1. Gary Nap, partner, and Brian Nap, plant supervisor, review plans to bid a job.

2. Josh Hilton creates shop drawings from architectural drawings.
Tom Fletcher builds wood molds according to shop drawings.
3-A. Tom Fletcher builds wood molds according to shop drawings.
Tom Fletcher builds wood molds according to shop drawings.
3-B. Tom Fletcher builds wood molds according to shop drawings.

4. Dan Houle builds a mold from wood.

5. Curry creates a mold using wood and steel.
DRY CAST

6. Production foreman John Echtinaw controls the state-of-the-art computerized batching system, which mixes sand, cement, pigments, admixtures for six standard and numerous custom blends.

7.The computer automated batching system controls the precise amount of ingredients dropped into carts to be carried to the mixer.

8. The zero-slump concrete is dropped from the mixer into wheelbarrows.

9. A proper mixture should adhere to itself and form a ball, like in this example of zero-slump concrete.

10-A. Aaron Buckmaster fills his mold with zero-slump concrete to be pounded.

10-B. He then uses a sand-rammer to compact the zero-slump concrete. This process is repeated in equal layers until the mold is completely filled.

10-C. Then he screeds the mold to remove all the excess concrete.

10-D. A trowel is used to smooth the top out.

10-E. The mold is flipped upside down onto a steel pallet.

10-F. Screws are removed so that the mold can be taken apart and removed from the concrete piece.

10-G. Screws are removed so that the mold can be taken apart and removed from the concrete piece.

11. The steel pallets are then pushed down a set of rollers and into the kiln.

12. Margin trowels are used to fix any imperfections in the piece.

13. Pieces are left in the kiln overnight for curing.

14-A. In the mornings, the product is stripped from the kiln. Pieces are removed from their steel pallets and placed on wooden pallets with dry wall.

14-B. In the mornings, the product is stripped from the kiln. Pieces are removed from their steel pallets and placed on wooden pallets with dry wall.

15. Patching imperfections in a cast stone wall cap arch.

16. Pieces are washed with muriatic acid and water to remove the top layer of cement.

17-A. After washing, pieces are stacked together on pallets, wrapped with plastic for protection and labeled according to the job it was made for.

17-B. After washing, pieces are stacked together on pallets, wrapped with plastic for protection and labeled according to the job it was made for.

18. After product is packaged, it is stored in the yard until shipment.

19-A. Product is loaded onto trucks for shipment to a job site.

19-B. Product is loaded onto trucks for shipment to a job site.

19-C. Product is loaded onto trucks for shipment to a job site.
WET CAST

20-A. 7” slump concrete is poured from the hopper into the mold.

20-B. A vibrator is used to consolidate the concrete.

20-C. Re-rod is placed in the concrete for reinforcement.

20-D. The concrete is screed to ensure proper height.

20-E. A trowel is used to finish the surface.

20-F. Forklifts are used to lift pieces off pouring tables.

20-G. The wood mold is removed to reveal the finished product.

20-H. The wood mold is cleaned, oiled and re-assembled for the next pour.


< < < RETURN TO TOP