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What we make › Heritage restoration moulds › Keystones and corbels

Heritage restoration moulds · Keystones and corbels

Keystone and corbel reproduction moulds.

Silicone moulds for carved keystones, corbels, brackets and consoles, so a single surviving feature can be cast again to match the elevation.

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Overview

Keystones and corbels, in plain terms.

Ornate corbel releasing from a flexible silicone mould and rigid case
Corbel mould opened to release carved undercuts

Keystones and corbels are the features people notice when they're missing. They're often carved, weathered and slightly different from one another.

We mould from the best surviving example, or from each one where they differ, and build moulds that release the carving without breaking undercuts.

What sets it apart

Four things that define this route.

01

Carved faces

Masks, foliage and scrolls reproduced with tool marks intact.

02

Deep undercut

Silicone flexes past carving that a rigid mould couldn't release.

03

Sets that vary

Where each keystone differs, individual moulds per piece.

04

Cast stone or GRC

Mould designed for semi-dry or wet-cast as required.

How we build it

From pattern to released tool.

For loose pieces we mould on the bench with a two-part poured silicone and a rigid case. For fixed pieces, in-situ brush-on with a sectional mother mould.

Back faces are designed to suit fixing — dowel holes, flat bedding faces, or a keyed back for mortar.

Sectional mother mould around a decorative stone fragment

The honest bit

What to know before you commit.

Heavily eroded carving may need a sculptor's input before moulding. We'll say if the survivor is too far gone to mould directly.

At a glance

The idea in a picture.

How a two-part mould fits together

Pour spoutAir ventSplit lineYour part in the cavityFlexible siliconeRigidmother mould

Swipe to see the whole diagram

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

FAQs

Questions we hear about this.

Can you reproduce a piece from photographs alone?

It's possible with a sculptor and a scan-free route, but fidelity is lower. A physical survivor is always better.

Different sizes?

Yes, via scanning and scaling to a new pattern.

In this family

Related routes under Heritage restoration moulds.

Heritage restoration mouldsThe parent service overviewCornice restorationReinstating lost runs from a survivorKeystones and corbelsCarved features reproduced to matchFinials and parapetsEcclesiastical and civic roofline detailsHeritage relief patternsRebuilding lost reliefs from records

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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