Purchase Cast Stone Lessons "Sale" Buy both GFRC and Cast Stone lessons and save $100.00

See summary of the 9 GFRC Precast lessons (included in the GFRC package)
and 1 Cast Stone lesson below, which is a separate stand alone lesson.

You will need the "DropBox" app to download the video files. Video and main website access may take up to 12 Hrs according to which country you are in.

Lesson 1-Making Knife 13:24

The first lesson, the knife, is the beginning of it all. Making the knife is the start of a rewarding journey. Made from a existing profile or a one from your imagination is what this lesson is all about. First you will learn how to sketch your first profile then cut the shape from the paper, glue the sheet to the sheet metal, cut the shape out then make the backing box.

Lesson 2-Making The Master 9:00

The second lesson, making the master shows you how to make your first master profile with gypsum, ready to make a mold. This is a rather difficult learning process, which requires patience to master. It's really a matter of trial and error, with a lot of persistence thrown in. We show you which gypsum to use, how to place it on the table, how to cut it with the knife and how to cut it for length.

Lesson 3-Master Wallcap 40:00

This third lesson, making a master for a wall cap shows you how to make a gypsum master for a popular item inour catalog, a 12" wide wall cap. Its a follow up lesson to lesson 2. As before, its a rather difficult skill to learn which requires patience, and this profile is even more difficult because it has undercuts on both sides. This video was made in real time to emphasize the time and patience it takes. Its quite long, so feel free to run the video forward at times.

Lesson 4-Wallcap Mold 35:00

For this lesson we will be making a wallcap mold from the master we made in the 3rd lesson. Molds with a undercut have to be made with a split, dividing the mold into two parts, this allows for the mold to be taken apart to remove it from the master and cement parts which we will be making from the mold. The split is usually done at a step or at a convenient mark in the mold to hide the join otherwise the split joint will show in the finished cement part.

Cast Stone Master Wallcap

Lesson 5-Cornice Mold 10:00

This time we will be making a cornice profile mold from a master. This time the mold doesn't need a split as it has no undercuts and the sides of the master is sloped to allow for the mold and the finished cement parts to be removed without sticking. Finished GFRC cement parts are usually made with a 1" wall and are hollow inside to save on weight, dry cast parts are usually made solid with a groove at the back for installation purposes.

Lesson 6-Smooth Facemix 12:00

This is the heart of the Cast Stone manufacturing processYou will learn the sand, cement, water and admixturedesign that no one will share with you until now, and is a closely guarded secret by Cast Stone manufacturers. This video starts with production staff actually making the smooth face mix batch in real time with a power drilland mixing paddle for spraying, with a hopper spray gun you can buy in most big box construction supply outlets, In the US, Home Depot or Lowes will have these for sale.

Lesson 7-GFRC Backup Mix 23:00

The fiberglass backup mix is the backbone of the GFRC process. Without it, the cement product will be weak and prone to cracking. You will see how the mix is made in a mortar mixer by our production staff in real time. We tell you which cement, sand, fiberglass and which additives or admixtures to use to make this strong backup mix. These products can be found easily in the US and in most European countries under different company names. We can also help with that

Lesson 8-Travertine Texture 9:00

Now we get to the fun and artistic part of GFRC and Cast Stone production. There are many secrets and tricks to making the different textures, some of them easy and some of them hard to learn. We will show you some of the easier textures to learn in this and some of the following videos, and also explain some of the harder textures in later e-mails if you are interested in learning these. But for right now, the textures we show you in these videos are the most popular with our clients and the easiest to learn.

Cast Stone Facemix

Cast Stone Travertine

Lesson 9-Tuscan Texture 11:00

Tuscan texture is a little harder to make, but we will show you how. It is one way to make your product stand out from the normal precast produced by other precast manufacturers. This texture reminds you of the centuries old buildings in Italy, with faux cracks and fissures. It requires a hopper spray gun to produce this texture, but it is one of the most beautiful textures possible to produce.

Lesson 10-Dry Cast 17:00

Dry cast is not just another texture, but a completely different product from the other products we manufacture. It is made from a special sand which can be found at most masonry yards in the US. Reminiscent of very expensive honed limestone but made from inexpensive sand and cement with special additives, it is one of the most beautiful Cast Stone products made. It does require special tools.

Old World Texture

This texture is made from the same mix as the Travertine mix but with a different technique. It looks very old and weather beaten. We will explain the process in our e-mail communication. All of these textures will be shown and explained in our videos or on our seminar web pages which you will get access to by purchasing the GFRC precast seminar. The Dry Cast lesson is a separate purchase.

Atlantis Texture

Atlantis texture looks as if it has been at the bottom of the ocean for a hundred years. Aptly named Atlantis after the mythical city of Atlantis which is believed to have been lost to the oceans in the distant past. This texture is very easy to produce, only needing a few secret ingredients which can be found at most grocery stores in the US. We will explain the process in our e-mail communication.