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Old 03-03-2013, 01:01 PM   #3031
Half Fast
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I just closed my business after 12 years. Didn't want to but forces within the economy reduced my client base too much over the last few years. Got a job in a related field but I made some things I'm pleased with over the years.

Here's a precast concrete fireplace from a couple years ago:


Wood pattern in process. I sculpted a different cartouche. That one was just there for mock-up. The over-mantle was done the same way.




Sculpting details




Casting




Demolding parts




Installed




I always thought it was cool to start with just some plywood, a block of clay, some buckets of mold rubber, and some bags of cement and come up with something like this.

.
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Old 03-03-2013, 01:03 PM   #3032
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WOW

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Old 03-03-2013, 01:15 PM   #3033
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WOW x 100

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WOW

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Old 03-03-2013, 01:36 PM   #3034
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That is pretty cool!
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Old 03-03-2013, 01:40 PM   #3035
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How do you move & install something like that without cracking it?
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Old 03-03-2013, 01:41 PM   #3036
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How do you move & install something like that without cracking it?
Very carefully!
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Old 03-03-2013, 01:41 PM   #3037
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That's a very cool looking fireplace!
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Old 03-03-2013, 02:18 PM   #3038
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Originally Posted by PunkinHead View Post
How do you move & install something like that without cracking it?
It's made in pieces just like if it were carved from stone. There were probably 30 or so shapes that were cast. They get nested on pallets with foam insulation for padding, shrink wrapped and shipped to the site.

Skilled masons receive the pallets and assemble per shop drawings. Each piece has a mark number. Some pieces are freakin heavy. I think we spec'ed 1/4" mortar joints for this project to keep it clean. 3/8" is typical for most work. Our parts are within 1/16" tolerance. Good enough for masonry.

Everything has coated mesh or rebar embedded and dowel pockets cast into the sides for anchoring.


Hey Rando, this job was in your neck of the the woods.

.

Half Fast screwed with this post 03-03-2013 at 02:23 PM
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Old 03-03-2013, 04:11 PM   #3039
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Beautiful work on that fireplace.

Just for kicks, what was the final cost? (fabrication and installation)
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Old 03-03-2013, 05:15 PM   #3040
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Originally Posted by Off the grid View Post
Beautiful work on that fireplace.

Just for kicks, what was the final cost? (fabrication and installation)

I just did fabrication and delivery to site. Usually the fireplace would be part of a package that was all exterior elements (door and window surrounds, watertable, cladding panels, chimney cap etc.) and the fireplace(s) would be the only interior work. To design from scratch (not use existing molds or shapes) you'd have to budget between 20 - 40k for this kind of work (fireplace only). This house had about 200k in precast and another shop won the exterior work. Don't know what the masonry tab was.

You can order cheaper from China. And hope it fits when you get it. There are also outfits that just sell fireplaces and can modify existing molds for a little less money sometimes. I dealt regionally and did my own field measurements so my jobs went pretty smooth. Seems there was often some oddball condition that had to be accounted for that made stock molds not work.

.
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Old 03-03-2013, 05:23 PM   #3041
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You can order cheaper from China. And hope it fits when you get it.
You could. But if you're gonna make the effort to spec precast, why not be sure it's worthy of the home?

I suppose if you wanted cheaper, you could make it from foam....

Anyway, I just wanna say again that it looks beautiful. Marvelous craftsmanship.
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Old 03-03-2013, 05:24 PM   #3042
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.
Brilliant. Would doing this in red preserve night vision?
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Old 03-03-2013, 06:25 PM   #3043
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Thank you.

Perhaps.

With that issue in mind, I ordered a low out put version.
Also the option to place fewer lights in there is always open.

The string, as many LED strings, is cuttable about every 3 lights and can be easily soldered into many configurations.

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Brilliant. Would doing this in red preserve night vision?
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Old 03-04-2013, 10:44 AM   #3044
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15 surplus military antenna mast poles, some paracord, and my Warbonnet Blackbird hammock.
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Old 03-05-2013, 08:31 AM   #3045
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Not "made" but restored/modified. Post for it HERE.


It's a 1950 International Harvester fridge and holds three homebrew (surplus pepsi) kegs.
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