Photo Overload... - Page 2 - Masonry Picture Post - Contractor Talk

Photo Overload...

 
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Old 07-16-2017, 04:55 PM   #21
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Re: Photo Overload...


I love how all the stages were captured in these photos. Perfect timeline of an amazing job. Great work!
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Old 07-17-2017, 04:04 AM   #22
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Re: Photo Overload...


By the time we'd finished the first exterior wall section, the interior of the building was ready for some stone.

First up; the 'widescreen' gas fireplace in the master bedroom.

The fireplace measures roughly 11 feet high by 19 feet long. There is a large steel I-beam which spans the opening just above the gas unit... an extra flange was welded onto the lower edge of the beam in order to support the 'floating' stone. Blackened steel panels flank the gas unit in the final picture.
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Old 07-17-2017, 04:06 AM   #23
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The rear wall of the Master bedroom fireplace, in what will be the Home Office;
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Old 07-18-2017, 05:37 PM   #24
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The Great Room fireplace begins...

Photo 1 shows the beginnings of the rough-in. the two main fireplaces in this house are completely supported on the steel structure... the bedrooms below prevented the masonry from running right down to the footings below ground. The beginnings of the block-work rest on a concrete slab poured on top of the I-beams hidden in the lower floor ceiling.

Photo 2 shows the rough-in continuing... the smoke chamber is underway at this point. The welder in the background is finishing off the steel structure which will ultimately support the stone chimney for the gas fireplace in the Master bedroom shown in the previous posts. the masonry rough-in underway will continue up to the I-beams above at which point another concrete slab is poured to bridge across onto the I-beams, which will ultimately support the chimney. The chimney is quite large, 14' 'long' by 3' wide. Purely for architectural reasons.... could have been as small as 2' square.

Photo 3 is the completed smoke chamber (constructed with refractory slabs) ready for the first flue.
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Old 07-18-2017, 05:46 PM   #25
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Photo 1... not a great shot, but this shows the completed rough-in. The plywood wall to the right of the block-work backs on to the home office behind. The finished stonework will cover both the masonry and plywood wall. A heavy angle iron has been welded to the steel posts, across the face of the plywood wall and masonry rough-in to support the stone which will appear to 'float' above the hearth.

Photo 2; the stone begins... wrapping around the end of the fireplace and up the stairs leading to the home office and Master bedroom. You can get a glimpse of the stone on the rear of the Master bedroom fireplace in the upper right of the frame.

Photo 3... making progress... and... following Superseal's lead, we invested in a 'dust deputy'... couldn't be happier!
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Last edited by bytor; 07-18-2017 at 05:52 PM.
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Old 07-18-2017, 05:51 PM   #26
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Re: Photo Overload...


We had a pretty sweet setup this winter... much of the interior stonework had to be completed before other interior finishes could be started... so we were able to pretty much take over each room we were working in. Here you can see our stone selection laid out, our wet saw set-up, and the continuing progress on the fireplace.
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Old 07-18-2017, 05:54 PM   #27
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Fireplace complete... initial cleaning underway... and scaffold removed.
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Old 07-18-2017, 05:58 PM   #28
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The finished product.

Cedar ceilings, Oak floors, blackened steel panels flanking the firebox and lining the wood storage box to the right and also creating the hearth. LED lighting is recessed into a strip at the top of the fireplace as well as in the wood storage area. Just a small 75" TV over the fireplace...
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Old 07-20-2017, 05:43 PM   #29
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The entry stairwell had no less that 1200 square feet of stone installed on the walls and columns flanking the stairs. 26 ft. from lower level floor to upper level ceiling.
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Last edited by bytor; 07-20-2017 at 05:47 PM.
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Old 07-20-2017, 05:48 PM   #30
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...
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Old 07-20-2017, 05:51 PM   #31
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.....
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Old 07-20-2017, 07:45 PM   #32
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Re: Photo Overload...


Quote:
Originally Posted by bytor View Post
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.
Funny. I just finished a fireplace using stone from your region...I'm about 90% sure from the same supplier. I was looking for weathered material with natural beds and they kept trying to sell me saw cut and thermaled. Made for a difficult process particularly since they were 600kms away and a day trip to see the stone in person wasn't possible
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Old 07-22-2017, 07:52 AM   #33
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Re: Photo Overload...


The four chimneys posed the biggest challenge on this job... they were each 3' 6" wide by 14' 6" long by 10' tall at their highest. From ground to eave was 30'. Thanks to our Beta-Max hoist system, getting the larger stones to roof level was pretty effortless. I can't imagine pulling those 3-400 pounders to the top of the scaffold by hand...

Getting one of the rough-ins up into the trusses and breaking through the roof early this past winter;
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Old 07-22-2017, 07:57 AM   #34
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Re: Photo Overload...


Our goal at the beginning of the winter was to get through the roof and get things water-tight for winter. Work on the chimneys began in earnest once the snow was gone this Spring and once we had completed all interior work.

Here is our set-up for the first pair of chimneys... guys on the ground prepping stones for the crew installing on the roof. The Beta-Max hoist mounted on the rail system at the top of the scaffold made the lifting pretty effortless.
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Old 07-22-2017, 08:00 AM   #35
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Re: Photo Overload...


Up on the roof, the first pair of chimneys awaiting waterproofing and stone. The chimney on the left services the indoor BBQ, the one on the right is 'false'... purely for architectural reasons.
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Old 07-22-2017, 08:02 AM   #36
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Re: Photo Overload...


The vent for the indoor BBQ had to be seamless, welded stainless steel, wrapped in ceramic insulation etc. ... hence, it had to be installed in one piece... Bring on the crane;
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Old 07-22-2017, 08:04 AM   #37
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Waterproofing and stone underway...
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Old 07-22-2017, 08:08 AM   #38
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Re: Photo Overload...


The finished chimneys with copper cowls installed;
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Old 07-22-2017, 08:59 AM   #39
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Re: Photo Overload...


I hope the architects, clients, etc. are extremely appreciative. Awesome work.
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Old 07-22-2017, 09:16 AM   #40
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Re: Photo Overload...


Beautiful work.... Quick question if I may, do you provide a firm quote or estimate for a project like that?

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