Many of us consider artificial stone to be a new material, however, it has been known to people since time immemorial. Ordinary clay brick, cement, gypsum and lime mortar are varieties artificial stone.

The popularity of this material began to grow after new polymer compositions and forms appeared that made it possible to use it for interior decoration and landscape design.

In particular, artificial stone can be used to make tiles for cladding walls and floors, steps and other elements of stairs.

It is used for the manufacture of countertops, decorative stucco and sculptural compositions, borders and paving slabs.

In terms of strength and durability, some types of artificial stone are not inferior to natural stone, surpassing it in ease of processing and ease of finishing. This material can be made into very thin tiles, which reduces its weight and reduces cost. For natural stone, such a thickness is unattainable due to its high fragility.

Not inferior to natural material in terms of color and variety of surface textures, artificial stone is more profitable to use for several reasons:

• it can be immediately made perfectly smooth, which eliminates expensive sawing, grinding and polishing operations;
• there is no need to transport it, since this material can be made with your own hands at the place of use;
• the amount of waste is minimal, since there are no losses for transportation and processing;
• In addition to a rectangular shape, it can be made figured or shaped, which allows you to finish surfaces exactly in place without additional adjustment.

Types of artificial stone

When considering the question of what artificial stone is made from, it is not difficult to choose a technology acceptable for use at home.

Depending on the raw materials and methods of processing, artificial stone is divided into the following types:

— Ceramic (tiles) – the manufacturing process requires the creation of high temperatures to roast raw materials and transform them into a monolithic conglomerate.

— Plaster (cast). It can be done at home. The costs of raw materials and production are minimal, however, such stone is suitable only for interior decoration, since it is not resistant to frost.

— Concrete molded. The cost of production is more expensive than gypsum, since the resource of molds for casting concrete is less. Suitable for self-production. Frost-resistant.

— Free-formed reinforced concrete. This artificial stone is made piece by piece, usually at the site of use (artificial cobblestones, boulders, slabs).

— Hot-curing polyester. In terms of its mechanical and decorative characteristics, it is superior to some types of natural stone, but the synthetic compound hardens only in a vacuum at elevated temperatures. It is not suitable for home production.

— Cold-hardening cast acrylic stone. Suitable for homemade. In the temperature range from +175 to 210 it is thermoplastic, therefore it allows additional molding after casting.

How to make artificial stone with your own hands?

This requires two basic components: mold and casting mixture. Home technology The production of artificial stone can be carried out both on a factory-made polyurethane mold and on a home-made silicone one. It all depends on the total footage of the finishing and the budget allocated for this work.

The polyurethane matrix is ​​quite expensive, but it allows you to make several hundred high-quality impressions. Silicone mold is more suitable for small-piece stone production and home sculptural crafts. Its resource usually does not exceed 20-30 castings.

For making your own silicone molds a set of natural stone or tiles is laid out on a horizontal, stable and flat surface, having previously covered it with polyethylene. After this, a frame made of wooden slats or plastic is placed on it. The height of its sides should be 1-2 centimeters higher than the height of the copied material.

The surface of the tile and the inside of the sides are coated with solid oil or cyatim. You can take the cheapest silicone - acidic. It is squeezed out of the tube into the mold in a spiral, starting from the center to the sides until it is filled.

To prevent the formation of bubbles, the silicone is smoothed with a wide fluted brush. It needs to be dipped in a solution of dishwashing detergent. Soap solution is not suitable here because it is alkaline and can ruin the acidic silicone. After filling the surface future form smooth it with a spatula, also moistening it in detergent.

Dry molds for making artificial stone at room temperature in a ventilated area. The drying rate of the silicone composition is approximately 2 mm per day.

Molding mixtures

Gypsum artificial stone

The mixture for gypsum stone is prepared from gypsum grades G5 - G7. It is made in small portions, counting on simultaneous filling of no more than two forms, since the setting time of this binder does not exceed 10 minutes.

Composition of the mixture: gypsum, citric acid to slow down hardening (0.3% by weight of gypsum), water - 60-70% of the volume of gypsum. The pigment is taken at the rate of 2 to 6% of the weight of the gypsum. The dosage of the coloring substance is selected on test samples of castings.

concrete stone

You can make artificial stone inexpensively and with high quality with your own hands from concrete. Unlike construction, here the initial composition of the components is slightly different: take 3 parts of cement for 1 part sand. The proportions of the pigment (you need to use an alkaline resistant one!) are the same as for gypsum stone.

The addition of polymer additives reduces the brittleness of this material and increases its abrasion resistance.

Cold hardening acrylic stone

This material is made on the basis of acrylic resin and hardener. The recommended volume of mineral filler to acrylic is 3:1. The amount of pigment is taken depending on the total weight of the filler (on average from 2 to 6%).

As an inexpensive filler, you can take gravel, stone chips or granite screenings. Before preparing the mixture, the filler is washed with dish gel, then calcined over a fire and rinsed with clean water.

The preparation process consists of three stages: first, the pigment is mixed with the filler. Then the acrylic resin is mixed with a hardener and a filler with pigment is added to it.

The time during which the acrylic mixture must be poured into the mold (from the moment the hardener is introduced into the resin) is no more than 20 minutes. The setting time of the mixture lasts from 30 to 40 minutes. The product requires 24 hours to completely harden.

If you are interested then the best materials They are made from concrete or acrylic. The concrete product is heavier and does not allow you to create surfaces as varied in pattern as when using acrylic resin. However, the low cost of raw materials and the simplicity of the casting process partially compensate for this disadvantage.

Release agents

For different types of artificial stone, different compositions are used to separate the form from the product.

For gypsum stone, the optimal solution is one consisting of artificial or natural wax in turpentine in a ratio of 1:7. To do this, add wax shavings in small portions, stirring, to turpentine heated in a water bath to +50 - +60 C.

For concrete stone, conventional lubricants are used (litol, emulsol, cyatim). Before pouring the acrylic composition, the mold is lubricated with a solution of stearin in styrene (proportion 1 to 10) or cyatim.

When using a homemade silicone matrix, it must be protected from deformation that occurs when the hardening gypsum stone and acrylic resin are heated. To do this, before pouring the working mixture, it must be placed in a tray with fine dry sand so that the thickness of its layer is from 2/3 to 3/4 of the height of the mold.

Useful video

Modern construction technologies make it possible to decorate facades using natural finishing stone. But the cost of such materials is quite high. Those who want to save money can make an artificial finishing stone from concrete. Wherein appearance stones made at home will be little inferior to the qualities of natural materials. Using artificial concrete stones, specialists manage to create amazing design solutions. If the rules are followed, the quality of home-made building materials will not be inferior to the characteristics of products created by professionals.

Areas of use

Externally, such materials look almost identical to natural stones. At the same time, the concrete that is used in their production is many times cheaper than marble, granite, boulders and others. natural materials. You can use such building materials for interior decoration and exterior decoration of buildings. Experts resort to artificial stone when performing indoor work, replacing ceramic tiles with it, decorating the appearance of sinks, fireplaces, window sills, furniture, etc. In addition, artificial stone and concrete are used to decorate architectural elements of large and small sizes. Many products can be created from this artificial material.

Advantages

Flaws

Such building materials have practically no disadvantages, since they are only inferior to their natural analogues in some characteristics. The disadvantages include the need for treatment with hydrophobic agents. Also, some artificial samples are not durable, but this only applies to agglomerates.

Manufacturing methods

When producing building materials, specialists resort to two methods: vibration casting and vibration pressing.

1. Vibration pressing. The technology is as follows: a concrete solution placed in a special form is processed with a special vibrating device - this makes the products as durable as possible. Vibrocompression is often used in the manufacture of sidewalk tiles.
2. Vibrocasting is used to create facing stones. The solution is poured into molds that replicate the texture of natural materials. Such forms can be plastic, polyurethane or plaster. It all depends on what kind of stone needs to be imitated. In this case, it is desirable that there be more than ten different forms. The more diverse the concrete elements are, the more natural the masonry will look. A quality product is determined by its texture: it is important that it be unique every three square meters.

Manufacturing technology

Specialists produce finishing materials using technology using molds made of polyurethane and plastic. First of all, you need to mix cement, resin and other components in a special mixer, then pour the mixture into prepared molds. To increase the strength of the building material, a metal mesh is placed in the solution. The next stage of the process is vibration compaction of the concrete solution, which is necessary in order to displace air and distribute all components of the mixture. Due to this, the top layer of material becomes stronger. Then you need to wait until the products harden (about a day). After this, the slabs can be removed from special containers.

Shape selection

Molds can be wooden or silicone. You can make molds of large or small sizes and any texture. Thus, you can realize your wildest ideas. For example, you can make an imitation of the seabed with shells or create a semblance of ancient arched openings or wood parts. The prepared solution should be poured into prepared containers. Cover them on top with polyethylene film and wait until the mixture is completely dry.

Preparing the Components

To make an artificial finishing stone, you will need various materials and tools. First of all, you need to prepare the forms. They can be purchased in specialized stores or made independently. To carry out the work you need a vibration stand. It is also necessary to purchase a release agent - it should be coated with the mold before pouring so that the finished product can be easily removed. In addition, you will need pigments that will help give the mixture the desired shade.

The required color can also be obtained by using dyes and pastes. In some cases, a heat gun is useful for decorating – it can be used to glue various parts and elements. In addition, you need a vibrating device. When producing concrete-based stones, cement, sand, and fiber fibers are used (allows you to create an imitation of brick and other materials).

Artificial stone production: 4 main business advantages + 11 pros and 3 cons + detailed plans business for the production of artificial stone and countertops from it.

Thanks to the development of technology, our lives become better and more convenient. You can also make good money from the production of countertops made of artificial stone.

Natural stone in construction is a strong and reliable material, but quite expensive. The technology for producing an artificial analog allows the price to be reduced significantly, while maintaining the advantages of natural stone.

Production of artificial stone is now growing and you can manage to take a good position in this market niche, as well as quickly develop your business through the use of products in a wide range of finishing and other repair work.

Is this business really that attractive?

When considering this type of business, it is important to weigh the pros and cons. While studying the artificial stone production business, we did not identify any serious shortcomings.

And here strengths business are convincing:

• growing demand,
• high profitability,
• small investment,
• wide scope of application.

Before making a production decision, it is important to clearly understand what we're talking about, and what niche to start occupying.

Artificial stone - its advantages and disadvantages

Artificial stone is a fake of natural stone. It looks the same; only a specialist can distinguish one from the other. It is made from a binder and filler. Depending on the required characteristics, the composition changes.

Advantages of artificial stone

• it is cheaper than natural;
• if necessary, its strength and wear resistance can be made higher than that of marble, and brought closer to the characteristics of granite - the strongest rock used in construction;
• low moisture absorption, which increases frost resistance;
• has less weight;
• easy to install and transport due to its many shapes;
• crumbles less, which makes it possible to make from it complex shapes with corners and curves to achieve sophistication in the interior;
• has a respectable appearance of natural granite or marble;
• allows you to provide the client with a huge selection of colors and textures;
• can be used for many types of construction and repair work, for the manufacture of furniture elements (countertops, sinks, tables, fireplaces, etc.) due to the capabilities of technology to impart the necessary characteristics;
• damage repairs and restoration are carried out on site;
• environmentally friendly material.

After listing all the advantages, the artificial analogue seems ideal. In fact, it is almost close to an ideal building material.

However, artificial stone also has some disadvantages.

• less durability than a natural one (but, in fairness, there are unlikely to be many who want to build a Colosseum that will last thousands of years);
• for the spectacular look of furniture, customers will have to pay more (the cost of artificial granite is much higher than MDF, laminated chipboard and other materials that are usually used to make countertops);
• acrylic artificial stone is widely used for making countertops, but it is easily scratched by cutlery and hot dishes cannot be placed on it; Agglomerated material does not have such disadvantages - it is only afraid of exposure to chemicals and abrasives.

Types of artificial stone and their areas of application

The most widely used are 4 types:

Porcelain tiles are the most reliable type.

It has high strength, frost resistance, abrasion resistance, chemical resistance, fire resistance, insulating, antistatic properties, and fire resistance.

Porcelain stoneware is used for cladding walls and floors inside and outside the building, paving elements for roads and sidewalks, and for the manufacture of fireplaces and stoves.

Colored concrete stone– imitates the texture of rock, but not its internal structure. Durable and moisture-resistant, it can additionally be equipped with reinforcing mesh.

Excellent for exterior cladding, but can also be used for interior wall decoration.

• Agglomerate is durable, but more elastic, moisture- and frost-resistant, and has a variety of colors. Used for interior work (tabletops, window sills), for facing work and sidewalks.
• Acrylic is durable, but less so than others, moisture-resistant, elastic, allows you to make a shape of any type and size without seams. Countertops, kitchen aprons, and window sills are made from it.

Production of artificial stone: detailed plan

150,000 rubles.
Payback period of the company: from 6 months.

What technologies are used to produce artificial stone?

The main materials for production are:

• binders (Portland cement);
• aggregate (coarse quartz sand, expanded clay sand);
• pigments and dyes;
• additives (plasticizers, polymer-latex additives, hardening accelerators, water repellents, chemical fibers for reinforcement and others).

Approximate consumption of components for production (per 10 sq.m):

• Portland cement – ​​60 kg;
• quartz sand – 200 kg;
• pigments – 1.5 kg;
• plasticizer – 0.6 kg.

Production technologies differ depending on the purpose of the product. We suggest you familiarize yourself visually in general terms.

Below are 2 videos showing home production and industrial production:

Home production:

Industrial production:

How should a production workshop be set up?

The production workshop takes up little space. To begin with, 40 sq.m is enough to set up a workshop and store consumables and the finished product.

For working equipment, a 380V power supply is required. And also the production technology involves the use of large volumes of water. The speed of drying of products depends on the temperature regime - in the cold season, heating and ventilation must be provided in the workshop.

The production of artificial stone is not noisy and does not harm human health or the environment.

Equipment for the production of artificial stone

• forms (also called matrices);
• vibrating table;
• mixer (concrete mixer);
• vibrating sieve;
• drill with mixer attachment;
• auxiliary tools: sandpaper, buckets, trowels.

It is worth dwelling separately on the forms. They can be made of silicone and rubber (not for artificial cement stone), formoplast (cheap, but unsafe for health), polyurethane (durable and environmentally friendly).

Forms (matrices) can be purchased, made to order, or made independently.

Instructions for making your own can be found in the video.

Please note that the equipment presented for the production of artificial stone, as well as the list of components, may differ depending on the choice of production technology and product requirements.

Company registration and personnel

The choice of organizational and legal form depends on the planned scale of the enterprise. This will do to get you started. No additional licenses required. The registration process takes 1 week.

To produce small batches, two workers will be enough: one trained specialist and one assistant.

Sales of products

Your target audience is construction and repair companies and Despite the growing demand, there are also enough offers, since this type of business is very attractive for both small and large businesses.

However, not everyone can correctly offer products and promote their business. Yours the main task– personal meetings with managers or owners of shops and companies and competent presentation your production.

Here are some tips to achieve maximum quantity transactions:

1. Make a business card website with high-quality photographs of your products and a short and understandable price list.
2. Order paper business cards.
3. Make product samples.
4. Be prepared to answer questions that arise clearly and clearly - you must know your product, production time and all its characteristics “by heart”.
5. Offer a good discount on the first batch.

Investments in business. Payback period

Franchise offers have already appeared on the market, or, for example, from the company “SISTROM” (http://www.sistrom.ru/prajs_list).

Let's estimate the payback period

• Having a minimum set of equipment and 2 workers, you can produce 120 sq. m. per month;
• cost price 120 sq.m. artificial stone on average - 9,600 rubles;
• regular business costs: (raw materials) + 30,000 (salaries) + 20,000 (rent) + 10,000 (utilities) = 69,600 rubles;
• The average price on the market is 800 rubles. for 1 sq.m. (96,000 rubles for 120 sq.m.);
• the profit in this case will be 26,400 rubles.

The average payback period for the project is 6 months.

Production of artificial stone countertops: detailed plan

Capital investments in business: 155,000 rubles.
Payback period of the company: from 2 months.

Tabletops made of artificial material are increasingly gaining popularity among furniture manufacturers due to:

1. Their aesthetic properties (can be made without visible seams, in various shapes and colors).
2. High strength characteristics.
3. Hygienic indicators (easy to care for, prevent the appearance of fungus).

The production of countertops made of artificial stone can be established from ready-made slabs, supplied to the market in a wide range of colors and sizes.

Detailed technology for making stone countertops is shown in the video:

You can also set up the production of cast countertops:

Of course, by setting it up, you will sufficiently reduce the cost of the product. However, this approach requires good technical training and professional workers.

Below we will look in more detail at the option of producing prefabricated countertops, which we recommend for starting a business.

Tabletop production room, tools and equipment

The workshop must be spacious, at least 30 sq.m., well ventilated and heated.

Required tools and equipment:

• milling cutter from 1600 V;
• Grinder;
• jigsaw (without pendulum motion);
• assembly tables;
• consumables (sanding papers, tool attachments, polishes, glue guns, clamps, trimmers).

Sales of products

Stone countertops are in demand among furniture manufacturers. You will have to establish cooperation with them. Approach to conducting successful negotiations similar to that described above in the section “Production of artificial stone - Sales of products”.

Investing in a countertop business

All regular investments (purchase of materials, wages of workers) can be made from the customer’s prepayment.

• With a minimum set of equipment and two workers, you can produce 15 countertops per month;
• average cost: 75,000 (raw materials) + 40,000 (salaries) + 20,000 (rent) + 10,000 (utilities, taxes) = 145,000;
• the sale of stone countertops will bring an average of 225,000 rubles;
• the profit in this case will be 80,000.

The average payback period for the project is 2 months.

Beautiful appearance, environmental friendliness, excellent sound-absorbing and heat-insulating characteristics, as well as resistance to high and low temperatures - all these qualities are inherent in artificial stone, which has become widespread in the modern building materials market.

This is easily explained by the affordable cost of the products, the ease of finishing work, as well as the ability to implement any design solutions. Artificial stone can be given any color and texture you want, and it fits perfectly with almost all types of interior decoration.

Why is the production of decorative stone a highly profitable and in-demand type of business? The low level of competition in this niche, the demand for the product on the market, the low purchase cost of raw materials, minimal energy costs and the simplicity of organizing the work of the enterprise make this type of activity attractive to every person who wants to open a profitable business.

What is artificial stone?

It is very convenient to work with artificial stone when performing finishing work, which is why it is popular among craftsmen and customers. This material is used for decorating interiors and exteriors of buildings. It is a special tile for covering various surfaces, the texture of which completely imitates brick or natural stone.

The production of artificial stone is carried out by casting, for which various mixtures are used, which are placed in special molds. The composition of the solutions can be prepared on the basis of porcelain stoneware, gypsum, acrylic, quartz agglomerate, concrete and other compounds.

Important: for interior decoration, decorative stone made from gypsum, agglomerate or porcelain stoneware is used. For external wall cladding optimal choice are products made of concrete, since this material is highly resistant to external aggressive environments and long time maintains an attractive appearance.

Exist various ways production of artificial stone, which makes it possible to produce facing products whose characteristics are in no way inferior to natural materials, moreover, the decor is much cheaper and lighter in weight.

To get an artificial stone High Quality, manufacturers use dyes exclusively on a natural basis. During manufacturing, they give the products the desired color, which does not fade when exposed to sun rays for many years. Artificial products for cladding have not only different compositions, but also shapes, while the stone can be made in the form of decorative cobblestones, bricks or tiles, which allows you to create beautiful original masonry.

Kinds

Depending on the type of cladding, natural stone chips, hardeners and polymer resins can be used to prepare mixtures. Let's consider the types of artificial decor that are widely used in construction and interior decoration, which are usually distinguished by manufacturing methods and materials used:

• Agglomerates. This type artificial stone is made from quartz sand, granite or marble chips, natural pigments and limestone. Polyester resins are used to bind these components. The main advantage of conglomerates (this is also the name of this type of cladding) is the high strength of the products and increased resistance to temperature changes. This material is widely used in decorating various surfaces; countertops, bathtubs and other products that require increased impact resistance are made from it. It is worth noting that agglomerates are not recommended for use in underfloor heating systems, since the resins that bind the stone and other additives are deformed during heating.

• Acrylic artificial stone. This material is usually classified as conglomerates. It has high strength, elasticity and allows you to get a product of any shape and size. Acrylic is used to make countertops, window sills and kitchen splashbacks. The material is highly moisture resistant, safe for human health, easy to maintain and can be easily restored in case of mechanical damage.

• Concrete molded. The material for the production of concrete stone is a cement-sand mixture. By adding natural pigments, the attractive appearance is maintained for a long time. Concrete stones are not afraid of frost and are used for walls and plinths outside buildings.

• Concrete monumental. This stone is made using the free-forming method with mandatory reinforcement of the product. As a rule, this method is used directly at the site of application of artificial decor. Cobblestones, boulders and stone slabs that have a natural appearance are produced individually from reinforced concrete.

• Gypsum cast. Finishing cast stone from gypsum is made using minimum costs. It is made only for decorating the interiors of buildings, since it is afraid of moisture and is not resistant to low temperatures. The mold method is ideal for producing artificial stone at home.

• Porcelain tiles. The production of this type of artificial stone has certain difficulties, since it requires the use of specific equipment, large areas, and a significant amount of electricity is consumed for its production. The composition of porcelain stoneware includes certain types of clay, natural dyes, feldspar and all kinds of mineral additives. All components are thoroughly mixed, after which the composition is compacted in a vibropress and fired. Ceramic artificial stone is highly durable, and its texture can be very diverse. It is used for finishing various surfaces, making steps, floor coverings, sinks and other products.

• Hot curing polyester stone. The decor is made using fillers of a mineral nature. For this reason, the compound will harden exclusively at high temperatures, for which vacuum ovens are used. This method making stone is not suitable at home due to the complexity of the technological process and financial costs. Polyester products are in no way inferior to their natural counterparts in strength and decorative qualities.

Products made from liquid granite are also widely used. Its preparation is carried out on the basis of a binding gel component, which is called gelcoat, and mineral fillers. This technology allows you to give the finished product complex shapes. You can use liquid stone for countertops, sinks, decorative elements or for making window sills, which are durable and original. In addition, liquid stone with your own hands allows you to make various products by casting, for which special molds are used. The finished composition is poured into them, then the “stone” hardens, after which it is removed from the matrix and subjected to mechanical processing.

Advantages and disadvantages

Above we have listed the advantages that artificial stone has. Here we should also add the excellent thermal conductivity of this material. If you decorate a room with such decor, it will be warm even in winter.

Artificial stone is resistant to mechanical stress, so products made from it do not break and they rarely chip. This material has no pores or microcracks, which completely eliminates the development of pathogenic microorganisms on its surface. The advantages also include:

• ease of product installation and transportation;
• the ability to carry out repair and construction work of any complexity;
• production of decorative elements and furniture of any configuration;
• ease of repair of damaged products.

Important: Please note that damaged surfaces are restored on site, so there is no need to take them to specialized workshops.

But like every material, artificial stone has some disadvantages:

• Products made from it have a significantly shorter service life compared to natural originals.
• If the customer wishes to make furniture elements from artificial stone, the cost of the sets will increase significantly. For example, a porcelain stoneware countertop costs more than the same element made from laminated boards or plywood.
• Acrylic “stone” surfaces look very beautiful, however, they are susceptible to scratches and are susceptible to exposure to high temperatures. Therefore, countertops made of this material are in less demand among buyers, since hot dishes cannot be placed on them and they quickly lose their attractiveness. For these purposes, it is better to use artificial agglomerated stone.

Artificial stone manufacturing technology

To make artificial stone yourself, no lengthy training is required. To produce decorative products, you need the preparation of cement mortar, as well as natural pigments. various colors, hardeners and plasticizers.

The technology for manufacturing artificial stone is quite simple, for this reason every novice entrepreneur can organize production. The most commonly used methods are vibrocasting or vibrocompression. If you use vibration casting technology, you will not need to purchase expensive equipment to start a business. This method allows you to obtain a wide variety of products, different color scheme, as well as excellent quality of finished tile surfaces. Preparation of the compound using a brick press is characterized by the low cost of artificial stone, and the entire production process is fully automated.

Important: There is a large amount of video material on the Internet dedicated to the production of artificial stone. It is necessary to first assess the conditions in which the production processes of the future enterprise will take place, which will allow you to decide on the choice of technology.

The production of artificial stone deserves special attention, the production of which will require plaster and polyurethane molds. This type of activity is considered highly profitable, since a 30-kilogram bag of raw materials costs about 340 rubles, while the price of the finished “stone” on the market fluctuates around 600-700 rubles per 1 m². From it you can make 8-10 “squares” of decorative cladding, which in monetary terms is about 6 thousand rubles. The benefit is obvious. The technological process is characterized by high speed and simplicity. The dry gypsum mixture is filled into the tank, after which it is diluted with water to such a state that the resulting solution itself spreads into the molds. Please note that liquid gypsum fills even the smallest depressions in the matrix, so no special equipment is required to prepare the solution. After a quarter of an hour, you can remove the “stone” from the mold, after which it should dry completely. After this, coloring of the finished product is allowed.

The good thing about gypsum “stone” is that it can be given color at the customer’s site, so there is no need to spend money on purchasing pigments. You can sell both unpainted plaster blanks and sell decorative elements, giving them a certain shade.

How to start the production of decorative stone?

Let's consider the main stages of starting the production of artificial stone.

Business registration

Entrepreneurs need to officially register their activities with the Federal Tax Service, for which they will have to register an individual entrepreneur (best). The following documents must be submitted to the tax office at your place of residence:

• passport of a citizen of the Russian Federation (copy);
• birth certificate (copy);
• application for opening an individual entrepreneur;
• receipt of payment of state duty.

Important: If you plan to organize a large production with the involvement of hired employees, it is recommended to form an LLC. To start activities, you will need to obtain permits from the fire inspectorate and sanitary and epidemiological station.

Since the production of artificial stone does not require businessmen to have certificates and licenses, this allows significant savings on obtaining permitting documents. As for the choice of taxation system, entrepreneurs can opt for UTII or simplified tax system.

Search for premises

Before starting production, you will need to find appropriate premises. They will house the equipment. As practice shows, production space outside the city limits can be rented much cheaper.

It is necessary to find a building for the enterprise, which will have premises for production, a warehouse for finished products, drying of products, as well as a workers’ living room. The total area must be at least 100 m². It is advisable to provide production with a good lighting and ventilation system.

Equipment purchase

For obvious reasons, most of the costs are the purchase of production equipment. For equipment you will need:

• vibrating table;
• vibrating sieve;
• polyurethane molds;
• drying chamber;
• concrete mixer.

In addition, you will have to purchase shovels, an electric drill, buckets, and spatulas. The purchase of a concrete mixer and a vibrating table will cost about 70 thousand rubles. As for matrices, for 1 unit you need to pay about 8 thousand rubles. At the initial stage of production, 5-6 pieces will be required. You can make matrices yourself, which will save you money. This will also make it possible to come up with new models of facing materials and expand the range of finished products.

Purchasing materials

Depending on the type of technology chosen, you should purchase raw materials for the production of artificial stone. If you plan to produce gypsum products, you will need gypsum in bags, powder citric acid(0.3% of the total mass), which slows down the hardening of the composition, and pigment. It needs about 5-6% of the total volume of the prepared mixture.

Artificial concrete stone requires the preparation of a cement-sand base. This requires cement and sand in a ratio of 3:1 (not to be confused with preparing a building mixture!). You will need the same amount of dye as in the case of making gypsum mortar.

If you plan to produce cast acrylic decorative stone, you need a hardener and resin. To prepare the compound, you should add a mineral filler. Its share, including the dye, is 3 parts of the finished mixture. The pigment in the mixture should not exceed 6% (standard ratio: 71% filler, 20% acrylic resin; 5% hardener, 4% natural dye).

Recruitment of working personnel

To start production, you will need to hire two people, one of whom will be a handyman. This employee supplies the necessary materials, prepares solutions, and also loads the finished stone. Another employee must be fully proficient in technology production process, maintain equipment, and also monitor the quality characteristics of the finished stone. If a large production is planned, in this case it will be necessary to invite a technologist who will be able to develop a unique recipe for the preparation of decorative stone, establish production technology and keep all processes of the enterprise under control.

Conducting an advertising campaign

An advertising campaign should be carried out when the exact range of finished products has been determined, selling prices have been established and possible production volumes have been determined. Initially, you need to create a business card website, where you should place high-quality photographs of images of the finished stone, a price list, delivery conditions and contact information.

It wouldn't hurt to make business cards to hand out to all potential customers. It is recommended to produce and show samples of finished stones to customers, which will allow them to evaluate the quality of the products. It is important to know the range of your enterprise and specifications all types of stone offered.

The work of your enterprise must be announced in the media (print, television, radio). Also, to promote your business, it is worth creating thematic communities in in social networks, which will allow you to quickly attract target audience(people interested in purchasing artificial stone). As an option, you can offer wholesalers individual terms of cooperation, which imply some discount, short production and delivery times.

Search for sales channels for finished products

How and to whom to sell the finished artificial stone? First of all, it is a specific product that is aimed at construction and repair organizations, as well as retail outlets for the sale of finishing materials.

Despite the demand for decorative stone in the construction market, many entrepreneurs do not know how to properly present their products and set up sales channels. The main task of every businessman is to establish relationships with the leaders of the above-mentioned organizations, personal communication with them about upcoming cooperation and the presentation of favorable partnership conditions.

IN mandatory it is necessary to take part in various events and exhibitions that are dedicated to the popularization of the construction business. This will allow a large number potential clients to learn about the work and products of your company. You should also establish collaborations with design firms, companies that offer architectural services, and building materials markets.

Production of artificial stone - financial plan

Before starting an enterprise, it is necessary to calculate the expenses and possible income in the future. This is not difficult to do. For example, let’s take the calculation of the profitability of products made from a cement-sand mixture.

To prepare 1 m² of artificial stone, you need 6 kg of cement (35 rubles), 19 kg of sand (15 rubles) and 60 g of plasticizer (2.5 rubles). You will also need to consider:

• electricity costs;
• fare;
• depreciation of the matrices used.

It turns out that the cost of 1 “square” of stone tile is about 73 rubles, and its market value can exceed 700 rubles. It is imperative that as production capacity increases, you should have your own team of builders and finishers and offer their services to your customers. This will allow you to earn additional profit.

As for production costs, we note that the most expensive purchase will be the purchase of a vibrating table, which will cost 50-70 thousand rubles. You will also need to take into account the costs of:

• rental of production space – up to 20 thousand rubles per month;
• desktop – 10 thousand rubles;
• equipment and electric drill – 15 thousand rubles.

To open the middle manufacturing enterprise, at the initial stage you will need about 350 thousand rubles. As practice shows, a business pays off by the end of the first year of operation.

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To summarize, we note that the production of artificial decorative stone is a highly profitable and low-cost type entrepreneurial activity. It is worth considering combined production options, where, along with the facing material, countertops, sinks and other decorative elements for finishing the premises will be produced. Only the production of high quality products guarantees the success of the enterprise.

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The technology and equipment have been around for over 50 years. Calibrated products made from cement-sand or gypsum mixtures of any surface texture are called artificial or decorative stone. It is used in all areas of construction: from the construction of fences, paving paths and to interior decorative finishing.

Advantages of artificial stone

The main advantage of artificial stone over natural stone is the low cost and uniformity of the products, which makes their installation easier. Newest technologies using airbrush equipment, they allow you to apply a pattern to the surface of the stone that most accurately imitates the natural texture.

The simplicity of the technology for manufacturing artificial stone, the availability of materials and equipment for organizing the production process, plus the demand for products in the construction market are the main factors that allow a novice entrepreneur to start his own business with minimal risk.

The entrepreneur is not limited by the choice of sizes and textures of the stone produced. Each type of product has its own niche in the market. At the first stage, you need to understand the minimum required set of equipment and materials that are needed to start your own production.

Production room

For production, first of all, it is necessary to prepare a room in which the equipment will be placed and finished products will be stored. IN ideal it should consist of 3 separate parts:

• basic production room;
• warehouse for storing finished products;
• warehouse for consumables.

The work shop in which the production equipment is located must have an area of ​​at least 50 m2 and be heated.

Space is necessary for comfortable movement of workers and convenient placement of equipment. To winter time the solution did not freeze, the air temperature in the workshop should not be below 00C. The optimal range is 15–250C.

The production premises are supplied with water supply and electrical communications with a voltage of 220–380 V for connecting equipment.

Warehouses must be connected to production workshop. The heated finished product warehouse is equipped with forced ventilation. The air temperature in it is maintained at 15–250 C. The warehouse area is calculated depending on the planned volume of products.

Production methods

There are several ways to produce decorative stone. The simplest and most accessible is vibration casting. Vibrocompression is mainly used for the production of cinder blocks. To organize full-fledged production, you will need to purchase expensive equipment. There are manual vibratory pressing plants, but they are used to produce stone for their own needs in small volumes.

Production by vibrocompression is cheaper in terms of the cost of consumables and energy costs.

In addition to the equipment for stone production, these technologies differ:

• product properties;
• surface texture;
• the ability to manufacture elements of complex shapes.

Stone made by vibration pressing has a specific “raw” surface, and the shapes are limited to a monolithic small size.

Vibration casting has great decorative possibilities and gives a smooth front surface of the stone. This method is used to produce decorative quality elements, fence sections, and countertops.

Stone made by vibration casting is well polished and painted.

Equipment for production of vibration casting

For the production of artificial stone by vibration casting, high-tech and expensive equipment is not used. Many craftsmen make the main working units with their own hands:

• vibrating table;
• concrete mixer or mortar mixer;
• vibrating sieve;
• precision weighing equipment for dosing pigments and plasticizers;
• work tables or workbenches;
• plastic containers for dispensing water and bulk materials;
• plastic molds for casting stone;
• wooden pallets for stacking filled forms;
• hand tools (ladles, trowels, spatulas, trowels, wheelbarrows).

The vibrating table is used to remove air bubbles from the solution in injection molds and compact it. If the form has a small pattern, the vibrating table ensures full penetration of the solution into all its parts.

Vibrating tables are often made independently. Depending on the location of the motor with the eccentric and their number, vibrating tables come in 2 types: with vertical and horizontal vibration.

A vibrating sieve is used to separate large fragments from bulk materials. To produce high-quality stone, the raw materials must be homogeneous. If the stone is polished, flaws will appear in areas of large fragments. The equipment is equipped with different types of meshes, which differ in cell calibration.

A construction mixer (mortar mixer or concrete mixer) is a device for producing decorative stone, which can be purchased or rented. The quality of the solution depends on the thoroughness and uniformity of mixing the ingredients.

Do-it-yourself mold making

Purchased because for continuous production cycle you will need 50 or more matrices of the same type. But for exclusive elements you can make them yourself:

• a master model is created from plaster;
• then a box is made from sheet metal or wood according to the dimensions of the model;
• the model is fixed in a box and filled with Por-A-Molda polyurethane compound;
• After a day, the frozen form with the imprint of the master model hardens. It is removed and used to cast stone.

Over time, the surface of the molds wears out, and the sets are updated by purchasing or making new ones.

Necessary raw materials for production

Artificial stone is made from a cement-sand mixture with the addition of fine crushed stone (for paving slabs) or from gypsum polymer mixtures.

For production you will need the following materials:

• cement;
• crushed stone;
• sand;
• gypsum polymer;
• chemical compositions (plasticizer, coloring pigments, oil for molds and acid for cleaning them);
• fiberglass;
• reinforcing metal mesh.

Gray or white cement is used, depending on the color options of the stone. Gray cement is used for coloring in the mass, and white cement is used for surface drawing.

Gypsum polymer is a mixture of gypsum and polymer, which reduces fragility, increases water resistance, and increases bending strength.

Monochrome products are obtained by dyeing in the mass. By applying paint with a compressor, brushes or airbrush equipment to the front surface of the finished element, a natural pattern that imitates natural materials is achieved. This technique requires a lot of experience.

Working staff

To establish a continuous process, which includes formulation development, production of artificial stone, packaging and management, the entrepreneur needs to think about the staff.

What to do first

The technologist, in addition to developing technical specifications, is engaged in the manufacture of new models and forms, selects equipment and controls the quality of products.

Continuous work process is ensured by two or three teams of 4 people. in each.

Packers ensure the formation of finished pallets in the warehouse and their proper storage, and managers ensure the sale of products.

A new entrepreneur usually performs the function of production manager himself, supervising the work of all employees and purchasing raw materials.

Production technology

The technology for producing artificial stone by vibration casting includes the following stages:

• preparation of the mixture;
• dye additive;
• pouring the mixture into half the mold;
• shaking on a vibrating table;
• reinforcement process;
• pouring the second layer of the mixture;
• repeated shaking on a vibrating table;
• transferring forms to drying.

The sand is sifted on a vibrating sieve. The solution is prepared from one part cement, three parts sand and one part water. First, water is poured into the concrete mixing equipment, then dry ingredients, pigments and plasticizer are added. The finished mixture should have the thickness of sour cream.

When producing colored artificial stone, to reduce the cost of production, the molding mixture is mixed in two concrete mixers. In one, a colored solution is prepared, in the other - a regular one. When filling out the form, the first layer is the tinted compound, and the second layer is the regular one.

After pouring the first layer, a reinforcing mesh is placed into the mold. Fiber fiber is added to the mixture during the mixing process.

For better adhesion of the stone to the mortar and the surface to be finished, stripes are applied to the freshly poured concrete mortar with a trowel-comb.

The solution hardens within 12 hours. The molds are stacked on pallets through spacers. After drying, the resulting artificial stone is removed from the molds and laid out in the warehouse until the concrete finally acquires strength.

After removing the stone, the molds are washed to remove any remaining solution. Dried deposits are removed with hydrochloric acid. Before reusing molds for making artificial stone, their surface is lubricated with special oil.

Equipment for the production of countertops

The manufacture of countertops is a high-tech industry. To organize it, you will need more expensive equipment, which is ready-made lines. If you have an idea to master this process yourself, then in addition to the specified equipment for vibration casting you need to purchase:

• milling cutter;
• grinding machine;
• jigsaw

When making countertops yourself Special attention paid to the reinforcement of the poured material, high-quality milling and grinding. To obtain a smooth surface, bulk materials are added to the solution, passed through the finest mesh of a vibrating sieve.