Behind the Scenes: CASTO’s Role in Hardscape Maintenance Programs
How Themed Finishes Stay Beautiful Long After Opening Day
Universal Epic Main Area Exposed Aggregate Repair
At CASTO, we believe that constructibility doesn’t end with installation—it continues through training, inspections, and ongoing maintenance. And when it comes to themed hardscapes, maintenance isn’t optional—it’s essential.
Whether it’s a high-traffic plaza at a theme park, a stylized boardwalk in a resort village, or decorative paving in a mixed-use district, hardscapes face a constant battle with foot traffic, weather, cleaning, and aging. The magic lies in helping them withstand the elements while preserving the illusion.
This week, we’re going behind the scenes to explore how CASTO supports long-term care and maintenance strategies for themed hardscapes—ensuring durability, safety, and aesthetics go hand in hand.
MMA Red Carpet: Bowser
The Challenge: When Beauty Meets Brutality
Themed hardscapes are highly detailed, multi-layered systems—textured, colored, sealed,
and sometimes hand-painted. But their placement in guest-facing, high-traffic areas means they’re also constantly exposed to:
Foot traffic (millions of visitors per year in some parks!)
Rolling loads (strollers, carts, show sets)
UV exposure, rain, and thermal movement
Power washing and chemical cleaning
Changes in site conditions over time
Even the best-designed surface will degrade without proper care. That’s where CASTO steps in.
CASTO’s Approach: Design-to-Maintain
At CASTO, we don’t just install hardscapes—we help clients maintain them through the life of the project. Here’s how:
Performance-Focused Design Reviews
We work early with creative and technical teams to ensure materials and finishes are selected based on long-term performance—not just aesthetics.Mockups and Test Panels
We test cleaning procedures and foot traffic resistance before full-scale installation begins. This allows clients to anticipate real-world durability challenges.Training for Maintenance Teams
We conduct hands-on field training for custodial and facilities staff, walking them through how to clean, reseal, and monitor themed surfaces without damaging detail.Maintenance Documentation Packages
We provide custom guides outlining proper cleaning products, resealing schedules, and visual benchmarks for assessing wear over time.On-Call Inspection and Repair Support
Whether it’s a last-minute touch-up before opening day or an annual maintenance audit, CASTO’s field team supports clients nationwide and internationally.
Case in Point: Epic Universe & Ongoing Support
At Universal’s Epic Universe, CASTO’s commitment to longevity and immersive storytelling doesn’t end when the concrete cures. Our team is actively embedded in multiple themed lands, executing long-term maintenance strategies that preserve finish quality, safety, and creative intent.
Here’s a look at how CASTO’s maintenance philosophy is being brought to life in real time:
MMA Floor Maintenance – Super Nintendo Land
We’re leading a year-long program inspecting, repairing, and analyzing MMA broadcast flooring in high-traffic zones. This includes twice-weekly site inspections, slip-resistance testing, localized recoats, and coordinating cleaning protocols with Universal’s Orlando and Los Angeles teams.
Vertical Surface Testing – Isle of Berk (and beyond)
From adhesion pull tests to moisture diagnostics and pH monitoring, our team is evaluating themed façades across multiple elevations—guiding repair, protection, or replacement strategies based on real data. Testing has expanded across all lands at Epic Universe.
Custom Patch Repairs – Exposed Aggregate Hardscapes
When railing posts or utilities interrupt a decorative surface, CASTO executes precision patching using color-matching and texture-blending to preserve the illusion without compromising durability.
Surface Exposure Corrections – Sandblasting for Creative Accuracy
In cases where exposed aggregate finishes didn’t meet creative intent, we’re refining surfaces through sandblasting to bring texture, tone, and visual depth into alignment with the original design vision.
Comprehensive Resealing – Across Universal Parks
Our teams are resealing hardscapes at Epic Universe, Islands of Adventure, and Hollywood Studios—addressing wear, weathering, and staining with strategic surface restoration efforts.
Training & Documentation – Universal Technical Services
We’ve cataloged all park-wide hardscape materials—pigments, texture stamps, embedded elements—and are developing a centralized material archive. Our team is producing training manuals, sample guides, and repair protocols to empower Universal’s in-house maintenance teams with long-term self-sufficiency.
Inspection: Japan’s Nintendo World
Why This Matters
Beautiful surfaces mean nothing if they fall apart after a year. In themed environments, realism and longevity must coexist.
By embedding ourselves in every stage—from design to installation to maintenance—CASTO builds a foundation for surfaces that endure as long as the stories they support.
“We don’t believe in one-and-done installs. Themed finishes are living parts of an environment. You don’t just build them—you care for them.”
— Lorenzo Casto, COO, CASTO
Key Takeaways
Themed hardscapes are durable—but only with the right maintenance strategy.
CASTO supports clients beyond installation, offering mockups, manuals, and hands-on training.
Long-term success means planning for both beauty and longevity from the start.
Maintenance isn’t just cleaning—it’s storytelling upkeep.
