How Does Our System Work? Plywood with tile board on top, melamine or steel can be used as forms. We have cast up to 10' x 5' pieces weighing 1,000 lbs. but most of our kitchens and sinks fit on a 4' x 8' or smaller sheet. The layout of the plant is set up in logical steps that are customized, taking into account a precaster's needs.

Individual stations are set up for each desired step in the process. Operations include:

• Vibrating / Casting Station
  • The vibrating table jumps up through the roller conveyer at the push of a button, once the molds are full and vibrated the table retracts and the mold is moved out of the way on the rollers.
  • Casting is a one person operation with minimal lifting.
  • We can cast a 40 sq. ft. kitchen in less than 1 hour using our equipment.

• Curing Areas
  • The entire roller area is level; pallets can be set anywhere on the rollers to cure.
  • The molds are covered with poly and electric blankets designed for concrete curing to accelerate the cure. The blankets heat the concrete to about 115 degrees, well within the limits of acceptable curing.
  • Products can be striped in about 16 hours (dependent on mix design) freeing the line for the next day's pour.

• Patent Pending Flipping / De-molding Station
  • Flipping / De-Molding is a one person operation designed to flip countertops up to 1,000 lbs. with no manual lifting.
  • A unique hinge design allows products up to 18" deep to be turned without binding. Countertops with integral sinks are no problem.
  • Can be used with an overhead crane or an engine hoist that has enough clearance.
  • Pieces take about 5 minutes each to turn. 

• The Countertops / Sinks are Loaded onto Roller Carts.
  • The pieces stay on the carts during polishing, staining, and sealing operations eliminating unnecessary lifting, moving.
  • Carts are designed to be ridged, keeping the pieces level and true during processing; if the floor out of true, 3 of the 4 wheels will touch the floor.
  • Capacity of each cart is 1,000 lbs. Each caster has grease fitting.
  • Countertops are never lifted by people during processing; they are rolled to each area.
  • Grinding and patching bugholes is reduced to minutes rather than hours.

• Countertops / Sinks are then Loaded into Delivery Trailers and Delivered.
  • A frames roll out of the trailer on tracks. Countertops can be loaded with a crane or by hand.
  • Loading with an overhead crane is a one person operation.
  • The A frames with countertops are rolled out of the trailer on tracks. Countertops are 2' off the ground and easily accessed for unloading unlike trying to get one out of the back of a pickup. Many times we will back to the edge of the garage, roll the A frame into the garage, walk the countertops 40’ to the kitchen and install.

• Larger Pieces are Loaded onto Patent Pending Multi-Task Delivery Carts; the Carts with Countertops are Loaded on Trailers.
  • Designed to deliver pieces to 1,000 lbs with 2 people. I designed these carts after watching 5 people set a 700 lb. granite island.
  • Unique design eliminates the need to ever lift the entire weight of the piece. Countertop is tilted into position and slid into place.  Slabs can be cast, striped, delivered, and installed without ever lifting them.
  • Cart can be locked into horizontal position to deliver countertops with integral sinks or vanities.
  • Can be easily driven up a 3' rise on 8' ramps. Pneumatic tires prevent damage to flooring.