|Conference room of
Continental Cast Stone, the most modern Cast Stone plant in the country. Here architects and
contractors discuss projects quietly, at their convenience. A fully-staffed estimating
department provides prompt reliable estimates on all projects.
|Of primary importance is the
drafting department. Architect's drawings for Cast Stone are detailed and reduced to
units of a size easily handled in the shop and on location. Each piece is numbered
according to a master plan.
|Here experienced pattern makers
follow the drawings so that the fine detail in delicate ornamentation is reproduced
faithfully. The simplest sill, no less than a decorative finial, demands accuracy in the
wood pattern. The final product must exactly fit the master plan.
|All the aggregates used in the
manufacturing of Cast Stone are washed, screened, graded and tested at the quarry. Exact amounts of every
ingredient are weighed by computer controlled scales for each batch. Test samples show a comfortable margin of
compression strength over minimum requirements and an absorption far below the minimum
|Special mixers turn, grind and
pestle the mass until every particle of aggregate is completely surrounded by Portland
cement. Mineral oxides are added to achieve the desired color. Water content is regularly
measured to keep the water-cement ratio as low as possible, thereby increasing the
hardness and durability of the Cast Stone.
|The mix is placed into a sturdy,
reinforced moulds, then vibro-tamped by machine. Every detail is observed in the
production process and an extraordinary degree of density is achieved. A superior Cast
Stone is the natural result of the painstaking care lavished through every step of
proprietary direct-fired hot steam curing process, under presence of
carbon dioxide and carbon monoxide, every piece of Cast Stone is carefully examined
by quality control inspectors before being passed for shipment. Each piece is
annotated with its own location number on the master plan.
| Finally, after twenty-four hours, the
Cast Stone is rubbed and etched to season a surface that will not be affected by
weathering. Trucks and trailers keep the jobs
moving: not too many pieces are piled up on location; contractors do not wait for
deliveries. Our production
schedules mesh expertly with the contractors' needs.