Tag Archives: Faux Stone Manufacturing

How Faux Stone Is Created

Many today use alternative stone products called faux stone and migrating from old methods of creating stone features in commercial and residential construction.

What many wonder and ask is “how is actually faux stone made?”

For some companies manufacturing this material the answer to the above question means revealing some in-house techniques that are somewhat confidential. Although the general idea is not a secret, some companies have their own way of mixing the components or even the types of paints used.

We did a bit of snooping around to find out what we could.

The base material used for faux stone is a polymer called polyurethane. This replica stone material is used for a variety of application but it performs quite well for interior and exterior stone applications. Some qualities such as flexibility, durability and insulations are very appealing to builders who avoid maintenance at all costs.
The owners of the building are also interested reducing heating and cooling bills so they are well motivated in using this material.

In order to provide a material that will last and withstand the outdoor elements some companies do two things:

–          Add more resin during the manufacturing process and make the stone more dense

–          Add barrier coats and outdoor paint coating.

This is the main factor that sets apart high quality faux stone.

Most synthetic stone densities ranges from 16 lb/sq.in to 20 and this definitely changes the pricing level offered to consumers.

The density level has to vary based on the use required. For example, in case of interior decoration you will want to use a higher density.

Interior decoration materials

Interior decoration materials

When parts are used for interior stone wall the density can be a bit lower but the high one can still be utilized.

stone polyurethane

Polyurethane Faux Stone

For foam used inside car seats or upholstery the density must be low in order to provide comfort.

low density foam

Low density foam for car seats

When it comes to paint some faux stone manufacturers try to save on the paint costs whereas others make a business decision to lose some revenue, by spending more for quality finish, but keep their customers happy and be referred to others.