UK Cast Stone Association - Excellence in the Use of Cast Stone Awards 2018

The UKCSA 2018 “Excellence in the Use of Cast Stone” awards competition was open to entries from cast stone manufacturing Full Members of the UKCSA, for projects that have used the Members’ own cast stone. Further details on all the project entries, may be seen on the Projects pages of this UKCSA web site. The decision of the UK Cast Stone Association (UKCSA) shall be final in all aspects appertaining to the competition, and by submitting an entry or vote, and by participating in the competition, then you are deemed to have accepted that this is the case.

... and the UKCSA Cast Stone Award Winners are .....

The winning cast stone projects were announced at the UKCSA 27th AGM, held on Wednesday 18th April 2018, and the Awards were presented by UKCSA Chair, Andy Cotton, as detailed below.

Please click on the links below to go to a particular awards category:
Category 1.   Best Innovative / Technical use of Cast Stone in a Project.
Category 2.   Best supply of Cast Stone to a Multiple Housing Development Project.
Category 3.   Best Overall Cast Stone Project
 

Awards Category 1.     Best Innovative / Technical use of Cast Stone in a Project.

 

AWARDS CATEGORY 1   -  AWARD WINNER:   NORMANDY MANOR, GUERNSEY

Pennine Stone Winner Category 1

Cast Stone supplied by UKCSA Full Member   -  PENNINE STONE LTD.

PCS Stone Specialists Winner Category 1

Cast Stone installed & fixings design by UKCSA Associate Member  -  PCS STONE SPECIALISTS

Normandy Manor supplied by Pennine Stone
 
Normandy Manor supplied by Pennine Stone
 
Normandy Manor supplied by Pennine Stone
 
Normandy Manor supplied by Pennine Stone
 

Project: - Normandy Manor, Guernsey.

In excess of 2,500 stone components were packed and shipped to Guernsey for the construction of one of the most impressive private homes to be completed on the Channel Islands in many years. This property was built to the most exacting of standards. Design excellence was paramount; and the UKCSA Full Member first began a dialogue with the property owner in 2012; initial project meetings commenced in 2014 but it wasn’t until 2016 that the first stones were shipped, with the final deliveries being made in 2017. The client set out to construct an outstanding property; classical elevations, impressive footprint, yet designed to be a family home, albeit with added extras such as an integral ballroom. With a 350 mile delivery route incorporating road and sea, a comprehensive understanding of the build sequence was essential. Production and delivery schedules needed to be agreed months in advance of products being required on site. Each product was bespoke and hundreds of moulds were needed – many moulds had to be stored for nearly 2 years in case additional or replacement items were required. There was to be no compromise on the quality of the materials used for this building; a challenge when the stone requirement for the property included 58 cast stone window surrounds and over 20 cast stone door surrounds. It was essential that the fitting teams were highly skilled, experienced and extremely professional and it was a godsend that the client had instructed an excellent installation team – an UKCSA Associate Member. A full understanding of the build sequence and excellent communications were required to make this project successful. It is a testament to the skill and focus of all those involved that, over the full length of the project, only 3 stones required replacement due to damage. The dentil string course was a particular challenge – this was not a project where standard lengths could be cut on site, due to restrictions and cast in fixings, so great care was needed by the production, packing and fitting teams in order to ensure that the right products could be identified and installed in the correct position in order to achieve the desired visual flow. The design also demanded that a different dentil solution was required for each floor, so, unfortunately, there would be no sharing of moulds. The moulds for the fluted columns were especially complex bespoke rubber lined GRP and timber, to produce the fibre reinforced final units. The columns at the front of the building were the same design, but a different height to the columns at the rear, again requiring additional moulds – a further example of design excellence and a refusal to compromise on this project. All the cast stone supplied to this project was fibre reinforced, which enabled the component weight to be minimised, but considerably added to the complexity of the mould design. The stone was supported and restrained by a stainless steel system designed in conjunction with the UKCSA Associate Member and installed by them. The finished home is a testament to the vision of the client, his design team and his suppliers – truly a “show stopper” building which would not have been possible without the full co-operation and co-ordination of all involved.

 

AWARDS CATEGORY 1   -  HIGHLY COMMENDED:   NEW LUXURY HOUSE, BEACONSFIELD

Haddonstone Highly Commended Category 1

Cast Stone supplied by UKCSA Full Member   -  HADDONSTONE LTD.

Cast Stone supplied by Haddonstone
 
Cast Stone supplied by Haddonstone
 
Cast Stone supplied by Haddonstone
 
Cast Stone supplied by Haddonstone
 

Project: - New luxury house, Beaconsfield.

When the UKCSA Full Member won the order for this project at the start of 2017 against competition from other cast stone manufacturers, a great deal of detailed work had already been carried out by consultation between the UKCSA Member's architectural sales & estimating, technical and production teams in conjunction with the developer. This luxury residential new build project had the usual challenges of an exacting end client, although the largest challenge – literally were the decorative structural portico panels which the client envisioned. The UKCSA Member had never before created such large pieces; more akin to pre-cast concrete than architectural and aesthetic cast limestone. The panels were designed not only to support their own weight but also the building above. The UKCSA Full Member's experienced team had to work together along with the clients engineer and designer in order to produce these massive panels, which needed to be not just structural but also of the fine finish expected of architectural cast limestone. Specialist lifting equipment had to be hired in to cast and manoeuvre the three 3.2m x 2.5m, 4 tonne panels. Everything from the mould, to the reinforcement and the method for pouring, curing, lifting and demoulding required careful consideration and planning, each panel had a value of over £5,000 so there was no room for error. The house in Beaconsfield is a magnificent luxury home with an extensive amount of cast stone totalling more than £100k, comprising of: window and door surrounds, columns, portico and cornice. The production of the stone for this project was completed without incident and on time for the client which could only have been achieved by co-operation from all parties; the cast stone manufacturer, the client, designers, and indeed the UKCSA Associate Member installation team on site. The UKCSA Member's team focused on the communication and relationships with all the other parties in order deliver such a successful project result.

 

Awards Category 2.     Best supply of Cast Stone to a Multiple Housing Development Project.

 

AWARDS CATEGORY 2   -  AWARD WINNER:   MULTIPLE HOUSING SCHEME, FYLDE COAST.

GreconUK Winner Category 2

Cast Stone supplied by UKCSA Full Member   -  GRECONUK.

Cast Stone supplied by GreconUK
 
Cast Stone supplied by GreconUK
 
Cast Stone supplied by GreconUK
 
Cast Stone supplied by GreconUK
 

Project: - Multiple housing development.
Building Type: - New build.
Cast Stone Material: - Dry-cast Cast Stone.
Location: Throughout North West of England.

An award-winning UK property developer with a reputation for building high quality, high specification homes. With a range of house types, they are renowned for building attractive and varied street scenes incorporating cast stone to their own individual specification. To meet their exacting demands, it is important to them that our product is of the highest quality, in terms of finished and durability. Semi dry cast stone products used on their developments include: heads, cills, jambs, mullions, quoins, date stones and copings. These units are all to the client’s unique design and, to comply with their technical and aesthetic requirements, incorporate special aggregates. As such the first issue encountered for us as a cast stone producer was to source and store the special aggregates required, consistency and assurance of supply was essential. Separate mix designs meant that careful sequencing of batching was required to ensure that production ran smoothly. Also with unique design of product a whole new range of moulds had to be manufactured and stored. It was also a requirement that the product be packaged in a way that best suited their site use and handling, leading to the development of a bespoke labelling system on all deliveries which has resulted in less waste and damage on site. We created a dedicated production space solely for our client and trained a team of production operatives to specialise in the manufacture and packing of their product to ensure that the high standards demanded by our client were met and maintained. Involvement at an early stage with the client, combined with a strong working relationship with dedicated points of contact has resulted in excellent service levels and a smooth-running operation. This is essential to accommodate significant growth over a short period of time across multiple sites with a wide geographical spread.

 

AWARDS CATEGORY 2   -  HIGHLY COMMENDED:   VILLAGE SCHEME, S. ENGLAND

Procter Cast Stone Highly Commended Category 2

Cast Stone supplied by UKCSA Full Member   -  PROCTER CAST STONE.

Cast Stone supplied by Procter Cast Stone
 
Cast Stone supplied by Procter Cast Stone
 
Cast Stone supplied by Procter Cast Stone
 
Cast Stone supplied by Procter Cast Stone
 

Project: - Village scheme .
Building Type: - New build development.
Cast Stone Material: - Dry-cast Cast Stone.
Location: - South of England.

This project consisted of multiple house types; the products supplied included heads, cills, band course, columns, copings, pediment & porticos. The project ran over several years to very specific site call offs and there were many variants of cast stone designs to try to make the project have a ‘village’ feel. The project has a wide variety of new properties built in a number of phases across its beautiful 100 acre site. As in any community with its range of ages and requirements, the homes will be in a mixture of styles, sizes and tenures to suit everyone from first time buyers, to families with young children and those entering retirement, all positioned in attractive and interesting street scenes. For example, one delightful feature is a stunning crescent of townhouses reminiscent of the elegant architecture of nearby Bath. The cast stone on the crescent phase had a value of nearly £70K worth of stone. The client’s objective was to develop a real community, a village square has been incorporated into the scheme, including facilities such as a community hall, doctors’ surgery, primary school and children’s’ nursery, with additional provision made for a care home and sheltered housing. Overall a fantastic project for all, including the UKCSA Full Member cast stone manufcaturer, to be involved with.

 

Awards Category 3.     Best Overall Cast Stone Project.

 

AWARDS CATEGORY 3   -  AWARD WINNER:   NORMANDY MANOR, GUERNSEY

Pennine Stone Winner Category 3

Cast Stone supplied by UKCSA Full Member   -  PENNINE STONE LTD.

PCS Stone Specialists Winner Category 3

Cast Stone installed & fixings design by UKCSA Associate Member  -  PCS STONE SPECIALISTS

Normandy Manor supplied by Pennine Stone
 
Normandy Manor supplied by Pennine Stone
 
Normandy Manor supplied by Pennine Stone
 
Normandy Manor supplied by Pennine Stone
 

Project: - Normandy Manor, Guernsey.

In excess of 2,500 stone components were packed and shipped to Guernsey for the construction of one of the most impressive private homes to be completed on the Channel Islands in many years. This property was built to the most exacting of standards. Design excellence was paramount; and the UKCSA Full Member first began a dialogue with the property owner in 2012; initial project meetings commenced in 2014 but it wasn’t until 2016 that the first stones were shipped, with the final deliveries being made in 2017. The client set out to construct an outstanding property; classical elevations, impressive footprint, yet designed to be a family home, albeit with added extras such as an integral ballroom. With a 350 mile delivery route incorporating road and sea, a comprehensive understanding of the build sequence was essential. Production and delivery schedules needed to be agreed months in advance of products being required on site. Each product was bespoke and hundreds of moulds were needed – many moulds had to be stored for nearly 2 years in case additional or replacement items were required. There was to be no compromise on the quality of the materials used for this building; a challenge when the stone requirement for the property included 58 cast stone window surrounds and over 20 cast stone door surrounds. It was essential that the fitting teams were highly skilled, experienced and extremely professional and it was a godsend that the client had instructed an excellent installation team – an UKCSA Associate Member. A full understanding of the build sequence and excellent communications were required to make this project successful. It is a testament to the skill and focus of all those involved that, over the full length of the project, only 3 stones required replacement due to damage. The dentil string course was a particular challenge – this was not a project where standard lengths could be cut on site, due to restrictions and cast in fixings, so great care was needed by the production, packing and fitting teams in order to ensure that the right products could be identified and installed in the correct position in order to achieve the desired visual flow. The design also demanded that a different dentil solution was required for each floor, so, unfortunately, there would be no sharing of moulds. The moulds for the fluted columns were especially complex bespoke rubber lined GRP and timber, to produce the fibre reinforced final units. The columns at the front of the building were the same design, but a different height to the columns at the rear, again requiring additional moulds – a further example of design excellence and a refusal to compromise on this project. All the cast stone supplied to this project was fibre reinforced, which enabled the component weight to be minimised, but considerably added to the complexity of the mould design. The stone was supported and restrained by a stainless steel system designed in conjunction with the UKCSA Associate Member and installed by them. The finished home is a testament to the vision of the client, his design team and his suppliers – truly a “show stopper” building which would not have been possible without the full co-operation and co-ordination of all involved.

 

AWARDS CATEGORY 3   -  HIGHLY COMMENDED:   KNOWLE HILL PARK COUNTRY ESTATE

Woodside Cast Stone Highly Commended Category 3

Cast Stone supplied by UKCSA Full Member   -  WOODSIDE CAST STONE LTD.

Henley Stone Specialists Highly Commended Category 3

Entrance Cast Stone Installation & Fixings by Associate Member  -  HENLEY STONE SPECIALISTS

Knowle Hill Park Country Estate supplied by Woodside Cast Stone
 
Knowle Hill Park Country Estate supplied by Woodside Cast Stone
 
Knowle Hill Park Country Estate supplied by Woodside Cast Stone
 
Knowle Hill Park Country Estate supplied by Woodside Cast Stone
 

Project: - Knowle Hill Park Country Estate.
Building Type: - Residential.
Cast Stone Material: - Wet-cast Cast Stone.
Location: - Cobham.

Knowle Hill Park Country Estate is one of the finest and most exclusive new property developments in Surrey. Set in Cobham, surrounded by forty-five acres of secluded private woods and parkland, the development comprised 4no. semi-detached and 3no. detached properties along with a 21 plot apartment block with undercroft parking, so as not to detract from the view. Working closely with our client, the UKCSA Member's Technical Department detailed the stone to meet the high quality specification design brief that the targeted house-buyers expected, with the manufacture then scheduled and deliveries made to meet a very compressed build programme over a 12 month period. Careful consideration was given to every step in the detailing, manufacturing, handling, storage and installation process to ensure a successful development completion on time with no delays with the client providing a large flat storage area for palletised products to minimise site damage. The wet-cast, etched Portland stone supply comprised units to form a variety of window and door surround styles, all with fully structural heads to remove the need for steel lintels. Other stone features included string, cornice and copings throughout with the showpiece feature of the development being a two storey high portico assembly to the front entrance of the Apartment Block. This assembly comprised large pedestals, fluted columns, architrave, cornice, balustrading and copings, all clad round a steel frame, providing the final, eye-catching centrepiece.

 
Please click on the links below to go to a particular awards category:
Category 1.   Best Innovative / Technical use of Cast Stone in a Project.
Category 2.   Best supply of Cast Stone to a Multiple Housing Development Project.
Category 3.   Best Overall Cast Stone Project.
 

 
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