as a result, great opportunities in the decor of the premises. It is more pleasant and warm to the touch than marble. natural origin which, in turn, expands the scope of its application. Also, due to the simplicity of its processing, it is possible to make a product of any even the most complex shape from artificial gypsum marble.
In order to make artificial marble at home, you must have at your disposal all the necessary components and a suitable silicone or polyurethane mold for the future product, which can be bought at hardware store.
Also, due to the simplicity of its processing, it is possible to make a product of any even the most complex shape from artificial gypsum marble. In order to make artificial marble at home, you must have at your disposal all the necessary components and a suitable silicone or polyurethane mold for the future product, which can be bought at a hardware store.
In addition, gypsum artificial marble is easy to maintain on a daily basis, as any detergent without abrasive is suitable for it, after which stains and stains do not remain on the surface. Products made from such material, if necessary, can be easily repaired by eliminating any defects, such as cracks, chips, etc. The production of artificial marble makes it possible to obtain, unlike natural stone, a wide range of colors and, as a result, great opportunities in decorating rooms. It is more pleasant and warm to the touch than marble of natural origin, which, in turn, expands the scope of its application. Also, due to the simplicity of its processing, it is possible to make a product of any even the most complex shape from artificial gypsum marble. In order to make artificial marble at home, you must have at your disposal all the necessary components and a suitable silicone or polyurethane mold for the future product, which can be bought at a hardware store. Michail Rybakov This form is laid on the table and treated from the inside with a special compound that will improve the quality of the finished product. Next, paint is applied on top of the corresponding shade, which is planned to receive the facing material. After that, the mixture of the working solution itself is prepared, which will become the basis of artificial marble. It should consist of two parts: dry and liquid. Gypsum and filler (sometimes only gypsum) are classified as dry, and water, a retarder and a dye, thoroughly mixed together, are classified as wet.
Then both parts of the dry and liquid components are mixed together and poured into a mold. When the finished solution hardens a little, you can use a notched trowel to remove all its excess at an angle of about 20 degrees, due to which on the back of the finished facing material small zigzag grooves are formed. They are not accidental, but necessary for better adhesion. this material with a base.
After about half an hour has passed, you can begin to extract the finished stone from its mold. Before you directly start using it for decoration, such artificial marble should lie in the room for some time to acclimatize.
Gypsum artificial marble in the form of tiles or other products can be mounted on a wall, ceiling, floor and other surface using any adhesive, such as PVA, water-based, acrylic glue, special mastics and others. Beforehand, the base for gypsum marble must be thoroughly prepared, that is, apply a primer or gypsum plaster. Then they apply adhesive composition on a small area, taking into account its rapid drying, using notched trowel. This work must be done with extreme care so that excess glue does not get on the front part. finishing material. In addition, it is important to observe the evenness of the rows. In the future, for the durability of the finished result, experts recommend using special protective equipment for such coverage. This applies, for example, to rooms where high humidity etc.
Reading the phrase cast marble”, we can assume that this is some kind of material. Actually this is not true. The term "cast marble" is usually understood as an abstract product made by mold casting from synthetic composite material coated with marble effect. At the same time, imitation can refer not only to granite, marble, but also to granite, malachite and other natural stone used for the manufacture of household items or parts decorative interior. The name "cast marble" became well-established because the first products made in this technique imitated it.
The composition of "cast marble".
As already mentioned, "cast marble" is a product made of a composite material, that is, a material consisting of several components:
- binder;
- filler;
- pigment;
- outer protective material.
Used as a binder polyester resin- an organic-synthetic binder material that has the property of solidifying in the presence of a catalyst in the open air at room temperature. Polyester resin has replaced the previously used epoxy resin due to a much lower cost with almost complete preservation specifications epoxy resin. Unlike epoxy, polyester resin is non-toxic. After hardening, it has excellent mechanical and strength characteristics and resistance to aggressive media.
The filler is used to reduce the cost of "cast marble", as well as to give the product the hardness properties of stone. Mineral chips are used as a filler - marble, granite, etc. The physical characteristics of the product and its texture depend on the percentage of filler content in the mixture. There is another type of filler that additionally performs decorative features. In this capacity, sea pebbles, various sand, colored quartz can be used.
A pigment is a dye that is used to give the finished product the desired appearance. Dyes can be varied in appearance and composition - practically the only requirement applied to them is non-toxicity.
Under the outer protective material refers to the coating that forms on the product during the manufacturing process. As the main material for it is used gelcoat – polymer composition, which has increased resistance to mechanical damage, acids and alkalis, as well as to the effects of solar ultraviolet radiation. It depends on the additives and pigments in the gelcoat what appearance the product will take - marble, granite or made of another material. If a transparent gelcoat without additives is used, the appearance of the product is determined by the composition of the filler and the shade of the dye in the main mixture.
Production process.
The production of cast marble takes place in several stages:
- application of the gelcoat on the injection mold;
- mixture preparation;
- pouring the mixture into the mold;
- curing the mixture;
- extraction of the finished product.
Application of the gelcoat can be done with a brush or sprayer. At the same time, it is important to keep required thickness applied layer - if too thin layer the main mixture can damage it, and the product will be damaged; an uneven layer can adversely affect the appearance of the product.
To prepare the mixture, an industrial mixer is required, with which you can quickly mix the polyester resin, catalyst, filler and, if necessary, pigment; unload the finished mixture into the injection mold and clean the working container from quickly solidifying material residues.
The hardening of the mixture occurs at a temperature of 18-23 degrees Celsius, it is this temperature that must be constantly maintained in the working room. The temperature of the mixture must also be within the specified limits so that the temperature difference during the curing of the product does not lead to its deformation.
If the technology of applying the gelcoat, preparing and pouring the mixture is followed, after the material has hardened, the process of extracting the finished product should not be difficult.
I offer as a home business a very interesting, real and at the same time accessible technology for everyone.
AS AN EPICGRAPH:
I was surprised to find that the Egyptian pyramids, steles, monuments and other architectural structures were built using a similar technology. Therefore, no company, be it the so-called creators of SHOCK, Corian, etc., can claim copyright. Art belongs to the people.
REDONT-3 was used for the test sample. It is a raw material in dentistry for the manufacture of bases.
Its analogues are ETACRYL and FTORAX. But these materials are convenient only for testing, since they are produced in a small package (250g) and are slightly more expensive compared to technical AST-T, BUTACRIL. And they can be freely purchased in dental materials, and sometimes even in a pharmacy. AST-T and BUTACRIL are sold in a minimum package of 5kg of powder and 5l of liquid. Those. to gain experience and skill, you can train on small volumes. As a filler, I used finely stuffed gravel (up to 4mm). Can be used
ordinary sand, painted gravel and sand. These plastics are also used to make injection molds for polyethylene castings and the like.
You can make a table, or a door, or a tombstone. A frame is made of iron of the appropriate shape. Well, let's say for a table meter by meter you made a frame with internal dimension meter per meter. It is desirable that this frame be detachable for ease of getting the finished product. The inside of the frame is milled to match the profile that you want to give to the edge of the table. And the main thing is well polished. This frame is placed on glass. The glass should be very perfectly wiped. Because at the contact of the casting with glass, an ideally transparent and even glossy surface is formed. And even an ordinary fingerprint will stick to the casting. Then a mixture of material with gravel or whatever filler you choose is poured into the frame. You can not be shy about the amount of gravel. The more - the less material consumption. Further - again, reducing the cost of the product - put it in a filled frame chipboard of the appropriate size, but slightly smaller from the frame, so that this slab is also filled with material at the edges. Let dry and warm up warm air. In half an hour everything will finally harden.
If you made a mold from polyethylene or plaster, then the resulting product will have to be polished. But my advice to you is that such a cool casting is obtained on glass that no polishing can achieve it. If any type of damage has occurred on the finished product, do not despair. Dilute some material again and fill in the damage. This material unites with itself so completely that it becomes a monolith again.
Gluing.
Products made of acrylic plastics stick together well. As glue, solutions of crushed organic glass 2-3% in dichloroethane, glacial acetic acid, chloroform, etc. are used.
Coloring.
Acrylic plastics are colored by mixing powder with pigments of the appropriate colors in a ball mill. When using fat-soluble dyes, the latter are dissolved in a liquid of acrylic plastics. Coloring finished products produce ready-made varnishes, oil paints, enamels, etc. by conventional methods.
Mechanical restoration.
Acrylic plastic products are processed by turning, milling, drilling, grinding, polishing, and other methods.
Information on safety precautions and industrial sanitation.
CAST MARBLE
In terms of chemistry, polymer concrete is a cured, highly filled polyester resin (18-21% resin and 78-81% quartz sand or other inert mineral filler). According to the conclusion of the Finnish company NESTE Chemicals, the protective and decorative coating of products made of artificial stone meets all the requirements for outdoor and indoor use.
Paving slabs of cast marble, laid on the experimental site 11IIZhB in 1967, and the sidewalk, laid out in the same years in Brest Fortress are still in good condition to this day.
In Central Asia since 1962. cladding of artificial marble slopes of hydraulic structures, subjected to a strong impact of discharged (60-80%) annual runoff and bottom sediments (40-100 thousand m3 of sediment). During periods between floods, the lining is exposed to atmospheric action and high solar radiation.
One of the areas of application of artificial stone is sanitary ware.
Almost all over the world you can find elements of facades and roofs, window sills, window openings, stair steps, railings, countertops, washbasins, bathtubs, toilet bowls made of artificial marble.
Search for additional information on the topic by keywords: SHOCK, Corian and cast marble
Natural stone is expensive, especially if you want to make a countertop or shower tray out of it, and therefore DIY artificial marble seems to be a better option. Moreover, there are quite a few ways to get a reliable imitation, using a variety of, sometimes quite unexpected components and technologies.
How to get artificial marble with your own hands
What is the stone we are interested in? It has a heterogeneous color, most often with veins penetrating the entire thickness, a granular-crystalline structure. Coloring can be snow-white, pink, blue, black or gray. Less common colors: red, purple, green, yellow. The easiest way to create the illusion of marble is with gypsum, which gives a dense, non-porous mass. However, this option is unacceptable if you need a countertop or cladding in a room with high level humidity. Therefore, we will consider alternative methods that allow you to make artificial marble with your own hands.
The simplest technology is casting in molds from cement-sand mixture. Cast marble is durable, waterproof and, most importantly, outwardly very similar to the real one. However, it should be noted that thin tiles will be quite fragile, and thick ones will turn out to be heavy. As a result, it is possible to make a countertop from such an imitation, but at the same time, the furniture body must be very massive in order to withstand the weight. stone slab. A thinner version can be made by taking the wooden plane of the table as a basis. Next, we'll look at both options.
Almost real artificial marble: manufacturing technology
What do we need to end up with a slab of cast stone, almost indistinguishable from natural? First of all - a form of polyurethane, sand and cement in a ratio of 2: 1, respectively, water (a fifth of one share of cement) and pebbles as a filler. You will also need a dye (1% of the share of cement) and a plasticizer in the same amount. In order for the technical process to succeed, we stock up on plastic wrap, construction mixer, a mixer or a special nozzle for a drill, as well as a spatula and a short rule.
Manufacturing technology of real artificial marble - step by step diagram
Step 1: Preparation
We thoroughly rinse and dry the form, which can be of any size, for example, just for the work surface kitchen wall. We prepare the solution, for which we combine cement, sand and pebbles in a dry state, mixing the components well. Pour 80% of the stored water, as well as the plasticizing composition, and continue kneading, achieving the highest possible mass uniformity. We add the rest of the water and, in unequal portions in different sectors of the container, the dye in order to achieve the least possible uniformity of the subsequent mixing of the color with the solution.
Step 2: Filling out the form
As soon as the dye has spread through the cement mass in thin veins, the composition is ready, and you can proceed to the most important phase of the process. We take the form, put it on absolutely flat surface to eliminate the bending of the bottom or walls, and pour the solution into it. Using a spatula, we clean the edges of the mold from excess, which can affect the smoothness of the plate, after which we level the surface of the mass with the rule and cover it with polyethylene.
How more stove artificial stone, the higher the probability of its breakage due to internal voids. Therefore, if possible, a vibrating table should be used, and in the absence of one, when mixing, try not to lift the mixer from the mass so that air bubbles do not form.
Step 3: Getting the finished artificial stone
After about 10 days, the solidification of the mass poured into the mold will end, while there is no need to intervene in the process, as is required by other work with cement. For example, regular moistening of the surface is not required due to the fact that the solution is covered with polyethylene, which prevents the rapid evaporation of the liquid. When the plate is completely hardened, carefully lift it, turn it over and, like a cover, remove the form from the finished tabletop.
To get artificial marble, the manufacturing technology does not have to be complicated, everything can be done in an apartment. As a result, we get a product with low porosity, high resistance to a humid environment and various household chemicals. If necessary, polish the slab with transparent polish and alcohol, alternating their surface treatments. In this case, it should first be treated with alcohol, then, after drying, with polish, and, without waiting for it to dry, we again take up the swab moistened with alcohol.
How to make artificial marble in the form of an illusion
If you want imitation stone to cover an elegant coffee table, the previously described technology will have to be abandoned, since it is unlikely that thin wooden legs withstand the load of a multi-kilogram plate. Instead, the easiest way is to partially turn the table itself into a marble table with the help of paints, by drawing the appropriate stains on it. To do this, you need a jar of paint for the background, for example, white or green, as well as a small container of color for the pattern. On a white background, it would be more correct to draw black or gray stripes, on green or black - white.
Before making artificial marble, all cracks and chips on the surface, if any, are filled with a special water filler for wood. Next, we moisten the countertop from the spray gun so that the swollen fibers reveal all the roughness, and, after the 30 minutes required for drying, we sand it as best as possible to a smooth state. Then, having cleaned the surface, we proceed to painting and apply two background layers with an interval necessary for the first of them to dry. To avoid streaks, it is better to use a brush or a foam rubber pad. After two hours, you can start applying the texture pattern.
The pattern of marble is familiar to many, sometimes it resembles zigzags of lightning on a surface dotted with many grains of inclusions, and sometimes it looks like randomly intersecting cracks. All this is not difficult to depict with a pen brush, with which you can change the thickness of the line. After waiting 5 minutes, mix a small amount of white paint with a transparent polyacrylic coating. Having dipped a wet sponge into the composition (you should definitely remove excess mixture from it), we draw along the drawing, without pressing hard and shading, thus making the lines more blurry. After another 5 minutes of drying, wipe the surface with a clean cloth, mixing the colors with light touches. Another 30 minutes of drying and again we take up the feather brush, emphasizing the previously applied and already modified pattern.
After two hours, when the surface is already well dry, we take a carefully mixed polyacrylic coating and cover our "marble" with a thin transparent layer. It is advisable to leave the countertop for a long time after this to allow the film to solidify thoroughly. Next, you need to polish the surface with the finest sandpaper, clean it with a damp sponge or cloth and, after allowing it to dry, process it again with polyacrylic. Again, we leave to dry the already almost formed imitation of stone for 2-3 hours, then polish and wipe again. We apply the last layer of a transparent coating, wait for it to harden (2-3 hours), and finally polish it, after which we forget about our piece of furniture for about a week.