The History of Artificial Stone

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Using artificial stone or cast stone instead of natural stone in construction may seem like a relatively new concept, especially to those not in the construction industry. However, the use of artificially created stone dates back centuries and has a long history that spans across countries and continents. Continuing innovations in technology have made artificial stone more readily available and expanded its uses, making it one of the most beautiful and versatile building materials in use today.

What is Artificial Stone?

Artificial stone has been known by many names over the years, including engineered stone, manufactured stone, and cast stone. As the name suggests, it is an artificially made stone-like material created using water, crushed stone, and other materials poured into a mold to create the needed shape for a given project. It has a stone-like appearance and texture to mimic the beauty of natural stone while allowing for more uniformity and versatility.

The Historical Origins of Artificial Stone

Some of the earliest recorded uses of artificial stone date back to the Roman Era. Architects of the time described the use of a material known as opus caementicium, meaning “cement work.” This was a structural material that, over time, would become hard like stone. It was made of natural aggregates like lightweight pumice, repurposed bricks, and pozzolanic cement. This imitation stone material was used to construct vaulted arches, gateways, and dome ceilings in buildings like the Colosseum and the Pantheon.

In England during the reign of King Henry VIII, this versatile building material became known as simulated stone. However, one of the king’s brewers also referred to it as “artificial stone or brick” in his records, and he used the stone extensively.

It soon became known as cast stone because manufacturing the stone required casting the material into molds. The use of limestone-based cast stone spread across Europe to medieval France, where it was used to fortify the walled city of Carcassone.

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As advancements in architecture progressed, so did the manufacture of artificial stone. The year 1769 saw the introduction of Coade Stone, named after Eleanor Coade, who purchased a failing artificial stone business in Lambeth, a district in South London, England. Under Mrs. Coade, the company demonstrated that molded materials such as imitation stone products could not only enhance and reinforce other building materials within a structure but also be used to create free-standing pieces for both ornamentation and architectural purposes. This led to more widespread use of the stone in detailings for gardens, facades, and statuary. Many sculptures and structures using the stone can still be seen today, such as the Westminster Bridge lion, Ham House pineapples, and elements on the rear-facing side of Buckingham Palace.

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In the early 19th century, artificial stone saw another significant development in its creation process with the invention of Portland cement, a product that is still used in cast stone mixtures to this day. This new cement, along with repetitive advantages in the technology of the day, allowed for smoother production of artificial stone at a lower cost than ever before. Architects enjoyed the added savings from the lower production cost, which encouraged them to use the material more often.

Modern Advances

Over the course of the latter end of the 19th century and throughout the 20th century, the process for creating artificial stone products has remained relatively the same. However, some cast stone companies have found new ways to make their products more affordable and versatile.

For instance, New Cast Stone has developed a process that enables its cast stone products to be more lightweight and cost-effective through the use of foam molds. These molds not only produce a product that is easier to work with than other forms of artificial stone, but they are also easier to customize to a specific shape without increasing costs or adding time to the overall time needed to complete the project.

Conclusion

Cast stone is far from a modern innovation. It has a long and rich history dating back to the time of the Romans. Over the years, it has been called by names, including artificial stone. Its composition and manufacturing process has changed and improved, becoming more versatile and cost-effective while maintaining the strength and beautiful appearance of natural stone.