Cast stone architectural mouldings in Jesmonite Penthouse balcony, Chelsea

Client:Private individual

The Scenario

A high-value penthouse property owner commissioned a stunning Jesmonite custom balcony installation for their home in Chelsea.

The Scope

The architect designed a curving and asymmetrical ‘rockery’ garden installation – a balcony feature with integrated planters and barbeque, plus a unique tiled walkway with metallic bronze finish. As a specialist Jesmonite manufacturer, we were asked to produce and install this stunning balcony feature and stand-alone planters along with bronze finish wall tiles.

Our Solution

The bespoke balcony installation was achieved by using 3D drawing files to enable CNC cut positive models to be produced for each unique section of the balcony feature. In turn, negative casting moulds were taken from the CNC positive models to enable the successful production of the Jesmonite casts.

To make each casting, Jesmonite AC730 was cast into each mould using quadaxial glassfibres for reinforcement. Jesmonite provided a blended AC730 material mix that met the customers chosen colour palette. Acid etch was applied to the external cast surfaces to add the desired texture once each piece had been cast.

All panels were manufactured to fine tolerances in-order to maintain regular panel feature flash gaps and achieve a uniform asymmetrical flowing surface across the whole installation. Each panel was mounted onto a custom framework providing rigidity, and purpose made recessed GRP plant pots provide positions for the property owners chosen foliage to be added.

The tiles for the balcony walkway are made from Jesmonite AC730 with a bronze Flex Metal Gel Coat surface. This uses real metal powder in the moulding process to provide a metallic finish that, in this case, looks like and behaves like bronze. Each wall tile was cast individually from a custom mould featuring a unique Coral relief pattern, and then hand polished to bring out the colour and unique striking coral texture. The surface can be waxed, sealed or have a patina applied just like real metal.

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