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CREATING A NEW STANDARD
GREENWAY, Inc. was created through the collaboration of two disciplines; Construction Science and Polymer Chemistry. Our chemist developed the polymer technology and process, the crux of which is utilized in manufacturing our products, from specific development on a consulting project for the “Theme Park” industry. Since that industry has a very unique set of requirements, and in essence a one-dimensional purpose, the challenge was to apply this new technology to the “Architectural Elements” field.

Making a mold and developing a process, by which to produce one unique piece, is vastly different than the mold and process technique necessary to produce thousands of a variety of pieces. To create a mold that would render a precise piece and yet retain its stability through multiple uses, was a difficult task. The type of materials and technique involved in this effort are crucial. Because of the nature of the high density polymers, of which are products are comprised, it is necessary to create molds utilizing a material with superior release properties. In many applications, such as the aforementioned “Theme Park” industry, rubber is often the material of choice. However molds made for that application are not subjected to the continuous service that our production requires. Because of this, our molds must demonstrate a high degree of endurance as well. We found the ideal material, for our purpose, in Germany. It is the most expensive and highest grade of silicon rubber in the world.

Having resolved these issues we were now ready to move forward with production. After almost two years and a couple million dollars more in research and development, we have successfully completed the transition. We are currently manufacturing more than a hundred different items in vast quantities on a regular basis, with many more to come.

This method of adding glass fiber to the stone mixture during the molding process lessens the weight of the material, while at the same time adding strength. Despite this, the “GFRC” is still weighty and difficult to work with, and still requires “masons” for installation. It is for these reasons that those within the cast stone industry have been searching many years for a lightweight replacement material that would also possess great durability, and a realistic “cast stone” appearance, that was not present in existing “EPS”(Foam) products. Marbons’ ownership was a leading force in this search.
 

Great Expectations