DIY concrete marble. Making artificial marble from concrete How artificial marble is made

Despite the obvious advantages of natural materials, they are expensive, for this reason many people pay attention to artificial marble. There are various ways, how to make it with your own hands, the simplest technology available at home is casting in molds.

A tabletop made of cast marble is durable, moisture-proof and perfectly imitates real stone. The only difficulty lies in the correct selection of parameters, since a thin product will have increased fragility, and a thick product, despite its modest size of one meter, will have a lot of weight. Any color can be selected for the material - snow-white, blue, gray, black with piercing veins, giving it a granular-crystalline structure.

What are the characteristics of the material?

High-quality cast marble is obtained by mixing polyester resin with pigment mineral dyes and hardeners. A simpler manufacturing method involves using a cement-concrete mixture with the addition of large or small quartz crushed stone, pebbles, and tinted sand. To master the mixing technique and obtain the desired color, texture with stains and stains, you will first need to practice and try to prepare cast marble in small volumes.

Artificial stone not only perfectly reproduces the appearance of natural material, but also has such positive characteristics as:

• resistance to heat and open fire;
• high dielectric properties, since it is not a conductor of electric current;
• resistance to treatment with any detergents, except those containing abrasive substances;
• high hygienic and environmental characteristics.

This is largely facilitated by the homogeneous structure, which continues long term does not delaminate during operation, and the outer surface treated with gelcoat has good decorative and protective functions.

Manufacturing technology using concrete filler

The method is very simple, affordable and requires minimal investment, so it is widely popular. Tabletops and cutting boards made using this technology have high strength and environmental characteristics.

To make them, you will need a mold made of plastic, polyurethane, gypsum, or other suitable material. If there are no special complaints about the matrix, then you can make it yourself from any metal corners, wooden blocks, using a glass blank as the bottom. The basic requirements for the design are that the surface must be perfectly smooth, dry, and, for ease of removal of the finished product, also detachable.

Having prepared the mold, the inside is coated with gelcoat - a special gel-like substance that differs in color, as well as in the medium of use, so you should choose a moisture-resistant option. When it is completely dry, the matrix can be filled with a solution made from concrete or gypsum. If necessary, to increase fluidity and normalize hydration processes, slaked lime and clay are used as a plasticizer.

The mixture is prepared in a mixer from sand and cement in a 2:1 ratio, using crushed stone and pebbles as filler. When a homogeneous mass is obtained, pigment dye begins to be added to the container in different portions and continues mixing until veins and spots form.

After this, the prepared mixture is poured in small portions into a mold placed in a horizontal plane. At this stage, it is important that the mass evenly fills all the voids, so it is added slightly more than the required volume. Wait a little until it spreads and remove the excess with a spatula.

Finally, the filling is covered with plastic wrap and left to dry in natural conditions at above-zero temperatures for at least 24 hours. In some cases, depending on the thickness of the workpiece, the time increases. After removing the dried slab from the mold, it is treated with a grinding machine, then with a transparent polish, which forms a durable and elastic film on the surface.

Polymer-based cast marble

In terms of money, this option will cost a little more, but the finished product is durable, lightweight, resistant to physical and chemical influences, and its texture perfectly imitates natural material.

The production of polymer concrete for pouring into molds can be carried out in several ways:

• Made from polyester resin, one part of which is mixed with 4-5 parts of filler. Quartz sand, another neutral colored mineral, crushed into fine crumbs, is well suited for these purposes.
• Using a two-component mixture of AST-T with butacryl (self-hardening plastic). The powder and liquid included in its composition are diluted in a 1:1 ratio and, depending on the volume obtained, the same amount of crushed stone and quartz sand is added. Painting in the desired color is done with acrylic-based pigments.

Having prepared the solution, fill the mold with it, and level the surface with a spatula. Then, applying force, they are compacted using a special blank. It can be cut from a chipboard board, the dimensions of which should be smaller than the contour of the matrix. The product is left to dry. Next, it is removed from the mold and subjected to further processing - cut, ground, polished, the necessary holes are prepared, or other types of work are carried out.

Gypsum based material

Gypsum is an affordable, easy-to-work material, so making artificial marble from it at home will not require special costs and effort. First, prepare a container and pour water into it, in which dry plaster with wood glue and resin dissolved in a heated turpentine bath are mixed. All components are thoroughly mixed and, without stopping the process, they begin to gradually add acrylic dyes and pigment, trying to obtain stains and veins.

To give artificial marble a milky color, white gumax, rubber-based glue and latex are added. But if brown shades or a coffee tone are needed, then orange humilax is added. A pronounced black polish can be obtained using aniline dye.

The prepared mass is poured into a mold made of plastic or polyurethane. To speed up the setting process and remove excess water from the mixture, additionally sprinkle dry plaster on top. Usually after 8–10 hours the product is removed and left to dry completely.

You can give the front surface waterproof characteristics by treating it with potassium silicate, for which the workpiece is lightly immersed in a bath of solution or applied with a brush. When the base is dry, they pass over it with soft felt, then add polish of the desired shade, and polish until the ideal result is obtained.

How to care for artificial marble?

Although created with your own hands artificial material It is highly durable, resistant to various impacts, and requires special care. By following the tips of specialists, you can significantly extend its service life. According to them:

• Do not use cleaning products that contain drying oil or silicone;
• sponges, brushes, and other coarse-bristled products are not suitable for cleaning as they can damage the top protective layer of marble;
• The surface should be wiped using soft fabric using, instead of abrasive products, exclusively gel-based products, and for regular cleaning - regular soap;
• To maintain the original glossy shine of the product, it must be wiped with a composition made from liquid soap dissolved in water, and then with a clean towel.

Artificial marble is a wonderful and affordable decoration for your home – kitchen, bathroom and other rooms. By approaching its manufacture with all responsibility, and then properly caring for it and protecting it from adverse influences, it will be possible, while maintaining an attractive appearance, to extend its service life.

Natural stone is an expensive pleasure, especially if you want to make a countertop or shower tray out of it, and therefore DIY artificial marble seems to be a more profitable option. Moreover, there are quite a lot of ways to obtain a reliable imitation, using a variety of, sometimes quite unexpected, components and technologies.

How to make 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, and a granular-crystalline structure. The color 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 produces a dense, non-porous mass. However, this option is not acceptable if you need a countertop or cladding in a room with high humidity levels. 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 a cement-sand mixture. Cast marble is durable, waterproof and, most importantly, looks very similar to the real thing. However, it should be taken into account that thin tiles will be quite fragile, and thick ones will be heavy. As a result, it is possible to make a countertop from such an imitation, but the body of the furniture must be very massive in order to withstand the weight of the stone slab. More thin version can be made using the wooden plane of the table itself as a basis. Next we will look at both options.

Almost real artificial marble: manufacturing technology

What do we need to end up with a slab of cast stone that is almost indistinguishable from natural stone? First of all, a polyurethane mold, 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 cement share) and a plasticizer in the same amount. In order for the technical process to be successful, we stock up on plastic film, a construction mixer, a mixer or a special attachment 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 wash and dry the mold, which can be of any size, for example, just for the working surface of the kitchen wall. We prepare the solution by combining cement, sand and pebbles in a dry state, thoroughly mixing the components. Pour in 80% of the stored water, as well as the plasticizing composition, and continue kneading, achieving the highest possible homogeneity of the mass. We add the remaining water and, in unequal portions to different sectors of the container, the dye in order to achieve as little uniformity as possible for the subsequent mixing of the color with the solution.

Step 2: Filling out the form

As soon as the dye has dispersed through the cement mass in thin veins, the composition is ready, and you can begin the most important phase of the technical process. We take the form, set it to absolutely flat surface to prevent bending of the bottom or walls, and pour the solution into it. Using a spatula, we clean the edges of the mold from any excess that could affect the smoothness of the slab, then level the surface of the mass using a rule and cover it with polyethylene.

The larger the slab artificial stone, the higher the likelihood of its failure due to internal voids. Therefore, if possible, you should use a vibrating table, and if this is not available, 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 approximately 10 days, the hardening of the mass poured into the mold will end, and there is no need to interfere with the process, as other works with cement require. For example, regular moistening of the surface is not required due to the fact that the solution is covered with polyethylene, which prevents rapid evaporation of the liquid. When the slab has completely hardened, carefully lift it, turn it over and, like a cover, remove the mold from the finished tabletop.

To obtain artificial marble, the manufacturing technology does not have to be complicated; everything can be done in an apartment. The output is a product with low porosity, high resistance to a humid environment and various household chemicals. If necessary, polish the slab using transparent polish and alcohol, alternating between surface treatments. In this case, you should first treat it 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 an illusion faux marble

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 will withstand the load of a multi-kilogram slab. Instead, the easiest way is to use paints to partially turn the table itself into marble by painting the appropriate stains on it. To do this, you will need a jar of paint for the background, for example, white or green, as well as a small container of color for the pattern. It would be more correct to draw black or gray stripes on a white background, and white stripes on a green or black background.

Before making artificial marble, all cracks and chips on the surface, if any, are filled with a special water-based wood filler. Next, we moisten the tabletop with a spray bottle 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 the interval necessary for the first of them to dry. To avoid streaks, it is better to use a brush or foam pad. After two hours, you can begin applying the texture pattern.

The pattern of marble is familiar to many; sometimes it resembles zigzags of lightning on a surface speckled with many grains, 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 mixture (be sure to remove excess mixture from it), we follow the drawing without pressing hard and thus shade the lines, making them 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 we take up the feather brush again, emphasizing the previously applied and already modified pattern.

After two hours, when the surface has already dried well, we take a thoroughly mixed polyacrylic coating and cover our “marble” with a thin transparent layer. It is advisable to leave the tabletop for a long time after this to allow the film to harden thoroughly. Next, you need to polish the surface with the finest sandpaper, clean it with a damp sponge or cloth and, after letting it dry, treat it again with polyacrylic. Again, we leave the almost formed imitation stone to dry for 2-3 hours, then polish and wipe again. We apply the last layer of 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.

Finishing work using natural stone is a very expensive pleasure. Choosing natural marble of the appropriate tone is quite problematic. Mastering the production of artificial marble with your own hands is not very difficult. Important point in the manufacture of artificial marble - a correctly made mold for casting.

In fact, artificial marble, the manufacturing technology of which is outlined in this article, is an alloy of acrylic resins and mineral fillers. This material has sufficient strength, and when making artificial marble with your own hands, it can be given the desired shape. This could be a countertop for the kitchen or for a bar counter, steps, a sink, a sink or an original vase for the garden.

Composition and special properties of artificial marble

The main components of cast marble are polyester resin and pigment mineral dyes and hardeners. Having mastered the mixing technique, you can get streaks and stains that are practically indistinguishable from stains and veins on natural marble.

1. The material is non-flammable and dielectric, i.e. does not conduct electric current, so it can be used for any finishing work without restrictions. Resistance to alkaline preparations and chemical solvents contributes to its hygiene and allows it to be used as countertops and kitchen sinks.
2. The composition of cast marble has a homogeneous structure, does not delaminate, is resistant to corrosion and is an environmentally friendly material. The outer surface of cast marble is gelcoat and has decorative and protective functions. The filler is polyester resin mixed with multi-colored mineral chips and pigment dyes. To obtain a durable mass, a hardener is added.
3. More simple methods The manufacture of artificial marble involves the use of cement-concrete mixtures and crushed stone as a filler. Pebbles, quartz fine crushed stone and tinted sand are often used.

Manufacturing technology of artificial marble with concrete filler

This method is very simple and affordable, both in terms of manufacturing technology and costs. Due to this, this method is widely popular. Countertops and kitchen boards are highly durable, and environmentally friendly materials are used in their production.

1. First of all, you will need a mold (matrix) made of polyurethane, plastic, gypsum or other suitable material. You can make a frame from a corner or wood, and make the bottom glass. It is important that the surface of the casting mold is perfectly smooth and dry, and that the frame is detachable for ease of removal of the finished product. The mold can be ordered from a workshop, but it is quite expensive.
2. The inner surface of the mold is coated with gelcoat. Gel coats vary in color and environment of use. Choose a moisture-resistant gelcoat and only after it has completely dried, you can fill the form with concrete or gypsum filler. Slaked lime or clay is used as a plasticizer or filler.
3. Prepare the filler for the bulk of the product. To do this, mix sand and cement in a 2:1 ratio, add crushed stone or pebbles and a plasticizer as filler. Mix thoroughly, preferably in a mixer, until smooth. Pigment dye is added to different sectors of the container with filler in uneven portions and mixed until veins and spots are created.
4. The form is placed in a strictly horizontal position and a mass of artificial liquid marble is poured into it in small portions. Make sure that all the voids in the matrix are filled. Excess mortar is removed with a spatula; cover the top with plastic wrap. Depending on the thickness, artificial marble dries within 24 hours in natural conditions and at above-zero temperatures. The dried slab is removed from the mold and processed with a grinding machine and transparent polish.

Cast marble based on polyester resins

This method is somewhat more expensive, but the result is a beautiful texture of the outer coating. The material is very durable and lightweight, resistant to external mechanical and chemical influences.

1. The first option is to prepare polymer concrete. Take 20-25% polyester resin and 80-75% filler. For this purpose, you can use quartz sand or other neutral colored mineral, finely crushed into crumbs.
2. In the second case, instead of polyester resin, you can use a mixture of butacryl with AST-T in a ratio of 50x50 and add 50% crushed stone or quartz sand. Coloring is done with acrylic-based pigments.
3. The form is filled and leveled over the surface of the matrix with a spatula. As a filler, you can use a chipboard board cut 5 cm smaller than the contour of the form. It is pressed into the mass, and the protruding excess is leveled along the back side of the casting.
4. The dried and hardened product is removed from the mold and can be easily processed. It is amenable to grinding, drilling and other mechanical processing.

Making artificial marble from gypsum

Making artificial marble from gypsum at home is an affordable process and does not require any special expenses.

1. First, water is prepared, dry gypsum, wood glue and resin dissolved in a hot turpentine bath are added to it. Acrylic dyes or pigment are added to the thoroughly mixed mixture and stirred until streaks and streaks are obtained.
2. To obtain the milky color of artificial marble, add 1000 technical alcohol and 50 dry gypsum to 200 grams of white gumax. For a brown or coffee tone, use orange humilax. To obtain a black polish, aniline dye is used.
3. The liquid mass is poured into a plastic or polyurethane mold. To remove excess water and set faster, the mass is sprinkled with dry plaster on top. After 8 - 10 hours the product can be removed from the mold. To create a waterproof front surface, it is treated with potassium silicate.
4. Can be immersed in a bath or brushed generously on both sides. After drying, the surface is polished with soft felt or a similar abrasive agent with the addition of polish of the desired shade. The surface is processed until a perfectly smooth mirror surface is obtained.

Modern analogues of traditional natural materials are widely used today. The advantages of using artificial stone in interior design are innumerable; it is enough just to mention the exceptional strength of the material and the relatively low cost. Possibility of self-production, ease of installation and processing of the finished product, as well as use innovative technologies in the manufacture of marble - all these aspects are described in detail in the information in this article.

Advantages of artificial marble

The use of natural stone in the design of residential and public premises has hundreds of years of positive use. Such cladding has always been the prerogative of the upper strata of society, but with the advent of artificial analogues, such luxury has become more accessible.

Advantages of using artificial stone in the interior:

• Excellent strength and performance characteristics.
• High degree of decorativeness of products made from artificial stone.
• Relatively affordable price.
• Possibility of self-production.
• Easy installation.
• The material is non-flammable and chemically inert.
• Relatively light weight.
• Surface durability.
• No special care required.
• Color fastness is maintained in direct sunlight.
• The material is low hygroscopic and can be used in humid environments.

Sinks made of artificial marble are distinguished by their excellent design and trouble-free operation. Self-production artificial marble will significantly reduce the cost and allow you to obtain original configurations and colors of finished products.

And the interior of the premises can be given a respectable look by using marble for decoration. It is believed that the owner of an apartment or company who resorts to this technique has good taste and high status. But natural stone is quite expensive, and its artificial counterpart can be made from concrete. To do this, you will need to use the simplest ingredients, including water, cement and sand.

Preparation

Before you make marble from concrete, you need to do some preparation. To do this, you should ensure that you have:

• pigment;
• cement;
• sand;
• plasticizer.

The latter is a substance that improves the characteristics of the material. To make marble you will need molds. For this you can use those made on the basis of polymers. If you cannot find any, then you can use plastic forms. But for the solution you will need cement grade M 500. When choosing a pigment, you can give preference to oil paint. It is presented in many shades.

Types of concrete for marble

The production of artificial marble from concrete may involve the use different types mixtures. The latter is a composition of aggregate, binder and water. Mixing the components can also be done in a concrete mixer if the amount of work is quite impressive. Taking into account different criteria, it is possible to classify the concrete mixture for marble by density.

You can get heavy, very heavy, light and very light material. In the first case, we are talking about grades in the range M 100-M 600. Lightweight concrete will correspond to the following grades: M 35-M 400; very heavy and very light concrete for marble corresponds to grades M 100-M 200 and M 25-M 200. In order to prepare a product with high strength, it is better to prefer concrete grades M 400 or M 500. The density of the concrete mixture will vary from 1800 up to 2500 kg/m2.

Materials and tools

If you decide to make marble yourself, you should ensure that you have special tools and materials. For this you will need:

• polyethylene film;
• water;
• oil paint;
• fine sand.

When preparing paint, you must take into account the shade of the material that you will end up with. The filler can be gravel or small pebbles. M 400 grade material is sometimes used as cement. For mixing, you should prepare a container and a drill. The latter should have a mixer attachment.

Composition and characteristics of marble preparation

If you decide to make marble from concrete, then it is best to ensure that you have a vibrating table, which you can rent. For the solution you will need two parts sand and part cement. The ingredients are mixed until smooth, and then the pigment is added. It can leave stains characteristic of marble.

You can experiment by adding paints of different shades. After filling, the form is shaken, and if there is a vibrating table, it is placed on it. By the way, you can make a vibration table yourself. It may also be useful for performing paving slabs. Last stage Making marble from concrete is the most labor-intensive.

It involves grinding. After the molds have dried, the products must be processed. This creates quite a lot of dust, so you should take care of several buckets of water in advance. An alternative solution is to connect a hose with good water pressure.

Technology requirements

Concrete marble can turn out no worse than natural stone. However, technology must be followed. Even window sills can be made from marble, but for this you need to find plastic trays. You can complete the forms yourself. For this plastic panels are fastened together. Using the same technology, polymer concrete can also be produced, but instead of cement in this case, binders in the form of thermoactive resins will be used. Among them:

• furan;
• phenolic;
• epoxy.

When making polymer concrete, more filler is added to the ingredients than when making conventional concrete mortar.

Concrete marble technology may look slightly different. As a proportion, you can use the standard ratio of one to three. The filler in this case will be calcium carbonate or other neutral fillers. If you decide to prepare polymer concrete, then the solution is combined in proportions of one to four. The fillers will be coarse-grained materials. For these purposes, you can use crushed gravel or coarse sand. The materials for this are:

• quartz;
• limestone;
• sandstone;
• dolomite.

When making artificial marble from concrete, it is not enough to prepare the solution correctly. It is important to follow other stages of the technology. For example, after pouring the mixture into molds, the surface is covered with plastic film. In order to achieve higher strength of the material, it is reinforced with wire.

As soon as the mixture is poured into molds, a reinforcement cage must be placed inside. After the mixture has hardened, the products are removed from the mold and sanded. To do this, you can use diamond discs in the form of cups or grinding machine. After performing this operation, the surface should be smooth, thereby resembling natural marble.

For reference

If you decide to make concrete marble with your own hands, you must remember that the products are quite durable, and they can only be processed with a diamond tool. Effective method this involves cutting reinforced concrete with diamond wheels and diamond drilling holes in concrete.

More about technology

You know the composition of concrete marble if you read the article. It is also important to take an interest in the features of the technology. In the process of such production, it is possible to obtain artificial marble, which is also called colored or decorative concrete, as well as systrum. However, these are just different variations of names that are combined into one technology.

It has absorbed all the advantages of the semi-dry forming technique and the vibration casting technique. This allows you to make a material that will be identical to natural marble. The components are the most affordable and simple. In general, decorative concrete is ordinary, but white shades of cement are added to it, which gives the products a noble appearance.

Sometimes the production of marble from concrete involves the use of special fillers, including marble chips. She may have the most different shades and colors. This approach is combined with subsequent processing. The surface must be polished so that you can achieve the effect of real marble. Besides, final stage allows the structure of the aggregate to be attractively revealed.

How and in what volume to add water?

After the dry ingredients have been combined, you can add them to the water. Combine it with the components in a ratio of one to two. First, pour in 80% of the liquid and mix everything well. Then a plasticizer is added, which increases the strength of the product.

This component will make up 1% of the total mass. Afterwards the mixture is mixed well and left for 10 minutes. During this time, the composition becomes plastic and viscous. Only after this can you pour in the remaining water.

In conclusion

In order to achieve the effect of natural marble, the cured product must be sanded and polished using appropriate tools. The surface is smooth and pleasant to the touch. Besides, she is very beautiful. Now all that remains is to install the marble in its place. However, before this, the surface is prepared: it is cleaned and freed from foreign objects. This is correct if the material is glued to a rough base. If dust is present, adhesion performance may be reduced.