Semi Dry Cast

Our semi dry cast pre cast mixes are formed with high quality aggregates from a local supplier. A blend of silica sand (fine), a grit sand (coarse) interlock to make the product stronger, high quality cement, colouring agents and water proofers are mixed and compacted in to moulds. Being a ‘dry’ cast mix the production process allows us to cast the mix into a mould and because the mix is dry once is compressed inside we can take the mould away. The product will hold its shape and that allows us to apply the finishing touches and carefully trowel up the product. This helps us create a cut stone feel and appearance in the finished product. The mould can be used multiple times throughout the manufacturing process allowing us to make more than one item per day out of the mould or make alterations to the mould and reuse in production of another item that differs in size. Additional water proof can be applied once cured to give the products extra protection from discolouration and longevity.

Where necessary we add strengthening rods to create a load bearing product. This is a major advantage in using manufactured pre cast products. Structural calculations can be made and our products are load baring where needed. This is a extra saving on structural steels having to be placed to support other products or building methods where the items used are not load baring. Another great benefit of precast stone is the ability to alter the colour or finish. We can match up colours to other stonework or age the finish with chemicals or simply a brushed finish to round off edges and give the product a stone that’s been weathered and aged over time.

Wet Cast Concrete

Wet cast concrete is a flow-able form of concrete which is  poured or cast into moulds. It has a higher water ratio. The manufacturing involves casting the concrete mix to a mould much the same as dry cast which will be vibrated to push any air bubbles out from the mix. Compressing the mix can’t be done as the mix is in a liquid form. When manufacturing with the wet mix the mould can not be taken away until the mix is completely dry. This means the mould can not be repetativly reused as it could be in the dry cast procedure. Any indiscrepancies in the mould will be replicated in the finished product and with no chance to finish or trowel the product up sat inside the mould attention to detail in the production of the mould is paramount. Smoother finishes on the surface can be achieved and usually the wet cast method of manufacturing results in a stronger harder wearing product. Ideal for uses in concrete furniture, countertops, tables, steps ect. A wet cast concrete can also be used to give products the industrial raw material look.

Once cast and out of the mould usually there are small air pockets or pin holes where air was trapped inside the mix they can be grouted up or left in for effect. Wet cast concret also gives you the perfect material for polishing.

Polished Concrete & Terrazzo Finishes

Polished concrete

Polished concrete is a multi-step process where a concrete is mechanically ground away. When polishing concrete you would use a special wet cast mix, the polishing process takes away the top layer of the cast stone. This process exposes and aggregates within the mix, this can reveal extremely unique and interesting finishes. Differing mixes sands/aggregates will give a endless variety of different finishes.

Terrazzo finishes

Terrazzo is a process of exposing specialist aggregates within a mix using the polishing process. Examples of the aggregates used could be chips of marble, quartz, granite, glass, or any other suitable material. These are used as part of a specialist mix as above. Once cast and cured the polishing process starts and the results can be unique and intersting. Exposing the aggregates and polishing the concrete products in the same process has amazing results. Another hard wearing product and its applications have been used in many, many different products over the years. Terrazo stone was once very common in the 1920s and became considered dated up until lately. Now its very much on trend and used in modern interior design, its unique and endless posibities of turning out one of a kind items is one of its many positive features. A fashionable material at the moment.

Upcoming Products Available

We are exploring the option of using Glass fiber reinforced concrete (GFRC). GFRC is a type of fiber-reinforced concrete. The product is also known as glassfibre reinforced concrete or GRC. It produces a extremely high quality high strength material, this means we will be able to cast the products thinner using less material and lighter products. Ideal with countertops, furniture, unique shapes. Using a spray gun to apply concrete to the moulds could push what we are doing to the next level. Not available from us at this moment but hopefully soon we will be introducing some very interesting products using our experience with the material and knowledge of technology and science helping us achieve what previously we couldn’t..