Dry cast stone production begins with the construction of the mold. Molds can be built to exact specifications from various materials including wood, fiberglass, and rubber. What separates dry cast stone from other products is that the same mold can be used to produce multiple pieces for the same job. This process ensures that each piece will be identical.
To create the cast stone mixture, fine aggregates are combined with white cement and additives before being mixed in automated turbine mixers. This mixture is then placed into the mold. Intense tamping is applied to densely compact the mixture. After tamping, reinforcement is added and the mold is filled. Tamping is reapplied, and the piece is finished.
Now the mold is overturned, and the piece is examined for quality. If the piece does not measure up to Edwards standards, it is returned to the mix and remade. The mold is then reassembled and is ready to be used again. A typical mold can produce up to 100 identical pieces in a day.
Finally, the piece is tooled and placed in a room with 100% humidity for hydration to be steam cured overnight. The next morning, the cast stone is removed from the steam room, sanded, washed, and inspected. Each piece is marked, palletted, and shrink-wrapped for delivery to the job site.
Dry cast stone production begins with the construction of the mold. Molds can be built to exact specifications from various materials including wood, fiberglass, and rubber. What separates dry cast stone from other products is that the same mold can be used to produce multiple pieces for the same job. This process ensures that each piece will be identical.
To create the cast stone mixture, fine aggregates are combined with white cement and additives before being mixed in automated turbine mixers. This mixture is then placed into the mold. Intense tamping is applied to densely compact the mixture. After tamping, reinforcement is added and the mold is filled. Tamping is reapplied, and the piece is finished.
Now the mold is overturned, and the piece is examined for quality. If the piece does not measure up to Edwards standards, it is returned to the mix and remade. The mold is then reassembled and is ready to be used again. A typical mold can produce up to 100 identical pieces in a day.
Finally, the piece is tooled and placed in a room with 100% humidity for hydration to be steam cured overnight. The next morning, the cast stone is removed from the steam room, sanded, washed, and inspected. Each piece is marked, palletted, and shrink-wrapped for delivery to the job site.