Large Scale Molds

 

 To the left is the mother mold with bracing needed to accommodate six fifty-five gallon barrels of rubber.
   
This image shows the finished part, made with 825 pounds of cast and sculpted wax just before the pouring of the rubber.
 

   

This picture shows one of the rubber sections still on the monolith at the time of demolding. The cast sculpture (brown) is poured grout, cast over the plumbing, but before the 900 pound and 1,1000 pound cap pieces we hoisted to the top of the rock feature.
   
The image to the right is a 3,000 pound twenty-two piece rubber mold used to cast a 30,000 pound rock and water feature.

 

The image to the left shows the mold being bolted to a footer pad just before we pump in the 30,000 pounds of intrinsically colored, fiber reinforced grout, all over a matrix of steel rebar. Note the water supple line in the center.
 

 

Above is the beginning of a 250 pound fossil mold containing dozens and dozens of fossils.

Lightweight Styrofoam Molds

 

 

To the left is one of four walls of an 18 foot tall mold used to cast a 120,000 pound monolith, indoors, in a California Pueblo-style home. The monolith will also serve as a chimney, venting a fireplace insert on two of the four sides.

 

The image above shows all four sides of the 18 foot tall mold. It is 4 feet wide and 8 feet deep. Note the cutout to receive the fireplace when we cast the monolith.

The image above shows the level of detail allowed by our styrofoam molds as well as the 18 inches of relief (the distance the rock will stand out from the wall).
   
And finally, this picture shows the incredible detail that will translate to the artificial rock cast. Everything you see here you will see in the side of the monolith.