Capture
Site measurement, silicone squeezes and 3D scanning of existing features.
TCI Construction · One-stop shop
Pattern, mould and support from one bench.
Most tooling problems happen at the hand-offs: the pattern shop that didn't know the mix, the mould maker who never saw the elevation. We keep the whole chain in one workshop, so nothing gets lost between stages.
Why it matters
Every hand-off is a chance for the intent to drift.
A texture drawn by an architect passes through a pattern maker, a mould maker, a precaster and an installer. If each one works in isolation, small decisions stack up: a splice in the wrong place, a draft angle nobody discussed, a material grade picked for someone else's mix.
Keeping capture, design, patternmaking and moulding together means one person holds the whole picture and answers for it.
What's under one roof
Six stages, one workshop.
Design
CAD, splice planning and design-for-manufacture on the panel or elevation drawing.
Master pattern
Machined, sculpted or scanned patterns, presented for physical approval.
Mould
Silicone and polyurethane poured, backed and cased for your bed.
First pour
Handling note, release regime and first-panel support where it helps.
Replacement
Pattern, drawing and spec archived so the next tool matches.
Where we stop
What we don't do, so you know where the edges are.
We don't cast your concrete, design your reinforcement or build steel beds. We make the tooling that shapes the concrete surface, and we coordinate with the people who do the rest.
Where some higher-volume production is better placed with a trusted partner, we'll say so and manage it — the paperwork still comes from us.
Start anywhere
You can join the chain at any stage.
At a glance
The idea in a picture.
From sample to finished cast
- 01Sample, drawing or scanWhat the finish must match
- 02Master patternCarved, machined or taken from the original
- 03Liner or mouldMade in the right elastomer
- 04Trial castChecked with your mix
- 05Production castsLiner reused across the run
- 06Kept on fileReady for repeats
Swipe to see the whole diagram
FAQs
Common questions.
Can we supply our own pattern?
Yes. We'll check it for draft, finish and undercut before we pour.
Do we have to use every stage?
No. Join wherever it suits you.
Who's our contact?
One named engineer, from first call to replacement.
Get in touch
Send us a photograph of the panel or the elevation.
One photograph tells us what surface you're chasing, and one line about the mix tells us what silicone or polyurethane will survive it.
Real people, a real workshop
You deal with the people who make it.
No call centre and no middlemen. When you contact TCI Construction, you speak to the team who design, build and check your mould.
- A real Warwickshire workshopUnit 15, Waterloo Park, Bidford-on-Avon, Alcester B50 4JG.
- Real people on the phoneCall the team on 01789 224228, Monday to Friday.
- The same team on every jobDesign, production and aftercare come from the people you see here.
- Part of TCI GroupFive specialist brands, one engineering team. Visit TCI Group.
Thomas LaneManaging Director
George PrestonDesign & Project Manager
Kelly BallingerHead of Partnerships
Jim AndertonProduction Manager
TheodoreEmployee Welfare