Due to the growth of individual construction, artificial stone has become increasingly popular. Not everyone can afford to decorate his home with dignity, acquiring a natural stone. Having many advantages, it has, from a practical point of view, a number of significant shortcomings. But the artificial "product" is largely deprived of them.
The technology of its manufacturing depends on the selected components. Consider the most common option, since it does not differ in complexity and is available to every "amateur" builder. The fact is that all other methods, as a rule, require the use of complex mechanisms and special equipment. For example, for acrylic stone you need a vacuum mixer. Not everyone can afford to take everything necessary for rent, and not everywhere it is possible.
Composition of
It is clear that the main ingredient is Portland cement. Fillers can be different materials. Everything depends on what properties the "master" wants to give to the final product. The choice is quite extensive, but we list the most common:
- Expanded perlite. Enhances the anti-corrosion properties of products.
- Pumice stone. Significantly reduces the weight of the artificial stone.
- Crumb ceramic( fine fractions).
- Expanded clay.
On the latter it is worthwhile to dwell in more detail. The properties of this material are well known. Adding it to the prepared composition, two problems are solved immediately: the artificial stone turns out to be quite light and at the same time is characterized by minimal heat losses, which saves on heat insulation materials.
In addition, depending on the conditions of further operation, various hydrophobizators, plasticizers, reinforcing the structure of the material( reinforcement) of the agent are introduced into the prepared composition.
Production methods
Vibrocompression: this technology is used for the production of plate material.
Vibration: used in the manufacture of workpieces for facing surfaces. The prepared mass is poured into special molds and compacted with a vibrator. Although at home it is usually done manually.
Method
Basic components 3 - sand, Portland cement and water. And the sand is taken only small fractions( sifted).
Form manufacturing
The necessary configuration and dimensions of the product are determined. The number of forms depends on the "scale" of production, so as not to waste time. On sale there are ready-made copies, but you can do yourself. The main thing is to choose a suitable "formwork", for example, a box of cardboard.
If desired, you can build it from a single sheet. As a sample, the finished stone is taken and placed on the bottom. To the walls of the box and the sample do not stick to the composition from which the mold will be prepared, they are abundantly lubricated with a solidol. When everything is ready, the volume is filled with silicone.
It only remains to wait, when the whole mass will dry out qualitatively. As a rule, at a natural temperature, this can take from 2 to 3 weeks, although it is possible to speed up the process by placing the molds in a warmer room( but not at too high a temperature).Artificial heating will lead to deformation of the composition.
After the drying process is completed, the formwork is removed and the sample is taken out. Defects on the inner surface of the mold( cracks, blotches) are eliminated by the same silicone.
Preparation of
solution It should be noted that the casting is done in two layers. The coloring material is previously diluted in water and added portionwise during the mixing of the solution. You can find the color you need by "training" on an experimental sample of the mixture. It is recommended to add dye not more than 3% of the volume of cement, although it depends on the ingredient used. Therefore it is necessary to experiment.
The composition is prepared at the rate of 1: 3( sand - cement).The main thing here is the quality of the "batch".The solution should be a homogeneous, thick mass.
It is better to enter different additives after studying this issue separately. Or consult a specialist.
Fill
- First the form is filled in half. The solution is compacted( it is possible to pierce, for example, with a nail, you can shake the whole structure - as it is more convenient).
- The reinforcement is then carried out. Typically, a fine-meshed metal mesh is used, which is cut to a size slightly smaller than the shape.
- The final pouring, to the edge. It is necessary to understand that the upper surface of the mass after hardening becomes the back side of the artificial stone and will be applied to the wall. To ensure a quality bond with the surface at the very top of the solution, you should make "incisions".After its hardening, grooves are formed, in which the adhesive composition will be fixed.
Common errors
- For the sake of economy, cheaper claydite is purchased - with large fractions. However, in the process of exploitation such an artificial stone soon begins to become covered with cracks and break into pieces. Therefore, it is necessary to use products only with small granules.
- Surface application of coloring composition to already finished products is carried out. This is undesirable, since such a coating will not serve for a long time, and it will be necessary to periodically restore it. It is more expedient to add the coloring composition immediately to the mixture being prepared.
Recommendations
- To decorate your home, it is not necessary to make a complete surface finish with an artificial stone. It is cheaper( and sometimes much more effective) to mount it on separate sites, creating a certain composition. The main thing is that it should be combined with the rest of the cladding. More about the stone in the interior read in this article.
- If, nevertheless, the coloring of the stone is made after the installation, it is necessary to use moisture repellent compounds and apply them in at least 2 to 3 layers.
- When choosing cement, pay attention to the figure after the letter "D" in the name of the product. It indicates the percentage of a specific additive. And its kind and properties, which it attaches to products, can be clarified with the Seller.
