How to make artificial “granite” from cement, water and polystyrene foam

Not everyone can afford to finish surfaces with natural materials, due to the high price of products and work. The process involves not only laying marble on a specific surface, but also processing it, which is done with a specialized tool. Various quantities of polymer concrete fall into the subcategories of artificial marble.

Marble finishing in large quantities can be done with your own hands, through organized production at home. An obvious advantage is the production of artificial marble of the required shape and consistency, which is unique and cannot be found on the market. The general composition of accessories for making artificial marble at home does not change depending on the required shape of the product.

Caring for liquid granite

In order for bathtubs made of cast marble and liquid granite to please the eye for a long time, it must be properly cared for.

1. You should not cut food on a surface covered with liquid granite, otherwise scratches will appear. They can be repaired, but this will lead to rapid wear of the surface.
2. Hot mugs, plates, pots and other utensils should not be placed on countertops coated with liquid stone. High temperature may damage the surface. You should also not pour hot water into sinks made of this material. The temperature should not exceed 80 degrees, and not lower than -50.
3. The surface should be cleaned with a soft towel or sponge without an abrasive layer. To make the coating last longer, you can use polish.
4. Liquid granite sinks can be cleaned with products containing chlorine. This will help update the appearance. If the surface is matte, it is better to use gel cleaning products. They are applied for a few minutes, then washed off with a sponge.

Photos of washable wallpaper for the kitchen can be seen here.

Peculiarities

• The color of the soil does not affect the color of the liquid stone;
• Pleasant to the touch;
• The material is non-toxic, odorless;
• Moisture resistance is achieved by adding a hardener;
• Does not lose its appearance over time, is durable - the service life of the products is more than 25 years;
• It is easy to remove dirt from the surface;
• When temperature changes, a product made of liquid stone does not lose its shape and properties.

Components for liquid stone:

• Plasticine;
• Fiberglass;
• Chemical resin;
• Filler;
• Hardener;
• Acetone;
• Calcinitis;
• Gelcoat;
• Hot melt adhesive;
• Chipboard, fibreboard.

Repair of artificial stone countertops

The material is aesthetically attractive, looks original, but requires careful handling. Even careful use of the countertop sometimes leads to various damage appearing on it over time.

You can repair your stone countertop yourself.

As already mentioned, artificial stone is easy to repair or restore. This will require a minimum of time and no special skills are required.

Crack repair

If cracks or chips are noticeable on the surface, first degrease the deformed areas. Then you will need a two-component glue, which is used to fill the crack itself.

Stone countertops are quite durable.

After waiting for it to harden, you should grind it, then carefully polish the tabletop by hand. In this way, it is possible to restore the beauty and original appearance.

Scratches

The appearance of stains and shallow scratches on the surface does not look aesthetically pleasing. Therefore, it is better not to delay in eliminating this problem. You will need a piece of sandpaper with which you can quickly sand the countertop.

It is recommended to first use coarse-grained material, then go through with fine-grained material. Some experts advise additional polishing of the stone using a drill with a felt attachment. The result is a smooth, even surface without scratches.

Blisters and spots

In addition to any chips, the surface may sometimes swell. In this case, a router will help out, with which you need to cut out the problem area. Then you will need a liquid stone for the patch; it must be poured into the place where part of the swelling was cut out. After hardening, polishing and grinding are also performed.

A real decoration of the kitchen will be a countertop made of artificial liquid stone, made by yourself. This product will last for many years, delighting you with its original appearance. At the same time, working on such a surface is a pleasure. It is easy to care for this product, just wipe with a sponge.

Take care of the countertop to avoid blisters and scratches.

If cracks or scratches appear, the material allows you to restore the coating yourself using a two-component adhesive. Also, regular sanding and polishing will help restore the original appearance.

Types of liquid stone

Depending on what material is used as a binder and on the proportion of quartz chips directly in it, artificial stone is divided into two types: quartzite and acrylic stone.

Quartzite kitchen countertops are resistant to high temperatures.

Acrylic stone is characterized by durability in use.

Quartzite (agglomerate)

Includes:

1. K vartz crumb (at least 9/10 shares of the total mass);
2. Coloring pigments (the final color of the countertop varies depending on their combination with the shade of quartz chips);
3. Polyester resin as a binder.

When they talk about the exact similarity of the qualities of polished granite with the qualities of artificial stone, they mean precisely this variety - quartzite.

Such a high content of the mineral component is achieved through a complex production process - vacuum high-temperature pressing of components. This results in an extremely durable material structure. The tabletop is not exposed to high temperatures that can occur in everyday life.

A boiling kettle or a hot frying pan set aside, or a lighted match or cigarette accidentally dropped will not leave a trace on the surface of the quartzite.

And it is clear that this version of the countertop cannot be made independently at home. The parts of the general design cannot be glued together. They are joined as a result of precise dimensional adjustment.

Quartzite (agglomerate) as a material for countertops will be very expensive for the buyer. However, in this case the quality fully corresponds to the price.

Acrylic liquid stone

The composition of this type of artificial stone is characterized by a high content of acrylic resin as a binder material, and, accordingly, a small proportion of mineral filler.

An acrylic worktop will easily fit into any design style of the kitchen.

The material also has its pros and cons.

• Due to the composition being full of acrylic, the tabletop will be less “afraid” of chipping.
• Low thermal conductivity creates a warm effect to the touch.
• Scratches accidentally left by a sharp object can be easily removed using sandpaper and GOI grinding paste.

However, the relatively low cost of materials and the absence of a complex technological component in the production process turn making acrylic artificial stone with your own hands into an entertaining and simple job.

Usage

The manufacturing process differs depending on the materials and purpose of the structure. Products made from artificial marble are widely used in the decoration of residential premises and administrative buildings. Artificial marble tiles are used for the manufacture of stairs, building facades, and other areas.

Artificial marble tiles

The cheap material, compared to natural stones, is used everywhere due to its waste-free production and ease of maintenance. Marble is being replaced by artificial stone and is used in various fields of construction; some forms and types are used by certain types of industry. It is possible to make artificial granite with your own hands using the casting method as an example, but the process will require a lot of effort as a consequence of the changed technological process.

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Making liquid stone with your own hands is quite simple. It is a modern finishing material, which is manufactured using technology that makes it possible to achieve an imitation of the resulting products with the appearance of natural stone. This name is explained by the fact that the finished product is the result of polymerization of a multicomponent liquid composition based on polyester resins. The resulting materials are used in various fields, such as finishing work, facade cladding, and the manufacture of plumbing fixtures. As a result, it is possible to obtain the following products:

• sculptures;
• decorative fountains;
• steps;
• countertops;
• baths.

Liquid stone is used, which you can make with your own hands, and for finishing rooms for various purposes. The products are cheap, but very durable and flexible, which is sometimes necessary. This is true when covering surfaces with an irregular configuration. Manufacturing can be turned into a profitable business.

Review of additional properties of liquid stone

Polyester resin is usually included in liquid stone, which is a polymer composition. She is the quintessence of plastic. Various fillers and components give this material special properties. Standard colors number about 120 units. If necessary, the material can be given almost any color, which will remain unchanged for a long time.

If you add polyester resin to the ingredients, then the surface after polymerization will require virtually no maintenance; it will be enough to wipe it with a soft cloth soaked in a soap solution. In most cases, such cladding is used when decorating interiors, as well as in the manufacture of furniture.

The coating is polymer, it imitates the color and texture of natural material, which, unlike natural material, is more plastic and warm. It makes excellent countertops and window sills, which can be made to imitate a concrete or brick wall.

The stone does not fade in the sun and has increased wear resistance. They are used to decorate walls near sinks, that is, they are simply used instead of regular tiles. Despite the fact that this finish resembles granite, it is more affordable and lighter in weight. The products are environmentally friendly, they are resistant to mechanical stress and temperature changes, do not corrode and do not become scratched during intensive use. The structure does not create environments that would be suitable for the emergence of pathogenic microorganisms. Wood, metal and glass components are often added to the layer before the mixture completely hardens. One of the fundamental properties of this material is its low cost.

Textures and shapes of countertops

The first difference that buyers pay attention to is the texture of the canvas. It can be matte, glossy, with an artificial aging effect, thermally processed, that is, a little rough. The classic shape is rectangular with a smooth, glossy surface.

Products can be with a rounded edge, square, rounded, curved, in the shape of the letters “G” or “P”. Quite often, their functions are combined with bar counters and window sills, combined with sinks and other interior elements made of the same material.

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Production of liquid granite

The technology for manufacturing liquid granite requires compliance with certain rules. The first of them says that the production premises should consist of two rooms. The first is required for casting, while the second is required for polishing the resulting product. The temperature is maintained at 24 °C, ventilation is required.

The production of liquid stone begins with degreasing the surface, removing dust and dirt. Before coating, the base is washed with water and dried well. All damage and cracks must be repaired. At the next stage, a mixture of transparent gelcoat with granules is prepared. You need to use a ratio of 2 to 1. The first ingredient is a polymer resin. Hardener is added before spraying. The resulting composition is applied to the base. To do this, you can use one of the two methods described above. The surface of a new product must be ground and polished.

Use in everyday life using the example of a kitchen sink

One of the most striking examples when a product made from such granite will be no worse than products made from natural granite is a sink.

Almost any person with taste would like to acquire such splendor instead of classic stainless steel. In addition to practicality, this solution will turn the process of washing dishes into a holiday, since a stone sink looks very nice and expensive.

Sinks made from artificial stone are perfect for any interior. Before the washing process, the customer can formulate absolutely any task. Due to the fact that artificial material is used as a basis, the sink can be of any shape, depth, texture and color.

Methods of spraying liquid granite

Before hardening, the artificial stone is a liquid mixture. Therefore, an artificial granite sink can be made in two ways:

• Sheet stone is a material ready for construction. Often these are slab-shaped chipboards or MDF sheets. The surface of the sheet is covered with liquid stone. This type of production is very expensive and impossible at home.
• Liquid stone is a material for lining the surface of a workpiece. As usual, the phrase “liquid stone” does not mean the material, but the process of lining the workpiece with the mixture.

The thickness of the layer at the end of this procedure should not exceed 15 mm. Often, a sink made of such granite has a thickness from 3 to 15 mm, depending on the wishes of the customer.

Technology for the production of sinks made of artificial granite material

Let's take a clear example of how sinks are made from artificial stone, and take a step-by-step look at the process of making them. To prepare the mixture, you do not need a large room - only up to 50 m2.

However, the apartment must consist of at least two rooms, one of which will produce artificial stone. In addition, the air in the rooms must be heated to at least 20C. All procedures can only be performed with good ventilation.

Artificial marble with concrete filler

The technology for producing marble using concrete is also very popular due to the use of environmentally friendly material and the ease of manufacturing products.

To create such a stone yourself, follow these steps:

1. Coat the dry matrix with a smooth surface with a moisture-resistant gelcoat and wait until the mold is completely dry.
2. Prepare a concrete mixture and add clay or slaked lime to it.
3. Prepare the filling. To do this, you need to mix 2 parts of river sand, 1 part of cement, 80% water and add pebbles to the composition. It is also necessary to add pigment to the resulting solution (1% by weight of the mixture) and mix the composition for artificial marble for 30-40 seconds. It is recommended to mix all components in a special mixer.
4. Add pigment to the finished filler (you need to add it unevenly to make the finished product more realistic). After this, carefully move the liquid composition.
5. Place the matrix in a horizontal position and pour the prepared mass into it in small portions. In this case, all voids in the form should be filled.
6. Remove excess mixture with a spatula.
7. Cover the surface with polyethylene and wait for the composition to completely harden at above-zero temperatures (depending on the thickness of the stone, it will dry from 24 hours to several days).
8. Remove the finished artificial slab from the matrix and treat it with a grinding machine and a special transparent polish.

If you are deciding how to make artificial marble yourself, then preference should be given to gypsum or concrete. However, you can purchase ready-made material:

• Ground marble (microcalcite). This raw material is made from crushed marble. This powdery substance of mineral origin is characterized by high strength and low chemical activity. In addition, the material is resistant to sunlight and does not absorb moisture.
• Liquid marble. In addition to marble chips, this material contains acrylic polymers, making this stone light and flexible. Such marble can be easily cut with a knife and pasted over walls. It is most popular when decorating irregularly shaped rooms.

Marketing Tips

When planning to open your own business, it is recommended to choose a specialized area of ​​activity, depending on which the sales system will be built.

When performing work at clients' homes related to the finishing of a room or building, you should consider the option of completing the order on their premises. This solution will be facilitated by small-sized equipment that is not difficult to place at the construction site.

When manufacturing products to order and performing work on the territory of a business entity, the contractor will need to go to the site to take measurements and receive an advance payment. The order is completed within a week.

To attract customers, you should use the option of promotions and discounts applied to the customer’s cost item for transporting finished products from the production workshop to the installation site. To do this, you should first highlight the delivery of the product as an additional service, and then present it as a bonus, offering the customer to receive the service at a reduced price or for free. Price parameters, as well as the level of applied discounts, should be formed taking into account the level of competition in the region.

To search for orders, you should establish relationships with construction companies, manufacturers and distributors of furniture and plumbing fixtures. Cooperation with interior designers will provide the entrepreneur with constant work based on recommendations.

Advantages and disadvantages of the material

Liquid granite allows you to achieve a complete imitation of products made from natural stone, and working with it is much easier. The composite has many other advantages:

1. Resistance to aggressive factors. The material does not delaminate, does not soften and is not destroyed under the influence of alkalis and acids, household chemicals. This allows it to be actively used in the design of bathrooms and kitchens. It is not afraid of ultraviolet rays or changes in air temperature.
2. Pore-free and hygienic. Unlike natural stone, liquid granite is not porous, so it does not absorb grease and dirt, does not create an environment for the growth of bacteria, and is easy to wash and wipe.
3. Strength. Granite can even be used to make stairs and flooring. It can easily withstand the most severe mechanical loads and does not crack from impacts.
4. Moisture resistance. The material is quite suitable for creating bathtubs, sinks, sinks, because it is absolutely not afraid of moisture.
5. Maintainability. If, during long-term use, a chip or crack does appear on the granite, it can be repaired without much difficulty using the same mixture. After drying, the “patch” will be completely invisible.
6. Large range and versatility. The areas of application of the composite are diverse; it has a spectacular appearance and extensive decorative capabilities. You can add different pigments to the stone to give its texture interesting effects (from slight roughness to a mirror-like shine).
7. Environmental friendliness and fire safety. The material is suitable for any room, including children's rooms. It does not emit toxins, is not flammable, does not support smoke and is suitable for finishing fireplaces and stoves.
8. Durability. On average, the service life of liquid granite products exceeds 25 years.

The disadvantages of liquid granite include its high cost, although it will be an order of magnitude lower than the production of products from solid stone. However, products made from plastic, wood, MDF, and porcelain stoneware may be cheaper.

Important! When using the spraying technique, the thickness of the products will be small (up to 4 mm), and this increases the risk of peeling off the coating if used incorrectly.

DIY plaster stone

The technology here is very simple. The only difficulty is the drawing process.

• Prepare the solution
• Apply the solution to the wall - you can apply it by hand, leveling it very roughly
• Use a knife, chisel, palette knife or other suitable tool to create a pattern of masonry
• Go over the resulting seams with a brush to remove tool marks and make the surface natural
• Smooth the surface, give it a natural look by using a sponge or a lint roller.
• Paint the resulting masonry

In addition to the paint itself, to give an interesting texture, you can use colored sand and other bulk mineral components (crumbs of granite, marble, etc.)

Definitions

Liquid granite is an artificial liquid stone.

Its advantages are due to the fact that, unlike the composition of granite, liquid granite contains purified marble chips (80%) and polyester resin (20%). It hardens when an accelerator and hardener are added to it. During the process of chemical reactions, all harmful substances are released, and the finished product will be environmentally friendly.

Liquid granite can be used in any premises: apartments, offices, schools and so on. The surfaces for spraying are: wood, stone, metal, porcelain, fiberglass, ceramics, chipboard and fiberboard. Products made from liquid granite resemble products made from natural stone, because it contains marble chips, and you no longer need to use large pieces of stone. The color range of the material is varied thanks to hundreds of color dyes that allow liquid granite to fit into any room.

What is liquid granite?

Externally, liquid granite is practically no different from natural stone, but when you touch it, you will notice that it is smoother, warmer, and very pleasant to the touch. By origin, it is an artificial polymer, which contains up to 80% stone chips and about 20% polyester resin with a hardener.

Thanks to the liquid form, a wide variety of products can be cast from such material, which, after hardening, will be no less beautiful and luxurious in appearance than natural ones. In addition, liquid stone is easier to process and is more convenient to use and operate.

Products made from liquid granite are safe and environmentally friendly. As polymerization proceeds, various chemical reactions occur in the mixture, and no harmful elements remain in the product.

Sink made of liquid granite

The composition of liquid stone can include crumbs with a fraction of up to 2-3 mm of other types of minerals - marble, quartz. This will help make the appearance of the finished products more original and attractive.

Advice! To give liquid granite the highest strength, polyester resin can be replaced with polyurethane glue.

Imitation marble according to Van der Steen

First, prepare the water in which the gypsum is to be ground. Wood glue and resin are added to it. The glue is dissolved in warm water in the usual way, and the resin is dissolved in a warm turpentine bath. Gypsum is diluted in the water prepared in this way. In such a way that the entire mass is enough to fill the form. After this, the paints necessary for painting the marble are added to the mixture. Paints should be prepared in special vessels.

The marble thus prepared and colored is poured into molds made of plaster, cement or rubber. For even plates - on glass or stone boards. This marble layer is applied with a thickness of 4 mm. Then a layer of dry gypsum is sifted onto it. This will remove excess water used to dissolve the colored plaster. As soon as this layer of powdered gypsum is thoroughly moistened with water contained in excess in the colored gypsum, a thin layer of well-dissolved, but not colored gypsum is poured onto it. And canvas or rag is placed on it.

This is followed by a layer of dissolved gypsum, to which crushed crushed stone is mixed. This last layer depends on the thickness that you want to give to the object made from artificial marble. As soon as the mass has hardened sufficiently (after 6-8 hours), it is removed from the plate or removed from the mold. Wipe with pumice. And the pores in the mass are filled with dissolved gypsum, painted in the main color of the cast object.

Manufacturing technology

The production of the finished product is not difficult and not expensive; you will need several available materials for making molds and a grinding machine. Do-it-yourself artificial marble is obtained by following the technological process; just follow a few simple steps. The production of artificial marble makes it possible to obtain a finished product of the desired type, give the structure uniqueness, and ensure the proper appearance.

Preparatory work

Before any work you will need the necessary materials. To obtain artificial marble you will need:

• Filler that is selected according to the budget. Ideally, marble chips are used; for a cheaper process, you should pay attention to crushed stone, quartz sand or a cement-sand mixture.
• Depending on the recipe and the desired result, a polyester resin is selected, preferably with an alcohol composition, as saturated as possible.
• Important parameters of high strength are achieved by using a hardener.
• Prepared dyes give the product color.

Do-it-yourself fillers for making artificial marble

The materials necessary for the production of artificial marble with your own hands can be purchased in specialized stores in construction markets. Only after all the preparatory work is it possible to begin work on the production of a mixture of material.

Preparation of the solution

The solution is prepared in a special container. The prepared ingredients are mixed in accordance with the proportions and recipe; the main requirements for mixing are the absence of lumps and a homogeneous mass at the output. For small volumes, it is possible to use an electric drill with a special stirring attachment, similar to a butterfly. Large volumes are mixed with a construction mixer.

Preparing and filling out the form

Before making a mold, it is necessary to determine whether it is advisable to produce a collapsible mold, because there are designs that are made once. The main materials for making molds are gypsum, polyurethane, plastic and others. The strength of the form depends on the volume and mass of the solution. Flow production involves division into sectors; this method is used when several products are made from a homogeneous composition.

The forms must be pre-polished and material applied to prevent adhesion. The gelcoat is sprayed onto the surface with a special cup device, then allowed to settle until completely cured. After pouring the material, it is necessary to remove air bubbles. This procedure is performed manually by piercing the mass over the entire area; for a faster, automated process you will need a vibrating table.

Hardening depends on the volume of the product and the ambient temperature. Filling is done in small layers to completely fill the form. The appearance of cracks on the surface of artificial marble is avoided by sealing with polyethylene or other available material.

Processing of the finished slab and subsequent care

The finished slab is processed with a grinding machine until shiny. Final polishing is done with felt; for a more pronounced shine, a polish is used, the color of which depends on the product.

Subsequent care requires special care; aggressive detergents can scratch the surface and remove shine. Removal of dirt is done with a soft cloth or a special sponge. To maintain shine, dilute a solution of detergent with water. The shine is maintained by rubbing with a towel after washing.

Making granite at home

There are two technologies for creating liquid granite that you can practice with your own hands - casting and spraying onto the surface. Before starting work, you need to prepare the solution and all the necessary components and tools.

How to make liquid stone

The basis for the solution is polyester resin, the rate of which can vary from 18 to 21% of the total volume of the composition. About 1% of the solution is occupied by a hardener, which usually comes complete with the resin or is sold separately.

Polyester resin

As a filler (78-81%), mineral chips of the desired type and color are selected; if necessary, part of the crumbs are replaced with quartz sand and pigments are introduced. First, the resin is combined with a hardener, mixed, stone chips are added and mixed again with a construction mixer.

Working conditions

When pouring stone, the temperature in the room should be within +18…+22 degrees. The ventilation system must work properly, and the technician must use personal protective equipment.

Important! When spraying, all surrounding surfaces must be well insulated.

Casting technology

Prepare a mold for filling. For complex products (bathtubs, sinks), it is better to purchase a ready-made form in the store. You can also make it yourself from clay, gypsum, silicone, chipboard sheets.

To produce curved products, the mold must be detachable. The inner surface is covered with a film or lubricated with a special anti-adhesive compound. Without such measures, it will be impossible to separate the form from the liquid stone. After pouring, the product is left to dry for a day, then taken out, ground, and polished.

Sputtering technology

To reduce the consumption of the composite, a spraying method is used, in which the thickness of the product will be smaller. Therefore, it will be much cheaper.

Usually, tabletops, window sills, and souvenirs are made in this way. The surface prepared for spraying is cleaned, degreased, and treated with a primer. After drying, a layer of liquid granite is applied using a sprayer immediately or in parts, in sections. Then the product is ground and polished.

Caring for homemade liquid stone

In order for furniture, plumbing fixtures or decorative items made from composite to last a long time and always remain beautiful, you need to follow a number of rules:

• do not cut food directly on the countertop;
• do not place cups, plates, or pots with hot food or water;
• do not pour boiling water into the sink;
• wash products with a soft sponge and soap or other detergents, but without abrasives;
• if necessary, treat with polishing pastes (to restore shine).

Liquid granite is a durable, reliable, moisture-resistant coating that is an excellent alternative to expensive natural materials. It fits perfectly into the interior and serves as its decoration, and with proper maintenance it will please the owners for many years.

Where is liquid granite used?

Due to its reliability, wear resistance and hygiene, artificial granite is especially popular in hotels and restaurants, clinics and laboratories, and in public areas. It looks no less beautiful in the interior of residential premises, country houses, dachas, and summer buildings.

The material can take any shape, even the most complex, and has a seamless surface, so it is suitable for casting spherical objects - arches, columns, balls. It is used to make stylish countertops, window sills, sinks, sanitary ware, pieces of furniture or individual parts, decorative elements and even facade tiles.

Liquid stone countertops

Liquid granite can be poured or sprayed onto the following base materials:

• ceramics;
• tree;
• metal;
• glass;
• stone;
• porcelain;
• Chipboard and fibreboard.