Our process

Our stonework is all made by hand.  Find out more about how we achieve the highest quality products.

Handmade by Haddonstone

At Haddonstone, we’re incredibly proud of the skill and expertise that goes into creating all of our products. Our in-house craftsmen use finely-tuned artistry, teamed with years of experience in order to produce the highest quality cast stonework on the worldwide market.

Every single Haddonstone design is made to order to meet our clients’ exact design and construction specifications. If the order is for a standard design, then production can start as soon as a colour has been decided. But if the order is for a bespoke design, a unique mould must first be made.

The moulds

There are two types of moulds we use in the production process: wooden moulds, for simple designs like window sills and coping stones, and rubber moulds for complex designs. Here’s how the fibreglass rubber-lined mould is created:

  1. The model is created within our wood shop, having been carved from scratch by an in-house craftsman.
  2. Once the master model has been created, the mould-making can begin, starting by rolling clay to a set thickness and covering the entire model.
  3. A fibreglass case is then formed. It’s completely inflexible, so has to be designed to allow for easy removal later on – in some cases this means the fibreglass comprises ten sections or more.
  4. The fibreglass case is then opened, the model extricated and all traces of clay removed before being reassembled.
  5. A specially developed rubber is poured in, with enough fluidity to fill every cavity while avoiding any air bubbles.
  6. Once the rubber is set, the fibreglass case is opened once again and the model is placed into storage. Once reassembled, the void left in the centre is the precise shape and size of the finished design.

The manufacturing process

For Haddonstone (semi-dry cast limestone), the materials involved in this are limestone, white cement, sand, a small amount of water along with some secret ingredients. This mix produces the Portland colour – for other colours, pigment is added.

We have two other materials as well: TecStone (wet-cast limestone) and TecLite (fibre-reinforced).

Here’s how it works:

  • Quality check To ensure complete control of the production process, every single batch of raw material is checked for quality before use.
  • Mixed in small quantities After being stored in high tonnage silos, the ingredients are mixed in small quantities via computer-controlled batching equipment, then taken to a workstation.
  • Mould packing The mixture is then gradually packed into a mould, usually by hand, although sometimes pneumatic hand rammers are used.
  • De-moulding Perhaps the most visually rewarding stage of the production process, the fibreglass case is stripped away, leaving the rubber around the stone. The rubber is then also carefully peeled away to reveal the stone design in all its glory.

We’ve been producing the highest quality cast stonework at our studio and manufactory for nearly 50 years. Learn more about our history and where it all began.

Speak to our team

Whether you’re working on a private residential or large commercial project, or if you are interested in home and garden products, our friendly and expert team are happy to discuss your requirements.

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