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What we make › Cast stone moulds › Balustrade moulds

Cast stone moulds · Balustrade moulds

Cast stone balustrade moulds.

Moulds for balusters, handrails, bottom rails, plinths and pier caps — period profiles matched or new designs developed with your architect.

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Overview

Balustrade moulds, in plain terms.

Row of split baluster moulds set out for repeat casting
Baluster moulds set up for repeated stripping

Balustrades are repetitive by nature: dozens of identical balusters, runs of rail. The moulds have to be quick to strip and consistent every time.

Balusters are cast in split moulds; rails and plinths in open or two-part moulds depending on the profile.

What sets it apart

Four things that define this route.

01

Balusters

Split moulds with seams on the least visible line.

02

Rails

Top and bottom rails with drips and mortices.

03

Pier caps and plinths

The pieces that finish a run.

04

Period matching

Profiles from existing balusters.

How we build it

From pattern to released tool.

Baluster moulds are keyed split moulds in a rigid case, designed for quick repeated stripping.

Rail moulds include mortice formers so balusters locate without drilling.

Keyed split baluster mould in rigid case beside rail mortice formers

The honest bit

What to know before you commit.

Balusters are small but numerous. For a large run we'll suggest a set of moulds so the caster isn't waiting on cure.

At a glance

The ideas in pictures.

How a two-part mould fits together

Pour spoutAir ventSplit lineYour part in the cavityFlexible siliconeRigidmother mould

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The silicone holds the detail, the rigid case keeps it true, and the split line lets the part come out without tearing.

From sample to finished cast

  1. 01Sample, drawing or scanWhat the finish must match
  2. 02Master patternCarved, machined or taken from the original
  3. 03Liner or mouldMade in the right elastomer
  4. 04Trial castChecked with your mix
  5. 05Production castsLiner reused across the run
  6. 06Kept on fileReady for repeats

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Each job follows the same route, whether it is one keystone or a full run of wall panels.

FAQs

Questions we hear about this.

How many baluster moulds should we have?

Enough to suit your daily output and cure time — we'll help work it out.

Can you match an existing baluster?

Yes, from a sample.

In this family

Related routes under Cast stone moulds.

Cast stone mouldsThe parent service overviewCills and lintelsCast stone cills, heads and lintelsQuoins and dressingsQuoins, surrounds and dressed stoneBalustrade mouldsBalusters, rails and plinths

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.

Send an enquiry 01789 224228

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.
The TCI design and project office.
The TCI design and project office.
The TCI workshop, with moulds on the bench mid-build.
The TCI workshop, with moulds on the bench mid-build.
  • Thomas LaneManaging Director
  • George PrestonDesign & Project Manager
  • Kelly BallingerHead of Partnerships
  • Jim AndertonProduction Manager
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