The 7 Steps of the Production Process
1. GRADING RAW MATERIALS
First process is selecting the best Stone for color texture grade. A fine mesh, along with extremely powerful magnets, is used to remove any contaminants and leave only the highest grade of stone.
The next step is to blend the stone 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. The natural Indonesian heat hardens the stone 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.