Our Process
It Goes Like This:
- Forming: A custom form is made using various rigid and flexible materials for each piece. These materials are attached to a flat surface table. Textures can be incorporated at this stage if desired. The forms are detailed, cleaned, and prepped.
- Spraying: Using precise formulas, the cement mix is created, and the pigment is added per weight of each batch. While maintaining a consistent temperature, large mixers blend the raw materials together. The batch is loaded into hoppers, which our expert crew then uses to spray the mix into the forms. Reinforcement materials are incorporated at this stage, strengthening the concrete to prevent cracking. Each piece is smoothed with hand trowel tools and measured for correct thickness.
- Curing: Once the cement is cleaned and finalized in the spraying stage, the pieces must cure and dry in a temperature-regulated environment for a few days.
- Raw Concrete: Once dried, molds and forms are removed, and the piece is flipped upright. The raw concrete structure is then ready for hand sanding, edging, and touch-up. This is the stage when the unique variation of each concrete piece is exposed.
- Finishing: The concrete is acid etched and pre-weathered, a technique used to condition the concrete to live outside in the elements. The finished surfaces of the concrete are then hand-rolled with multiple layers of sealer formulated for stain resistance.
- Packaging: A custom wood crate is constructed, and the concrete is carefully packaged inside with rigid foam for protection, ready to ship out to it’s new home.
