Facing the facade with an artificial stone with your own hands - step by step technology!

Houses faced with artificial stone are gaining more and more popularity lately. And although the very technology of making artificial stone is already more than 70 years old, in our country it began to be used only at the end of the 20th century. The delightful and unique architecture of medieval castles, luxurious palaces attracts, but due to the design features and high prices, not everyone can afford to order the facade decoration with natural stone. In this regard, artificial material is an excellent alternative.

Ease of installation, high technical features, a variety of colors distinguish artificial stone favorably among other finishing materials.

Of course, it is in many ways inferior to the stone of natural origin. But modern manufacturing technology makes it possible to achieve such a variety of colors and textures, to increase its technical characteristics, that in many cases artificial stone can seriously compete with materials of natural origin.

In this article we will tell you about the technical features of an artificial stone and will teach you step by step how to complete finishing work and properly revet the house with artificial stone.

Manufacturing technology of artificial stone

Artificial stone can be classified by production technology and components included in the composition. There are two technologies for the production of artificial stone.

1. Vibration casting. In terms of costs, this is a more budgetary technology, since there is no need to purchase expensive equipment to produce the material. And the speed of production significantly increases profitability, and due to the fact that less water is needed to make concrete, manufacturers are able to achieve a richer color. Vibration casting is usually used for small industries, therefore, it does not allow the production of stone to be delivered to a wide flow.

   

   Vibration casting technology for the production of decorative stone

2. Vibration pressing involves the purchase of more expensive professional equipment.

   But, in the end, the cost of the facing material comes out less, since less manual labor is used in the manufacture. Vibrocompression is usually practiced in large factories and requires special training of personnel.

   

   Vibration pressing, workshop

What is the artificial stone produced from

Before talking about the advantages and disadvantages of this material, you need to understand what it is made of and what affects its operational properties.

The composition includes sand, cement and various chemical additives.It is thanks to the addition of various chemicals and acrylic compounds that manufacturers achieve an amazing similarity of the material with granite, marble, onyx, jasper, limestone, etc.

Depending on the filler fraction, a certain structure of the stone is achieved. The larger the crushed stone chips will be introduced into the mixture, the more porous and more structured the resulting material will be. A special pigment is responsible for the color, which has increased resistance to UV rays. Even after 15-20 years, the facade, finished with artificial stone, retains its original color. Binders, fillers and colorants are used as the main components.

There are several main types of materials that are used in the production of artificial stone.

1. Porcelain stoneware . This material is highly durable and resistant to mechanical damage. It is resistant to large temperature fluctuations and can be used for facade cladding in almost any climatic zone. Porcelain stoneware is obtained by pressing clay, feldspar, dyes and acrylic fillers, followed by firing.

   The tiles can be of any finish, texture and color.

2. Agglomerates (conglomerates). This material is practically indistinguishable visually from such natural materials as onyx, jasper, granite, malachite, lapis lazuli, etc. Here, the basis for production is polyester resin, which is combined by pressing with marble chips, limestone, granite and quartz sand. The pigment allows you to simulate almost any kind of rock.

   Such an artificial stone is highly resistant to deformation and frost. But a significant disadvantage can be called exposure to ultraviolet radiation, abrasion.

3. Concrete-based stone is one of the most affordable building materials. The basis is sand, cement, various chemicals, plasticizers, water repellents and ceramic chips.

The technology for the production of artificial stone allows you to create material of different shapes.

Standard tiles, long panels, irregularly shaped bars or precision-made stone allow for any design idea.

According to its appearance, artificial stone is of the following types:

• clinker stone. Perfectly imitates brickwork;
• concrete stone is the cheapest material, perfectly imitates granite;
• ceramic is produced in the form of bricks or tiles with a polished surface;
• architectural has a high price and is an exact copy of limestone, sandstone;
• polymer sandy reminds "chipped" or "torn" stone.It is a thin plate of different sizes;
• resin stone is produced in the form of rectangles and has a high similarity with natural stones, since it contains natural chips.

Prices for various types of facing artificial stone

Facing artificial stone

Advantages of artificial stone

Very often houses decorated with artificial stone can be found in northern latitudes.

This is due to the poor thermal conductivity of the material. During the production of the stone, bubbles remain in it, which, like foam, do not allow cold air to pass through. Thus, a house faced with artificial stone often does not need additional insulation. These bubbles also create a sound barrier. In such houses, it is especially cozy and quiet, since extraneous sounds from the street do not penetrate well inside.

Another advantage is weight. At the first glance at the house, in the decoration of which artificial stone was used, one gets the impression of a mighty monumental building. However, this impression is misleading. The weight of individual slabs is much lighter than bricks, which allows such cladding to be used on thin walls made of foam blocks, etc. This also reduces shrinkage during house operation and extends the service life.

Where there is no way to sheathe a house with natural stone without damaging the supporting structures, artificial stone becomes an excellent alternative. Even frame and wooden houses can be faced with this material.

The rest of the advantages of decorative stone are associated with the installation technology. Unlike brick, which is often used in facade decoration, special glue is used for fastening. As a result, fewer gaps are formed during operation, which also contributes to heat retention.

The material itself does not require antiseptic treatment, mold and fungi do not form on it and other microorganisms. It is very malleable and you can easily make grooves for electrical wiring in it. Even after the completion of construction and finishing the facade, if necessary, you can always make additional openings in the stone.

So, summing up all the advantages, the following advantages can be distinguished:

• excellent thermal insulation and sound insulation;
• ease of installation;
• affordable price;
• the ability to imitate almost any rock;
• mold and mildew are not formed;
• good frost resistance;
• environmental friendliness;
• variety of colors solutions;
• material flexibility in processing;
• light weight.

Cons of artificial stone

Compared to ordinary natural stone, artificial stone is less durable.

Average exploitation of the material is no more than 20-25 years. The material is very fragile. It is about transportation and installation. Therefore, during work, you need to be very careful not to damage fragile plates.

Another significant drawback is the permeability of the material.

The stone consists of concrete and if it is exposed to contact with water for a long time, then its operational properties may be impaired. After installation and special processing, the technical properties of the artificial stone are significantly improved. Therefore, the disadvantage associated with water permeability must be taken into account during the transportation and storage of the stone (this is typical only for some types of material).

When further maintaining the facade, lined with artificial stone, you need to take into account its low resistance to abrasive substances. It is better to choose mild detergents that will not destroy the outer shell of the stone.

• fragility of the material;
• low resistance to abrasive substances;
• water permeability.

Choosing the type of installation

Despite the amazing beauty of the facades, which are faced with artificial stone, the installation process is not as complicated as it seems at first glance. Accurately following the step-by-step instructions, even a beginner will be able to decorate a house with artificial stone with high quality and beautifully.

Important! The temperature for finishing works of the facade should be in the range of 5-25 degrees Celsius, otherwise the laying technology may be violated, which will reduce the operational properties of the material.

There are two ways to lay artificial stone: wet and dry.

Each of these types has its advantages and disadvantages, so when choosing, take into account the characteristics of the house, the budget and the material chosen for the building cladding.

Wet styling has nothing to do with moisture or water. The method got its name due to the fact that the facing is made on glue (cement) mortars, and the "dry" method involves fixing the stone with screws (self-tapping screws) to a pre-assembled frame.

Wet technology is performed more quickly, because the preparatory work does not imply the installation of the frame. Slabs of stone are tightly adjacent to one another.

You can create decorative seams, retreating no more than 12 mm between the stones, but then you will need a special grouting mixture to seal the joints. Typically, this technology is used for houses that do not require additional insulation and the preparatory stage will only be high-quality wall cleaning and a primer.

Advantages of the "wet" method:

• less labor-intensive;
• high speed of work;
• no high qualifications required and experience to perform the work.

This method is not suitable for high-rise buildings, and the service life of the cladding is much lower in comparison with the "dry" method. Average service life is 20-25 years.

While with the dry method, the period can be increased to 40 years.

"Dry" method creates the correct air gap that protects the building from overheating and hypothermia. Installation can be carried out at almost any temperature, since there are no special requirements for materials. As for the additional care of such a structure, it is quite simple and practical. You can always quickly replace one element with another.

Advantages of the "dry" method:

• creating additional ventilation;
• long service life;
• suitable for cladding high-rise buildings;
• wide temperature range for facade work;
• compliance with modern fire safety requirements (by creating proper ventilation);
• repairs are quickly carried out if one of the elements is damaged.

Wet cladding tools

1. Building rule, level.
2. Pencil and ruler.
3. Spatula.
4. Nippers.

5. Circular saw (or grinder).
6. Trowel.
7. Brush with metal bristles.
8. Paint brush.
9. Electric drill (or construction mixer).

Of the materials for the "wet" cladding method you will need:

• artificial stone;
• building glue for stone or cement mortar;
• rags to remove glue residues from the surface;
• grouting mixture.

Prices for popular models of electric drills

Electric drills

Facing the facade with artificial stone: step by step instructions for "wet method"

The whole process can be divided into 5 stages:

• preparatory work;
• selection and preparation of material;
• facade cladding;
• grouting;
• finishing. Stone processing.

Stage 1. Preparatory work

Step 1.

Align the walls. We remove all door and window frames and thoroughly clean the surface. The evenness of the walls and the thoroughness of the preparation largely depends on the material itself. If cladding with relief slabs with pointed uneven edges is supposed, then you can simply level the surface and check the plane with a building level. Please note that control of a flat plane should be carried out not only vertically and horizontally, but also in a diagonal direction.

If the distance between the rule and the wall is not more than 4 mm, then you can immediately start finishing work.Too obvious irregularities must be carefully plaster and let the mortar dry well (at least 24 hours).

Step 2. Priming the walls. This is a mandatory step that protects the wall from the spread of mold, mildew and other microorganisms.

In addition, the correct primer will significantly increase the hydrophobic properties.

Video - Facade priming

Prices for front primer

Front primer

Step 3. Before finishing work, carefully refer to the instructions on the adhesive to ensure the correct masonry temperature is selected. Consider also that the working state of the solution is no more than 60 minutes. Therefore, knead exactly as much glue (cement) as you can handle at one time.

Step 4. You can, of course, choose a ready-made "wet" mixture, which will not regulate the time of the masonry process, but the best are adhesive solutions prepared from dry ingredients directly at work.

Stage 2. Preparation of the material

Step 1. Prepare the material with which we will sheathe the walls.

Check each tile carefully for defects and possible defects. The slightest crack, chip can spoil the appearance of the facade, so feel free to put aside all the defective parts, they can then be used in places with less visibility. Consider the color scheme of the stone. Try to evenly distribute color accents so that after cladding on the wall, too obvious stains do not form. It is better to open several packages of material at once and take several pieces from each.

Store all blanks that match in color and structure at once in one place to facilitate the masonry process in the future.

Step 2 . If necessary, the tiles can be adjusted to the desired size using a circular plate.

Step 3. If you want to create a beautiful pattern from the slabs around the door or window openings, it is better to immediately spread the workpieces on the ground, and after that take a stone and fasten it to the wall.

Step 4. Now all the selected workpiece material must be thoroughly cleaned with a metal bristle brush from dust and dirt.

Stage 3. Wet cladding

Step 1 . Choose the way you will lay the stones: seamless or with jointing.

When facing a façade with jointing, control the distance between the slabs and try to avoid straight horizontal or vertical lines. With the seamless method, it is important to ideally match the shape of the stones themselves, so that they fit as tightly as possible to each other.

Step 2. If you chose the "seamless" method, then you will need to move from bottom to top, carefully placing the top row of tiles on the bottom.

Step 3.

Apply glue to the back of the tile and the work surface of the wall to which you are going to attach the stone, avoiding the compound on the face of the stone. Wait a few seconds and press firmly. You do not need to be zealous in order not to damage the integrity of the tile. Carefully remove the remnants of the squeezed out glue with a rag. Make sure that some of the glue comes out all the time, otherwise the stone will not be firmly fixed on the wall.

If you have chosen a seamless method, then glue not only the back of the tile, but also the side parts well with glue, so that it adheres more tightly to each other. This is not necessary with the jointing method.

Step 4 . When laying tiles near door and window openings, start at the corners, and then move to the side. If you use tiles of the same shape, then always check the horizontal line with the level.

It doesn't matter when stacking shapeless stones.

Step 5. The bottom layer of masonry should be at the level of 60-70 mm from the ground. Otherwise, due to the high moisture content of the soil, the stone may fall off.

Step 4.

Grouting

This step will protect the facade from moisture penetration and provide reliable sealing. If for decorative reasons you want to highlight the seams on the facade, then add a little pigment to the ready-made mixture. Trowelling works, as a rule, are performed one day after the facade cladding.

If you chose seamless masonry, this does not mean that you need to skip this step. Simply the solution is applied neatly between the tiles using a pastry bag (try using a regular plastic bag, cut the corner to the width of the seam).

You can take a special construction gun for grouting, which will facilitate the process. If some of the grout spills onto the face of the tile, remove immediately with a dry cloth.

The "jointing" method is easier. Use a trowel to carefully apply the grout to the joint to avoid staining the front of the tile. Iron the stitches after 30 minutes.

Construction grout prices

Construction grouting

Stage 5. Finishing. Stone processing

Take a brush and apply a special composition (water repellent) in a thin layer to all elements of the masonry. Do not forget to brush over all the drops of the elements in order to apply the composition to the entire stone.

As you can see, the process of laying artificial stone is quite simple, and its color variety, strength and affordable price will allow for you to decorate the facade of your house beautifully and practically.

Video - Facing the facade with artificial stone