Cast Stone – A Beginner’s Guide

One of the most popular products that clients of 3D Pattern and Mouldmakers manufacture is Cast Stone. This highly refined form of masonry is the preferred choice of many construction projects. It offers exceptional strength and the ability to adjust colour to suit specific requirements. And the process isn’t new either, having been found throughout history. In this guide, we’ll walk you through everything you need to know about stone casting to help you understand if it’s the right option for you.

What is cast stone?

Unlike natural cut-stone, cast stone is when a blend of fine and coarse aggregate is mixed with water. The amount of water used determines whether a semi-dry or wet-cast method is used – we looked into the benefits of each of these in this blog post. Depending on the finished product required, these methods allow you to be as precise or rough with the design as needed.

The choice of aggregate used will also determine finished aesthetics. You can use a blend of natural stones, crushed stone, natural gravel cements and even mineral colouring pigments to get the exact look required. Depending on the use of materials, cast stone can produce exceptionally strong and durable items that stand the test of time.

Benefits Of Stone Casting:

Versatile – Being able to create and mould any item of choice makes cast stone an extremely versatile building material. It can be used to create curves as well as straight edge components and intricate details originally reserved for carving.

Easy to handle – Larger stone-cast items can be made with features to make handling and moving easier. This reduces the risk of damage and injury to tradesmen.

Duplicates – As stone casting uses specific moulds, it makes it easier to replicate existing units and features. You can also produce a number of the exact same item quickly and for distribution.

Colour matching – By varying the amount and type of aggregate used in every blend, you’re able to carefully match existing concrete or colour requirements.

Visually appealing – With the added versatility, you can create more attractive buildings that suit brand requirements and attract buyers.

Shorter lead times – In contrast to quarried concrete, stone cast concrete can be made and ready for use in a shorter time frame.

Greater precision – By using rubber moulds, you are able to create very specific designs – no matter how intricate.

Different Uses For Cast Stone

Cast stone can be used for a number of different purposes, primarily in the construction and design industry. It can be found in:

Building trim.

Ornamental trim.

Facing buildings.

Structures.

Statues.

Garden ornaments.

To simulate evenly veined and coloured stones.

Construction of buildings, including libraries and churches.

Chimney caps.

Spandrel panels.

Achieving Precision With cast stone

One of the main reasons why cast stone remains so popular is the ability to create very exacting and precise products using moulds. Rubber moulds are one of the ways we meet the needs of architects and designers all over the country. Being such a versatile material, our professionals are able reproduce specific designs which can then be used to cast concrete into ornate items. Silicone rubber material is highly flexible and meets this need perfectly, ensuring that decorative details can be replicated and produced with relative ease.

The work we have done over the years has seen us gain recognition through awards, including the 2019 Concrete Society Awards shortlist and the Highly Commended place the year before. We put the use of cast stone as one of the reasons we have been able to meet the high standards of our customers so well.

Cast stone is an age-old technique that has developed alongside current technology. In today’s construction and design industry, it gives precast companies the freedom to work with an extremely durable material while also meeting the requirements of every single customer. There are benefits of cast stone that meet each and every project, ensuring you can fit a brief effortlessly.

If you would like to speak to a member of our professional team here today, we can advise on the right mould construction methods for your project. And we’ll ensure that precision is kept at the height of priority at all times too. Contact us today for more information.