Cast Stone, Wood & Iron Co. Services

We copy or originate 2&3 dimensional decorative building elements in glass fiber reinforced concrete hand-mixed and laid ("pre-mixed") on a short-run (less than 100 pieces) basis according to Manuals 128 and 130 of the Precast Prestress Institute ("PCI").

All products are decorative i.e., non-structural.

Decorative elements and finishes (to include integral coloring and faux finishing, clay and lime plasters, casein and lime paint and coatings) we can copy or originate include:

terra cotta (speckled, plain (and aged) white, integrally colored and glazed and surface decorated and glazed;

interior and exterior limestone, marble and other stones,

floor and wall tiles;

old wood (exterior and interior ancient-looking entrance doors, beams/vigas, columns, heavy benches that might be out in the weather, etc.);

decorative metals ("iron") that include new as well as older brushed aluminum, iron, brass, copper, stainless and, of course, gold, via powdered metal/resin coatings on our GFRC castings; andf

so-called "natural" paints and plasters, such as lime and clay plasters and lime and casein paints.
These are very old coatings that create unique appearances, some of which we do ourselves and some of which we producer with others, which come through our Tucson office from Native Americans and Mexicans as well as early Midwest American applications and some from the Mediterranean and Mideast. Our mosaic supplier is in the Mideast. Natural coatings are starting to be included in what we offer because most buyers prefer a single source for all cementious materials.

In order to produce what might seem to be a wide range of product types, we focus on a short list of core skills and areas of knowledge:

(1) concrete mix design chemistry,

(2) model repair and origination,

(3) 2&3 dimensional casting and shop-to-shop-site engineering cooperation, including casting in of S/S fasteners and wood fastening surfaces to spec',

(4) finish development, including polishing and faux finishing; and

(5) modern coatings.

We start with the:

(a) high tensile strength of GFRC (via polymers, glass fibers and fine-grain, high silica sand); and

(b) the suitability of this high tensile strength to "pan and beam" (rib and void) casting to produce much lighter and more flexible-chip/scratch/cracking resistant castings.

Next, we leverage GFRC's fine-grain sand:polymer combination for:

(a) more consistent (than normal concrete) integral coloring; and

(b) smooth surface casting that is well-suited to detailed faux finishing and acceptance of modern UV-resistant and food surface-suitable coatings.

We believe that our combined leverage of GFRC's well-known advantages with our core skills enables us to produce and re-produce virtually any interior or exterior decorative building element in 2 or 3 dimensions.

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Cast Stone, Wood & Iron Co. Services