Cast stone, also known as reconstituted stone, is a building material produced in moulds. Using a blend of fine and coarse aggregate, it is designed to simulate natural cut stone. This new material is stronger, has better moisture penetration and textural consistency. It also gives manufacturers better control over colour while still performing the same roles as traditional concrete.

Here at 3D Pattern and Mould Makers LTD, we help our clients use two different processes to produce cast concrete – wet cast and semi-dry cast. In this blog, we’ll take a look at the differences and the reasons why you may choose either one.

Wet-Cast Concrete

Wet-cast concrete uses a higher volume of water. It is the mix-design that dictates how the final product looks. Fine aggregates are mixed into water while computerised batching ensures that the percentage of each ingredient is at the optimal level. From here, the mix is poured into the desired mould and then placed on a vibrating table. This ensures that every cavity in the mould is filled.

Pros:

  • Better suited to projects requiring very fine and specific detail.
  • Ideal for larger items and structural elements.

Cons:

  • Longer lead times – generally only one cast can be produced per day.

Semi-Dry Cast Concrete

In contrast, semi-dry cast concrete uses a smaller volume of water. Again, the mix is created and then compacted into the desired mould. The difference here is that the more solid blend allows the products to be removed from the mould much quicker for curing. Computerised batching is used again to ensure consistency and guarantee a solid hold once the concrete has been cast.

Pros:

  • Suitable for creating multiple components that are exactly the same.
  • A quicker process than wet-cast.

Cons:

  • Items are non structural or load bearing.

Here at 3D Pattern and Mould Makers LTD, we specialise in offering a variety of mould making services to the construction industry. With the freedom to create exactly what you need in a high-quality and extremely durable material such as concrete, these casting methods prove to be one of our most popular services. The team have built up years of expertise in this field, ensuring they are always on hand to answer any questions you may have.

If you are producing wet cast or semi dry units and would like to discuss this further, please get in contact today.