Banding, Columns, Door & Window Surrounds Columns & Arches Medallions, Coping, Arches, Columns, & Banding Balustrades, Newel Piers, Sphere Finials, & Planters Pool & Wall Coping Garden Elements Pier Caps Commercial Signage
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Your Vision—A Reality

 

Whether your project is a downtown monolith, a gothic revival home, or a decorated arboretum, we can assist you with the complete design of your project, from start to finish. Our master designers, draftsmen, and project engineers, trained in computer-aided design, work with you every step of the way to make your vision a reality.

 

With the help of computer-aided design, we work with you to create a master plan. Then, once your plan is approved, our design team goes to work drafting the individual elements that form the complete plan. Each item is carefully designed and detailed to ensure proper fitting and handling for installation into the finished design.

 

Fitting The Mold

 

Once the project has been detailed by our master designers and draftsmen, the mold shop creates the individual molds that will become your final piece. Molds are made from many materials, with the most common being wood. Experienced pattern makers use the detailed drawings of the master plan to ensure 100% accuracy.

 

Fine detail and artistic elements make use of plaster and terra-cotta bases, eventually becoming plastic or rubber molds for such items as balusters, and fireplace headers and legs. Medallions, finials, lion’s heads, and more can be creatively designed using this concept as well. The exquisite detail within each piece can be so intricate that a mold maker will concentrate on the detail and design, so that the finished element meets your utmost satisfaction.

 

Batching the Elements

 

Once the molds for each element are approved by the customer, they go to the batch plant to be loaded with sand and aggregates. Our 35,000 square foot, state-of-the-art batch-plant houses the silos of cement and aggregates used in manufacturing cast stone elements. The cements, additives and aggregates are of the finest quality. The ground stone we use is washed, screened and graded at the quarry to our specifications.

 

Our trolley carefully measures the correct amounts of White Portland cement and aggregates with electronically controlled scales, which are then carefully lifted and deposited into the individual batch mixers. Additives and color mineral pigments are added based upon the desired design and color, by our special mix team. Then, water is carefully measured and added to keep the moisture ratio at an ideal consistency. Without this extra step, unwanted slug, and irregularities would occur that can discolor and disrupt the process. Once the mixers have thoroughly mixed and turned the cement, aggregates, water, and additives, the tamping team is ready to tamp each piece using pneumatic tampers.

 

Tamping Process (Vibrant Dry Tamp Method)

 

We use the Vibrant Dry Tamp Method, that is, vibratory ramming of earth moist, zero-slump concrete against a rigid mold until it is densely compacted. Each mold is reinforced to defy the sturdy tamping of the cast stone material. Special attention is given to the detail of each piece to measure accurate density and any additional requirements such as proper re-bar reinforcement or added supports like straight coil loops or anchor systems to assist in lifting and placement of material during installation.

 

Special hydraulic lifting tables assist the tamping team in lifting and turning the tamped material onto the curing racks. Specialized personnel strictly inspect and verify that every piece is made accurately. Edges are fine and crisp. Rounded edgings are smooth. Lengths, widths, and angles are measured for accuracy.

 

Curing the Stone

 

Once each stone is tamped, the stone is inspected, and carefully reviewed to confirm it meets design specifications. Then, it is rolled onto the curing racks for overnight setting in our climate controlled heated steam curing room. Throughout the evening, timers control the steam room for the best curing of the stone. The next morning, our quality assurance team re-inspects each piece to determine accurate measurements after the stone has hardened. We take an extra step in this process by letting the stone rest an additional 2-5 days before shipment to guarantee that the piece has properly cured.

 

Finally, each stone is washed, dried, sandblasted or detailed as required by project specifications. Then, we separate each piece with foam and shrink-wrap on pallets for shipment.

 

Logistics

 

We work with several ship, rail and truck companies to deliver product to our customers, or can arrange in-house shipping via Espinoza Cast Stone trucks. Please speak with an Espinoza Cast Stone sales representative for more information about shipping options.