TCI Construction · What we make

Twenty services, 42 detailed routes, one pattern room.

Formliners, unit moulds, GRC tooling, cast-stone moulds, heritage replication, street furniture, master patterns and replacements. Silicone for detail. Polyurethane for the workhorse. Whichever one your job needs.

How this page works

Grouped by what you're trying to cast.

Different mould and formliner types arranged on a pattern room bench — A mix of moulds and liners for different castings

Each service has its own page, and most branch into two to four detailed routes underneath. If your job doesn't obviously fit one, ring us and describe the panel — most jobs are a combination of two or three.

Formliners & precast

Silicone & polyurethane formliners

Surface tooling for precast — wood grain, stone, brick, custom relief. Sized to your bed, spliced at the joint.

Plastic formliners · Elastomeric formliners · Single-use formliners · Reusable formliners

Textured formliners

Standard-relief textured formliners — ribbed, striated, rope, board-mark — sized to your bed with proper splices.

Rope-effect formliners · Board-mark formliners

Replacement formliners

Matched replacements for tools reaching end of life — no visible drift across the programme.

Matching from a sample · Planned replacements

Precast concrete moulds

Unit moulds for balustrades, copings, capstones and structural precast pieces.

Wall panel moulds · Column and pier moulds · Beam and lintel moulds

Precast panel tooling

Full-panel moulds for architectural precast — face, edge returns, cast-in fixings, spliced to elevation.

Retaining wall moulds

Face-textured moulds for retaining wall units — grippy soffit, clean stackable face, mould stays put on the bed.

Large-format moulds

Oversized formliners and panel moulds spliced at the joint and handled sensibly.

Spliced large-format liners · Oversize unit moulds

Textured formliner mats with replacement section beside a worn original — Textured formliners and a matched replacement section

Architectural

Architectural cladding tooling

Bespoke moulds for façade panels, spandrels, cornices and feature elements.

Sandwich panel face tooling · Feature bands and string courses · Returns and reveals

GRC tooling

Thin-shell silicone moulds for glass-reinforced concrete cladding and cornices.

GRC panel tooling · GRC relief tooling · GRC column tooling

Cast stone moulds

Sharp-edged moulds for keystones, cills, quoins and dressed-stone reproductions.

Cills and lintels · Quoins and dressings · Balustrade moulds

Faux brick & stone formliners

Realistic brick and stone formliners for precast — from a squeeze of the reference brick, not a catalogue photo.

Custom texture & relief

Bespoke surface patterns — from a photograph, a sample, or a hand-drawn concept.

Artwork to relief · Timber grain replication

Heritage & restoration

Heritage restoration moulds

One-off moulds that rebuild a lost detail from a single surviving section.

Cornice restoration · Keystones and corbels · Finials and parapets · Heritage relief patterns

Landscape & street furniture

Moulds for benches, bollards, planters, paving relief and public-realm bespoke.

Bollard moulds · Bench and seat moulds · Copings and capstones

Planter & vessel tooling

Moulds for concrete planters and vessels — drainage cast in, base feet moulded, no post-work.

Large planter moulds · Tree surrounds and edging

Decorative concrete moulds

Small-format silicone moulds for planters, homeware, feature pieces and retail props.

Garden ornament moulds · Signs and lettering

Tooling & support

Master patterns & scanning

Pattern-making from drawings, samples or 3D scans. Where the tool's success is decided.

3D scanning · CNC machined patterns · Hand-sculpted patterns

Split-mould tooling

Multi-part moulds for undercut and closed geometry — flanged split lines, matched keys, no witness lines on the face.

Multi-panel tooling

Sets of moulds that keep panels matching across a whole façade.

Matched tool sets · Modular formliner systems

Durability & release

How we specify a mould for the pour count, the mix, and the release regime you actually run.

Release agent selection · Mould repair and refurbishment

By buyer

Eight kinds of yard, workshop and studio.

The tooling is the same underneath — the conversation is different, so we've written a page for each buyer type.

Precast yards

For precast yards

Formliners, unit moulds and replacements that survive the bed, the wash and the second pour.

Cladding manufacturers

For cladding manufacturers

GRC tooling, matched multi-panel sets and architect-signed reliefs, delivered as a system.

Heritage restoration

For heritage restoration

Moulds taken from surviving sections, in situ or on the bench, for listed replication.

Landscape yards

For landscape yards

Bench ends, bollards, planters and paving relief — for yards that mix repeat lines with civic bespoke.

Architects & specifiers

For architects & specifiers

Written material specs, bespoke reliefs, and early-stage tooling advice — before the design is frozen.

Cast stone workshops

For cast-stone workshops

Cills, keystones, quoins and dressed-stone reproductions with the arris held pour after pour.

Public realm

For public realm projects

Bespoke bollards, seating, planters and paving relief for town-centre and waterfront schemes.

Hard landscape

For hard landscape contractors

Copings, steps, edging, retaining units and bespoke specials for contractors casting their own or buying in.

All sectors

Also useful

Where to read next.

Applications

Where the tooling gets used, in plain language.

Processes

How each moulding route works, from bench to bed.

Materials

Which silicone, which polyurethane, and when.

One-stop shop

Capture, pattern, mould and support in one place.

Knowledge hub

Twelve guides on choosing, briefing and running concrete tooling.

Projects

Twelve anonymised project records.

Designed and developed in the UK. UK moulding capability, with some higher-volume production placed with trusted partners where that's the right commercial answer.

At a glance

The idea in a picture.

Planning liners across a wall

Swipe to see the whole diagram

We draw the layout with you so repeats, joints and returns line up before any liner is made.

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 workshop, with moulds on the bench mid-build.

Thomas LaneManaging Director
George PrestonDesign & Project Manager
Kelly BallingerHead of Partnerships
Jim AndertonProduction Manager
TheodoreEmployee Welfare

Meet the team