Finishing various surfaces with natural stone in view of the high prices for such material is not available to everyone. In addition, it is difficult to do stone processing on its own, as this requires a certain experience + the appropriate tool, and the services of hired craftsmen are also not cheap. Yes, and the selection of products from polymer concrete of the desired shade is associated with numerous problems.
By the way, this name is often applied to different samples of artificial marble. But this is not entirely correct. Polymerbetone is a stone made on the basis of polymer resin, although it is used and not always.
Optimal solution of the problem - to organize the production of injection marble by oneself at home. Consider the main varieties of this imitation of natural material, which are nothing more than a solidified mixture of certain ingredients and fillers( + various additives in the form of plasticizers, dyes, additives, etc.).The undoubted advantage of this method is that it becomes possible to get exactly that( in form, color, and so on) that is required, rather than being content only with what is available at the outlet. Saving time, nerves and money is obvious.
The owner himself knows that he needs to make and in what quantity - a vase, countertop, facing tile, sink or something else. From this depends on the parameters of forms, and the amount of materials purchased. But the general composition of the basic devices and materials for the production of injection marble does not change significantly. Let us consider in more detail what we will need:
Accessories( if necessary):
- forms;
- half mold.
Materials:
- filler. Often in its role stands a marble crumb, although in order to reduce the cost of "production" can be used quartz sand, crushed gravel, even mixtures for the preparation of concrete( CSP).Everything depends on the dimensions of the samples( first of all, on the thickness) and purpose;
- polyester resin, alcohol-based, unsaturated( eg PN-12);gypsum;cement or chalk( depends on the specific recipe);
- hardener( to improve strength);
- dyes;
- grease( separating) - gelcoat;
- is a colorless gel.
All necessary materials should be purchased in specialized stores. Sellers will help pick up the necessary components. At least, they understand this often better than those who trade "on the street"( in small bazaars and so on).The last afterwards, and the claims are not presented, if they will.
Form manufacturing
First of all, you need to decide on some points:
- such a matrix is needed for 1 time or is it supposed to be reused? In the latter case, it is advisable to make a collapsible construction;
- strength( after all, the mixture poured into it is characterized by a certain weight, and it depends on the dimensions of the mold, including its depth);
- what should be the surface of the cast marble - smooth or rippled? The latter option may be in the manufacture of facing tiles, although this is a rare case.
The choice of materials for the matrix is unlimited. The main criteria are the required strength and convenience of work. It can be plaster, polyurethane, RTI, plastic, wooden box( or frame with a glass bottom).
Sometimes the matrix is divided into sectors - half-molds. This is useful when making small( same type) samples from the same mixture( a kind of in-line production).
Matrix preparation
Inner surfaces are coated with grease. It is therefore called "separative", which prevents the form from sticking the mixture. Although if in the future it is assumed that the surface treatment of the cast marble( grinding), then the masters also dispense with a thin film of PE, which fits inside. The meaning of this stage is understandable.
Kneading
The technology is simple. The main requirement for mass is the homogeneity and absence of lumps( large particles).Therefore, during preparation, the mixture must be thoroughly mixed. This will be greatly facilitated by the use of technical means. For example, a construction mixer( for large volumes) or an el / drill. The nozzle is made of thick wire( in the form of a "butterfly" or something like that).
But the components of the mixture for casting marble and their ratio - a separate issue. About this just below.
Loading the
matrix After filling the mass, it is necessary to remove air bubbles from it. Often this is done manually, banal "piercing" the solution throughout the area. A more effective technique is the installation of a matrix on a vibrating table( if there is such a possibility).
The intensity of solidification of the cast marble is determined by the temperature in the room, the ratio of the components and the thickness of the "load", so the time can be required from half an hour to half a day.
After loading the entire mass of artificial marble, the mold is covered with a foil film. This will prevent the appearance of cracks on the surface during the evaporation of moisture.
"Extrusion" and additional processing
The finished sample is taken out of their matrix. After his inspection, a decision is made about the advisability of machining and finishing polishing.
Preparation of a mixture for injection marble
The composition depends on the purpose of the samples. Here are some of the proven recipes.
Based on cement
Sand( quartz) - 2h, cement - 1 hour. Mix thoroughly and add filler( small gravel or crushed gravel, granite is better).Mix again and add, if necessary, additives( dyes, plasticizer).All components are added in batches, while mixing is constantly performed.
Here it is necessary to give the first attention to pigments. With them you need to work more cautiously, as you can always add them, but you can hardly remove excess dye. On the readiness judged by the homogeneity of the mass and its hue( monophonic, veined and so on).The master must achieve the expected result.
Based on resin( polymer concrete)
Option 1
Resin( polyester) + filler. The same sand( or a crumb of any color mineral, then the dye will not be needed).Resin - from 20 to 25%( depends on the required strength).Accordingly, the filler is from 80 to 75%.
Option 2
A mixture of AST-T and butacryl( in equal parts).Filler - sand or fine gravel( ½ of the mixture weight).In this case, acrylic dyes are used.
Sometimes as a central "body"( to save a solution) a piece of cut-off( slightly smaller than the shape) chipboard is used. He plunges into a mass of cast marble and is coated with it from all sides.
Based on gypsum
1 h lime + 4 h gypsum. All this is rubbed and mixed well. This one composition. Then the second one is prepared - 1h of water( distilled) + 1.08 hours of lime with sulfuric acid. Then both compounds are mixed until a dough-like mass is obtained. After that, it must be stretched to remove air from the structure. Next, this "plasticine" is given the right shape. This is just one way of making decorative plates( plates), tiles made of cast marble.
Based on chalk
Most often, this technique is used to produce solid color tiles. The components are stirred when the container is heated: chalk( 42 h) + white sand( 28 h) + cinnabar and ultramarine( 1 h) + burnt lime( 4 h) + rosin( 24 h).The resulting homogeneous mass is loaded into the matrix.
Who is interested in producing a wider range of artificial marble samples will find many other recipes on the Internet. But do not immediately prepare them for large volumes of mixtures. It is not a fact that all the share ratios given as examples are correct.
Recommendations
- All technological operations must be carried out in rubberized gloves.
- It's not even possible for every professional to exactly match the required ratio of components, especially if you want to get the product "in color."Therefore, to begin with, it makes sense for to be trained with small volumes of .Spending a bit of material on this, you can drastically reduce the percentage of rejected casting marble.
- Polishing of the surface is done by felt( soft) with the addition of special equipment( polishes).The color of the composition is chosen individually for each sample( or group).
