Colour matching and mixing is an especially critical part of the process to make cast stone products, because there are a number of key factors we have to take into account. Firstly, there are the relative quantities of different ingredients in the mix which have to be right to ensure the end product is of the correct finish and strength.
Next there's the consistency of the mix with the exact right quantity to ensure
a) that the product colour is exactly as specified, and
b) that colour is consistent across multiple products for the same job.
Moulds are made from timber and to the exact dimensions and form taken from the CAD drawings. We have our own team of joiners who are highly skilled and have many years' experience behind them. Once the moulds have been tested and checked to ensure they are perfect they are approved and ready for the next stage of manufacture.
The moulds are then filled using the exact mix and reinforcing bars then compacted using vibrating tools, turned out and finished to a high standard before being put into the climate-controlled curing chamber that ensures consistent high quality products and reduced lead-times. Final quality checks before approving the product and packing on pallets with shrink wrapping, ready for delivery.
Procter Cast Stone have made a major investment in a fantastic, state of the art manufacturing facility that combines all the production operations into one building. The new investment includes a computer-controlled batching plant to ensure consistent colour matching and mixing. Also a new integrated and well equipped joinery facility with new machinery for highly accurate mould-making.
As well as the production investment Procter Cast Stone has expanded and reorganised its stock yard to cater for increased demand and hold more standard cast stone products in stock.