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Founded in The Cast Stone Company Ltd is a leading supplier to the building industry, with 2 working directors taking their knowledge and professionalism.
Table of contents

Reinforcement is used to enhance the structural integrity of the piece to withstand shipping, handling and minimal structural stress. Bear in mind that reinforcement does not allow cast stone to be used in a structural capacity. Cast stone has many advantages over cut limestone when ornate profiles and decorative pieces are required.

Cast stone is almost identical in appearance to cut limestone and can be provided at a fraction of the cost. Due to the composition and curing process, cast stone will have a higher compressive strength and a lower cold water absorption rate. The composition and method of manufacturing are entirely different. Cast stone has a more refined appearance and looks like cut limestone. The same as with cut limestone, the compressive strength of cast stone is higher and the cold water absorption rate is lower.


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In most cases, cast stone can be matched to blend with existing stone. Since cast stone is individually made, there will be natural variations in the stone which add to its beauty and uniqueness. Since jobs are made from the same batches, this will be slight but still noticeable. If a stone is darker, it is often because it has not yet completely dried and the stone will lighten as the moisture evaporates. Yes, although our inventory mainly consists of balustrade, pier caps, and keystones, we do have other material in stock and certain pieces available at a discount.

Our staff can discuss the details involved from the beginning design through to the final completion. Some molds can be slightly altered with no up charge.

How is wet cast stone made?

If additional custom work is required, the molds can be designed and built to meet your specifications. The more custom built molds used the greater the job cost. Every bid is unique and all factors of the job are taken into account in preparing the final bid.

Value engineering is a term describing the relationship between the inherent design of cast stone and cost effectiveness.

Natural Stone vs. Cast Stone - Materials Marketing

One aspect that has been previously discussed is the cost of custom molds. The other point to consider is the actual design of the mold. It is essential to keep in mind the nature of the stone. It is essential to include one major flat unexposed side in the design of the basic section and in the returns.

Avoid designs with small projections. All jobs are bid and produced on an individual basis. In order to receive an accurate bid, please fax or mail all elevations, floor plans and details requiring cast stone. Once your proposal is accepted, a signed contract and deposit is required to begin any design or shop drawings. Certain jobs require numerous shop drawings and submittals for approval. Please allow adequate time for this phase of processing.


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On fireplace orders, the balance is due prior to shipment. On other orders, progress payments are required. Upon approval of shop drawings, orders can take anywhere from weeks to produce. Custom and large orders that require extensive shop drawings can take longer with progress shipments for up to six months, depending on the size of the order. Cast stone takes 28 days to reach full strength.

CCS is not responsible for damages incurred due to early shipment. It is understood that all shop drawings furnished by CCs shall be checked and approved by the client. Any change orders require written confirmation and approval. The number and size of custom pallets and the size of the job will determine the number of shipments. Pallets cannot be stacked; therefore the truck space is limited.

How cast stone products are made

Due to the nature of the product, shipping is expensive. In order to keep freight costs at a minimum, all shipping quotes are based on the least number of shipments possible. The product is palletized, insulated and shrink wrapped. The truck must be a flatbed, air-ride trailer.

Cast Stone

We contract your shipping with a nationwide broker. You are notified when the truck leaves our warehouse and then 24 hours prior to delivery, so that you will be able to have your forklift on the job a minimum amount of time. Yes this is possible, but two important factors must be considered. If the trucking company is outsourced, there is no tax charged. If you as the client, own the trucking company, then Texas sales tax must be charge. This may lead to minor time delays in scheduling a truck.

If your job is affected by time constraints, we will be more than happy to reschedule your freight with a single shipment cost, but please note this will be considerably higher. Pallets arrive via an 18 wheeler transport truck. These trucks are not allowed in all residential areas, so secondary arrangements must sometimes be made. A level space should be made available to unload and store the number of pallets on each truck delivery.

A 24 hour notice will be given prior to all deliveries. Pallets should be inspected on delivery for any apparent damage. The Bill of Lading will indicate the number of pallets and contents of each one. This should be checked against the delivery. CCS will replace any damaged piece and be responsible for filing a claim with the trucking company. The product should be stored in a dry, flat space until ready for use.

INNOVATIVE DESIGN

CCS accepts no responsibility for any installation errors made by an installer, requiring remakes of pieces. Cast stone is extremely heavy and may require more than one person to lift and place or in some cases mechanical assistance. The edges are initially fragile and should be moved carefully. When actually installing the stone, it is important to mask off the joints with tape, so that the mortar does not attach to the surface of the stone. Fill dowel holes and anchor slots completely with mortar or non-shrink grout.

Set units in full bed of mortar, unless otherwise detailed. Remove excess mortar from unit faces immediately after setting. All told, your recipe should be as follows:. Mixing as you go, add liquid slowly and stop when you can squeeze the mix into a ball and it holds its shape without excess water. The mix should be wet enough to hold together. Line your form with plastic wrap and push a small amount of mix into the bottom of the form, pushing down all around the bottom to compact the mix. The bottom should be at least a half-inch thick for small pots and one-inch for larger pots.

Place a form such as a bottle into the center of your pot at this time. Keep on adding and compressing the mixture around the bottle in the form with your fingers or ceramic tools as you slowly fill it to the top. For small pots, the wall should be between one-half and one-inch thick, and for larger pots at least one-inch thick. If you split your mixture at the beginning and added oxide colorant to one of the batches you can alternate layers as you go. You will end up with layers of beautiful color variations in your finished pot.

Add layers, firmly pressing down. Before the mixture sets, remove the inside form by slowly rotating it and pulling it up. Place the mold in a frost-free environment, cover with plastic and mist with water for at least two days. Once the stone has hardened, flip upside down and gently release the pot. Sand the outside edges of the pot or leave rough. Use 3M Pro-Grade Precision sandpaper, which can be used on wood, paint or metal. Cover it with a plastic sheet, lifting it to mist daily for a month.

Buy and collect materials on a different day than making the pot. Go over the checklist beforehand to make sure all supplies are on hand. It should be crumbly but hold together in a ball when squeezed. To attract moss and lichens, use peat or coconut coir as an aggregate. Just stick to the ratio for the dry mix. For instance, you could use two parts coconut coir to one part sand and one part cement.

If adding coconut coir, soak overnight before adding it to the mix. If making a large batch, divide mix in half to prevent unused mix from setting. Make a small pot first before attempting a larger size to get familiar with the process. If you feel you need better drainage, you can drill a hole in the bottom after it is completely cured.

Clean and dry all tools. Wear a dust mask while preparing and cleaning up and while making your pot.

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If using a shop vac, use a filter for fine particles. Work in a well-ventilated space. Claire mixing concrete oxide for color.