Reconstituted Cast Stone

Recon Split
Introducing

Reconstituted cast stone

Cast stone has been used as a core building material for hundreds of years, with its earliest use being traced back to the year 1138 at Carcassonne in France.

Cast stone is a Portland cement based architectural precast concrete product, manufactured to incorporate high quality fine and coarse aggregates.

The British Standard definition for cast stone is ‘any material made with natural aggregates and a cementitious binder that is intended to resemble and be used in a similar way to natural stone’.

The wet cast stone manufacturing process provides a close grained, smooth and dense surface, which offers precise rendering of fine detail. Wet cast manufacturing offers a through colour homogeneous mix which when etched exposes the natural aggregate colours within the material. This gives the finished stone the look and feel of quarried natural stone.

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Benefits

Cast stone has caught the imagination of architects, and indeed their clients, as it offers distinction by greatly enhancing and complementing the other building materials on a facade.

It is regularly used in areas with sensitive planning constraints, or where quarried natural stone is the prominent material.

The use of cast stone also offers the designer flexibility to choose their required colour, texture, finish and stone unit dimensions.

Frequently manufactured products include finishes to replicate quarried natural Portland and Bathstone, however its performance is superior to quarried natural stone with regard to its increased strength and reduced moisture absorption, resulting in improved freeze/thaw durability. This opens up a new range of options to the designer such as bespoke sized units with stand-alone structural performance, which is not achievable from quarried natural stone.

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Methods of

Manufacture

Wet cast /

The wet cast stone manufacturing process provides a close grained, smooth and dense surface, which offers precise rendering of fine detail.
Wet cast manufacturing offers a through colour homogeneous mix which when etched exposes the natural aggregate colours within the material. This gives the finished stone the look and feel of quarried natural stone.
The wet cast manufacturing process yields one cast per mould, per day, and can be produced in large units with complex reinforcement to form structural units of high tensile strength.

Semi dry /

The semi-dry process facilitates multiple casting from each mould at a faster rate than wet cast due to the reduced moisture content. In most cases the moulds can be stripped from the finished product almost immediately. 
Having the ability to quickly turnaround the use of each mould as part of the semi-dry process, can offer significant cost savings over the wet cast process. 
In addition, this method of manufacturing requires no secondary treatment, and can be supplied in most colours to match existing stonework. The process is highly suited to regular building features such as Copings, Cills, Heads and String Courses.

Gallery

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Key features

No pigmentation /

Taylor Maxwell’s wet cast standard Portland and Bathstone finishes contain no pigmentation, and are solely the natural colours of the aggregates within them.

Superior performance /

Reconstituted cast stone's performance is superior to quarried natural stone with regard to its increased strength and reduced moisture absorption, resulting in improved freeze/thaw durability.

Additional options /

A new range of options is available to the designer such as bespoke sized units with stand-alone structural performance, which is not achievable from quarried natural stone.

Highest quality /

Due to the use of the highest quality handmade moulds, the finished product presents the designed level of precise, sharp detail.

Reconstituted Cast Stone