What is Cast Stone?

Cast Stone, also known as artificial stone, is a type of building material used for construction that is made from a mixture of crushed stone, sand, gravel, and cement and colored with mineral coloring pigments. The mixture is cast into reusable molds at the factory, cured in a controlled environment, and then transported to the building site. The end look of the material is very similar to natural stone and it can be used for exterior or interior design, as well as for support in construction such as pillars. This provides the edge of better quality since the conditions can be controlled, as opposed to molding on site.

Advantages of Using Cast Stone

Cast stone is also better than regular stone as it does not deteriorate from weather conditions as a normal stone would. Natural stone tends to have deep cracks which expand and contract with temperature changes, causing the stone to wither. Cast stone, compared to cast-in-place stone, provides the edge of better quality since the conditions can be controlled, as opposed to molding on site.

It is very hard to find natural stone in consistent colors for building projects; this could make the building look poorly and cheaply done. Casting stone can be colored with pigments to the exact required shade every time, improving the overall aesthetic of the build. Cast stone is perfect for very complex, intricate designs accurately to suit the architectural needs of the building.

Maintenance of cast stone is much easier as, with age, it can blend in with the property’s aged look or, it can be cleaned to remove water stains and fungus easily. Additionally, the composition of the stone can be varied depending on the purpose, a support pillar would be capable of bearing a very large amount of weight compared to a décor piece, so the cost can be adjusted accordingly.

Wet Cast Stone

There are 2 methods of casting stone, wet casting, and dry tamping or dry casting. You can talk to your cast stone supplier for further information on these but, in essence, wet cast stone is made by diluting the concrete mixture, oftentimes, using chemicals instead of water to improve the quality of the final product.

This is more suitable when you need a smooth finish on the final product since the liquid can be made to settle using techniques such as vibration. Pouring into the mold is also easier as the paste can get into all the crevices, unlike dry cast stone. Removing it is also more convenient since the stone is fully set before demolding so the end-product does not get damaged in the process. Mold requirements for wet cast stone are less restricted, making the molds cheaper and easier to make. Furthermore, texturing additives can be applied to the mold before casting to give textured finishes to the final product, or post-cure treatments such as sandblasting to get the desired results are also an option.

The downside of this type of stone is that it has to be set fully, in the mold, before it can be released, meaning that the production is time-consuming unless you use a large number of molds which is expensive. The immediate strength of wet cast stone is less than that of the dry cast and it also requires detailing work after demolding. If you’re going for a limestone look with the stone, you will need to use surface treatments so, dry tamp stone works better for this purpose

Dry Cast Stone

A dry tamp cast stone is made with sand, gravel, cement, and a very small amount of water so that, similar to making sandcastles on the beach, the mixture can be pressed into the mold using special tools such as air-powered tampers and demolded immediately after. After removal, the excess stone is scraped off and the structure is left to cure, often in humid environments as water introduction during curing increases the strength of the stone.

The advantages of this stone include the fast demolding time, meaning that the mold can be used several times a day. The immediate removal also means that repairing is easier while the stone is still soft. The finished look of dry cast stone is very natural, resembling limestone or sandstone so, no treatment is required. Lastly, it is stronger than wet cast stone, as discussed earlier.

The drawbacks of this method are that the result is never a smooth finish like a wet cast stone; it also requires a humid curing environment, which is done with steam or water misting. This is a costly setup to have. Adding to the costs is the detailing required after demolding.

Which Type is Best?

Both these types of cast stones have different finishes, cost structures, and compositions. Your cast stone contractor can discuss the type that suits your project best depending on the aesthetic that you are going for. Cast stone is an architectural material more so than a construction one however, there are still regulations on the composition of the stone to ensure a structurally sound, strong material that will last with your house so, regardless of which part of the world you belong to, this is a safe way to elevate the look of your build.