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DESIGN

The design can begin from a simple sketch, then working with the client we will form a brief, outlining all the primary elements of the project.

This may then be refined on a computer where dimensions and surface details are indicated in a 2D plan and elevation.

After client approval a 3D model can be created to enable the client to see the overall design more clearly.
This often enables us to identify and remedy manufacturing challenges at this early stage.

A site visit is not unusual at this point (though not always necessary) to enable additional measurements to be taken and a template to be created and taken away.

Once the template is created the mould can be made.

MOULDING
The mould can be created from wood, fiberglass, rubber, plastic, metal or any combination of these.

Mould or pattern making is a very skilled pro
fession. Moulds are created in reverse and negative to the required final product. Each new project requires careful consideration to achieve the best design of the mould for release angles and strength.

Any additional design elements such as fossils, metal rods, glass beads etc. are fixed securely to the mould prior to the pour.


REINFORCEMENT
Some projects require additional steel, carbon fibre or glass fibre reinforcement to provide additional strength for overhangs or large spans.

The type of material used to reinforce the product determines how it is used, some are added to the mould before pouring the concrete and some are added to the mixer during the mix.

 


THE MIX
Using the base ingredients of stone, sand and cement combined with a number of advanced chemicals and fibres the mix is poured into the mould and allowed to cure.

Decorative stones, broken glass, sea shells, pieces of metal or plastic are some of the materials that can be used to customise the mix to achieve a unique look.

Once broken from the mould the new concrete product is then ground, to show the stones and glass if required, and/or polished to the required level of shine then sealed to resist staining.


GRINDING & POLISHING
We can grind the surface with graded diamond wet or dry pads to expose the aggregate to achieve a Terrazzo like finish.

When the required look is achieved we move on to the graded diamond polishing pads. These pads can polish the surface of the concrete to a gloss finish.


SURFACE SEALING
The surface can be treated with a hardener which reacts with the concrete resulting in a greater scratch and wear resistant product.

Sealers are used to help reduce the risk of staining and to make the surface more easy to keep clean.


DELIVERY & FITTING

Once completed we can deliver and fit the product or alternatively the client can organise collection and fitting by a third party.


PROJECT DURATION
The average duration for projects is 4 - 6 weeks. The duration is largely dependant on the size and complexity of the specific project and the number of projects we are handling at the time. As with any business we have maximum number of projects we can handle at the same time. Due to this we must operate on a first come first served basis.
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