1. Design - Whether we start with an architect’s CAD drawing or a rough sketch, every project is fully drawn in CAD with the desired stone pattern. We start by laying out the stone pattern specified for the project, and then overlay the mortar joint with the specified thickness. Finally, the project is exported to a digital proof showing each stone numbered and in its final position in the completed project.
2. Approval - The digital proof of the job is sent to the architect, builder or homeowner coordinating the project. Unlike traditional techniques changes can be made at this stage quite easily.
3. Cutting the Stone - This is the high tech component of our process, which incorporates computer driven equipment. Each stone is cut using our patent pending process, which combines high pressure water, sand and a number of mechanical processes to produce stones cut so precisely each one fits perfectly to those stones around it when installed. A unique number, used to identify the location of the stone in the project, is etched on the back side of the stone and is not visible after the stone is installed.
4. Hand Finishing Edges - All the edges that are visible after installation are finished by hand using traditional chisel and hammer techniques. The result is a perfectly cut structural stone with face surfaces and visible edges equivalent to the finest stonework available. We have tremendous flexibility at this stage to create a look that is extremely refined with tight fitting stones or more rustic with rough irregularities. All of which is specified in advance by the customer.
5. Palletizing for Shipment - All the stones for a project are packaged on a pallet in the recommended order of installation so that they each stone can be “picked and placed” to minimize extra handling of the stones. Each pallet is neatly wrapped and then secured with shipping bands to ensure every stone arrives undamaged and ready for installation.
6. Installation - Because all the stones are pre-cut, the vast majority of installation labor is already complete when the stone arrives on the jobsite. From there, the stones are assembled according to the provided plan, much like a giant puzzle. Depending on what was specified by the customer, the stones will be set into place with the dry look, a mortar joint or adhesive. Click on the Demo icon below to see an animated segment on how a fireplace front is assembled using our system.
