Making Dry Cast Stone
Producing dry Cast Stone begins with making a mold. Molds are built to exact specifications from various materials. They could be made from wood, fiberglass, or rubber. The same mold can be used to produce many pieces for the same job - up to 100 per day from one mold. That ensures that each of these pieces will be identical.
Next is the mixture. We combine fine aggregates with white cement, coloring, and other necessary additives. This is all combined in turbine mixers to ensure a uniform blend. This mixture is then placed in the mold, and then intensely tamped to densely compact the mixture.
Once the piece is ready, we'll remove the mold and examine the piece for quality. If it doesn't meet our standards, we return the piece to the mix and remake the piece. No pieces leave our facility without meeting our standards.
The last production step is placing the tooled piece in a room with 100% humidity to steam cure overnight. The next day it's sanded, washed, and inspected. Once the piece passes inspection, it's marked, wrapped, and palleted for delivery.