Fault zones play a key role in controlling subsurface fluid migration, influencing hydrocarbon accumulation, CO₂ sequestration, and geo-energy storage safety. Most previous experimental studies, however, have been restricted to static outcrop or core observations, which fail to capture the progressive evolution of fault zone structures in time as a response to changing stresses. Moreover, existing analogue experiments often use unconsolidated sediments, which cannot accurately represent brittle faulting in consolidated rocks, and quantitative analyses remain limited. To address these challenges, a new method based on ring-shear experiments was developed to physically simulate fault zone formation in consolidated sandstones. The method simulates shear deformation under variable stress and displacement conditions, followed by multi-scale quantitative analyses, including computed tomography imaging, thin section analysis, and porosity-permeability testing under confining pressure. This comprehensive testing routine allows to quantify changes in fault zone thickness, particle and pore size distributions, and grain orientations during progressive deformation and depending on shear parameters. The results demonstrate systematic relationships between effective normal stress, shear displacement, and fault zone structural attributes. The fault zone thickness shows a nonlinear trend with stress, while cataclasis and compaction intensify with increasing displacement. This work provides a methodological foundation for future applications in fault seal analysis, fluid flow modeling, and numerical simulation, offering a practical reference for petroleum systems studies, hydrogeology, and underground gas storage including CO₂ and hydrogen.