Stone Barn project-photos

[K_Tile]

I have been on this forum for a while now and have never shared any photos of my work. So I figured I would take a few photos of an on going project we have been working on since June 05. The barn is almost complete except for the breezeway garage wall and a 48"x48" masonry fireplace.

The barn is a all cedar wood, post and beam construction. There is about a 120 tons of flagstone that we have field cut to make building stone. The stone ranges from 6-8" in width and vary in sizes from 1/2" to 6" thick.

I'm sure the resizing wont so to much detail, sorry!

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[K_Tile]

Two more...

[davem]

Wow. That's beautiful. :nod:

[cx]

That's pretty work, Kevin. :)

I don't wanna be the one to hafta tell you, but that ain't tile. :D

You got pichers of the inside?

[Eric Philson]

Very cool kevin. Welcome everyone to the new, improved, Stone Your World website and advice forum. :dance: :dance:

[NVC]

Pretty work Kevin, too nice for 'ani-mules' IMHO :)

You said 'we'? I hope you had the Mrs. schleppin' the stone up the scaffold, and didn't put your back at risk. They're tuffer than ya think, I wouldn't dare try giving birth. :D

Nice work. It's a shame we don't see as much stonework here in Shakey Town, because of all the reinforcing(steel) needed to pull it off.

thanks for sharing the pics,

Mark

[K_Tile]

Thanks guys!
I'll post interior photos on Tuesday.

The fireplace is being constructed in seismic proportions. Within the chimney there is 5-#4 rebar running vertically to the chimney flue (15" round flue) and horizontal rebar connecting the vertical to form a cage which will all be filled solid with cement. The block also has horizontal wire in between the joints. The chimney will probably extend 25-30ft with a 3ft chimney pot on top.

The breezeway wall is being constructed with a different stone in a rubble pattern. SEE PHOTO!

TILE RELATED:)...The floor in the breezeway will be constructed of 12" slate with nice big 24" x 20" x 3/4" thick sandstone which will also be in a random pattern.

The barn exterior stone looks dry laid but is mortared between the back 4" of the stone and backfilled solid with mortar 1-3" thick. For reinforcement the walls are anchored with ties spaced out every 12"oc with 12 ga continuous wire connecting the ties in between the stone.

The customer wanted a new barn that looked as old as the house which was built 1890s. She has had people stop and ask if she was "restoring that old barn." I knew then I meet her objective. ;)

[cx]

The barn exterior stone looks dry laid but is mortared between the back 4" of the stone and backfilled solid with mortar 1-3" thick. I'm curious how y'all constructed the walls behind the rock veneer, Kevin, since you have no air space between the rock and the outside surface of the wall.

[LadyGodiva]

Wow! You're almost as good as John :D

He paid me to say that :rofl:

[jvcstone]

I'm curious how y'all constructed the walls behind the rock veneer, Kevin, since you have no air space between the rock and the outside surface of the wall.

Have done similar rock work a few times on veneer walls. One job out of granite boulders was over framed walls with the black celotex (sp) sheathing behind the stone. Those walls were about 12 inches thick. Other time (also on a barn) the construction was out of some bazzar styrofoam/concrete panels that the architect came up with. Our stone was a wainscoting 4 foot high with stucco above. Not aware of any problems with either job although the lack of air space is questionable. Suppose if you can keep a sufficient moisture barrier, it's OK :suspect:

Good looking job kevin. Isn't it amazing what people will spend their money on. Many years ago I was doing a lot of masonry work for the "home ranch" of a big black angus syndicate--the bull was like an 8 million dollar stud. We rocked veneered the barn including the interior of the office w/ fireplace. The barn had air conditioned stalls, and hot and cold showers for the critters- nicer than any house I've ever had. ;)

JVC

[K_Tile]

Cx,
As John mentioned you have to keep the backing waterproofed. I guess we could argue that it might not have a min 1" air gap but once the mortar dries it does pull away from the backing a little bit. :nod: If we follow the MIA standards we are all OK, right?

[John Bridge]

Very fine work, Kevin. I just love it. :)

[cx]

If we follow the MIA standards we are all OK, right? OK, I'll bite. :)

My concern would be the same as with a stucco exterior. We always use two layers of moisture barrier under the lath and stucco because the Portland cement mixture is known to attack and seriously compromise many barrier materials when it's in direct contact. I would think you could have the same problem with your application.

[John Bridge]

You could have the same problem with a mud shower. ;)

[cx]

Yep, and I've wondered about that. Don't know if it happens with poly, but it can with felt, for sure. And I've read something recently about the Tyvek-type materials, but I don't recall what it said. :(

Not a sure failure, but there is so much more temperature change, freeze/thaw, continuous wetting, etc on an exterior wall that the problems are even more likely to appear there than with a frequent-use shower situation.

My opinion; worth price charged.

And I know a mud-man who has installed a whole lot of mud showers over nothing but the paper on the sheetrock, too. Some for me, even, before I knew better. And I know he's been doing it for more than 20 years.