Procter Cast Stone

Our client is building a truly unique and diverse development whilst creating a centre for the local area. This stunning development was to include an appealing blend of styles and designs that included two and three storey terraces, semi-detached and detached properties.

Five bedroomed semi-detached family homes with accommodation over ground, first and second floors, set within a gated community at the heart of Broughton Park.

We had a three week window to manufacture and deliver the stone from receiving the order. All the stone had to be installed before the grand opening of the store. The order comprised of a mixture of straight and radius copings. We provided various colour samples for the client to choose the suitable match. The order was fast tracked through the drawing department and following on from drawing approval, the units were manufactured and delivered to site on time.

Procter Cast Stone and the architect developed a scheme that achieved the desired distinctive visual appearance alongside brickwork and glass, but with cast stone units that were as economical to manufacture as possible. This enabled the architect to meet the client's brief while maintaining tight control over budgets. Procter Cast Stone then prepared manufacturing drawings, incorporating appropriate reinforcement and threaded bosses for lifting eyes. The moulds were made from these drawings by Procter Cast Stone's in-house team of skilled joiners, enabling the production of the cast stone units to proceed on time.

At Procter Cast Stone we have a range of standard cast stone window cills and door cills We manufacture cills in either standard profiles or bespoke profiles. Standard stooled cills are available with either 100mm or 150mm stools. Slip cills are installed within the window opening. Bay cills manufactured to the specific site requirements such as square or curved. Cills over 1200mm are generally supplied in two pieces. Our standard cills are available in two different depths 150mm brickwork and 170mm rendered external walls. Often other items such as heads and string course would be chosen to complement our cills.

We also make products in non-standard colours, and can match colours and textures on existing cast stone or natural stone features. If you require a non-standard colour, just send us a sample and we will match it or send an image and we will propose our nearest match. Procter Cast Stone is offering architects and specifiers FREE colour sample. These provide an ideal opportunity to view the colours and finish available on cast stone - and to see how similar it is to natural stone. Cast stone units can be produced to mimic, for example, Dark Portland Stone, Cheshire Red, Aire, Milstone Grit and Yorkstone, as well as many others. Procter Cast Stone can also manufacture products in custom colours to match existing materials.

We manufacture heads in various styles plain, chamfered, splayed and bespoke. Heads can also be manufactured to incorporate a keystone. These non-load bearing heads are an attractive feature that will enhance the look of a building. Heads can also be used in conjunction with surrounds/jambs and cast stone mullions. We have the flexibility to manufacture heads in either standard or bespoke sizes even incorporating arches when required. As with all our products our art stone heads and manufactured to a standard that exceeds BS:1217 using the very latest vapour curing technology.

Our cast stone quoins form the corner of a building and can be both structural and aesthetical or simply aesthetical. In an architectural sense, quoins are typically used to create a feeling of strength and as a visual frame to a building. The cast stone process allows for total consistency of building products in terms of size, quality and finish. However, this is only true if the quality of the mould is perfect and at Procter Cast Stone the skills of our outstanding craftsmen ensure this is always the case. Cast stone quoins can be created to be used in two ways: Built-in - this means that the quoin forms a structural role as well as visual and is literally built in to the corner of the building

Window Surrounds can include cills, heads, jambs and mullions. We have two standard styles-plain and chamfered. Jambs are manufactured with fixing anchors (dovetail slots) For tall windows jambs and mullions are connected via stainless steel dowels. Procter standard profiles are available to suit stone, brick and rendered buildings. Our cast stone window surrounds are compatible with most types of window such as aluminium, timber and UPVC. We undertake many projects where bespoke art stone surrounds are required. These could include restoration such as churches and listed buildings as well residential and commercial projects.

We provide a complete range of cast stone balustrade designs, and we can also produce cast stone balustrades in any design to an architect's specification. Procter Cast Stone Balustrades are used for creating beautiful interior and exterior features for use in commercial and residential projects including hotels, shopping centres, private and residential homes. The craftsmen at our facility in Leeds are able to produce moulds of the highest standard which are then used for the cast stone balustrades. The end result is so realistic that most observers will think they are natural stone balustrades.

Columns and pilasters from Procter Cast stone that reflect the spirit of classical architecture. Although exterior applications are more usual - e.g. for exterior porch columns - cast stone columns can equally be used for interiors instead of, or to replace, natural stone columns and natural stone pillars. In all cases, the cast stone product will be far more cost effective than the natural stone equivalent. We have an in-house design team always available to discuss designs and offer proposal drawings and there is also the option for us to offer a site consultation from a member of our team.

An ideal choice for new and existing walls. Replacing natural stone wall copings with cast stone for a restoration project is a more cost effective and quicker option over natural stone. We can expertly replicate and colour match accurately and because the texture and finish of cast stone is so authentic, the end result will look almost indistinguishable from natural stone. Procter Cast Stone designs, manufactures and supplies high quality coping stones for walls in both traditional and contemporary designs. At Procter Cast Stone we hold stocks of standard cast stone wall copings ready for quick delivery in a range of colours. A separate division of Procter manufactures steel railings in a very wide range of styles and we can also install these.

A keystone is the wedge-shaped stone at the apex of a vault or arch, or similar shaped window or door. If used structurally (with cast stone it can also be purely cosmetic as a facing with an actual keystone behind), the keystone is the final piece placed during construction and locks all the stones into position and therefore allows the arch to bear weight. Keystones are a popular architectural feature that can greatly enhance a buildings façade and create a stunning focal point. Keystones used for arched windows and doors are an attractive addition to a more traditional new property, with research showing that the use of cast stone features adds value to new properties

A stone porticos creates an impressive entrance to a property. Procter Cast Stone's expertise and flexibility mean we can help you with everything from design to installation. Adding a portico makes a great statement (kerb appeal) at the entrance of your property with the benefit of providing you with shelter from the weather. At Procter Cast Stone we produce a range of porticos in standard designs, and our design team can produce one-off bespoke designs to meet an architect's requirements. All our porticos are manufactured using the latest technology making them both cost effective and robust.

Steps have two main components - treads and risers, cast stone step treads and risers are ideal for many property types, as the cast stone process allows for the exact dimensions and style to be created at a fraction of the cost of natural stone. We can produce cast stone steps in both traditional and contemporary styles, both for interior and exterior applications. A great solution for renovations, replacing all or some natural stone step treads and risers with cast stone is a more cost-effective option rather than using natural stone. And because we can colour-match so accurately to the original stone steps, the new cast stone steps will blend in relatively seamlessly.

Cast stone, which is sometimes referred to as reconstituted stone or simulated stone, starts with a drawing, from which subsidiary drawings are prepared so that a skilled pattern maker can create a wooden mould. Depending on the product and finish required, cast stone is made using a semi-dry mix of white and/or grey cements with natural or manufactured sands. The appearance of natural stone is achieved using crushed natural stone, well graded natural gravels and mineral pigments. A waterproofer is added to minimise moisture absorption and improve resistance to frost damage. On larger components, a coloured facing mix is used on the outside of the mould, with a higher-strength, noncoloured backing mix in the interior.

Extensive ranges of standard products are available either for delivery from stock or on short lead times, or bespoke products can be manufactured to order in colours and finishes that, to the untrained eye, are indistinguishable from natural stone. Cast stone also offers an exceptional degree of design freedom; almost any three-dimensional geometric form can be cast, incorporating elegant curves as well as straight-edged features and intricate details.

Cast stone is an extremely versatile material that is suitable for all types of construction project, from renovations, conversions and extensions, through to new-build houses, commercial properties, schools and places of worship. While it is often used to replicate traditional stone features, cast stone is equally effective for adding striking details to contemporary designs.

Standard colours are available to match those of natural stone, such as York stone, Bathstone, Red Sandstone or Portland stone, while non-standard colours can also be produced to meet a client's specific requirements, Procter Cast Stone offers a PDF datasheet with photographs of samples in standard colours, or colours sample packs are available on request. Unlike natural stone, the colour of cast stone is very consistent both within a batch and from one batch to the next. If required, however, controlled variation can be introduced to mimic the effect found in quarried stone. Over time, cast stone weathers the same way as natural stone.