Our Manufacturing Process
At Olde World Cast Stone, we hold our products to the highest standards from concept to completion. Every step in our process is designed to deliver precise, high-performance cast stone with exceptional consistency and care.
Project Planning
Planning is the foundation of everything we do. We partner closely with architects and homeowners from the very start to ensure our work aligns perfectly with their vision. Our estimating department provides detailed, transparent quotations well ahead of bid time, allowing ample opportunity to refine the project scope and pricing.
Drafting & Engineering
Precision begins on paper. Our engineering team produces fully detailed shop drawings that specify exact dimensions, attachment points, and setting details. This step ensures seamless execution during both manufacturing and jobsite installation.
Mould Manufacturing
Our master artisans use precision tools and custom design drawings to fabricate high-accuracy moulds. By ensuring every mould precisely replicates the original specifications, we deliver consistent parts that streamline installation for masons on-site.
Raw Materials & Computerized Mixing
Quality control starts with our raw materials, which are carefully managed from the moment they arrive at our facility. Materials never touch the floor or any unapproved surfaces. Ingredients are measured and blended using a computer-controlled mixing module, guaranteeing absolute consistency in every batch.
Casting the Part
Using a zero-slump mix, our experienced craftsmen pack the concrete into specially designed moulds using pneumatic hammers (Vibrant-Dry-Tamped method). The part is then immediately demoulded, freeing the mould to repeat the cycle with complete accuracy.
Advanced Vapor Curing
We utilize an advanced vapor cure chamber engineered and installed by Kraft Energy—a high-performance technology used by only a select few manufacturers nationwide. By combining high heat, relative humidity, and carbon dioxide, this process:
Accelerates Strength:
Reduces a standard 14-day curing cycle down to just 24 hours.
Eliminates Efflorescence:
Virtually removes surface salt deposits for superior finish and color integrity.
Improves Site Handling:
Allows masons to handle and install the stone sooner without risking structural damage.
Packaging, Shipping & Quality Assurance
We maintain strict accountability through individual craftsman ownership. The worker who creates a part is directly responsible for inspecting, packaging, and preparing it for shipment.
Traceability:
Every part features an embedded tracking number corresponding directly to the shop drawings.
Organized Manifests:
Pallets are individually numbered with a detailed manifest listing every enclosed piece.
Protective Packaging:
Pallets are fully heat-shrink wrapped in heavy-duty plastic to safeguard the stone during transit.