September 2024
Crafting excellence: A step-by-step guide to Haddonstone's production methods from Katherine Kates
Here Katherine Kates, Production Director at Haddonstone, delves into their meticulous production methods, from the initial design phase to the final finishing touches. She uncovers the journey of transforming raw materials into stunning building and construction, and home and garden cast stonework - a process that combines traditional craftsmanship with modern technology, resulting in exceptional durability and aesthetic appeal.
How does Haddonstone craft excellence?
Our teams define project requirements through personalised customer service; at the core of everything we do is a commitment to providing the highest levels of personalised customer service. Whether working with technical drawings or a simple photograph, the team collaborates closely with the client while the architectural solutions cater to a wide range of projects, from private residential new builds and extensions to large-scale commercial developments and renovation projects. Haddonstone's expertise in both cutting-edge technology and traditional techniques allows us to create cast stonework to almost any specification.
The award-winning Building and Construction team is celebrated for exceptional customer service and expertise. Each person is dedicated to giving the very best individual care and attention and, by maintaining complete control throughout each project, the team guarantees a smooth process and delivers the highest-quality cast stone. We also provide details of trusted independent contractors who offer comprehensive installation services.
What do we do?
Technical advice and product support - comprehensive packages including quotations, detailed CAD drawings, product schedules, and installation guidelines, all at no extra cost.
- Transparent lead times - honest and accurate timelines for all projects.
- Competitive pricing - clear and fair pricing with no hidden costs.
- Quick, accurate project drawings - the experienced technical team provides drawing assistance and support while a free and user-friendly product drawing package, compatible with AutoCAD software, is offered. This package features a complete library of Haddonstone components in Dynamic Blocks for easy use.
Benefits:
The client can:
- Compare different stone component profiles and products
- Identify cost-effective, standard stonework design solutions early to minimise additional bespoke project costs
- Specify from a vast range of high-quality Haddonstone products.
- Seamlessly include rendered 2D images of Haddonstone stonework in your drawings.
Manufacture
Haddonstone's own in-house production facilities, including design studio, extensive mould shop and laboratory, allows us to cater for everything from lightweight retrofit designs to large structural units. Every component is handmade to order and, by crafting all our own models and moulds, and overseeing every step of the process, we ensure that each project specification is met with precision. The teams specialise in creating bespoke components and, impressively, over 80% of stonework is custom-made and remains only marginally more expensive than standard designs.
In addition, Haddonstone excels in producing replica stonework for restoration projects utilising the latest in 3D technology alongside traditional techniques. By taking detailed impressions of the original components onsite, the replicas are crafted with meticulous attention to detail, preserving the integrity and beauty of the original structures.
Integrating structural reinforcement
Cast stone's strength, durability, and impressive compression resistance make it an ideal material for a wide range of commercial and residential architectural solutions. Whether for new construction projects, retrofits, or restoration commissions, Haddonstone's cast stone offers unparalleled versatility. The in-house manufacturing team can create steel cages and bars needed for additional structural reinforcement in many weight-bearing components in collaboration with a structural engineer, prior to crafting the bespoke cast stone components.
Offering high-quality cast stone material options
At Haddonstone, three premium cast stone material options are offered, each surpasses British manufacturing standards and are the highest-quality, most durable products on the market today. The materials are produced in-house, combining British limestone sourced from an ethically responsible supplier, as well as other ingredients including water, cement, sand and glass fibre (TecLite). The bespoke colour and material match service also means that we can meet any project's exact specifications. The Haddonstone (semi-dry cast) material is packed into a mould either by hand or a pneumatic rammer. The TecStone (wet-cast) and TecLite (fibre-reinforced) are poured and agitated, with the filled moulds then left to cure overnight.
As a founding member of the United Kingdom Cast Stone Association, Haddonstone is committed to not only meeting but exceeding industry standards and stringent technical performance requirements. The rigorous Quality Assurance procedures include computer batch controlling, ensuring consistent mix and colour in every batch; automated tracking systems to monitor the performance of each batch to maintain high standards and regular testing of our materials and products, including evaluations by independent experts, to ensure they surpass industry standards in areas such as water absorption, compressive strength, and fixing pull-out tests.
Perfecting designs with finishing touches
The meticulous production process is completed in a series of steps beginning with demoulding intricate designs from wooden or rubber moulds. The Haddonstone semi-dry cast limestone designs then undergo chamber curing, a controlled process that enhances their durability and longevity. With TecStone products, acid etching is employed to achieve a smooth, sealed finish which is much more akin to Coade stone. This makes it ideal for larger architectural products and contemporary designs as it does not weather quickly and is usually easier to clean.
Each item is then thoroughly checked and meticulously hand-finished by the skilled team which removes any imperfections.
Finally, our dedicated transport fleet and drivers deliver the finished products to clients, ensuring they arrive in perfect condition.
For further information, call 01604 770711 or visit www.haddonstone.com
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With Compliments:
NOTE TO EDITOR:
Haddonstone is a trusted specialist in the design and manufacture of architectural and garden stonework. The ranges comprise cast stone architecture for residential and commercial projects, and beautiful formal and informal garden, home and landscape products.
All products are made to order in Northamptonshire and are available in both standard and bespoke designs. Stunning Show Gardens are in East Haddon, near to the manufacturing facility.