Do-it-yourself steps from marble chips. How to make marble out of concrete: technology. Artificial Concrete Marble

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• The use of concrete marble
• How to make illusory marble concrete

Marble made of concrete is a simple material to manufacture, which is convenient to use for a variety of purposes. Not everyone understands why it is necessary to produce material that mimics a natural stone of amazing beauty, so for a start it should be explained why it is so valuable.

What is marble and where is it used?

Marble is a unique material that has been used in the decoration of buildings and interiors for centuries. But not everyone can afford to perform such a finish, since marble is not only rare material, but also quite expensive financially.

Deposits of high-quality marble are located in hard-to-reach places, and its extraction is carried out using special equipment, which must be lifted into the mountains and installed. Both production and delivery and processing of material increase its cost by an order of magnitude.

Thanks to the use of new technologies that are constantly being developed in the construction industry, the range of materials for construction has been significantly expanded. Now it is possible to make marble from concrete with your own hands and do it in normal home conditions, without the use of equipment, which is not cheap.

To make marble from concrete, you will need such materials:

• cement grade M400 or higher;
• water;
• plasticizer C-3;
• polyurethane mold;
• fine sand;
• polyethylene film;
• pigment additive;
• fine gravel as aggregate;
• drill and mixer nozzle.

Natural marble is an expensive pleasure. therefore faux marble  from concrete it seems sometimes as an option practical and profitable. To obtain a good simulation, which is very similar to natural stone, there are many technologies that are suitable for use at home.

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Obtaining Artificial Marble

Natural marble is a stone with a heterogeneous color, granular structure, with veins permeating the entire thickness. The stone may be pink, blue or snow white, gray or black. Other colors are also found: green, red, yellow, purple. You can create a material that imitates marble from gypsum: it turns out a dense mass, devoid of pores. But this method will not work if the product is planned to be used in a room with high humidity. You can consider alternative methods that make it possible to make marble yourself.

The simplest technology - marble from concrete is cast in molds from a mixture of sand and cement. It turns out to be very strong, impervious to moisture, and looks very much like a real one. But it must be borne in mind that thin tiles will be fragile, and if you make them thicker, they turn out to be too heavy. It is possible to make, for example, a countertop from such imitated stone, but the furniture must have a massive body that can withstand the considerable weight of the plate. You can make a subtle version, while taking on the basis of a wooden countertop.

In order to end up with a cast plate indistinguishable from a real stone, you will need to stock up on the materials and tools necessary for work in advance. It is necessary to have a form of polyurethane or other material, dyes and plasticizers, which will need to be mixed with the cement mixture. For the construction mixer you will need a mixer and nozzles on the drill, as well as a short rule, a spatula.

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Step-by-step instructions for making concrete marble

By what technology it is better to make marble from concrete, it is necessary to decide depending on the specific conditions of use. The basic principles are the same. Making artificial marble at home will look like this:

1. The first stage is preparatory. The mold (or molds) must be thoroughly washed and dried. It can be of any size: for example, it can be specially made in accordance with desired values for the kitchen wall. To prepare the solution, dry ingredients must be mixed to a homogeneous state: sand, pebbles and cement. After receiving the composition, pour in almost all the water, add a plasticizing ingredient. Continue kneading to the level to achieve maximum mass uniformity.
2. Add the rest of the water, then dye - it must be introduced in portions of different sizes, be sure to different parts of the container. Thus, an uneven mixing of the solution and the color is achieved, which gives a greater similarity to the artificial material with natural stone.
3. Filling with a solution of the form. When the dye is thin veins disperse in the cement mass, we can assume that the composition is finally ready. Now you can move on to the most important phase of the process. The form must be set on a smooth surface - this will help to eliminate the bending of the walls and bottom. Pour the solution into it. Using a spatula, the edges of the mold are cleaned of excessive influxes that can affect the appearance and smoothness of the surface of the plate, then the surface is evened out with a rule and closed with polyethylene.

The larger the size of the artificial stone plate, the more likely it can break due to the appearance of voids inside. Therefore, do not neglect the use of a vibrating table, which will help to make the structure more continuous. In its absence, the inability to use it is worth trying not to remove the mixer from the mass during mixing - so less air bubbles are formed.

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How to get ready-made marble or “marble concrete”

It will take about ten days to solidify the mass poured into the mold. Do not interfere with the process, as is done when performing some other work with cement. For example, regular wetting of the surface will not be required: the solution will be covered with a plastic film, a material that will exclude excessively quick exit of the liquid from the thickness of the concrete mass. After the plate has completely hardened, it must be raised, turned over, then removed from it like a cover.

To increase the strength of concrete, you can additionally reinforce it with wire. For this, it is recessed into molds after a cement-sand mixture is poured into them. The hardening of the contents of the forms should be complete.

It is not necessary to think that in order to obtain high-quality concrete, the technology must be especially complex.

In fact, all the necessary actions can be performed in a city apartment.

The output is a material with a small porosity, resistant to household chemicals, moisture resistant. If necessary, the plate can be polished: for this, its surface will need to be treated alternately with alcohol, a transparent varnish, then again with alcohol. Alcohol should be used only after the layer of polish has dried, but it can not be dried.

Marble is a material that has been used for many centuries in the design of interiors and exteriors of houses. And not everyone can afford such a finish. Marble is a rather rare and expensive material. Its deposits are found high in the mountains, where it is extremely difficult to raise the necessary equipment. The extraction, processing and delivery of this material significantly increase its cost. In addition, the extraction of marble entails the destruction of limited reserves.

The use of the latest technologies in the construction industry has significantly expanded the range of materials and made it possible to manufacture marble from concrete, and this can be done at home with your own hands without the use of expensive equipment.

Materials required for the manufacture of marble:

• cement M400 or M500,
• polyurethane form
• plasticizer C-3,
• water,
• fine sand
• polyethylene,
• water-insoluble pigment
• filler (fine gravel),
• drill with mixer nozzle,

Step-by-step instructions on how to make marble from concrete with your own hands:

• Step 1.In a clean container we put cement, fine sand, gravel and pigment. No need to achieve uniform staining of the composition. The mixture should have an uneven color - one of the main conditions. Then, in the finished form, the material will have spots and streaks like natural marble.
• Step 2. Place the container on a vibrating table and remove excess air from the mixture. If there is no vibrating table, just shake it well several times.
• Step 3. Add water and a plasticizer (pre-dilute the plasticizer in a small amount of warm water) approximately 80% of the total. Stir thoroughly until a homogeneous composition is obtained. Then add the remaining plasticizer and water. Stir the mixture with a drill with a mixer.
• Step 4. In pre-prepared dried polyurethane forms, pour the resulting solution and cover the forms with polyethylene. To increase the strength of artificial marble, reinforce it with a wire - after the mixture is poured into shapes, drown the wire in them. Wait until it solidifies.

Concrete marble is widely used in landscape design, exterior decoration, in the manufacture of balustrades, columns, sidewalks, framing fountains, vases, flower girls, etc.

The undeniable merits of concrete marble

• The main advantage of artificial marble is its accessibility to the mass consumer.
• Light weight in comparison with natural material makes it possible to clad walls and surfaces placed at an angle. Marble concrete does not need additional processing. Depending on the requirements, the shape and thickness of the tile are initially set. In addition, using this material, you can recreate a relief surface without losing its perfect smoothness. For example, the front part can be stylized as sea ripples, wood, brick.
• The connection of tiles is carried out according to the principle of a puzzle, which creates all the conditions for a good adhesion between the elements and ensures high reliability of the entire formation. In addition to numerous forms, artificial marble can have a variety of colors.

Products that simulate natural stones have high strength, resistance to chemicals, environmental friendliness, shock and heat resistance, as well as other advantages. Artificial marble is made of concrete, gypsum and polyester resin  and is used not only for cladding houses, but also in the manufacture of countertops, stairs, window sills, fountains and much more.

To make artificial marble with your own hands, you need to decide on the technology of its production.

Cast marble

The basis for this material is polyester resin and any mineral filler (marble chips, crushed white quartz and other fine components). The latter allow to produce slabs stylized as granite, malachite, jasper and onyx.

To make cast artificial marble at home, you will need to prepare a solution:

1. Polymer concrete. To do this, mix 20-25% of the polyester resin with 75-80% of the crushed neutral mineral.
2. Butacryl. In this case, instead of the resin, AST-T and butacryl are used in equal proportions, after which 50% of silica sand or crushed stone is added to the mixture.

You will also need to prepare river sand, pigment, gelcoat and plasticizer. The manufacturing technology of artificial marble from resin includes the following steps:

1. Gelcoat the matrix for future artificial stone and let the mold dry.
2. Prepare the solution using one of the methods described above.
3. Put the liquid solution in the matrix and remove its excess.
4. Cover the mold with plastic wrap and wait 10 hours.
5. Remove the finished artificial stone from the mold and leave it outdoors for a while.

The hardened stone can be additionally sanded or left without machining.

Despite the simplicity of manufacturing such artificial raw materials, the casting method of marble production is of high cost, so it makes sense to consider other methods of creating stones.

Artificial gypsum marble is a gypsum mass, shuttered with a mixture of water and glue, which is polished until a mirror shine appears. Such “tinting” allows you to simulate such natural minerals as malachite and lapis lapis lazuli.

To produce this artificial marble will not require expensive materials. You can prepare it as follows:

1. Knead dry gypsum and wood glue in water.
2. Pour melted resin into the mixture.
3. Stir the composition and add pigment to it.
4. Stir the mixture again until it contains natural patches and stains.

Useful! If you want to get a product of a natural color, then you need to mix 200 g of white humilax, 1 kg of alcohol (technical) and 50 g of gypsum. To get a coffee shade, use orange humilax, and to create a black stone, add aniline paint.

1. Pour the liquid mass into the plastic matrix.
2. Remove excess mixture. To do this, sprinkle the solution with dry gypsum.
3. Wait about 10 hours and remove the finished product from the mold.
4. Treat the surface of the product with silica potassium to give the finished stone water resistance.
5. Dry the marble and polish it with a soft felt (you can also use specialized abrasive products that give the finished product a more saturated shade).
6. When the surface of the stone becomes almost mirrored - artificial marble will be ready.

Such production of artificial marble and mosaic is considered the most simple and affordable. Thanks to gypsum, the stones are very light and strong. Such products are successfully used in residential premises.

Artificial concrete marble

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

To create such a stone yourself, follow these steps:

1. Spread a dry matrix with a smooth surface with a moisture-resistant gelcoat and wait until the mold has completely dried.
2. Prepare the concrete mix and add clay or slaked lime to it.
3. Prepare the filler. To do this, mix 2 parts of river sand, 1 part cement, 80% water and add pebbles to the composition. In the resulting solution, it is also necessary to add pigment (1% by weight of the mixture) and knead the composition for artificial marble for 30-40 seconds. Mixing all components is recommended 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 transfer 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 the voids of the form should be filled.
6. Remove excess mixture with a spatula.
7. Cover the surface with polyethylene and wait until the composition hardens at plus temperature (depending on the thickness of the stone, it will dry from 24 hours to several days).
8. Remove the finished artificial plate from the matrix and process it with a grinder and a special transparent varnish.

If you decide how to make artificial marble yourself, then preference should be given to gypsum or concrete. However, you can purchase finished material:

• Ground marble (microcalcite). This raw material is made from chipped marble. This powdered 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. Besides marble chips  the composition of this material includes acrylic polymers, so that such a stone is light and flexible. Such marble can be easily cut with a knife and pasted over its walls. It is most popular for decorating irregularly shaped rooms.

In custody

The manufacture of artificial marble is different based on the material used (more on the video). However, no matter what source material you have chosen, you need to properly care for the stone. For example, to preserve the luster of the marble surface, use a soap solution (1 cap of any detergent must be added to 3 liters of water).

Recently, the technology of manufacturing concrete products with colored stains that imitate marble has gained great popularity. There is a logical explanation for this, because marble is able to give prestige and sophistication to the facades of buildings or to decorate the premises from the inside. In addition, the advantages of this technology include the fact that marble can be made of concrete at home.

General information

The technology for the production of artificial marble from concrete is quite simple, so every home craftsman can make such a material. However, some knowledge is still necessary.

If the work is done correctly, the material will turn out to be so similar to marble that an ordinary passer-by is unlikely to guess that, for example, an artificial stone was used for the fence.

In addition, this material has several advantages:

• Environmental friendliness;
• Excellent physical and mechanical properties;
• The technology of marble made of concrete without waste, which is an important factor;
• Ease of restoration;
• The price is much cheaper than natural marble;
• Good moisture resistance;
• The ability to obtain any color and any form of material.

Artificial marble technology

Materials

Before we begin to make stone, we should prepare a certain set of materials:

• Sand;
• Cement brand M500;
• Pigment - for these purposes, high-quality oil paint is suitable;
• Plasticizer is a special composition that, when added to concrete, significantly increases its characteristics.

In addition, you will need more forms in which the solution will be poured. For these purposes, it is best to use special polymer forms. If you can’t find them, you can use any other forms made of plastic.

For example, if you want to make window sills from concrete marbled, then you should look for suitable plastic trays. In extreme cases, you can execute the forms yourself by fastening plastic panels together.

It is also desirable to have a vibration table, which can be done with your own hands. If you will be engaged in the production of marble once, then you can do without it by shaking the mixture manually. Vibration will allow the solution to condense and eventually make a denser material.

I must say that the same technology can produce polymer concrete.

The only thing, instead of cement in this case, thermosetting resins are used as a binder:

• Phenolic;
• Furan;
• Epoxy et al.

Note!
  In the manufacture of polymer concrete, a larger amount of filler is added to the composition than in ordinary concrete mortar.

Marble making

After all the materials have been prepared, you can begin to work. The manufacture of artificial marble and polymer concrete begins with the preparation of the mortar.

Concrete mortar is mixed in a standard proportion - 1: 3. At the same time, calcium carbonate or other neutral fillers similar to it is best used as a filler.

If polymer concrete is kneaded, then a solution in the ratio of 1: 4 should be performed. Coarse fillers are used as filler.

In particular, crushed in the form of gravel or coarse sand are suitable for these purposes:

• Limestone;
• Quartz;
• Sandstone;
• Dolomite.

Further instructions are as follows:

• After the solution is ready, dye should be added.. I must say that diligently stir the composition until a homogeneous mixture is not necessary. To get a similarity to marble, it is better to do it casually, so that characteristic stains are obtained.
    You can experiment, for example, by adding a few drops of paint of different colors. In general, this stage can be called a creative process that allows you to feel like an artist and show your imagination.
• After the solution is colored, shake the container or place it on a vibrating table. If you spend time on the manufacture of this device, then in the future it may come in handy in the manufacture of paving slabs, cinder block and other building materials.
• Then, prepared in advance and well-dried polyurethane forms, pour the resulting solution and cover with a plastic wrap. To increase the strength of the material, it should be reinforced with wire. To do this, after the mixture is poured into molds, it is necessary to drown the wire into it.

• After the final, you should remove the resulting product from the molds and sand the surface. For these purposes, you need to use an angle grinder and diamond disc-cups. After performing this operation, the surface will become smooth, resembling marble as much as possible.

Here, perhaps, is the entire composition of the production of artificial marble from concrete. I must say that there are other technologies for the manufacture of artificial stone. Moreover, some of them are even simpler and do not require finishing polishing.

However, at home, the above method is the most affordable.

Note!
  Since the resulting material will be strong enough, it can only be processed with a diamond tool, in particular, in addition to the above grinding, an effective method is cutting reinforced concrete with diamond wheels, as well as diamond drilling holes in concrete.

In the photo - artificial marble in the bathroom

Use cases for faux marble

Most often, artificial marble is used to decorate fences outside. However, such material can be a great alternative. ceramic tile, for example, in the bathroom. In addition, "concrete marble" can be used as countertops in the kitchen.

It can also be an excellent decoration for fireplaces, which are not only the center of home comfort, but also a sign of luxury. If the interior of the room is made in a classic style, then the material can be used as a floor covering.

In any case, wherever you use marble, its use will be a sign of good taste and luxury!

Conclusion

From the video in this article, you can get more information on making artificial marble at home.

Marble, which has excellent aesthetic qualities, has always been a valuable material, but because of its high cost, it is rarely bought. Therefore, artificial marble was invented, which is not inferior in its characteristics to natural.

The current situation in the field of building materials, especially made of artificial stone, can be described as accompanied by growing demand. At the same time, beginning and experienced businessmen who want to engage in this production should not only satisfy such demand, but also stimulate it.

Basic properties

Artificial marble is a material that is made on the basis of acrylic resin and filler, imitating the properties and appearance of natural stone. It is environmentally friendly and wear-resistant, easy to operate and maintain. The substance is characterized by high strength, reliability, excellent aesthetic characteristics and most importantly - it is cheaper than natural. Various textures and colors make this material unique and popular in the construction market.

The scope of its application is wide, it is used for external surfaces (countertops, tables, window sills, bar counters), during construction, restoration of premises and in industry.

Manufacturing technology

The manufacturing process as a whole is simple. It consists in mixing the ingredients and placing them in a mold until hardened. Depending on the components, marble is divided into types:

1. injection molding;
2. liquid;
3. chipped;
4. gypsum.

Cast marble

He is one of the most popular species. It is a composite material made of mineral filler (quartz, marble chips), cured polyester resin and pigments, dyes.

Manufacturing technology lmarble:

1. Prepare forms - clean them from the previous cycle, polish, grease with a release agent.
2. Prepare the consistency by mixing all the components. The presence of pigments determines the final color of the product.
3. Pour the substance into specially prepared forms that will determine the future shape of the product (for example, the surface of a countertop or window sill).
4. The mold moves to the vibration platform for several hours, where it is processed to reduce the porosity of the material.
5. After hardening, the resulting marble is removed from the mold (about 12 hours).
6. If necessary, mechanical processing of the finished product.

The technology of manufacturing marble from concrete:

The technology for the production of artificial marble from concrete makes it possible to obtain a durable material that externally practically does not differ from natural stone. For its manufacture it is necessary:

1. cement;
2. quartz sand;
3. pigments, dyes;
4. plasticizers.

The resulting products have a streamlined glossy surface. After removal from the form, further processing is not necessary. Tiles using this technology are made from frost-resistant concrete in various author's forms, which imitates old paving stones or paving glossy surfaces. Such material is durable and reliable, does not lend itself to mechanical damage.

Liquid marble

This type of marble is one of the newest. decoration materials. It consists of acrylic polymers and marble chips. The result is liquid marble - a flexible, flexible, durable and lightweight material. It can be easily cut, covering them with different surfaces. It gives you the opportunity to align the curved walls, hide oversights and flaws. This material is faced with columns, arches, stairs.

Financial calculations

The amount to organize this business depends on many factors - the scale of the project, assortment, and manufacturing technology. Consider a rough financial business plan for faux marble.

Starting costs:

1. purchase of basic equipment - 120 thousand rubles;
2. inventory acquisition - 40 thousand rubles;
3. room preparation - 40 thousand rubles.

The production of cast and flexible marble requires the following monthly costs:

1. purchase of raw materials - 160 thousand rubles;
2. salary fund - 120 thousand rubles;
3. rent - 40 thousand rubles;
4. utility and tax payments - 60 thousand rubles.

The price depends on the thickness of the product, type and final product to be manufactured. For example, to buy a window sill made of cast marble costs 8800 rubles per square meter.

On average, the gross revenue of this type of enterprise will amount to 500 thousand rubles. (minimum threshold taken). In this case, the net income will be 120 thousand rubles. (500-160-120-40-60).

Given these production indicators, the payback period will be 2 months.

Business Registration

For the production and sale of products, you must register as an individual entrepreneur or LLC. Registering an IP is simple, with a minimum package of documents required. The procedure for opening an LLC is more time-consuming, but it opens up great opportunities and eliminates financial risk (since the founder of the company is responsible for the business only with the authorized capital, while the IP is the personal property). The choice of legal form depends on the volume of production, source of financing, distribution channels.

To sell products you will need:

1. Sanitary and epidemiological conclusion - a document that confirms the right to manufacture and sell products and indicates its safety;
2. Certificate of Conformity - a document confirming compliance of manufactured products with safety standards established by law.

Equipment

This business idea does not require the purchase of high-tech equipment. Since the manufacturing technology is simple, it is necessary to buy the following equipment for the production of artificial marble:

1. Mixer for mortar - used for mixing and turning into a homogeneous mass. The service life of the mortar mixer does not exceed 2-3 years, after the expiration of the terms it is better to purchase a new installation, since repairs and adjustment are not cheaper.
2. Vibrating table with a connected vibrator. Filled forms are installed on a table that is responsible for the absence of pores and bubbles inside the material.
3. Forms (from 20 pieces).