"sandstone" Archives | Browse Articles & Resources Written By Experts https://usenaturalstone.org/tag/sandstone/ Articles & Case Studies Promoting Natural Stone Mon, 19 Feb 2024 18:15:26 +0000 en-US hourly 1 https://usenaturalstone.org/wp-content/uploads/2019/07/cropped-use-natural-stone-favicon-2-1-32x32.png "sandstone" Archives | Browse Articles & Resources Written By Experts https://usenaturalstone.org/tag/sandstone/ 32 32 Timeless Beauty: Chicago Landmark Restored to Its Natural Stone Glory https://usenaturalstone.org/timeless-beauty-chicago-landmark-restored-to-its-natural-stone-glory/ Fri, 16 Feb 2024 21:30:36 +0000 https://usenaturalstone.org/?p=11442 After the 1871 Great Chicago Fire, many homes made of wood were destroyed. When it came time to build new homes, laws were passed to prevent a similar disaster. Fireproof materials such as brick, marble, limestone, and terracotta tile became the preferred building materials since constructing buildings with wood was banned in the downtown area. Eight years after the fire, construction of the Nickerson House on Chicago’s near northside neighborhood began. The three-story, 24,000 square foot Italianate mansion was reported to be the largest and most extravagant private residence in Chicago at the time it was completed.

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Timeless Beauty: Chicago Landmark Restored to Its Natural Stone Glory

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All photos unless otherwise specified appear courtesy of the Richard H. Driehaus Museum Archives.

Exterior 1883

After the 1871 Great Chicago Fire, many homes made of wood were destroyed. When it came time to build new homes, laws were passed to prevent a similar disaster. Fireproof materials such as brick, marble, limestone, and terracotta tile became the preferred building materials since constructing buildings with wood was banned in the downtown area. 

Eight years after the fire, construction of the Nickerson House on Chicago’s near northside neighborhood began. The three-story, 24,000 square foot Italianate mansion was reported to be the largest and most extravagant private residence in Chicago at the time it was completed. The exterior façade is made of limestone and Berea sandstone from Ohio. Known as the “marble mansion,” the property is even more impressive inside. “The interior stonework consists of at least 17 different types of French, Italian, Belgium, and American marble as well as onyx and alabaster,” says Sally-Ann Felgenhauer, director of collections and exhibitions for The Richard H. Driehaus Museum. 

Exterior Pre-Restoration

Soon after it was built, the light-gray sandstone exterior would lose its luster due to environmental issues. “Over the years, the naturally light stonework blackened due to the build-up of soot and grime from industrial pollutants,” Felgenhauer says. As the exterior became dark and unsightly, the decorative stone elements also began to erode. 

The Nickerson House became The Richard H. Driehaus Museum when Richard H. Driehaus, a Chicago investment manager well known for his interests in preserving historic buildings, bought the home in 2003. According to a New York Times article, Driehaus purchased the home from the American College of Surgeons, a professional association that had owned it since the 1920s and soon afterward hired M. Kirby Talley Jr., an Amsterdam-based author and art historian, to oversee the restoration.

“My marching orders were to take it back to 1883,” Talley says in the New York Times article. “It’s remarkable to find a situation like this where you can honestly say that no expenses were denied to do the job the right way.”

In 2003, the same year Driehaus acquired the property, major restoration of the building began, including restoring the exterior façade.

Restoration of a Historical Landmark

“The Driehaus Museum as a Gilded Age mansion is an important piece of Chicago’s history and a window into the past that looks forward by exploring the interplay between historic and contemporary art that honors the legacy of Richard H. Driehaus,” Felgenhauer says.

Restoring the exterior required careful work by skilled teams. According to Felgenhauer, none of the stonework has been changed, but it has been restored. 

The sandstone and limestone used were both native materials to the Midwest. Berea sandstone, quarried in Ohio, was a common choice for buildings. Sandstone is a soft and porous material and while fireproof, would eventually absorb the soot billowing from the smoke from nearby coal plants. By the time Driehaus purchased the property, “those industrial pollutants had morphed into a kind of 100-year-old crust. In some places, that crust was 20 millimeters thick,” according to the Driehaus Museum blog post on why the Nickerson House used to be black.

“During the restoration, the Driehaus Museum contracted the Conservation of Sculpture & Objects Studios, Inc. (CSOS) to clean the façade using handheld lasers through a process called ablation,” Felgenhauer explains. “They removed 20,000 square feet of black crust from the stonework over a period of 18 months between 2004-2005. This was officially the first building to be cleaned in North America using this process.”

The reason lasers were used instead of more aggressive approaches such as micro-blasting was because the exterior was so soft that a harsher process would have resulted in worsening of the erosion and in some cases bleaching out the sandstone’s natural yellowish color. 

According to the Driehaus Museum website covering the natural stone exterior restoration project, the laser cleaned at a rate of approximately 2.5 square feet per hour. 

The website shares a bit more detail on the process of using the laser. “A beam of light from a handheld contraption is pointed at the building, and it breaks the molecular bond that had formed between the stone and pollutants,” according to Driehaus Museum. 

According to Felgenhauer, the CSOS team spent more than a year clearing 20,000 square feet of black crust and it was all done with small handheld instruments.

The building was added to the National Register of Historic Places in 1976 and designated a Chicago landmark on September 28, 1977. In 2008, the Commission on Chicago Landmarks awarded the Richard H. Driehaus Museum with the Chicago Landmark Award for Preservation Excellence, Felgenhauer adds.

Keeping Natural Stone Looking Great

Exterior Post-Restoration

While the restoration project was completed in 2004, the museum continues regular maintenance which includes restoration and conversation. “More recently, as part of the museum’s maintenance program, the building façade underwent tuckpointing,” says Felgenhauer.

It’s a testament to its longevity that with proper upkeep and maintenance, natural stone can withstand even the harshest elements and last for centuries. 

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Las Vegas Rock: A Rainbow in the Desert https://usenaturalstone.org/las-vegas-rock-a-rainbow-in-the-desert/ Tue, 02 Jan 2024 22:01:08 +0000 https://usenaturalstone.org/?p=11387 Las Vegas isn’t known for its subtlety. But just beyond a city defined by glitz and sparkle, one can experience a whole other color spectrum—one dictated by nature rather than neon lights. The desert offers a dramatic interplay of hues and textures, as canyons and cliffs in shades of russet, mahogany, and bronze echo across the landscape. These iconic rocks are ancient sand dunes that have become frozen in time; a vast deposit of richly-colored stone that has a myriad of uses.

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Las Vegas Rock: A Rainbow in the Desert

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Note: This article is part of a series about American quarries. If you work for a quarry that’s a member of the Natural Stone Institute and you’d like your quarry to be featured here, contact Amy Oakley. Thank you!

Type of stone: Sandstone

Quarried from: Goodsprings, Nevada

Las Vegas isn’t known for its subtlety. But just beyond a city defined by glitz and sparkle, one can experience a whole other color spectrum—one dictated by nature rather than neon lights. The desert offers a dramatic interplay of hues and textures, as canyons and cliffs in shades of russet, mahogany, and bronze echo across the landscape. These iconic rocks are ancient sand dunes that have become frozen in time; a vast deposit of richly-colored stone that has a myriad of uses. 

Sweeping Sandstone

The American Southwest is currently a desert, but in the Jurassic Period, it was an even more inhospitable place. A huge area of windblown sand dunes stretched across hundreds of desolate miles, similar to the Sahara Desert today. 

Wind makes an especially beautiful signature in the rocks it creates. Coaxed by the persistent breeze, sand grains pile up into ripples and dunes. Over time, dunes migrate and shift, stacking new layers on top of older ones. Older layers are buried and bathed in silica-rich groundwater, which binds the sand grains tightly together, yielding a solid, dense rock.

The layers inside sand dunes are made up of graceful curves that are only visible once erosion – or a quarry saw – cuts open the deposit to reveal the beauty within. 

Las Vegas Rocks quarries into a layer called the Aztec Sandstone. The stone is 180 to 190 million years old, and it formed as dinosaurs were wandering the region. The Aztec Sandstone is the same rock as the famed Navajo Sandstone that defines beloved landscapes such as the massive cliffs of Zion National Park, the deep canyons of Canyonlands, and the iconic stone arches of Arches National Park.

“A world away” from Vegas Strip to High Desert

The quarries of Las Vegas Rock sit about an hour’s drive southwest of Las Vegas. Following a dirt road north from the tiny settlement of Goodsprings, the road enters a narrow valley flanked by ridges of desert sandstone. “It feels a world away when you’re up at the quarry,” says Jeremy Adams, CEO of Las Vegas Rock.

Atop a rocky knob, the quarry opens up layers of brilliant rock which have been nicknamed Rainbow Quarries. The region was once home to 17 different quarrying sites which produced more than 20 different colors of stone.

The original quarry was started in the 1940s by a Syrian immigrant named Peter “Pop” Simon. The colorful sandstone was used in enigmatic Las Vegas buildings such as the original Flamingo Hotel, the Desert Inn, and the Thunderbird Hotel. As development boomed, use of the stone expanded beyond the local market and found its way to primetime architecture in Los Angeles, Hollywood, Carmel-by-the-Sea, and Honolulu. 

The quarry went dormant in the 1980s, and was reborn in 1991 as Las Vegas Rock, Inc. 

One of the original goals of the new operation was to produce landscaping rock that could help local residents adopt drought-tolerant outdoor environments that are evocative of the desert region, rather than thirsty lawns and lush plantings. The palette of vibrant red, orange, purple, and rich brown evoke a natural, native feel that connects the human-built environment to the natural one. 

A Rainbow of Color Options

The presence of several colorful layers of sandstone allows for multiple products from a single operation. Stone is produced in three different palettes.

  • Sierra Smoke is a red color range, including burgundy, pink, and purple, with some yellow and white. 
  • Tupelo Honey covers the golden end of the spectrum. This blend contains yellow, tan, camel, and mustard with some pink, purple, white, and brown. 
  • Desert Blend offers the full spectrum of colors produced by the quarry. It’s a lively blend of browns, oranges, reds, burgundies, yellows, and more.

In addition to the colors, the stone has beautiful layered patterns formed by windblown sand. They layers can be horizontal, diagonal, or curving  – or sometimes all three in a single piece. The intricate patterns make the stone much more expressive than a typical sandstone, appealing to those who seek a one-of-a-kind aesthetic. 

Customers are invited to visit the quarry and select their blocks. Adams notes that people enjoy the hands-on, personal process, like the “farm to table” concept, but with natural stone.

The World’s Only Cradle to Cradle Certified Stone

Las Vegas Rock is the only Cradle to Cradle (C2C) certified stone to date, and the company obtained the certification in 2007. Some of the forward-thinking attributes of the operation are their use of environmentally safe and healthy materials, the use of renewable energy, efficient use of water, and strategies for social responsibility. Impressively, the company’s stone production generates zero waste, as everything that’s extracted is put to good use, from massive blocks down to pure sand.

Up to 10 LEED points are possible with the use of Las Vegas Rock, and the company intends to pursue the Natural Stone Institute’s sustainability certification in the coming year. 

American Values

Adams exudes enthusiasm for his work and has a clear-eyed vision for the strengths of his company. “What customers love about our stone and our company is first that we are easy to deal with,” he says. “We are easygoing people and are looking to help and provide solutions.”

“Being an American quarry in the southwest is appealing for most people, but not for all,” explains Adams. “For the customers that are price conscious, the appeal of American is not the deciding factor, price is. Being an American quarry with American labor and wages is tough trying to compete internationally. The projects that come to fruition are the ones that value the American-made aspect and our unique natural stone.”

Adams is excited for the growth of both the company and its people. “I like to train and educate people about stone and all the possibilities,” he says. Despite the challenges of a tough industry, Adams is undaunted. 

“The strength of the stone industry and the strength of our company is the same, and that is in its diversity,” he says. “There is a seat at the table for all of us.”

More from the American Stones Series

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The Perfect Match: Digging Deep to Restore the Wyoming State Capitol https://usenaturalstone.org/the-perfect-match-digging-deep-to-restore-the-wyoming-state-capitol/ Tue, 14 Nov 2023 17:55:18 +0000 https://usenaturalstone.org/?p=11276 Four years of overhaul—the complex’s first major renovation since 1917—resulted in a state capitol worthy of the accolades it has received. The stonework received the 2021 Grande Pinnacle Award from the Natural Stone Institute, while awards for the total project streamed in from many trade organizations: the American Public Works Association, Building Design and Construction magazine, the American Council of Engineering Companies of Colorado, the Construction Management Association of America, and Engineering-News Record Mountain States.

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The Perfect Match: Digging Deep to Restore the Wyoming State Capitol

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An earlier version of this article originally appeared in the Fall 2022 edition of Building Stone Magazine.

Wyoming State Capitol. Photo courtesy of Dan Schwalm Photography.

Just one highway leads to Rawlins, Wyoming, a small city 150 miles northwest of the state capital of Cheyenne. Rawlins straddles interstate route 80, but otherwise has drawn little attention to itself since its glory days in the 1800s, when it served as a freight and passenger stop on the Transcontinental Railroad. 

In the late nineteenth century, a quarry here produced sandstone for construction projects throughout the region. Rawlins sandstone glows in sunlight with a warm gray that lends a stately air to building exteriors, making it particularly attractive to designers of ornate government edifices. Overseeing the quarry’s production, owner Hans Larsen knew that this high-quality stone should be the fundamental material to grace the Wyoming territorial capitol building, for which construction began in the mid-1880s, several years before Wyoming received statehood. However, the architects had specified sandstone from Loveland, Colorado for the foundation and the capitol steps, with plans to bring more of this stone from Loveland to create the ornamented façade. 

Hearing of this insult to Wyoming quarries, Larsen stormed into Cheyenne, demanding that the local government use materials from its own resources rather than importing stone from another territory’s quarry. Government officials, no doubt taken aback by this fiery businessman, saw the wisdom in his point. Larsen won the contract, making Rawlins sandstone the material of choice for the capitol’s impressive exterior. Skilled stone masons created hundreds of detailed sculpted features by hand. Each column, corner, and cornice was a unique tribute to the sandstone’s quality and durability. The finished structure, including the towering rotunda, opened in 1888. 

Not even Wyoming sandstone can last forever, however, so some 130 years later, Wyoming’s infamously harsh winters had taken their toll on the original building, as well as the additions to Capitol Square constructed in 1890 and 1917. In 2013, the state began a massive $299 million renovation of the entire capitol complex, bringing top talent from across the region to Cheyenne to restore the grandeur of this splendid Renaissance Revival façade. The state determined that the restored capitol should look exactly as it did when the first crew completed it in 1888, so the team of architects, masons, and fabricators looked northwest to Rawlins once again for stone to match the building’s worn exterior. 

But Rawlins no longer had a working stone quarry. The quarry had closed in the 1920s, nearly 100 years before.

Unearthing the Stone

A block of sandstone is hoisted by a stiff leg derrick in a sandstone quarry owned by the Kerr Marle and Stone Company near Rawlins, WY between 1890 and 1910. It is believed that this photo might be the same quarry used in the Wyoming State Capitol restoration. Photo courtesy Wyoming State Archives.

The land containing the former quarry now belonged to Overland Trail Cattle Company, a major ranching and cattle operation and a subsidiary of Anschutz Corp, a private equity company based in Denver, Colorado. 

“Eldon Strid, a local person, provided a tremendous amount of knowledge about where the quarry was and who the owners were,” said Jeff Callinan of J.E. Dunn Construction Company, the general contractor for the state capitol project. “The land had recently changed hands—they were about to put a wind farm on this land.”

J.E. Dunn tried to contact the owners, but when they received no response, they enlisted the help of the governor’s office of the State of Wyoming. Governor Matt Mead and his staff approached Anschutz and “managed to shake it loose,” Callinan said, striking a deal that allowed the state to take 253 tons of sandstone from the former quarry for a reasonable price, providing the state found its own people to bring out the stone. J.E. Dunn tackled this tall order and located a mobile quarry operator in South Dakota. 

“We’d never had to set up a mobile quarry before,” said Callinan. “Normally, we are in the business of going out to the quarry to select big blocks of stone. In this case, we had to learn about the front end and getting the stone extracted. It’s a logistical project to get the stone out of the earth and get it to the people who can create a piece to go into the building. This team knows how to go through that logistical challenge.” 

The governor’s office of the State of Wyoming helped in the access in the capitol’s former quarry source in Rawlins, WY, which had closed nearly 100 years before. 235 tons of sandstone were quarried and used in the restoration effort. Here, cuts are made in the sandstone where sections of block will be extracted using a wire saw. Photo courtesy State of Wyoming.

Setting up a mobile quarry came with its own package of obstacles, Callinan explained. “We had to build a road. We had to coordinate with the Department of Corrections because there was a prison nearby. Then the Fish and Wildlife Department identified that a golden eagle was nesting in the area.” Golden eagles are a protected species under the Bald and Golden Eagles Act of 1940, so the quarry team had to wait for a month to begin their work until the eaglets had fledged and the birds abandoned the nest. 

The effort to reopen the long-dormant quarry proved to be more than worthwhile, said Tom Van Etten, president of Galloy & Van Etten, Inc., an award-winning family-owned stone fabrication company in Chicago. Van Etten led the twelve-person team that turned the Rawlins sandstone into meticulously cut and sculpted replacement pieces for the Wyoming project. “It’s a perfect match,” he said. “They found not just the right quarry, but the right stone matching in color.” 

Choosing exactly the right cuts of sandstone—matching the color of each to the existing stonework in the capitol façade—became the full-time job of preservation architect Katie Butler of CSHQA, headquartered in Boise, ID. Butler and CSHQA principal John Maulin came into the state capitol project in 2015 at the request of HDR Architecture, Inc., the architect of record. “I visited the site in Wyoming almost every other week for three years and attended numerous trips to quarries and fabricators to select the stone, review samples, and ensure the processes were in compliance with the construction documents,” said Butler. 

The process began with the team comparing a series of seven Rawlins sandstone samples, ranging in color from gray to buff, to each building level and elevation of the three building periods. “After a day on a lift, three samples were consistently found to match the existing stone at all areas,” said Butler. “These three samples established the range of colors we would use to select blocks from the Rawlins quarry.” The team visited the quarry three times between October and November 2015 to determine if the 3’ x 3’ blocks were in the correct range for color and veining. 

The project team compares samples to quarry blocks. Tom Van Etten, president of Galloy & Van Etten, led the twelve-person team that turned the Rawlins sandstone into meticulously cut and sculpted pieces for the Wyoming project. Photo courtesy State of Wyoming.

“It was quite the process,” said Butler. “At each site visit, we reviewed stone from different parts of the quarry—south pit, middle pit, and north pit. It was all the same type of sandstone but varied from each part of the quarry. It was tough trying to make sure that the underlying color and variation would be appropriate, especially with the building having been built in multiple phases.” After each visit, the team documented the process with photos and summarized it all in a field report. 

When stone became available from the Colorado quarry in Loveland for repairs of the stairs on the north and west side of the building, Butler and her team repeated this painstaking comparison until they found the right match for the existing steps. 

With this process completed, Butler and the rest of the team—Scott Evett from masonry contractor Mark 1 Restoration Company; Mike Ford, senior associate with stone restoration architect Wiss, Janney, Elstner Associates, Inc. (WJE); and representatives from J.E. Dunn, HDR, and the State of Wyoming met on site regularly to review mockups, trial repairs, and overall project progress. 

Enormous Scope

The process began with the team comparing a series of seven Rawlins sandstone samples, ranging in color from gray to buff, to each building level and elevation of the three building periods. “After a day on a lift, three samples were consistently found to match the existing stones at all areas,” said Butler. Photo courtesy State of Wyoming.

While the historians searched for exactly the right stone, Ford and the WJE team worked with Mark 1 Restoration to determine the scope of the required repairs. “It was about developing a repair approach that we thought was good and sound, but prioritized enough that we could do the repairs we felt were most important, deferring others,” said Ford. “We went on site, did an investigation, and provided options for repair.” 

Placing life safety above all other priorities, the WJE team discovered that the stone at the base of the building—the two courses quarried in Loveland—had deteriorated enough to raise concerns about its continued viability. A clear surface treatment had been applied to this stone in the 1990s, but it did not prevent damage from water and weather, and it “likely accelerated deterioration,” a report on the project noted. Many of the cornices and column capitals showed “severe delamination,” the document continued, also due primarily to water exposure. Some areas had been patched with mortar and stabilized with protective netting, applied years before to slow the progression of the inevitable—and to keep pieces of the façade from raining down on passersby.

The ornate elements throughout the Capitol façade had deteriorated during more than a century of Wyoming weather. Photo courtesy Wiss, Janney, Elstner Associates, Inc.

When it came to the restoration of these decorative elements, Ford and his team presented the state with options. “Often people look at these projects and say, ‘I can’t do that,’ instead of ‘Yes, I can do it, and this is what it will look like,’” he said. “For example, if you have snow and it sits on cornices and ledges and it melts, it gets into the stone and it absorbs. Then it freezes, and it happens again and again—that’s called thermal cycling, or freeze/thaw. A lot of the distress we were seeing was at these projecting ledges. We said that we could do dutchman repairs to match the original, and could improve water management; however, another approach could include installation of a sheet metal flashing. This may address water management and be more cost effective, but it would have an aesthetic impact.”  

WJE installed a mockup of both the stone dutchman and flashing approach and showed the state. The state chose the dutchman approach. “That is fine; they were able to make a good decision with the mockups and an understanding of the benefits and drawbacks we presented,” said Ford. “It’s a historic building. You want to keep the historic character and integrity.” 

In all, a total of 1,135 individual pieces throughout the building’s exterior required repairs or replacement, using 3,160 cubic feet of stone. “We put the stone in a local yard until we shipped it to Galloy & Van Etten in Chicago,” said Callinan. “There were truckloads and truckloads and truckloads.”

As if the size and scope of the project were not complex enough, the original architect in the 1880s, Davis W. Gibbs, had designed just about every feature of the ornate European-inspired façade to be unique.

“As a masonry restoration fabricator, Mark 1 created a shop drawing for each additional piece,” said Callinan. This shop ticket included the type of stone, its dimensions, the dutchman repair styles required, the number of the actual block of stone from which this piece would be cut, elevation drawings, and tooling requirements. “These would be approved, and it would go into fabrication. A lot of times they oversize them a little bit, so onsite they can tool it a little bit to get a perfect fit. Some have similar profiles and textures, but each piece was fabricated for a specific place and purpose.”  

The masonry team worked to develop standardized details for categories of stone profiles—so all the cornice ledges, for example, had the same basic shape and required the same kinds of onsite work once they arrived at the job site. “Every stone on the building was assigned a number, so you could see all of these on the elevations,” said Butler. Tom and Susan Van Etten led the effort at their Chicago facility to fabricate the profile of each element, roughing in the shape and preparing it for the decorative carving to be done by hand in Cheyenne. 

On site, masons from Mark 1 installed the dutchmen that had been fabricated in Chicago at Galloy & Van Etten with planers, pneumatic chisels, combing tools and other shaping devices to create exact replicas of the original detail for each column and cornice. Portions of the building were hand-finished on site—the rock face of the base stone, for example, using a small pitching tool to remove bits of material at a time.  

Butler totaled up the various kinds of repairs the project required: four different kinds of joints, eight different resurfacing techniques, 33 kinds of dutchmen, and two types of surface treatments. “WJE and CSHQA worked as a team,” she said. “WJE reviewed each repair for structural integrity and watertightness, while CSHQA would take the lead on the aesthetic appearance. There were only a couple of occasions where we had to change something because the stone wasn’t a good match.” 

Every facet of the stone restoration required meticulous work by hand using small tools. Photo courtesy Wiss, Janney, Elstner Associates, Inc.

The Reopening

Four years of overhaul—the complex’s first major renovation since 1917—resulted in a state capitol worthy of the accolades it has received. The stonework received the 2021 Grande Pinnacle Award from the Natural Stone Institute, while awards for the total project streamed in from many trade organizations: the American Public Works Association, Building Design and Construction magazine, the American Council of Engineering Companies of Colorado, the Construction Management Association of America, and Engineering-News Record Mountain States.    

“A project like this takes extraordinary skill, but it takes a team that knows who the right players are to accomplish it,” said Callinan. “It was extremely helpful to bring the right artisans to the table. The stone masons who were carving the stone onsite were the same people who worked with us on two other state capitol projects.”

State capitol restoration stands in a class of its own, said Butler, making this her favorite kind of work. “There are only fifty state capitols,” she pointed out, “so it’s a really special building type. It’s fun to see how things can be put back together and preserved without it looking like it was ever touched.”

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Cleveland Quarries: Bringing the Art of Stone Carving Into the 21st Century https://usenaturalstone.org/cleveland-quarries-bringing-the-art-of-stone-carving-into-the-21st-century/ Wed, 01 Sep 2021 21:39:52 +0000 https://usenaturalstone.org/?p=9427 Berea sandstone is famous for good reason; it’s a durable stone with few irregularities. The sandstone straddles the all-important line of being hard enough to withstand the elements, yet soft enough to be workable.

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Cleveland Quarries: Bringing the Art of Stone Carving Into the 21st Century

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Note: This article is part of a series about American quarries. If you work for a quarry that’s a member of the Natural Stone Institute and you’d like your quarry to be featured here, contact Karin Kirk. Thank you!

 

It’s not every day that sandstone makes national news, but when Cleveland’s baseball team changed its name to the Cleveland Guardians, the name prompted an outpouring of curiosity. What, exactly, are Cleveland’s guardians?

As many have since learned, the team’s new name refers to the Guardians of Transportation, which are eight massive statues that grace a bridge across the Cuyahoga River. The art-deco figures were completed in 1932, and they symbolize the spirit of progress in transportation.

The vicinity around Berea, Ohio, is known as “the Sandstone Center of the World,” and the guardian statues are one of many examples of exquisite carvings made from Berea sandstone.

Berea sandstone is famous for good reason; it’s a durable stone with few irregularities. It can yield large blocks with an even grain and consistent coloring, and it can be carved, sawn, or chiseled to suit nearly any taste. The sandstone straddles the all-important line of being hard enough to withstand the elements, yet soft enough to be workable.

Though the stone was first used to make grindstones, its abilities as building stone became readily apparent, and northern Ohio became a hotbed for quarries, stretching westward from Berea into Elyria and Amherst. Beginning in the mid-1800s, holes were sunk into the ground and became ever larger and deeper, as the extracted blocks found their way onto churches, courthouses, banks, and monuments, and the reach of the stone extended past Ohio into Chicago, New York City, Canada, and beyond.

During the heyday of Berea quarrying, it was one of the largest industries in the state, and the Buckeye quarry reached a depth of 240 feet, said to be the deepest quarry of the time. The May 1887 edition of The Manufacturer and Builder heralded the stone and, saying “the production and sale of this valuable material employ a small army of men.” Dozens of quarries and mills operated throughout the region. Eventually the smaller operations were bought up by larger ones, until two large companies had amassed most of the quarries. The Cleveland Stone Company was formed in 1886, and rival Ohio Quarries formed in 1903. In 1929, the Cleveland Stone Company bought out Ohio Quarries, launching the Cleveland Quarries Company, which continues today.

Though there are many fewer active quarries in the region, the tradition of quarrying and stone masonry has never stopped. Cleveland Quarries is keenly aware of its deep history, but it’s also embracing innovation. While the techniques, customers, and applications have all changed over the nearly 200-year history of Berea sandstone, the stone itself remains as dependable and useful as ever.

 

An evolving business model

​Dave Dunn, the Director of Sales at Cleveland Quarries, describes why Berea sandstone has remained desirable for so long. “It has a very tight matrix binding the minerals. It is very predictable. At the same time, it’s workable enough to make it easy to carve, yet hold fine details. And then, you combine that with the inherent strength and properties of the stone itself. It’s very desirable. Carvers like working with it.”

In one sense, Cleveland Quarries continues to do what it always has: quarry stone for use in paving, slabbing, and dimension stone. But Dunn explains that the company has “evolved quite drastically” in recent years. The combination of high-end residential clients and a focus on cutting-edge methods has ushered in a new chapter in the company’s long history.

Zach Carpenter, company President, reflects on the transition over the past decade. “We focused at the beginning on the very simple projects. We didn’t have the capacity to do a lot of the things we do now. And every year, we’ve added more to our capacity.” Carpenter points out that the company hasn’t abandoned its original focus. “We still do what we’ve always done—but we’re really pushing on the more complex because of the level of expertise we’ve gained.”

“We will always promote our stone,” says Carpenter, “but we also are really starting to promote our capabilities.”

 

Carving out a niche

Cleveland Quarries went high-tech in 2013, when they purchased their first 5-axis CNC machine to carve stone. CNC stands for computer numerical control, and it’s an automated cutting tool that follows a programmed pattern while carving and shaping every side of the stone. A 5-axis machine costs about as much as a single-family home in the Vermilion area, and since 2013 the company has since added two more 5-axis machines. The combination of a reliable stone, skilled craftspeople, and computer power have made Cleveland Quarries a leader in a niche market. Carpenter expresses a sense of satisfaction: “We’ve taken on jobs that we simply never could have taken on before.”

The use of computerized tools has changed the flow of production. “Those machines run in the evenings when we’re not there,” says Carpenter, “so a lot of that work can be done by a single operator along with some labor to load up saws.” Carpenter explains that programming and operating the machines are high skill jobs, but “they’re less labor intensive than when we needed to do it all by hand.”

Hand-carving remains an essential part of the process. “We have several hand carvers and a couple artists here as well,” says Carpenter.

Dunn describes the balance between using computer power and skilled hand labor: “It’s a finely choreographed dance of how much work is done on the CNCs and how much is done by our hand carvers,” he says.

Dunn explains that the CNCs are best used to “bulk out” blocks of stone, beginning with a rough block and shaping it partway into the finished piece. Then the piece is passed to the artists.

“These hand carvers are fully capable of taking a square piece of stone and turning it into a very organic carving,” says Dunn. “But it’s not always the best use of their time to bulk out and remove material when the saws could do that overnight.”

“There is a lot to be said for having work done by hand and just that artistic touch on some things, you can’t replace with a machine,” Carpenter says.

Dunn adds, “That’s what our clientele want. They don’t want something done by a machine because anybody can buy that. They want something unique.”

 

A “high skill set”

High-end work rests on the shoulders of a high-end workforce. Cleveland Quarries employs seven carvers, who have “a very high skill set” says Dunn.

“Our lead carver, I think he’s got at least 25 years of doing this,” says Carpenter, adding that old-world skills are passed on within the company. “It happens somewhat naturally, believe it or not. It’s not a structured program. It’s sort of a natural process,” he says.

On the computerized side of things, Carpenter explains, “you could go to school to be a CNC programmer, but the machines in the stone industry are unique to the stone industry,” he says. “Stone is a totally different animal.”

The bottom line is that the skills of the trade are honed on the job, and a lot of education and training happens within the company.

“It’s not just about programming saws, but how do you handle it, how does it work, what does it look like, do you cut with the grain or against the grain—there’s a lot of intricacies,” says Carpenter. “This isn’t something you can go to school for.”

 

Carrying on a 175 year-old legacy

Cleveland Quarries operates the only fully functioning quarry in the Berea sandstone; thus the company has inherited the legacy of all the buildings made from the stone.

“There are federal buildings and courthouses and cathedrals all over the country built out of this stone,” Dunn says. Because of that, there’s a steady flow of projects to repair, restore, or expand historical buildings.

The Michigan state capitol is one such project, completed in 1879 and clad “entirely out of our sandstone,” says Dunn. Some of the original hand carved elements of the building’s stonework were replaced with newly carved versions in 2015, and a new visitor center will be built with the same stone that was used on the building in 142 years ago.

The list goes on: “We’re doing a city park project down in the southern tip of Florida,” says Dunn. “We’ve got a couple restoration projects going on in the New York area. We’re doing some work out on Long Island— private residential projects. We’ve got a very large-scale project taking shape in Wyoming. We’re continuously doing work on the Canadian parliamentary complex in Ottawa.”

The scope of projects shows both the historical importance and the modern utility of Cleveland Quarries’ stone.

“That’ll give you a sense of how far spread out we are,” says Dunn. “The farther outside of Cleveland we get, the more unique things typically become.”

 

A geologic mystery

Berea sandstone is a familiar stone amongst masons and architects, but to this day it remains a bit of an enigma in the geological community. The age of the rock has been hotly debated by geologists over the past 30 years. Depending on exactly who you ask, Berea Sandstone is from either the late Devonian Period, or the early Mississippian Period. The dividing line between those two epochs of geologic time was 359 million years ago.

The problem stems from the fact that there are few fossils in the sandstone, and fossils are what’s commonly used to establish the age of sedimentary rocks. In the absence of fossil evidence, geologists are left with more subtle clues about the age, such as how the rock relates to the layers above and below it. Berea sandstone spans several states and at present, the geological surveys in different states have assigned slightly different ages to the stone.

It’s always gratifying to watch the march of science as fuzzy questions become increasingly clear with better techniques and new analysis. For now, we’ll have to be content to call the age of Berea sandstone as somewhere around 360 million years ago, give or take a few million years.

Rewinding back to that part of geologic time, rivers were cutting deep channels down into the shale layers that sit below the Berea. Over time, the channels were filled with fresh sand that was carried in by the rivers. Sediments from river deltas piled more sand on top of the channels, creating a more or less level plain. Then sea level began to rise, washing in marine sand, like you’d find in a shallow beach. Each of these three phases laid down slightly different layers of sand, and by studying the patterns and ripples in the sediment, geologists can tell if the sand was left by a river, a delta, or an ocean.

Eons after the sand grains came to rest in a watery current, a mason’s chisel methodically and expertly uncovers them. With the swipe of a blade, daylight spills across the sand once again.

 

 

More from the American Stones Series

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Greener Pastures: Krukowski Stone Company Began as a Wisconsin Dairy Farm https://usenaturalstone.org/greener-pastures-for-krukowski-stone-company/ Thu, 20 May 2021 14:10:31 +0000 https://usenaturalstone.org/?p=8930 Krukowski Stone Company quarries two distinctly different stone types: Aqua Grantique and Quartz sandstone. Although they are quarried only a mile apart, they’re separated by more than 1 billion years of geologic time.

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Greener Pastures: Krukowski Stone Company Began as a Wisconsin Dairy Farm

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Note: This article is part of a series about American quarries. If you work for a quarry that’s a member of the Natural Stone Institute and you’d like your quarry to be featured here, contact Karin Kirk. Thank you!

Jeff Krukowski and Joanie Krukowski-Whitt grew up on a small dairy farm, owned and operated by their parents. As the farm developed new pastures, one thing stubbornly stood in the way: rocks.

“Everywhere in the fields, there were boulders,” recalls Joanie. “In order to expand the farm and get the land ready, there were all these stones.”

With the pragmatism that’s become famous in the Midwest, the family began to view the field stones as an asset rather than an obstacle.

“Our parents hand-chiseled stones for local masons” says Joanie, and in 1978 her brother Jeff “took it upon himself to get a truck and to start picking those boulders.” He found customers in Chicago, and Joanie offers fond memories of the early days. “When I was a little kid, I’d ride with him into Chicago, I thought it was the neatest thing crossing that state line,” she muses. “We’re in a rural area, so getting out of state was a big deal.”

“Jeff is my older brother…” she explains.

“Wiser, also!” Jeff adds, as they both laugh.

“And I’m very impressed with what he’s done,” Joanie says.

 

From hand-gathered stone to nationwide sales

Krukowski Stone Company has grown mightily since the days of a single delivery truck, but it remains a family-centered business. In all, six family members work in the company: Jeff works alongside his wife Joyce and their two sons, Brad and Chris, and sister, Joanie Whitt, and brother-in-law Ted Kijak.

Jeff Krukowski with his two sons, Brad and Chris.

Beyond the family members, the company employs an additional 25 people, and works in six quarries spanning over 1,000 acres. The company built a state-of-the-art fabrication shop and a separate splitting facility – totaling over 50,000 square feet of production space.

Jeff’s sons oversee much of the fabrication; Chris runs the saw shop and polishing department, while Brad manages the splitting shop, shipping department, and retail sales. Together they do wintertime trade shows, “which are nonexistent right now,” adds Joanie.

Stretching far beyond its humble roots of gathering field stone, the Krukowski Stone Company now ships products throughout the U.S., Canada, and beyond.

“We’ve even shipped stone to Dubai,” says Jeff. “And Hawaii,” Brad adds.

“Oh yeah, Hawaii. Yeah, all over!” replies Jeff enthusiastically. “There’s only about two states out of the 50 that we haven’t shipped to,” he adds.

Joanie credits the family’s ingenuity and persistence for their success. “If there was something that could be done with this stone, Jeff tried it,” she says. “Back 25 years ago, he went to Europe, because they’ve been doing stone forever; he found great equipment and great companies to work with. Now we have the best equipment in the industry,” she says proudly.

 

Aqua Grantique

Krukowski Stone Company quarries two distinctly different stone types, but the quarries are only a mile apart.

Aqua Grantique is their best seller; it’s a dark grey metamorphic rock, infused with a greenish blue color and ribbons of white. “That blue color, nobody else seems to have it,” says Brad. “To me it’s really unique. When we do trade shows, it’s the first thing people look at.”

When polished, Aqua Grantique is nearly black, which sets off the lighter colored veins and lively movement. But in its unpolished state, the stone reads as soft greenish grey with a subtle sparkle – an entirely different character than the high-contrast patterns in the polished stone. It’s dense and durable, allowing it to withstand freeze-thaw cycles, saltwater, and other forms of abuse.

Thanks to the hard work of recent glaciers, boulders of Aqua Grantique dot the property. These are popular to use as landscaping elements, especially Asian-themed gardens. The unusual blue-green color lends itself to water themes, “We do lots of ponds,” says Jeff. The stone has been used in public gardens, commercial installations, and high-end private projects.

 

Quartz sandstone

The company’s quartz-rich sandstone comes out of the quarry as either slabs or blocks. Sandstone blocks can be used in the naturally layered shapes that come out of the quarry or can be split or sawn into various products. “We grade it in the quarry for potential use: flagstones, random dry wall, veneer stone, or stair treads,” says Joanie.

The quartz sandstone is an overall cream color, with darker shades of chocolate brown, orange, and tan on the weathered faces. The natural colors are sorted into different blends, to create either uniform coloration or mixtures of different hues, depending on the aesthetic style of the project.

Krukowski’s manufacturing facility sits in between the quarries, putting everything in close proximity. “Logistically it’s a great thing,” says Joanie.

 

Northern Wisconsin’s old rocks

Although the quarries are only a mile apart, they’re separated by more than 1 billion years of geologic time. Aqua Grantique is one of Earth’s truly ancient stones – around 1.8 billion years old. The quartz sandstone is a relative newcomer a mere half billion years old. How did such different stones end up right next to each other?

Northern Wisconsin is largely made up of rocks that are more than one billion years old, dating back to the Precambrian Era. These rocks contain geologic signatures of the comings and goings of mountain ranges, continents rifting apart, new landmasses adding on, and periodic volcanic eruptions. A lot can happen in a billion years, as it turns out.

Aqua Grantique is what geologists call a meta-volcanic rock. It once was molten magma that cooled and solidified into a dark-colored lava rock like basalt or gabbro. Later, the rock got buried, compressed, and heated, becoming a metamorphic rock through these processes. The high pressures of the subterranean environment created the stone’s wavy texture and chemical reactions gave rise to new minerals and colors.

By the end of Precambrian time, around 500,000 years ago, the tectonic action that created Wisconsin’s diverse collection of rocks had calmed down, and the landscape of Wisconsin had been eroded down to a fairly flat plain. During the Cambrian period, sea level began to rise and waves lapped onto the landscape, creating a beach. The geologic signature of encroaching seas is the same, no matter when and where it occurs: a layer of sandstone. Thus, a layer of fresh sandstone was laid down on top of the old, contorted metamorphic rocks.

This Cambrian sandstone layer is one of the most common and prominent rock types in southern Wisconsin, but in the northern part of the state, it was wiped away by erosion, once again exposing the ancient metamorphic rocks. But a few protected locations were overlooked by the erosive forces of water and glacial ice, and isolated pockets of sandstone were left behind. The Krukowski quarry is one such place.

The quarry has gained celebrity status amongst geologists, as it’s home to an extremely rare stash of jellyfish fossils. As you can imagine, a jellyfish is not an easy thing to fossilize, since it doesn’t have teeth, bones, or any durable body parts. But sure enough, certain sandstone layers in the quarry are dotted with round imprints of jellyfish that got stranded on the beach as the tide went out. The discovery made the cover of Geology, a high-profile scientific journal, and helped scientists learn more about the fauna of Cambrian seas.

It also made the quarry famous. “We get bombarded with phone calls,” says Joanie. “People are always asking, ‘Can we come see your fossils?’” Due to ongoing quarrying activity, fossil-hunting is not permitted.

American stewardship

In an era when so many products are made overseas, the Krukowski family prides itself on its local roots. “We are one of the few companies in the U.S. that make countertop slabs,” says Joanie. Jeff adds, “But it costs ten times as much to produce in America as it does in Brazil, or India, or China.”

The upside of American production is that the higher labor costs translate to good local jobs, and the shorter shipping distance helps offset the higher price of production compared to an imported stone. “It’s more cost effective, freight-wise,” says Joanie.

Local architects appreciate that Krukowski stone earns LEED credit for locally-sourced materials, and customers are drawn to the stone because it’s American-made. “We should all try to sell ‘Made in the USA,’” Joanie says.

The family has adopted numerous sustainability measures, not to bolster a green image for their brand, but simply out of a longstanding tradition of not being wasteful.

“We use everything, from end-to-end, once we quarry it,” says Brad. Smaller rock fragments are crushed into landscaping chips or a DOT-approved road base.

Cardboard gets reused as corner protectors for shipping stone, and shredded office paper is mixed with molding plaster to secure blocks during the sawing process. Broken pallets are repaired, and new LED lights illuminate the manufacturing and office spaces. Saws are used during off-peak hours whenever possible.

Joanie summarizes their outlook: “We were green before green was a term. We’ve always done everything we could to be very responsible with the environment.”

 

‘Can-do, will-do’

One thing that’s abundantly clear when talking to the Krukowski family is their ability to work hard. Even while running their stone business, they still tend the family farm. “Jeff grows corn and soybeans and raises beef cattle,” says Joanie. Undaunted by Wisconsin’s bitter climate, they quarry right through the winter, “as long as it’s above 10 degrees,” says Brad. The team appears easygoing and collaborative, though allegiance to the Green Bay Packers vs. Chicago Bears causes an occasional intra-family dustup.

Joanie reflects on the arc of her career as a woman in the stone industry. “They look to the man to answer the question,” she says, recalling instances where her expertise was overlooked. “It’s been a big struggle at times, but it’s getting better.” She credits programs like Women in Stone to help encourage a more diverse workforce in the industry. “Plus I’m older and more confident now,” she says.

“We have a can-do, will-do attitude,” says Joanie, but the sentiment is already completely evident.

Brad and Chris both became first-time fathers in September, a happy development for everyone. “And as soon as those kids can walk I’m going to teach both of them how to do book-keeping,” Joanie laughs, “and answer the phone!”

The pandemic has driven a major upswing in sales, so it looks like the Krukowski family won’t get to rest on their laurels anytime soon. “Our retail sales went up 200% last year,” says Brad. By late January, they had already received enough orders to carry them through the end of 2021. “We just got a 15,000 square foot job ten minutes ago,” says Brad.

Joanie chimes in, “Yeah, you never know what that next call is gonna be.”

More from the American Stones Series

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Preserving a Sandstone Heritage https://usenaturalstone.org/sandstone-heritage/ Fri, 02 Nov 2018 17:40:56 +0000 https://usenaturalstone.org/?p=4594 Sandstone heritage lives on through the work of master stone carver Keith Phillips who uses traditional hand tools to carve stone at a modest workshop known as The Shed, he is passing on his skills to a new generation of Tenino stone carvers.

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Preserving a Sandstone Heritage

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Keith Phillips with Celtic cross.

The city of Tenino is a speck on the map of southern Washington. On a drive from Seattle to Portland, you’d probably miss it. But from the late 19th century well into the 20th, Tenino (pronounced Tah-NINE-oh) was known as the Sandstone Capital of the West. Builders from California to Montana kept its three quarries humming as they replaced scores of wood structures destroyed by fires with a stronger, more durable material. Tenino sandstone built the east wing of Washington’s first capitol building and Seattle’s first public library, as well as the Northern Pacific Railroad station in Missoula and churches and schools as far south as Stockton, California. The city’s own business district was lined with gracious sandstone buildings.

In the 1920s, the boom began to fade as builders switched to less expensive materials like brick, concrete, and steel. In what some considered the death blow, Tenino’s own school board chose brick over its native stone to build a new high school. The industry fell into decline and never recovered.

 

Bringing Sandstone Back

Bag of Groceries sculpture at Tenino Market Fresh Supermarket. Carved by Keith Phillips.

Though the industry is gone, Tenino’s sandstone heritage lives on through the work of master stone carver Keith Phillips, 71, who uses traditional hand tools to carve stone quarried from the last of Tenino’s three quarries. At a modest workshop known as The Shed, he is passing on his skills to a new generation of Tenino stone carvers.

Phillips’ handiwork can be spotted throughout the city—in a large mortar and pestle sculpture in front of the pharmacy, an elaborately-carved cross in front of First Presbyterian Church, and a whimsical sandstone bag of groceries next to the local supermarket. He started carving as a hobby in college after relatives gave him some Tenino sandstone. Later, he made stone fireplaces and did other small jobs. When a position as the quarry’s night watchman arose, he seized it, hanging around old-time quarrymen by day to gain pointers about cutting the stone. He learned carving by trial and error and through books.

Around the same time Phillips began receiving commissions for sculptures, the city started taking an interest in its history, commissioning restoration work on its old buildings. “I fell into a situation made in heaven,” Phillips said.

Ed Salerno carves Hard Candy sculpture.

His reputation spread and he soon had more work than he could handle. He has helped restore the state capitol in Olympia, buildings at the University of Washington, a historic museum in Oregon, a lighthouse, and many other buildings, as well as doing sculptures.

These days, Phillips gets help from Ed Salerno, who visited his studio a few years ago after seeing photos of his work at the city’s museum. A graphic designer, Salerno was intrigued by stone carving but had no experience.

Phillips taught him to carve leaves, then letters, and eventually, entire sculptures. “He built my confidence level, always pushing me toward the next thing,” Salerno said.

Dan Miller at The Shed.

“I shared with Ed as much as I could and he’s pretty much on his own now,” Phillips said. The two do projects together and separately, and recently collaborated on traditional “green man” and “green woman” carvings—faces surrounded by leaves—for a Tenino park.

Several years ago, Phillips and Salerno were joined by Dan Miller, who trained as a stone mason in his native England but had trouble finding work in Seattle, where he moved with his American wife. Impressed with a YouTube video showing Phillips making a sundial, he hunted the artisan down, and now works at The Shed two days a week.

“Working with Keith has changed my life,” Miller said. “It’s real stone carving and he’s a master mason. We’re passionate about what we do, and I can learn a lot from him.”

 

Keeping Traditions Alive

Though the carvers use electric saws and drills to break down the huge blocks of sandstone they get from the quarry, for restoration and carving jobs they use traditional hand tools, including a mallet, a chisel, a stone cutter’s framing square, and a compass. “It makes you appreciate how skilled the medieval masons were,” Miller said.

Ed Salerno, Dan Miller, Colby Russell, and Keith Phillips.

Softer and easier to carve than granite or marble, sandstone is well-suited to the old instruments. Though there are slight color variations, ranging from bluish-gray to tan, its texture is smooth and uniform. “It has the evenness of white bread, with no bumps,” Phillips said. “You can carve an angel’s face and it will come out with no blemishes.”

In addition to their carving and restoration work, Phillips and Salerno teach stone carving classes at The Shed. Salerno also has a new apprentice, 17-year-old Colby Russell, who is the great-great-great grandson of the founder of one of the local quarries. Like many of the city’s residents, Colby wants its sandstone tradition to live on. “Even if I don’t make carving a career goal, it’s something to hold onto for future generations,” he said.

“It’s important for young people to be exposed to traditional, age-old architecture,” Phillips said. “So many beautiful old buildings that should have been preserved have been torn down. That kind of thinking can change if there are more people like Dan, Ed, and me.”

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Sussing Out Sandstone https://usenaturalstone.org/sussing-sandstone/ Sun, 22 Jul 2018 14:11:48 +0000 http://usenaturalstone.org/?p=4139 Sandstone, by the most basic definition, is any stone that’s made mostly of sand-sized pieces that have been stuck together into a solid rock. That loose definition leaves a lot of room for variation.

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Sussing Out Sandstone

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This is the stone that started it all for me. In the throes of a kitchen remodel, I ventured to the local stone yard and worked my way down a tantalizingly long aisle of slabs and remnants. My husband was wise to let me make the first cut on my own, because I had to admire, examine, and/or fondle almost every slab. Whoa, a pegmatite! Oooh, is that amphibole? Breccia, niiiiice! Ahhhh, my sweet marble (presses cheek up to slab). Oh hey, look at the fossils! Yep, I’m a nonstop stream of exclamation points when it comes to rocks.

Wild Sea sandstone. Photo courtesy of Karin Kirk.

But of all those delectable choices, it was sandstone that stole my heart. Wild Sea. A grey to pale green color with graceful, swooping movement, showing how the water flowed just so, a few million years ago. I imagined gentle waves lapping across my kitchen, and of course, I could hardly wait to tell every houseguest about cross bedding and paleocurrents.

Sandstone sometimes gets a bad rap when it comes to its usefulness and durability, but all sandstones are not equal. Some sandstones are porous and not suited for indoor use, but they make excellent dimension stone and are a natural fit for landscaping projects. Other sandstones are dense and impermeable, making terrific countertops and backsplashes. Read on to learn about the all-important differences in sandstones.

Sandstone is made of… wait for it… sand

Presumably, you’ve wiggled your toes on a sandy beach or river bottom. So you’ve experienced the precursor to sandstone: sand. To a geologist, sand is any piece of mineral or rock that is within a certain size range. Sand is between 1/16th of a millimeter to 2 millimeters. That’s somewhere between fine sugar and coarse cornmeal. Particles larger than sand are called gravel or pebbles, and specks smaller than sand are officially called silt.

Sandstone, by the most basic definition, is any stone that’s made mostly of sand-sized pieces that have been stuck together into a solid rock. That loose definition leaves a lot of room for variation. What minerals are in the sand? How tightly is it stuck together? This is why you can’t lump all sandstones together.

Colors tell us where the stone was formed

For starters, it’s helpful to know what kind of sand we’re talking about. Far and away the most common type of sand is quartz, and hence the most common sandstone is quartz sandstone. Quartz sandstone can be white, light grey, red, yellow, or tan. It’s almost always light colored because quartz is clear or white. The colors come from the mineral cement that binds the quartz grains together.

If a sandstone is dark grey or dark brown, it’s probably made of something other than quartz. Bluestone is a well-known example of sandstone that’s made of feldspar, quartz, mica, clay, and rock fragments. Geologists call bluestone a lithic sandstone or “greywacke.”

Dark brown to dark red sandstones and brownstones are a mix of quartz and feldspar and have iron oxide cement. Red sandstones are significant in geology because they formed at times when the atmosphere had abundant oxygen. These “red beds” are also an indicator that the rock formed on land or in very shallow water. Sediments in deeper water are not exposed to as much oxygen, so they tend to be dark grey or black.

Patterns in sandstone

The thing that attracted me to Wild Sea was the pattern made as sand grains were carried along by currents. This is called cross bedding and it’s one of the hallmarks of sandstone. Cross beds look like graceful, diagonal lines that have a gentle curve to them. You know how water flowing over sand leaves a rippled pattern? If you were to slice down into those ripples, you’d see cross beds. The swooping layers show the direction the water flowed.

Small cross beds are made by small stream channels. Giant cross beds are formed by sand dunes. Cross beds that flow one direction, then the opposite direction are caused by water that alternates flow direction—in other words, tides. Cross beds that look like lots of U-shaped patterns show that the water was flowing toward you rather than side to side.

Rainbow Teakwood sandstone. Photo courtesy of MSI.

Geologic minutia like cross bedding may seem superfluous. Ah, but no. Cross-bedding is a quick and reliable way to recognize sandstone. This is especially handy because sandstones are sometimes labeled as quartzite or granite. Being able to recognize this distinctive pattern will help you understand what type of stone you’re dealing with.

Some sandstones, like Rainbow Teakwood, have a woodgrain look that is similar to cross bedding. These patterns are caused by dissolved minerals carried in groundwater and they’re called Liesegang rings. You know how a red wine stain on your mother-in-law’s best white tablecloth leaves a distinct, red outline at the farthest reaches of the stain? The same thing happens with minerals too, only with a lot less guilt.

Sandstone evokes ancient landscapes

Think of all the places you encounter sand—on a beach, in a river, or across a desert. These are the same types of environments that brought us sandstones.

The thing we love about sedimentary rocks is how they offer a glimpse into former worlds. Even a billion years ago, beaches and sand dunes formed the same way they do today. We can use what’s happening around us now to infer what happened long ago. That’s one of the fundamental rules of geology.

Sand can be deposited in vast blankets, such as in the Sahara desert. The Navajo Sandstone that spans Utah, Arizona, and Colorado tell us this was a Sahara-like desert during the Cretaceous Period. Massive cross beds, like those seen on sandstone cliffs in Zion National Park, are the remnants of huge sand dunes that marched across the desert floor.

Rivers carry sand, too, with bluestone coming from sandy river channels and river deltas. On the banks of rivers, floods deposit alternating layers of sand and mud. As floodwaters recede, the sediment dries out, shrinks, and cracks into polygon shapes. That’s what made Stone Wood and Palomino. The sand developed a network of cracks, and then dark brown clay filled in the cracks and created a stark geometric pattern.

Beach sand tends to be more pure that river sand, because wave action winnows out everything but the quartz grains. White sandstones like White Sea are most likely from former coastlines. Today, pure white sand can be admired on the beaches near Pensacola, Florida. Someday, those beaches will make a gorgeous sandstone (maybe for my next kitchen?).

How does sand turn into solid rock?

Loose sand can become a super strong stone, or one that’s disappointingly crumbly. It’s all a matter of how well those sand grains are stuck together. Groundwater circulates between sand grains, carrying dissolved minerals along for the ride. Over time, minerals fill in the spaces between sand grains and glue everything together. Geologists call this mineral glue ‘cement.’ The cement can be iron oxide, silica, clay, or calcite. More importantly, the cement can fill in all the spaces between the sand grains, or only some of them. When a lot of those spaces are left open, you end up with a porous sandstone. Some, like Rainbow Teakwood, suck up water like a sponge. Others, like Wild Sea, have very little pore space because minerals have thoroughly filled the spaces between the sand grains, making a low-porosity stone that will repel water. In general, the older the sandstone and the more deeply it was buried, the less porous it will be.

Evaluating sandstones

Given this big disparity in sandstones, it’s important to match the right stone with the right use. For interior use, like countertops, bathrooms, backsplashes, or flooring, you want a low-porosity sandstone. Fortunately, testing the porosity couldn’t be simpler: pour or spray some water on an unsealed sample of the stone and watch what happens. If the water readily soaks into the stone, it’s not a good candidate for use where the stone will get wet. If water doesn’t visibly soak into the stone but it leaves a dark spot, then the stone has moderate porosity, and would be safe for most uses as long as sealer is applied regularly. And if the water neither soaks in nor leaves a dark area, you’ve got a tightly-cemented sandstone that will resist whatever your 4-year old can throw at it.

Quartzite is a former sandstone

Quartzite is all the rage right now. An unfortunate side effect of this wave of popularity is that some stones are being labeled as quartzite when they aren’t. This is most common with marbles that are labeled quartzite, but some sandstones are being called quartzite, too.

Quartzites start out as sandstone, and then they’re subjected to so much heat and pressure that the sand grains fuse together into one solid mass. Even if you look really close, you won’t see individual sand grains. This makes quartzite less porous than sandstone. That said, this process is not definitive. Some stones straddle the line between sandstone and quartzite. Usually this is recognizable by the patterns in the stone. If you can see cross beds, it’s either a sandstone or a quartzite that has only been subjected to a mild amount of heat and pressure. White Macaubus, Nuage, and Infinity White quartzites are examples of lightly metamorphosed quartzites, while White Sea ‘quartzite’ is actually a sandstone. So, regardless of the label, if a stone has cross bedding, check the porosity before falling deeply in love with it.

Many iconic buildings are made of sandstone

Sandstone on the Smithsonian Castle in Washington, DC.

Sandstone makes wonderful dimension stone, because it’s hard and impervious to the elements, yet it’s still relatively easy to cut, shape, and carve. That said, quartz-based sandstones and quartzites may require some additional fabrication costs due to additional time or tool wear, since the minerals are so hard. Sandstone buildings are commonplace all over the world, from Manhattan’s brownstones to Washington DC’s Smithsonian Institution to Jordan’s ancient Petra. The US is home to many productive sandstone quarries, such as the Potsdam sandstone in upstate New York, the Dakota sandstone in Colorado, and the Berea sandstone in Ohio.

The University of Wyoming in Laramie takes sandstone construction to a whole new level. They have their own sandstone quarry near campus, with a ready supply of dimension stone. Most of the campus buildings are made of this stone, tying together the campus and lending a native feel to the architecture.

Sandstone is versatile for landscaping

Sandstone has a special place in outdoor spaces. It’s easy to work with and it naturally cleaves into flat slabs for patios, stepping stones, and stone walls. The grainy texture offers grip in wet weather, and it’s manageable to work with as a DIYer. Local sandstones are readily available in most places, and each region has its own sandstone vernacular. In Arizona, red sandstone slabs are a proper fit. Sienna Buff, Sienna Grey, and Moss Rock all hail from southern Colorado. In the northeast, bluestone is right at home.

Here in Montana, I’ve become somewhat addicted to working with our native Frontier sandstone. Most years I buy a couple tons of it and have way too much fun building walls, borders, and pillars. My husband jokes that soon our entire property will be covered in sandstone. Like that’s a bad thing?

 

More from the Geology Series

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Bluestone: Rivers and Deltas Create a Versatile American Sandstone https://usenaturalstone.org/bluestone-versatile-american-sandstone/ Thu, 31 May 2018 13:41:13 +0000 http://usenaturalstone.org/?p=3892 Bluestone is a fine-grained sandstone from Pennsylvania and New York, characterized by its grey-blue color—but it’s not always blue.

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There are a few different stones called “bluestone.”

The term “bluestone” is not unique to the northeastern US. Around the world, other types of stone go by the same name. One famous type of bluestone is found at Stonehenge, where it was used for some of the smaller pillars. The Stonehenge bluestones are dark grey igneous rocks that naturally cleave into pillars or standing stones. Curiously, these bluestones hail from Wales and were somehow transported 140 miles to Stonehenge. At around 2 tons apiece, this was no easy feat!

There is also a fine-grained limestone called bluestone that comes from Virginia; and if you’re in Australia, bluestone refers to basalt, which is a dense, igneous rock. These other bluestones are all well and good, but forgive us if we think our homegrown original is the best of all.

Bluestone: Rivers and Deltas Create a Versatile American Sandstone

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Bluestone. It’s blue. It’s a stone. End of story, right? Oh no, dear reader, you won’t get off the hook that easily. There’s a lot more to bluestone than its refined good looks. Did you know that bluestone only comes from one region? And that it’s the remnants of a mountain range that doesn’t even exist anymore? And that it can be all kinds of colors? If there’s one thing that’s always true with natural stone, it’s that there’s more to these rocks than meets the eye. Read on to learn why bluestone is a unique American stone that’s as useful as it is beautiful.

 

Bluestone is not just blue

Bluestone is a fine-grained sandstone from Pennsylvania and New York, characterized by its grey-blue color—but it’s not always blue. “There are so many color variations,” explained Bill Mirch, Vice President of Tompkins Bluestone. “Light blue, grey, green, brown, lilac…” Mirch ticked down the list of colors expressed in bluestone. “There are a lot of nice choices.”

Ancient rivers gave birth to bluestone, and this sandstone is the result of a region-wide river system. As with all sedimentary rocks, the particulars of the stone reveal details about its formation. For example, the different colors tell us if the stone was exposed to oxygen during or after its formation. Orange, red, or brown colors are caused by an oxygen-rich environment. Green, turquoise, or blue tones are a result of oxygen-poor conditions, which can occur when decaying organic matter in the sediment uses up all of the available oxygen.

A variety of different ingredients make up bluestone: feldspar, quartz, mica, clays, and rock fragments. In geologic terms, this stone is called a greywacke (pronounced “gray whacky”), which is a sandstone made of a mixture of different particles. Furthermore, ‘greywacke’ is yet another example of how geology is rich with unusual/ridiculous vocabulary terms!

But this jumble of ingredients tells us something about bluestone. As sediments are transported farther from their source, they sort themselves out into similar minerals of similar sizes. But bluestone, being made of a diverse mix of ingredients, is made up of sediment that travelled a relatively short distance down a river. It also hints at the fact that all bluestones are not identical. The range in colors, layering, and texture is one of bluestone’s best assets.

 

Bluestones are the remnants of an ancient mountain range

Let’s do a little time travel back to the Devonian Period, nearly 400 million years ago. A mountain range, called the Acadian Mountains, was being uplifted along the east coast of North America. As a tectonic collision cranked the mountains upward, erosion sought to wear them back down. Rivers carved out valleys and carried away the sediment. At the foothills of the mountains, the rivers met an inland sea, the currents slowed, and the rivers laid down blankets of sand, gravel, and clay. More sediment piled on top of that, and the pressure from the overlying layers helped glue the particles together to create solid rock.

A huge range of rocks got deposited in this manner, and all together they are called the Catskill Delta Formation. This deposit is up to 10,000 feet thick, and covers parts of eastern Pennsylvania and southern New York. The Catskill Formation includes black shales, thick beds of coarse red sandstone, occasional limestones, and lenses of bluestone. The bluestones were formed from sandy deposits in river channels and river banks. Layers of shale and siltstone are usually found above and below the bluestone layers.

Bluestone was not laid down in a continuous blanket. Instead, rivers and deltas left behind pockets of sand. As rivers shifted across the landscape, the sandy layers did too. As a result, bluestones are found in small, discontinuous layers scattered throughout the region.

It’s amazing to think that the Acadian Mountains that shed their sediments to create the Catskill Formation no longer exist at all. They’ve been erased by erosion and overridden by the Appalachian Mountains, which formed in a similar way, about 50 million years after the Catskill Delta. The Appalachians, of course, are still with us today, but at some point they’ll lose the battle with erosion too, and will be worn away by restless rivers.

 

Geologic variability leads to a versatile stone

The geologic origins of bluestone conspired to create a particularly useful material. The sand grains of bluestone have been tightly cemented together, yielding a strong and durable stone. It has a consistent texture that can be left as-is, or can be worked into a variety of different finishes.

Bluestone’s natural layering allows the stone to be cleaved into agreeable flat shapes, and variations in the thickness of the natural layers provides a range of stone for different uses, from chunky blocks to thin sheets.

The way that bluestone was deposited in individual layers and pockets gave rise to small quarries scattered throughout eastern Pennsylvania and southern New York. The small scale of the operations favored close-knit crews working by hand rather than with heavy machinery. “Information was handed down from generation to generation,” explained Mirch. “It was a family thing.”

Because bluestone layers fade in and out across the landscape, quarrying it “is really an art,” said Mirch. In some places the sandstone beds are thick, which are useful for stair treads, curbing, and sills. Thinner layers are well-suited for paving or patio stone. Broad slabs are ideal for sidewalks. Because of the variability, “it’s harder to understand how to extract it,” offered John Malyshko, owner of Natural Stone Resources, Inc., but the upside is that, “different products come from different parts of the formation.”

 

“The precursor to concrete”

Bluestone has been a useful stone since the 1800s, when it began to be quarried for curbs, sidewalks, door sills, window sills, and paving stones. Much of the stone was shipped to nearby New York City, where “it was the precursor to the concrete sidewalk,” said Malyshko. “You can still see 200 year old bluestone steps and paving material.”

A spectacular example of early bluestone construction is the Starrucca Viaduct, a 1,000-foot long, stone railroad bridge in Lanesboro, PA. The viaduct was built of Ashlar bluestone in 1848, and was completed in only a year, thanks in part to the fact that the quarry was just 3 miles from the viaduct. If you had any doubts about the strength and durability of bluestone, take a look at that structure and appreciate that it’s still being used for commercial rail freight today.

 

Many uses for bluestone

Today, bluestone remains a popular choice and is one of the most abundant American natural stones. Patios, stair treads, stone walls, and pool coping are common uses of bluestone. In part, bluestone remains in demand because of its versatility. Daniel Wood, natural stone consultant for Lurvey Supply and chair of the Natural Stone Institute’s education committee, described the many facets of bluestone. “You can work it and craft it. You can have different sizes, different surface textures. It can be layered or not.”

The natural layers of bluestone can be “cleft,” or broken apart, yielding a naturally flat surface with just a hint of texture. In the early days of bluestone, its tendency to break along flat layers was part of its appeal.

But now, Mirch explained, diamond-blade saws have transformed the industry and ushered in myriad new uses for bluestone. No longer reliant on natural layers, stone cutters can saw the stone into specific sizes and thicknesses for architectural use, and mill it into thin tiles. “We’ve expanded our market to the [home’s] interior,” said Mirch.

Different finishes can mesh with different parts of a home. Bluestone can be tumbled to give it an antique look, it can be brushed or honed for smooth floor tile, or a ‘flamed’ finish can be applied, which leaves a planar surface with a slightly rough texture. Mirch summed up bluestone’s adaptability: “It goes from rustic to contemporary, very easily.”

Using the same stone in different ways can unite different parts of a project. “There’s a rhythm; a simplicity of materials,” said Wood. “It ties together into a cohesive design.”

Even bluestone’s leftovers are useful. Thinner layers can be made into tile, and crushed bluestone can be used as gravel. “There’s so many things you can do with it, or to it,” remarked Wood.

 

‘The industry is thriving’

Even though the bluestone industry is made up of small and medium-sized quarries, the stone has a huge reach. Demand for bluestone is highest in the northeast. “It fits the vernacular of the region,” Wood said.

But bluestone is shipped far and wide. “It’s very popular, nationwide,” explained Malyshko. “It’s like bread or butter. People know the material. It’s a safe choice.”

“The industry is thriving. The quarries are doing great,” observed Wood. “They can’t make it fast enough.”

Malyshko echoed this sentiment: “Every block that’s extracted is sold.” Mirch added, “We never have a surplus. Ever.”

For example, Tompkins bluestone supplies 6,000 to 8,000 square feet of bluestone sidewalks for historical neighborhoods in New York City every year. Mirch appreciates the continued use of traditional natural stone. “I really can’t get jazzed over a concrete sidewalk,” he quipped.

Furthermore, this American stone fosters American jobs, and not just in the quarry: “Trucking, machining, diamonds, blades…” Malyshko counted off the ways that bluestone stokes the local economy.

Perhaps bluestone is the quintessential American success story. A geologic remnant became a useful product, and small-scale quarrying fostered a bustling industry. Over time, quarriers, masons, and architects innovated new ways to use this old stone. And all the while, customers have flocked to it, keeping the industry vibrant and allowing the cycle to continue. Bluestone’s easygoing versatility shows us that sometimes the simplest ideas are the most durable.

Photos courtesy of Natural Stone Resources, Inc.

More from the Geology Series

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Versatile Bluestone: From Landscape Pavers to the Sidewalks of New York https://usenaturalstone.org/versatile-bluestone-landscape-pavers-sidewalks-new-york/ Wed, 29 Nov 2017 00:28:00 +0000 http://usenaturalstone.org/?p=3441 Bluestone has become a popular choice across the nation for home patios, pavers, pool decks, and wall coping. Learn about natural bluestone colors and recommended applications.

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Versatile Bluestone: From Landscape Pavers to the Sidewalks of New York

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Once hewn by East Coast pioneers to build stone fences on their land, and later used for sidewalks and curbs from Boston to Washington, DC, bluestone has now become a popular choice across the nation for home patios, pavers, pool decks, and wall coping.

Photo courtesy of Susan Schlenger.

A sedimentary sandstone found in abundance in New York and Pennsylvania, bluestone appeals to designers and homeowners today for its natural beauty and variety. It’s award-winning landscape architect Susan Schlenger’s favorite stone. “The best thing I like about it is that it’s natural stone, rather than a manmade product like concrete pavers,” said Schlenger, who also uses the stone for walkways, steps, and coping for landscape walls. “It’s beautiful and versatile and goes with many types of homes. If you have a painted house, it goes with all colors. It also looks great with brick or stucco.” A big part of bluestone’s appeal is its variation in color and texture. “If you’re looking for a stone that has different colors and character in the texture, you can get it. If you’re looking for a monotone color and uniform texture, you can get that, too,” said Bill Mirch, who along with his brother Rich owns Tompkins Bluestone, which was passed down to them by their father.

Two Types of Bluestone

Photo courtesy of Tomkins Bluestone.

How can the same stone be both colorful and rough-edged or smooth and monochromatic? The answer lies in the way the stone is processed. Natural cleft bluestone is split with a hammer, wedge, and chisel along its natural seams into pieces two to four feet wide. It has a rough, somewhat uneven surface. “Architects love natural cleft because it has character and you can see the grain of the stone,” Mirch said. It’s also a good choice for pool patios because the rough finish prevents slipping. The layers of stone provide a wide palette of colors, created as glaciers receded millions of years ago. They exposed outcroppings to freeze-and-thaw cycles, allowing water laden with multicolored minerals to seep in. Today, architects and designers can choose from among five color ranges: blue/blue-gray; earth tones of green and brown; lilac or lavender; gunmetal brown; and rust, which results from iron.

Photo courtesy of Tompkins Bluestone.

To create a more finished look, denser varieties of bluestone are sometimes put through a spalling process, in which they are cut along horizontal sections, soaked with water, and then heated with a propane and oxygen torch. The result is thermal bluestone, which is uniform in color and texture. Many designers, including Schlenger, prefer its smoother finish. With the exception of gunmetal brown, thermal bluestone has the same color variety as natural cleft. The difference is, individual stones are the same color, rather than containing a variety of hues.

Many Uses

If you like large stones, bluestone is a good choice. Because it contains fewer fissures or cracks than other stone, it can be cut in large sections. “We can produce pieces that are 10-foot by 10-foot in natural cleft stone,” Mirch said.

Photo courtesy of Tompkins Bluestone.

Traditionally used in landscaping, bluestone is starting to catch on for interiors, Mirch said. Mirch has seen people use bluestone in mudrooms, foyers, kitchens, and the bath houses of pool patios. It’s also used for fireplaces, steps, and indoor flooring. Some designers are using it for shower walls in New York City apartments. New York still has many old bluestone sidewalks that are treasured by city dwellers. When construction workers dig them up, historic preservation rules require them to be replaced with new bluestone, bringing a sense of continuity and timelessness to the bustling city streets. “People really get excited about the beauty of bluestone, said Mirch.” “It’s really unique.”

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Cobblestone and Sandstone Bring a Slice of History to Homes https://usenaturalstone.org/cobblestone-sandstone/ Thu, 31 Aug 2017 20:52:15 +0000 http://usenaturalstone.org/?p=3214 Create old world style in your designs. Get ideas for your walkways and sidewalks using natural sandstone and cobblestones.

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Cobblestone and Sandstone Bring a Slice of History to Homes

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Cobblestone & Sandstone Walkway and Fireplace Design Ideas

European cobblestones have withstood centuries of hoof beats and carriage wheels, and they’re still going strong.

The stones, set in place 100 to 400 years ago, once formed transportation networks, but have since been paved over with asphalt. When European construction workers build a new avenue or install a sewer line, they invariably dig up old cobbles.

Durable Beauty

Photo by Monarch Stone International – Discover living room design inspiration

Reclaimed cobblestones can be used to make beautiful and exceptionally hardy driveways and garden walkways to complement modern French Country, Spanish Colonial, and Tuscan-style homes.

“This type of driveway lasts forever,” said Anthony Van Liefde, who worked as a stone mason for over 40 years and now travels to Italy, France, and other parts of Europe to collect cobblestones for Monarch Stone International in San Clemente, which he owns along with Lisa Van Liefde. If it’s installed properly, a cobblestone drive will last hundreds of years.

Cobblestones have a unique beauty. Some are granite, ranging in color from dark gray to gray-green or gray-blue. Others are sandstone, which oxidizes to form a warm, earth-toned patina. Sandstone cobbles have a flatter surface, and are sometimes used as flooring for rustic interiors or wine cellars.

Traditionally, cobblestones were set in sand, with their narrower ends firmly entrenched at the base and their wider tops nearly touching, with just a little sand between them. No mortar was used. Many people still install them the traditional way, though others attach them to a concrete base and grout the joints with mortar.

Either way, no maintenance is necessary. “People ask if they should seal them, but there’s no need,” Lisa said. “They’ve already been tested in freezing weather for hundreds of years.”

Architects and landscape designers appreciate cobblestones for their visual versatility. Not only is there a wide color palette, but the stones were made in a variety of square and rectangular shapes, ranging in size from three to seven inches long, with a normal height of five or six inches (if set in concrete, they can be sawn a couple of inches shorter). Old curb stones are more massive, from 16 to 18 inches high, with varying lengths.

Cobblestones were used not only in Europe, but in early America, where they were originally brought over on ships as ballast, and later were sourced locally. Because most American roads were built using macadam, tarmac, or asphalt, it is easier to find the stones in Europe.

Traditional Building with Local Stone

Photo by Monarch Stone International – Look for landscape pictures

While using European cobblestone conjures up images of the liveried coachmen and gilded carriages of a distant era, using local stone provides a link to a geological history closer to home.

For Anthony, the local stone of choice is Santa Barbara sandstone, which he fell in love with as a young man when he vacationed in the area. Though these stones are not reclaimed, the material has an illustrious past—it was used to build the Santa Barbara Mission and many other historic buildings in the area.

Like cobblestone, Santa Barbara sandstone is not quarried, but excavated—in this case, from building sites, where boulders that tumbled from the surrounding Santa Ynez mountains centuries ago lie nestled in the soil.

“In the old days, they cleared the land and used what God left there to build. Here, that’s still true,” Lisa said. Masonry crews excavate the boulders, hand-split them, and shape them into blocks using hammers and chisels, just as they did 200 years ago. “It’s an art you don’t often see today,” Lisa said.

The rocks range in color from cream to yellow and golden brown. The most popular shade is called Montecito Gold. Builders like the chisel-friendly material, which is used not only for building facades, but for carvings, veneers, stair treads, wall caps, and windowsills. “It’s made in heaven for stone cutters,” Anthony said. Some builders plane the stone for a smooth surface, while others prefer to preserve its rough-hewn edges.

Area architects seek out the stone in part because it’s sourced locally, which means it’s readily available and gets delivered faster. Using local stone also gives them points towards LEED certification.

Reclaimed cobblestones and locally-sourced stone put homeowners in touch with materials and building methods of the past. In a world filled with asphalt and concrete, they are a visual and tactile reminder of earlier days, when we were more closely connected to the earth.

Photo by Monarch Stone International – Browse landscape photos

Photo by Monarch Stone International – More exterior home photos

 

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