Common Methods of Faux Rock Construction

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Boulder Crete in Port Coquitlam, BC

There's more than one way to build a faux rock.

When concrete is the material of choice, a variety of construction techniques can be used, but most fall into two main categories: cast or sculpted.

Casting techniques produce the most realistic-looking artificial rock because the molds against which the concrete is cast are copies of real rock surfaces. Manufacturers make the molds by applying silicone or latex rubber to the natural rocks they want to mimic. After the material hardens, the skin is peeled off and used to apply realistic stone textures to artificial rock surfaces.

For sculpted rock, contractors apply layers of shotcrete to a framework of reinforcing bars and metal lath. Then they use hand tools to sculpt the concrete into the desired shape and texture. Because the concrete is reinforced, this is an ideal technique for tall or cantilevered rock formations. Depending on the situation, contractors may use a straight mortar mix or a fiber-reinforced synthetic concrete (FRSC) mix. When the latter is used, rebar and lath may no longer be necessary for support. Even when applied at a thickness of only 2 to 3 inches, FRSC is extremely strong.

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