SUN Precast Wins CSI Manufacturing Excellence & Unique Architectural Feature Awards

This project consisted of fabricating (5) large decorative Cast Stone chimney extensions for a very large private residence, incorporating (5) unique designs and shapes, to fit over the original chimneys.

The Cast Stone chimney designs created significant mold fabrication and casting challenges. Each chimney had unique dimensions and radii, each with different architectural artwork on the exterior. The
“through the wall” decorative patterns near the tops of the chimneys, ultimately serve as the outlet for
the chimneys, while creating the striking architectural appearance. Incorporating all of the various architectural details into the relatively small mold space, proved to be a significant challenge.

The molding process was extremely complex, as each chimney had unique designs, and different radii, requiring a new mold for each chimney. The recessed architectural features required hundreds of individual elements to be handmade and custom shaped to fit the radius of the mold surface.

The largest challenge of the project was incorporating the unique architectural elements while meeting the overall functionality requirements of a chimney extension. The Cast Stone chimneys also have a solid one-piece cap, which prevents rain and snow from entering directly into the chimney flue.