Sierra Concrete- Info Center

As specialists in the craft of custom pre-cast architectural embellishments, Sierra Concrete Design (SCD) has developed comprehensive and unique expertise in our design and manufacturing procedures, which have resulted in trademark patented materials and methodologies. This evolvement has given SCD the capabilities and resources with which to serve all clients, from the individual homeowner to the developer with large-quantity orders.

Often, customers will come to SCD with an idea to remodel their fireplace surrounds. Upon receiving dimensions and specifications from the customer, SCD then provides a thorough consultation on the variety of designs and materials available to determine the right plan, with regards to cost and aesthetic requirements. If clients request a product based on a detailed sketch, SCD can produce it within 1/16" of its specifications.

Sometimes customers request restoration or reproductions of an existing design, submitting nothing more than a photo or rough sketch. SCD gladly extends our capabilities to creating close reproductions in such cases. Since these designs are unique to SCD, they are also considered custom designs, requiring just a few extra steps.

While custom design is not the entirety of SCD's business, it is the essential feature that drives our artistic integrity, attention to detail, and professional approach. The ability to fulfill custom orders is why SCD has earned the respect of large builders, who operates on the reputation of delivering quality and value.

To better understand SCD's techniques for creating a unique fireplace surround, following is a step-by-step demonstration of the design and manufacturing process.

In just days, SCD's designers create detailed architectural renderings to represent the customer's ideal. Upon the customer's review, the designer makes the necessary modifications. A design is then determined and materials are selected for the project.

Professional mold makers create a master copy of the mold to follow, out of wood, plaster, and other shaping materials required by the specifications of the design.

SCD's engineers examine the dimensions and details of the master plug to ensure that it meets design specifications and the customer's requirements. Once approved, the engineers sign off on the master and the final mold goes into production. This step is crucial in providing excellent quality assurance and precision of the final product.

The actual urethane mold is created from the master plug by carefully brushing on multiple coats of polyurethane until a thickness of approximately 1" is achieved. This density will make for a very durable mold that can also be used to create numerous reproductions. Its durability and resulting utility for future orders provides cost-effective, non-custom alternatives for those with strict budgets.

Within several days, the master mold is ready for its overlay of multiple coats of epoxy, a sturdy fiberglass cloth and the custom-designed steel-frame reinforcements, upon which completes the mold.

With SCD’s artistic insight, streamlined operations and precision, the entire process is carried out smoothly and in a swift lead time of approximately one month—from conception to finished product.

One of the valuable benefits of our service is cost efficiency. Custom molding and tooling required to produce a custom-designed surround, similar to the one shown, costs approximately $5,000.