How you can make a sink from artificial stone with your own hands, and what are its features: the sequence of work. How to make a do-it-yourself artificial stone countertop - we will show and tell Liquid artificial stone for countertops

The countertop is a convenient horizontal work surface, which is usually installed in kitchens. It is easier to cook food and do other household chores. Instead of buying this thing in stores, you can try to build it yourself based on artificial stone.

Drawings and dimensions

Before constructing a countertop yourself, you need to make a ready-made formwork. If the product is repeated already existing, then the template is made in accordance with it. If the shape of the new thing is more complicated, then before creating the formwork, you will need to complete its drawing. First, it is done on a scale, and then transferred to the base, which has the dimensions of the future product. An example drawing for construction is shown in the picture:

To create a drawing, you must first create an outline on which the dimensions will be marked. They must be removed from the place where it is planned to install the manufactured product. The tabletop can be divided into several equal parts if it is installed on kitchen set corner type. In this case, the formwork still remains alone, but it is separated by jumpers. This option is especially relevant when a concrete mixture is used in the work, since large products are formed on its basis.

If the countertop has right angles, then you can make a template for it directly on the spot, without removing the dimensions. In this case, rails of the same length are used, laid out along the old one, and linked together. After that, the manufactured template is moved to a smooth big table, where the required part will be assembled.

As the bottom of the formwork, you can use the old surface. In this case, you need to make sure that the base is strong enough. The walls are fixed on the end sides of the old table.

Necessary tools and materials

The simplest option is to use sheet acrylic stone. In this case, there is no need to create formwork, since the artificial stone is already ready for use. Depending on the dimensions of the product, 1-2 sheets are enough. Standard sizes it is 3760X760 mm, while the thickness varies from 3 to 12 mm. The higher it is, the stronger and stronger the material. It is also easier to handle.

Moisture resistant plywood 3 cm thick is also used. Chipboard or MDF is not recommended, because under the influence of moisture they tend to swell. This causes damage to the stone or its deformation.

To bond these two materials together, a two-component adhesive is required. Approximately 150–200 ml of the substance is spent on each sheet of acrylic stone.

To others necessary tools relate:

• electric jigsaw;
• circular saw for cutting plywood sheets;
• clamps;
• guides;
• roulette;
• ruler;
• building corner;
• pencil;
• Sander;
• milling manual machine equipped with a milling cutter based on hard alloys;
• electric drill;
• glue gun;
• a vacuum cleaner.

Step by step instructions for making

Acrylic product dimensions should be calculated as accurately as possible. Each measurement should be immediately moved to the drawing. Washing openings and panels for cooking are necessarily indicated there. If necessary, they are also performed for a mixer or other kitchen utensils.

In order not to be mistaken when transferring dimensions, you should make a template that has the natural dimensions of the countertop. As a material, it is best to use cardboard, the length of which can be increased by connecting the sheets with tape. The creation procedure consists of the following steps:

How to polish

To give the acrylic stone a more natural look, it is necessary to polish the entire product, and mill the end border. The shape is selected based on the thickness of the acrylic. Usually, rounding is enough for countertops, but there are also more complicated reliefs, used mainly for dining rooms or living rooms. After milling, the edges are wiped with sandpaper of medium grit, then with the same material, but already moistened.

The top side of the tabletop is polished in the same way as the ends. To grind a large surface, use an eccentric type grinder with interchangeable nozzles. Polishing is done carefully, without emphasis, since the acrylic material interspersed with stones may lose some of the plastic on its surface.

A do-it-yourself artificial stone countertop is easy to manufacture. It looks great and saves money.

Acrylic artificial stone consists of polymers (methyl methacrylate, polymethyl methacrylate, aluminum oxide) and mineral additives that form the color and pattern, such as sand, glass and coloring pigments. The main component of acrylic artificial stone is polymethyl methacrylate, the greater its content, the stronger and better the finished product.

A bit of history

Acrylic artificial stone - an environmentally friendly and safe material for human health - was invented in 1962 by DuPont for the production of human bone prostheses. But it gained popularity and distribution when it began to be used for the manufacture of work surfaces of countertops and window sills. In 1981, DuPont's patent for exclusive production expired, and other companies, such as Samsung and LG, began to produce acrylic artificial stone. The growth of competition favorably affected both the quality of the material and its price.

Today, acrylic artificial stone is produced in the form of 3680 × 760 mm sheets with a thickness of 12 mm. There are sheets of other sizes, but they are less common, as they are not suitable for making countertops and window sills.

How is acrylic artificial stone processed?

Cutting and milling
Acrylic artificial stone is cut with aluminum discs, milled with milling cutters for wood, if it is necessary to drill a sheet, then this is done either with drills or crowns for metal or wood.

thermoforming
If it is necessary to give the countertop a complex shape, to make a sink or sink from acrylic artificial stone, then the material is heated to 180 degrees. It becomes plastic, and the master can create products of various shapes.

Creating an aesthetic edge
The thickness of a standard acrylic artificial stone countertop is 40mm, and only 12mm of that is an acrylic sheet. The remaining 28 mm is a substrate made of MDF, plywood or other materials. To make the product look like it is completely made of acrylic stone, the master forms an edge, that is, pastes a piece of material over all visible parts. It is impractical to make a countertop entirely from acrylic artificial stone: this increases the cost and weight of the product, but does not give it additional useful properties.

Substrate fabrication
For the manufacture of substrates, MDF, chipboard, plywood, cellular polypropylene and other materials are used. Our company offers substrates made of MDF (for kitchen worktops) and plywood (for bathrooms and other rooms with high humidity). The substrate is made in two ways, depending on the type of construction:

1. Whole backing. It is chosen when the finished countertop or window sill is not mounted on a furniture base, but stands on separate legs, hangs on brackets or is used as a bar counter (it rests on one wall and on the leg of the bar counter). The master saws through the inside of the substrate so that it remains flexible.
2. Substrate of several elements. If the substrate is not solid, the craftsman makes stiffening ribs from plywood or MDF 70 mm wide and passes them along the perimeter of the product and along all the bases on which the countertop will lie.

Installation of products

The tabletop (one-piece or consisting of several parts) is delivered to the customer's site, after which the master proceeds with the assembly. There are several mounting options depending on the product that the specialist will work with.

Windowsill
Window sills cannot be installed on mounting foam, plywood or MDF substrates, only on concrete screed or other solid foundation, which the builders must prepare in advance. The masters themselves, involved in the manufacture and installation of window sills made of artificial acrylic stone, do not prepare this surface.

Solid top
Small solid countertops are assembled directly in the workshop, then the craftsman brings the products to the site and attaches them to the base.

Multi-part table top
Large, L-shaped, U-shaped countertops consist of several parts. The dimensions and shape of such countertops do not allow them to be assembled in the workshop and delivered to the facility in ready-made. Therefore, the assembly takes place directly at the place of operation. The parts of the product are installed on a base, for example, on a kitchen set, bracket, etc., after which they are glued together so that the joints are not visible.

How are seams handled?

1. The master mills two parts that will be glued together, that is, he makes a mirror joint. Thanks to this procedure, the parts perfectly converge with each other without any gaps and gaps.
2. The junction is reinforced with a piece of material, that is, a piece of material 12 mm thick and at least 70 mm wide is glued from the bottom of the countertop or window sill.
3. The master wipes the place of the intended gluing with acetone, removing dirt, dust, grease stains or other elements that may affect the quality of the gluing.
4. The master places the parts opposite each other, leaving a gap of 1-2 mm between them, after which he pours special glue into this gap.
5. The master tightens both parts together with clamps. It is important to pull the parts together so that there are no cracks or gaps left: you can’t tighten them too much or not too tight, otherwise the seam will be noticeable.
6. The glue dries in about 20 minutes, after which the master polishes the joint and removes excess glue.

1. You need to clean the countertop or window sill with ordinary soap or gel-based detergents. Do not use abrasive products, they can leave scratches on the surface.
2. Do not allow moisture (especially regular or in large quantities) to get on the inside of the countertop.
3. Do not pour boiling water into the sink made of acrylic artificial stone. If such a need arose, first turn on the cold water.
4. Old, dried-on stains can be removed with non-aggressive acids, such as vinegar or citric acid. If this does not help, you can try to scrape them off the surface, but this must be done carefully, otherwise there is a risk of scratching the countertop.
5. If the countertop is covered with scratches, call the master who will polish the product. You can carry out this procedure yourself with sandpaper or a sanding sponge with extra fine grain (SuperFine). Before carrying out work, we recommend consulting with a specialist.

Repair of products made of acrylic artificial stone

Even significant damage to a countertop or window sill made of acrylic artificial stone can be hidden. To do this, you can polish the product, cut it and glue it again, make inserts of the same material at the site of damage, fill cracks with glue, etc. But the cost of a quality repair is often commensurate with the cost of a new product. Therefore, before repairing, it is recommended to contact the master, he will evaluate the feasibility of the work.

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Countertop made of artificial stone: DIY

It takes ~5 minutes to read

Artificial stone is a practical and inexpensive material that is widely used in decoration. Such materials allow you to give the kitchen a solid and attractive appearance, while they are durable, durable and resistant to moisture. In this article we will tell you how to make such a countertop with your own hands.

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What to make? Brief description of the material

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Artificial stone is a composite material that is made from various fillers, binding polymer resin and pigments of natural origin. Its type will directly depend on the type of polymer resin used. Artificial acrylic stone, which is durable and resistant to various chemicals, is very popular.

If earlier the cost of such an artificial material was high, and working with it presented certain difficulties, today you can find liquid acrylic on sale, which is easy to use and allows you to independently make high-quality kitchen worktops.

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Of its advantages, we note the following:

• Complete environmental friendliness.
• Ease of care.
• Maintainability.
• Variety of colors.
• Long service life.
• Strength.
• Water resistance.
• Affordable cost.

At the same time, it is necessary to note the presence of certain shortcomings. First of all, it is a tendency to the appearance of scuffs, scratches and chips on the surface. Therefore, such a surface should be handled carefully and carefully. However, you can independently repair the surface, restoring its original appearance.

Manufacturing technology of countertops made of artificial stone

The manufacturing technology of such a countertop is not particularly difficult, so it is quite possible to do such work on your own. To do this, you need acrylic and the simplest materials. Each of us will be able to carry out such work, even if he does not have the appropriate experience in repair work.

To make it yourself, you will need the following:

• Two component adhesive.
• Waterproof plywood, which is used as a substrate.
• Artificial sheet stone.

Of the tools needed:

• Frazier.
• Drill.
• Circular or miter saw.
• Jigsaw.
• Grinder.

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Before proceeding directly to repair work you should decide on the appearance of the countertop and its dimensions. It is necessary to measure the available free space at the sink in the kitchen, and then perform a detailed drawing with detailed accurate calculations.

In the event that sheet material is used, we can recommend the following dimensions. Length - 76 centimeters and width - 60 centimeters. The height of the ends is 36 mm. Wall plinth and sides are made up to 7 centimeters high. Cutouts for the hob and sink are made with a milling cutter, after which the edges of the holes are processed manually with sandpaper.

Strips of about 8 centimeters wide are cut from plywood. Such stripes will subsequently form the frame. An appropriate frame is made of plywood, into which a cut and processed “surface” of stone is glued onto the sealant. The ends of the board material should be pasted over with decorative edges or adhesive tape.

The manufacture of stone countertops from slab material is complex, so this technology is not widely used today. Most homeowners prefer liquid acrylic, which is easy to use and allows you to perform this work with your own hands.

Acrylic liquid stone countertop

Liquid acrylic stone is an extremely simple, inexpensive and environmentally friendly material that allows you to create original kitchen countertops. The homeowner can easily purchase a ready-made liquid material or make it with his own hands.

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The manufacture of countertops from such stone can be carried out in a direct and reverse way. When using the direct method, it will be necessary to make blanks from chipboard or fiberboard sheets, after which the “liquid stone” is applied to the blank from a gun. The thickness of the layer of material is about 2 centimeters. It remains only to wait for hardening and carry out grinding with an appropriate grinder and manually with fine sandpaper.

The use of the reverse manufacturing method is more labor intensive, but the material consumption is significantly reduced. In this case, you will need to make blanks from fiberboard, which are 5-6 millimeters larger than the size of the future countertop. Such blanks should be glued with epoxy glue, after which the corresponding holes for the hob and sink should be cut out, glued along the contour of the plywood blank and processed with a grinder.

The completed workpiece is installed in the kitchen, plumbing is installed, after which the existing gaps are covered with plasticine. All that remains is to spray the liquid stone, which is carried out in full accordance with the instructions. The prepared composition quickly hardens, so you need to act carefully and quickly. It is recommended to lay fiberglass on top of the completed workpiece, and then spray. This will ensure the necessary strength of the structure.

Subsequently, the surface is ground, the edges are milled, and the countertop is leveled if necessary. All such works are not difficult, so making a similar piece of furniture with your own hands is not difficult.

Stone countertop repair

No matter how carefully you use such a countertop, over time, microscopic chips, cracks and other damage will appear on it. Repairing artificial stone surfaces is not difficult, which will restore the original appearance of the kitchen surface.

To eliminate large chips and cracks, it is necessary to degrease the damaged area, slightly widen the crack and fill it with a two-component adhesive. After the glue hardens, grinding and manual polishing of the surface is carried out.

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Small spots and shallow scratches can be sanded out with sandpaper. To do this, initially use sandpaper with a large grain, gradually moving to a fine grain. You can also additionally polish the surface with a drill and a special felt nozzle.

If it is required to eliminate blisters and stains, then a defective area is cut out with the help of a milling cutter, after which a patch is poured from the remnants of the liquid material. It remains only to wait for the material to harden, to polish and grind the repaired countertop.

Conclusion

Making a stone countertop with your own hands is not difficult, so you can do this work yourself. The use of liquid stone allows you to produce original, strong and durable kitchen worktops. At the same time, the affordable cost of such material significantly reduces the cost of the homeowner. If necessary, you can independently repair the coating, restoring the original appearance.

We make a tabletop with our own hands (video)

A faux stone countertop will add a unique look to any kitchen or bathroom. Choosing an artificial stone countertop is practical and durable, since such a countertop is durable, wear-resistant, not afraid of moisture, temperature changes, after many years it does not lose its original appearance. The store has a wide selection of ready-made products, but a hand-made artificial stone countertop will help save the family budget and become a source of family pride.

Sheet worktop

For the manufacture of countertops by an inexperienced craftsman, it is better to trust the industrial creation of artificial stone. Sheet artificial stone usually measures about 3.5 m long and just over 0.5 m wide. Also, prepare a two-component adhesive and a stone tool. To create a tabletop with your own hands, follow the step-by-step instructions:

• The first step is to create a tabletop drawing. To do this, you will need thick cardboard or any other paper that does not bend under its own weight. Take measurements, set aside the required size of the countertop on cardboard. In the same place, draw holes for the sink, taps, hob if you are making a countertop in the kitchen. Cut out the resulting tabletop layout.
• Put the cardboard layout on a sheet of stone, press down with a long ruler and circle around the perimeter. Don't forget to circle all the holes.

• Cut out the tabletop using the guide rail. To cut holes, you will need another tool: for rectangular holes, you need a drill, and for round holes, a crown or a round cutter.
• Turn the sheet inside out, use a cutter to make a recess for the edge. Cut the edge itself out of stone, its length is equal to the outer perimeter of the countertop. If the corners of the tabletop are smoothed, warm up the edge and attach it to the tabletop, give it the desired shape.
• Wipe surfaces from stone dust, degrease and apply glue. Set the edges in place and press with clamps. Wait for it to dry and remove excess glue.

The countertop made of sheet artificial stone is ready!

Liquid stone countertop

When using sheet material, most often some part of the artificial stone remains unclaimed, and due to the size of the segments, it becomes impossible to use them anywhere. There is a way to make an artificial stone countertop with even greater savings - use liquid stone. On sale you will find ready-made formulations that must be diluted with water immediately before use. But to create a unique shade and appearance, you can create a “liquid stone” yourself. To do this, you will need resin, filler and hardener in a percentage ratio of 60:39:1.

Mix the resin and filler, which can be used as granite or marble chips, mix with construction mixer. Add the hardener to the composition immediately before using the mixture. Cut out the base of the countertop from chipboard, do not forget to immediately make the necessary holes. To spray liquid stone, use a pneumatic sprayer with a compressor (operating pressure of 7 atmospheres). Clean the base from dirt and dust, degrease and prime thoroughly. After the primer has dried, apply liquid stone to the base in 1 or 2 layers, about 2 mm thick. Wait for it to dry, then sand and polish the surface. The liquid stone countertop is ready!

Countertop installation

When the creation of the countertop is over, it seems that the easiest step remains, to put the product in place. But in fact, if the creation of a countertop requires care and strict adherence to the sequence of actions, then installing the countertop will require physical strength, especially if the countertop is made of sheet artificial stone. The stone is a heavy material, and the fall of the finished countertop threatens with chips, cracks and scratches of the material. With the help of friends, carefully turn the countertop right side up. Place in the prepared place, fix, install the sink, hob and taps. Wipe the surface with a damp cloth.

Installing a do-it-yourself artificial stone countertop may seem like an easy procedure. But in fact, it is necessary to carefully prepare materials and tools, study the theory and enlist the support and help of friends.

Furniture sets for the kitchen in the standard version, as a rule, are completed by the manufacturer with a worktop made of thick chipboard with a finish MDF panels. With time lacquered surface becomes unusable, so many owners prefer to replace the tree with a more reliable countertop made of artificial stone at the first opportunity.

The work is difficult, but quite affordable even for an ordinary amateur to work with his own hands. The manufacture of a thick and heavy stone shelf requires, first of all, accuracy and endurance, and the technology and formulation of artificial stone can be gleaned from the text.

How to make a stone countertop

In general, the procedure for manufacturing a countertop from a monolithic artificial stone is no different from casting facing tiles or massive decorative elements, the difference is only in the size of the product and the right materials.

There are two ways to make a stone countertop for a kitchen or bathroom:

• Cast an array of artificial stone directly in place, according to the dimensions and supports of the old countertop;
• Pour the countertop with artificial stone mass into the formwork assembled in the garage or any other utility room.

The technology for manufacturing a monolithic slab of artificial stone in both cases is practically the same, so the decision on how to cast the countertop is made based on local conditions. First of all, the material of stone casting, the weight of the finished countertop and the possibility of safe transportation are taken into account. Even if the casting is made in two parts, it is not so easy to bring and install a multi-kilogram plate in a small bathroom or kitchen.

The second factor influencing the choice is the complexity of the countertop configuration. A simple rectangular block made of artificial stone can be delivered and installed on a supporting frame without any problems. A stove with numerous bends, corners, openings for a sink, sink and hob is easier to cast in place of the old countertop. As a rule, furniture makers who developed the design of a wooden tabletop did not really think about a possible replacement. wooden shelf artificial stone slab. Therefore, the supporting frame has to be strengthened, and the tabletop itself has to be slightly simplified and modified for finishing and polishing.

Advantages of artificial stone

The difficult procedure for forming an artificial stone casting often confuses the owners, is it worth it to even bother with the installation of a stone countertop, if you can order and install a regular shelf made of pine board, varnished with polyurethane varnish or lined with MDF film.

The main advantages of a stone countertop over a wooden slab become apparent within a few days after the completion of installation and finishing work:

• Heat resistance and high surface resistance to mechanical damage;
• The strength of a stone countertop is much higher than that of wood;
• Possibility of carrying out local repairs without the need to re-varnish the entire surface of the slab;
• High resistance to moisture and condensation.

A slab made of artificial stone is much safer and more durable, in most cases the fall of objects stored in kitchen wall cabinets does not even leave scratches, while serious damage is possible on the varnish.

A countertop made of artificial stone casting withstands the difficult conditions of the bathroom no worse than sanitary faience. Installed instead of a traditional plastic or wooden shelf, a wide artificial stone panel will last 3-4 times longer than competitors and at the same time decorate the interior with a beautiful stone pattern.

Customers really like the fact that you can safely put a hot kettle, dishes from the oven, and in some cases even chop meat on an artificial stone countertop. According to the reviews of the owners, the shelf made of stone casting is primarily valued for its excellent appearance, unpretentiousness and a huge margin of safety of the structure.

When choosing, you need to take into account the fact that not all materials can withstand high temperatures, especially since the artificial stone is made on the basis of polymers. For example, a polyester matrix can easily withstand temperatures of 200-250°C, while a chemically cured acrylic resin can withstand a maximum of 150-170°C. Therefore, before trying to make a cast stone slab, you need to get an accurate idea of ​​\u200b\u200bthe dimensions and the planned material for making the countertop.

Materials for the manufacture of countertops for the kitchen

Artificial stone is made from 7-8 types of materials and their compositions, this includes mineral fillers and polymeric matrix materials. For the manufacture of kitchen countertops, the list of polymers is half as long:

• acrylic resin;
• Epoxy matrix;
• polyester compounds;
• Gelcoats or liquid stone varnish.

In addition to polymer matrices, fiber materials, quartz, ground silicon, titanium oxide, granite, basalt and marble screenings with a ground and polished surface are widely used. Approximately half of the countertops are made using high-strength concrete and polymer concrete composites. Therefore, isopropyl alcohol, ethylene glycol, calcium chloride, hydrogen peroxide and synthetic dyes, mixture stabilizers are added to the list.

Concrete kitchen worktop

The idea of ​​making a countertop based on a cast concrete may seem a little outdated and even out of place, due to the huge weight of the material and the unattractive appearance. In fact, any parts can be made from high-quality concrete, the strength and durability of which, in some respects, is not inferior to aluminum alloys and impact-resistant plastic.

The main advantage of a concrete countertop is its high strength and versatility. If you use high-quality cement and plasticizing additives, you can cast a table top 3-4 cm thick, the strength of which can be envied by any artificial stone.

In addition, from concrete mix it is quite possible to cast a countertop directly at the installation site, and for the most vulnerable places of casting, for example, in openings for a sink, it is quite possible to make a monolithic niche from artificial stone. The metal sink will fit into a concrete pocket, after which problems with water leakage or deformation of the drain pipe will disappear by themselves.

Quartz countertop

Quartz sand, ground calcite and crushed natural quartz are considered to be one of the most successful materials for the manufacture of artificial stone countertops. Natural materials are thoroughly washed, dried and separated into fractions. The matrix for quartz artificial stone is a purified or white marine epoxy resin or a polyester compound with the addition of titanium oxide.

The result is a homogeneous monolithic countertop made of artificial stone, in color and texture reminiscent of the most beautiful natural stone - limestone marble. If pellets from quartzite, granite or any other ornamental and decorative stone, then you can get a fairly large range of colors and textures of artificial stone.

The most difficult thing to make at home is an artificial stone based on a polyester compound, this material provides high hardness and strength of the casting, but for polymer curing it is necessary to use a thermostated box or chemical polymerization accelerators.

Therefore, home options for polyester stone countertops are heated with hair dryers and blowers after pouring, but there is still a risk of forming a raw core of artificial stone slab. If you install a countertop made of artificial stone without waiting for the complete rejection of polyester, over time, a deflection may form on the plane.

Ceramic tile countertop

Plain cladding ceramic tiles can replace expensive epoxy or polyester materials. Particularly successful are the combinations of porcelain tiles with the texture and pattern of natural stone, with a countertop cast from high-strength concrete.

The technology of forming a countertop finish from a tile under an artificial stone is no different from normal styling on the walls of the kitchen or bathroom, but there are a few tricks that are important to consider:

• The concrete base of the countertop can be glued only after 2-3 weeks of exposure to the shrinkage processes of artificial stone;
• The front plane of the concrete stone is carefully ground and trimmed with emery to remove any slopes and irregularities;
• Tiles are carefully calibrated, sized and, if necessary, cut into one size with an accuracy of tenths of a millimeter.

If all the requirements for facing artificial stone countertops are met in accordance with the preparation technology, then the tiles laid on concrete, metal or even thick bakelite plywood form a single canvas of artificial stone, thin, tenths of a millimeter joints after grouting are simply not perceived by the eye.

In a similar way, you can lay out a temporary countertop in the kitchen or in the bathroom, for example, when carrying out a rough repair in a new building. Ordinary tile on a wooden base appearance inferior to artificial stone, but just as strong, withstands strong heat and even small impacts.

Acrylic artificial stone countertop

Of all the listed materials available for home use, acrylic is best suited for self-manufacturing countertops with imitation of natural stone.

Casting of artificial stone based on chemically hardened acrylic turns out to be absolutely safe according to sanitary standards, with a smooth monolithic surface. Artificial stone does not react with any liquids available in the kitchen, does not let water through, there are no pores and microcracks in which dirt would accumulate. Acrylic artificial stone is best repaired and restored, therefore, even if a chip or deep scratch has formed, the treatment process takes a maximum of 10-15 minutes.

The correct selection of filler, for example, marble pebbles or polished granite screenings, basalt dust in combination with a dye, allows you to create very beautiful, light and at the same time durable objects. kitchen furniture and interior, not necessarily just countertops.

Manufacture of artificial stone countertops

The technology of stone casting and molding of artificial stone, at first glance, very simple and even ingenuous, can present serious surprises, first of all, when using low-quality materials, this is the first and main problem of possible failures in the manufacture of homemade countertops. Acrylic resin with hardener must be purchased in one batch, preferably in a specialized store or salon. The material will need to be pre-tested with a trial batch on a purchased filler, for example, on ground quartzite or washed sand. If the plate 120x50x5 mm could not be broken by hand, then the proportions for the artificial stone were chosen correctly.

The first step is to measure the future place under the countertop and draw up a rough sketch with exact dimensions plates. Based on these data, you can easily calculate the volume of artificial stone and the required amount of materials. The proportions of the mixture for casting countertops are as follows:

• Acrylic polymer - 30%;
• Dry screened filler -60%;
• Hardener - 4%;
• Pigments -6%.

For a countertop 60 wide, 250 cm long and 3 cm thick, a total of 40 liters of the mixture will be required, excluding the sink window. The third part - 13 liters will fall on acrylic resin. In addition to the casting mixture, you will need an aluminum corner, plywood 10-15 mm, plasticine, window glass or several PVC panels, liquid paraffin oil.

A set of necessary tools

The most time-consuming part of the countertop manufacturing process is the construction of a finished mold for pouring the stone mixture. Only an experienced carpenter can make a shape for the countertop exactly according to the sketch; those who are at odds with carpentry will have to go for a trick. From a large piece of wallpaper or paper, a template or profile is cut out with all the openings for the sink and stove. Next, the tracing paper is transferred to the bottom of the mold and the contour of the future artificial stone slab is transferred.

To make a mold, you will need a whole arsenal of tools:

• A container for mixing resin, a spatula and a wide paint brush;
• Electric jigsaw, drill with a set of drills;
• Set of corner clamps;
• Wide pincers;
• Metal tubular mandrel;
• Industrial dryer.

First of all on flat surface the bottom of the mold is laid out on a workbench or desktop, it can be made of PVC panels or plywood with glass laid on top. In order to achieve the most flat surface of an artificial stone casting, the glass has to be cut into separate sectors and laid out on the bottom, the joints are rubbed with mastic or plasticine.

The side walls are cut with a jigsaw with a margin, the height is taken 4 cm above the estimated thickness of the countertop. The boards are pulled together with clamps into a box and laid on the bottom of the mold.

Note! The width of the form is planned 6-10 cm more than the actual size of the countertop.

Technological process

All cracks and joints are carefully rubbed with automotive plasticine to avoid leakage of the poured mixture of artificial stone. At the last stage, the walls are lubricated with the thinnest layer of petroleum jelly or liquid paraffin.

Acrylic resin is poured into a clean container and mixed with a hardener, then pigment is added, and everything is thoroughly mixed. After laying the filler into the mixer, the casting mixture for artificial stone is kneaded for another 15-20 minutes.

The casting mass is poured into the mold, and the first layer is actively punched with a spatula to avoid the formation of shells. After the level of artificial stone has reached the mark on the mold wall, the filling is stopped. Next, a reinforcing fabric is laid and the rest of the mixture is poured.

Finishing the table top

After two days, the clamps are removed and carefully separated from the artificial stone. Using a sharpened sliver, pry and remove glass or PVC panels from the plane of the table top. Paraffin and dirt are washed with a clean cloth and soapy water. All sharp edges are trimmed with a knife.

The end face of an artificial stone slab is squeezed with aluminum strips, heated with a hair dryer and bent at an angle of 90o with tongs with wide jaws. After the artificial stone has cooled down, the bent edge is cut with a grinder to a width of 5-6 cm. It turns out that visually the artificial stone countertop looks thicker than its actual size, in addition, the rounded edge and the stiffening rib provide additional rigidity to the canvas made of artificial stone mass .

Mirror milling of ends

In order for the acrylic stone slab to look as natural as possible and not betray its artificial origin, the entire surface will need to be polished, and the ends also mirror milled.

Polishing is carried out with an automobile grinding wheel with a felt nozzle. The ends milled or cut with an electric jigsaw are initially rubbed with emery, then with wet emery cloth, and at the end of processing with dry felt with polishing paste.

Polishing must be carried out with little or no pressure, as an artificial stone based on a solid filler and an acrylic matrix can easily lose some of the plastic and turn into a “pumpy” surface.

Do-it-yourself liquid stone countertop

In practice, another method of manufacturing countertops is used, with a coating that imitates artificial stone. The technology is called "spraying with a liquid artificial stone." The process of manufacturing a slab with an artificial stone coating takes half the time and cost. The meaning of the technology is to apply a liquid epoxy or polyester mass with finely ground filler to the prepared surface.

The only drawback of the liquid stone casting technology is the poorly predictable behavior of the liquid mixture of artificial stone on the sprayed surface. It is necessary to test first by experience various formulations mixtures to imitate an artificial stone surface in order to obtain an even, smooth finish with a strong grip on the countertop.

We make liquid stone ourselves

A compressor and spray gun are used to apply artificial turf. high pressure with a 3 mm nozzle. Ready mix contains approximately 30% filler, so the torch does not give out a cloud of sprayed liquid stone, but rather a stream of tiny drops that should be evenly distributed on the surface of the countertop.

To form a polymer-stone layer, soil and a top coat are used, the soil is prepared from:

• Finely ground calcite - 75%;
• Epoxy gelcoat -20%;
• Hardener - 1%;
• Softener - 5%.

After priming, after 4-5 hours, a finishing mixture is applied, in which the specific proportion of the gelcoat is doubled. Polyester gelcoats are not used for the manufacture of artificial stone countertops due to the low hardness of the material.

direct way

The simplest way to make an artificial stone countertop involves direct spraying of the material onto the original surface, it can be a concrete blank made of artificial stone or an old primed countertop. To make the coating as durable as possible, with the direct method, 3-5 layers of material are applied.

Reverse way

The technology of the reverse method will require the manufacture of a mold for the countertop, as when casting from artificial stone. In this case, after applying a separating layer, the walls and bottom of the mold are filled with filler and blown out with liquid stone.

The rest of the cavity is filled metal profile and can be filled with polymer concrete or polyurethane foam.

We make a form

With the direct method of forming the countertop, you can even use the old plate, you will need to carefully dismantle the panel, remove the decorative layer, cut, clean and sand the defects.

For the reverse method of obtaining an artificial stone, a foam mold is cut out. The inner surface is varnished. The walls must be absolutely even. The styrofoam box is installed on a flat and hard surface, such as a desktop.

Preparing the mixture

Liquid artificial stone is applied in three layers:

• The first layer with a minimum filler content, most often a translucent hard layer is applied, which will provide the artificial stone with shine and gloss;
• The second layer of artificial stone contains the estimated amount of filler and dye;
• The third layer is applied with the resurfacing of the surface with a reinforcing cloth.

Any gelcoat recipes contain resins dissolved in styrene, so artificial stone mass should only be applied under heavy draft or outdoors.

Getting Started with Tabletops

The first layer in the reverse method is applied separator. The air temperature must be at least 18o C. Then, after 20-25 minutes, a thin layer of epoxy varnish is sprayed. Thus, a decorative glossy shell is obtained.

After about an hour, an intermediate layer of a liquid mixture with a filler is applied, a reinforcing mesh and embedded elements - brackets and anchors are laid. The next layer on top of the gelcoat with a spatula and a brush is glued an epoxy mass with a high content of reinforcing fiberglass.

The reinforcing frame made of steel profile is laid last, voids and gaps are filled with foamed polyurethane.

Countertop installation

The weight of the new countertop, made of liquid stone, allows you to install the stove using the old frame. Brackets laid in the frame of the tabletop allow you to level the slab of artificial stone mass and fix the stone surface in a perfectly horizontal position.

Stone countertop repair

The surface of the artificial stone panel is inferior in hardness and wear resistance natural material Therefore, the countertop must be regularly inspected, checked and restored in order to stop the destruction at an early stage.

Types of possible damage

The most common types of defects are delamination and mechanical damage. In the first case, the cause may be poor adhesion of the polymer layer to the base. Mechanical scratches and chips are almost always the result of a sharp object being struck or dropped.

Cracks, scratches and their elimination

Acrylic artificial stones have a high surface hardness, but scratches or cracks can be easily removed by polishing. A crack in an artificial stone is filled with polishing paste, and with a felt circle, the edges of the damaged area are polished in the direction from the ends of the area to the central part. Deep damage on the surface of the artificial stone mass is sealed with clean acrylic and polished.

Elimination of blisters and stains

The most difficult case is associated with the formation of fistulas and blisters under the varnish layer. Most often, the fistula point on the surface of the artificial material is pierced to the depth of the defect and filled with a repair compound. After the mixture has hardened, the surface of the stone is cleaned and polished. The stains are washed detergent and cleaned with isopropyl alcohol. Gloss gloss is shaded on the surface of at least 20-30 cm2 to blur the border.

Conclusion

Making countertops from artificial stone mass requires a certain amount of experience and skill in working with polymers. Unlike whimsical natural stone, artificial material provides an opportunity to create real multi-colored masterpieces, from imitation of a satin jasper pattern to a complex pattern, serpentite or calcite, which are a great success even for experienced craftsmen to find in natural conditions.