Molded stone architectural product having a foam core

An architectural cast stone product, comprising:

• a lightweight foam core;
• a single continuous cementitious shell comprised of a molded cementitious material and that partially surrounds the foam core, wherein the cementitious shell is affixed to the foam core and has an outer surface configuration that is non-planar with three-dimensional features;
• and
• a mounting surface comprised of an exposed surface of the foam core and an end surface of the cementitious shell.

An architectural cast stone product, comprising:

• a lightweight foam core;
• a single continuous cementitious shell comprised of a molded cementitious material and that partially surrounds the foam core, wherein the cementitious shell is affixed to the foam core;
• and
• a mounting surface comprised of an exposed surface of the foam core and an end surface of the cementitious shell, the end surface of the cementitious shell including a wraparound portion that extends laterally into a recessed portion of the foam backer.

An architectural cast stone product manufactured according to a method comprising:

• obtaining a front pattern having a desired surface configuration for the architectural cast stone product;
• obtaining a foam core;
• affixing the foam core to a backer;
• affixing the front pattern to the backer, wherein the front pattern and the backer together form a mold having a mold cavity between the foam core, front pattern and backer;
• introducing a cementitious material into the mold cavity and into contact with the foam core;
• partially curing the cementitious material to form the architectural cast stone product comprised of a cementitious shell at least partially surrounding the foam core;
• removing the front pattern and backer from the architectural cast stone product while the cementitious material is only partially cured and before it is fully cured in a manner so that the foam core and cementitious shell remain attached together as the architectural cast stone product;
• and
• polishing a surface of the cementitious material to yield an architectural cast stone product comprised of the cementitious shell affixed to the foam core and having a polished surface finish.