Artificial stone from cement

Concrete, or artificial stone made of cement, is a durable and adaptable material that has transformed the construction sector. This amazing material is made by combining cement, water, and aggregates such as gravel and sand to create a solid, stone-like substance. Architects and builders love it because it can be molded into a wide range of sizes and shapes.

Although artificial stone has a long history, recent developments have greatly enhanced both its quality and uses. Concrete of today is used in sidewalks and skyscrapers alike, demonstrating its versatility and toughness. The chemical reaction between water and cement, known as hydration, creates a hard matrix that holds the aggregates together and gives concrete its strength.

The sustainability of artificial stone made of cement is one of its main advantages. It can use repurposed materials, cutting down on waste and protecting the environment. Furthermore, concrete constructions are renowned for their durability; they can go for decades with little upkeep. Because of this, concrete is a sustainable material option for both large-scale infrastructure projects and smaller-scale residential uses.

Cement-based artificial stone can have aesthetic appeal in addition to its practical uses. Technological advancements have made it possible to create a wide range of textures and finishes, giving designers the ability to create custom surfaces or replicate the appearance of natural stone. This adaptability creates countless opportunities for imaginative and useful architectural designs.

Artificial stone made of cement stays at the forefront of our construction material innovations and advancements. Its strength, resilience, and adaptability guarantee that it will remain a fundamental component of contemporary construction methods. Concrete provides a dependable and flexible solution for any type of construction, from building a cozy backyard patio to erecting a tall office building.

Cement-based artificial stone is changing the building industry by providing a practical, long-lasting, and affordable substitute for real stone. This novel material offers improved strength and weather resistance while simulating the texture and appearance of genuine stone by combining cement, aggregates, and pigments. It’s becoming more and more common for flooring, countertops, facades, and decorative accents. Artificial stone, which is simple to work with and modify, creates new opportunities for architectural design by enabling imaginative and useful solutions that satisfy both aesthetic and functional requirements.

Instructions for making artificial stone from cement

Although the technology for creating artificial structural or facing stone is fairly straightforward, it will need the creation or purchase of specialized tools, such as mold matrices for artificial stone pouring.

Although building supply stores sell pre-made matrices, it is recommended to create the molds by hand. In addition to being significantly less expensive, you will have the precise element configuration that is best suited for a given set of circumstances at your disposal in this instance.

The following supplies are needed to create mold matrices:

• Master model. A natural or artificial stone of suitable configuration, size and surface texture acts as a master model. A master model can be selected in a quarry, on the river bank or in a store selling natural or artificial stone.
• Formwork. The internal dimensions of the formwork should be larger than the master model by 15 cm around the perimeter and 30 cm in height. As formwork, you can use a ready-made cardboard box, juice packaging or a square (rectangular) frame made of plywood, boards, fiberboard.
• Material for pouring forms – liquid silicone. The material can be purchased in face-to-face construction stores and online. Popular types: Super Mold 30 (990 rub./kg), Poly Food (RUB 1,345./kg), Mold Max10 (1158 rub./kg) and others.
• Release agent. You can use a budget option – solidol or any other consistent lubricant for bearings and rubbing parts of mechanisms. You can buy a branded material: Elasteks RS (455 rubles./kg), Izola-FTB (85-160 rub./kg), Barrier-8(154 RUR./kg) and others.

Forms for artificial stone

Once the necessary materials are ready, you can start the mold’s direct production. stages of technology:

• Lubricating the inner surface of the formwork and the surface of the master model facing the silicone with a release agent.
• Laying out the master model in the center of the formwork.
• Filling the formwork with silicone, leveling the silicone surface with a spatula.
• After the silicone has hardened, disassemble the formwork, remove the master model, clean the finished form from the release agent. For reference! The curing rate of silicone is about 2 mm / day. Therefore, you should not rush to remove the formwork.

It makes sense to create multiple pieces or multiple dozen forms in order to expedite the production of artificial stone and to make efficient use of cement and other components.

Once the necessary quantity of matrix forms has been created, you can start making cement artificial stone. You will also require the following supplies and equipment in addition to the forms:

• Portland cement CEM I 32.5N PC or CEM I 42.5N PC, clean coarse quartz sand of fraction 0.63-1.5 mm, granite screenings or marble crushed stone of fraction 5-10 mm, clean water.
• Superplasticizer C-3.
• Colors for concrete brands: Bayer, Dupont, Kemira, etc.
• Reinforcing mesh for plaster.
• Concrete mixer.
• Measuring containers.
• Metal shears, trowel, spatula, nail.

Proportions of materials for the solution

Materials needed to produce one part of artificial stone from cement are as follows: one part cement, five parts sand, one to two parts crushed marble or granite screenings, two to five parts superplasticizer, five percent dye of the solution weight, and six parts water (approximately).

The concrete mixer is filled with cement, sand, granite screenings (crushed marble stone), and dye, and everything is well mixed. Next, incorporate water and superplasticizer, and thoroughly mix everything once more. The final mixture ought to resemble thick sour cream in consistency.

The solution is spread out in a mold-matrix, lubricated with a release agent up to half, and compacted by vibration and "bayoneting" with a trowel or spatula. The reinforcing mesh is cut to size with metal scissors and inserted into the form in accordance with its configuration. The form is then filled with a solution to the upper cut and compacted once more.

Filling the forms

Making notches with a nail in the shape of a mesh is the last step in filling the artificial stone. For the element to adhere to the base more effectively, the notches are required. After the solution-filled forms are left in the shade for 12 hours, the artificial stone is taken out of the forms, the forms are thoroughly cleaned, and the finished products are dried for 14 days in the shade. The artificial stone can be used for its intended purpose once it has completely dried.

There are times when the mortar drips need to be carefully removed or the cladding elements need to be adjusted to each other. Non-experts in the field of stone processing may wonder how to cut artificial stone made of cement in this regard. An angle grinder and a diamond disc with the proper diameter are your only options. Diamond discs from well-known brands include Grost, TURBO DS SORMA, KEOS Standart, KEOS Professional, and Diam Almaz RV.

An important development in building materials is the creation of artificial stone made of cement, which provides a strong and adaptable choice for construction projects. In addition to having an appearance similar to natural stone, this material has improved qualities like increased uniformity, ease of production, and customizable aesthetics. Because of its versatility, it can be used for anything from structural components to decorative elements.

The affordability of artificial stone is one of its main advantages. Utilizing easily accessible resources such as pigments, aggregates, and cement, producers can create a superior product for a fraction of the price of natural stone. Artificial stone is a desirable option for both residential and commercial projects because of its cost-effectiveness, durability, and minimal maintenance needs.

In addition, compared to natural stone quarrying, the environmental impact of using artificial stone is negligible. Waste can be reduced during production by using controlled procedures, and the sustainability of the product can be further improved by using recycled materials. Cement-based artificial stone sticks out as a considerate and creative choice as the building sector continues to emphasize environmentally friendly methods.

In summary, artificial stone from cement offers a practical, economical, and environmentally friendly alternative to traditional building materials. Its flexibility in design, strength, and ease of installation make it an excellent choice for modern construction needs. As technology and techniques continue to improve, we can expect artificial stone to play an increasingly prominent role in the future of construction.

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