"wall" Archives | Browse Articles & Resources Written By Experts https://usenaturalstone.org/tag/wall/ Articles & Case Studies Promoting Natural Stone Tue, 29 Aug 2023 19:41:07 +0000 en-US hourly 1 https://usenaturalstone.org/wp-content/uploads/2019/07/cropped-use-natural-stone-favicon-2-1-32x32.png "wall" Archives | Browse Articles & Resources Written By Experts https://usenaturalstone.org/tag/wall/ 32 32 Connecting with Natural Stone https://usenaturalstone.org/connecting-with-natural-stone/ Tue, 29 Aug 2023 18:33:26 +0000 https://usenaturalstone.org/?p=11172 Andreas and Naomi Kunert, co-founders of Ancient Art of Stone, know they don’t easily fit into one category. Together they create one-of-a-kind art installations using natural stone, crystals, and bronze. Andreas and Naomi are artists, first and foremost. It’s not unusual for their art pieces to be 25’ tall. An upcoming project will include a 900-foot mosaic wall, with 20 feet surrounding it and large doorways with 350 ton standing stones that one can walk through.

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Connecting with Natural Stone

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Andreas and Naomi Kunert, co-founders of Ancient Art of Stone, know they don’t easily fit into one category. Together they create one-of-a-kind art installations using natural stone, crystals, and bronze. 

“We’re not stonemasons, we’re not necessarily sculptors, and we’re not mosaicists. Yet we use all of their skill sets,” Andreas says. 

Andreas and Naomi are artists, first and foremost. It’s not unusual for their art pieces to be 25’ tall. An upcoming project will include a 900-foot mosaic wall, with 20 feet surrounding it and large doorways with 350 ton standing stones that one can walk through. 

“From a megalithic point of view, it’s very moving and very to the point,” Andreas adds. 

Listening to clients and to the stone

Their clients don’t always know what they’re looking for at first. While this approach can be challenging for some people, for artists like Naomi and Andreas, it’s an opportunity to develop a design that is 100% personalized for their clients.

Their most recent client approached them to design a piece to add to their home, which was on 40 acres of land. They were referred by their landscape architect to create a focal point at a roundabout leading up to their home down the long driveway. When they first met with the client, it was clear the client didn’t have a design in mind. In fact, the client had no idea what to suggest; no idea of height, scale, or colors. So Naomi and Andreas came back to their studio and leaned into their process by channeling who they met and hearing what was shared.

“What did they tell us about their life? What was important to them?” Naomi asks. 

The discussion moved from what they felt to what might be important. Family and community seemed important. What Andreas noticed from their initial meeting was the couple was the nucleus of a larger family and they cared about the people in their community. 

“We developed this design of a taller stone standing together, which represents them, husband and wife, and then a sphere, emerging from the two stones, which represents this family and this caring community,” Andreas says.  

When presented with the design, the client loved it without any edits. 

Choosing the right stones

Years of experience have taught Naomi and Andreas what’s possible and working with talented engineers has allowed them to create award-worthy projects for their residential and commercial clients. 

The design is one part of the equation. Another is finding the right stones for each project. Those stones come from a variety of places. While they source some stones in their travels, some come directly from the client. In one instance, Naomi recalls a client whose father collected arrowheads that he found on his land. Those pieces were incorporated into a fireplace design as a way to honor their father. Those types of scenarios aren’t uncommon. 

“I think it does depend also on the client, and what their needs are as part of that listening and as part of my interest in health and healing,” Naomi says. “So through that, listening and getting to know them, there are certain stones that will kind of come more forward in my mind.”

Finding connections

Connections to the ancient art of natural stone used in projects are important to Andreas and Naomi. When it comes to the philosophy of their work, Naomi says it’s wise to look at the ancient ways natural stone has been part of all of creation. For Andreas, whatever they build, they build it with longevity in mind and what they create will outlast our generation and generations to come. 

Commissioned designs are completed in their studio in Cowichan Valley on Vancouver Island and then shipped to the client’s location. It’s not uncommon for a client to become emotionally moved once they see a piece in real life. That’s when Naomi knows the spirit of the stone is speaking to them. Once they’re in front of the artwork, and allow the piece to speak to them, it moves them in a way that cannot be explained.

One project, two minds

Clients love getting the opportunity to work with both Andreas and Naomi. “I think that’s very unique to us, working together as a couple,” Andreas says. “Naomi has an amazing ability to tune into people. When we meet a new client, she can really zero in on who they are and ask them things that stop them in their tracks, makes them think. And ultimately, when the artwork is produced, and it happens every time, they’re very moved; that this is very specific to them. And this pretty much Naomi initially tuning into them. And it is the two of us, that’s really important.”

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Cascading Marble Panels and Sustainable Materials Shine in New Community Health Center https://usenaturalstone.org/cascading-marble-panels-and-sustainable-materials-shine-in-new-community-health-center/ Thu, 22 Dec 2022 11:00:54 +0000 https://usenaturalstone.org/?p=10710 Occupying almost an entire city block in the Park Slope neighborhood of Brooklyn is the NewYork-Presbyterian Brooklyn Methodist Hospital Center for Community Health. The new 400,000-square-foot building, which took the last decade to construct, was designed using a variety of sustainable materials, most notably the Calacatta Caldia marble that adorns the walls, reception desk, kiosks, café counter, and credenza in the main lobby.

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Cascading Marble Panels and Sustainable Materials Shine in New Community Health Center

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An earlier version of this article appeared in the Spring 2022 edition of Building Stone Magazine. Photos appear courtesy of Jantile Specialties LLC.

Occupying almost an entire city block in the Park Slope neighborhood of Brooklyn is the NewYork-Presbyterian Brooklyn Methodist Hospital Center for Community Health. The new 400,000-square-foot building, which took the last decade to construct, was designed using a variety of sustainable materials, most notably the Calacatta Caldia marble that adorns the walls, reception desk, kiosks, café counter, and credenza in the main lobby.

Upon entering the lobby, guests are greeted by an 18-foot-tall feature wall, created using honeycomb-backed Calacatta Caldia panels. Custom cut into different sizes, the panels are installed in an overlapping staggered pattern, offering a contemporary aesthetic in a classic material. Because the wall is positioned like a corner, with the unique design wrapping around one side to the other, it is visible from all parts of the lobby, serving as the architectural focal point.

“We developed several different schemes and looked at a variety of different materials [for the feature wall], including large-format tile, mosaic tile, wood, glass, and backlit glass, and we proposed one in stone,” said Steven Wright, Associate Principal at Perkins Eastman Architects in New York, NY. “One of the clients’ requirements was that there shouldn’t be any horizontal shelves for dust to collect on because it’s an infection control issue. Our team, which included Senior Associate, Rico Stanlay, came up with the design for the stone wall. We were all in agreement that this design warranted special treatment and stone would be that material.”

The feature wall consists of 106 custom-made Calacatta Caldia marble panels assembled into six tiers, each partially cascading over the panel beneath it.

“Because the stone panels are three-dimensional, we had to get the grain to work around all the corners so when they were laid out, the grain would wrap all the exposed corners to make it look like massive chunks of stone,” Wright explained. “We were not consciously trying to mimic the look of a stone quarry, but there is a strong affinity between the different graining patterns and those square cuts.”

To harmonize with the wall’s design intent, the 20-foot-long, angular reception desk utilizes the Calacatta Caldia in a 2-cm-thick format. Adjacent to the wall and reception desk are two check-in kiosks and a credenza, which were also crafted from the 2-cm Italian marble.

Around 3,000 square feet of the stone was used for these elements, which was supplied by Marmi e Graniti d’Italia (MGI) in Massa, Tuscany.

 

Sourcing a prestigious stone

The team at Perkins Eastman collaborated with the client and stone contractor, Jantile Specialties, who helped procure the Calacatta Caldia. “The client purchased this specific block for another project and since it was not utilized for that site, the client wanted to incorporate it into NewYork-Presbyterian Brooklyn Methodist Hospital,” said Jennifer Coyne, project manager at Jantile Specialties in Armonk, NY.

Calacatta Caldia is a very prestigious material, which is extracted in the MGI-owned Rocchetta quarry in the Apuan Alps, one of the most renowned marble sources in the world.

“There is something special about the Apuan Alps, the ‘moon mountains.’ In this area, the extraction of ornamental stones has a centuries-old history, with the production of a great variety of marble that is unmatched elsewhere,” said Nicoletta Caruso, COO of MGI. “Apuan Caldia stands out for its value and interest, a contemporary material of excellence in the range of ‘whites.’ It is extracted in the Rocchetta area, located about 10 kilometers from the town of Massa in the province of Massa Carrara, from which the quarry takes its name.”

Excavation—at almost 3,000 feet above sea level—evolves on three fronts, in an environment designed by the unprecedented vertical and horizontal geometries of the marble bench walls at the Rochetta quarry.

Although a honed finish was applied to the Calacatta Caldia panels used for the project, the material sparkles when the light hits it, especially in the lobby where daylight is abundant.

 

Crafting the feature wall

After a handful of trips to MGI’s facility in Italy, the Calacatta Caldia marble was carefully hand selected and purchased before being shipped back to the United States. “There was a total of five visits to the factory throughout this project to ensure quality and consistency in material,” Coyne said.

“Working with natural stone, especially with a material like this, you start to cut through a block, and as you go from one side to the other, you often get surprises,” Wright added. “You don’t know what it’s going to be until you cut it open, so we had to scramble a bit in order to select the right pieces for the right locations.”

Of the five visits made to MGI, the final visit was for a dry lay approval. The teams at Jantile and Perkins Eastman, as well as the client and its design team, were all present for the dry lay of the feature wall to ensure color consistency and veining. “We needed to make sure they were wrapping the corners that we wanted and that the whole thing felt balanced, with the grain running in consistent patterns,” Wright said. “They laid the two walls out on the floor next to each other and I got up on one of the lifts to look down and make sure everything was flowing properly.”

Since the feature wall is composed of 106 different-sized pieces, with no two panels measuring the same, Wright and his team devised a special numbering system for fabrication and installation. Perkins Eastman provided templates for use in laying out the stone on the actual slabs. “Everything was labeled, boxed, and shipped like a jigsaw puzzle,” Wright explained. “We developed a system where each of the pieces was numbered in rows. Then, working from one side and then around the corner on the other elevation as well. Each piece was unique. We developed the geometry then gave it to Jantile to complete the shop drawings and fabrication.”

Although Wright has completed similar wall designs for other projects, this was “unique in every way.” The owner had high expectations, and “we all wanted to assure that this came out as envisioned,” he said. “The hospital was very concerned about this wall, especially since a few pieces of the shipment included for the reception desk were broken and we had to scramble to reselect some pieces and recalibrate the overall composition.”

 

An intricate installation

Once all pieces arrived in the United States, strategic fabrication and assembly were required to execute the feature wall as it was designed. “Putting together this wall, which is about 1,000 square feet of stone, wasn’t straightforward,” Wright said. “It took a lot of effort from a number of people all working together to get it right.”

Each panel had its own individual clipping system of varying lengths, which was integral to achieving the overall design. “The clips were all custom fabricated,” Wright said. “Each one had to be a precise size. Each piece of stone had at least two clips, some had more. You could imagine how difficult it was to put together.”

It was imperative every individual panel be placed in the precise location, according to Coyne. “In order to achieve the wall’s dimension, six custom J anchors were made in lengths varying from 1 to 6 inches to create the final ‘push/pull effect,’” she explained of the installation process, which allowed installers to hang the panels like picture frames. “A specific drawing was created to coordinate all anchor locations on both the substrate and the stone panels, guaranteeing all would align during the installation process.

“For the first course, the panels were either epoxied directly to the substrate or hung on one of the project’s shorter anchors,” Coyne shared. “The anchors in the second course were slightly longer than those used in the first course and the process continued up the wall. To alleviate the weight of the stone panels on the anchors, extra layers of plywood were added to the substrate for the third through sixth courses. This somewhat mirrored the ‘stepping’ effect seen in the stone and allowed the stone panel weight to be more evenly distributed across the wall.”

It took approximately eight months for complete fabrication of the feature wall, with an additional four weeks for drawing approvals and four weeks for onsite installation. “An initial crew of two was used to uncrate and lay out all materials. Once the team started installation and got into a rhythm, a second crew of two was added,” Coyne said. “The process was rather slow, as the panels fit like keys and required a specific order of installation. Each panel could only be installed after a specific panel before it. If one panel was installed even slightly out of place or out of level, it would have an impact on the panel that followed thereafter and thus impacting the entire wall.”

Coyne and Wright both agreed that the feature wall required extra thought and focus, as it was the most intricate aspect of the entire project. “All in all, I think it was a really good team effort from Jantile, the construction manager, the owner and their interiors department/design team,” Wright said.

While the feature wall was completely fabricated in Italy, with onsite modifications in the United States, the marble slabs used for the reception desk, kiosks, credenza, café, and other elements throughout the hospital were shipped directly to Jantile’s facility in Armonk, New York, where they were fabricated and dry laid before being transported to the hospital for final finishes and installation.

“We also designed the adjacent café, which features the same Caldia marble on the counter, as well as a small area in the Cancer Center on the sixth floor,” Wright said. “There’s something really nice about looking at natural stone opposed to other materials. It feels nicer and has a high visual interest.”

With COVID-19 delays and other supply chain issues, the entire hospital took around 10 years to complete, with most of the hands-on work completed in the last five years. “I think the building fits into its neighborhood as well as any building of this size could,” Wright said. “The experience of coming into the lobby – a very calm space – really helps patients feel welcomed and appreciated. I think it’s an uplifting space without being overwhelming. The stone really helps to ground that feeling of being the center of the experience.”

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Natural Stone vs. Manmade Materials for Exteriors https://usenaturalstone.org/natural-stone-vs-manmade-materials-for-exteriors/ Tue, 21 Jun 2022 19:40:40 +0000 https://usenaturalstone.org/?p=10333 While design trends come and go, natural stone remains a timeless and flexible option for many exterior applications including cladding, paving, and hardscapes. It is important to know how the material chosen for an exterior project will perform under a variety of circumstances, conditions, and uses.

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Natural Stone vs. Manmade Materials for Exteriors

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Comparing the performance attributes of natural stone with manmade materials

 

Exterior Design

While design trends come and go, natural stone remains a timeless and flexible option for many exterior applications including cladding, paving, and hardscapes. This is due to the variety of natural stone types available that are beautiful, durable, and versatile. No wonder so many manmade materials try to emulate or replicate these characteristics and qualities.

It is important to know how the material chosen for an exterior project will perform under a variety of circumstances, conditions, and uses. It is also essential to understand how natural stone compares to manmade materials used for the same applications in order to select the material that will perform the best. At the same time, knowing how the material impacts the environment will ensure that you are choosing the most sustainable material for the application.

Photo courtesy of Connecticut Stone.

Performance Matters

A material’s optimal performance is based on a combination of the attributes of the material itself, how the material is installed, and the conditions to which it is exposed. There are many different issues to consider:

  • How will the material hold up under freeze/thaw conditions? Continued cycles of freezing and thawing can cause some materials to degrade more quickly.
  • Does it have good UV resistance and solar reflectance? Many materials will break down over time or change appearances when exposed to UV light.
  • Does the material have a low absorption rate? Materials with lower absorption rates tend to be more stain resistant. Sealing a material can lower its absorption rate and improve its performance.
  • Is the material slip-resistant? Slip resistance is the level of traction needed for a walking surface to remain safe for those using it. Slip resistance is impacted by the material’s texture and porosity, as well as any surface treatments used and elements it is exposed to, including water and dust.

Performance attributes should be addressed no matter what material you’re considering or what type of project you’re working on. These factors play an even more important role in sustainability and in the long-term performance of the material. Let’s examine how natural stone stacks up to manmade materials from the perspective of these performance objectives.

Photo courtesy of Gallegos.

Exterior Applications for Natural Stone versus Manmade Materials

Cladding and Veneer
The possibilities for natural stone cladding and veneer are endless. Limestone, granite, marble, travertine, basalt, slate, quartzite, and sandstone are among the many options. These stones are versatile, meaning they can be cut and finished into different shapes, textures, and patterns, creating a cohesive aesthetic. Many stones are durable in extreme weather conditions. When discussing vertical stone applications, the installation standards and techniques can make even vulnerable stones durable. Most stones have a long life span. Light colored stones have a high solar reflectance index, meaning they will reflect the sun well, reducing heat gain on the building or site. Stone also has a low embodied energy, an important consideration for sustainability requirements. This is because natural stone was created by the Earth and very little energy or additional resources are needed to quarry, fabricate, and finish it. Some stones are porous and may stain if subjected to contaminates over time. Depending on the stone’s mineral composition it may be susceptible to the effects of acid rain. Natural stone may sometimes have a higher initial cost than manmade materials, but it often proves to be the most cost-effective choice because it lasts so long. This is especially true because natural stone can also be refinished, repaired, restored, or recycled.

Manmade materials including porcelain, concrete, GFRC panels, metal, and terracotta are also options for exterior cladding.  Concrete and porcelain are durable and UV stable; good choices for the exterior and the exposure to sunlight and the elements they must withstand. However, these materials do not typically last as long as stone. Concrete, in the form of cast stone and cultured stone, is often tinted and can fade heavily from sunlight/UV exposure. Some manufacturers are improving the color fastness of cultured stone, but that adds chemicals and cost to the final product. Some manmade materials can also sometimes look flat since they are often made to be uniform in appearance and lack the natural veining and textures of natural stone. Most of them also have a high embodied energy because they require a wide range of other materials and energy intensive processes to be manufactured.

Paving
Natural stones including granite, sandstone, basalt, limestone, slate, travertine, marble, and porphyry are good options for paving. Again, one of the main performance aspects of using natural stone in this manner is its incredible durability. Surfaces can also be finished for slip-resistance and design options abound with more edging, pattern, surface texture, and color than manmade surfaces. Many natural stones perform very well in freeze/thaw environments and conditions. In some cases, natural stone will cost less than porcelain or concrete imitations. Once again, the low embodied energy of natural stone makes it a great option for meeting sustainability goals. The installation of natural stone may be more costly than some manmade materials and it may need to be sealed, depending on the type of stone, location, and environmental conditions. However, as mentioned previously, natural stone’s long life cycle makes it a very cost-effective choice.

Concrete, clay, and porcelain are among the manmade materials used for paving. A few of the pros of using these materials include the possibility of lower replacement and maintenance costs for concrete, and that porcelain is UV stable. There are limited texture options for concrete, which can contribute to a lower cost for the material. Quite often though, concrete fades and the material takes on a very aggregate-like appearance and will lose its color. New technologies are improving surface wear, color fastness, texture, and stain resistance. However, these add quite a bit to the cost and in some cases will make it more expensive than natural stone. For clay, the use of sand mold and wire cut production methods will yield a paver that has a high absorption rate and may have significant issues with salts and efflorescence. These pavers require a more costly installation process due to their larger sizing tolerance issues created by the moisture and firing process. There are pavers created with a compressed production process which perform better but still have performance issues and are not as durable as most natural stones.  High fired or vitrified clay pavers can be very hard and durable, but also very brittle. Porcelain behaves like glass and can also be very brittle, especially in a dry set application in a freeze thaw environment, so it will need to be set with spacers to protect itself in the winter. Porcelain has no absorption, so water will just sit on the surface. The water needs to evaporate or surface drain, so in the winter this can create a very slick surface and be dangerous. These products also have high embodied energy, which creates a negative impact on the environment.

Eden limestone dimensional flagstone. Photo courtesy of Lurvey Supply.

Natural Stone and Sustainability

Natural stone has demonstrated considerable durability in local and regional environments and applications. In many cases, these have lasted for hundreds of years, even millennia. Most manmade materials have not been around long enough to demonstrate that level of performance. The qualities of longevity and durability have proven that natural stone is also a great choice for meeting green building goals. The initial material and installation costs are offset by the long life expectancy and low maintenance requirements. Little to no cleaning or chemicals are required to maintain the material and as mentioned, natural stone can also be refinished, repaired, restored, or recycled. Natural stone is 100% natural. Engineered quartz, concrete, and porcelain require many different materials including chemicals to be manufactured and many of them are not recyclable.

So, as Oscar Wilde once said: “Imitation is the sincerest form of flattery that mediocrity can pay to greatness.” Choose natural stone and you will be contributing to the long legacy of great, high-performing, sustainable projects in the world.

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Natural Thin Stone Veneer Patterns Explained https://usenaturalstone.org/natural-thin-stone-veneer-patterns-explained/ Fri, 20 May 2022 17:26:30 +0000 https://usenaturalstone.org/?p=10273 If you have researched natural thin stone veneer or spent any time on the internet seeking inspiration, you already know one thing: there are more options to personalize your space than you imagined! With the right planning and approach, the range of choices is beneficial because each pattern has different characteristics

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Natural Thin Stone Veneer Patterns Explained

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Reprinted with permission from Delgado Stone. All photos courtesy of Delgado Stone.

If you have researched natural thin stone veneer or spent any time on the internet seeking inspiration, you already know one thing: there are more options to personalize your space than you imagined! Natural stone is quarried across the world in a variety of types, color schemes, patterns, and shapes.

With the right planning and approach, the range of choices is beneficial because each pattern has different characteristics. The traits you like the most about a particular stone can be enhanced by the pattern you choose. This article covers five popular patterns: The Mosaic, Strip, and Roughly Square and Rectangle patterns feature the stone face, while the Ledgestone and Ashlar patterns showcase the end grain. Here is a closer look at each.

 

Ashlar

The Ashlar pattern is a combination of approximately 50% rectangular Strip pieces, 25% Ledge pieces, and 25% small squares. The combination of these three patterns provides the mason with the flexibility to create a unique design for each project. In the photo below, Northeast Walls and Patios installed Colonial Tan thin stone veneer in the Ashlar pattern for the new home’s entryway, pillars, and arch siding.

 

Ledgestone Pattern

Ledgestone (otherwise referred to as Ledge) is made up of thin cut pieces of natural stone often used for siding. These end-grain pieces run in size approximately 1”-4” in height and 6”-14” in length. This pattern creates a unique, layered look when used for stone walls or fireplaces, as you can see in the photo below, featuring design and install by Rockport Post and Beam and Larry Luce Masonry, LLC. The smallest pattern of the five in this article, Ledgestone can be used for a wide range of projects, from home siding to step risers.

 

Mosaic Pattern

The Mosaic pattern includes irregular shapes that fit together like a puzzle, allowing you to create your own unique design. The face surface ranges from approximately .25 to 1.25 square feet. Mosaic patterns are a popular choice to give projects a more natural, rustic look. The accent wall below, featuring Connecticut Blend thin stone veneer and the talents of JJ Stone Design and Masonry, is a great example of how a little stone makes a big impact.

 

Roughly Square and Rectangle

Otherwise called Square & Rec, these pieces are roughly 6”x6” and larger, while the rectangle pieces are longer. In contrast to the Mosaic pattern, Square & Rec is used to create a clean and more modern look. Often used for exterior siding, Square & Rec offers a smooth, consistent shape that puts the focus on the color choice and range. The photo below shows a Connecticut project by J. Salvatore & Sons using Square and Rec on the entrance to coordinate with the front of the home.

 

Strip Pattern

Strip is the pattern that most resembles the layout of brick. The face ranges from approximately 5-8” in height and 12-18” in length. Stones are all cut to almost the same size so they fit together to create a smooth, flat surface. The rectangular shape makes the Strip pattern a good fit for projects needing consistent and longer stones. The fireplace below features the talents of Lakeside Masonry using Spruce Mountain strip patterned thin stone veneer.

Even with a wide range of options, there are no bounds for imagination and creativity. Patterns can be mixed and matched. Homeowners often coordinate with their masons and stone dealers to select a truly customized design that fits their individual project. We love seeing the way these projects maximize the impact of natural stone and showcase the talents of the designers and installers!

 

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4 Ways to Use Natural Thin Stone Veneer https://usenaturalstone.org/4-ways-to-use-natural-thin-stone-veneer/ Fri, 04 Jun 2021 20:59:10 +0000 https://usenaturalstone.org/?p=9068 Natural thin stone veneer is only at the beginning of its potential. It continues to have a positive impact on many different design concepts and features.

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4 Ways to Use Natural Thin Stone Veneer

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All photos courtesy of Delgado Stone.

Natural stone is mother nature’s oldest building material and has been used throughout history to create countless commercial and residential features. The characteristics of natural stone provide a balance of beauty and functionality to any project. Thin stone veneer was introduced in the twentieth century, but only in the last 5-7 years has it become a premier choice in the natural stone industry.

 

What is natural thin stone veneer?

Thin stone veneer is a form of natural stone veneer that has been sawn to approximately 1” thickness with a ¼” tolerance allowed. To be classified as thin stone veneer, each piece must weigh less than 15lbs per sq/ft.

Thinstone Thickness

The introduction of these sawn, lighter-weight pieces created ease of installation and provided the appearance of full-depth stone without sacrificing any of the beauty of natural stone. Here are four of the most common applications for natural thin stone veneer.

 

1. Fireplaces

Natural stone has always been a popular choice for fireplaces, due to its heat-resistant properties and versatile appearance. Designers and stone masons are now often choosing natural thin stone veneer to save time during construction while still offering the beauty and impact of other natural stone options. Natural thin stone veneer can be used on both interior and exterior fireplace projects to create unique designs.

 

 

2. Exterior Stone Cladding

Stone cladding is an ever-growing use for natural thin stone veneer because of the material’s durability and look. When building a home, longevity is an important factor to consider and choosing natural stone cladding is a commitment to durability. Natural stone cladding can be used for entryways, to cover cement foundations, or for the entirety of a home’s exterior. Regardless of the amount of natural stone used, choosing natural stone for home design will continue to be a common trend as long as natural stone continues to complement other home design features. As an added perk, natural stone holds 93% of its original value at its peak, which is a higher percentile than most cladding options.

Connecticut Blend Mosaic Exterior Cladding

 

3. Natural Stone Walls

If you’re ever been to New England, you’ve seen stone walls that look like they have been there forever. Before mortar, wall caps, and decorative walls, property lines were marked by fieldstone walls that also helped keep animals out. Now retaining walls with decorative natural thin stone veneers are more common because of the ease of building cinderblock walls and adhering natural thin stone veneer to the surface. Walls like the one seen here still serve a function, marking the property line while also contributing to the appeal of the landscape design.

Nutmeg Ridge Mosaic Landscape Wall

4. Outdoor Living Features

Landscape and exterior home improvement projects continue to be a major trend, and natural thin stone veneer plays a major role in these types of projects. More outdoor kitchens, fire pits and fireplaces are created every day. Even using a small amount of natural thin stone veneer can transform a pool project or turn a fire pit project into a statement feature.

 

 

Natural thin stone veneer is only at the beginning of its potential and continues to have a positive impact on many different design concepts and features outside of these popular applications. With the sustainable, beautiful, and functional characteristics of natural stone, we will inevitably see more projects choosing natural thin stone veneer.

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A New Take on a Classic Icon: The Winged Goddess of Victory https://usenaturalstone.org/a-new-take-on-a-classic-icon-the-winged-goddess-of-victory/ Thu, 18 Jun 2020 19:05:00 +0000 https://usenaturalstone.org/?p=7725 A Hellenistic sculpture of Nike of Samothrace is one of the world’s most celebrated sculptures. In 2017, it inspired a private Fortune 100 company in Portland, Oregon to reinvent the iconic artwork in the form of a stone wall carving.

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A New Take on a Classic Icon: The Winged Goddess of Victory

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An earlier version of this article appeared in Building Stone Magazine.

 

In Ancient Greece, the goddess Nike personified victory. She was a messenger whose wings enabled her to fly over the Earth rewarding victors of battle or athletic competition with fame and glory. The most famous depiction of Nike is the Winged Victory of Samothrace, also known as Nike of Samothrace. This marble Hellenistic sculpture dates to the second century BC and is one of the world’s most celebrated sculptures. In 2017, it caught the eye of a private Fortune 100 company in Portland, Oregon, who tasked a talented team of professionals to reinvent the iconic artwork on the wall of the executive boardroom at its corporate headquarters.

 

Reimagining a Classic

Peter Andrusko, master sculptor and owner of The Andrusko Group in Portland has been crafting stone sculptures for over thirty years. “The Winged Goddess of Victory,” a 15-foot-tall, 18-foot-wide bas-relief comprised of basalt and granite, is one of the most complicated and technically challenging projects he has ever worked on. “I’ve never done anything even remotely as complex,” he said.

“In May of 2017, I was approached by the project manager for special arts projects’ at Hoffman Construction Company and began a dialogue about the viability of creating a massive stone bas-relief sculpture. When I was approached by one of the West Coast’s leading general contractors, I was thrilled. They had found me, which in a sense partly validated decades of effort on my part in trying to become known as a source of quality and innovation in a very obscure artisan niche.”

Andrusko learned some “old school” stone techniques from his father, a successful brick and stone mason, but is mostly self-taught, specifically in robotic Computer Numerical Control (CNC) technology, which has been beneficial to his business. “Robotics is not only the future, more importantly, it’s an absolute gift of life to the carver,” he said. “About 15 years ago, the robotics industry changed and started becoming accessible to workshops. Let’s just say it’s a very natural fit and what I know of hand-craft and my natural abilities in technology found a very, very interesting nexus.”

To create The Winged Goddess of Victory sculpture and wall design, which relied on robotic CNC machinery, Andrusko utilized a basalt quarried in Moses Lake, WA, which was supplied by Stone NW in Vancouver, WA, and Indian Black granite from Savema in Pietrasanta, Italy. “This work is constructed from a very hard, dense and brittle local black basalt, which was then inlayed into a field of waterjet textured Italian black granite tile,” Andrusko said. “There is also some lettering carved into the granite, which is also the product of my studio and hand.”

The basalt used for the sculptural elements is a ubiquitous Pacific Northwestern material that is available in various colors, textures, and forms. “In this particular case, it’s an amazingly tight-grained satiny black that takes a polish,” said Andrusko, who worked with a local stone company that cut the rough blocks to-size and supplied the slabs, which were then cut to fit the super tight specs needed for the project. “The core block dimension is 3 x 6 x 24 inches. Of that overall depth, the carving is contained within just 2 1/2 inches of depth and is then inlayed into the Graffiti granite paneling covering the wall.

According to Andrusko, there are over 300 parts in the finished piece, many of which were first roughed into shape with CNC robotics technology, then hand-finished and fitted into the cut-to-fit granite. “It is a process essentially similar to the one used by many stone carving studios throughout time—in this case, using robotic machines instead of human workers, such as those famously employed by Rodin in his studio to perform the roughing from the original models, which in this case are digital files.”

 

Technology and Design

When designing the 7,500-pound sculpture, Andrusko worked with a professional digital art team, which created the digital renderings from which he worked. “The first and most important aspect of the project was the artwork,” the sculptor explained. “Initially, I was asked to provide the artwork, but the delivery date required for the completed work was rapidly approaching, so they hired a professional digital art team. We worked closely together during the first few months to refine the design. I produced an initial scale model of the carving in high-density urethane along with a full-size section that was approximately 4 x 5 feet.” After receiving feedback on the first scale model, a second was commissioned to confirm the changes would meet the demanding attention to detail.”  Based on feedback of the first scale model, a second was commissioned to confirm the changes would meet the demanding attention to detail.

According to Andrusko, the anticipated weight of the stone on its own was intimidating.  “The immediate need was to minimize the overall mass—getting as much detail as possible for something of this scale necessitated a balance between weight reduction (thickness of the module) and down-lighting. Also, keep in mind that all of this mass is hanging off the wall structure along a thin ribbon of floor inside of a modern-constructed building on an upper floor. Due diligence required some engineering attention.”

A compromise was found by creating a 3-inch thickness overall, with a 2 1/2-inch maximum range to work within. “This got us our range and the digital arts team was able to model the lighting and the relief topography to maximize the effect visually,” Andrusko said. “The reality is that there is a massive amount of ambient light in the space, which interferes to some degree with the LED down-light effect during the day, but some of the imagery was taken at night and one can see an amazing depth and clarity of surface that is truly a wonder; it appears far deeper and more defined than the 2 1/2 inches would suggest. A success by the design team and lighting specialists.”

The design team used displacement mapping to create the digital renderings, an alternative computer graphics technique that uses a texture map or heightmap to cause an effect where the actual geometric position of points over the textured surface are displaced, which gives surfaces a great sense of depth and detail, permitting self-occlusion, self-shadowing and silhouettes.

“The value of this is that the computer software I used to develop the cut files can accurately manage the range of black (lowest point) to white (highest point), which are, in essence, user-definable, which allows the Z-axis to be established properly so that everything fits in 3D,” Andrusko detailed. “The hand-carving is to blend and fit everything and to put the finishing touch into the carving.

“There was a great deal of struggling with the size of the file initially and trying to solve some problems like positioning into the fixed grid of the field materials that needed to be discussed and established before breaking the image into precise parts,” Andrusko explained. “Also, the client insisted on 1/16-inch tolerances between parts. Once all the grid issues were worked out, then the parts were segmented into the modules. I broke out the grid elements in granite from the basalt and cut stencils to mark and fit the granite part by part — hand-cut with a ring saw. I initially proposed that this be done with a waterjet, but in the midst of the time crunch, I elected to keep this in-house to cut by hand while the CNC machines were running. It turned out to be a very good decision for reasons I wasn’t expecting having to do with the final fitting. The G-code files were generated to run the machines and smaller parts were nested into the stones in groups. Everything was coded and numbered so that the parts could be fitted and mapped for the installation team.”

Constructing the 300 parts for the project required an intricate process. “The parts cutting involved an initial ‘roughing’ stage of milling,” Andrusko explained. “About 1/16 inch passes to get to the core shape of the part. The secondary stage of milling involved a smaller bit and a change of trajectory that netted the finished part fairly close to the final dimensions needed. That final step involved stacking the stones into a grid, hand-finishing and cleaning, and tightening the cuts and sharp edges in order to have a smooth transition between adjacent parts. The largest single area I was able to get flat at one time in the studio was approximately 4 x 4 feet.”

While the digital technology was needed to create a sculpture of this stature in such a short amount of time, Andrusko believes that hand-carving was still a key factor in the project’s success. “The robotics utilized in the studio amplifies the productive output of the carver manifold, but it still requires the breath of life of the master carver to perform the final steps by hand to finish and detail the sculpture,” he said. “However, what the technology allows is for a single individual to perform the work of dozens of people working practically non-stop for months on end.”

Even with the aid of technology, completing the project was still an arduous task. “I was able to keep running six CNC machines alone for most of four and a half months,” Andrusko said. “My day started at around 5 a.m. and ended at or near 10 p.m. Cutting hard stone requires a very attentive focus. Water supply is critical or there could be a fire, bit break, damage to the work piece, or at minimum a whole bunch of wasted time, so there was no practical way to run the machines all day every day as much as I wanted to or would have liked to. The machines needed to be monitored constantly and any instances of failure caught and corrected as soon as possible. I was often literally running and constantly on my feet moving between machines, changing parts out, swapping bits, clearing obstructed water lines and quickly became attuned to the sounds (healthy and otherwise) of each machine in the studio. I stopped keeping track of time, but it was a relentless grind of 14 to 18 hours a day, seven days a week, and other than a few hours for Thanksgiving and Christmas with family, it didn’t stop until I was done.”

 

The Installation

Andrusko gives the majority of the credit for the success of the installation to the project manager at Hoffman Construction Company and the installation team at Western Tile & Marble. “This was very much a team effort and the success of the whole was really a shared collaborative effort,” he said.

The installation, which was completed in about a month, required one stone mason and three tile setters. The team bonded the wall tiles to USG Corporation’s Durock Brand Cement Backer Board using Laticrete’s 257 Titanium thinset mortar, which is designed for the installation of large-format tiles and gauged porcelain tile panels and slabs. “Thicker carved stones were installed with Latapoxy 310 Stone Adhesive,” said Floyd Goodwin, project manager at Western Tile & Marble. “We used copper wire anchors into studs.”

Goodwin explained how the heavy, irregularly shaped tiles needed to be carefully installed to ensure flatness and desired joint thickness. “Maintaining joint dimensions and plumb was crucial because the carved stone had irregular edges and the substrate was wavy,” Goodwin said.

In addition to Laticrete’s 257 Titanium and Latapoxy 310 Stone Adhesive, the installation team also utilized Laticrete’s Permacolor Select cement grout and Latasil silicone sealant.

“They are truly professional craftsmen and I know they were also working under extreme stress and with a really tight schedule,” Andrusko said of the team. “They took my work and completed the site installation without a break or a scratch. I wasn’t needed onsite. There wasn’t a single punch list item related to the sculpture.”

Since the project’s completion, visitors have been amazed by the artwork and its resemblance to the original Winged Victory of Samothrace. “The client loves it,” said Goodwin.

The project received a 2018 Pinnacle Award from the Natural Stone Institute in the Architectural Carving/Lettering/Sculpture category. “One would assume the hope of any artist is to somehow imbue the breath of life into the inanimate; to effect in some profound way the beholder of the work,” Andrusko said. “That this now exists in the physical world where others can experience it makes me very happy.”

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The DNA of Stone Design https://usenaturalstone.org/the-dna-of-stone-design/ Fri, 21 Jun 2019 00:20:48 +0000 https://usenaturalstone.org/?p=6621 Designers are always waiting for the rumor that something astonishing has been found, so passion can engineer gigantic ideas that will surpass our previous project. We seek to create a design that will pay great respect to the geological wonders.

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The DNA of Stone Design

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Note: An earlier version of this article originally appeared in Masonry Design Magazine.

The author at a quarry in Northern Italy.

As a stone designer, I am intrigued with and will collect anything unusual extracted from the earth. Since childhood, I’ve been fascinated with the journey of a stone and inspired as an artist to find spectacular, awe-inspiring gems that will become a masterpiece in a designer’s portfolio.

Designers are always waiting for the rumor that something astonishing has been found, so passion can engineer gigantic ideas that will surpass our previous project. We seek to create a design that will pay great respect to the geological wonders.

One never knows how deep, far, or long one must dig, sifting through the dirt before finding a worthwhile stone. But once an unusual find is exhumed, it soon becomes the talk of the industry and the centerpiece to a new luxurious space.

 

Quarry Tales

Photo courtesy of Neil Landino for Gregory Lombardi Design.

The quarry has a mystical charisma that shimmers and whispers behind the shadows, releasing intense captivating stories and energy from the past. Natural stone like granite, marble, and quartzite takes you back in time and contains millions of years of geological history. It extracts secrets, history, and beauty. It creates a deeper understanding of the turbulent creation of our earth. As stone specialists, we try to understand and predict prehistoric materials and how they might be relevant today.

Passion for natural stone leaves many breathless and is the collateral for many sparkling unique friendships. I have met exciting, high-voltage collectors from all over the world who need tranquilizers when talking about their love of natural stone.

Stone projects of all kinds rely on imaginative design. When I see a new rock, I can’t wait to create its new use and locate its new home. The design world is small and the adventure to be the first to use something just discovered is a world of adventure for any stone professional. My design clients are always hoping to be the first to see new stone. They are waiting for my call alerting them that something new is on the market, perfect for the project they are brewing.

 

Turning Dreams to Reality

Photo courtesy of Gregory Lombardi Design Inc., Zen Associates..

Our quest to be surrounded by the marvels of Mother Nature is influencing design more than ever.  Once the unique stone has been found, we return to our blueprints feeling inspired. Design masters worldwide will use their talent and imagination to create a dreamy space that can shake our soul and make us feel brand new. Once we have procured the objects, we then seek the advice of stone masons and fabricators who will cut, grind, carve, and polish the dream into reality.

New England is a region that craves outdoor living spaces. With short balmy seasons, designs must be flexible, top performing, stable, and engineered with extreme weather consideration. Extreme freeze-thaw cycles can create an expansion that can crack, chip, and irritate elegant installations.

Ruggedly built spaces that remain delicate and worthy of royalty have designers like me on the hunt for materials that can stand the test of time. Natural stone serves as both exquisite and invaluable for the outdoor room.

There is a thin, almost invisible wall that divides the world of interior and exterior stone use. Walls of glass with continuous rock gardens allow one to enjoy these spaces year-round. Clever placement of natural stone can connect your home to the beauty of the outdoors.

 

Design that Awakens the Spirits of Another Time

Stone chambers and modern-day fire pits have us designing spaces that reach back to a time when fire was first used for warmth, protection, cooking, and bonding. We create these spaces as unique and intimate gathering spots that reconnect us, perhaps, to our ancestors.

Photo courtesy of Gregory Lombardi Design Inc., Zen Associates.

Outdoor kitchens embellish our landscape and have become works of art that draw us to the outdoors. They yank us from the screens of our electronic devices and return us to simpler times surrounded by the stars, wind, trees, birds, and wildlife. Outdoor spaces give you a spot to hear yourself think, dream, appreciate, and improve.

There is nothing like the original New England recipe for using natural stone. There is something magical about driving down an old country road and seeing earthy, moss-covered, textured patina covered rocks that some of our greatest writers have written about.

I am only one writer among many who enjoys telling this tale. Writer John-Manuel Andriote writes in his incredible article about geologist Robert M Thorson’s study on the walls of New England: “It was American Poet Laureate Robert Frost, perhaps more than anyone else, who imbued New England’s stone walls with mythological significance. Frost’s poetry helped solidify the heroic, all-American image of the Yankee farmer — independent, self-reliant and resilient — standing up, defiantly, to the relentless stone.” Thorson says that for Frost, “stone walls were more than symbols. They were oracles.”

 

The Enduring Legacy of Natural Stone

The fusion of wood, glass, stone, and metal truly awaken my design spirit as an artist. I have been weaving these materials together since I was a teen. These unique combinations support each other and cast their own spell. Unique stone structures tell dazzling stories that speak to stability and the significance of preserving our great outdoors. Natural stone remains popular because it sings the rhythm of the earth.

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Bookmatching: Geology Meets Geometry https://usenaturalstone.org/bookmatching/ Fri, 21 Dec 2018 08:00:10 +0000 https://usenaturalstone.org/?p=4800 Bookmatched slabs sometimes look like butterflies, or Rorschach (inkblot) tests, or many other fanciful shapes. Bar none, bookmatched slabs are one of the most dramatic and impressive ways to use natural stone.

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Bookmatching: Geology Meets Geometry

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You probably came here to read about marble, but for now, let’s talk about marble rye. The perfect medium for a salami, Swiss, and arugula sandwich. When it’s time to make a sandwich, I reach in the bag, grab two neighboring slices of bread, put them on a plate, and then flop them open like I’m opening a book. (A book about sandwiches, no doubt.)

Bookmatched Azul Imperiale.

The same idea – minus the salami – applies to marble stone slabs, as well. When two neighboring slabs are ‘opened up’ and polished on the surfaces that were facing each other, the pattern on each stone will be virtually identical, except they will be mirror images of each other. These twin slabs can then be arranged along a common edge to produce a stunning, kaleidoscopic pattern. Bookmatched slabs sometimes look like butterflies, or Rorschach (inkblot) tests, or many other fanciful shapes. Bar none, bookmatched slabs are one of the most dramatic and impressive ways to use natural stone.

Best places for bookmatching

A pair of bookmatched slabs commands a lot of attention. For maximum effect, these statement pieces should be used where there’s ample room to accommodate a large expanse of stone, like a big kitchen island, a conference room table, a wall, or an oversized shower. If you have a large area to cover, bookmatching is a handy way to ensure that the pattern runs fluidly from one piece to the next.

It’s not a great idea to cram a bookmatched pattern into a surface that’s interrupted by corners, cutouts, and appliances. The bigger the expanse, the greater the impact. That said, a bookmatched pattern need not be limited to full slabs. Smaller pieces of bookmatched stone are often used in flooring tile or backsplashes.

Variations on the bookmatch

Diamond matched marble wall. Photo courtesy of United Marble Fabricators.

If the standard two-slab bookmatch is somehow insufficient to satisfy your design tastes, you can take it up a notch with diamond-matching (also called quad-matching). This arrangement uses four pieces of stone, and is so named because it commonly produces a diamond-shaped pattern.

Bookmatched pieces needn’t be all on the same plane, either. A vertical slab on a wall can be mated to its twin on a horizontal countertop or bathtub surround, for example.  This gives an immersive effect, as if you are sitting inside of a vast block of stone.

Another variation on the theme is called vein-matching (or slip-matching), where the key visual elements of the slabs are matched to flow across seams and produce a continuous pattern. Vein-matching is commonly seen on ‘waterfall’ arrangements, where a horizontal countertop joins a vertical panel of stone that runs from the countertop down to the floor, or from the countertop up to the backsplash. Vein match in these instances is typically preferred over bookmatch.

Considerations when hunting for slabs

At the quarry, large blocks of stone are removed from the ground, then shipped to a facility for processing. Here, the big blocks are sliced into slabs. When the slabs are all polished on the same side, it’s called “consecutive” polishing (also called “sequential” polishing). These slabs are usually numbered so you can purchase neighboring slabs if needed.

To create a near-perfectly matched pattern, the surfaces of two neighboring slabs have to be processed so the surfaces that were facing each other are both polished. This operation is usually done when the slabs are cut from the block, and is not commonly done at a fabricator’s shop. In some cases it’s possible to convert sequential slabs to bookmatched slabs by polishing the back side of one of the slabs. But it’s less hassle and more reliable if the slabs were originally processed and polished with bookmatching in mind.

Because bookmatched slabs generally originate at the sawyer, there can be significant lead time if stone needs to be ordered. Plan ahead and be patient – the wait will be more that worth it.

Bookmatching tends to be more expensive than a standard layout, because in every case two slabs are needed, even if the area to be covered is not that large. And if one slab is lost to breakage or other issues, the entire layout of slabs can be lost due to the irreplaceability of the one slab. The painstaking planning and fabrication required to execute a precise match-up of the pieces may also add to the cost.

Any of the four edges of the slabs can be aligned. Showrooms often have bookmatched slabs on display like an open book, but keep in mind you can swap them left to right – or top to bottom – if you want. Each arrangement will yield a different pattern. You can mock up different variations to visualize the possible outcomes. The images below were created in PowerPoint by importing a single picture of a slab, copying it, making a mirror image of it, then dragging and rotating the two shapes to make different designs. For those who prefer a hands-on approach, you can print two photographs of the slab and fiddle with various layouts. (Warning: Regardless of the method, this is a mesmerizing and addictive process!)

While these graphics are electronically generated and show perfect mirror images, such perfection is not attainable in actual stone fabrication due to variation within the stone. Even in neighboring slabs, the patterns can vary over short distances, depending on the nature of the pattern and the direction of the grain. So, it is wise to expect a certain amount of non-uniformity amongst sibling slabs.

Since bookmatching requires two pieces of stone to be placed exactly next to each other, the edges of the slabs that are destined to be joined together have to be in near-perfect condition. Any chips, cracks, or awkward areas that are trimmed off of one of the slabs must also be removed from its mate.

Patterns: The good, the bad, and the whaaat?

Bookmatched Fusion granite.

The natural colors and patterns in stone will almost look amplified when presented in the mirror-image arrangement of a bookmatched pair. A certain amount of movement is required to create a visually interesting effect, but an overly complex stone can cause sensory overload. Stones with soft hues and flowing movement, like marble, will create a beautiful look that’s not too jarring. Vivid slabs with bright colors and high-contrast patterns are not for the faint of heart, but offer an unforgettable statement.

It’s practically inevitable that you’ll see images in the adjoining stones. Maybe it will look like a beautiful flower or a snowy owl. Or… maybe you’ll see the face of a malevolent goblin, or, heaven forbid, something resembling the, ummm, human anatomy? Once seen, these forms can’t be unseen; they will greet you every time you walk in the room. So take your time and carefully examine the potential designs and shapes you’ll end up with once the stones are cut and assembled.

Craftsmanship and communication

A downside to bookmatching is that there is little room for error in the fabrication and installation. The trimming and alignment of the slabs has to be spot-on. For this reason, careful communication with your fabricator is absolutely essential. Don’t assume you both know which way the slabs will be oriented and which parts will be cut off. Make sure that the fabricator has plenty of experience with bookmatched slabs, and that you share the exact same vision for the final product.

The best way to visualize and communicate the plans is with is with photographic images, mockups, and a dry-lay of the stone panels prior to installation. Many fabricators have the ability to import images of the slabs into computer software and then decide where each cut and seam will go. It’s imperative to go through this step together, and to sign off on the final plan. Neither the customer nor the fabricator wants any surprises on installation day, so if there was ever a time to be extra-careful in the planning phase, this is it.

Bookmatching is natural stone at its best

The coolest thing about bookmatching is that it takes the patterns of geology, which are plenty awesome on their own, and boosts them to an almost supernatural aesthetic. If you feel there’s no artist that can rival Mother Nature, then bookmatching might be for you. Pairing your own imagination with the inherent beauty of the Earth can forge a phenomenal result.

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Zaha Hadid’s Stunning Feature Wall Showcases Masterful Craftsmanship https://usenaturalstone.org/zaha-hadids-feature-wall/ Thu, 06 Sep 2018 18:49:47 +0000 http://usenaturalstone.org/?p=4360 Envisioned and designed by late renowned architect Zaha Hadid, residential condominium building in New York City’s Chelsea neighborhood features a stunning piece of wall art carved from Grigio Brasile marble that expands 34 feet.

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Zaha Hadid’s Stunning Feature Wall Showcases Masterful Craftsmanship

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Architects have called it futuristic and compared it to spaceships. Envisioned and designed by late renowned architect Zaha Hadid, the 520 W 28th Street residential condominium building in New York City’s Chelsea neighborhood features a stunning piece of wall art carved from Grigio Brasile marble that expands 34 feet. Sting and his wife Trudie Styler are reportedly renting an apartment in the upper floors of the building while Ariana Grande and her fiancé Pete Davidson dropped $16 million for a condo in the building.

“The Modern organic design from Zaha Hadid gives the building a unique and impressive dynamic shape which changes from one viewing point to another,” says Colin Addley, CEO and president of Port Morris Tile & Marble.

Port Morris Tile & Marble was tapped to engineer and execute the artistic stone feature wall and matching floor design in the building’s lobby, no small feat, to be sure. The company is no stranger to working on large scale and challenging projects that involve complex engineering throughout the New York City area. “By having an international talented and experienced team which have worked with very well-known architects on numerous projects gave us the edge to add value and bring a skilled service to compliment the [Zaha Hadid] Design team,” says Addley.

Still, Hadid’s reputation for creating unique and challenging designs wasn’t lost on Addley and his team and the question raised several times when they first reviewed the drawings and renderings was how to turn this concept design into a reality.

Sourcing Natural Stone

Choosing the natural stone to meet the needs of the space and realize Hadid’s vision was an important part of the process.

The Grigio Brasile marble, quarried in Greece, proved just the right color variations and quantities for the monochromatic design with beautiful smoky grey color tones. It also featured highly-durable characteristics which made it attractive for this project.

“The structure and the grey background of the natural marble emphasized the organic 3-dimensional shapes and made it the focal area in the space,” says Addley.

The natural stone was then shipped to Italy for a highly-detailed fabrication process before all of the feature wall stone pieces were specially and individually crated like pieces of art sculptures and shipped to New York City.

Port Morris Tile & Marble worked closely with Hadid’s design team to refine the layouts required to accommodate the block size limitations in order to allow for proper installation, which involved everything from considering different engineering options, several sketches, technical drawings, 3D modeling, and mockups.

“Full-scale mockups were required from the design team in order to ensure and check the precision of the stone to the 3D model files. The wall stone pieces were shaped using a CNC machine from custom cubic stone as the first step and then finished by highly skilled and qualified craftsmen,” says Addley, who admits it would have been very difficult to realize the same wall with the same precision, budget, and schedule without involving CNC machines.

“The latest technologies represented in CNC machines played a big role in achieving this extraordinary design and vision,” he shares.

To reduce the waste factor, the stone was divided to custom cubic measurements to match with each stone piece.

Installing a Zaha Hadid-Designed Sculpture

The installation process took about three weeks to complete the wall stone pieces, which required between four and five mechanics from Port Morris Tile & Marble’s highly skilled union stone craftsmen and seven weeks to install the complete lobby stone (floor and wall) under direct daily supervision of its staff.

“We used a classic anchoring system, as recommended by the engineer,” says Addley. “The anchors were used around the stone pieces in different angles and were epoxied to the marble and bolted to the concrete substrate wall.”

The installation sequence of the expansive and very heavy organic curved stone with odd and pointy edges was the most challenging aspect of this project. The stone was rigged and installed in a creative planned process to put the wall puzzle together and turn the project into a reality.

The design of the lobby feature wall as a new standing landmark in New York City represents how an inspired vision combined with skill and engineering can push natural stone design and the industry standards to new limits by the integration of the latest technological innovations.

Having the once-in-a-lifetime chance to work on Zaha Hadid’s last designed project was an honor for Addley and his company. It recently was honored for its work by the Natural Stone Institute’s highest honor, the 2017 Grande Pinnacle Award for Best Overall Project and a Pinnacle Award of Excellence in the Commercial Interior category. These highly-coveted awards are given to projects whose beauty, creativity, ingenuity, and craftsmanship exemplify professional mastery in the use of natural stone in commercial and residential applications.

Looking Ahead

Technology helped make this project possible and Addley believes we’re going to be seeing more work pushing limits as a result.

“The stone industry is in the process of pushing the limits of stone design to a higher level and creating a new realm of possibilities by integrating the latest technology,” he says.

Working on a project designed Zaha Hadid might have been a personal and professional highlight for Addley and his team, but working with challenging projects and buildings designed by architects pushing the boundaries is their trademark.

For those who want to get a glimpse of Zaha Hadid’s space age 11-story residential building, it can be seen hugging New York City’s High Line. It’s worth a step off the beaten path to stroll through the lobby and see the landmark and masterful craftsmanship created using natural stone.

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What You Need to Know About Stacked Stone https://usenaturalstone.org/stacked-stone/ Tue, 31 Jul 2018 17:06:36 +0000 http://usenaturalstone.org/?p=4154 A strong trend in home design is adding texture to vertical surfaces, such as fireplaces and backsplash. Stacked Stone is a three-dimensional veneer is made of cut pieces of natural stone that are attached to a backing and installed like tile.

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What You Need to Know About Stacked Stone

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Photo courtesy of Delta Stone Products.

A strong trend in home design is adding texture to vertical surfaces, and a beautiful way to do that is by using stacked stone. The three-dimensional veneer is made of cut pieces of natural stone that are attached to a backing and installed like you would tile. The material uses no grout; in fact, the dry stacked look is part of its appeal.

“Stone use goes through trends, from the size of grout joints to colors,” says Bryce Harding, national sales manager for Delta Stone Products in Heber City, Utah. “Today the look is a ‘ledge-y’ material. It used to be rough and rugged with lots of alternative textures, and now people are also choosing stacked stone with a smooth, contemporary finish and cut sharp edges.”

Where to Use It

Appropriate for all design styles, stacked stone can be used indoors and out. In an interior, it’s the perfect material for an indoor feature wall, such as around a fireplace, in a bathroom or in a foyer, or as a backsplash in a kitchen.

Stacked stone can also be used to highlight the exterior of a home or building, such as around a front door, chimney or on columns. It’s often paired with siding and applied on the bottom half of the front exterior surface. And it can be used in landscape applications.

“It’s seamless and looks like a solid wall,” says Scott Lardner, president of Rocky Mountain Stone in Albuquerque, New Mexico. “The veneer is adhered directly to a substrate. If it’s thin, it will work on any application interior or exterior.”

Choosing the Stone

Because it’s made of natural stone, stacked stone will have a variation in color and this can dictate the look of your project.

“Natural stone should be chosen well in advance because it’s easy to alter things like stucco color, wood color and paint color,” says Harding. “Select your stone first, and build your palette and design around it.”

Stacked stone comes in a natural or polished finish, depending on the type of material you choose. If you want a polished look, harder materials, such as quartzite or granite, should be used. Softer stones are good for applications where a natural finish is preferred.

The price of this project can vary; the more you alter stone from its natural state, the more it will cost.

“Keep that in mind when you build your budget,” says Harding. “The more you can keep it the way it looks out of quarry, the less money it will be. And the more it needs to be handled and cut and finished, the more time and money will be spent.”

“From a labor standpoint, it’s more intensive,” adds Lardner. “It’s definitely best used as a feature.”

Caring for Your Stacked Stone

RMQ Contemporary Ledge Stone. Photo courtesy of Northern Stone Supply.

Once installed, stacked stone is easy to care for because it is used on vertical surfaces, says Jacqueline Tabbah, vice president of International Stoneworks in Houston, Texas.

“Nobody eats on it or walks on it,” she says. “It gets a lot less wear and tear.”

Tabbah recommends regular dusting: “The ledges that jut out can hold the same dust as an average windowsill, and a handheld vacuum or a duster that traps the dust instead of spreading it around would be best.”

Certain areas might requiring using a neutral stone cleaner with a pH of seven or eight.

“Just spray and wipe down,” says Tabbah. “You don’t need to do it every week; just as needed, especially if the stacked stone is around the fireplace or in a kitchen.”

Tabbah also recommends sealing stacked stone that is installed around a fireplace, or in a kitchen or bathroom.

“You don’t want black soot or grease to get embedded in the porous texture,” she says. “Seal it with a penetrating impregnated sealer once a year. It doesn’t change the appearance of the stone at all. It goes into the pores of stone to repel oil and dirt, and help you clean the stone easier.”

Wherever it’s applied, stacked stone will add warmth and beauty to your space. The look is a perfect mix of rustic and modern style, turning a wall into a natural work of art you’ll love for years to come.

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