Concept overview 
Limestone Molding

 A specific method divided in 4 steps :
1 - Realization of a simple mold or formwork reproducing the shape and the style of the architectural stone element that you want to reproduce, using traditional and cheap materials  like water-repellent woodboard and styrofoam.

2 - Realization of a mortar composed of an abundant natural limestone aggregate comming from a local quarry, some white cement, some natural lime, and a natural dye oxide.
3 - Pouring and mold removing, by following a relatively precise timing, determined by the desired result.

4 - Juste after removing, application of a finishing surface work like the one practiced by stoneworkers, but faster and less tiring, to retrieve the typical aspect of the old carved limestone. 


Homemade wooden mold

Arcade 7 éléments en pierre reconstituée
Molded stones

 The force and the tools of the concept :  
  • Very easy to apply, flexible and adaptable, accessible for every handymen and craftsmen.

  • No limite in stone shape and style. All the tools are avalable on this site to make your own molds.

  • A unique solution to perform the restoration of old stone houses, respecting the traditional local architecture, when the stone quarries are closed or reserved.

  • A stoneworkers ancestral finishing method for a final aspect very near natural cut stones and old natural limestone.

  • A handicraft molding method adapted for landscaping, creation and decoration of modern or old houses.

  • Ten times less expensive cast stone elements, thank to the use of very common aggregates, available at the materials wholesalers or at the local quarries.

  • The concept is fully detailed and illustrated in the ebook "the cut limestone moulder's manual", with several molds plans and an access to the Moulders Workshop.

  • A set of online Molds plans is available for easily build molds for gate or terrace pillars, for archs, for hoods and coping, for wall and quoin stones, for cladding stones, surrounds and lintels…

  • A set of online documents and plans is available for the realization of the styrofoam hot-wire cutting tools. 

  • A method of test and measurement of the physical properties of the stones is provided with the ebook and in the Moulders Workshop.

Reconstituted limestone pillar

On the wall formwork

Restored old stones

3 points flexion method

More about the Concept...
  • Moulding and casting stone with moulds and formworks
This concept is very old since it seems to have been used by the Egyptians, testifies the polemic about the construction of the pyramids. It is used massively in cast stone industry and by some stonemasons. In the hands of an handyman, it enable to cast any architectural stone, out of limestone, from the technique of pouring a concrete in molds or formworks. The molds, very simple, are built out of wood and water-repellent woodboard. They are reusable many times. Plans and examples of realization are proposed for you on the site.

You plan to restore your house or to build a new house. You are able to cut a piece of wood, make a hole with a drill, use a screw driver, make a formwork, mix concrete in a small concrete-mixer and pour it in your formwork. So do not renounce to give your house a little of the beauty and the nobility of the stone because it is too expensive. Make your stones yourself. That will not be more expensive than the gray concrete and you will be extremely proud of the result…

  • The basic material, limestone mortar and concrete
The concept is based on the original use of a very abundant aggregate, dedicated until today to an other utilization, and on the use of very traditional hydraulic binders in masonry. The recipe, the composition and the proportioning of the basic mortar depend on the stone application. All is detailed in the Molders' Manual. The stone obtained contains only materials comming from natural mineral origin, contrary to much of the market cast stones that contain resins.
The “limestone concrete” (fr - béton calcaire) is used since the beginning of the years 2000 in the realization of architectural monuments with particularly beautiful esthetics.
>> See the site du CRIT
(Centre of Ressources and technical informations).

To make your stones, you must be able to find in a store, a deposit of materials or a limestone quarry in your neighbourhood, fine crushed limestone aggregate, called “fine limestone 0-6 or 0-4” (fr - calcaire fin 0-6 ou 0-4).
  • A decisive advantage in traditional restoration of old stone houses
By using a natural binder, a limestone aggregate comming from a local quarry and possibly using natural oxides powders, you are able to obtain cast stones offering color, texture and natural properties very close to the natural cut stones of your old house. It is then easy to repair old stones damaged by the time, or to supplement existing stones.

  • Beautiful and resistant, for the interior and for the exterior
The cast limestone concrete provide same aesthetic and physics qualities than the natural stone, with also the ingelivity. It slightly absorbs moisture and bear freezing. It can thus be used as well for architecture and interior decoration as for external architectal elements, cladding, paving, pillars and walls, fountains and other elements and objects out of stone, for the house surroundings or for the garden.

Old stone aspect cast limestone pillar pedestal
Old limestone aspect pillar pedestal

Limestone mortar restoration of a cut stone door surrounding, with on the wall formwork.
Limestone mortar restoration of a door surrounding, with "on the wall" formwork.

Cast stone flower stand "Jardiniere"
Cast stone flower stand "Jardiniere"

Realisation of a French traditionnal gate pillar with limestone concrete

Realization of a French traditionnal gate pillar with limestone concrete
  • Determining steps for the final aspect of the stones
The concept involve inescapable stages, well defined in the time, that make possible to obtain without effort a consistency and a surface quality of your stone elements almost identical to those of natural calcareous stones. Thank to the use of some traditional gestures of the stone mason, the stone obtained is more realistic than the majority of the cast stones available on the market of buiding materials. These determining steps are very quite detailed in the guide.

The limestone obtained patinates naturally. It can be cut, brushed, be passed to French drag, be sandpapered, polished, glossed tinted and aged, exactly like natural stone. It's easy to  obtain an ancient stone aspect.

French drag stone aspect, cut stone style.
French drag finishing for cut stone aspect.
  • An extremely low cost
Cost price of the cast limestone :  Less than 130€/m3
                                              approximately 65€/ton (1000kg)
Cost example of a terrace hollow pillar with mouldings, with a size of 30cm x 30cm and 2.7m height, including :         
- 1 base 40cm x 40cm, 50cm height
- 4 body elements 30cm x 30cm, 50 cm  height
- 1 capital 40cm x 40cm, 20 cm height
------------->  Master plan available on the site in the moulders space...
Cost of the 3 moulds (wood and agglomerated wood materials) :              43€
Cost of the limestone concrete by pillar (binder + limestone, 170 Litres) : 19€
Cost of the related materials used by pillar (5 inserts) :                      7€
Total cost of only 1 pillar :                                                          69€ 

Total cost by pillar for 4 pillars realized :                                  37€ / pillar
Average cost of an equivalent pillar on the market :   from 300€ to 800€

5 elements pillar with mouldings, made of limestone concrete, obtained by casting.5 elements pillar with mouldings, made of limestone concrete, obtained by casting.
cast limestone stone
5 elements pillar with mouldings,
made of limestone concrete,
obtained with homemade molds.
  • Let work your imagination...
Rather than to do it out of cement, why not to make your lintel, your door sill, or even your arch or your porch, out of limestone? Do yourself your cladding stones, and even, simplify you the life by casting your surrounding stones directly on your walls using formworks…

Plans of molds are proposed on the site. You can modify and adapt them according to your need. With ideas and a few imagination, we can make many things. You will quickly notice that the limestone mortar is an extraordinary material, and so easy to use…

Homemade wooden and styrofoam molds

Molds plans available
in the Moulders Workshop.

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