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Faux Rock Features Roll Out Exciting New Opportunities for Concrete In San Diego
On the one hand, creating synthetic rock may be a complicated technical task. Creating geologic replicas and making them appear – naturally — like the genuine stone is, on the other hand, a proper art form, from the back yard to the theme park.
Features made of synthetic rock are not new. There are instances from the turn of the century in the United States and worldwide. But it was perhaps Walt Disney and his Anaheim, California-based Disneyland that gave fake rock a simple push. Synthetic stone is now found at theme parks, zoos, aquariums, museums, resorts, hotels, and various other locations, with an increasing demand for residential applications. Synthetic concrete rocks are used in swimming pools, ponds, waterfalls, fire pits, outdoor dining areas, retaining walls, and exterior veneers, to name a few applications.
Building a rock may be done in a variety of ways.
Concrete is an excellent synthetic rock material. Cement hasn’t changed all that much throughout time, but the equipment and procedures have. Concrete is relatively inexpensive and easy to utilize compared to the expense and engineering issues involved with natural rock. On the other hand, fiberglass is a carefully controlled method that is frequently used to manufacture artificial rock. Acrylics, urethane, and plastics can also represent rock, although they’re more expensive and don’t always seem as realistic. Concrete rocks are difficult to beat in durability (no pun intended). Concrete rocks may acquire such high levels of concrete strength that they may endure longer than some natural rock kinds.
According to Jacob Stoddard, operations manager at J.P.J. Technologies L.L.C., a synthetic rock training school in Wickenburg, Arizona, “there are different processes utilized to manufacture synthetic rock out of concrete.” Synthetic rocks can be molded or cast, molded over a support structure, composed of fiber-reinforced synthetic concrete (typically in panels), or constructed by hand. He explains, “re-bar and lathe are conventional,” but synthetic rocks may be made with hollow or solid fillings when it comes to the support structure. Shotcrete or gunite are utilized in several applications. In other cases, the simulated rock can be applied directly to a brick wall or to a home.
Synthetic rocks can be molded or cast, molded over a support structure, composed of fiber-reinforced synthetic concrete (typically in panels), or constructed by hand.
Regarding the support structure, he adds that re-bar and lathe are typical, but synthetic rocks may be made with hollow or solid fillings.
A portion of the construction may occur off-site at times. Glass fiber reinforced concrete, a traditional substitute for fiberglass, may be utilized to make 360-degree complete products or panels constructed on-site. “GFRC is handled and processed in the same way as fiberglass is,” says Stoddard.
Coloring Rocks And Faux Rocks
To make a fake rock appear like the actual thing, it must first be shaped and textured before being colored. Synthetic rocks are usually molded or free-formed. “The best feasible reproduction is a mold.” In terms of realism, there is no better way to accomplish it. Stoddard explain, “You emulate Mother Nature.” “That’s when it becomes exciting,” he adds of free-forming.
In large-scale projects, free-forming is fairly prevalent, and numerous texturing techniques may be employed to get distinctive outcomes. Textures can be imprinted on mats and other things. Carving or sculpting a design may be done with a variety of tools. The material might be placed on — “reverse carving.”
According to Stoddard, coloring synthetic rock may be divided into numerous types. Although many contractors believe it is unneeded, one category is dyeing or inherent color. On the other hand, Integral color may be ideal if the overlay is thin or if you wish to show particular material, such as mica or pebbles. The employment of a penetrating stain is the most popular coloring method. Another common approach is painting using latex paints.
Waterproof synthetic rocks are required when they are immersed in water. It’s vital to avoid difficulties in the future. On the other hand, synthetic rock sealing is dependent on the application and the contractor; some do, while others do not.
Waterproof synthetic rocks are required when they are immersed in water. It’s vital to avoid difficulties in the future.
According to Stoddard, coloring synthetic rock may be divided into numerous types. Although many contractors believe it is unneeded, one category is dyeing or inherent color.
If you talk to a dozen synthetic rock companies, you’ll see that they all create their rocks slightly differently.
Everyone Does It In Their Unique Way
If you talk to a dozen synthetic rock companies, you’ll see that they all create their rocks slightly differently. It’s understandable given the large number of variables involved in this project – location, site considerations, materials, building procedures, texturing process, coloring and sealing method, and so on. Stoddard refers to this as the “X-Y-Z” factor. “Everything happens at the right moment and the right place.” It’s not difficult; it’s just a matter of knowing when to do what.” And each task may have several approaches and construction procedures, so there isn’t just one X-Y-Z.
For the past 30 years, David Long, C.E.O. of Lakeland Co. Inc. in Coeur D’Alene, Idaho, has created synthetic rock work with GFRC panels or positive carved rock work techniques. “All the elements in the mix are crucial” in the GFRC panels, he says. “Indoor applications are usually hollow, but exterior applications might be solidly filled.” Shotcrete serves as the foundation for his positive carved rocks, with a brown coat layered on top and a cement/plaster coat textured with texture matting.
Costs Vs. Realistic Expectations
GFRC panels offer a more realistic appearance, but they are more expensive because of the additional labor and equipment requirements. Bob Wallace, Director of Sales at Custom Rock International in St. Paul, Minnesota, says that assembly time isn’t always excessive. Shotcrete, he says, is less expensive, can be put more quickly, and is a suitable alternative if the final appearance isn’t as important or the viewing distance is greater.
GFRC panels offer a more realistic appearance, but they are more expensive because of the additional labor and equipment requirements.
If hand-carving is necessary, keep that in mind while creating your blend; it’s all a delicate balancing act.
Custom Rock fabricates panels off-site for its panel-only applications. The panels are around 600 pounds and measure seven feet by seven feet. Wallace explains, “We prepare a sample panel for approval and to keep on the site [for reference].” The GFRC panels are installed on-site using a forklift or crane. Wallace claims that they use metal lath and hand-applied concrete to join their panels, with textured skins to mix them in. “When numerous panels are connected together, the composite strength increases [and] the seams are virtually undetectable when done correctly.”
Large-Scale Projects Need Varying Degrees Of Natural Resources
Long notes, “The degree of detail required depends on the viewing distance.” “Take, for example, zoos. Because the audience will be far away, a shotcrete background may be all that is required. If a museum wants to create a mining shaft for visitors to go through, he argues, “a molding process with GFRC is a superior approach because you get the intricacy of the rock.”
If hand-carving is necessary, keep that in mind when designing your mix — it’s all a balancing act, according to David Taplin, vice president of CemRock in Tucson, Arizona. “It’s easier to carve with smaller aggregate, but you’ll need more cement with smaller aggregate.” Cement makes the mixture slicker, but it also hardens up faster. However, you may use retarders to make it take longer to set.” Taplin is adamant about having a low droop for minimal shrinking.
Long is concerned about the rock’s natural appearance. “In order to balance the project with other aspects, such as flora and architectural features, we’ve avoided doing too much rock work.” “We want the rock work to seem as though it’s a natural element of the surroundings rather than an afterthought.” To achieve so, he frequently incorporates plant pockets.
Wallace believes that knowing a little bit about geology is essential for attaining realism. He also notes that being an artist helps with coloring. He notes that topical color is preferred in Custom Rock, with light colors acting as a basis and darker colors and varied hues used to produce shadows and differences in the surface colors.
CemRock colors its synthetic pebbles with water-based latex paints diluted down “almost like a stain,” according to Taplin. Spray, splatter, pouring, sponging, and ragging is among the application methods he mentions.
Concrete-based artificial rocks “What do you visualize?” he asks consumers when dealing with them. Then he does a pencil sketch, but it always shifts from paper to the backyard because you get imaginative. There’s a lot of variation in small-scale tasks for the home.
Synthetic rock is seeing an increase in demand for residential projects. Mike Davis, president of Rock Pools by Mike Davis in Quartz Hill, California, has designed and built full pools with waterfalls and rock slides, koi ponds, retaining walls, and rock-veneered residences, as well as a picnic table. “It’s highly creative; no two tasks are the same,” he says. “What do you visualize?” he asks consumers when dealing with them. He then does a pencil sketch, but “it always changes from the paper to the back yard, because you become creative,” he says.
Davis involves his consumers in the process. “I give them a trowel and ask them to assist carve the rock – the kids, parents, and dad,” says the sculptor. As a result, he says, his consumers have a greater sense of ownership over the product since they contributed to its creation.
Breck Valley, the proprietor of Breckenridge Rock Works in Santa Ana, California, works on various outside projects, including pools, waterfalls, and water features. Still, he’s also produced synthetic rocks for a wine cellar that now appears like a cave. “We can accomplish everything you can conceive of.”
It’s Vital To Stick To A Schedule
Valley makes it a point to teach consumers how to properly care for and preserve their synthetic rocks. He recommends sealing every two years.
“Smaller projects, such as pools, ponds, waterfalls, and retaining walls,” Taplin adds, “are an excellent niche for pool contractors and concrete contractors.” These projects might take anywhere from a week and a half to two weeks to complete. Adding them to a normal project, on the other hand, can boost the job’s profitability. “If someone spends $25,000 to $35,000 on a pool, they could spend an extra $10,000 to $12,000 on rock work to make it unique.”
But be careful not to go overboard. Paul Horton, manager of Roseburrough Tool Co. in Orange, California, says, “I’ve seen folks get carried away and everything is out of proportion.” “An eight-foot high boulder in a modest backyard seems like a volcano.”
Putting Everything Together
Because of the market’s expansion, there are plenty of opportunities to be had.
“A lot of the very big people are booked out for two to three years,” says Long, who adds that commercial facilities are searching for smaller businesses. While it is not economically feasible for a major corporation to execute a smaller work, the “big guys” occasionally seek out local talent for some of their larger projects. “We’ll hire people from the area. The advantage is that we will be working with specialists. They are familiar with concrete; we demonstrate fresh use to them. Everyone is reimbursed, and the clients are pleased.”
Smaller businesses that desire to take on greater initiatives might appeal to larger businesses for help. “Molds and manufacturing panels can be costly and need specialized equipment, but large commercial installers can provide them to small contractors,” Taplin explains.
Now is the time if you want to learn how to make synthetic rocks out of concrete. There is greater demand than supply across the country in both residential and commercial uses. Fortunately, if you’ve worked with concrete before, you’ll likely use the same equipment, materials, and stains. It’s also a good idea to keep building notes, just like you would on any other work. You never know when you’ll be asked to add on again. Contact us at Spring Pools and Spas for more details.
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