How To Make Rocks From Styrofoam (1/5)

Making fake rocks from styrofoam is a great method to build extremely
realistic looking artificial rocks and boulders which are strong and
able to weather outside in all climate conditions. Some people like to use
expandable foam to make fake rocks, which is also an option for making
the base form. The only problem here is that the expandable foam
product is actually quite expensive, but also it will not cure to any
appreciable thickness. If you want to have something large then you
would have to do multiple layers of expandable foam with dry time
allowed in between each layer. The problem is that the cans of
expandable foam are single use only, making a multiple layered approach
not exactly practical.

Through this tutorial process you will follow along step by step as we
make a fake rock from styrofoam. This will include a steel armature,
concrete mix design, sculpting and texturing the concrete, as well as
finishing details such as scraping, sanding, multi-stage paint and then
a concrete sealer application layer.

Episode 1 - Styrofoam shaping & steel reinforcement:

Episode 2 - Mix concrete & Add rock texture:

Episode 3 - Scraping & sanding:

Episode 4 - Painting fake rock finish:

Episode 5 - Apply concrete sealer:

00:00 - Introduction
00:53 - Beginning with a styrofoam form
01:32 - Finding scrap styrofoam for projects
02:22 - About layering styrofoam to build form
03:14 - Dangers of using PVC primer to melt styrofoam for rocks
04:45 - Expectations of finished rock
06:50 - Why steel mesh is used
07:52 - Protect yourself working with steel mesh and concrete
08:54 - Wrapping steel mesh armature to foam form
09:44 - Importance of placement of steel mesh
10:37 - How to secure steel mesh to styrofoam form
12:49 - How to shape the steel mesh
13:41 - Example of what to avoid with steel mesh placement
14:17 - Cutting the steel mesh
15:15 - How to finish securing steel mesh to foam form
16:30 - Folding and bending steel mesh to set firmly in place
17:35 - Dealing with the excess steel mesh
19:13 - Folding steel mesh on top of rock form
20:05 - How to compact steel mesh layers
21:16 - Last steps to finish the form
21:57 - Getting the steel mesh tight to form
22:57 - Fake rock form making conclusion

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[kalinystazvoruna]

Back around 2010, I took a course called "Art in the Garden" from my local University. The Sculpture professor was teaching the course. One of the things we did was take large pieces of foam, sculpt them, then covered them with concrete lath (like what you're doing here) which we pinned in place with some type of heavy-duty wire, then covered the same with concrete.
My project was to build a type of "tori gate-like butterfly fountain that could also be used as a seat", which I was going to put in my "Zen" garden. Unfortunately, the "Zen garden" has only come into existence now, 13 years later! (😸) In the meantime, in some places, the pieces of lath that were attached to the foam came lose and fell off with the concrete. Lesson learned from that was to make sure the concrete is at least 1 inch thick when applying to lath, chicken wire, or whatever. So now I have to repair it. (😿)
Since then I've been making "fake rocks" using those blasted foam containers you get when buying meat or fish. While I haven't had too much problem with them because they're small (only about 4 to 6 inches wide by maybe 12 inches long and only about 1.5 inches thick), covering both sides with concrete can take up to 2 days because I have to do one side, wait until it's dry, then flip it over and do the other side. I found if I make them too thick, the concrete doesn't really stick to the foam very well.
What she did was to dip fabric in the medium (in her case a kind of epoxy resin) and then drape it over the form so that when it dried, it kept the shape of form. I'm going to try dipping fabric pieces into a slurry of mortar mix and then drape it over the foam rock "form". After it dries, I should be able to continue to add concrete on top to build up the form so it looks like the way I want the "rock" to look.
What do you think? Think this will work?

[Fred.pSonic]

This is exactly what I'm looking for as I'm planning to build a small water feature. Subscribed so I don't miss an episode, will likely have questions at the end of it all. Thanks for all the effort Steve, it's appreciated.

[elloohno]

I love that you explain things so thoroughly. Thank you !

[cchemmes-seeseeart]

I am so thrilled to find these awesome videos. They are so well done too. It was exactly what I need to learn, as a person seeking info as a sculptor (applying the method to structures other than rocks, like figures, etc). As I watched, some possible ideas came to me of alternative methods to try in order to get the lath secure on the styrofoam, instead of so many nails, I'm thinking of trying to section the styrofoam, so each side is a thin sheet, & then use galvanized steel wire to sort of 'sew' the lathe onto the styrofoam... & then recombine all the lathed styrofoam sides- maybe by wrapping wire around them too; or maybe use a scrap wood inner armature to attach all the outer styrofoam sheets. I think a roll of wire would be less expensive then all those nails?? & could hold the lathe secure. what do you think, in light of your experience?

[kjirstenboucher]

Perfect for the plans I have of making fountain birdbaths. With styrofoam I could make any size or shape so the water can fall the way I'd like it too. Thanks for sharing.😊👍

[jarredsegal]

If you want to delete the wire lath just use polymer modified cement mixed with fibreglass fibres and just spray it on
It would be light enough it could float however it won’t stand up to the abuse of a more traditional stucco finish it is more versatile in its uses

[MrJmhess]

You just saved me a TON of money, and my back! Do you think if I applied a couple of thin layers of mud along with the 2 coats of sealer it would hold up "around" a pond/water feature?

[bananaclairedesigns]

You can use a different type of lathe that’s much easier to work with. Spider lathe. It comes in different types and sizes. Most vertical concrete artists use it. I’m working on a log right now and am actually using a GFRC backer coat for my scratch coat.

[LVSpeedweLL]

Thank you for showing me the how to of using styrofoam. There’s a septic tank lid i need to disguise and the store bought faux rocks look🙄 so fake. This seems like a fun project. Working with lathe = blood offering for the project, in my experience 😂even with gloves!

[shaymarie]

Do you prefer 1/2 or 1/4 metal mesh/hardware cloth and why?

[lettybromenschenkel]

Measure and cut before you start wrapping. can get more flexible mesh/screen/....

[TheCozyDeerCabin]

I want to build a boulder wall 150 ft by 6 ft. Do you think this would hold up?

[Major-xmbh]

Maybe I should come back when my patience is a little more tolerable😂

[johnnyllooddte]

how much does it weigh per cubic foot..and is there anything lighter

[tankiescraftingmom]

What are your thoughts on using cardboard as the base instead of Styrofoam

[naturalbeauty]

Can I use something else and not the steel mesh? "Looks dangerous!" 😩

[kayprins]

Does chicken wire work? the fine sort?

[CanadianMason]

Styro Napalm? Someone has spent time w a certain cookbook w an A on it. Lol

[nataliegist]

I have used glue all to glue Styrofoam.

[modeler]

great series. But, you try explaining way to much, at least for me. Could have had same results with 3 parts.