Our Authentic & Versatile Cast Stone
At New Cast Stone, we bring innovation and technological advances to the cast stone industry.
What is Cast Stone?
Cast stone, also known as architectural precast concrete, is a highly refined architectural concrete building material manufactured to simulate natural cut stone. It is made by mixing fine and coarse aggregates, cementitious materials, pigments, and water, and then pouring the mixture into molds to create various shapes and sizes.
The Process
The molds can be designed to replicate the appearance of natural stone, including details such as texture, color, and intricate architectural features. Once poured, the mixture is vibrated or compacted to remove air bubbles and ensure proper consolidation. After curing, the cast stone units undergo finishing processes such as grinding, honing, or polishing to achieve the desired appearance.
Cast stone offers several advantages over natural stone, including lower cost, faster production times, and greater consistency in color and texture. It is widely used in architectural applications such as building facades, cladding, columns, balustrades, and decorative elements. Additionally, cast stone is durable, weather-resistant, and can be customized to meet specific design requirements.
Authenticity of Cast Stone
Although cast stone is designed and manufactured differently than natural stone, our cast stone pieces age, look, and feel like natural stone because they are made from real limestone. Handcrafted finishing processes for each piece produce a highly authentic look normally found only with natural carved stone.
Versatility of Cast Stone
Our cast stone process is very customizable, which is perfect for those looking to create a unique commercial or residential design.
Shapes
It can be difficult to find the perfect shape due to the infinite design possibilities of foam molds. Thus, our shape catalog is here to help. You can choose a mold directly from the catalog or use it as an inspiration to create your own shape!
The shapes used can make a huge difference to the final appearance. Typically, there are very limited options for traditional cast stone—it’s either you choose from the existing mold shapes or pay extra for custom-made fiberglass molds. However, New Cast Stone has a unique position because it uses foam molds. The EPS foam molds are made for each job and there is no extra cost or time for customizing the profile.
Colors
We have 16 standard color options to choose from; however, if there isn’t a standard color option you like, we can do a custom color match!
Our biggest tip is that physical samples should be used to make the final color choice. There can be slight color variations because the final color will be affected by the texture selected.
Texture
There are two different textures to choose from.
The Honed Finish creates a consistent and smooth surface, which is both contemporary and elegant. It is achieved by grinding the stone to a matte-finish using abrasives. The Stone finish, on the other hand, has a textured, organic surface that is similar to the cut stone. It highlights the natural beauty and variations of color in the stone. This is achieved by techniques like sandblasting. These finishes have distinct advantages that can be used to create beautiful and functional spaces using natural stone.