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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 profession.
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.
REINFORCEMENTSome 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.
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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
SEALINGThe 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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