Decorative stucco elements, all kinds of bas-reliefs, plinths, cornices, sculptures and architectural elements They have been decorating buildings for many centuries, both outside and inside. Nowadays, this tradition continues and is supplemented by new types of gypsum products. Artificial decorative rock, a new production, but the products are often used in construction and decoration. It’s easy to work with gypsum even at home, and the material is not very expensive. The main thing is to have a cast from which the mold will be made, and then it’s a matter of technique. How to make DIY design a profitable business?

Mini business plan for the production of gypsum products

By combining all components of a business into a common process, rational interaction is ensured to achieve an efficient production economy.

The main questions to focus on are:

1. Shop– correct location and arrangement.
2. Raw materials- everything for working with this mineral.
3. Equipment– without it it is impossible to establish production output.
4. Staff– experienced employees, these are high-quality products.
5. Manufacturing technology– an experienced technologist, a faithful assistant in work.
6. Sales of products– following the previous points, the products will not be delayed in the warehouse.

Cast from plaster various types products, but the most profitable production is large, dimensional items, including rosettes for walls and ceilings, decorative parts of columns and also the columns themselves used for decoration, figurines for the garden, piggy banks and other artistic products.

All kinds of huge panels decorating the walls. Borders for decorating ceilings, pilasters and domes. All products manufactured without the use of now outdated casting processes. It is possible to open the production of figurines made of plaster, stucco, making souvenirs from plaster and decorative tiles.

We save money

You cannot do without a business plan - it will take into account in detail all financial and other expenses. The profits that are expected to be received, as well as the losses that are expected to occur, are calculated. Be sure to calculate the feasibility and profitability of the project, as well as the amount of investment in starting a business, according to market conditions.

Expenditure:

1. Selection of suitable premises, this is one of the main points of cost accounting. There are no great requirements for the premises, but its location should not be in a residential area. Dry room with good ventilation.
2. Preparation of molds for production of gypsum products. It is better to make the forms yourself; it is much cheaper than ordering from the appropriate company.
3. Conclusion of an agreement with a wholesale organization for the purchase of alabaster and additional material.

Gypsum: technique, techniques, products.

How can a novice businessman open a workshop for the production of gypsum products?

Properly organized production of gypsum products will make it possible to save labor resources, increase the creativity of the staff, and the personal interest of everyone. To provide conditions that will help implement production activities in all areas.

For a workshop in which alabaster products will be made, it is better to choose an industrial area. Gypsum products, or casting, are environmentally friendly production. But first of all, professional workers are needed for technological specialization.

Glass-plastic molds, without which such casting is impossible, are the main production for the start of the main production of products. Polyester resin and styrene when polymerized give the corresponding result. The necessary copies can be made by a young artist. Since the work is temporary, you can conclude an agreement with the student. A copy is placed in an airtight container and filled with silicone. The frozen polymer, in the resulting form, is removed and cut in half. These molds are then used to make gypsum products. Reusable forms.

The workshop must have a molding chamber with a local exhaust system located directly above the table. A mandatory attribute is the use of protective equipment respiratory system personnel (respirators).

There are no difficulties in organizing production and manufacturing gypsum products, and the business has high production profitability. From one bag of plaster weighing forty kilograms and costing around two hundred rubles, ten rosettes are cast. The diameter is seventy centimeters. With costs within two hundred rubles, the profitability of gross output is up to ten thousand percent. Calculating income is not difficult. And income, plus satisfaction from the work done, gives a wonderful result.

So, the multi-purpose direction of production of products from alabaster has shown that it can be used in different areas, even in medicine (it is used for broken limbs). But in construction it is an indispensable material. There is no construction site where gypsum is not used, and how auxiliary material, and as decorative. This is because the technological properties of this material are very easy to use and durable. Has low fuel and energy capacity. Fire-resistant material that does not succumb to the fire elements. The adhesive properties and rapid hardening of the solution make it possible to use technological capabilities in the manufacture of all kinds of products. The product range of products depends on the imagination of the manufacturer. The main thing in implementation is to prevent marriage. You should remember the high architectural requirements; all products must meet them. All products are made only from environmentally friendly and safe materials. The manufactured products will objectively provide the advantage of gypsum materials during operation. As a result, it has priority weight when used in construction, as well as reconstruction of buildings.

The multi-purpose use of this material and all its capabilities have been confirmed by domestic scientists and industrialists, who have substantiated many years of research in their works.

Industrial premises

The production workshop is not one closed large space, but has isolated rooms independent from each other:

1. Change house– a room for personal needs of personnel, where workers can change clothes, wash, rest and eat food.
2. Work room– for assembling models produced by casting molds. Such a room is equipped with solid tables made from welded iron corners. The room should have shelves for placing plumbing tools and electrically driven tools on them.
3. Forming room- well insulated, small room, in which molding is carried out, followed by polymerization of molds for casting. Here they cut and polish finished forms. And since all actions performed in this room are related to chemical reactions, which emit harmful fumes and dust, this room must be well insulated. A good, securely reinforced table is installed in the room; it is made from fifty-millimeter corners. A high-quality and local hood for air filtration is placed directly above the table. A room with good lighting, the light is low and without casting shadows.
4. Decor room- in this room they are engaged in the process of casting decorative parts. The tables are welded from corners, but the height is adjusted to the height of the person casting the decor.
5. Stock– in this room they store the raw material for making plaster products, spare tools, buckets and all kinds of utensils.
6. Warehouse space– finished products are stored in it. But this room should have some features and it is advisable to consider them in more detail. The manufacturing process of products has its own functions, but you need to be able to preserve the finished product. When drying, the cast product should not change its geometric shape, remaining the same as during manufacture. The warehouse should be equipped with racks for drying products. They are made from metal corners by welding, and a metal square is used to support the corners. The correct installation of this structure requires checking with a level. The surface is covered with paint in several layers. The finished product warehouse has flow-exhaust ventilation for constant air circulation.

Raw materials and supplies for the production of gypsum products

Gypsum products are made from quite accessible materials:

1. Gypsum- the main component of the entire production. It is good to use material under the brand name “G-5”. For the production of your decorative products, you cannot use material with a long shelf life; the resulting product will be of poor quality. Where the source material is purchased, construction stores or wholesale warehouses, a certificate must be issued indicating the date of release of the powder.
2. Water– use ordinary water, but without all kinds of impurities. Not allowed for production dirty water, it must be clean and transparent in consistency; no rust is allowed. All foreign excesses present in the water will subsequently begin to appear in the form of inclusions on the surface, ruining the presentation of the product.
3. Polymer material- it is included in the expense item, it is used when casting forms from fiberglass: for this, they purchase gelcoat, molding polyester resin, a hardening catalyst for three types of glass mats, and a release paste.

To search for suppliers, you should use the Internet, just use the keywords Neste Chemicals and Reichhold. These supply companies often provide training opportunities through courses for personnel to learn the forming techniques required in the production of fiberglass molds.

This plan has its own charms, since it is possible to produce stucco molding from gypsum without bulky and expensive equipment. The savings are that many items are made on our own, purchased only hand tool.

Items that will be needed to organize the entire gypsum production process:

1. Tables– welded from metal corners and coated with paint.
2. Hood– installed for the molding room exhaust system, the box of which is located directly above the table, and the electric motor, the snail of which is mounted on the wall outside. Two fans are located at opposite ends of the room, performing supply and exhaust ventilation of the finished product storage area. Fastenings are made in holes made in the wall.
3. Electrical tools– small electric drill, medium electric drill, for use when preparing plaster mortar, using a special one, the right size, mixer. An electric jigsaw is used for cutting shapes, an orbital sander is used for sanding products, and a mini drill is used when working with shapes. A device for tightening screws, and an angle grinder with speed control at medium power.
4. Scales– you will need floor-mounted and small ones that are used when placed on a table.
5. Additional expenses– polishing paste - used for finishing casting forms, sandpaper - used in different grain sizes, auxiliary metalworking tools.

Staff

1. Workshop manager– his duties can be performed by the owner of the business; it is necessary to organize the work of production, control the uninterrupted supply of materials, search for and place orders.
2. Caster– two people are enough. The work is not hard, so there is no need to be picky about the selection of foundry workers; even a woman or a teenage child can do the work. The work is not classified as harmful or difficult, and the result of the work is immediately visible. The work is monotonous, the skill comes quickly and there are rare cases of defective products. Payment is made according to the quantity and quality of work performed, that is, piecework.
3. Moulder- Two people are needed for the job. Preferably with experience, since successful production will depend on the experience of the molders. They are required to prepare polyurethane models (release agents will help in training), assemble structures on which the models will be attached. Form and successively process, that is, polish and grind the parts.
4. Installer– It is advisable to use two people. Their responsibilities include installation of finished goods for the customer. This operation must be carried out carefully and with a great deal of responsibility; the installer’s work is paid dearly.

The selection of candidates for the upcoming work is carried out carefully, only experienced employees are accepted. In the absence of such, it is worth forming a duet in which there will be an experienced installer and a very diligent, diligent student.

Technology for the production of gypsum products

The casting process is reminiscent of children's games in the sandbox. Open the bag of gypsum powder. Eliminate lumps and foreign inclusions by sifting through a sieve; use only fresh material.

• 1. From prepared material, the required norm for work is weighed. It will not be possible to determine which norm is used for the manufacture of, for example, a ceiling rosette during the first pour. Take a larger volume than required, reducing each subsequent fill rate, in this way to reach the optimal rate of use. You should keep detailed records of data, recording everything for each specific type of product.
• 2. Water is combined with gypsum in a one to one ratio, the same part of water is added to one part. The resulting mixture turns out to be a liquid consistency, but this prevents the appearance of holes; they appear where air bubbles exit and spoil the casting surface. Experience shows that the influence of such a ratio of the components of water and gypsum does not increase the hardening time of the alabaster fill and does not in any way affect the quality and strength of the product. Not only are there no annoying holes on the surface of the finished products, but there are big savings without the use of a vibrating table. A vibrating table is an expensive device; it is large, bulky and very noisy during operation.
• 3. The mixture is being prepared, according to the principle of kneading dough. A special drill is inserted into a construction mixer and a batch is made in a plastic bucket: water is poured, the amount is determined by trial, and it is poured into the water required quantity powder.
• Just wait a few seconds, and when the powder goes under the water, you can start kneading. It all starts with gentle stirring, using a mixer at low speed, helping the air to come to the surface. Such a mixture does not allow marriage in the final result.
• 4. Pouring begins in a special way, using refined sunflower oil, you should not use expensive oil, for the sake of economy you use cheap oil, this does not affect the quality. A flute brush is used to apply the oil. The surface of the mold is covered with front side, the oil is applied without excess, rubbing well, without making any passes.
• 5. The mold is filled with the mixture, little by little, so that a thin stream flows, this requires patience, haste and slowness will ruin the part. Only experience will help the solution spread smoothly over the entire surface of the mold; in this way, air is gradually squeezed out, preventing defects in the product.
• 6. The form is filled completely to the very edges. The mixture stands for several minutes. After the plaster has set, but not completely, the following actions are performed. Using a flat bar (you can use wood, aluminum, plastic), the excess mixture is “cut off” by pressing the bar on two opposite sides of the mold at the same time. After this procedure, there are no flaws on the pouring surface. The material begins to heat up as it hardens, but the beginning of cooling is a signal for the finished casting to be removed from the mold.
• 7. The work is completed by carefully cleaning the edges. The edges of the form are bent along the entire perimeter, all this is done with extreme caution. Next, the form is turned over, slowly, supporting the frozen material in the middle, and carefully lies on the table. Holding the upper part of the form, you need to bend the edges in a circular manner, while simultaneously lightly and frequently tapping along the entire surface of the structure. Up to a certain point, these actions are performed until the product leaves the mold, falling out of it. The actions are completed by carefully lifting up the empty form.

That's all, this completes the process of producing gypsum products. You can check the quality of work. If light reflections from the sun's rays are reflected on the surface of the finished product, it means that the grinding and polishing of the entire surface of the matrix was done perfectly.

Production of gypsum figures, stucco moldings, souvenirs, decorative tiles- here is another approximate range of possible areas of production.

How to properly sell finished products?

Most often, the owner of the enterprise is responsible for the sale of products. It is possible to achieve results different ways. You can use printed materials by placing advertisements there, describing in detail all the properties of the product.

A good, and perhaps main, distribution channel would be through construction supply stores. To do this, samples should be placed on the store shelves and anyone who is interested in these products can individually place an order directly through the seller.

Even a fireplace can be decorated with plaster construction

Gypsum– the material is resistant, not afraid of fires, so decorating fireplaces with stucco is not prohibited, but on the contrary is encouraged. Plaster stucco very often decorates classic and so-called false fireplaces.

These can be fireplaces framed with plaster sculptures or decorated with individual stucco elements. In any case, it is durable, comfortable, original and very beautiful. decorative solution. And by covering it with gold, royal comfort and extraordinary beauty are created in the house.

Babylonian cuneiforms mention the use of this mineral in those ancient times. Near the Euphrates, it was used as construction material. Even in Egyptian pyramids solutions consisting of burnt lime and gypsum were used. They were used to fill voids or vertical seams. And the builders of the island of Crete erected the walls of the royal palace with gypsum stone, sealing the seams with a solution of this mineral. All decorations of the palace—ceiling stucco, column bas-reliefs, exterior walls, and even palace sculptures—were made of plaster. Fragments of these decorations, preserved to this day, were found during excavations. “Business made of plaster” is still relevant in our time, although many do not see any prospects.

Sep 27, 2015 Sergey

Gypsum is a material widely used in creativity and construction since time immemorial. It is known for sure that it was used in antiquity for making sculptures. Today, professional architects and sculptors use gypsum in their work. Each of us can purchase this material at a hardware store for personal needs. Plaster sculptures are easy to make at home without being a professional. detailed instructions and work tips - especially for you.

Main characteristics of gypsum

In any hardware store you will find gypsum powder or gypsum plasters. The material is made from sedimentary rock - gypsum stone. So diverse and widespread use V construction work gypsum owes its availability combined with low cost. Working with this material is quite simple. It is necessary to dilute it with water, after which you can begin pouring molds or modeling. Attention: gypsum hardens very quickly in air and at the same time increases slightly in volume (no more than 1%). Prepare the solution for one time, immediately before starting to work with it. The material is capable of transmitting the smallest details. If desired, plaster sculptures can be decorated with paints and other finishing compounds to create a high-quality imitation of precious stone or metal.

Methods for making plaster sculptures

If you are not a professional sculptor, it makes sense to start working with plaster by making sculptures using the molding method. This technology involves obtaining finished products by pouring gypsum mortar into molds. Molding is a very simple way to create sculptures, which is suitable even for children's creativity. For children under 12 years of age, creative activities must be conducted by an adult. Alternative option, how to make a sculpture from plaster - model the desired figure from diluted plaster on a frame. It is convenient to use a variety of spatulas and other tools in the work. What sculptures can you make from plaster with your own hands? The frozen material is quite porous and fragile. But despite this, it can be used to make outdoor sculpture. Plaster is ideal for creating interior elements and decorative figurines. If you are just starting to work with this material, try doing something small and simple in shape for the first time. Gradually improving your skills, you will learn to create real masterpieces from plaster.

Ready-made form or homemade?

For the manufacture of plaster sculptures You can use ready-made forms. They are sold in craft stores. Interesting idea- use culinary molds, for example for ice, cupcakes or candies. In joint creativity with children, you can use sand molds for casting plaster. If you couldn’t find anything interesting, try making a mold yourself. Simple sculptures (for example, interior columns or large mushrooms for garden decoration) can be made using household tools. For example, a mushroom cap can be cast in a basin or bowl of a suitable size, and the stem can be cast in a cut-off plastic bottle. Casting molds can be removed from any existing figures and figurines. Upholster the selected product cling film. Then cover it with clay or plasticine. Wait for the material to harden, then carefully cut the mold and pull out the figure hidden inside. Your homemade mold is ready, now you can make sculptures from plaster.

Preparing the mold and pouring plaster

The form requires special processing before starting work. Carefully coat the inner walls with Vaseline, vegetable oil or paraffin. Special attention pay attention to small casting elements. Professional sculptors often prepare a special lubricant for processing forms. Take 2 parts grated soap, add 1 part vegetable oil and 7 parts water. Mix the ingredients until smooth. The lubricant is ready - you can start processing the inner surface of the mold. Do not skip this step under any circumstances, otherwise you will not be able to remove the finished product after it has hardened. How to make a sculpture from plaster with your own hands, how to properly dilute the dry mixture? Simply mix the powder with water until it reaches the consistency of sour cream. Be sure to leave the plaster for a few minutes, and then, after mixing thoroughly, proceed to filling the mold. You can add to the water for preparing gypsum mortar: a large number of PVA glue - no more than 25% of the total volume of liquid.

Product protective treatment

The optimal temperature for drying gypsum products is 16-25 degrees. Sculptures made by molding should be removed from the molds after complete hardening. At this stage, you can smooth out any uneven areas with a brush or wet sponge. If you are completely satisfied with the shape of the plaster sculptures, leave them for a while to dry completely. Next stage- preparing figures for painting. Apply a special primer in several layers to the entire surface of the product. You can replace it with PVA glue diluted with water. If you have made a sculpture that will stand on the street, you can additional protection treat it with drying oil or shellac.

Sculpture decor

After the primer has dried, you can begin the most creative part of the process - designing the sculpture. Garden sculptures made of gypsum must be painted with the most durable paints. Small figures and children's crafts can be painted with gouache. To paint a sculpture that will be located indoors, you can use any paints and techniques for applying them. After painting, you can additionally coat the product with a layer of transparent varnish to secure the decor. If appropriate, additionally decorate plaster sculptures decorative elements. These can be individual beads and rhinestones, bows, textile parts or special plastic figures.

Follow all rules for working with plaster and consistency technological stages. Very often, problems in working with this simple material arise when the sculpture manufacturing technology is violated. Be sure to thoroughly dry the products after removing them from the mold and only then proceed with their further design. Try using different shapes to make sculptures. Any small figurines, children's toys and household items. Using the technique described, you can make impressions of your hands at home. Making sculptures from plaster is an interesting and accessible form of creativity for everyone!

Several types of this powdery substance are produced. There are medical, high-strength autoclave and construction (called alabaster in the old days) gypsum. The produced material is marked with the letter G with digital indexing indicating the compression force withstood by the brand. The higher the index, the better the score.

Indexes from five to twenty-five refer to construction alabaster. The best brand (autoclave) can easily withstand two hundred and fifty kilograms of compression and is labeled G-250. The last type of material is considered to be the least suitable for products. But it is widely used in construction as a component that ensures rapid setting of putty solutions (lime-gypsum).

Due to the high setting speed, only a small portion is prepared per operation. However, with compositions that retard setting, the working time can be increased. One of them is animal bone glue. For example, good solution for greasing cracks, it can be prepared from one part of such building plaster, two parts of chalk and five percent bone glue, with which the sifted mixture is diluted to a working thickness.

It is better to manufacture products from gypsum using an autoclave high-strength type (it is preferred by dental prosthetists), but also medical type will do too. In general, both of them are often used for molding and casting all kinds of panels, architectural parts, cladding slabs and other products in both medicine and construction, and other industries.

Proper use must take into account the property of the material to increase its volume by up to one percent when hardening. The powder has a certain shelf life and gradually loses its ability to harden over time.

Technology for manufacturing gypsum products - basic rules

When gypsum products are created, the technology must be strictly followed, from mixing to casting. If production rules are not followed, products may have various voids, cavities, or even fall apart. The quantity of ingredients is taken by volume.

So, one part of water no warmer than twenty-five degrees Celsius is poured into the container for preparing the solution. According to the rules, you cannot pour water into the powder. On the contrary, the material is poured into it in a volume of two to two and a half parts with constant vigorous stirring. You should get a solution with the thickness of homemade sour cream.

During the preparation process, the composition is constantly tapped to remove air bubbles from it. It should be noted that it is unlikely that anything can be sculpted from diluted dough. It hardens too quickly and is therefore used for casting. So the mixed mixture needs to be poured into a pre-prepared mold with walls coated with a release agent.

This composition is prepared from a saturated soap solution or heated Vaseline or other oil. Usually the solution begins to harden at the fourth minute, and after that it becomes completely solid. The process continues for about another day, it is by this time that the product will acquire the required strength.

Decorative plaster products - little secrets for good quality

Technology for manufacturing gypsum products provides the ability to accelerate or slow down the hardening of the composition. At the same time, acceleration is considered as a factor deteriorating the properties of the product and is rarely used. Slowing down, on the contrary, has a positive effect on the quality of the resulting casting and is quite widely practiced.

Hardening proceeds more slowly, and the final strength of the product increases if the mixing is carried out with solutions of borax, sugar, ethyl alcohol or, as mentioned above, bone glue. These sealers are prepared using water with a concentration of three to six percent, depending on the selected substance. The volumetric parts of the powder are the same.

By the way, if a completely hardened product (in water without a moderator) is boiled for twenty minutes in the already indicated borax solution, its strength increases. You can prepare a good mold from talc mixed with PVA or silicate glue. Instead, red brick ground into dust or fine porcelain chips are also suitable.

For casting miniatures from metal, the classic one is a collapsible two-part mold - plaster or silicone. Experience with this type of mold allows us to list its disadvantages: a relatively large amount of silicone is required for the manufacture of each of the two halves, the time for silicone vulcanization is 8-12 hours for each layer of silicone at room temperature, and when there are three such layers, then the manufacture of two halves Silicone mold takes two days. And the main drawback is flash - metal that gets into the gap between the two halves of the mold. Anyone who cast knows how difficult it can sometimes be to get a casting on which the flash line is invisible and exactly matches. The method of making the mold that I want to demonstrate successfully overcomes all three difficulties and allows you to obtain high-quality molds and, therefore, high-quality figurines at home.

Photo 1. As an example, we take a 28 mm master model of an elf for the Blood Bowl game, made of Quick-Wood epoxy patty.

Before starting to make the mold, you need to prepare the model itself. First, place the model on the sprue and the fence. The models that I sculpt myself have a wire frame of legs, and I use the ends of the wire to make a sprue (a piece of such wire is clearly visible in the first photo). So, the sprue has a conical shape, there is only one protrusion, not too thick, to the other leg. If it is difficult to install the sprue and the support separately, then sometimes you can do without the support at all. Next, the entire structure is installed and glued to a cardboard base. Secondly, in order to easily separate the model from the silicone later, I paint the model with a thin layer of metallic acrylic or some kind of nitro aerosol. If your master model is metal, then I recommend tinting it with nitro, and if it is plastic, epoxy or green stuff, then acrylic metallic is quite suitable.

Why metallic? From experience, it comes off most easily and can be applied in a fairly thin layer. It is necessary to pay attention to the fact that all undercuts are covered with paint (in other literature the names “undercuts” or “negative angles” are found). The third step - optional, but highly recommended - is to draw an imaginary line dividing the halves of the form with a felt-tip pen - this will greatly help to subsequently make an accurate cut of the silicone shell.

In the photo, the model is prepared for the start of manufacturing the mold itself. The sprue and the projection are visible, and the cut line is visible, at least on the legs. Don't look for it on your head - it's not there. The cut will only reach the fingertips of the left hand and the top pole of the ball. The entire model is mounted on a base.

Second part. Silicone cocoon and stone coffin.

We begin to apply silicone layer by layer. The first layer requires a lot of attention and patience. The task is to introduce silicone into all the cracks, crevices and depressions. Silicone is a rather capricious material and will not fit in there of its own accord, so I take a small drop of silicone and put it in there, indentation by indentation, checking again and again to see if I have forgotten any other crack.

The already applied silicone can be pressed down with a damp finger. Another reason I prefer to work with clear silicone is that you can see if any air bubbles are forming under the silicone layer. At the end of this stage of work, our model should be completely covered with a thin, preferably less than a millimeter, layer of silicone.

In the picture: like this, drop by drop, silicone is applied to all “problem” areas.

Next we need to let the silicone dry. Drying time may vary depending on different types silicones, but in most cases the next layer of silicone can be applied after eight hours. And never apply the next layer until the previous one has dried! After the first layer of silicone has dried, carefully inspect the “cocoon” again; if there are no bald spots in the silicone layer, then move on! If there is, then fill the gaps with silicone and move on anyway! And then - the second, third and further, as needed. These layers should tightly wrap the model in a single cocoon without any undercuts. How thick should it be? Let's just say that an extra layer of silicone won't hurt it, but it will be too thin layer can lead to deformation during casting, especially in the area where the mold is cut. On the model shown here, silicone is applied in four layers and in selected places I added another additional fifth layer. When the application of silicone is completed, the excess cardboard of the stand is cut off.

Now we have a silicone mummy from which our model is barely visible. It's time to build a "stone coffin". I make formwork from Lego parts, spread plaster and pour the first half of the coffin, half-burse the cocoon in the plaster, and wait.

Pay attention to the rubber cup for diluting the plaster. An extremely easy-to-use item, a veteran of production. Initially, it is a dental instrument, but can also be made from half a rubber ball. Working with the same container for diluting plaster, over time you learn to dose water and plaster “by eye” so that there is not too much waste, and after work, clean off the hardened plaster - simply by turning it inside out.

When the plaster hardens, which is determined by its heating, I move the formwork higher, but under no circumstances remove the cocoon from the plaster! Then you must remember to lubricate the surface of the plaster with some cham, so that you can then separate the halves of the plaster. No special mixtures! Dishwashing liquid or liquid soap will do. We dilute the second portion of gypsum and pour it into the formwork. Again, wait until the plaster heats up. When the plaster has hardened, remove the formwork, separate the halves of the “coffin” and take out the mummy.

Part three. Surgical.

At this point we already have a fully manufactured injection mold. Now all that’s left to do is take the model out of the mold and graphite the casting surface. In fact, opening the silicone and removing the model is the most important operation, so it must be taken very seriously. Swinging a knife is not like smearing silicone. First, I highly recommend getting a brand new scalpel blade. Secondly, take your time, examine the mummy and remember or try to carefully find the cut line that we drew when preparing the model. And only after thinking about how the cut should go, start. You need to cut slowly, little by little, but with a “steady hand.” Start making cuts, your guideline is the line, it’s not for nothing that we drew it, meanwhile, gradually and very carefully separate the silicone from the model. Although silicone is very elastic, tearing a piece from it or cutting off anything extra with a scalpel is not so difficult, so no use of force or haste. The final task of this operation is to twist the silicone shell so that the model can be pulled out, but at the same time leave the shell intact, so that when it is released it will again take its original shape.

When removing the mold from complex-shaped models, you can make additional cuts to remove individual parts from the silicone, but do not cut off anything completely. As if we wanted to peel the whole orange. This is the meaning of the method. We succeeded! Now the surgeon can take off his mask and gloves, brew coffee and light a tired cigarette.

Before casting internal surfaces The molds must be properly treated with graphite powder (I use the insides of batteries as a source of graphite, although it can be the graphite lead of a pencil), the excess graphite must be blown off and the entire mold must be reassembled. The mold is completely ready for casting. The clamp is simple and incredibly convenient - two sticks and two elastic bands.

Of course, it would be nice to give the plaster time to dry, at least a couple of days, but who can resist the pleasure of making a couple of test castings when I already have a completely finished mold? I can’t resist either...

Time consumption.

Preparing the model: making sprues - half an hour, painting and applying a dividing line - let it be another half an hour (of course, this is the maximum time spent, all this can be done even faster). Applying the first layer of silicone takes about twenty minutes. Subsequent layers are operations that do not require super precision, so they take 5-15 minutes of time. Drying each layer of silicone, as I already said, takes about eight hours, but there is a little trick here. If you put the model in a warm place, probably 60-80 degrees, it’s hard for me to say for sure without a thermometer, the silicone will vulcanize in an hour. I put it in an electric oven. Disadvantages: unpleasant smell in the oven and throughout the kitchen. If the smell is very unpleasant, try lowering the temperature. You can, of course, turn on the hood, if anyone has one. A total of five layers will harden in six hours. I prefer to take my time and leave the outermost layer (it's the thickest anyway) overnight at room temperature. The next day: to make a plaster coffin - about 20 minutes for each half. Trick: dilute gypsum in salted water. Salt is a catalyst for the crystallization of gypsum. In total, it took an hour to do everything, including cleaning. Without cleaning - 40 minutes and my wife would be very angry. The operation of opening the “cocoon” took me 15 minutes, timed by the clock. It took another fifteen minutes to graphite the surfaces of the mold and assemble everything in full combat readiness.

So: yesterday at 11 am I started making the mold, today at 1 pm I was already holding the cast figures in my hands.

Method capabilities.

I have been making molds this way for two years now, and I have seen from experience that there is a significant saving of silicone and time compared to other methods of making molds. Now I make molds from two silicone parts only for completely flat parts, and everything else - arms, bodies, heads - just like that. The quality has improved, especially in terms of flash and accuracy of alignment of the halves of the mold. This method can be successfully used to make molds for figures of any shape and complexity. I used it equally successfully for casting 28 mm 54 and even 75 mm figures.

In conclusion, I want to say a few words about silicones.

Making molds for stucco with your own hands

Finding the right material for the job is not easy. I have to try a lot of varieties. To save money, do not look for dental silicones and jewelry for casting metals (they are proudly called “ liquid rubber") – they are not heat-resistant. There are probably exceptions, but as a rule they are also expensive.

I use the most common construction silicone, Silirub, from the Belgian company Soudal. Syringe 330 g. You can hardly smell the vinegar from it. It comes in three types: black, white and transparent. The first and last temperature of tin casting, i.e. Holds 300-400 degrees well. After several pours, white becomes covered with cracks and a “burning” crust. After repeated pouring, it practically does not deform. All that remains is to wish good luck to all those who like to smear themselves in silicone.

How to cast plaster molds

This business plan is designed to invest in production of gypsum tiles.

Purpose of developing a business plan: to receive a grant;
Volume of work: 42 pages;
Business planning horizon: 3 years.

Last year, the volume of gypsum tiles sold in the Russian Federation amounted to more than 7 million square meters, while maintaining a steady growth trend. The bulk of products are produced for the domestic market, export volumes are small. Tiles from Russian manufacturers are mainly exported to the countries of the former CIS, since transportation of these products to long distances unprofitable. The same applies to imports; the list of importing countries is limited to Germany, Finland and Ukraine.

The development of the production of the project initiator in this type of activity has a large social and economic role, therefore, carrying out activities in the production and sale of tiles is advisable, this is due to the fact that similar products from local suppliers are practically not represented in the region and nearby areas.

Rented area production premises is 90 sq.m. The project initiator will produce gypsum tiles, and subsequently paving slabs. professional level using modern equipment.

When starting the project, it is planned to purchase the following equipment and inventory:

• airbrush;
• compressor;
• spray gun;
• concrete mixer;
• vibration forming table;
• polyurethane molds;
• silicone molds 20 units;
• heat gun 2 units;
• table for unpacking products (metal);
• office furniture.

In a year, it is planned to reach tile production volumes equal to the output of the mini-factory. The number of workers involved in the production process at the time of opening will be 3 people. Over the next three years, with the expansion of production, increasing the range and volume of products, the staff number will be increased to 15 people. The staff will include specialists in the following specialties: loaders, product casters, general workers and others.

The advantages of gypsum tiles over other materials are:

• cost-effective finishing material existing on the market;
• biostability - gypsum tiles eliminate the appearance of fungi and mold;
• environmental friendliness - all components of gypsum tiles are natural;
• lightness there is no need to strengthen the walls, the tiles can be mounted on drywall;
• the ability to regulate indoor humidity;
• ease of application in hard-to-reach places;
• effective use in building renovation.

New business ideas

A practical guide on how to open a workshop for the production of gypsum products. The material addresses the following issues: workshop arrangement, necessary raw materials, required equipment and personnel, manufacturing technology and advice on organizing the sale of finished products.

Types of products that can be cast from gypsum

• It is profitable to make large objects: ceiling and wall rosettes, wide cornices and moldings, capitals (the top of the column) and decorative columns.
• Large size wall panels.
• Pilasters, ceiling borders and domes.
• Anything that cannot be made using old technology castings from plastic molds.

Organization of a production workshop

The workshop premises should be located in an industrial area, away from residential buildings.

Casting from gypsum is an environmentally friendly production, but the heart of this production is the production of fiberglass molds from which this casting will be made. This is associated with some inconveniences: it is necessary to have a forming chamber with a local (above the table) exhaust, protective equipment for the respiratory system. We will be dealing with a polyester resin, which emits styrene during polymerization.

The production workshop should have six rooms isolated from each other:

1. A service area where personnel change clothes, eat, wash and rest.
2. The room where models are assembled for the production of injection molds. This room is equipped with tables welded from angle iron, shelves with plumbing and electrical tools.
3. A small isolated room where the molding and subsequent polymerization of injection molds takes place. Also, their trimming and subsequent sanding. All these operations involve the release of chemical fumes and very unpleasant dust. Here you need a reliable table, welded from a 50 mm corner, a local hood above the table itself, and lighting located low and not casting shadows.
4. The room where the decor casting process takes place. Tables welded from a corner, the height adapted to the height of the casters.
5. Warehouse for raw materials, buckets and other utensils.
6. Finished goods warehouse. We need to dwell on it in more detail. The fact is that casting a product is not everything; it is equally important to preserve it so that it does not twist when drying, and the geometry of the casting remains correct. To do this, you need to build drying racks in the warehouse, which are cooked from metal corner, and between the corners for support there is a metal square. The entire structure is checked with a level and then carefully painted. The warehouse must be equipped with supply and exhaust ventilation.

Necessary raw materials and materials

To produce gypsum products you will need

• Main production material gypsum grade G-5. When purchasing in hardware stores and wholesale warehouses, you must require a certificate with the date of issue. Gypsum stored for a long time is unsuitable for production.
• Ordinary water. You need to make sure that there is no rust in the water; the water should be clean and transparent. Otherwise, all inclusions that may be in the water will appear on the surface of the casting.
• Another expense item is polymer materials for the production of fiberglass injection molds: gelcoat, molding polyester resin, curing catalyst, three types of glass mat, release pastes. Suppliers can be found through advertisements and on the Internet using the keywords Neste Chemicals and Reichhold. Typically, these supply companies offer courses that will train your staff in the molding technology required to produce injection molded fiberglass molds.

Necessary equipment

The beauty of making stucco from gypsum is that you do not need bulky and expensive equipment. Everything you need can be made with your own hands, and you can buy hand tools:

To organize production you will need:

• Tables welded from angle iron.
• The exhaust installation in the molding room consists of: a box above the table, an electric motor, which with a volute is mounted behind the wall on the street. Supply and exhaust ventilation consists of two fans at different ends of the finished product warehouse. They are mounted in holes made in the wall.
• Power tools: small drill, medium drill, it will be used to prepare gypsum mortar by inserting a special mixer into it. Jigsaw, orbital Sander, a mini-drill for working with forms, a screwdriver for self-tapping screws, a medium-power grinder with a speed control function.
• Scales: floor and table scales.
• Tools and consumables: sandpaper of different grain sizes, polishing pastes for finishing injection molds.

Staff

• Foreman(business owner): organizes all the work, monitors the uninterrupted supply of materials, searches for and places orders.
• Foundry workers- two people. Recruitment is not critical. Both a woman and a teenager do an excellent job as a foundry worker. The work is not harmful or difficult, the result is visible right away. With little skill, mistakes are rare. Payment is piecework.
• Molders- two people. These are the ones on whom the success of the whole business depends. Their responsibilities include: preparing the polyurethane model (training with release agents), assembling the structure on which the model is attached, molding and subsequent processing (polishing and grinding).
• Installers- at least two people. They are engaged in the installation of finished products for the customer. This operation is very responsible and thorough, and also not cheap. Candidates are selected from experienced installers. As a last resort, such a tandem should consist of an experienced person and a diligent student.

Plaster ceiling rosettes

Technology for the production of gypsum products

The process of casting from plaster is simple: open the bag of plaster. The material must be fresh, without lumps or foreign inclusions. If you come across lumps, you must sift it through a sieve. You can use a sieve through which the flour is sifted.

1. After this, the required amount of gypsum is weighed. You definitely won’t be able to find out how much solution is needed to fill a mold for, say, a ceiling rosette from the first pour. You need to take more volume than needed, and with each new fill, bring the volume to optimal quantity. It is helpful to keep detailed notes for each type of form.
2. The ratio of gypsum to water is one to one.

   Copying figurines. Making molds for casting.

   The mixture turns out to be somewhat liquid, but this prevents the appearance of holes (where air bubbles escape) on the surface of the casting. From experience: this ratio of components does not affect either the rate of hardening of the mass or the final strength of the product. But, in addition to the absence of unpleasant holes on the surface, we save on a vibrating table - an expensive, bulky and very unpleasant thing to hear.

3. We insert the mixer into the drill, pour the required amount of water into a plastic bucket, and pour the plaster into it. In a few moments he will disappear under water. We begin to carefully stir it with a mixer at low speeds, trying not to air the mixture.
4. So, let's start filling. Using a flute brush, apply refined mixture to the front surface of the form. sunflower oil, the cheapest possible. We do not apply generously, but rather rub it in.
5. Pour the mixture into the mold in a thin stream, taking your time, but not hesitating either. The solution should spread smoothly throughout the entire mold, gradually squeezing out the air.
6. Leave the mold filled to the brim alone for a few minutes. After the plaster has thickened, but not completely, you need to use an absolutely flat bar (wood, aluminum, plastic), while leaning on the opposite ends of the mold, to “cut off” the excess so that the pouring surface is even. As the plaster hardens, it warms up, but when it then begins to cool, this is a sign that the casting is ready and it’s time to remove it from the mold.
7. Carefully clean the edges and very carefully bend the edge of the mold around the perimeter. After this, holding it by the middle, we turn the mold with the frozen plaster over and place it on the table. Holding the top of the mold, we begin to bend the edges in a circle, at the same time lightly and often tapping the entire structure on the table surface. At some point the product will fall out of the mold. Carefully lift up the now empty form.

That's it, you did it! And if the surface of the matrix was well ground and polished, then the surface of the product will reflect the glare of the sun.

Principles for selling finished products

The business owner is responsible for the sale of finished products. The methods for achieving results are different - from giving advertisements describing the properties of products in the media, to installing advertising stands in places with high human traffic.

One of the main sales channels is sales through construction stores: samples of finished products are displayed in the store and everyone can make an individual order by contacting the sellers.

Decorating a fireplace and chimney with plaster structures

In conclusion, a few words about production profitability.

I will give just one example, from which everything will be clear.

A bag of plaster (40 kg) costs 200 rubles, from it you can cast up to ten ceiling rosettes with a diameter of 70 cm, costing at least 200 rubles, the gross profitability is more than 10,000%!

Questions and answers on the topic

No questions have been asked about the material yet, you have the opportunity to be the first to do so

Gypsum is natural, natural, durable, environmentally friendly pure material. Is it possible to build a profitable business in the manufacture of gypsum products? When opening your own business, you need to decide for what purposes the products will be produced and whether their sale will be profitable.

The business of creating large products from plaster is more profitable, since it gives greater profit than the sale of small piece products: a variety of garden figurines, souvenirs, figurines, which in great demand don't use it.

Business idea for manufacturing and selling gypsum products, can bring its owner a pretty good stable income.

Beginning entrepreneurs need to consider the following points::

• which production processes are planned;
• what is the volume of capital investment;
• expected profitability.

Gypsum stucco molding is used for external and internal decoration of buildings. For interiors, decorative products are used to decorate ceilings, walls, and niches. Most often, stucco is used to create classic style. Lighting fixtures are decorated with small decorative elements.

Gypsum is considered the most popular and cheapest finishing material. It is durable, aesthetic, non-flammable, fire-resistant, and increases heat and sound insulation. When hardening, the gypsum heats up, expands and is able to penetrate into the most inaccessible places of the prepared form. The shelf life of the material is no more than three months. It must be kept in a dry, ventilated area. Plaster products can be restored and any part can be repaired.

For creative people, gypsum is the embodiment of various ideas and fantasies. Modern technologies make it possible to produce molded elements that imitate a natural stone. This finish gives both interior and exterior cladding a graceful, elegant, luxurious and cozy look.

Execution technology gypsum stucco easy to use and affordable. The mold blank is made of silicone, wood or cardboard. Plaster is poured inside. You can make the mold yourself or order it from craftsmen who do this kind of work. She must be High Quality, since it depends on how the finished product turns out.

It is best to use a silicone mold. Otherwise, you will have to use liquid oil to lubricate the surface of the table and the internal parts of the mold in order to remove the finished products.

For organization of production of gypsum products you will need to carefully select the premises. A large building with several rooms, equipped with good ventilation, is suitable. It should not be located within the city, but in the suburbs.

For the production of different products, the required strength of gypsum is selected. There are several grades of this material, designated by the letter “G” and numbered from 2 to 7 and from 10 to 25.

Gypsum is divided into three types:

• building;
• sculptural;
• molding

Coarse raw materials are used in construction; fine gypsum is used for sculptures. To make disposable molds, the most fragile type of grinding is used - molding. This material has a reddish tint.

To produce gypsum products you will need plumbing and power tools.:

• drill with a nozzle for mixing the solution;
• jigsaw to remove excess;
• Sander;
• screwdriver;
• drill;
• Bulgarian.

For smaller workpieces, molding and plastering blades, chisels, cycles, knives, and wooden stacks are used. Tools for working with solid or liquid gypsum must be made of of stainless steel or brass. You will also need sandpaper from the coarsest to the finest grit; floor and table scales.

You don’t have to purchase expensive equipment for your business; you can get by with simple means at hand. Employees involved in production necessarily need personal protective equipment.

How to organize sales of finished products for a beginning businessman?

There are many ways to sell your plaster products using:

• post photos of products and advertisements on stands or on social networks;
• enter into an agreement with a network of construction stores;
• take individual orders.

If the business is only initial stage, it is recommended to make small-sized plaster products in the form of various garden figurines, busts, and figurines. When you have already acquired some experience in this craft, then you can set your sights on larger-scale works in the form of columns, statues, and so on.

In our age of all kinds of innovative technologies, gypsum products remain as popular as in past centuries. Working with this material guarantees the realization original ideas, development creativity, getting pleasure from what was planned and implemented.

If it's a hobby, you can always turn it into a business and earn extra income.

That’s probably all, for those who are also interested in business ideas, we have made a selection of the best ones, and of course, don’t forget to subscribe to