Concrete Cornice & Pediment — The Process

This project for the J.Pinelli Company required the product to be as durable and to match the historical stone facade.  We won a Heritage Society preservation award for our work on this building at 811 Congress Ave.  The process is described at the right.

We started by creating a full size clay model of the cornice with the corner piece on each side.

We then made a case mold with rigid polyurethane rubber and plywood.

Once we removed the original clay, we poured rubber in the sides to create a removable plug filling the corner pieces.

This enabled us to make 20 straight sided sections and each of the two corner pieces from one mold.

The castings were done in glass fiber reinforced concrete over a stainless steel frame.

The frame had tabs which were anchored to the building and stuccoed over.