National Trust- ‘A Dodecorative Solution’

The requirement

On the eastern edge of Plymouth, near the banks of the Plym estuary, lies the 466-acre Saltram Estate, managed by the National Trust since 1957. Welcoming around 180,000 visitors each year, Saltram is renowned for its Georgian mansion, picturesque parkland walks, and beautifully maintained gardens, which feature rare plant species, elegant avenues, and unique decorative elements.

In October 2017, Senior Gardener Dr Martin Stott approached Aldermans with a request to fabricate a custom-built concrete mould. The National Trust wanted to create perfect dodecahedral ornaments as decorative garden features. The mould needed to be strong enough to support the weight of concrete, precisely shaped for geometric accuracy, and securely fastened to prevent concrete leakage. It also had to be easily dismantled and reassembled for future use.

Dr Stott had already built a wooden prototype, which provided a starting point for the development of a more durable, long-lasting metal version. Given the precision and strength required, Aldermans’ expertise in laser cutting, metal fabrication, and welding made it the ideal partner for the project.

The solution

Using the wooden prototype as a reference, Aldermans created 3D CAD drawings in SolidWorks, ensuring that every detail met the client’s exact specifications. These drawings were reviewed and approved before production began.

The first stage of fabrication involved laser cutting 12 mould panels from 3mm CR4 mild steel using Aldermans’ Amada CNC Fibre Laser. This advanced laser cutting technology provided rapid programming transfer, high precision, and efficiency, making it a valuable asset for projects requiring geometric accuracy.

To assemble the mould, 30 brackets were fabricated and welded to the panel edges, allowing the unit to be securely fastened together and easily dismantled. Each bracket was precisely folded using a CNC press brake, ensuring a perfect fit. The bracket positions were etched onto each panel, aiding precise alignment during assembly.

Aldermans’ skilled welding team then meticulously assembled the unit, attaching the brackets, screws, and wing nuts to create a fully functional mould. The design ensured ease of use, allowing it to be reused for multiple concrete ornaments while maintaining durability.

The outcome

From order to delivery, Aldermans completed the entire project in just one month, providing the National Trust with a high-quality, reusable metal mould.

Dr Stott and his team were delighted with the result, as well as the appearance of the first dodecahedral ornaments created using the mould. To enhance its longevity and corrosion resistance, the unit was later coated in primer.

Following successful trials, Dr Stott requested a minor modification—a small hole in the top panel to allow excess concrete to escape, improving usability. The project has been such a success that additional sizes may be developed in the future.

This collaboration between Aldermans and the National Trust highlights Aldermans’ ability to engineer bespoke, precision metalwork solutions that support heritage conservation and landscape design, ensuring that Saltram Estate continues to offer unique and visually striking garden features for visitors to enjoy.

Client testimonial

‘Having searched online for a local metal engineering firm, I was pleased to discover Aldermans on our doorstep. The service from them has been excellent, and swift. It’s a high-quality mould which will help us create some stylish pieces to enhance the gardens.’

-Dr Martin J Stott, Senior Gardener National Trust, Saltram, Plymouth

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