Workshop mould making

Left click on images to enlarge

The original insitu moulds were solid lime plaster without "Scotch" bracketing this contributed to the ceiling failure where the lath rivets behind the moulding being overloaded.

The replacement ceiling mouldings and ceiling roses were reinstated using the fibrous plaster mouldings to the exact original profile. This reduced the weight of the moulding from the original insitu lime plaster mouldings weighing in at a  total of 2  tonnes; to the new replacement mouldings including the ceiling roses at 0.5tonne. A weight saving of 1.5 tonne

Moulds and casts were manufactured in our workshop in Stevenston

Mould samples were taken prior to strip out.

These sections were transferred onto sheet metal and horsed up running moulds prepared

Original moulds were bench run in casting plaster

Fibreglass case jackets were prepared and fitted over the bench mould. Silicone moulding compound was filled into the case to produce the reverse mould When cured the silicone reverse mould was removed from the original plaster mould

Precast fibrous plaster cast consist of layered up plaster and Hessian scrim. Oven dried prior to delivery to site

Brush applied silicone being prepared to the special ceiling rose.