Albion Stone's factory at Portland is one of the largest and most technically advanced 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.
The journey of a block of Portland Stone from beginning to end in our factory on Portland.
Primary Sawing is the first cutting process to the block. The block is cut into a series of slabs.
We currently have two types of primary saw; the large 3m circular bladed Van Voorden and the diamond belted Benetti Fast Belt. Both of these are operated by workman in the factory.
The secondary sawing process cuts the slabs from the Primary Saws into the stones for ashlar cladding, pavers or 'sawn six side' cubes ready for further processing through the masonry operation.
Albion also have automated separate ashlar and tile lines for producing large volumes of highly accurate repetitive sized ashlars, tiles or even pavers.
The masonry operation involves the shaping of the stones utilizing either profiling saws, planers or the handwork of a skilled mason.
The profiling saws and the planers are typically used to work a moulding onto a long run of stones such as a string course, coping or cornice. The planers, adapted from engineering workshops, produce highly accurate stone mouldings from zinc templates produced in the drawing office. The 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.
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 individually checked for tolerances and stacked onto a pre-determined pallet ready for despatch.