Wet Cast Manufacturing

Overview

Our Wet Cast Reconstructed Cast Stone units are manufactured using high grade aggregates and cement which achieve a minimum 40N/mm2 with a high early strength. The cured component is then normally acid etched using controlled methods to remove the laitance and expose the natural aggregate colours in the mix. We do not add any pigments to our standard Bath and Portland products which contain only the natural colours of the aggregates used within the mix design. Wet Cast products are single casting per day from each mould, and can be produced in large units with complex reinforcement within to form large structural units. Finishes can vary from exmould or light acid etched, to deep retardation which exposes large elements of aggregates and can if the surface allows, be ground or polished.

Detailing

Vobster Cast Stone undertake detailing of all components prior to manufacture. The performance of a finished stone is partially dependent on the accuracy and suitability of its design. All units will be designed to maximize their performance in relation to weathering, structural integrity and site handling, without compromising on its detailing or the stones aesthetical requirements.

Specification

Moulds are manufactured from solid timber, fiberglass or rubber. Timber moulds are painted with three coats of Hybuild Extra polyurethane varnish to ensure the timber does not absorb any water or moisture which could distort the finished faces of the stones. All moulds are sprayed with a mould release agent prior to filling, to ensure the cast units release from their moulds without damaging arises or faces. All moulds are manufactured to be entirely waterproof with the use of rubber inserts, to ensure that zero grout-loss occurs through mould joints during manufacture. This ensures all arises and edges remain crisp and sharp, particularly important with units of high level detailing. Our computerised batching plants ensure precise and through mixing which produces units with compressive strengths well in excess of British Standards and UK Cast Stone Association requirements. A high specification water proofer is included within each mix which ensures finished products are virtually impermeable to water ingress. ISAT (Initial Surface Absorption Tests) have been carried out by UKAS accredited laboratories which have resulted in results indicating that less than 0.05ml/m2s of water had been absorbed at 60minutes. The certification remarked that “the Cast Stone is too impermeable to be sensitive to a longer term test”. Due to the impermeable properties of our Wet Cast Stone, water is prohibited from migrating through the concrete which would reduce both its alkalinity and its strength. This eradicates the cause of leaching which would otherwise result in leaving unsightly deposits on the surface of the units or brickwork etc below.

Click here to view the specification benefits of using Vobster Cast Stone Wet Cast