Q–I am in the planning stages of an upcoming building project that requires stone work. After obtaining quotations for this work, I am over budget. A friend suggested that I look into the artificial stone products. On visiting a local supplier of these products I was amazed. The samples looked like real stone. What can you tell me about these products? Are they affordable? Would you install them on one of your projects?
A–I couldn’t agree more with you. Artificial stone products are extremely realistic. In fact, I was a geology major in college and many of these products look exactly like the rocks that I used to study and crack with my rock hammer.
I am very impressed with these materials. Many artificial stone products are both lightweight and durable. These two qualities are achieved by manufacturing the stones in a controlled environment.
Just about every artificial stone is made by mixing small, lightweight pieces of aggregate, Portland cement and different iron oxide pigments. This mixture is poured into hundreds of different flexible molds that vibrate. This vibration is the key to producing realistic textures and color variations in each individual stone. Because these stones are very similar to concrete and are manufactured under ideal conditions, they will probably outlast both you and me.
The fact that these products are lightweight gives them a definite advantage over natural stone products. Artificial stone products do not require foundations beneath them for support. They are attached to buildings in a manner very similar to applying stucco.
If your house is wood-framed, a wire lath is applied directly to the wood studs or over the exterior wall sheathing after a weather-resistant barrier has been applied. This barrier can be either standard asphalt felt paper or one of the many waterproof air infiltration barriers. Once the metal lath has been securely fastened to the wall framing members, the installer simply applies a 1/2- to 3/4-inch-thick layer of mortar onto the lath. The stones are set directly into this fresh mortar. Many manufactures recommend using specific colored mortars depending upon the color of the stone being used.
If the structure is masonry to begin with, you simply apply the coat of mortar directly onto the concrete block, brick or poured concrete. It is a fairly simple procedure.
There is virtually no limit to where artificial stone can be used. You can use them for any exterior wall surface, free-standing exterior perimeter or garden walls, coverings for exterior metal or masonry chimneys, interior fireplace fronts, columns, wainscoting, whirlpool structures, mini-indoor waterfalls, etc.
You can even do the interior of your office if you desire to simulate a room in a castle. Some manufactures even make artificial cobblestones for driveways and walkways. Artificial brick is available as well.
In the past, some people have expressed concerns about the color fastness of artificial stone products. For the record, natural stone will fade and discolor as a result of oxidation and exposure to weather.
Artificial stone products are manufactured in such a way that the color is integral throughout each piece. Some manufacturers have developed an additional process that imparts shade variations directly from the face of the molds. This makes the stone products virtually indistinguishable from their natural stone counterparts.
Artificial stone products should help you with your project’s budget problem.The cost of a complete installation of artificial stone is typically 50 to 60 percent that of a similar natural stone installation. The current retail cost of many of the artificial stone products is about $4 to $5 per square foot. Labor, mortar and other costs may add $4 to $8 per square foot, depending upon your location.
I wouldn’t hesitate to use the artificial stone products on one of my projects.
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Have questions about the remodeling process? Write to Tim Carter, c/o The Chicago Tribune, P.O. Box 36352, Cincinnati, Ohio 45236-0352. Questions will be answered only in the column.
For a list of manufacturers of artificial stone, sources of product literature, detailed installation guidelines and design and use ideas, send $2 and your name and address to Tim Carter at the above address. Ask for Builder Bulletin No. 63.
