Mark Murphy from Owens Corning shows Bob a new man-made stone product for the exterior of the modular home project. Southern Ledge Stone and Dressed Fieldstone (both in the color Bucks County) are molded from natural stones. Cultured Stone product is much lighter than natural stone as pumice, a volcanic stone, is used as filler in combination with Portland cement. It is colored with iron oxide and other natural pigments to give it the �fresh from the ground� look of real stones. The installation of manmade stone is much simpler than real stone, as without the weight, the stones are adhered directly to the wall with standard mortar and no sill or base is needed to hold them. Owens Corning produces nineteen types of cultured stone in a variety of colors. The cost of the product installed is about 50 percent of natural stone.
On the exterior of the Rowley home, extensive retaining walls, foundation work, and curving stairways in cement block are ready to be dressed out and finished in Cultured Stone from Owens Corning. Mark Murphy, from Owens Corning, joins Bob to explain how Cultured Stone is created and installed. These cast cement, pumice, and iron oxide products are made in molds taken from real field stones to look like regional stones in both shape and color. Cultured Stone is lighter than real stone and has a flat back for easy mortaring. It is applied like traditional stone and shaped by the vision of the mason who leaves an individual stamp by the pattern created. Cultured Stone costs about 50 percent less than a traditional stone facade because it is a huge timesaver. It even comes with 90 degree returns for easy corners, which make this project ideal for do-it-yourselfers. Cultured Stone layouts are figured based on linear feet and number of corners. With over 100 different stone type and color combinations, there is enough variety to suit any style.
Here are some tips for laying down a nice stone walkway outside your home. After making the walkway with string, the first step is to lay a foundation of stone dust. When it's level, begin laying in the stone pieces. It may take a bit of planning to get a perfect fit. Once they are in place, tap tham tight with a hammer and a piece of scrap wood. Finally, sweep the excess dust into the cracks to prevent shifting and insure a compact fit.
The structure for the fireplace is now being trimmed out with real stone. Bob talks with John Nadler of Plymouth Quarries about the stone being used. In this case, real stone is cut thin so it can be applied like a manufactured veneer. The stone is a New England fieldstone from Connecticut. The stone can be cut with a hammer, a four-inch grinder, or a wet saw. Because the stone is so thin, it can be cut quite easily. It costs approximately $12-15 a square foot. In contrast to traditional stone which weighs about 50 pound to the square foot, this is a lightweight stone product weighing less than 15 pounds to the square foot. The installation can go from the top down as it does not require any structural footings underneath. Bob talks with Joseph McDonough of McDonough Masonry. McDonough built the original chimney when the house was built over 25 years ago. A grout bag is used to squeeze the mortar into the joints between the stones. After two to three hours, once the mortar is set, McDonough uses a pointed stick to scratch out the joints. He then brushes the joints to clear any fine leftover particles.
Bob meets with Mark Marini of Schumacher Landscaping to discuss the installation of the bluestone pavers on the lower terrace. Bob helps lay several of the stones and watches as a stone corner is cut to fit around a planter box.
Moving to the backyard, the hardscape material in the backyard changes. Natural flat field stones were used because of the relaxed feeling. The loose retaining wall in the backyard was already in place when the landscapers arrived and they wanted to preserve that relaxed look. The shape of the functional area was defined by the slope. The field stones were layed in stone dust, no concrete was involved, with pea stone on top. The pea stone is a natural bank-run mixture that is not crushed and has all the natural colors of the region.
Bob meets with landscape designer Ruth Foster, about her plan for a stone patio, a hot tub, and outdoor lighting. Low voltage outdoor lighting is also being installed in-ground for unique effect.
Bob joins Jay Seminara of Seminara Construction who is in the process of laying down a new cobblestone apron at the edge of the driveway. The apron serves two purposes: as an aesthetic feature, and also to act as a barrier for the seashells in the rest of the driveway. Before the stones can be put in place, Seminara digs a trench and lays in stone dust. The dust acts as an adhesive, holding the stones in place. Next, Seminara dry-fits the cobblestones, making sure he gets a nice fit. To finish the installation, he taps the stones into place with a 20-pound hammer and fills in the gaps with more stone dust.
Bob meets up with landscape mason Hector Santos who is building a dried laid stone retaining wall. He is using Corinthian granite from Champlain Stone in upstate New York. Hector's rule of thumb for configuring the wall's proportions is that the base of the wall should be as wide or a little wider than the wall is high (in this case 3 ft.) tapering up in the back (which will be covered with soil and sod) as it rises. Hector also angles the wall's face back slightly so that if it's pushed forward when the ground heaves, it will settle back; whereas if it were plumb and it heaved forward, in time it would creep and fall over. Hector's main concern is creating an even face to the wall. Abutting stones should come up level allowing the stone placed in the next course to span the stones beneath it. Stones shouldn't wobble. If a stone does wobble (and they will because not every stone is perfectly flat), stick shims under it to level it. The caps should be as flat as possible creating an even rather than a wavy top line. Hector uses a string as a guide to keep the tops on one even plane.
Bob discusses the bluestone floor being installed in the floor of the greenhouse. A landscape cloth set below the stone dust to prevent water from seeping through causing the stones to wobble. The stones are being installed in a diagonal pattern and with enough space for drainage.
