UK Cast Stone Association - Excellence in the Use of Cast Stone Awards 2017

The UKCSA 2017 “Excellence in the use of Cast Stone” awards competition was open to entries from cast stone manufacturing Full Members of the UKCSA, for projects completed in 2016 that have used the UKCSA Full Members’ own cast stone. Further details on the project entries, and further images, may be seen on the Projects pages of this UKCSA web site. The decision of the UK Cast Stone Association (UKCSA) shall be final in all aspects appertaining to the competition, and by submitting an entry or vote, and by participating in the competition, then you are deemed to have accepted that this is the case. The winning cast stone projects were announced at the UKCSA 26th AGM, held on Wednesday 29th March 2017, and are detailed below.

... and the UKCSA Professionals Choice Award Winners are .....

The Professionals Choice Winners were kindly judged and presented by Mr Martin Fear, President of The Concrete Society, seen below presenting the Winners Awards to UKCSA Members Haddonstone Ltd, Henley Stone Ltd and Smart Crosby International for their work on the Winning Project, The Royal Pavilion, Poundbury.

UKCSA Professionals Choice Award Winners 2017
 
 

PROFESSIONALS CHOICE   -  AWARD WINNER:   THE ROYAL PAVILION, POUNDBURY

Cast Stone supplied by UKCSA Full Member   -  Haddonstone Ltd.

Cast Stone installed by UKCSA Associate Member   -  Henley Stone Ltd.

Design Consultants were UKCSA Associate Member   -  Smart Crosby International

The Royal Pavilion, Poundbury
 
The Royal Pavilion, Poundbury
 
The Royal Pavilion, Poundbury
 
The Royal Pavilion, Poundbury
 

Professionals Choice Winner: - The Royal Pavilion.
Cast Stone supplied by: - Haddonstone Ltd.
Building Type: - Residential Apartment Block, New Build.
Cast Stone Material: - Wet-cast Cast Stone.
Location: - Poundbury, Dorchester, Dorset.
Client: - HRH The Prince of Wales / Duchy of Cornwall
Architect: - Ben Pentreath Ltd
Main Contractor: - CG Fry & Son

This most impressive building, being visible for many miles is the focal point for Prince Charles' prestigious development of national importance. The apartments, enjoying unrivalled views of the surrounding countryside, have been built to the highest specification and, with UKCSA Member Haddonstone Limited's wet-cast cast stone elements to the fore no compromise was allowed on design or quality.
The design of the building was clearly influenced by the works of John Nash and Sir John Soane, incorporating classical and contemporary features and combining Greek Revival forms and details with Roman arcaded architecture. Meticulous attention to detail has created interesting façades which hold the attention and emphasises the opulence of the residences. The main building has a striking colonnade to the ground floor, covered terraces to the first floor and private open terraces above. The highest structure in this development is the tower to the South East corner which is fully clad with cast stone to the first two stories.
Haddonstone's cast stone package exceeded a thousand tonnes of material, comprising nearly ten thousand individual pieces of more than a thousand different components, all custom designs. The smallest item weighed just four kilograms and the largest came in at 1.4 tonnes.
The ground floor to the main building features a plinth course of varying height, attached columns, an arched colonnade with subtle differences in design and contemporary balustrading. The cornice, apparently of a constant profile actually comprised six different depths to accommodate various construction details. The cornices and architraves to the first, second and third floors, while appearing similar in profile also enjoyed slight variations necessitating multiple mould production, far in excess of what would normally be expected. To minimise site cutting the entablature components were all produced to length, sometimes only a few millimeters different all contributing to a complex jig saw of stonework requiring accurate casting, labeling and packing and it is of great credit to the mould studio, factory and loading staff that that the project suffered minimal problems with the stonework supply.
The project also includes fluted columns to the first floor terraces, balustrading and custom finials to the roof terraces to the main building. The cladding to the tower incorporated plinths, pilasters, niches and massive arches and keystones with intricate moulding detail. The accuracy of the Haddonstone mould production is exemplified by the perfect alignment of the joints giving perfect transitions to the arches and smooth interiors to the niches.
Inevitably with a project of this size and complexity and with the fixing and other details often being designed as the project progressed there were issues with conflicts within the design but these were overcome promptly and efficiently to the satisfaction of all parties. The resulting construction is justifiably a source of pride for HRH The Prince of Wales and the Royal Family clients, including The Queen who opened the building, the architect Ben Pentreath Ltd and the main contractor, CG Fry & Son. It also showcases the effective collaboration between the UKCSA Full Member cast stone manufacturer Haddonstone Ltd and the cast stone installers Henley Stone Specialists Ltd and structural design and detailing consultants Smart Crosby International, who are both UKCSA Associate Members.

 

PROFESSIONALS CHOICE   -  HIGHLY COMMENDED:   HURLINGHAM WALK, FULHAM.

Cast Stone supplied by UKCSA Full Member   -  GreconUK

Hurlingham Walk, Fulham
 
Hurlingham Walk, Fulham
 
Hurlingham Walk, Fulham
 
Hurlingham Walk, Fulham
 

Professionals Choice, Highly Commended: - Hurlingham Walk.
Cast Stone supplied by: - GreconUK.
Building Type: - Residential Apartment Block, New Build.
Cast Stone Material: - Wet-cast Cast Stone.
Location: - Fulham, London.

This stunning residential project utilised wet-cast cast stone supplied over a period of eighteen months concluding in the summer of 2016. Cast stone was used to highlight key features of the building on all elevations including the prominent main entrance. The scheme located in the borough of Hammersmith and Fulham consists of one, two and three bedroom apartments and came about in direct response to the demand for residential accommodation within the borough.
The design brief was to include a well-proportioned and thoroughly considered scheme which enhances the various streetscapes with a form that harmonises with the surrounding context. The area had been a mismatch of residential and low rise industrial and commercial units that had in part lost direction to the detriment of the existing surrounding residencies. The project is built upon former low rise industrial units thus reinstating and enforcing the new direction and local planning briefs.
The cast stone manufacturer had to undertake a higher level of project management on the scheme as the site was limited in both access and storage. The building itself commanded a large footprint and the main frame was completed before the external cladding was erected. High levels of co-ordination were employed to ensure components were supplied elevation by elevation on lift by lift as work progressed
In addition to the full window surrounds, columns and feature bands, custom oversize blockwork was supplied for adjacent to the main entrance, balcony cladding bands and the roof level cornice and copings. The cornice at roof level was supplied in lengths of approximately 2.4 to 3m and as per the fore mentioned tight restrictions to site and limited storage, the manufacture and supply of these cornice components were required to be co-ordinated critically with the build programme to ensure the correct pieces arrived on site in the correct order. Failure to do so could literally bring the build to a stop. The cornices were supplied continuously over a period of weeks from commencement to completion. Fixing solutions were also sought to restrain the top heavy units that offered 3 dimensional tolerance to ensure line and level across the installation.
The balcony cladding proved to be a further challenge as the in-situ concrete backing complete with upstand was to be clad with a combination band coping , T shaped in section that had very limited working space and a special fixing system had to be developed between main contractor, subcontractor, the cast stone supplier and specialist fixing supplier. The cast stone supplier also undertook a site survey with the main contractor to establish and confirm the curved work to the balconies above the main entrance to ensure a consistent ‘fit’ to the structure.
In addition to the above, all the balconies required special pieces that maintained a smooth transition from the adjacent feature band to the coping, whether as a continuation of line or to include perpendicular or irregular angles. These transitions had to take into account building movement joint positions or include special joints for the ‘floating’ balconies.

 

... and the UKCSA Peoples Choice Award Winners are .....

The Peoples Choice Winners were voted for on-line by clients, specifiers and users of cast stone, and presented by Mr Andy Cotton, Chair of UK Cast Stone Association (UKCSA), seen below presenting the Winners Awards to UKCSA Members Haddonstone Ltd, Henley Stone Ltd and Smart Crosby International for their work on the Winning Project, The Royal Pavilion, Poundbury.

UKCSA Peoples Choice Award Winners 2017
 

PEOPLES CHOICE   -  AWARD WINNER:   THE ROYAL PAVILION, POUNDBURY

Cast Stone supplied by UKCSA Full Member   -  Haddonstone Ltd.

Cast Stone installed by UKCSA Associate Member   -  Henley Stone Ltd.

Design Consultants were UKCSA Associate Member   -  Smart Crosby International

The Royal Pavilion, Poundbury
 
The Royal Pavilion, Poundbury
 
The Royal Pavilion, Poundbury
 
The Royal Pavilion, Poundbury
 

Peoples Choice, Winner: - The Royal Pavilion.
Cast Stone supplied by: - Haddonstone Ltd.
Building Type: - Residential Apartment Block, New Build.
Cast Stone Material: - Wet-cast Cast Stone.
Location: - Poundbury, Dorchester, Dorset.
Client: - HRH The Prince of Wales / Duchy of Cornwall
Architect: - Ben Pentreath Ltd
Main Contractor: - CG Fry & Son

This most impressive building, being visible for many miles is the focal point for Prince Charles' prestigious development of national importance. The apartments, enjoying unrivalled views of the surrounding countryside, have been built to the highest specification and, with UKCSA Member Haddonstone Limited's wet-cast cast stone elements to the fore no compromise was allowed on design or quality.
The design of the building was clearly influenced by the works of John Nash and Sir John Soane, incorporating classical and contemporary features and combining Greek Revival forms and details with Roman arcaded architecture. Meticulous attention to detail has created interesting façades which hold the attention and emphasises the opulence of the residences. The main building has a striking colonnade to the ground floor, covered terraces to the first floor and private open terraces above. The highest structure in this development is the tower to the South East corner which is fully clad with cast stone to the first two stories.
Haddonstone's cast stone package exceeded a thousand tonnes of material, comprising nearly ten thousand individual pieces of more than a thousand different components, all custom designs. The smallest item weighed just four kilograms and the largest came in at 1.4 tonnes.
The ground floor to the main building features a plinth course of varying height, attached columns, an arched colonnade with subtle differences in design and contemporary balustrading. The cornice, apparently of a constant profile actually comprised six different depths to accommodate various construction details. The cornices and architraves to the first, second and third floors, while appearing similar in profile also enjoyed slight variations necessitating multiple mould production, far in excess of what would normally be expected. To minimise site cutting the entablature components were all produced to length, sometimes only a few millimeters different all contributing to a complex jig saw of stonework requiring accurate casting, labeling and packing and it is of great credit to the mould studio, factory and loading staff that that the project suffered minimal problems with the stonework supply.
The project also includes fluted columns to the first floor terraces, balustrading and custom finials to the roof terraces to the main building. The cladding to the tower incorporated plinths, pilasters, niches and massive arches and keystones with intricate moulding detail. The accuracy of the Haddonstone mould production is exemplified by the perfect alignment of the joints giving perfect transitions to the arches and smooth interiors to the niches.
Inevitably with a project of this size and complexity and with the fixing and other details often being designed as the project progressed there were issues with conflicts within the design but these were overcome promptly and efficiently to the satisfaction of all parties. The resulting construction is justifiably a source of pride for HRH The Prince of Wales and the Royal Family clients, including The Queen who opened the building, the architect Ben Pentreath Ltd and the main contractor, CG Fry & Son. It also showcases the effective collaboration between the UKCSA Full Member cast stone manufacturer Haddonstone Ltd and the cast stone installers Henley Stone Specialists Ltd and structural design and detailing consultants Smart Crosby International, who are both UKCSA Associate Members.

 

PEOPLES CHOICE   -  HIGHLY COMMENDED:   FOSSEWAYS, St GEORGES HILL, WEYBRIDGE

Cast Stone supplied by UKCSA Full Member   -  Woodside Cast Stone

Cast Stone installed by UKCSA Associate Member   -  Henley Stone Ltd.

Fosseways, St George's Hill, Weybridge
 
Fosseways, St George's Hill, Weybridge
 
Fosseways, St George's Hill, Weybridge
 
Fosseways, St George's Hill, Weybridge
 

Peoples Choice, Highly Commended: - Fosseways.
Cast Stone supplied by: - Woodside Cast Stone.
Building Type: - Private Residential, New Build.
Cast Stone Material: - Wet-cast Cast Stone.
Location: - St George's Hill, Weybridge.

Positioned in a prime location on the exclusive and internationally renowned ‘St Georges Hill’ private estate near Weybridge, the 26,000ft2 Fosseways development certainly makes a statement. The main feature on this private residence is a 12m high Porte Cochere assembly on the main entrance area with 8no. fluted columns, spanned with a bullnosed architrave beam, suspended soffit and a gable pediment assembly that projects 11m forward of the main building line that is hung from a steel frame.
Other than this main assembly, one particular component within the supply that took a lot of thought and consideration was a 6.7m long moulded cornice beam, cast in one piece and weighing in excess of 4.5t that was designed to carry the 20t building above.
The stone to the first floor sweeping and curved balconies form permanent shuttering and were installed at the very start of the main build process when the concrete frame was cast. A lot of care was taken by the UKCSA Member Woodside, the developer and installers to protect these features from damage during the build programme and the results of this diligence are clear to see. Other stone features include 66no. 3.5m high columns on the balconies as well as a 1.94m high entablature assembly at eaves level, topped with 20no. bespoke urn finials to add to the effect of grandeur.
As well of the main building that occupies three spacious floor levels there are two substantial detached buildings (one that is two–storey and the other that is three-storey) that house garages with six parking spaces and staff quarters. To give an idea of scale, these two, supplementary, detached buildings occupy 3,500ft2, which is the size of a typical, detached four bedroom house.
Large scale units were designed with the brief to minimise jointing visibility and a special wet-cast, etched, stone mix was designed by ourselves, containing Nordic Spa aggregates, to conform to the client’s wishes for the stone to be as white as possible. This is certainly achieved as when you drive past the development it catches your attention with the brightness and freshness of the stone.
The cast stone manufacturer's Technical Department worked closely with the developer from the outset to ensure that the design brief was implemented, giving careful consideration to every step in the detailing, manufacturing, handling, storage and installation process to ensure a successful development completion. Units were delivered to meet the complex choreographed sequence of installation as any damage would have had a catastrophic effect on the build programme whilst a replacement unit was manufactured.

 
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