Holy Trinity Church

Gainesville, VA

Cast Stone Institute 2010 MANUFACTURING EXCELLENCE Award Winner

The new construction Holy Trinity Church contained a large amount of Cast Stone, which included a complex one-piece “Trinity Ring” window surround, door surrounds, coping, medallions, and an 8-foot high cross.

To accommodate the multi-paned custom stained glass panels, a one-piece Cast Stone window surround was designed. The complex mold was fabricated in sections, then pieced together to create the large mold.

The molding process was extremely complex, as the radii of the Cast Stone unit had to accept the stained glass panels perfectly. As the surround was 13’8” across and 24” thick, the molding tolerances were exceptionally critical.

The intricate Cast Stone surround was originally designed as multiple pieces around each stained-glass panel, however that facilitated connections. A one-piece Cast Stone unit was designed, which overcame the issue.