Process and Materials
At Melgrand we manufacture all products in Australia and utilize various materials in traditional and innovative production methods. Our divisions are Lightweight, Wet Cast, GRC and Reconstituted Stone.
Our Lightweight Cement Coated Architectural Profiles will help to transform any building project and create a unique and impressive design. Mouldex® Profiles are lightweight, very easy to install, well within budget and aesthetically pleasing. The low installed cost in most settings combined with traditional appearance equals great added value.
The automated process of combining a tough cementitious coating with a lightweight core allows us to deliver products with maximum tolerance consistency at the best possible price. We are committed to complete customer satisfaction.
Mouldex® Profiles are composed of an expanded polystyrene (EPS) core, reinforced with tough fibreglass mesh and coated with 1 or 2 coats of an impact resistant and flexible polymer modified cementitious render. The coating provides a smooth, durable exterior ready for painting.
Our LightCast™ Technology uses a carefully designed concrete formulation to make lightweight precast elements with a fine surface finish. Lightweight materials and fillers are used to create an authentic element with greatly reduced weight.
This approach is recommended for ornamental decorative elements which are non-structural, or for profiles in high traffic areas where our Mouldex® products are less suitable.
LightCast™ products are durable and robust, and easy to paint with an acrylic based paint.
(Lightweight Precast Concrete)
Wet cast concrete is a fluid concrete mix which is poured into specially constructed mould.
Wetcast™ concrete is a standard technique in the precast industry, where it can effectively reproduce the shape of any architectural pattern. After setting, it is stripped, finished and marked prior to shipping.
At Melgrand our WetCast™ method is often used for larger pieces and more complex shapes, which need a fluid concrete mixture in order to fill the mould and to adhere to cage reinforcement.
WetCast items are in most cases sufficiently cured for delivery after 7-10 days. Solidity of form, precise castings, price-competitive, structural
(Classical Precast Concrete)
ShellCast™ is our process of manufacturing elements with thin walls up to 20mm GRC, the surface is fine and easy to paint. ShellCast™ elements can be made with a coloured finish to suit the owners scheme, there is no need to paint.
Glass reinforced concrete (GRC) is generally manufactured using glass reinforced concrete, a cement based composite material with alkali-resistant fibres that are randomly dispersed throughout the product. Because the fibres add flexural, tensile and impact strength, the result is a strong yet lightweight architectural material.
Super- durable, non-combustible, high strength to weight ratio, design flexibility, paint or colour to suit.
(Fibreglass reinforced concrete, or GRC)
In this process a carefully controlled mixture of washed river sand, cement, fines and polymers is mixed with a limited amount of water until it achieves a damp malleable state and can be compressed either by hand compaction or by a small mechanical ram-tool. Every element is hand fashioned by experienced craft workers.
Quarried stone look and feel with grain texture, no need to paint. Colour and texture are inherent in this process. High mpa scores and low permeability add up to a material superior in almost every respect to Heritage quarried sandstone.
After an initial curing period of around 12 hours the FormStone™ element is removed from the mould and kept in a humid environment for at least 24 hours. Full curing is not achieved until 28 days at which point the element is carefully packed for delivery.
(Reconstituted stone, or dry cast)