Curved
Curved facade panels, formed to a radius instead of cut.
A quarried block can only be cut. A cast panel takes the shape of its mould, so the radius, the return and the fixing rebate arrive in one piece — up to ten metres long.
NKSTONE forms curved cast stone panels in a mould to the project radius rather than cutting them from a block. Curved pieces run to 10 m in a single length where transport allows, with the edge rebate and return cast into the same mould. Minimum radius depends on the profile and thickness, and is confirmed against the project drawing.
What forming changes
Cutting a radius from a block wastes most of the block and leaves a joint where two cuts meet. Casting works the other way: the curve is a property of the tool, so a column wrap or a curved parapet can be delivered as one element with no vertical joint at the tangent point.
The same mould carries the edge detail. A rebate for an undercut anchor, a channel for a kerf fixing, or a return that turns the corner — all cast, not machined afterwards. That is what makes a 10 m curved piece installable as a single lift.
What has to be decided early
| Item | Why it matters |
|---|---|
| Radius, to the face | Sets the mould and the minimum piece length |
| Maximum piece length | Constrained by transport and site access |
| Section profile | Flat, fluted or rebated — each needs its own tool |
| Quantity in m² | A custom mould is a one-off cost spread over the area |
| Joint positions | Decided on the drawing, not on site |
Where the curved run meets a flat run, the pieces come from the same mix and pigment batch, so the face reads continuously across the transition. On projects with a strong vein direction, we set the batch and the casting sequence together.
Below roughly 20 m² of curved work, the mould cost dominates the piece price. We would rather say that at quotation than discover it at production.
Questions buyers ask
- What is the longest single piece curved stone panel?
- Ten metres, in one piece, where the transport route and site access allow it. Beyond that the limit is handling rather than production.
- What is the minimum radius for curved stone panels?
- It depends on the section and the thickness, so we confirm it against the drawing rather than quoting one figure. A flat 20 mm panel and a fluted section do not bend to the same radius.
- How much does a custom mould cost?
- A mould is a one-off tool cost, quoted with the piece price. It is economic from roughly 20 m² of curved area upward; below that we will tell you the tool dominates the price.
Send the drawing. We will return a joint layout.
Panel layout, area, substrate and required delivery date are enough to start. Quotation within 24 hours.