Do-it-yourself acrylic countertop at home. How to make a do-it-yourself artificial stone countertop

When setting up your kitchen, it is important to find the right work surface. The tabletop should fit well into the overall interior, while having reliability, durability, scratch and household chemicals resistance. Today in stores you can find a lot of options for countertops, but what if the price or appearance does not suit you?

You can order the production of artificial stone countertops from professionals, or you can do it yourself.

From our article you will learn how to make a do-it-yourself countertop made of artificial stone, get step-by-step instructions on how to create a do-it-yourself countertop.

Choosing a material before making a do-it-yourself countertop

• The most common for most kitchen countertops are particle board and MDF. In their manufacture, the postforming method is used - covering the surface of the base with a thin layer of plastic. This tabletop is resistant to moisture and detergents, does not fade under the sun's rays.
• Also for this purpose, you can use drywall, reinforcing the structure with mosaic ceramics. However, this option is not particularly economical compared to the previous one, and at the same time its strength is much lower.
• Plywood can be an alternative to drywall. It is much stronger. However, it looks quite simple, and usually such a tabletop is used in the country or in village houses.
• The most popular are countertops made of artificial stone. They are reliable and resistant to chemicals or damage, and have high moisture resistance. At the same time, they are quite simple to manufacture.

In addition, countertops are made of acrylic or natural stone. However, their creation requires professional skills and specific tools.

DIY stone countertop

The basis for the production is a polyester resin, to which a filler and mineral dyes are added. You can purchase a ready-made sheet, liquid stone, or mix the solution yourself. Artificial stone has excellent characteristics:

• Increased strength. Such a working surface is not afraid of either a knife or physical influences. Even with long-term use, you are unlikely to find cracks, chips or scratches on it.
• Ecology and hygiene. The absence of microscopic pores in the material prevents water from being absorbed and creates favorable conditions for bacteria. This countertop is easy to wipe down and safe for all types of food.
• Easy to repair. Any damage to the surface is easy to fix without the use of special technologies and money. If you have the right tool, you can easily cope with this task at home.
• Flexibility. Using a regular building hair dryer, you can give any geometry to the artificial countertop. Its form and functionality will be limited only by your imagination and the interior of the kitchen. Among other things, there are a lot of pigment additives that will make it possible to make almost any stone texture. The table top made of this material is not cold, pleasant to the hands.

Worktop manufacturing instructions

There are three ways to make a countertop out of artificial stone yourself.

1. Sheet artificial stone

This is the easiest way if you don't want some incredible shape or unique texture on your countertop. You will need a sheet of faux stone. Its standard dimensions are 376 * 76 centimeters with a thickness of 3 to 12 millimeters. Plywood with a thickness of 30 mm is also required. We do not recommend using chipboard due to swelling when absorbing moisture. This can damage the stone. The last component will be a two-component adhesive.

Advice: If you take sheets of artificial stone of greater thickness, then it will be easier to process them, and the product will turn out to be more durable.

In addition to materials, you need tools:

• sanding machine;
• electric jigsaw;
• Circular Saw;
• drill;
• milling cutter with a carbide blade;
• guide rail;
• clamps.

Take measurements and make a drawing of the future artificial tabletop. On it, mark the holes for the sink, hob and taps. Cut along the lines you have drawn and you have a layout for your future work surface. Further:

1. Place the layout on the stone and transfer the contours to its surface.
2. Cut the outside of the workpiece with the guide bar and mill the edges.
3. At the points where the holes are rectangular, use a drill to drill holes in the corners. Using a jigsaw at low speeds, cut out the places for the sink and hob along the markings. Round openings for cranes are made using a cutter installed in a drill.
4. Cut a border out of the artificial stone. Its length should be equal to the perimeter of the outside and openings.
5. Turn the sheet over and make a groove for the hem using a router bit. The width of the groove should be equal to the thickness of the hem. Its height after fastening should not exceed the plywood frame.
6. Degrease the surface and apply glue. Place the hem into the prepared grooves and press down with clamps. Remove glue residues from the drying area with a chisel.

From plywood, cut strips 7 centimeters wide. Glue them on the underside of the countertop along all edges. You can also reinforce the frame with transverse stripes. If there are gaps between the frame and the border, fill them with silicone. To smooth the layers of glue after drying, process them with a cutter, sand and paint the plywood. At the end of the work, turn the tabletop over to the front side, round off the border with a router and polish the surface.

If you are making a corner countertop, you need to sand both parts at the same time, after gluing. The work surface is ready, all that remains is to mount it in place.

2. Composite materials

You will need resin, filler, hardener and pigment dye. The consistency of the mortar should be quite thick. Put filler granules in a bucket and pour over resin. After that, mix the mixture thoroughly with a mixer. Add color and hardener and stir for 5 seconds. It should be remembered that the hardener is added before pouring.

1. Make a natural size blank for the matrix from 16 mm chipboard with all the necessary holes.
2. Using a jigsaw, cut it out along the lines and sand it.
3. Attach the workpiece to the second sheet of chipboard and trace the contours with a small allowance, and then cut it out with a jigsaw.
4. Use clamps to fix the sheets, mill and grind the ends and surface.
5. Degrease the workpieces, glue and fix with self-tapping screws.
6. When the glue has polymerized, you need to re-mill and grind the resulting workpiece.

Place the workpiece on a horizontal surface using a spirit level and glue the beads. They can be cut from chipboard or thin plywood. They should protrude above the workpiece by the thickness of the future product.

After that, prepare a mold for pouring the "stone with your own hands." To obtain the desired shape, plasticine should be applied along the sides with the help of models. Treat the entire inner surface with a release agent. The form is ready to be filled.

3. Liquid stone

There are two ways to create liquid stone countertops - spraying and casting. Making the first way will save your budget. However, by the injection method, you can get a tabletop, the thickness of which is several centimeters, if during spraying it does not exceed a couple of millimeters.

The spraying method is based on the principle of applying a thin coating of liquid stone to the finished countertop. Direct spraying is possible when the working plane is covered with liquid stone without dismantling. Furniture to be coated must be cleaned, degreased and primed. When the primer is dry, use a spray gun to apply the required number of coats of the mixture. To carry out such work, a pneumatic atomizer and a compressor with a working pressure of 6-7 atmospheres are required. After drying, it is sanded and polished.

The backspray method for countertops will take longer. The surface of the matrix is ​​coated with a liquid stone with a pistol. After 30 minutes, the primer is applied. In this case, the base should not show through. After that, the mixture is poured in a thin layer and covered with the same workpiece, which must be pressed with a load. Then the load is removed and resin is poured on top of the workpiece. In the second blank, openings are drilled to allow excess resin to escape. When the polymerization process is over, the product can be sanded.

The injection molding method is quite similar to spraying. When casting, you can immediately fill the mold with a solution or initially treat its surface with a gelcoat. It is made from polymer resin. It is highly durable and UV resistant. After that, the mold is poured with the ready-made mixture.

At first glance, the process of making a countertop at home looks pretty simple. However, some points may require you to have a certain experience and dexterity, as well as the availability of the necessary tools.

Or you can always order the production of artificial stone countertops from the professionals of the E-stoun.ru company. You will be able to choose the material, color, texture and thickness of the product, and the craftsmen will take all measurements, make and install the countertop.

An artificial stone countertop for the kitchen is a practical and original solution available to most Russians. Do it yourself if you have the skills to work with decorative materials. The countertops have replaced the old counterparts made of plywood, chipboard and other materials for more modern ones. They are aesthetically pleasing, safe, strong and durable. The price depends on the complexity of the design. The product is not afraid of hot dishes, water and light damage from knives or forks.

In the article, we will consider in detail:

• main pros and cons;
• forms and characteristics;
• rules for the care of products.

Artificial stone countertop for the kitchen - advantages and disadvantages

An artificial stone countertop for the kitchen has both advantages and disadvantages. Consider the positive properties and characteristics.

• Decorative stone furniture is pleasing to the eye. Its aesthetic appearance suits any interior and design.
• The strength and durability of the material allows pieces of furniture to serve not for years, but for decades. They are difficult to scratch, and serious damage is difficult, such as chipping off a corner or hitting so that a crack forms.
• The materials from which such countertops are made can be processed. They are given absolutely any shape, the main thing is that the piece of furniture fits into your kitchen.
• A variety of patterns and a huge color palette allow you to create a product that suits any interior style. From imitation of natural stone to metallic sheen.
• Products are simply repaired, amenable to restoration. If the countertop is damaged during use, sometimes dismantling is not required to give it its original appearance, depending on the type of product.

We will divide the products into two groups according to the type of materials:

Photo	Material type	Description
	Acrylic agglomerate	● Heavy, the composition contains a large amount of natural stone. In this case, installation becomes difficult. ● Despite all the massiveness and strength of sintered products, they can hardly withstand the impact of abrasive materials. Do not think that by cutting a loaf or meat on such a tabletop with a sharp knife, there will be no traces on it. Scratches, albeit subtle, but will be. ● If the product is large, seams will be visible. They are not striking in the eye, but upon close examination you will see them. This does not affect the appearance, but is considered a disadvantage.
	Acrylic stone	● Easy to scratch. This cannot be avoided, due to the properties of acrylic stone, so choose models of light colors. If scratches appear, the tabletop is restored.

Acrylic or quartz countertop?

When choosing a countertop for their kitchen, most people are faced with an important task - to choose quartz or acrylic. These materials have their own technical characteristics and are suitable for certain purposes. Let's take a closer look.

Quartz agglomerate

Icon	pros	Explanations
	Color base	The color scheme of the countertops is striking in its variety. In quartz models it is possible to choose a base color. It will be basic, and besides it there will be only inclusions of natural stone.
	Safety	The agglomerate is non-toxic. It consists of 90% natural materials, does not emit toxic substances when exposed to temperature. Completely safe for living quarters.
	Strength	Products of this type are not afraid of chips or cracks. If you drop a hot, heavy frying pan, in the worst case, there will be a small scratch.
	Plastic	Despite its strength and heavy weight, agglomerated quartz countertops are malleable. They are mounted not only on a complex frame, but also on legs, even if the area of ​​the product itself is large.
	Moisture protection	The materials do not absorb water and are not susceptible to mold. The acids in detergents will not damage the agglomerate. And the smell does not penetrate into its structure. No greasy stains remain.
	Cutting capability	A hole is cut in the countertops for a sink or for a hob, without fear that the product will burst or crack.
	No expiration date	Agglomerated models can not only serve for a long time, but easily outlive more than one generation of owners.

Cons of this type of product.

• Seams. Due to their weight, agglomerated countertops are not produced in a large area in a single layer. If their size exceeds 1.5-3 meters, the segments are neatly glued together, and the seams are filled with sealants and colored pigments. The seams are almost invisible, but they will not hide from an attentive eye.
• Small thickness of the countertop. In standard models, it is 2-3 centimeters. To increase this parameter, another layer is glued to the product. This is especially done for the restoration of complex damage.
• Due to its strength, the agglomerate is cut with special cutters and discs designed for working with marble.
• The big disadvantage is the difficulty of transportation. It is important to transport the slab vertically, and if it is angular with edges of 2.5 meters, then not every car will fit.

Acrylic stones

Positive properties and qualities of artificial stone countertops for the kitchen:

Icon	pros	Explanations
	Color	The palette is huge, several tens of times larger than that of quartz. Manufacturers have nearly 500 shades. This will allow you to find the perfect countertop for your kitchen.
	No seams	If you ordered a product 10 meters long, it will not have seams. It is beautiful and gives a plus in the form of waterproofing.
	Acrylic softness	To work with the product, wood processing materials are used. You can make the surface perfectly flat, wavy or with any fancy relief.
	Lack of pores	There will be no accumulation of bacteria, mold or mildew. Corrosive substances in detergents will not penetrate into the structure of the plate itself.
	Easy to clean	Any dirt can be removed with a soft cloth or a regular sponge without the use of aggressive detergents.
	Easy to restore	Any damaged area can be cut, sanded, glued, and sanded again. Not a single trace of work will be left.

• If the slab is solid, scratches will be visible. They can be applied by inadvertently moving the dishes.
• Slab sinks are cast immediately, you cannot install a metal sink model in them. Pouring boiling water without an open cold water tap is not recommended. There are no such problems with quartz models.
• Do not place a frying pan or pot that has been removed from the heat on the acrylic surface. This will cause damage.

Specifications

The artificial tabletop has its own technical characteristics. They are different for quartz and acrylic, which affects the cost, the first is more expensive, the second is cheaper.

Strength and durability

Decorative stone countertops are the most durable among competitors from materials other than metal models and some types of natural stone. Their service life is calculated for decades, and their relatively low cost makes them affordable. Compared to their counterparts from MDF and laminated chipboard, they can easily withstand heavy loads.

Quartz samples are not afraid of high temperatures. According to the assurances of the manufacturers, they can withstand 180 degrees of heat. They are scratched, but the restoration brings it back to its original appearance. This applies to acrylic models that cannot withstand high temperatures. They can be easily removed from scratches, even if they are deep.

Nice appearance

Artificial stone kitchen countertops imitate natural material. Granite and marble are popular. Many colors and shades allow you to create harmony in the interior of the kitchen and decorate the room. On sale are flat and embossed slabs.

Environmental friendliness

Countertops are non-toxic, do not emit harmful substances under the influence of temperature. Ideal for the kitchen, you can cook on them without fear for your health. Accordingly, not directly on them, but on cutting boards, otherwise you will completely damage the glossy surface of acrylic boards.

Possible tabletop shapes

The worktop material is processed at the production stage, it is cut, bent, glued. Let's consider the common options in more detail.

Photo	Form	Description
	Rectangular	Standard shape, suitable for any kitchen. If the length does not exceed 3 meters, it is a solid slab. If the tabletop is made of acrylic, the length will be any, and the slab will still be solid. But quartz has seams, since the products are heavy in weight and it is almost impossible to produce a large solid slab, otherwise it will burst.
	Square	Suitable for tables and corner tables. Small meter by meter, excellent appearance and suitable interior will make a small table a highlight of the kitchen.
	Arcuate	Used to make reception tables or bar counters. Massive structures serve for years and are suitable for an interior in a simple business style.
	Non-standard forms	These are undulating slabs, models with semicircular cutouts, square holes, and so on. They are made according to individual sketches and sizes.

Variants of the profile of edges and sides that kitchen worktops have

Every tabletop has edges. They are designed to protect the product from chips at the edges, to make it smooth and safe to use. The edges are made in the form of sides - this will not allow water from the surface of the product to spill onto the floor. Consider the main types of edges and sides:

Edges

Image	Name	Explanation
	Rectangular	Standard option. Suitable for classic interiors.
	Bevel at 45 degrees	The bevel is made along the top edge. Brings solidity to the style of the product if it is made to imitate natural stone.
	Rounded on 1 side	Rounded at the top. Perfect for small stoves and bar counters.
	Rounded on 2 sides	The edge is made in round products. It is used in tables for cafes and restaurants.
	Rounded with insert	The original version. The slab can be beige and the insert dark.
	Radius	Used in large rooms or studio apartments.
	With side	Performed with a raised edge. Avoids overflow of water.

Bumpers

Image	Name	Explanation
	Rectangular	A detail designed to protect your countertop from overflowing water. Finalizes the overall style and finishes the product.
	Semi-integrated	It is used as a part that protects the seams between the wall and the worktop.
	Integrated carryover	It is executed in the same height as rectangular, serves as a semi-integrated one.
	Integrated	Protects seams between wall and worktop from water and has a radial cut for easy cleaning.

Artificial stone countertop with sink

The sink is an integral part of the kitchen. The artificial stone countertop with a sink has two types of integration into the overall structure. In quartz products, models with a built-in sink made of stone itself are rarely found.

A hole is cut in the slab and a metal model of the sink is inserted. In acrylic models it is different. They have a niche that serves as a sink.

Advice: Professionals say that it is wiser to put a separate metal sink. It can withstand any temperature and is not afraid of scratches and chips.

Do-it-yourself artificial stone countertop - installation tips

When self-assembling an artificial stone countertop with your own hands, we recommend that you follow the tips:

1. Do not work alone if working with quartz products. They are heavy: if you do not hold the stove, you will damage the product and get injured.
2. First, assemble the frame, and only then install the plate itself.
3. Use silicone sealant when sealing joints. Then trowel the seams with a diamond disc.
4. When drilling into the slab, use a high speed drill to avoid chipping around the edges of the drilling holes.

Care features

Countertops have similar characteristics to natural stone counterparts. They are washed with various detergents, except abrasive ones. It is advisable not to drop objects made of steel or glass on the surface, there is a risk of scratching the surface.

Important: Do not make sudden changes in temperature on the surface: we do not recommend cutting frozen chicken and then putting in a hot frying pan or kettle.

It's all about the rules of care, otherwise the material is practical.

TOP 5 countertops with prices

Below is a table of the most popular models of artificial stone countertops for the kitchen on the market:

#	Photo	Name	Area, sq m	Color, polish	Edge profile	Price
5		With backsplash	0,7	Magna Savannah, semi-gloss	top 6 mm, bottom 1 mm	RUB 16,300
4		Made of light-conducting material	1,1	S304 Ruby, semi-gloss	top 3 mm, bottom 1 mm	RUB 44,100
3		Radius bend	1,9	S111 Dark night	–	RUB 52400
2		With wall panel	2,1	Cocoa Brown, semi-gloss	top 1 mm (technical chamfer), bottom 1 mm (technical chamfer)	RUB 53,000
1		With hob gantry	1,8	4805, matt	top shaped chamfer, bottom 1 mm	RUB 54,300

Photos in the interior

The furnishings of the kitchen space are formed based on the hostess's requirements for functionality, practicality and safety of furniture and equipment. In this regard, the countertop is the most profitable object, since it makes it possible to perform culinary operations of any complexity without requiring special care measures. Since the cost of high-quality models of this furniture is quite high, an equally reliable home-made countertop made of artificial stone becomes the optimal solution for many. It is not difficult to do it with your own hands - the main thing is to adhere to the rules of manufacture and installation. In addition, it is important to have an understanding of the principles of repair and maintenance. Although the countertops are not demanding on maintenance, intensive use in the kitchen still determines some nuances in the content.

Tabletop design and parameters

Artificial stone forms the work surface of the countertop, which can have different thicknesses. For example, for a bar counter, a 3 mm version is quite suitable, which does not imply high loads. If you plan to make a do-it-yourself countertop made of artificial stone for intensive use, then dimensions of more than 1 cm are preferable.By the way, according to existing standards, the maximum thickness of the coating should not exceed 3 cm.

Stone tiles are glued to the base with a special glue. With the help of this material, the edges and the top of the countertop are also made, and a different material can be chosen for the bottom - the main thing is that it is able to hold the plate. Artificial stone is often used for wall cladding in the area of ​​the countertop, so this moment of stylistic combination should be taken into account initially.

Quartz conglomerate or acrylic?

Modern models of artificial stone are distinguished by a high degree of protection against external damage, which, in fact, makes this material one of the most successful in relation to the kitchen environment. It is worth considering two materials from which a do-it-yourself artificial stone countertop can be made - these are quartz conglomerate and acrylic. They differ in the type of polymer resins that are used as binders.

Quartz conglomerate contains polyester resins (epoxy), which have higher rigidity, heat resistance and strength compared to acrylic counterparts. The disadvantages of this stone include a small selection of textured designs and laboriousness in processing. Among the strengths of acrylic boards are more affordable price and moisture resistance with a variety of stylistic solutions.

Calculation and design

During the planning phase, the exact dimensions and configuration of the countertop should be calculated. It is wrong to think that such furniture has nothing but a work surface. However, for some kitchens, a simple U-shaped countertop made of artificial stone is also suitable. It will not be difficult to make it with your own hands, but in terms of functionality, it will lose to more complex structures. At the same time, it is important to take into account the presence of a sink with a hob on the working surface - the main calculations are carried out specifically for these areas.

If it is planned to organize a kitchen corner, then the base of the countertop should be calculated taking into account the appropriate placement of adjacent objects and the ways of their possible connection to the network. Standard custom-made artificial stone slabs usually have standard sizes of 366x76 or 140x305 cm. Approximately from these indicators, the future countertop must be calculated, however, it is not excluded that the material can be adjusted during work. The depth of the working surface is usually 60 cm, but if we take into account the end part and the edge, this figure will increase by another 5-10 cm.

Layout preparation

In order to visually represent the image of the future structure, it is necessary to reflect its general appearance on paper. On the sketch, it is not necessary to indicate the technological elements (holes for pipes, grooves for sinks, etc.) that the artificial stone countertop will have. It is quite possible to do them with your own hands already on a finished curbstone, outlining their placement in a real setting. To create a full size layout, you can use sheets of thick cardboard. Of these, it is easy to glue the box and attach it to the walls. More laborious in the manufacture of the layout of the corner-type table top - in this case, miscalculations should not be allowed when forming the docking places. If the prepared base corresponds to the parameters of the workplace and enters the place for the countertop planned in the kitchen, you can disassemble it and start creating an analogue of stone.

Making the base for the countertop

It is not rational to use slabs of artificial stone for assembling the frame, therefore plywood is used as the material for this part. It is cut into strips of 7 cm wide, focusing also on the parameters of the manufactured model. Other materials can also be used for the base on which the do-it-yourself artificial stone countertop is made. A photo of the model made of plastic panels is presented below.

However, chipboard options are more common as they are more affordable. The only thing that is important to consider is the thickness of the plywood sheet. To support a massive stone slab, at least 3 cm sheets are required.

Base and stone slab connection

For this operation, a two-component adhesive should be used, the choice of which depends on the materials. For example, epoxy effectively acts as a bond between wood and acrylic. It is necessary to cover the entire surface of the substrate with a thin layer of the composition, and it is advisable to use a spatula for its uniform application. When processing stone slabs, the adhesive should only be applied in areas where direct contact with the plywood base is expected. After this procedure, the two parts of the future countertop are combined into one structure. In order to increase reliability, you can make a countertop from an artificial stone with your own hands in such a way that the composition of the glue covers the entire area. During the installation process, it is necessary to press the stone sheet in the center and distribute the load on the sides.

Fitting the ends

Aligning the ends is a very crucial step that should be performed after the glue has dried. In general, it is advisable to use a manual milling machine for this procedure, but since it is not available in every household, a coarse-grained sandpaper block can be offered as an alternative. As a result, the ends will turn out to be not so even and smooth, but this does not matter, since in the future they will have to be pasted over with the same stone. For this reason, you should not buy sheets of acrylic or quartz conglomerate exactly for the dimensions of the working surface - at least for the ends, it is worth adding a few centimeters in length or width. With processed and beautifully designed ends, you get an aesthetic and outwardly pleasant kitchen countertop made of artificial stone. With your own hands, you need to cut the strips with a width corresponding to the parameters of the edges. Then degrease their surface and use glue to fix the strip to the end.

Installing the countertop

You can start installation when the glue at the end dries up and it will be sanded. The place where the new kitchen object will stand is cleaned and washed. All communication lines must also be prepared. As a rule, installation is carried out using screws, since the use of glue will not give positive results. The base is screwed to the pedestals, racks or walls - depending on which surfaces the object will be adjacent to. It should be noted that installing an artificial stone countertop with your own hands involves only fastening operations with the frame. This means that the worktop as such is not fixed to walls or adjacent furniture. Fasteners are mounted in plywood, after which holes for the hob or sink are created in it with an electric jigsaw.

Countertop repair

It is difficult to find kitchen furniture that is more protected from external damage than a stone countertop. Nevertheless, contact with hot surfaces, impacts of sharp and heavy objects, cutting food without using a cutting board and other operations do not go unnoticed. Defects remain in the form of chips, cuts, texture changes, etc. Minor damage is usually dealt with by fine-grained polishing, polyester products and sanding. But if the depth of the defects is more than 3 mm, then you should perform a more thorough repair of the artificial stone countertop with your own hands using a hand mill and restoration with patches. Two-component polyester glue, which is usually used to restore the places of chips and cracks, will also help in repair. The liquid mixture spreads over the problem surface, filling all the grooves with itself.

Countertop care

To prevent a situation where repair becomes inevitable, surface testing with high physical and temperature loads should be minimized. At the same time, it is recommended to clean it regularly with ordinary detergents. Once a month, polishing the countertops made of artificial stone will not be superfluous. With your own hands, such care can be done using felt or mild abrasives. This procedure will improve the appearance of the countertop and prevent the formation of stagnant stains. But care of the surface itself should be directed not only to its immediate protection and maintenance of performance. Since this piece of furniture is in direct contact with food, it is necessary to include in the care measures and disinfect processing. There are special preparations for cleaning the same acrylic, which provide both the removal of dirt from the pores and the formation of antibacterial coatings.

Furniture sets for the kitchen in a standard design, as a rule, are completed by the manufacturer with a worktop made of thick chipboard with MDF trim panels. Over time, the lacquered surface deteriorates, so many owners prefer to replace the wood with a more reliable artificial stone countertop 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 an artificial stone can be gleaned from the text.

How to make a stone countertop

In general, the procedure for making a tabletop made of monolithic artificial stone is no different from casting facing tiles or massive decorative elements, the only difference is in the size of the product and correctly selected materials.

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

• Casting 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 of manufacturing a monolithic slab from 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 the stone casting, the weight of the finished worktop and the possibility of safe transportation are taken into account. Even if you make a casting in the form of two parts, it is not so easy to bring in and install a multi-kilogram stove in a small room of a 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 the 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 countertop did not really think about the possible replacement of a wooden shelf with a slab made of artificial stone. Therefore, the supporting frame has to be strengthened, and the tabletop itself must be slightly simplified and modified for finishing and polishing.

Advantages of artificial stone

The difficult procedure of forming a cast from artificial stone often baffles the owners as to whether it is worthwhile to bother with installing a stone countertop at all, if you can order and install a regular shelf made of pine boards, 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 a wooden countertop;
• The ability to carry 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 turns out to be much safer and more durable, in most cases, falling objects stored in kitchen wall cabinets do not even leave scratches, while serious damage is possible on the varnish.

The worktop made of artificial stone casting can withstand the difficult conditions of the bathroom as well as the sanitary ware. A wide panel made of artificial stone installed instead of a traditional plastic or wooden shelf 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, oven dishes, and in some cases even chop meat on an artificial stone countertop. According to the owners, the stone casting shelf is primarily appreciated 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 artificial stone is made on the basis of polymers. For example, a polyester matrix can easily withstand a temperature of 200-250 ° C, while a chemically cured acrylic resin is a maximum of 150-170 ° C. Therefore, before trying to make a slab from stone casting, you need to make up for yourself an accurate idea of ​​the dimensions and the planned material for the manufacture of countertops.

Materials for making kitchen countertops

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

• Acrylic resin;
• Epoxy matrix;
• Polyester compounds;
• Gelcoats or liquid stone varnish.

In addition to polymer matrices, fiber-fiber materials, quartz, ground silicon, titanium oxide, granite, basalt and marble screenings with a ground and polished surface are widely used. About 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 countertop

The idea of ​​making a countertop based on concrete casting may seem a little outdated and even inappropriate, due to the enormous 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 high-impact plastic.

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

In addition, it is quite possible to cast a tabletop from a concrete mixture 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 rightfully considered one of the most successful materials for making artificial stone countertops. Natural materials are thoroughly washed, dried and separated into fractions. The matrix for quartz artificial stone is refined or white marine epoxy resin or polyester compound with the addition of titanium oxide.

The result is a homogeneous monolithic countertop made of artificial stone, which in color and texture resembles the most beautiful natural stone - marble limestone. If pellets of quartzite, granite or any other ornamental and decorative stone are added to the composition, then you can get a fairly wide 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 to cure the polymer, it is necessary to use a thermostatted box or chemical polymerization accelerators.

Therefore, home versions of a polyester stone countertop after pouring are heated with hair dryers and blowers, but there is still a risk of the formation of a raw core of an artificial stone slab. If you install an artificial stone countertop without waiting for the polyester to completely cure, over time, a deflection can form on the plane.

Ceramic tile worktop

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

The technology of forming a countertop finish from a tile under an artificial stone is no different from the usual laying on the walls of a kitchen or bathroom, but there are several 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 the artificial stone;
• The front surface of the concrete stone is carefully ground and cut with emery to remove any slopes and irregularities;
• The tiles are carefully calibrated, selected to size and, if necessary, trimmed to one size with an accuracy of tenths of a millimeter.

If all the requirements for facing a countertop made of artificial stone are fulfilled 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 joints in tenths of a millimeter after grouting are simply not perceived by the eye.

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

Acrylic artificial stone countertop

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

Casting from an artificial stone based on chemically cured acrylic is absolutely safe in terms of sanitary standards, with a smooth monolithic surface. Artificial stone does not react with any liquids in the kitchen, does not allow water to pass through, there are no pores and microcracks in which contamination 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, a marble pebble or polished granite screening, basalt dust in combination with a dye, allows you to create very beautiful, lightweight and at the same time durable pieces of kitchen furniture and interior, not necessarily just countertops.

Making countertops from artificial stone

The technology of stone casting and molding of artificial stone, at first glance, is very simple and even artless, 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 by a trial batch on a purchased filler, for example, on ground quartzite or washed sand. If the 120x50x5 mm plate could not be broken by hand, then the proportions for the artificial stone were selected correctly.

The first step is to measure the future space for the countertop and draw up an approximate sketch with the exact dimensions of the slab. From this data, you can easily calculate the volume of artificial stone and the required amount of materials. The proportions of the mixture for casting the countertop are as follows:

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

For a countertop 60 cm wide, 250 cm long and 3 cm thick, a total of 40 liters of the mixture will be required, excluding the window for the sink. The third part - 13 liters will fall on acrylic resin. In addition to the foundry 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 considered to be the construction of a finished form for pouring a stone mixture. Only an experienced carpenter can make a shape for the countertop exactly according to the sketch; those who are not in tune with the carpentry business will have to go for a trick. A template or profile with all the openings for the sink and stove is cut from a large piece of wallpaper or paper canvas. Next, the tracing paper is transferred to the bottom of the mold and the contour of the future slab of artificial stone 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;
• Jigsaw, drill with a set of drills;
• A set of corner clamps;
• Wide pliers;
• Metal tubular mandrel;
• Industrial dryer.

First of all, the bottom of the mold is laid out on the flat surface of the workbench or desktop; it can be made of PVC panels or plywood with glass laid on top. 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 higher than the expected thickness of the tabletop. The sides are pulled together with clamps in a box and placed on the bottom of the mold.

For your information! The width of the form is planned to be 6-10 cm larger than the actual size of the countertop.

Technological process

All cracks and joints are carefully rubbed with automobile plasticine to avoid leakage of the filled-in 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 placing the filler in the mixer, the casting mixture for the artificial stone is kneaded for another 15-20 minutes.

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

The final design of the countertop

After two days, the clamps are removed and carefully separated from the artificial stone. With the help of sharpened chips, pry and remove glass or PVC panels from the plane of the table top. Wash off paraffin and dirt with a clean cloth and soapy water. All sharp edges are trimmed with a knife.

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

Mirror end milling

In order for a slab of acrylic stone to look as natural as possible and not give out its artificial origin, the entire surface will need to be polished, and the ends should also be mirrored.

Polishing is carried out with an automobile grinding wheel with a felt pad. The ends milled or cut with a 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 practically without pressure, since an artificial stone based on a solid filler and an acrylic matrix can easily lose some of the plastic and turn into a "pimpled" surface.

Diy liquid stone countertop

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

The only drawback of the liquid stone pouring technology is considered to be the poorly predictable behavior of a liquid mixture of an artificial stone on the sprayed surface. It is necessary to pre-experimentally test various mixtures for simulating an artificial stone surface in order to obtain a uniform, smooth coating with a strong adhesion on the countertop.

We make liquid stone ourselves

The artificial turf is applied using a compressor and a high pressure spray gun with a 3 mm nozzle. The finished mixture contains about 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, a soil and a topcoat are used, the soil is prepared from:

• Fine 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 gelcoat is doubled. Polyester gelcoints are not used for the manufacture of artificial stone countertops due to the low hardness of the material.

Direct way

The simplest method of making an artificial stone countertop involves directly spraying 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, 3-5 layers of material are applied with the direct method.

Reverse way

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

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

We make the form

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

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

Preparing the mixture

Liquid artificial stone is applied in three layers:

• The first layer with a minimum content of filler, most often a translucent solid 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 re-laying of the surface with a reinforcing cloth.

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

We start making tabletops

The first layer in the reverse method is applied with a separator. The air temperature should be at least 18 ° 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 epoxy mass with a high content of reinforcing fiberglass.

The last to be laid is a steel profile reinforcing frame, voids and gaps are filled with polyurethane foam.

Installing the countertop

The weight of the new liquid stone countertop allows the slab to be installed using the old frame. The brackets placed in the frame of the table top allow leveling the slab made of artificial stone mass and fixing the stone surface in a perfectly horizontal position.

Repair of artificial stone countertops

The surface of the artificial stone panel is inferior in hardness and durability to natural material, so the countertop must be regularly inspected, checked and repaired in order to stop the destruction at the initial stage.

Types of possible damage

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

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 a polishing paste, and 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.

Removal of blisters and stains

The most difficult case is associated with the formation of fistulas and swellings 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 with detergent and cleaned with isopropyl alcohol. The gloss of the gloss is shaded on the surface of at least 20-30 cm2 to blur the border.

Conclusion

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

Today we will figure out how to do artificial stone countertops... The surface of such countertops is resistant to moisture, mechanical damage, and also sufficiently heat-resistant (that is, it painlessly tolerates temperatures up to 180 ° C). So, the manufacturers say ... Let's not ignore their shortcomings.

When used in real conditions, knife marks remain on the acrylic surface, that is, you cannot cut on it without using cutting boards. Putting a hot pan on it is also not worth it (its temperature is slightly higher than the declared 180 degrees, and why, it is fraught with the formation of stains. Acrylic countertops should be washed with detergents without abrasive components, and therefore, stubborn stains are removed rather tightly.

But there is one big BUT here. All defects, including stains, can be simply sanded off with subsequent plating.

The article will be about sheet stone and the technology of working with it. So, such sheet acrylic is produced in the form of standard sheets of 3660 x 760 mm, moreover, the thickness can vary (3 mm, 6 mm, 10 mm, 12.7 mm, 30 mm.).

Before starting work, you should take measurements and decide on the configuration of the tabletop. If we take a straight tabletop, then no special problems are expected. If we change the old chipboard countertop, then we can take all sizes from it. Alternatively, you can first make a full-size cardboard template. We put this template in place and make the necessary adjustments to it, so you can avoid almost all inaccuracies that you will actually encounter later in the installation process.

Let's analyze the most budget options for countertops, that is, the thickness of the stone that we will use will be 12 mm or less). Such a thickness in isolation may not give sufficient strength to the product, so a backing or frame is required. The ideal material for her is plywood, or better, bakelite plywood, which is not susceptible to moisture or MDF.

Some manufacturers use laminated chipboard, but in my opinion, it is less reliable, because during operation, the base can swell, which can lead to a discrepancy of the adhesive seam.

The frame can be made either from plywood strips, which are assembled around the perimeter of the tabletop, or use a solid sheet, which is much simpler, but somewhat more expensive.

To make the frame, we just need a cardboard template that we made earlier. So, we cut out a substrate for a stone from plywood.

The stone itself is cut either on a panel saw or with a circular saw on a tire.

The size of the acrylic sheet should be greater than the thickness of the substrate by the thickness of the edge (i.e. the thickness of the stone sheet). For example, if we glue a 7 mm stone countertop, then the backing should be 593 mm wide (for a standard 600 mm countertop), and the acrylic stone sheet should be 600 mm wide.

To connect the substrate with acrylic, we need any two-component glue designed for gluing acrylic and wood, for example, epoxy resin or Kleiberit, Solupren X2 adhesives.
The entire base should be covered with a thin layer of this glue, which is spread over its surface with a spatula (some glues of a more liquid consistency can be applied with a spray gun - read the instructions). On the acrylic sheet, glue is applied only at the points of contact with the substrate.

Then both parts are superimposed on each other (do not forget about the offset to the edge) and pressed tightly. This will require a sufficient number of clamps.
If the base is solid, then, having combined the sheets, we begin to press from the center to the sides, first moving to one edge of the tabletop, and then to the opposite.

We proceed to gluing the edge. She is served by strips of the same acrylic along the thickness of the future countertop. Thin strips can be glued in half.

Radial edges (as in the photo) are made by heating the strips in a special oven and then applying them to the base, on which they cool down, taking the desired shape.

It is better to use a two-component glue for gluing the edge with a proprietary one from the manufacturers of acrylic sheets (LG, Samsung, DuPont), and its color should be selected according to color tables.
Before gluing, for best results, the surfaces to be glued must be cleaned with P60 sanding paper. Then degrease with a solvent (for example, industrial alcohol).

After that, the glue is applied to the edge of the edge,
the edge itself is superimposed on the right place, rubbed a little so that the glue is evenly distributed over the joint, and then it is attracted to the tabletop with clamps. The top of the tabletop should completely cover the edge, possibly a slight overhang. A lot of clamps will be required))).

After the glue has dried (about 40 minutes, depending on its type - see the instructions), remove the clamps and proceed to remove excess glue, and at the same time the acrylic overhangs in the upper part of the countertop. For this, a cylindrical copy mill () with an upper or lower bearing is used.

Then a molding cutter of the desired profile is placed and a roll of the desired radius and profile is formed.

Then the final grinding of the countertop surface and the joint itself is carried out.

Such a tabletop is attached to the kitchen boxes with self-tapping screws, which are wrapped in a base. It should be checked that the screws remain within the plywood, without reaching the acrylic sheet.

I gave the manufacturing technology for a relatively budget countertop in artisanal conditions. In factories, this technique is used when the edge is glued into the quarter cut, which is milled at the bottom edge of the top sheet.

This makes the joint even less visible. An example of such manufacturers of acrylic stone countertops is Moscow Mos-Kamen company mos-kamen.ru.