A Stone's Throw :: a blog about stonework, history and happenings around Raleigh, NC or farther than a stone's throw away.

Carrying A Torch For Bluestone

02/24/2012 13:50:00

Besides the variety of vivid colors and styles available, there's another reason to love bluestone - thermalling. Thermalling or flaming is the process of using an acetylene torch to remove imperfections from stone. And, it works really well on certain types of natural stone like bluestone.

So why would you use a torch on a rustic material like stone? Over the last ten years, bluestone has become an increasingly popular choice for Raleigh homeowners. It's a great design pick for sidewalks, patios and steps because it pairs so well with brick and comes in an array of sizes and shapes.

For sidewalks and patios, stone centers offer bluestone in both cut pattern and random shapes. Cut pattern shapes are dimensional and sold in 6" increments. Random pattern is irregularly shaped, and the surface is generally rougher than cut pattern. Thermalling can be used to remove flaws, scratches or even paint marks from bluestone sidewalks and patios under construction.

In addition to the thinner bluestone that's sold for flatwork, step treads are available in 2"-6"+ pieces. These thicker pieces are sometimes hand cut, carefully shaped and then used with the edges visible, like in the photo above.

Those steps were custom designed and crafted for a family in Wake Forest who wanted a more dramatic entrance to their home. They were made from 1,200 lb. rectangular slabs that measured 6½' long x 2½' wide x 6" thick. During the installation process, grinders and saws were used to create the curved shapes seen above.

Before thermalling, the sawn edges looked obviously fabricated. They were lighter in color and unusually smooth. During thermalling, a thin layer of stone was removed for a more natural looking surface that matched the other unworked surfaces.

The photo above shows a similar piece of bluestone being thermalled. The area on the left has not been thermalled yet. Of course, safety precautions are necessary when using an acetylene torch for any reason. It's also a good idea to wear a dust mask with a HEPA filter when working with stone.

Thermalling is probably not a job for do-it-yourselfers, but ask your masonry contractor about it the next time you're shopping for stonework. When done right, thermalling ensures you'll get the most professional result with bluestone. For ideas and inspiration using bluestone, browse our portfolio.

Your questions and comments are welcome below.

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Back To The Future: Belvidere Park Installs A Time Capsule

01/11/2012 16:57:00

A small neighborhood project was a big reminder of how different Raleigh was in the 1950's. When Belvidere Park received grant money for a community improvement project, a time capsule with neighborhood history was not part of the plan. It was only after construction began on new entryway columns that the idea cropped up.

We realized, after tearing down the remains of the old columns, that it would've been fun if workers had left something behind for present-day residents. Who had built those columns? We knew they weren't original to the subdivision. Many older residents were no longer available to fill in the history - memories fade, people pass or move away. Since there was no formal neighborhood association, there were also no archives to reference.

With little to go on initially, a picture of the past began to develop - quite literally. A local business owner shared an aerial photo of the subdivision. It was taken by a customer and World War II vet who had flown over Belvidere Park in 1957.

The first thing you notice is how few cars there were in the driveways. There was a small business on the corner of Dennis and Myers, and Capital Boulevard was just a sleepy two lane road. But there were no columns yet on Dennis Avenue. They must have been built after 1957.

As work on the new stone columns progressed, residents stopped by to share their thoughts about the project. One neighbor filled in the details of how the original columns came to be. There had been a ladies garden club, and they had hired someone to build them. And yes, in true 1950's form, there was a kid's club called The Belvidees too. You could imagine them wearing Mouseketeer-like beanies, but so far no photos have emerged.

Jim Bailey, a longtime resident and founding member of The Belvidees, was kind enough to share his mother's memorabilia with us. His mother, Mrs. F.E. Bailey, had been the president of the Belvidere Park Garden Club. There was a Mad Men era photo of a Christmas party (above) and newspaper clippings of officer elections.

Interestingly, the news clippings were attached to City of Raleigh letterhead with personal notes from Tom Davis, Chief of Police, congratulating them on their work. The capital city may have been where Barney Fife moved for career advancement, but in the late 1950's, Raleigh was still small-town friendly.

More recently, the neighborhood gathered on a windy Saturday in November to install the landscaping plants. Close to ninety trees, shrubs, grasses and flowers were planted to accent the new stone columns. Having lots of eager volunteers allowed us to finish it in one busy day.

With the planting phase completed, we were ready to install the time capsule. Included in it were the old photos and clippings as well as contemporary photos and articles about the neighborhood. We hope that whoever discovers the time capsule will have as much fun with it as we had putting it together.

If you have memories or old photos to share, especially of those elusive Belvidees, we'd like to hear from you too. Let us know below.

An Update 4/6/12:

A big thank you goes out to Linda (Poole) FitzSimons who grew up in Belvidere Park and generously shared her old photos with us.

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Two Coins In The Stonework

11/23/2011 17:07:00

The tradition of placing coins in stonework that's under construction goes way back, but I came upon it in the late 1990's. A stonemason from England had found my business online. I guess European Stone Masonry sounded like a good bet for employment. I couldn't offer him work, but I told him to look me up if he ever made it to North Carolina.

To my great surprise, a few weeks later he was in town and stopped by for a beer. I showed him some of my work around Raleigh, and he asked me if we threw coins in our stonework here. He said it was an old tradition dating back to Roman times. As superstitious as he was, I don't recall my Italian grandfather doing this though. My cousins and I spent Pennsylvania summers working for him as teenagers.

There's a long and interesting history of including offerings like grain and wine in building projects, as well as animal and even human sacrifices. In modern times, coins have become an easy way for stonemasons to leave their mark.

Recently, there were a couple of news stories about finding old coins in stonework. The BBC reported that two Georgian coins dated 1804 were discovered during a church restoration in Worchestershire, England. They had been carefully placed in a buttress eighty feet up in the church tower. The church plans to display the old silver coins and will replace them with new 2011 coins. What's the exact location of the new coins? Well, that's the stonemason's secret.

In Washington, DC, stonemasons found coins while repairing damage to the National Cathedral after the August earthquake. They discovered them in the mortar between sections of stone. Joe Alonso, head stonemason, said that the coins were saved and will be put back into the mortar when the stonework is reattached to the towers.

I usually throw whatever I have in my pocket into my work for good luck. I enjoy history, and my customers and their kids have fun with it too. One customer decided a quarter wasn't enough and ran into the house for a Sacagawea dollar. Occasionally, a euro or other currency garnered from traveling gets tossed in as well.

There is timeless appeal in being part of an ancient custom. Everyone wants to leave something of himself behind. Imagine someone's delight, centuries later, upon discovering your pocket change. Keepers of the tradition, there seems to be an unwritten rule among stonemasons to respect the past and leave a piece of history for the future. I love that idea.

If you place coins or anything else in your stonework, tell us about it below.

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Porches And Steps May Cause Separation Anxiety

09/22/2011 10:23:00

This stone porch has had surgery but you can't see it - a kind of nip/tuck for masonry. It's a common problem with older homes and even some new ones around Raleigh.

The footing for the steps isn't attached to the porch or worse yet, there's no footing at all. A footing is just a concrete substructure that provides a solid base for masonry.

That Sinking Feeling. Over time, without a solid footing, the steps may separate from the porch or the porch may separate from the house or both. If the porch drops or pulls off the house, it's certainly not a pretty sight, not to mention a safety hazard.

However, the more urgent problem is that water may collect behind the porch causing moisture damage to the home. This is when anxiety sets in. Typically, the steps pull away from the porch and drop maybe 1/2" on one side and 1" or so on the other side. There might be a small crack between the steps and the porch as seen in this photo:

This scenario probably won't keep you up at night. Although, the worst case we've seen probably would. It was a job that had a 20' long porch at the front of the house with no support along the back.

The exterior of the house had been constructed with 6" thick building stone that sat on top of the unsupported back edge of the porch. The porch buckled under all the weight.

The stone on the exterior of the house dropped 6" in some places. The window sills on the first floor cracked in half. When it rained, water flowed behind the porch and into the basement through the foundation.

The drainage pattern in a yard and events like hurricanes and drought can impact whether masonry will shift too. During Hurricane Fran, which swept through Raleigh in 1996, this house had 5' of water in the basement. You can imagine the time and expense involved in fixing these types of problems.

Masonry Makeover. Getting back to the bluestone porch above - here's what it looked like before it was reconstructed. The porch was off-center and in disrepair, but it was firmly attached to the house. To recenter the porch in front of the doorway, it was rebuilt several inches to the left.

The landing was built from 2" thick cut pattern variegated bluestone. The loose steps were pinned to the porch with rebar and then covered with 3" thick single pieces of bluestone. The risers were built from local granite.

Once the original steps and porch are secured, the new stonework can correct for level and risers of varying heights. When done well, these types of repairs should be permanent and invisible. Now, if only we could say the same for celebrity face-lifts. Visit our portfolio to browse other stone steps, porches and staircases.

Your comments and questions are welcome below.

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A Stone Wall From The Inside Out

08/08/2011 12:25:00

Twitter followers may remember a series of tweets about this job last year. Here's a more detailed look at the anatomy of a stone wall we built in downtown Raleigh. For this project, a large oak tree was key to how the stone wall was designed and constructed. Located on the grounds of an historic church, it was important to protect the mature tree during the installation of a new sitting wall and wheelchair ramp.

To minimize digging around the roots, an above-ground footing was designed. Footings can vary depending on the type of stone wall construction. Typically, it's a concrete substructure onto which the stone is layed. Sometimes, it's a trench with compacted, crushed stone, as in traditional dry wall construction.

On this jobsite, the above-ground footing projects only 3” into the ground but has a side shelf for the stone to sit on. There are 3 or 4 places where the concrete footing projects 18" into the ground with a 12” thick cylinder. In Raleigh, winters are mild so the ground doesn't usually freeze below 12”.

The core of the sitting wall (built by Hopco Construction of Raleigh) is 10” thick x 22” tall and reinforced with rebar. Instead of regular wall ties, vertical steel channels with adjustable wall ties can be seen. It's essentially a concrete structural beam with a stone wall built around the outside.

The above-ground footing only allowed enough room for 6” thick granite. To match the stonework on the church, corner pieces were sawn out of larger stones, giving the appearance of up to 12” thick corners. The stone wall was finished with 4” thick limestone caps.

If you're not from this area, Raleigh is known as the "City of Oaks". With an innovative solution for protecting this handsome oak, it continues to remain healthy while shading a school playground. You can read more about the Christ Church project on our website.

Your comments or questions are welcome below.

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Stonework Along The Iron Heritage Trail

06/30/2011 11:44:00

This month, we're more than a stone's throw away from Raleigh. On a recent visit to Connecticut, we discovered the historic stonework along the Iron Heritage Trail. The Iron Heritage Trail is a series of 58 blast furnaces, lime kilns, forges, iron mining and mill sites in northwestern Connecticut and the surrounding areas of Massachusetts and New York.

At one time, this area was the center of America's iron industry. Today, it's a beautiful drive along lush rolling hills, quiet New England towns and for stone enthusiasts, more rambling walls than you can shake a chisel at. Here's a handful of interesting stops along the way:

The Beckley Blast Furnace (above and four photos below) is located in East Canaan, Connecticut. It was constructed of locally quarried marble in 1847 and stands 40 feet high. Originally built 32 feet high, you can see where masons added 8 more feet to the top at some point during its operation. Stabilization and preservation of the furnace was completed in 1999. The furnace is on the National Register of Historic Places. With an annual river walk celebrating local heritage, it's the centerpiece of the Iron Heritage Trail.

Tuyere arches are found on three faces of the furnace

Retaining wall adjacent to the furnace

Quarry marks on a massive marble corner piece

Cutaway view of the hearth

These conical charcoal kilns sit stoically along Deep Hollow Road just off Highway 22 in Wassaic, New York, a hamlet of Amenia.

Top of the charcoal kiln above

Looking up from inside the dark kiln

The restored Sharon Valley Lime Kiln in Sharon, Connecticut was constructed of coarsely cut limestone around 1880. Stone for the kiln was quarried on-site. The stack was stabilized with white oak timber binders installed at two levels.

Kent Furnace, located on Route 7 in Kent, Connecticut was put into blast in 1826.

Interior view of the stabilization of Kent Furnace

The Iron Heritage Trail is a fun exploration if you love stonework, industrial monuments or history. Locals recommend viewing these sites in the spring and fall, as the heavy vegetation of summer can obscure the aging remains. Special thanks to Elizabeth Shapiro with the Sharon Historical Society. She was more than willing to share her obvious love of history with us even though they were closed for the day.

Your comments and questions are welcome below.

References:

Echoes Of Iron In Connecticut's Northwest Corner by Ed Kirby

Sharon Historical Society

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New Stone Bench Marks Belvidere Park Entrance

05/09/2011 09:07:00

Belvidere Park residents had fun yesterday placing a new stone bench near the Vale Street entrance. The project is funded by a neighborhood improvement program through the City of Raleigh. The stone bench is the next step in a lengthy process which began with the construction of new stone columns at the main entrance on Dennis Avenue.

The bench is a seat with a past. The nearly twelve hundred pound block of stone is antique granite reclaimed from Central Prison in Raleigh. Central Prison was built in the late 1800's with granite (known locally as Old Wake County) that was quarried just outside the east wall. Here's an old photo of what must have been an imposing sight in 19th century Raleigh.

An interesting bit of trivia was found on the NC Highway Historical Marker Program website. Among the master stonemasons hired to aid the construction was W.O. Wolfe, father of Asheville native and novelist Thomas Wolfe. You know - the guy who said you can't go home again.

A couple of things point to the stone's history. You can see that it has small drill marks along the edge. Later on, stoneworkers used larger drills to quarry stone. Also, it was hand-faced with a point chisel to create a flat surface on three sides, making it ideal for carved lettering and seating today.

The stone bench, set under a mature magnolia tree, will be a place for residents to pause and appreciate the wonderfully fragrant blooms of a southern favorite in early summer. (Pictured left to right: Mike Baker, Joe Valles, Jamie Bort and Adam Skelding.)

The landscaping plan around the main entrance calls for a variety of native plant species. Drought-resistant trees, shrubs and perennial flowers were chosen by the designer for ease of maintenance and water conservation. Planting, unfortunately, has been delayed until the fall.

The recent tornadoes which crashed through Raleigh and across the South have sidetracked the staff who handle the disbursement of the City's grant money. The weather gurus should assign names to deadly tornadoes like they do with hurricanes. A force so destructive shouldn't be allowed to hide behind such a generic weather description.

Our suggestion: 'Helen' with the emphasis on hell. Let's hope that all the families who lost their homes can go home again very soon. Check back right here for more updates on the Belvidere Park project.

Your comments and questions are welcome below.

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A Buying Guide For Stonework: Choosing Your Contractor

04/01/2011 09:15:00

This post is a continuation of A Buying Guide For Stonework: Choosing Your Stone

Do Your Homework. So how do you choose a residential masonry contractor? As with most home projects, it's well worth the effort to do a some research. (Oh sure, we've learned the hard way too. Don't ask about the bathtub debacle.) Look for an experienced stonemason with great references, a solid reputation and one who offers a guarantee. Ask to see what they're currently working on. Look at their past masonry projects on-site.

Ask lots of questions pertaining to how they work. If your work will be outdoors, find out if heavy equipment will be used. Will existing trees and plantings be protected? We know a woman whose favorite specimen tree was killed when her contractor used a Bobcat to dig a small patio space. Yes, it was quicker and maybe less expensive, but at an unhappy cost.

Ask Away. Will the jobsite, your treasured yard, be completely cleaned up after the work is finished? If your work is planned for indoors, can dust be contained and kept to a minimum? Will the area be off-limits to the rest of the house? This may be important to people with small children or health concerns.

Ask specific questions about how your project will be built. How will the site be prepared? What kind of foundation or footing will your stonework have? For patios, it's important to know how drainage will be handled. For more information on patio construction, read Keys To A Quality Stone Patio.

Here are a few general questions to ask your contractor. How will your pets be accommodated? No, they won't be put up in a pet spa. But you may need to have a backyard gate closed at all times to contain a rowdy dog. Will workers be mindful of that as they go in and out all day long?

And finally, who will perform the work? Will your stonework be done by the same stonemasons who did the work in the photos on the website or brochure?

Count On Quality. Remember that quality stonework takes longer but comes with peace-of-mind. Think of it as time well spent on a product of superior craftsmanship and value. Masonry work that is done properly is a significant investment in your home, lasts a lifetime, requires little if any maintenance, and should not need repairs.

If you want even more detail, read How To Recognize Quality Stonework. If you can't imagine asking so many questions of a potential contractor or builder, read this North Carolina home buyer horror story. You may change your mind.

As always, we welcome your comments and questions below.

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A Buying Guide For Stonework: Choosing Your Stone

03/31/2011 22:15:00

Ah, spring! It's that exciting time of year when we put into action those projects we've been dreaming about all winter. Are you thinking about including stonework in your home or landscape this season? Maybe a new garden wall to define your planting beds? Or a stone patio and outdoor fireplace for summer celebrations?

If you haven't worked with a masonry contractor before, you may be wondering where to begin. Here are some guidelines to help you through the buying process. They're based on our years of experience working with customers, listening and learning along the way.

Get Inspired. Most homeowners want to focus on color first. It's the obvious place to start and makes good sense to a point. So begin by examining your space and focus on a color that unifies the area. Notice the style and color of surrounding elements like paint, cabinetry or landscaping and choose stone that is complementary.

After you've chosen your color palette, consider using light and dark elements to add visual interest. For a cohesive look, let unity play the lead and keep contrast in the supporting role. Sometimes a contrasting color scheme is the better and more dramatic choice.

One example is monochromatic bluestone set against red brick. It's a classic pairing that works well for sidewalks, patios and steps. Another option is to mix different types of stone for a custom result that makes a beautiful impression.

Draw On Nature. Be aware that natural stone which is exposed to the elements will sometimes change color over time. Walls will age with lichen and moss. Patios take on a patina. Efflorescence (deposits of minerals on the surface of the stone) may form. If your stone is planned for outdoors, keep this in mind during the design process.

As important as color is, the attributes of size, shape and texture play an equally important role. Examine the properties of the stone - is it sleek, rustic, textured, round, angular? Think about how these properties relate to the look you want to achieve and work them into your design plan. Whether it's installed inside or in the garden, you can draw on the natural characteristics of stone to bring your project to life.

Plan Ahead. It's a good idea to see an example installed before you buy so you can visualize the finished project. Ask your stone center if they have sample boards on display. Request photos from your masonry contractor. Call on your contractor's expertise to help you choose a material that works best for your particular application and budget.

Most contractors will be glad to meet you at a stone center to discuss the range of products available for your job. Choosing the right stone is easy with some planning and makes all the difference in the quality of your stonework project.

This post continues with A Buying Guide For Stonework: Choosing Your Contractor

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Old Stone Fireplace Has A Porcine Past

02/28/2011 18:31:00

If you've ever traveled along Highway 64 west towards Raleigh, you may have wondered about this old stone fireplace from another era. It sits on an embankment on the right just past the Neuse River.

On a rainy winter day when this photo was taken, it had a spooky vibe, but you could imagine that it had once been a place where people had fun. These days, the substantial granite fireplace is forlorn with smilax vines getting the better of the terraced walls nearby.

Several years ago, The News & Observer ran an article about this fireplace based on the memories of area residents. Turns out, it could have been constructed as part of a rest area along the old road from Raleigh to Tarboro.

In her book, "The Historic Architecture of Wake County North Carolina," Kelly A. Lally wrote that it may have been built in the early 1930's by the Civilian Conservation Corps or Works Progress Administration. The remaining stone columns, built from Rolesville granite, look like they might have supported a wooden picnic structure adjacent to the fireplace. The grapevine joints seen in the photo were often used locally to finish stonework during that period.

Other readers remembered that it had been used as a barbecue pit prior to World War II and maybe into the 1950's. Workers would roast a pig in the heavy stone fireplace and carry the food across the street to customers of King's Barbecue. Everyone recalled that the food at King's was good, and people came from as far away as Rocky Mount to dine and dance.

Eventually, the restaurant was sold and later torn down when Highway 64 was expanded from two lanes to four lanes. Running across Highway 64 with food in your hands today – now that's hard to imagine.

If you remember when this abandoned stone fireplace was in operation, please share your thoughts below.

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