PHPD visits Haddonstone, the family-owned cast stone manufacturer
The consistent use of stone in construction goes back longer than records themselves. Indeed, from castles and pyramids to churches and cottages, it is a material that has always been as prized for its strength as its beauty. This long history doesn’t just go for natural stone either. Cast stone has a storied history of its own. In fact, the use of cast stone as a structural material dates back thousands of years to ancient Rome, where pozzolanic cement was used along with other natural aggregates. Many important buildings and structures were created using this new combination of building material, including the vaulted arches and gateways of Rome’s Colosseum and the large span dome of Athens’ Pantheon. Now, in modern housebuilding, and as potential homeowners place increasing value on aesthetics, it seems to be having more and more of a resurgence.
As David Barrow, Chairman of Haddonstone, former MD for over 40 years and son of the company’s founder, puts it: “Housebuilding in the 21st century is as much about creating quality places in which people want to live, as it is about the construction itself. We are all encouraged to value sustainability, quality and ‘kerb appeal’, as much as functionality and space. So, it’s no surprise that we are seeing a resurgence of interest in beautiful, traditional and classical architecture. This is where Haddonstone has always excelled – in manufacturing authentic and high-quality cast stonework for both new build properties, and in restoration and replication projects.”
Quality first
The first thing you’re struck by when visiting the East Haddon production site is the dedication to quality. Don’t expect to find an army of robots mass producing one simple template again and again. Haddonstone, while embracing new tools of assistance, is most certainly a man-made operation. The company’s offering comes in three different versions:
Haddonstone (semi-dry cast limestone)
This is a unique form of cast limestone, with a surface texture, feel and strength similar to Portland or natural limestone. The principal materials for this are limestone, white cement and sand, a mix which has a feel of damp sand or earth. This stone is packed into the mould either by hand or a pneumatic hand rammer. No finishing is required with this material due to the quality of the mould manufacture and casting, resulting in a look that’s virtually indistinguishable from natural quarried stone and weathers beautifully. The vapour curing process gives the stone the equivalent of 14 days’ strength overnight, which results in reduced delivery lead times and improved handling.
TecStone (wet-cast limestone)
Denser than the standard Haddonstone, TecStone is made of much larger particle sizes and exhibits a higher water content. Vapour curing isn’t required but hand finishing is necessary at the end to ensure a high quality product. The TecStone mix is poured into a mould. This process gives a finish, once acid etched, much more akin to honed limestone. It has a smooth and sealed surface, which makes it ideal for flooring, fireplaces, complex statuary, larger architectural products and contemporary designs where clients prefer a surface finish that does not weather quickly. Importantly, it can incorporate structural reinforcement and cast-in fixings.
TecLite (fibre-reinforced)
This revolutionary cement-based material contains alkaliresistant glass fibre (Glass Fibre Reinforced Concrete). Although it closely resembles cast stone in appearance, the use of thin wall construction teamed with GRC/GFRC technology means the component weight is reduced by approximately two thirds when compared with similar Haddonstone and TecStone pieces. Robust and lightweight, TecLite can be used in conjunction with Haddonstone architectural components.
Customer focus
Haddonstone boasts a vast and ever-growing catalogue of moulds (both for ornamental and architectural pieces) that are expertly maintained and remade when required. Its real beauty, however, comes with its flexibility. The company has a fantastic team who are consistently working with housebuilders to create bespoke moulds for projects which are assembled in an impressive workshop of expert joiners. It’s this dedication to quality and a working relationship with customers that keeps housebuilders coming back for future builds.
For more information, please visit www.rdr.link/dbf031
