50% High Grade Resin / 50% Limestone
The material is expensive, roughly five times the cost of regular acrylic bath.
Over the past 10 years this manufacturing process has continually updated and technically improved.
The particles are needle-like, when mixed with resin these particles bond together to create an incredibly strong web
Benefits of Cast Stone
· Harder and more durable than regular acrylic
· As rigid and strong as cast-iron
· Renewable surface
· Easy to clean and repair
· Tap holes can be drilled on site
· Matt finish
1. GRADING RAW MATERIALS
The Classic stone baths are constructed from limestone, which is first processed to remove any impurities. A fine mesh, along with extremely powerful magnets, is used to remove any contaminants and leave only the highest grade of limestone.
The next step is to blend the limestone with a high-grade resin compound to create the patented Cast Stone material. This mixture is then subjected to a high vacuum environment, which removes any unwanted air bubbles.
Once out of the vacuum, a catalyst is added to the mixture to begin the hardening process before it is poured into a closed mould. A temperature-controlled environment allows the mixture to cure before the top half of the mould is removed mechanically. The bath is now in the Green State, ready for post curing.
4. WASTE AND OVERFLOW
At this point the bath is removed from the mould so that the waste and overflow outlets can be drilled using diamond tipped hole saws.
5. POST CURING
With the bottom half of the mould still attached to the bath, to prevent any twisting or warping during the process, the bath is hung by the rim and passed through a tunnel oven for three hours. The heat from the oven fully hardens the limestone and resin mixture to the shape of the mould ready for its final stages of preparation.
6. QUALITY ASSURANCE PROCEDURES
In the final quality check, the surface is inspected for defects and the bath is thoroughly tested to ensure there is uniform thickness throughout.
Following the Quality Assurance inspection each bath is cleaned and polished to an extremely high standard.