Dry Cast Stone

As the most commonly used building material in the world, concrete has hundreds of product benefits and can be used over an endless number of applications.

Dry Cast concrete has a very low water content allowing it to have a rapid curing time. The production process is completed by fully trained Casting Operatives and entails the Dry Cast mix being pressed into moulds in layers, achieving a compact result with no entrapped air within the concrete or between the walls of the mould. Due to its fast drying time, the forms can be removed almost straight away, allowing them to be reused several times within the same day. This enables Dry Cast to be extremely and efficient option for mass manufacturing projects.

Why choose our Dry Cast Stone?

Amber Precast supply an extensive range of Dry Cast products and features for use in both residential and commercial schemes of any size. With the ability to supply standard or custom made pieces, the unique cast limestone materials can be moulded to almost any shape giving you the opportunity to create or reproduce cast stonework that is both cost effective and attractive.

Producing Dry Cast in a factory allows for it to be monitored, tested and controlled resulting in a high quality product. At Amber Precast, our Compliance Department ensures that our Dry Cast products go through rigorous strength testing to ensure that its tolerances are always above industry regulations and standards. We also hold an ISO 9001 accreditation for quality management.

The cast limestone material can be used in every design from standard window cills and heads to intricate architectural designs. Our products exceed the cube test compressive strength and water absorption requirements of BS1217 and those of all other United Kingdom Cast Stone standards. Dry Cast concrete has a multitude of qualities to reassure you that it’s fit for purpose over a vast range of applications. Not only does it provide strength, durability, and protection against the elements, but is also rot proof, fungus proof and mildew resistant.

Examples of projects where we’ve used Wet Cast concrete include Cast Stonework at Coutts House and Dry Cast Stone for TLC Care Homes.

Take a look at our other Product Profiles on Wet Cast Stone, Precast Concrete and Glass Reinforced Concrete (GRC) to see which material is suitable for you. Our Engineers are always happy to advise you on the most suitable material for your project needs and welcome the opportunity to work closely with you from design to completion and aftercare.

Amber Precast has the capabilities to design, shape and create precast products of almost any design, so the only limitation is your imagination. If you can dream it, we can shape it.

Contact Amber Precast

For further information on our precast concrete products and capabilities, or to discuss specific project needs, please contact us on 01773 540707 or email us at info@amberprecast.co.uk

 

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Dry Cast Process

Dry Cast manufacturing method involves compacting a semi-dry cast stone mix into moulds, and with certain products the finished casting can be demoulded almost immediately for curing.

 

As the name implies, semi-dry casting involves the use of low water content or ‘earth moist’ mix. The fine aggregates used in the mix are graded so that thorough compaction can be achieved. Computerised batching is typically used to ensure the consistency of materials and measure water content. Semi-dry  products can either be manufactured  using a high quality cast stone mix throughout or by employing  a  backing mix with a cast stone facing mix.

 

The semi-dry approach enables repetitive elements to be cast in considerable numbers and relatively quickly. The finished surface of the semi-dry cast stone products tend to have an open texture, like sawn natural stone.

 

The process is most suited to traditional sized elements such as cills, heads, string courses and copings.  Structural items can be produced so long as the reinforcement requirement does not inhibit compaction.  The ability to reinforce semi-dry cast stone is yet another advantage over natural stone.

 

Units are generally cast face down into wooden moulds using pneumatic or electric sand rammers. Alternatively, steel hand moulding machines or ‘machine mould’ can be used to produce consistently sharp, crisp arrises suitable for ashlar and details such as L quoins and plain band courses.  The benefits of machine mould are even shorter lead times and lower cost.