Stacey Freed, Author at Use Natural Stone https://usenaturalstone.org/author/s-freed/ Articles & Case Studies Promoting Natural Stone Fri, 01 Mar 2024 16:17:19 +0000 en-US hourly 1 https://usenaturalstone.org/wp-content/uploads/2019/07/cropped-use-natural-stone-favicon-2-1-32x32.png Stacey Freed, Author at Use Natural Stone https://usenaturalstone.org/author/s-freed/ 32 32 Solidity, Place, and Character: Why TWTBA Uses Natural Stone https://usenaturalstone.org/solidity-place-and-character-why-twtba-uses-natural-stone/ Thu, 29 Feb 2024 23:25:46 +0000 https://usenaturalstone.org/?p=11479 Billie Tsien and Tod Williams credit their love of stone with their frequent visits to Rome. As Tod Williams Billie Tsien Architects | Partners, the pair has designed and built more than 40 buildings, a large percentage of which are made using natural stone. “We’re interested in solidity, place and character,” Williams says, with the ultimate goal of creating projects “that have a long lifespan, are meaningful to the community, and will be loved for centuries.”Their choice to use natural stone is both practical and philosophical.

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Solidity, Place, and Character: Why TWTBA Uses Natural Stone

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An earlier version of this article appeared in the Fall 2022 edition of Building Stone Magazine. All photos courtesy of TWBTA unless otherwise noted.

Photo courtesy of Taylor Jewell.

Billie Tsien and Tod Williams credit their love of stone with their frequent visits to Rome. As Tod Williams Billie Tsien Architects | Partners, the pair has designed and built more than 40 buildings, a large percentage of which are made using natural stone. “We’re interested in solidity, place and character,” Williams says, with the ultimate goal of creating projects “that have a long lifespan, are meaningful to the community, and will be loved for centuries.”

Their choice to use natural stone is both practical and philosophical.

The Day to Day of Stone

With each commission come client wants and needs for certain materials. Cost plays a factor. Durability and permanence play a factor as do future maintenance, longevity, and return on investment. These are all part of the practical side of material selections.

“Stone,” says Williams, “is a really good and durable permanent material. You go into the cathedrals, synagogues, mosques — the floors are made of stone, and they’re usually a patchwork quilt with headstones embedded in it and so on. It actually becomes more rich over time. I never go into the Pantheon without being absolutely riveted by the floor and the different colors that are there and the way it wears. I love the wear.” Stone is also a “wonderful and protective shell. It gives an exterior dignity.”

Tsien says that they are passionate about maintenance and longevity. “The idea of longevity is not abstract,” she says. Tsien and Williams connect with maintenance people and ask questions: How long does it last? Can this be cleaned? Who will clean it, and how? “Longevity,” Tsien says, “is very much based on the care of the stone.”

 

Character Development

The other side to design decisions and material choices is the emotional. It is Tsien’s and Williams’ innate senses that give a project a feeling of calm and quiet or energy and movement.

Tsien says she has always believed in “the importance of ‘showing the hand.’ We don’t believe in having a perfect, smooth stone that all looks the same from piece to piece. We’re interested in stones that have a vivid character.” It’s an important quality but hard to define. Some of it comes from natural stone’s irregularities, its “defects” that are not truly defects. Stone is a material pulled from the earth that is perfect in its imperfection. But beyond that, Tsien and Williams feel stone’s character more deeply. Says Williams, character includes “the person who cuts it and dresses it, how it moves along from being extracted from the ground to its final place. Even that has its own specific character.” 

Choosing the right stone starts with quarries, where the couple spends a lot of their time. Williams likens quarrying to “farming building material.” He enjoys meeting the quarrier, he says, “because that person knows how best to remove the stone from the ground and where the best pieces are of a certain quality or character. As with purchasing vegetables from a farmer you might say, ‘Well, what’s good today? What stone do you feel is best at this time in this place?’ I think that anyone who really loves stone, likes that it came from a specific place.”

When he visits a quarry, Williams says he imagines the quarried walls as buildings. “They’re negative buildings. I look at the wall of the quarry that we’re using, for example, getting Granite Tapestry stone from Tony Ramos’s quarry. [Ramos is a stone carver and founder of New England Stone.] That 80-foot-tall wall in the quarry is a building. There’s inspiration there.”

The relationship with the quarriers is important. “An awful lot of the stone industry is family owned,” Williams says. “That has a special resonance for us. We [Billie and I] are both married and partners and that goes deep in our studio; we all work in essentially one room. There’s conviviality and kindness and a sense of family.”

Tsien adds that “one of the great things about the stone industry is that it is personal, unlike something that’s manufactured like sheetrock — you can’t actually go to the source of sheetrock and talk to the person who owns the sheetrock. Whether it’s a quarry in Europe or India or Western Massachusetts, it’s always about the people together with the material. For us, that’s a very rich relationship.”

Good quarrying practices are also important to them. “You want to make sure the quarry is tended to in such a way that it is actually good for the earth,” Williams says. “Maintaining an efficient quarry, with as little disturbance to the surrounding ecological and community conditions is deeply important in stone sourcing. So, the quarriers have the same responsibilities that we do to make buildings that are meaningful.”

Source Code

Many of their projects take five years from inception to completion. “Within the first six months,” Williams says, “we’re investigating the stone.” They look at stone for the exterior and interior of their projects. “As we get into the interiors, we might find that another stone comes forward, or we look at the same stone in a different finish. We like to have at least two to three different kinds of stone that are similar so that we can make sure the owner and contractor have a voice in the selection. From the outset, we learn as we go.”

They look first for stone that might be local to a project but what’s more important is to find the right stone that will accomplish the project’s goals. For the LeFrak Centre at Lakeside, a covered ice rink in Brooklyn’s Prospect Park, Williams says they wanted stone from New York but they couldn’t find what they wanted and got it from Canada. “We had it chopped in a particular way so that it would feel a little bit like it was done by hand years ago, or at least compatible with that. That’s a perfect example of where we couldn’t get the stone locally, but we could try to make sure it was grounded and quiet so that the landscape itself came forward.”

Tsien and Williams never demand that a client use a particular stone, but they will tell clients they have a strong preference for a material and offer their reasons for why it’s the best choice. “But our vision has to be their vision, and their vision has to be our vision,” Tsien says.

By way of example, Tsien recalls the design for the welcome center at the Frederik Meijer Gardens & Sculpture Park in Grand Rapids, Mich. The client wanted to use a “less expensive and more subtle stone which came from Minnesota versus a wild and crazy stone that came from Brazil,” Tsien says. “And so, we used the stone from Minnesota, and the project turned out to be beautiful, but in my heart of hearts I’m still curious what the result would be with the other stone.”

Williams and Tsien look at color and veining, often creating a “kind of tapestry of colors,” Williams says. He adds that they have a penchant for using dimensional stone. “I’m not interested in techniques that somehow try to thin out stone. Basically, we’re interested in the stone as an embodied material, something that has body; it should have depth both in meaning and dimension.” 

When asked if they ever disagree on what materials to use, Williams laughs and says, “almost always, but we always end up in the place where we agree.”

Ultimately their vision is part of a dialogue between the project and the earth, as well as an ongoing conversation with the stakeholders.  “We want our buildings to grow from the earth to the extent that they can,” Williams says. “When you’re talking about stone, you need to be humble because it has been around for a very, very long time.”

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A Concrete Argument for Stone: Building for Longevity at Freedom Place https://usenaturalstone.org/a-concrete-argument-for-stone-building-for-longevity-at-freedom-place/ Fri, 06 Oct 2023 19:47:34 +0000 https://usenaturalstone.org/?p=11218 A former hospital complex originally built in 1894, the Old Parkland campus in Dallas, Texas, has seen its share of reclamation and renovation in the past decades. The most recent addition, Freedom Place at Old Parkland, echoes the campus’ existing Jeffersonian buildings in style and design. Designing and building a 140-foot, six-story structure that includes 8,310 pieces of limestone required massive planning and coordination — particularly because the original design plan was created for cast stone.

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A Concrete Argument for Stone: Building for Longevity at Freedom Place

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An earlier version of this article originally appeared in the Fall 2022 edition of Building Stone Magazine. All photos, unless otherwise noted, appear courtesy of Steve Hinds Photography.

Freedom Place at Old Parkland in Dallas is the newest addition to what was originally a 19th-century hospital complex done in the Jeffersonian style.

A former hospital complex originally built in 1894, the Old Parkland campus in Dallas, Texas, has seen its share of reclamation and renovation in the past decades. The most recent addition, Freedom Place at Old Parkland, echoes the campus’ existing Jeffersonian buildings in style and design. Designing and building a 140-foot, six-story structure that includes 8,310 pieces of limestone required massive planning and coordination — particularly because the original design plan was created for cast stone. 

Despite challenges that ran the gamut from an increased need for collaboration to fabrication difficulties to unique engineering needs and the impact of weather conditions, the masonry was completed in a little more than a year.

An Argument for Longevity

Freedom Place fits seamlessly with the other older buildings in the complex, one of which was built using Indiana limestone.

“I really believe certain structures like churches, institutions, and government buildings should have a higher calling. Those areas of the market should be built for longevity,” says Rob Barnes, president and CEO of Dee Brown Inc., whose company did the stone installation on the Freedom Place project. Dee Brown was awarded the contract based on the architectural drawings that included cast stone. Barnes was instrumental in convincing building owner Crow Holdings, a privately held real estate investment and development firm, whose offices are on the campus, to switch from using cast stone to natural stone — specifically, durable Indiana limestone.

As Barnes laid out his argument, “cast stone has a shortened lifecycle compared to natural stone, which is denser, generally less porous, and doesn’t craze like cast stone. Craze, or ‘spider veins,’

is a characteristic that has to do with the amount of product produced and how much water is put on it during the curing phase,” he says. Once water makes its way into the material it begins to create problems with longevity. “There’s a lot of subjectivity in the manufacturing of cast stone that you don’t have with the natural product. It’s extracted; it’s solid. It has a longer history of performance. If you’re going to build a 100-year building, you want to use natural stone.”   

Market forces also bolstered Barnes’ argument. While many people assume natural stone is more expensive than cast, that depends on supply and demand. At the time the documents came out for bid, he says, “there was a lot of volume in the market [for cast stone], a lot of speculation on a lot of projects, and [enough cast stone] couldn’t have been produced in a timely manner.” All of which made the cost of the natural stone competitive. 

As it turned out, owner Harlan Crow didn’t have to be pushed too much. In addition, one of the original buildings, circa 1902, was built from Indiana limestone. As Barnes says, using natural stone on the newest building “would close the chapter.” 

Material Challenges 

Barnes says that making the switch forced the project to move from the traditional bid-for-award to design-build because of the increased level of collaboration needed. There would be significant adjustments to shop drawings and the engineering process. This added stress to the time allotted for stone procurement, so schedules had to be adjusted. 

The fabricators at 3D Stone in Bloomington, Indiana, were concerned with how the new material would be anchored to the structure. 

PICCO Group developed 205 pages of what were essentially bespoke connection details. The engineers point to piece “D67,” top right in photo, as one example. That piece sits on the structure but “it really wants to tip out,” says main stone engineer Matthew Innocente. “There’s a big rotation that we were trying to restrain using that D67 plate and four pins.” Drawing courtesy of PICCO Group.

 For the engineers, the switch to natural stone meant a real shift in their work. PICCO Group, a Canadian firm with a long history of specializing in stone cladding, had been brought into the project during site excavation when the design still showed cast stone. But natural stone pieces would likely be much larger, and some would be heavier. In some cases, the engineers would have to add steel to the building to be able to support the stone. If the limestone took up two courses of cast stone, the building angles might be off. “These were massive cubic stones in a design with large overhangs and corners. There was some tricky engineering that meant we had to be creative with solutions,” says project manager Dustin South. 

 

South and main stone engineer Matt Innocente were tasked with developing the connections to attach the stone to the structure. “We have 205 pages of connection details,” Innocente says. “That’s more than 200 different connection types we created because of the way this building is designed. It’s not just a flat wall where every piece can be repetitively connected in the same way. These are bespoke connections for a lot of unique dispersed elements like soffits, keystones, corners, columns.” 

The connections — dowels, pins, stainless steel plates — had to be able to carry the weight of the stones, keep them from falling off the structure, and hold the stone back from wind loading. 

They also had to consider whether their designs could be implemented by an installer. “We can invent a crazy connection,” South says, “but if you can’t reach your hand around it and bolt it down, it’s useless.” 

That meant a lot of back-and-forth coordination with the installers and general contractor. PICCO Group worked on the project for about a year, South says.

The entry door under the portico proved a particular challenge. Above the door is a 13-foot wide triangular piece, two feet six inches thick and weighing in excess of 10,000 pounds. It was more than any crew could handle.

The limestone supplier suggested breaking it into three pieces and have vertical joints in it. The architects found that aesthetically unacceptable. The installers had to figure out a way to get a crane small enough but with enough capacity to reach under the porch and fly this piece into place — and be accurate to within a 16th of an inch.

Their biggest challenge was the sheer size of some of the limestone pieces. South points to one 7,000-pound stone by way of example. “Once you add in the lateral forces, that’s another 1,000 pounds of wind load that acts on the stone,” South says. With such large surface areas, the “connections have to take those loads into account as well as the stresses imposed on the stone to make sure, for example, that the pins don’t burst from the stone, that the plate is stiff and large enough, that we have enough anchors going into the structure to support the stone.”

Then there were the carvings and a balcony railing that had to be held in place and designed to carry the weight of people possibly leaning against or sitting on them. 

New Technology Helps

Kevin Newton, senior project manager at The Beck Group in Dallas, which provided architectural and construction services, marvels at how such large and complex buildings with dentals, Ionic columns, and Corinthian capitals were built in the past without benefit of technology. Working on this project has given him a new appreciation for this style of architecture, he says. “Knowing we have cranes and hoists and forklifts with 12,000-pound capacity — how did the ancients build these kind of stone buildings with hand tools and no machinery?”

Kneelers, six-foot sections of stone, cantilever off the corners of the roof triangle. Each is a single piece of stone, nearly 7,000 pounds. Installing each one tied up the tower crane that had to hold it in place for hours, bracing against the wind, while masons anchored it. If the winds were over 20 miles an hour, the crew couldn’t set the piece for that day because it couldn’t tolerate that kind of movement.

There was, in fact, a lot of technology that went into this project, which began as a watercolor rendering drawn by Craig Hamilton, the design architect, who works from his office outside London. Once the building owner blessed the design, Beck Group, the project’s architect of record, turned the renderings into construction documents — some in CAD, some 2D computer drawings, floor plans, and elevations which also addressed local building code compliance. The ultimate finished product was a 3D Revit model for the design. From there, the process moved to the construction side, Newton says, where they used Building Information Modeling (BIM) to check for “clash detection,” i.e., identifying where two parts of a building design interfere with each other. 

Although a natural element, the limestone pieces themselves underwent some changes that required technological assistance. The design called for stone cladding that was eight-inches thick, but to reduce some of the weight and give the stone full depth, the backs especially at the corners of the stones were “gutted out and hooked,” says Shawn Culbertson, vice president of drafting and project development at 3D Stone in Bloomington, Indiana. This took a lot of time and required a special tool made by a blacksmith to plane or scrape the material to get the right profile.

“This was definitely not something we went at like we normally would,” says Culbertson, whose company was also responsible for the hundreds of detailed carvings that adorn the building. “There was a lot of time management and networking with other fabricators as we worked on the carvings.” 

The rosettes were modeled by architect Craig Hamilton. Then they were scanned and duplicated on a CNC machine. 3D Stone worked with Dee Brown to design a threaded stainless-steel insert. Once the builders set the arches, they could spin the rosettes and lock them in place. The threaded insert was timed so the rosettes all face the same direction.

Those carvings — 66 large-scale oxen crania, for example — required the use of CAD cam software and CNC equipment. “The oxen were originally modeled out of wood and clay. Then a 3D scanner scanned that and created an STL model (a 3D file format). Then we were able to bring that into our CAD system,” Culbertson says. “It probably took a million lines of code to move the machines the way we needed to carve them out. We’d run six of them over a weekend to meet the deadline.” 

The other helpful building tool was decidedly old-fashioned — an actual mockup. 3D Stone provided stone samples to the installers at Dee Brown, which then built a two-story mockup, approximately 16’ X 13’. “It had all the detail we could build into it,” Barnes says. They used it as a building guide, and the architects were able to see the aesthetics of the variegated limestone, which moved in color from silver to buff and back to silver with seams that naturally occur in the earth. 

Dee Brown built an approximately 16’ X 13’ two-story mockup with as much detail as possible to test the design. Photo courtesy of Dee Brown Inc.

Barnes says the mockup helped them “work through the building challenges, so when we transferred to the project, we were able to see some things that needed to be done to make the install go better.”

They looked at how the flashing needed to interface with the vertical jambs, how the anchorage interfaced with the backup, how they could create that seamless, waterproof back and how best to work out the brick patterns. “It was a collaborative effort with the project team and the install team,” Barnes says. “It helped us work through finalizing the schedule, too. It’s a very complex façade. A steel structure is more complex than one that’s concrete. There’s more tolerance and give in the steel and we had to work through the challenges of how the building is built and how you lock it in, so you don’t have movement in the backup structure as you install products. The mockup was a beneficial exercise for everyone.”

Fifteen months; 180 individual carvings; 8,310 pieces of Indiana limestone brought in by 155 truckloads and the end result is a stunning structure that will stand the test of time. “Freedom Place’s one-of-a-kind limestone, brick, and zinc façade is really a jewel in the Dallas skyline,” Newton says. “Everyone on the team is so proud to have overcome the unique design and construction challenge. The clients and tenants are elated.

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Off the Wall: Using Natural Stone to Create a Unique Staircase https://usenaturalstone.org/off-the-wall-using-natural-stone-to-create-a-unique-staircase/ Tue, 21 Feb 2023 16:33:02 +0000 https://usenaturalstone.org/?p=10808 A stair project is typically all in a day’s work for an engineer, but what PICCO Group put together for a Toronto homeowner counters logic and the perceived limitations of natural stone.

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Off the Wall: Using Natural Stone to Create a Unique Staircase

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An earlier version of this article appeared in the Spring 2022 edition of Building Stone Magazine. Photos appear courtesy of PICCO Group.  

A stair project is typically all in a day’s work for an engineer, but what PICCO Group put together for a Toronto homeowner counters logic and the perceived limitations of natural stone.  

The home in question, nestled a few meters down a ravine and surrounded by dense forest in an exclusive neighborhood, was being renovated by Toronto contractor Clemmensen Builders. Sophisticated and modern, the multi-level home with a flat green roof needed a staircase worthy of its simple, elegant geometry.

Clemmensen Builders sought to incorporate stone into the feature stair that would run from the lower level to the main kitchen level. The original solution, developed by architect Peter Clewes of architectsAlliance in Toronto, would be stone “plank” treads cantilevered from an adjacent foundation wall. But that would “create more complexity, challenges, and issues by disturbing the existing old wall, which was thick and made of rubble stone,” says Karl Doucas, principal of the structural engineers PICCO Group, called in to work on the project.

With the intent to fit the home’s contemporary style, Clewes designed the first iteration of the stair with a zig-zag profile. “We wanted to 100 percent respect that design intent but alleviate the structural approach they’d been considering. We envisioned a post-tension stair where the tensioning would be done after the installation. It would be a self-supported stair that wouldn’t rely on the existing structure to support it,” Doucas says. “Although what we proposed was a complicated structure, it would simplify construction and be less disruptive.”

It took a leap of faith on everyone’s part to agree to what eventually would be a five-ton floating stone staircase.

 

Sourcing and Fabricating  

The kitchen, at the top of the soon-to-be showpiece staircase, had basalt flooring. PICCO Group looked locally for stone that would match the kitchen floor but were unsuccessful. Generally,” Doucas says, “with flooring tile it’s slab or tile material. The stair is cubic material. Although the source may be the same, the procurement process is different.”

Doucas attended a building show while sourcing the basalt, where he met Chinese suppliers who might have what he was looking for. “Basalt is a common material in China but comes from only a few quarries that are under government control,” he says. Doucas decided to go directly to the source in China and began making phone calls to find a quarry/fabricator that could secure enough of the specific material, black basalt G684. He landed on Gonmar Trading Company in Xiamen, China.

“They walked us through the procurement process. We provided detailing of the stair and the quantities we needed as well as shop drawings, which they reviewed carefully,” Doucas says. While Gonmar committed to the project, Doucas admits he was still nervous. “Saying and doing are two different things.” After the initial mock-up and review of the first few treads, Doucas says PICCO Group was more comfortable with their choice. Then, the company air freighted material samples to PICCO Group’s Concord, ON office for inspection and material acceptance before work began. During the process there were a lot of virtual meetings and calls.

Aside from matching the kitchen flooring, PICCO Group also chose basalt because of its strength and quality, Doucas says. “In a staircase like this so much stress goes into the material. We needed to make sure the material would be appropriate for the function. But there are tradeoffs. Being a strong material makes it more difficult to fabricate. You need the right fabricator to do this.” Gonmar sent “small but specifically dimensioned stone to conduct ASTM tests domestically.”

Gonmar quarried the blocks from its own mountain quarries in Fujian and processed and cut them to the size needed. They flamed the basalt, heating the stone to a high temperature with a torch then quickly cooling it with water. Small bits of stone pop off the surface, giving it a jagged edge. Then they wire brush it to wear down the sharp edges. The stone has a subtle rough dimpled surface and is naturally non-slip.

The stones needed to be keyed, stepped, and notched to fit into each other. Each step also had to have three holes through which tension cables would run. The holes had to line up perfectly. “That was a key consideration,” Doucas says. “Would the fabricator have the capability of cutting the stone to our specific requirements and be able to do the coring?” Because the stones would be connected along a tension wire as if they were giant beads on a string, “even subtle misalignment of these holes would have presented risks of cable kinks and increased cable stresses.”   

PICCO Group worked closely with Gonmar via telephone, virtual meetings, and video exchanges in addition to quality control reviews by PICCO’s sourcing representative in the region to do dry laying and stone mock-ups. “The precision of drilled holes within tight tolerances through consecutive treads proved more difficult than we expected,” Doucas admits, but in the end, quality control at the Chinese factory showed fabrication and craftsmanship created near-perfect hole alignment.  

Once this almost nine-month process was complete, the stairs traveled for six weeks by boat to Vancouver and then by truck to Toronto.

Assembly Required  

Five pallets of stone were delivered to the site. Small booms craned the stones from the trucks to the pool deck on the home’s kitchen level. Master masons Precision Stone, from Westbury, New York, were tasked with erecting the staircase to exact specifications. Masons wrapped the heavy stones in chain falls (hoists) and dollied them into the house.  

At the top and bottom of the staircase, masons installed robust and heavy stainless-steel plates. On the bottom level, the plate serves as a stop to all the weight and load of the stair above it and was anchored with 12 bolts to an existing lower-level concrete slab that required the addition of a reinforced stair foundation pad.

They then set up a wood “crib” of scaffolding to mimic the final design and used a pulley system to lower each basalt step into place. Masons placed each block of basalt stair in its appropriate spot on the wood crib. They built the staircase from the bottom level up. 

The 19 steps, each weighing 550 pounds, are made up of ten-inch treads and 6 3/16-inch risers. Each step also has three one-inch holes bored through its middle (to house the tension cable) and one through its side (for the handrail connector).

As each block of basalt stair was set in place, masons fed the three 1/2”-steel tension cables through matching holes in the treads consecutively. Pulling wire became more difficult as each tread was placed upon the one below. It took about four days to erect the treads.

“Once you get to the top, you essentially tie off the bottom with a nut and cut off the excess cable. You pull from the cable at the very top to create the tension,” Doucas says.  

There were still a few critical finishing steps. They pumped Hi-flow, quick curing grout, into each cable chase and then sealed each outlet. The grout took a week to consolidate. Then they could remove the temporary wood crib and grout the joints between riser and tread.

The final critical moment for Doucas came when they piled the steps with CMU blocks to simulate the load. “It’s impressive to see all those blocks on there and the stair is really floating. You stand underneath it and say, ‘I hope this thing holds.’ But we had confidence this would work. Post tension stone has been done for hundreds of years in many applications.”  

Once the stair was complete, they incorporated the glass rail system. “We asked the test lab to further confirm the stone material capacity for the type of railing anchor installation specified,” Doucas says. The masons installed and epoxied a stainless-steel threaded rod into the side of each stone step. The design called for a two-pinned look on every tread. The pin goes from the step through the glass, and a decorative nut finishes it off. “It was important to be precise as the glass guard holes were pre-drilled. We had to make sure the final fit was as you see it.”

There is no hiding the “wow” factor of this staircase. “It just wouldn’t have been as impressive in wood,” Doucas says. Its sheer weight and size convey the difficulty in fabrication and engineering. And, he adds, “If you want to evoke a sense of authenticity and communicate durability and longevity there’s no alternative to natural stone. It’s historical, timeless.”

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Using Natural Stone and the Golden Ratio to Add Functionality and Inspiration https://usenaturalstone.org/using-natural-stone-and-the-golden-ratio-to-add-functionality-and-inspiration/ Sat, 17 Sep 2022 14:04:59 +0000 https://usenaturalstone.org/?p=10483 Ancient Art of Stone creates one-of-a-kind stone portals at their studio in Cowichan Valley, British Columbia, Canada. They first source stones, then design and build artistic and functional fireplaces, stone doors, spas, mosaics, megaliths, and murals and ship and install them across North America.

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Using Natural Stone and the Golden Ratio to Add Functionality and Inspiration

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Note: An earlier version of this article appeared in the Spring 2022 edition of Building Stone Magazine. All photos appear courtesy of Andreas Kunert and Ancient Art of Stone.

Philosophers and artists have long been fascinated by geometric forms and what gives them meaning beyond their shape. In art and nature there are aesthetically pleasing proportions found, as Michelangelo purportedly did, in what’s referred to as sacred geometry, or the golden ratio (1:phi or 1:1.618…). By channeling an innate sense of this proportion, stone artists Andreas and Naomi Kunert can imbue their unique works with movement, depth, and feeling.

Owners and principal artists of Ancient Art of Stone, the Kunerts create what they call “one-of-a-kind stone portals for individuals, businesses, public museums, and art galleries.” At their 15-acre studio in Cowichan Valley, British Columbia, Canada, they first source stones, then design and build artistic and functional fireplaces, stone doors, spas, mosaics, megaliths, and murals and ship and install them across North America.

According to Andreas, “Everything we do is personal — it’s an intimate experience — and built intuitively. We delve in and go down the rabbit hole and become inspired; our work is the product of this experience.”

 

Meeting of the Minds

Andreas credits Vermont for his love of stone. He grew up in a sparsely populated rural area in that state and spent a lot of time on his own outdoors. An artist by nature — he would eventually dabble in painting and photography — he always loved what he could do with stone, “from the minute to the megalithic; it’s very appealing,” he says.

As a younger man, Andreas was an avid extreme skier and discovered a passion for “life’s mysterious flow.” His adventures took him to the mountains of Europe, and wherever he went he photographed the landscape. He was intrigued by the patterns he saw in nature. He moved to Canada and started K2 Stone Quarries on Vancouver Island. The business grew and was successful. In 2009, he met Naomi, who had been on her own journey.

“I had an early fascination with archaeology and the native Cree people,” Naomi says. She grew up on the Saskatchewan prairie in a home located near a stone grotto and a natural spring where people would visit on pilgrimages for healing. “We’d find arrowheads, stone hammers, teepee circles,” she says, which ignited an “interest in the ancient in terms of stone and how people used it.” In 2000, she got an undergraduate degree in fine arts at the University of Saskatchewan and focused on sculpture and extended media, stone being one of them. Faced with cancer in her late 20s, she found solace and healing with the First Nation medicine people. She credits them with helping her develop visionary abilities that still guide her today. By the time she met Andreas, she says, she had already dreamt of him. More than a decade and five children later, they complement each other in spirit and in business.

 

Passion Embedded

The Kunerts’ projects usually take a year or more and begin with individual stones—lots and lots of stones. While clients often offer them stones, the Kunerts also travel around to fill a trailer with stones from gravel pits and glacial moraines, or they’ll select pallets of natural stone from quarries. “The First Nations also gather stone for us. We’re always searching,” Andreas says, adding that the type of stones they prefer are flat and curved, formed by glaciers. “They’re not river stone. A river tumbles stones round: it doesn’t flatten them. But a glacier will cleave them. We often find them wherever a glacier has been and has left stones behind, even in [a place you wouldn’t expect] like Utah.”

The fireplace project known as “Memories Surround Me” was commissioned by a couple in Spokane, Washington, who were about to move to a home they were having built. While the project did begin with stones, it also began with a client wanting to have something that represented love writ large.

“They met as teenagers and have been married 50 years. They love fly fishing. Every time they go fishing, they bring home a pebble or a saucer-shaped stone. The wife joked that [they’d collected so many stones] they could hardly park in the garage anymore,” Andreas says. The husband asked the Kunerts to use the stones to create a fireplace that he could give his wife as a Christmas gift in tribute to their years together.

The Kunerts work hard to know their clients. “Naomi has the ability to tune into a client and who they are and what we should bring to them in stone or crystal,” says Andreas. She sees working with clients as a spiritual journey. “Not necessarily something religious,” she says, “but the nature of the stones and their honoring can bring connection and peace and stability to our clients’ lives. We build with that intention. We’re building a sacred space that’s also functional artwork.”

As the Kunerts spent time with the Spokane clients, they learned about their hobbies like fly fishing and traveling, that they loved their old home’s unique architecture, and that they wanted to include niches on their fireplace to feature pottery and other small artworks. “We channeled the inspiration into three different design options for them,” Naomi says. Although their hand-drawn sketches can sometimes be detailed, the drawing ultimately has to be open ended. “We tell clients that we let each stone speak. You can’t always find an exact stone for the design.”

The Spokane couple brought about 10 percent of the stones to this project, and the Kunerts supplied the rest of the approximately 15 tons of stone used. Once the sketch was approved the heavy work began.

 

 

Built For Legacy

The fireplace eventually would live in a great room that had yet to be built on a home in a residential neighborhood. When completed, it would stand 22 feet tall. The first step was to make a poured-concrete and rebar substructure of about 18 feet that would be strong enough to hold the stone design embedded on it.

The fireplace was built from the bottom up, in two parts that would be connected on site. On the bottom half of the fireplace, the design incorporates two vertical pieces of sandstone, each two feet thick and each weighing one and a half tons, placed on either side of the firebox. These are connected across the top of the firebox by a 40-inch horizontal piece of sandstone, which is topped by a 12-inch layer of intricately placed individual stones and then an organic-edged granite mantle. Once on site they would add a hand-polished basalt hearth at the base.

The sandstone arrived as square blocks. Using a hydraulic chainsaw, ring saw, hammer, and chisel, Andreas carved into the basic shape to create alcoves and nooks. He then bolted the blocks from behind to the concrete substructure.

The top half of the fireplace holds the central inspiration stone to which the thousands of individual smaller stones find their way.

When the stones arrived, the clients’ contribution and others (from quarries in Colorado and British Columbia), the Kunerts organized them by color and hue, shape (flat or curved) and size. “Some were covered in lichen. Some could be used as feature stones; some would create flow,” Naomi says.

The stones were not numbered or laid out. Knowing where to place the stones, which are essentially a cladding, is where the magic happens. “As much as possible, even though we’re sculptors, we try not to alter the stone, and we use its natural form,” Andreas says.

While there’s a sketch to go by, “We try to honor the shape and color of the stone and how it connects to a particular client. We listen to the stone to see how it wants to be honored or incorporated,” Naomi says. “A stone is as much of a living thing as a plant; it has a certain biology and a matrix.”

The Spokane clients had one large round stone that they wanted to use as the central focal point. “The idea was that the design showed their life together leading to this stone,” Andreas says. “The stones would mean nothing to the average person; they would see just a pile of stones. But to us, they have meaning.” Adds Naomi, “We talk about noticing if a stone is missing from a pile of thousands. They become part of you; it’s like an artist knowing if they have all their tools.”

As with every project, while Andreas mortars the stones to the substructure, he says he takes his time and “feels the stones, listens to the stones. Every day you don’t know which stone is next. You go with a feeling and follow that feeling. It’s hard to describe.”

Which brings us back to the golden ratio and sacred geometry. Andreas says that his perception of the world has always been mysterious and remarkable, and that he has an innate ability to see the sacred geometry and recognize this pattern in nature, people, and materials. “As a child, I discovered I could play with stones on the ground and make these patterns. I wasn’t told about sacred geometry and the math behind it until well into my career.”

Working from the bottom up on this fireplace, Andreas placed the stones in curve and swirl patterns with mortar, bolts, or fastening pins depending on the stone’s size. He also incorporated arrowheads, hammerheads, scrapers and other “hidden treasures.” It was a complex dance to match the design to the concept and make the piece still feel natural and unassuming.

Conscious that the final product would flex and stress on a truck bed, Naomi says, “It’s overbuilt. Probably stronger than anything someone might have built in their home.” Within the concrete is a metal substructure of rebar and plates that runs all the way to the top to connect with lifting eyes, or eye bolts, so a crane could hook into and lift it.

Once the structure was completed, the Kunerts had it loaded onto a truck in two parts and driven 450 miles to Spokane, where the next challenge faced them: craning the 30,000-pound artwork into an exclusive residential neighborhood with homes surrounding the client’s newly built but unfinished home in freezing temperatures. “Usually, our clients have major acreage. This was a tight site,” Andreas says.

The house itself sits on a concrete slab. The great room would be built around the fireplace, whose own foundation goes six feet into the ground. Once the fireplace was craned into place, the two parts, bottom and top, were welded together on the back with steel plates.

“The fireplace will be the strongest part of the house,” Andreas says. “The builders ran the beams into the top, so the fireplace is actually holding up the roof.”

The fireplace’s concrete structure is embedded into the wall, along with the firebox. The builders placed drywall against the sides of the fireplace “nice and snug,” Andreas says, with few gaps for the Kunerts to fill in.

 

Letting Go

The clients are thrilled with their fireplace, their amazingly beautiful and unique piece of functional art that captures their love for one another and their lives together. “On the day it was delivered and lifted into place the client’s wife cried, exclaiming her joy,” Andreas says. Now that the home is complete, they describe the commission as the heart of their home and their favorite room to sit in.

For the Kunerts, after a year of living with and working on a project, it’s always difficult to say goodbye. “It’s personal to us. That’s a piece of our life. Everything that happened in our lives during that year is written into that artwork. Each piece becomes a part of us. When the truck leaves, it’s like ‘There go the children.’ We’re happy and proud but we’re hurting.”

 

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How a Common Local Stone Helped Create Jobs and Inspire Design in Rwanda https://usenaturalstone.org/how-a-common-local-stone-helped-create-jobs-and-inspire-design-in-rwanda/ Thu, 21 Apr 2022 16:02:13 +0000 https://usenaturalstone.org/?p=10183 In Rwanda’s Burera District, the volcanic rock pumice was undervalued and unappreciated. The mundane natural stone proved itself to be a change agent in this landlocked African country.

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How a Common Local Stone Helped Create Jobs and Inspire Design in Rwanda

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This article originally appeared in the Fall 2021 edition of Building Stone Magazine. Photo courtesy of Iwan Baan.

We often dismiss the things with which we come into daily contact. They are undervalued and unappreciated. In Rwanda’s Burera District, it’s pumice. These volcanic rocks are everywhere, and farmers remove them from their fields as if they are garden pests. As it turns out, the mundane natural stone proved itself to be a change agent in this landlocked African country.

In 2007, the Rwandan Ministry of Health brought in Partners In Health to rebuild Burera’s nearly non-existent health system. Partners In Health is a global consultancy that works with governments to bring health care to some of the world’s poorest places. The following year, Partners In Health aligned with volunteer architects from Boston and Kigali-based MASS Design Group to create the site design and supervise construction for what would become Butaro Hospital.

At the time, Rwanda imported most building materials such as steel and glass from Kenya, Uganda, Turkey, and Dubai, making construction projects expensive. “Much of the construction happening was using imported materials and we wanted to see what could be produced locally to keep economic impact within the region to reduce cost and the environmental footprint,” said architect Alan Ricks, MASS Design Group’s founding principal. “What we saw in this very fertile region of Rwanda on the southern border of a chain of volcanoes was pumice stone.”

Photo courtesy of MASS Design Group

While it wasn’t unheard of to build with the local stone, doing so didn’t have the cache of using imported materials. “Stone was seen as a low-value material, but it was available and affordable,” Ricks said. “We had to transform the perception of value from one focused on this commodity to one focused on craft. The inhabitants saw the stone as a nuisance with little value, but it was beautiful.”

 

Architecture of Service

MASS (Model of Architecture Serving Society) Design Group was founded by Ricks and Michael Murphy as a nonprofit architecture firm devoted to improving lives through beautiful and impactful buildings. Ricks told a New York City TED audience in 2014 that “we start by rejecting the notion that some deserve the full benefits of architecture and others the bare minimum…. We need to constantly ask how the choices we make have the greatest impact on the communities we serve.”

That philosophy would serve Ricks and Murphy well when, as students in the Harvard Graduate School of Design, they began volunteering on the Butaro project. They, along with others from MASS, would put in 25,000 hours of volunteer labor over the course of a decade.

When it came to hospital design, Ricks and Murphy had read the studies that showed that tuberculosis spread in hospitals via crowded, unventilated hallways and waiting rooms. They’d read the studies that showed that patients recover 25 percent faster with a view of nature. They considered that data as they designed Butaro Hospital. “We really immersed ourselves in Partners In Health’s philosophy of health care delivery and tried to imagine what that meant for architecture. They saw that physical space was important but so were aesthetics. They invested in building gardens around the clinics they built to creates spaces for healing and also of dignity,” Ricks says. Using the local volcanic stone became a part of that philosophy.

MASS designed a 64,583 square-foot, two-story hospital with external covered walkways, and took into account patient and staff flow and natural ventilation systems to mitigate and reduce the transmission of airborne diseases. The buildings were designed to be “passively ventilated without heating or air conditioning. Instead, we used basic design principles to achieve thermal comfort,” Ricks said.

Butaro Hospital District. Photo courtesy of Iwan Baan.

Built on land formerly used as a military encampment, the project also includes gardens, fishponds, landscaping, and small houses for doctors. “Recovery is about more than hospital structure,” Ricks told his TED audience. “We designed a hospital to be healthy, effective, efficient. This is what you’d expect an architect to do. We wanted to make a statement to create dignity in the community. A garden helps people feel joy and happiness and recover more quickly.”

 

The Promise of Pumice

Since the volcanic rock is ubiquitous, there was no need for extraction, Ricks says. Farmers pulled the pumice stones from their fields and piled them up or used them as boundary markers. Construction crews drove through agricultural zones loading the stones on trucks to bring to the site.

Partners In Health and MASS found people in the community who knew the craft of masonry. “It’s not uncommon to have 1,000 people working onsite,” Ricks says. Partners In Health hired and paid four-person teams to lead crews and teach apprentice-level employees. While some local laborers had experience building with volcanic stone, that wasn’t common, “and achieving the level of precision needed was a departure,” Rick says.

The masons learned to do the rough cutting to get the stones to a manageable size. They form fitted a piece of wire, chalked that shape on a stone, chiseled it and refined it. Then they tested it. “At first, masons did mockups of the walls to see how tight they needed to get the joints between stones. Early on, one mason could cut, shape, and install two stones a day,” Ricks says. “Today, the pros can do about seven stones. It’s a laborious task. The first wall and the last wall of the first building look different because the masons got better and increasingly precise over time.”

The rocks are mortared into place with cement prepared onsite and applied as a veneer to the back of the stones. “The stones are a ‘rain screen’ on top of a structural masonry wall, CMU [concrete masonry unit] or in some places compressed earth block,” Ricks says. The mortar is a cement applied to the back of the stone, then placed onto the structural masonry wall. The stone is applied as a self supporting veneer, mortared to the superstructure with steel tension ties as required.

From an environmental standpoint, “the most radical thing is going back to stone foundations,” Ricks says, explaining that the majority of the carbon impact of most buildings is the reinforced concrete in the foundation. “Going back to a stone foundation (which Butaro has) is the biggest improvement we can make in a building’s embodied carbon.”

 

Building Dignity

As Ricks pointed out, the hospital project was more than designing a facility. The project made a dramatic impact on the local economy and the lives of those living in the community. One mason, Anne-Marie Nyiranshimiyimana, began her masonry training while working on the hospital project. She had a limited educated and had difficulties finding a job and supporting her family.

Despite her inexperience and the difficulties of being a woman in a male-dominated industry, Nyiranshimiyimana grew passionate about the work, mentoring and training other women in masonry techniques. She earned the nickname “Kankwanzi,” the name of a Rwandan radio show character, the only female working on a construction crew. The name is loosely translated as “a rising star that refuses to conform to society’s expectations.”

In a MASS-produced video, “Beyond the Building,” Nyiranshimiyimana says, “They told me, ‘No woman builds; no woman climbs.’ They told me, ‘Women can’t do a lot of things.’ They harassed me.” She would prove the naysayers wrong, becoming a team leader and ultimately rising to the rank of master mason. Her new skills and earning power have boosted her confidence and self-esteem and inspired other women in the community. “Women look up to [me] so much when they hear about me. They want to come work with ‘Kankwanzi,’” she says.

“Around the village she is changing the life of her colleagues,” says Kayihura Nyundo, engineering consultant to MASS, Rwanda. “She’s paying school fees for many kids and helping her husband to build a house.”

Kankwanzi, along with a group of 200 women, has most recently been working on the new University of Global Health Equity campus, a Partners In Health initiative just across the valley from the Butaro hospital. She says masonry “dignified” her and that she is happy; “everything is because of the hospital project.”

 

Think Local. Impact Local.

Butaro Hospital opened in 2011 as part of a 15-year master plan that also includes phase two of doctor housing, a cancer center, and a university — all featuring local stone.

Photo courtesy of Iwan Baan

MASS co-principal Murphy described the effects of these projects to Architect magazine in 2014: “When I first got to Butaro in the beginning of 2008 there was no electricity in the town; there were mostly empty businesses. Not even six years later, there’s a hydroelectric dam in town. In the whole village below the hospital, there’s lots of fresh coats of paint on businesses. A Bank of Kigali has opened, and middle-class families are moving to this community because there’s ongoing work at the hospital both in terms of service, nursing, as well as in construction.

Over the course of these projects, we’ve been able to find skilled workers. What’s even more exciting is that we’ve seen these people take those skills and find other jobs because of the recognition they’ve received for the work on these projects. We’ve seen that in different trades such as masonry, welding, weaving, and pottery.”

MASS continues to work on health care projects throughout the developing world in places like Liberia, Burundi, and Haiti. MASS is currently working on a “purpose-built campus” for the Ellen DeGeneres Campus of the Dian Fossey Gorilla Fund, the world’s largest and longest-running organization focused solely on gorilla conservation.

Photos courtesy of MASS Design Group.

“We’re committed to developing architecture that’s of its place, that looks to the resources of the region. We figure out how we can showcase them and think about social and environmental implications of what we choose to build with,” Ricks says. In the case of Butaro Hospital, “to know [we’ve used] low carbon, climate positive materials that create jobs and are ethically sourced, produce, and installed — that’s what we [in the building industry] should be thinking about. Even when you’re not able to do that all yourself, it’s worth asking the questions, ‘Where do these things come from? Are they ethically harvested, manufactured, and extracted?’ and ‘What is the social and environmental footprint that they have?’”

 

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