Molded simulated stone product and method

摘要

An inexpensive, lightweight, strong and durable casting that has a surface appearance simulating carved stone, and is especially adapted for use as a transition between a brick or stone wall and window and door openings. Further, it provides architectural detail to building constructions, especially as a surround for window and door openings. The casting is produced from a mixture of graded aggregates and a resin binder, combined in predetermined proportions to make a soupy mixture that is cast in a mold. The mold is vibrated to cause migration of air bubbles away from the surface of the molded product, and to cause realignment and orientation of the aggregate materials in a way to enhance the structure and surface density of the product. After the casting has set, it is removed from the mold and cured and the surface is sandblasted to erode away some of the resin binder and portions of the aggregate at the surface to produce an appearance that is an accurate simulation of carved stone. The cast product, when used as a trim component for architectural detail in building construction, may have shaped portions to accommodate straight runs of brick or stone work, minimizing the need for cutting or shaping the bricks or stones to fit around the casting.