The Art of Craftsmanship: Unveiling Haddonstone’s Manufacturing Process

Designing the Vision

At Haddonstone, the journey of creating a made to order cast stone component always begins with a clear vision.

Whether it’s a design from our extensive standard range which has been manufactured time and time again, or a bespoke architectural component tailored to a client’s unique specification, the manufacturing process starts with design.

Some components are faithfully replicated from historic stonework, painstakingly preserving the intricate details and charm of the original.  In these cases, our team may obtain 3D imagery or impressions of the original stonework either onsite or at our manufactory.

For newer creations, our skilled team employs the latest in Computer Aided Design (CAD) technology, as well as traditional pencil drawings to bring concepts to life.  They can even work from a client’s photograph before meticulously turning them into a design.

These designs serve as the blueprint for the entire manufacturing process.

Crafting the Moulds

The heart of Haddonstone’s manufacturing process lies in the creation of our moulds.  This step is crucial in ensuring that each product captures the essence of the design.

Depending on the complexity of the item, two methods are employed.  For straightforward pieces, wooden moulds are crafted with meticulous attention to detail.  These wooden moulds serve as the foundation from which the stone is directly cast.

In contrast, more intricate designs undergo a different process.  Specialised rubber moulds, encased in a fibreglass shell, are used.  The flexibility of rubber allows for the gentle removal of the stone, preserving even the finest details and mouldings.

In each instance, our in-house studio and woodshop teams collaborate in order to produce the best possible moulds, thereby ensuring that the highest-specification cast stone design can ultimately be achieved.

The Art of Casting

Casting, a pivotal stage in the manufacturing process, varies according to the material used.

We offer three high-specification materials, each offering different benefits and providing an ideal medium for different cast stone designs.

Firstly, designs cast from our Haddonstone semi-dry cast limestone are hand-pack and compressed into the mould.  This process bears a resemblance to the joy of building sandcastles on a beach, but with far greater precision and attention to detail.

TecStone, our wet-cast limestone, on the other hand, is poured into moulds, benefiting from its self-compacting nature.  During this phase, the moulds are carefully agitated to eliminate as many air bubbles as possible, ensuring the product’s structural integrity.  Our TecStone material can also be reinforced with structural steelwork to make it suitable for structural projects.

Finally, our fibre-reinforced TecLite material follows the same casting method as TecStone.

Finishing with Excellence

After a 24-hour curing period, the products are demoulded and the finishing touches are added.

Designs made from our Haddonstone material are vapour cured in our special chamber, providing the stone with the equivalent of 14 days’ strength overnight.  This results in reduced delivery lead times and improved handling.

TecStone products, meanwhile, undergo a meticulous acid wash to remove any cement or mould residue.  This process also reveals the natural limestone aggregate, imparting a finish that closely resembles the beauty of natural stone.

Regardless of the material in which it is produced, each Haddonstone design is then finished by hand, by carefully wiping away any residue, softening out any seam marks and filling in any tiny, hairline cracks.

Ready to help with your next project

Our experienced and friendly team has been helping clients complete their projects, with and without structural reinforcement, for the past 50 years.

Whether you have a new project in mind, or would like to chat through some ideas, our team are on hand to assist you.

Arrange your free project consultation today.

Call:    01604 770 711

Email: [email protected]