Weekend Warrior Mold & Brick Casting Guide

This guide provides clear, practical instructions for preparing your molds, casting your bricks, and finishing them for installation. It is designed for weekend warriors and small business owners who want reliable, repeatable results.

 

Recommended Mold Quantities
 

For Non‑Business Owners

• For our largest circular gravine or rope molds, purchase at least 5 molds. This allows you to cast two sets of five bricks per circle.

• Minimum purchase: 2 molds.

For Small Businesses or Startups

• To maintain production speed, plan on 10 molds per style and diameter.

• Minimum purchase: 2 molds.

Mold Specifications

• Approximate size: 18" × 9" × 4.75"

• Lifespan: 800–1000 uses with proper care

• Production capacity: Up to 100 circles with a 47.75" inside diameter
  
   

Preparing Your Molds
 

First Use

• Apply Pol‑Ease 2650 release agent (Polytek).

After Each Use

1. Wash molds thoroughly.

2. Allow them to dry completely.

3. Reapply release agent before casting.

Casting Your Bricks
 

Concrete Mix (Makes 3 Bricks)

• 1 bag (80 lb) ready‑mix concrete

• Optional strength boost:

  • Add 2 lbs (approx. 4 cups) high‑strength Portland cement

• Mix thoroughly, adding water slowly.

  • The mix should be firm enough to trowel or scoop.

  • Avoid excess water — it weakens the brick.

Filling the Mold

1. Scoop the mix into the mold.

2. Shake gently side‑to‑side and tap with a rubber mallet.

   • A vibrating table produces the best finish.

   • This reduces air bubbles on the face of the brick.

3. Fill each mold to the same height on a flat, level surface.

Curing

• Minimum: 24 hours

• Recommended: 48 hours

• Full cure: 7–28 days (concrete cures chemically, not by drying)

Demolding
 

1. After 24–48 hours, place the mold on a level surface.

2. Lift from the flat side.

3. Shake gently and pull upward with a slight lateral motion.

4. The brick will release cleanly.

Finishing (Dressing) Your Brick
 

Begin finishing after 7 days, when the brick is dry and slightly dusty.

1. Dust off with a dry 2–3" paintbrush.

2. Spray the brick with watered‑down exterior white latex paint.

3. After drying, apply a light coat of paint sealer.

4. Brush on a semi‑transparent concrete glaze.

   • Wipe raised surfaces, leaving glaze in the grooves.

   • Follow the glaze manufacturer’s drying instructions.

5. Once fully dry, apply a final exterior concrete sealant.

   • Allow 24 hours to cure.

Mold Care & Storage
 

• Made from high‑strength polyurethane rubber.

• Clean thoroughly after each use.

• Store in a dry, shaded area — sunlight shortens mold life.

• Proper care ensures molds pay for themselves many times over.

Installation
 

After casting and finishing ten bricks, visit our installation guide to see how easy the process is.

Additional Notes
 

• For professional antiquing or faux‑finishing techniques, consult reputable experts online.

• Call 727‑642‑2886 to verify mold availability.

• Use the cost calculator in the link below to compare your DIY cost to industry pricing — typically $35+ per linear foot for decorative concrete borders.

Use this calculator to see the industry cost for decorative concrete borders, on average it is more than $35 per linear foot.

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