In-situ moulding
Brush-on silicone and a rigid mother mould, taken from scaffold.
What we make › Heritage restoration moulds › Cornice restoration
Heritage restoration moulds · Cornice restoration
Cornice restoration moulds from a single surviving section.
Silicone moulds taken in situ or on the bench from a surviving cornice section, so lost runs can be cast to match in cast stone, GRC or plaster.
Overview
Cornice restoration, in plain terms.
Cornices fail in sections: frost, water ingress, corroded fixings. Usually enough survives to mould from, and the lost runs can be reinstated to match.
We mould the survivor, make good on the mould where the conservation team agrees, and build production tooling for the caster.
What sets it apart
Four things that define this route.
Bench moulding
Poured silicone around a salvaged section for maximum fidelity.
Returns and mitres
Internal and external corner pieces moulded or built from the straight run.
Cast in your material
Cast stone, GRC or fibrous plaster — the mould suits the caster.
How we build it
From pattern to released tool.
We agree a written methodology first: how the original is protected, whether loss is made good on the mould, and how trial casts are approved.
The production mould is sized to the caster's preferred length, with ends designed for clean butt joints.
Corner returns are often the hardest part. Where no original corner survives, we build it from the straight profile and get it approved as a pattern.
The honest bit
What to know before you commit.
Profile is easy to reproduce. Weathering and surface are harder. We always recommend site trials in daylight before committing to production.
At a glance
The ideas in pictures.
How a two-part mould fits together
Swipe to see the whole diagram
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
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FAQs
Questions we hear about this.
Will the original be damaged?
It shouldn't be. We use a barrier and test first, and the method statement sets out protection.
Do you cast the cornice?
No, we make the moulds. We can recommend casters if needed.
In this family
Related routes under Heritage restoration moulds.
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