Cast stone masonry

Cast stone products have been developed over many years to provide the ideal solution to recreating the charm of natural stone construction. It will add character to new buildings and allows traditional appearances and designs to be maintained in refurbishment work whilst working within modern costs and performance parameters. Cast stone is welcomed by planning authorities throughout the country, especially in conservation areas where the continuance of traditional building methods and materials is seen as being desirable. The products are renowned for their quality and finish and all are produced by craftsmen using long established skills. This provides the ability and versatility to adapt standard shapes and colours or create purpose made units to meet all architectural and designer requirements

Cast stone is manufactured by two different processes. The semi-dry method involves the mixing of aggregate, cementitious binder, water proofing admixture and a pigment, where necessary, with a limited amount of water to form an 'earth dry' mix that is compacted into wooden or steel moulds. Once finished, the product is immediately demouled and set aside to cure. The manufacturing process produces the texture that resembles smooth sawn natural stone. The alternative method of producing cast stone is by the wet method. Here aggregates, cement and pigment, where necessary, are mixed together with sufficient water to produce a workable concrete that is vibrated in rubber moulds under vacuum conditions to ensure good compaction. After de-moulding the units are acid etched to give a stone like texture.

Galvanised high yield reinforcement is used for handling purposes only. All units are non-structural and non-loadbearing although loadbearing units can be produced to a structural engineer's drawing.

Window surrounds have been designed for use with multiples of modern single light, windows of wood, uPVC or metal manufacture. They can feature continuous or bonded jambs and a choice of flush or overhanging cill. A label moulding is an optional extra. Heads and cills, supplied in window unit lengths, are jointed at mullion positions. The surrounds are designed to accommodate a 4mm waterproofed mortar joint (material supplied on request) which should not be exceeded otherwise weather proofing may be impaired.

Dowels are provided for jointing between units, jambs are cast with stainless steel dovetail slots and fishtail cramps are supplied for tying into brick/stonework. Cills

A wide variety of cill profiles are available that can be used to enhance the appearance of windows externally and internally, without the expense of a full surround. They can be particularly effective when combined with one of the heads from the range. Due to the nature of the product semi-dry cast products are not suitable for use as a door or patio threshold.

To accommodate large window widths, cills are normally supplied in left and right hand sections (plus centre section as necessary). Cills are generally of the overhanging type and are supplied with a drip groove as standard. The cills supplied will suit either single or two brick course heights. End stooling is an option available on many cill profiles.

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London Gardeners and Landscapers