Business plan for cement-based artificial stone. How and where to sell decorative stone? To open a business you will need

Recently, decorative stone has become in great demand. After all, this material is ideal for interior and exterior decoration of premises and buildings. The main reason for this lies in the low cost and practicality of the material. In addition, today you can purchase decorative stone of any shade and texture. The range of such products is quite large. In addition, the production of decorative stone can bring good income.

Where to start

Where to start producing decorative stone? A business plan is an important component of any enterprise. The future of the organization depends on how it is compiled. The future activities of the enterprise are based on this document. In addition, preliminary planning makes it possible to consider all options for organizing production, calculate risks, and assess how feasible the project is.

In addition, a business plan allows you to determine the amount of initial capital, identify ways to sell finished products, calculate approximate profits, and so on. Of course, you can develop such a document yourself. But if you have no experience, then you should seek help from highly qualified specialists.

Technologies and raw materials

To start the production of decorative stone as a business, you need to know what technologies are used today. As for the components of the solution, for its preparation you will need:

• plasticizers;
• hardening accelerators;
• mineral pymentes of various shades;
• fillers;
• cement.

Setting up the production of decorative stone is not so difficult. After all, a fairly simple technology is used to produce such material. In addition, the work does not require specific equipment or extensive experience. To produce facing material, two technologies can be used: vibration casting and vibration pressing.

Features of vibration casting

This technology for the production of decorative stone has its own characteristics. Therefore, you should think carefully before choosing a manufacturing method. Among the advantages of vibration casting, the following should be highlighted:

• color saturation;
• high surface quality;
• relatively inexpensive equipment;
• large range.

As for the advantages of vibrocompression, we should highlight the low cost of finished products, as well as fully mechanized production.

Selecting a room

To start producing artificial decorative stone, you should select a room. It is best to choose a building located away from residential areas of the city, for example, on the outskirts of a populated area. In this case, the rental price will be significantly lower.

As for the area of ​​the production workshop, this figure should be more than 100 square meters. In addition, separate rooms are required for the arrangement of the staff room, warehouse and drying. There are no special requirements for the building where the decorative stone will be produced. The main thing is that the premises are not in disrepair.

What equipment is needed

The production of decorative stone is simply impossible without special equipment. To start the enterprise you need:

• drying chamber;
• concrete mixer;
• forms;
• vibrating conveyor or vibrating table;
• vibrating sieve

To make such a finishing material, complex devices are not required. You will have to spend no more than 40 thousand rubles on a concrete mixer and a vibrating table.

In addition to the above, for normal operation of the workshop you need to purchase shovels, buckets, hammers, spatulas, an electric drill, and so on. The biggest expense item is molds for the production of decorative stone. To start your own business in this area, you need 6 pieces. Moreover, one such form costs about 8 thousand rubles.

To reduce their costs, many manufacturers make their own molds. In addition, this allows you to start manufacturing products of any shape and texture at any time.

Is staff required?

As a rule, production requires at least two workers for normal operation. One of them usually does physical work. His responsibilities include carrying materials and tools, mixing solutions and loading ready-made finishing materials.

As for the second employee, he must be well versed in the technology of manufacturing finishing materials. The specialist must strictly monitor not only the quality of the finished product, but also how the equipment operates and whether there are any failures. It is better to hire a former builder or foreman for such a position.

The production of decorative stone can be made more profitable if it is supplemented with the production of foam concrete. In this case, a third employee will be required, preferably with the qualifications of a technologist. Such an employee will not only develop the recipe, but also organize the entire manufacturing process and control technological aspects.

Cost calculation

The production of decorative stone is not a complicated process, but it requires certain costs for raw materials. To make 1 square meter of finishing material you will need:

• 6 kilograms of cement - 35 rubles;
• 19 kilograms of sand - 15 rubles;
• 0.06 kilograms of plasticizer - 2.5 rubles;
• 0.15 kilograms of pigment - 9 rubles;
• depreciation of 6 forms - 6 rubles;
• electricity costs - 0.2 rubles;
• transportation costs - 5 rubles.

The figure increases significantly when using ready-made mixtures from other manufacturers. As a result, to produce a square meter of finishing material you need 72.2 rubles. But that's just the cost. The average cost of material on the market will be at least 650 rubles. To increase profits, you can launch and offer services for laying decorative stone to clients.

Costs of a medium-sized enterprise

Typically, large enterprises do not buy the mixture for the production of decorative stone. They make it themselves. As a result, the costs are:

• manual equipment - from 8 to 12 thousand rubles;
• table workers - up to 10 thousand rubles;
• electric drill - up to 5 thousand rubles;
• vibrating table - from 30 to 70 thousand rubles;
• monthly rent - from 10 to 20 thousand rubles.

In order to increase the range of their products and offer regular customers new textures of facing materials, such enterprises must use at least 10 different forms. Moreover, the cost of each can range from 4 to 7 thousand rubles. A project like this pays for itself within a year. In general, to start your own business in this area, you need at least 300 thousand rubles.

Advertising and sales of products

The dry mixture for the production of decorative stone is very convenient for making facing material at home. However, this option is not suitable for a medium-sized enterprise. Purchasing individual components of solutions allows you to save significantly. And to increase profits and attract customers, you need properly designed advertising and reliable points of sale.

After production starts, you can place advertisements on the Internet and in the media. Advertising must be effective and noticeable. If necessary, you can distribute brochures and leaflets directly on the street or distribute them through mailboxes.

It is best to sell finished products yourself, without resorting to the help of intermediaries seeking to purchase a quality product and resell it to receive a certain percentage. This will keep the cost of decorative stone within retail prices.

Most often, such finishing materials are purchased by designers, architects and companies involved in the construction and renovation of buildings. If the production of decorative stone is fully established, then you can take part in various exhibitions. Don't miss events related to the construction industry. This will make it possible to conclude more profitable deals for the supply of large quantities of decorative stone.

Is it possible to succeed

The production of decorative stone is a fairly simple, but profitable process. If you correctly draw up a business plan and follow it, you can create a medium-sized enterprise. This will significantly increase your income. In addition, such production pays off within a year if the advertising campaign is carried out correctly. If you have the necessary initial capital, the production of decorative stone is a profitable and promising business. The most important thing is the creation of a reliable market for the sale of finished products, as well as the production of high quality material. Without these components, it is difficult to succeed in such an industry.

The construction business today is growing rapidly. The production of artificial stone at home is a profitable investment for those who want to open their own enterprise. Thanks to the latest technologies, it is not difficult to make decorative stone using an artisanal method today. The scope of its application is quite wide:

• landscape design;
• external cladding of buildings;
• interior decoration of premises;
• restoration of historical buildings.

Properties of artificial facing stone

Artificial stone is more profitable than its natural counterpart. It is stronger, cheaper and comes in a variety of colors.

Types of artificial stones

They can be used to design an interior of any stylistic direction. It has specific advantages over natural stone:

• It is environmentally friendly and hygienic, as it does not have scratches or microcracks on the surface, which contribute to the proliferation of harmful bacteria.
• Artificial stone is much lighter.
• Has high sound insulation.
• It is unpretentious: easy to install, easy to install.
• Retains all its positive qualities for a long time.

Decorative facing stone does not lose its properties under the influence of temperature changes, excess moisture in the atmosphere, or chemicals. It does not change color under the influence of ultraviolet rays. It also has high thermal conductivity - a quality that is very valuable when finishing interior surfaces of a room.

Classification of decorative stone

Depending on the production technology and the raw materials used, artificial stones come in several types. Some of them can only be produced in industrial enterprises. In artisanal conditions, decorative stone is produced from gypsum, cast acrylic and concrete (reinforced or molded) stone.

Artificial stone for external cladding, in particular reinforced concrete, is made from the following materials:

• sand;
• cement;
• fillers;
• colored mineral pigments;
• hardening accelerators;
• special plasticizers.

Concrete stone is used to make decorative cobblestones and boulders, which do not differ in appearance from natural ones, as well as for cladding the outside of buildings.

Artificial acrylic stone is made on the basis of acrylic resin with the addition of a composite material, hardener, and colored pigment. It is used for interior decoration in residential and public spaces. The disadvantage of this material is that it can be easily scratched.

But it is compensated by the ability to restore the glossy surface with simple polishing.

The composition of gypsum cast stone includes:

• gypsum;
• white cement;
• pozzolanic additions;
• oxide pigments.

Such additives make gypsum less brittle. It is used only for interior decoration, as it is not resistant to low temperatures.

Decorative gypsum tiles are environmentally friendly, practical to use, maintain natural humidity in the room, are also suitable for long-term use and are inexpensive.

DIY artificial stone

Organization of the workroom

Before starting the production of decorative stone, you should properly plan the upcoming work and think through options for marketing the products.

The production of gypsum tiles at home and other facing stones in small quantities can be done in a small room - a personal garage or barn. If you want to organize an enterprise on a larger scale, you need to select a building of a larger size and taking into account certain requirements.

• Renting premises. It is more profitable to rent a work space on the outskirts of the city - it is easier to find a spacious and inexpensive building here. In addition, you will not have to deliver products from the center to customers.
• Water. The manufacture of artificial building material requires significant use of water. Therefore, you should rent a room near water wells or a water treatment plant. In such conditions, process water will be much cheaper when purchased, and its delivery to the place of stone production will cost minimally.
• Heating. Heating is not required for the warehouse space. If the finished product warehouse is located outside, it is necessary to make a rain shelter over it. The temperature of the main room reserved for the production of decorative stone must be positive so that the water necessary for work does not freeze. In a place specially designated for drying the stone, you must constantly maintain 30 degrees of heat and dry air. Rooms for auxiliary workers are also heated. We must not forget about ventilation in the room.
• Wiring. An important point is proper electrical wiring. When producing stone, a lot of electricity is consumed. Therefore, electrical wires must be in perfect condition and of the required size so that equipment breakdown or fire does not occur in this enterprise.

Faulty electrical wiring can lead to irreversible consequences

The production of stone in large quantities requires the recruitment of working personnel - at least two people: a technologist and an auxiliary worker.

Before starting a business, it should be registered with the relevant authorities.

Equipment and work tools

To make artificial stone at home, you need equipment and various tools, which are purchased depending on the scale of production. A small volume of decorative stone can be made using a vat, a drill-mixer, a trowel and self-made molds. For example, you can make your own plaster tiles.

Special equipment for the production of artificial stone on a large scale includes:

• Vibrating table It is used to compact the material by removing air bubbles from it.
• Vibrator - for moving the vibrating table.
• Vibrating conveyor for moving bulk materials.
• Concrete mixer and mortar mixer for mixing water and dry material until smooth.
• Elastic silicone or stone molds. A varied assortment is obtained by using various forms in production.

Silicone mold for making artificial stone

But you also need tools and other work equipment:

• work tables;
• drill with a special attachment for mixing;
• boxes for finished stone;
• scales;
• racks with pallets;
• drying chambers;
• forklift for transporting goods;
• container for coloring pigment;
• pallets;
• vibrating sieve

Technological process

The technology for producing artificial stone is divided into two types.

The first is vibrocompression. This method is characterized by low cost of goods and fully mechanized production. This technology is suitable for the production of a large number of products.

The second method is vibration casting. Its advantages are inexpensive equipment, high-quality surfaces, a large selection of products, and the rich color of artificial stone. Vibratory casting technology is appropriate for the production of medium quantities of products.

The technological process includes several sequential actions:

• Creation of a master model. To get started, three pieces are enough.
• Preparation of forms. There should be at least ten of them if you need to get different textures, since each of the forms is used only once a day.
• Prepare a mixture of the required components by mixing them in a mortar mixer until smooth.
• Pouring the resulting mixture into molds.
• Compact the solution on a vibrating table for at least two minutes. Thus, air is expelled from the solution.
• For several hours (8-10) at a temperature of 30 degrees, the solution in the molds is in the dryer until it hardens. Then it is transferred to a room with normal temperature and humidity for two days.
• The molds with the frozen mixture are transferred to a special work table and the products are separated from them. Then high-quality finished products are selected, placed on pallets and sent to the warehouse.
• At the end of the work, the molds are washed with acid to remove any remaining solution.

Acid for cleaning solution residues

The production of gypsum tiles has some differences from the production of other types of artificial stone:

• casting molds - small in size and weight;
• a vibrating table is not used for production;
• the process of painting the finished stone is quite simple and inexpensive;
• ready-made gypsum mixture has a low price.

Producing decorative stone is quite simple and profitable. A competent approach to the enterprise and excellent product quality will make your income high and stable.

Video: Making stone from gypsum at home

The idea of ​​producing decorative stone as a business is interesting. We’ll talk about whether it’s profitable to do this below. After all, even before starting a business, you need to evaluate the market and weigh all the pros and cons.

Due to its aesthetic properties, as well as its low cost, this material is in high demand. And if in your region there are not yet enough competing companies producing it, then it makes sense to invest a certain amount of money and soon achieve a net profit.

The advantages of such a business

Artificial stone today has many advantages, which make it so popular in construction, renovation and decoration of houses, both internally and externally. Among them are especially distinguished:

• environmental friendliness, safety for human health;
• resistance to any aggressive external influences (ultraviolet radiation, chemical agents, temperature changes, moisture, mechanical damage);
• using casting molds it is given a variety of configurations;
• is light in weight;
• it is easy to work with;
• has a long service life;
• There is a choice of a wide variety of colors;
• high levels of aesthetics.

For the manufacturer, such parameters as low production costs, ease of production, and the possibility of selling in large volumes are important, since this material is very popular among public and private developers and decorators.

In order to cover all market needs, it is advisable to produce it in two versions at once:

1. For external use, pigments, various protective additives and dyes are added to cement and sand.
2. To create decorative stone for finishing the interior of a room, the base is made of gypsum, which is already supplemented with oxide pigments, cement and pozzolanic substances during the process.

This type of building material is used not only for cladding walls, creating steps or window sills. Decorators use it to make magnificent countertops, bar counters, fireplace portals, unique sinks, etc. It is not surprising that the production of decorative stone as a business is a promising and successful direction even for a beginner.

Another feature of this business is that you can start with small capital investments. If you produce decorative stone with your own hands, for example, at home, this will significantly save the cost of special equipment and renting a separate production facility. This is a great opportunity to see if this type of business is worth pursuing and expanding.

Where to begin?

In order to think through all the steps in advance and correctly build the organizational process, you should start drawing up a competent business plan. At the same time, you will evaluate the market, the demand for products, the main areas of production in your region, the number and level of competing companies, your financial capabilities and development prospects.

Only after this can you decide whether it is profitable to start such an enterprise and proceed to the next stages:

• company registration;
• search and preparation of premises;
• purchase of special equipment;
• independent creation or search for ready-made suitable forms for the manufacture of decorative stone;
• purchase of raw materials in sufficient quantities to produce the first order;
• conducting an advertising campaign;
• searching for a sales market and large clients.

Download a free stone as a sample.

Documentation

As in any business, in this case you cannot do without registration documents. To produce decorative items, it is enough to create a legal entity (firm) or become an individual entrepreneur. No special licenses or certifications are required.

You need to register with the tax service and choose the appropriate taxation system. You will also need to prepare the premises in accordance with the requirements of the SES and fire inspection and obtain a positive conclusion from them on the progress of the inspection.

If you are unsure of your abilities, then you can use the help of accountants and lawyers to properly prepare the papers, but you will have to pay a considerable amount for this.

What do you need to buy?

To produce decorative stone in sufficiently large volumes, you will need to purchase specialized equipment:

1. Drying chamber.
2. Concrete mixer.
3. At least 6 different shapes.
4. Vibrating table or conveyor.
5. Vibrating sieve.
6. Scales.
7. Carts.
8. Tools – shovels, buckets, spatulas, hammers, drills, measuring spoons, brushes, sandpaper, etc.
9. Packaging material.

To reduce the cost of molds, which are considered quite expensive, some entrepreneurs create them themselves. This will require some skill and knowledge, but as a result, you will not only save money, but will also be able to offer your customers a unique product.

To produce artificial stone, you need to purchase enough high-quality material:

• cement;
• gypsum;
• plasticizers;
• fillers;
• dyes and mineral pigments;
• components for accelerated hardening of the material.

Technological process

The production of decorative stone itself is not difficult:

1. Sand and cement are mixed according to a special recipe. Usually they try to maintain a ratio of 1:3.
2. Plasticizers are added.
3. Knead evenly and sift through a vibrating sieve.
4. Gradually add water so that you get a solution that has a consistency similar to thick sour cream.
5. If necessary, select a dye and add it in an amount of 2-3%.
6. At the end, it is important to thoroughly mix the ingredients.
7. The resulting solution is poured into molds to approximately a third of their volume.

After 12 hours you can get the finished material. To give the product an aesthetically attractive appearance, the front side is additionally processed - cleaned and painted. This technology can be mastered even by a beginner and does not present any particular difficulties.

Preparing the premises

It is very important to correctly find and select the building where you will cast stone. Of course, this can be done in a garage, but for high production speeds it is advisable to rent, build or buy a separate room. To save money, it can be located on the outskirts of the city, in an industrial zone.

The area should be about 500 m2. Of these, 150 m2 is allocated for the production itself and equipment, and 300 m2 is for storage of finished products and raw materials. The remaining area is left to create an office for the manager and accountant.

It is worth noting that decorative stone, due to its quality characteristics and resistance to various temperatures and moisture, can be stored even outdoors. It is enough to fold it into neat piles and cover it with a canopy. This will significantly save costs on renting premises.

There are no special requirements for the workshop. It is important that the building is not in disrepair and that relatively comfortable conditions for workers are maintained. It is enough to comply with the following parameters:

• air temperature above 15 degrees;
• good ventilation;
• working electrical networks with suitable load for the equipment.

And for the convenience of loading products, you need to consider access roads for large vehicles.

Transport

Of course, customers can decide for themselves how to deliver the purchased products. But your company will benefit significantly if you perform this function.

For a good reputation and well-established activities, you will need to purchase a loader and an onboard gazelle. You can rent them, but this will significantly reduce your profit.

Staff

For medium-sized production, a sufficient number of employees of different qualifications will be required:

1. A technologist who monitors the correct composition of the solution and thinks through new unique recipes.
2. General workers (up to 6 people).
3. Drivers for forklift and car.
4. Accountant.
5. Storekeeper if necessary.

It is worth mentioning separately about managers. You can search for clients and carry out marketing campaigns yourself if you have sufficient knowledge and skills to do this. But to quickly develop your business, it is advisable to hire a professional. And although such activities will not be directly related to the production of goods, the success of your enterprise largely depends on it.

Financial calculations

But there will also be monthly expenses.

If you sell finished products at a price of 650 rubles and at least in a volume of 1000 m2 monthly, then you will be able to recoup the initial costs in 2-3 months. And these are very high profitability indicators. Obviously, by finding a large wholesale client and setting prices above the minimum, you can make a big profit.

Search for clients

To increase your income and expand your business, it is advisable to conduct a high-quality advertising campaign. To do this you can:

• place an advertisement in local media (newspapers, radio, television);
• disseminate information about the company on the Internet (on forums, specialized websites or create your own page on social networks);
• order more expensive advertising (signs, banners);
• hand out leaflets on the streets or place them in accessible mailboxes.

If you manage to conclude an agreement with a large developer or a company for the repair and decoration of buildings, then you will be able to ensure constant supplies of goods in large volumes for a long period.

Video: business from scratch - production of decorative stone.

• • • • Similar business ideas:

Artificial stone is used to decorate the facades and interiors of buildings. With the help of this material you can add amazing beauty and originality to any structure, as well as convey a certain appearance of the Middle Ages. The cost of producing artificial stone is not much different from the production of ordinary stone paving slabs. But the selling price differs significantly. Artificial stone is an expensive finishing material, the cost of which starts from $30 per 1 m2, which makes the business of producing artificial stone very profitable.

What materials are needed for the production of artificial stone

For the production of artificial stone, matrices made on the basis of polyurethane rubber are used. Plastic injection molds for the production of paving slabs are not suitable in this case. Why? Because to produce stone, you need matrices that have high elasticity, which is what conventional plastic molds lack. However, not all rubber (polyurethane) matrices are suitable for this. Most of the forms offered on the market are either prone to severe deformation (which is unacceptable for stone) or are not strong enough. Therefore, real casting dies for making stone are not cheap. Only with the help of highly elastic and high-quality molds can surface details, even fingerprints, be accurately reproduced. This is what makes artificial stone a valuable and expensive finishing material.

In other matters, the high cost of injection molds is more than compensated by the selling price of the stone. With a production cost of $5 per 1m2, the market value of the product is already $30-40 per 1m2. The benefits are obvious.

Artificial stone production technology

The technology for producing stone is not fundamentally different from the production of the same tiles. The technological chain includes such stages as: preparing a concrete solution, pouring the finished mixture into a casting mold, compacting on a vibrating table, stripping, holding/drying the product. The composition of the concrete mixture is still the same: cement, sand, water, coloring pigments, modifying additives. The differences, perhaps, are in the proportions of elements and types of dyes (which should give a natural color to the stone).

What equipment to choose for the production of artificial stone

Similar production technology involves the use of similar equipment. The production uses: a vibrating table for forming and molding, a concrete mixer, casting matrices, weighing equipment, a drying chamber, transportation means, shelving and other workshop equipment. The cost of a complete set for organizing a mini-production is at least 300 thousand rubles. In this case, the main share of costs, as noted above, is the purchase of elastic forms.

Features of artificial stone production

Despite the similarities in the production technology of artificial stone and paving slabs, there are also many differences. It is these differences that make ordinary colored concrete an elite finishing material, which is extremely popular among banks, diplomatic centers, expensive restaurants and other “major” establishments:

1. Some types of artificial stone can be produced using the free pour method. That is, without the use of vibration casting. Free pouring is used only in the manufacture of artificial facing stone. This stone is produced on the basis of modified universal-purpose gypsum (GCP).

2. The production site takes up much less space than in the production of other similar materials (tiles, printed concrete, etc.). The reason here is simple - the holding time of the concrete mixture in molds during the production of stone is 2 times less than during the production of paving slabs. And for gypsum-containing concrete - as much as 10 times.

3. Equipment for the production of stone must be configured for increased dosage accuracy. The slightest inaccuracies are unacceptable - the parameters of the external gloss and the color of the finished stone depend on this.

4. The profitability of the stone production business is higher than the production of conventional paving slabs. Even though the cost of technology is the same, retail prices differ significantly. Why? Yes, because luxury finishing, by definition, cannot be cheap. And the elite quality of artificial stone is determined by the fact that it is visually indistinguishable from natural stone.

5. A high price difference suggests targeting different buyers. Hence the differences in product sales mechanisms.

Step-by-step plan for opening an artificial stone production business

Even one person can start a business producing artificial stone in his own garage. To do this you will need:

• Analyze the market, study competitive products;
• Register with the tax office;
• Prepare premises for production;
• Purchase special equipment and inventory;
• Purchase matrices, forms;
• Purchase raw materials;
• Conduct an advertising campaign;
• Organize sales of products.

How much can you earn on products?

When selling 100 sq. m of artificial stone, the monthly profit is more than 60 thousand rubles. Payback of activities occurs within 2 months. You can increase profitability by diversifying the assortment and organizing sales through hardware stores.

How much money do you need to start a business?

To organize a business you will need about 170 thousand rubles:

• Vibrating table and vibrating sieve - up to 70 thousand rubles.
• Drill - up to 6 thousand rubles.
• Concrete mixer - 20 thousand rubles.
• Tables for work - up to 10 thousand rubles.
• Inventory - 14 thousand rubles.
• Rent of premises (if necessary) - 20 thousand rubles.
• Racks for finished stone - 15 thousand rubles.
• Registration at the tax office - 1 thousand rubles.
• Other expenses - 14 thousand rubles.

Which OKVED code to choose when registering a business

23.61.1 - manufacture of products from concrete, cement.

What documents are needed to conduct business?

To run a business producing artificial stone, you will need to register as an individual entrepreneur. To do this, the tax office at the place of registration of the applicant must provide:

• Statement;
• Photocopy of passport and birth certificate;
• Receipt for payment of state duty.

When using hired labor, it is advisable to register an LLC. It is also necessary to obtain permits from the SES and fire inspection.

Which tax system to choose

When producing artificial stone, preference is given to the taxation system of the simplified tax system or UTII.

Do I need permits for the production of artificial stone?

Own production of artificial stone is not subject to certification and licensing.