Our Factory

Albion Stone's factory at Portland is one of the largest and through an extensive and continuing programme of investment has become most technically advanced and environmentally aware in the UK. It produces a wide range of Portland stone products from slabs, cladding panels, pavers, and tiles to the most intricate hand carved stones.  We have also constructed an extension capable of handling full storey height off-site pre-stressed columns and strong back stones preassembled and ready to be shipped direct to site. 

We have a proven track record of delivering a quality product to an agreed programme. 

 

Estimating / Setting Out Shop

The first stage of the manufacturing process is the estimating and preparation of the manufacturing instructions, as virtually all stones are bespoke and produced to the customers details for their project.  Our very experienced team are happy to help you through this process and will discuss your requirements and often suggest ways to reduce wastage and therefore cost and the stone’s carbon footprint.  

 

Primary Sawing

The Primary Sawing process is the first stage of the manufacturing which involves cutting the Portland Stone blocks produced in the mine into slabs ready for the secondary cutting.  Typically, the Portland stone slabs for cladding are 50mm thick, and paving 30mm or 40mm and flooring 20mm.  We have 5 Primary Saws working 24 hours a day, 6 days a week, so have the capacity to sell large quantities of slabs as well as finished stones.    

 

Secondary Sawing / Ashlar Line

The secondary sawing process takes the slabs and cuts then into the finished dimensions ready for further processing. 

The ashlar line takes the slabs and produces finished ashlar with the computer controlling the crosscut saw reducing the wastage to a minimum. 

 

Masonry Work

The masonry operation utilises the latest technologies blending them seamlessly with traditional skills and handwork of a skilled masons.  

The profiling saws are typically used to produce the detailed profiling work including notch quoins, cornices, and copings. The team of experienced masons in the Mason's Shop have a wide variety of tools at their disposal to produce the intricate carved stones, ranging from simple cornice returns to massive Corinthian capitals.

 

Finishing

All stone goes through the final finishing process which involves putting a rubbed finish on all seen sides (typically 50 grit) to remove all saw cutting and tool marks.

Each stone is again individually checked for tolerances and geological characteristics and once approved in accordance with the ISO 9001 Factory Production Control scheme it is stacked onto a pre-determined pallet in line with the fixing sequence ready for despatch. 

 

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