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Photo Overload...

 
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Old 07-15-2017, 08:57 AM   #1
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Photo Overload...


In the process of putting together a photo book of one of our recent projects and though I'd share with y'all... It's been a while...

We started getting our feet wet on this project in September 2016 with some foundation modifications (we did not do the foundation work). Bounced in and out of the job as the contractor needed us. Really got the ball rolling in November/December 2016 with fireplace Rough-Ins and getting hoarded in for winter work.

Over 8000 sq. ft. of stone on the walls... split 50/50 between interior and exterior. Essentially stone planks, 4,6,8,10" heights by up to 8 feet long by 3.5" thick... definitely a bit of weight to these puppies...

Stone install began early January and we were complete by end of June.

Last edited by bytor; 07-15-2017 at 09:10 AM.
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Old 07-15-2017, 09:06 AM   #2
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Re: Photo Overload...


North end progression - 1
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Old 07-15-2017, 09:08 AM   #3
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Re: Photo Overload...


North end progression - 2
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Old 07-15-2017, 09:09 AM   #4
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Re: Photo Overload...


North end progression - 3
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Old 07-15-2017, 09:13 AM   #5
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Re: Photo Overload...


South end progression - 1
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Old 07-15-2017, 09:15 AM   #6
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Re: Photo Overload...


South end progression - 2
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Last edited by bytor; 07-15-2017 at 12:07 PM.
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Old 07-15-2017, 09:19 AM   #7
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Re: Photo Overload...


South end progression - 3
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Old 07-15-2017, 09:23 AM   #8
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Re: Photo Overload...


Sweet.
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Old 07-15-2017, 09:30 AM   #9
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Re: Photo Overload...


Driveway progression - 1
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Old 07-15-2017, 09:31 AM   #10
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Re: Photo Overload...


Driveway progression - 2
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Old 07-16-2017, 04:47 AM   #11
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Re: Photo Overload...


Damn Bytor, I was just thinking about you the other day and how I miss seeing your work! Welcome back and please hang around more often!
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Old 07-16-2017, 06:13 AM   #12
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Re: Photo Overload...


That looks like an interesting/fun project Bytor. How were the joints finished? I'm assuming that's granite of some kind?
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Old 07-16-2017, 09:00 AM   #13
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Re: Photo Overload...


Quote:
Originally Posted by artisanstone View Post
That looks like an interesting/fun project Bytor. How were the joints finished? I'm assuming that's granite of some kind?
Hi Bill...

Yes, it's a 'granitic gneiss' local to our area in central Ontario.

The stones were laid tight with 1/8" joints max. For the interior we left the thin-set mortar recessed slightly to give a 'dry-stacked' look. Exterior work used a micro-fiber reinforced thin-set tinted a dark grey. We let the mortar squeeze out of the joints and simply cut off the excess with a slick at the end of each day.
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Old 07-16-2017, 09:02 AM   #14
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Re: Photo Overload...


Some of the 'Raw' material...
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Old 07-16-2017, 09:09 AM   #15
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Re: Photo Overload...


We started the stone install in January in a heated tarped enclosure on the lakeside of the house. (top photo in post #6)The coursing runs in continuous bands around the house, so starting at the lowest point was logical. We used an external diesel furnace to heat our shelter which proved to be surprisingly efficient.
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Old 07-16-2017, 09:13 AM   #16
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Re: Photo Overload...


It took us a little while to become comfortable with the installation... maintaining the crisp lines called for in the design was tricky to say the least... lots of 'corners' in this first section of wall.
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Old 07-16-2017, 09:25 AM   #17
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Re: Photo Overload...


...
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Old 07-16-2017, 12:27 PM   #18
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Re: Photo Overload...


Tell us about the fabrication at the quarry. I assume sawn into slabs and then split with a hydraulic breaker? Is this a readily available product or custom made for this job?

With the thinset mortar, did you control joint thickness with "U" shims, or???
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Old 07-16-2017, 03:18 PM   #19
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Re: Photo Overload...


Quote:
Originally Posted by artisanstone View Post
Tell us about the fabrication at the quarry. I assume sawn into slabs and then split with a hydraulic breaker? Is this a readily available product or custom made for this job?

With the thinset mortar, did you control joint thickness with "U" shims, or???
Gone, it seems, are the good old days when a load of hand-split building stone would show up at the job-site and a good amount of time would be spent rummaging around picking out potential corner stones, quoins, voussoirs and the like... with the rise in popularity of contemporary architecture (at least in our area), natural stone has definitely become more 'processed'.

In this instance, although the product is not 'off the shelf', producing the custom order was not too difficult, just VERY time consuming.

Large blocks were pulled out of the quarry using large drill and wire saw. Blocks were then transported to the production facility just up the road where the blocks were sliced using a stationary wire saw into 3-1/2" slices... much like slicing a loaf of bread...only different...
Slabs were then 'flamed' and then sliced into the 4,6,8 and 10' strips using a 24" diamond saw (bridge saw, rail saw or radial arm saw depending on who you ask) ends of each strip were either squared by us on site or to a lesser extent, at the production facility with a smaller bridge saw. the majority of the strips were over 6 feet long with a good percentage in the 7-8 foot range.

Exposed corners were 'water-blasted' (high pressure pressure washer with sand mixed in with the water) to avoid the risk of rounding off the corners with the torches.

On site we always tried to have two teams working... one preparing the courses of stone, one setting the stone. Each course of stone ran in a continuous band along the foundation or fireplace or stairwell etc. i.e. a continuous band of 4' then 8' then 6' then 10' etc. etc. This allowed the prep crew to prepare fairly long runs of each dimension, keeping ahead if the installation crew. Stainless 'Z' clips were notched into every second course of stone and anchored into the back-up block, wooden studs or concrete foundation depending on location.

We did use the plastic U-shims during installation. We used the 1/16" and doubled or tripled them up if necessary depending on the particular stone. The dimensions of stones did vary slightly so a perfectly consistent joint was next to impossible without endless grinding.
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Old 07-16-2017, 03:46 PM   #20
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Re: Photo Overload...


That's interesting. There is a very big granite quarrying and processing region not far from here that mostly serves the monument industry. They also produce some building stone, but it's typically produced as I described. Very big circular saws that can process a whole quarry block. I've always assumed wire saws were used mostly on limestone and marble.

Anyway, I can get material like you are using, except split faced (guillotine), very economically (like 135 a ton or so). It comes in long sticks like your material, but can be easily broken into squares and rectangles on site. Unfortunately, I can't convince anyone to try it. Everyone is reminded of tombstones. The company I have dealt with sends most of their material to New England. Ironic.

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