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Boone Stonemasons

9/18/2011

We had the opportunity to build a front entrance with steps for a client with a creative and artistic side recently. She was dissatisfied with her simple wooden steps and wanted some stone steps to make a statement and help tie her entrance to the stonework and boulders around her home. I worked closely with her on the design of the project, using her input each step of the way to create something unique and unusual to welcome guests to her home.

Pouring a 12" thick steel reinforced footing.

Roughing in the steps with cement blocks.

We built columns on each side of the steps with irregular shapes. We used stones to tie in deeply with rubble and cement fill. This is not a veneer, but solid stone construction. We also installed conduit for the electricians to come back and add lighting.

Finished product. The owner will set planters on top of the columns and steps to further integrate the design.

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Repairing a chimney near Boone NC

8/27/2011

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One of the main things we do is repairs to existing masonry. We find it very rewarding to help homeowners solve problems with leaky chimney and sketchy sidewalks. The last two jobs we did were of this type.

Here you can see how the mortar joints were failing, allowing water to penetrate the chimney and stain the interior fireplace.

Here Josh uses a small chisel to remove mortar from in between the stones so that we can "tuckpoint", (grout the chimney with fresh cement).

Here you can see the fresh cement. The only thing left is to scratch and brush the joints! The owners should have decades before this chimney needs maintenance again.

This picture shows a walkway we recently repaired. The owners were concerned because the walkway was uneven, with large gravel joints between the stones. The opted to have us completely rebuild the sidewalk, salvaging as much material as possible and using cement between the stones. The result is a beautiful stone sidewalk that will be safe and maintenance free for years to come.

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Catching up.

8/14/2011

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After a brief absence of blogging, including a broken camera, we are back and better than ever with new camera, and fresh photos. We finished the project from the previous post, and I have completed some other projects as well. A consistent theme lately has been homeowners requesting that we fix or redo other masons work. That is why choosing the lowest priced contractor doesnt always pay; good stonework should last for decades or more with only minimal upkeep.

We installed acrylic plaques provided by the homeowners with each of their astrological signs.

Dave welds the hand-forged hooks which will support a hammock.

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Diggers.

6/16/2011

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We started a new job monday building a patio, walls, walkway, columns, and steps. The job is for some of my former clients who brought us back to enhance their property. Last year we built their outdoor fireplace and some walls. But first we had to dig....

the yard is fenced off so equipment cannot reach the site. all excavation must be by hand, and materials must be carried in from the road at the top of the hill.

Tyler takes a break.

we spent considerable time with the layout and design for these walls and patios. After 4 people digging nonstop for a day and a half, we finally got to lay some stone...

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Boone Chimney Repair

6/12/2011

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Hey there- its been a while. We have worked our way through lots of micro jobs lately, appearing at as many as 4 jobsites in 3 days! Following are some photos and descriptions of our travels.

The scaffolding on this chimney repair was a job in and of itself.

The stone was falling off, so we had to strip it down to the roofline and even lower on the front. This chimney had been repaired previously, but all that was done was to gob caulk and roofing cement everywhere- a real mess, but not a long term fix.

The chimney was flashed incorrectly, so I hired my friend Tasha (who is an expert at metal roofing) to install heavy gauge metal flashing and counterflashing so the owner will never have a problem with leaks.

We poured a 3" thick steel reinforced chimney cap then replaced and grouted the stonework. A repair like this will last 25 years or more.

Then we built a set of columns Bluestone wild using sawed veneer stone. It is used like artificial stone, but has the look, durability and strength of natural stone.

the client wanted a stone column here, so my proposal was to use the sawed veneer because it faster and less mess to install.

we furred out the column then fastened wire lathe to which we attached the stone.

finished product- the client was thrilled!

next job was to build a courtyard area in between the front door and the garage. first we had to excavate to a depth of 6"

Here Josh is using the level to "range between stones. Since we usually slope our patios the stones dont read level, but the surfaces must be on the same plane to create a safe walkway.

Josh fits the last few pieces. We used a gravel footing here, but the owners requested grouted joints for and easier-to-clean surface.

The finished product. Simple, functional, durable, and built within the owners budget.

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Boone Boulder wall.

5/17/2011

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Finished the boulder wall thursday, and was pleased with the results. Walls of this type a a great alternative to traditional masonry walls because of the lower cost and shorter time to construct. To build the equivalent wall from stacked stone would have taken at least twice the money and probably four times as long.

I think we made a huge improvement over the previous wall and steps.

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Drystone wall finished, then a wall with BIG stones.

5/11/2011

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We finished the drystone wall in Daisy Ridge last week and we were very happy with how it turned out.

Next project was to use a small excavator to remove a wall and steps that were failing and replace them with boulders supplied by Solid Ground grading.

"Before" picture. Note the lean of the wall--it seems to be defying gravity.

Josh used a jackhammer to remove the concrete steps.

Next I had to pick out a boulder and start building.

This pile of boulders might look look chaotic to some people, but all I see is opportunity.

Since our machine lacked a "thumb", we had to chain each stone and lift it into place.

Here you can see the steps coming up, and I am using rubble and dirt to backfill the wall next to the steps.

Finished photos coming soon!

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Stone retaining walls in Boone NC

4/28/2011

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We had great weather today and were able to work on our tans, which is always a plus! I made good progress in capping the wall, but we were slowed down by a feature of this project. The owner requested part of the wall rise above grade so the stonework would be visible from the driveway. The challenge here was to transition from a retaining wall to a 2-sided wall.

Josh searches for that special stone.

Here Josh demonstrates a "through stone", which is a stone that extends to both sides of a 2-sided wall. Through stones add strength to a wall and help them to last for many years.

Section of wall completed by Josh. My only concern is that his work might look better than mine...

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Building a drystone retaining wall.

4/27/2011

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Today we worked on the drystone retaining wall in Daisy Ridge. Walls like this are different, and much more labor and stone intensive, than a mortared or veneer stone wall. The reason is that the wall has to be structural, as well as look good, so the stones have to tie back deeper into the backfill and be fitted much more carefully.

Notice how much more stone is extending back into the wall than what you see on the face of the wall. These are called "tie stones" and they are critical to building a strong drystone retaining wall.

Another "tie stone". Every third rock at least should be a tie stone. We use rubble, rock chips, and 3/4" washed gravel for the back fill, which allows water to pass freely through the structure. The white fabric prevents soil from infiltrating the gravel and inhibiting drainage.

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Very tall chimney, cont; building a drystone retaining wall.

4/26/2011

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Yesterday we finished the chimney for http://kingfishcabin.com and our next project is a stone retaining wall in the Daisy Ridge development of Valle Crucis. The owner had a wall built from pressure treated 6X6 and it was rotten and starting to fail after 15 years. Our job is to replace the wall and build a smaller wall to stop water from flowing down a set of steps during a flood.

This picture shows the finished chimney cap. I didn't have the camera when we poured it, so no photos from that.

Excavating the footing for the retaining wall. It is important to have a solid base for the wall and to dig far enough back to provide adequate depth in a wall like this.

Next I took a trip to the quarry to buy washed gravel for the footing and backfill. The loaders there are massive. I also got to see the "pit".

the "pit"

Tom builds the smaller wall. We use strings to help keep our work straight and level.

Establishing the footing course. We use the biggest, roughest rocks in the footing because they provide a solid base for the rest of the wall. The white fabric is a soil separator I use to keep dirt out of my gravel so water drains freely through the wall. Also we use the scrap stone from trimming as fill because it settles and moves less than gravel.

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Boone Stonemasons

Repairing a chimney near Boone NC

Catching up.

Diggers.

Boone Chimney Repair

Boone Boulder wall.

Drystone wall finished, then a wall with BIG stones.

Stone retaining walls in Boone NC

Building a drystone retaining wall.

Very tall chimney, cont; building a drystone retaining wall.

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