Jesmonite has become a favourite alternative to cast concrete due to the reduced weight and high strength it offers.

On this project, we were asked to design, manufacture and install a bespoke portico and columns that were to imitate stone.

A mockup design in plaster was cast to show the final design for approval by the client.
Once we had the design approval, we commenced manufacturing a full-scale model of the portico in plaster. Then we could take a reverse jacket mould using silicone and fiberglass.

Once cured, we de-moulded this and set it up on the bench so we could then cast it in Jesmontie AC730 Bath Stone. The finished portico took over 300kg of Jesmonite.

After curing in the mould for a week, we de-moulded the cast and did the etching which reveals the aggregate within the mix, giving a stone like texture.