Due to our ability to custom make all our products, Rustic Stone can make any stone type, colour and size a customer may wish. Our work is cultured to your requirements.
Custom works for heritage styles of building a specialty.
Recommended Installation of Rustic Stone
Preparation of New Structures
When a new structure is to be built using conventional stud frame, stable timber should be used, e.g. Pine, at 400-500mm centres faced with 6mm fibre cement sheet, rough side out, nailed at 300mm centres using 40mm clouts. Sheet to be laid horizontally. If stumps are to be used, the spacing and sole plates should be suitable to take the additional load.
Preparation of Existing Structures
If existing wall is constructed in brick, concrete or masonry and in good condition, simply ensure the surface is thoroughly clean. Painted surfaces must be scarified to provide mortar key.
If existing wall is constructed of weather boards, plasterboard etc., cover with 6mm cement sheet laid horizontally with staggered joints rough side out. Nail with flat head galvanized nails at 300mm centres ensuring nails penetrate a minimum of 25mm into studs.
If existing wall is constructed of cement sheeting, additional fixing is recommended re nailing sheets at 300mm centres along studs for extra strength. If the sheets are old, brittle, bowed or cracked, nail new sheets as described previously.
Note: Fibre cement sheets must be fixed horizontally (not vertically). Joints must be staggered to avoid movement. If the wall is supported on piers or on stumps, check spacing and sole plates are suitable for the additional load.
Preparation of Wall Surface
This step is necessary to ensure a suitable surface for Rustic Stone adhesion. Mix 4 cups mortar adhesive, 4 cups sand and 4 cups of cement with a cup of water. Stir until a smooth paste is obtained. Use textured paint roller to apply paste to wall, ensuring a rough surface. This mixture will cover approximately 6 sq. m Allow about 1 hour for paste to dry on the wall.
Preparing the Mortar
Mix thoroughly one bucket each of bricklayers sand, washed sand and cement. Mix 3 litres of water to 1 litre mortar adhesive and colouring, if required. Blend the wet and dry mixture together to a stiff mix. More water may be required depending on sand or weather conditions. This mixture will be sufficient to cover approximately 1.5 sq. m of wall.
Fixing the Stone
If applicable, fix corner stone by applying mortar 20mm deep to back of each stone and firmly press into position.
Fix Flat Stone
Using a string line to ensure a reasonably straight course, starting from the bottom of the wall and working your way up, apply mortar 12mm thick to the back of each stone and press into position ensuring mortar is pressed out around stone. Hold for a few seconds for mortar to grip then proceed with next stone. Should the stone face become marked with mortar, clean off with a damp cloth before mortar dries. When mortar has dried sufficiently, rake out joints to desired depth.
Cleaning Down and Finishing Off
Clean down as you go with a stiff brush and damp sponge. Do not allow mortar to dry on stone face. Do not use Spirits of Salts as this will affect colour.
It is not necessary to move doors and windows as the protrusion of the stone gives the appearance of traditional stone work. However, if required, timber surrounds can be fitted.
Architraves should not be removed as Rustic Stone can be butted up directly.
Expansion Joints should be incorporated where there are long unbroken areas exceeding 6 metres - e.g. expansion joints can be made around windows by allowing a 5mm gap and filling with silicone.
Cutting Rustic Stone is easily achieved by making a shallow groove along face with masonry abrasive disc; break by tapping. Broken Stones unavoidably occur. These you will find useful for cutting or filling irregular areas.
Hot Weather conditions - Wet wall and back of stones prior to fixing.
Wet Weather conditions - It is not recommended fixing Rustic Stone in wet or damp conditions. Allow extra drying time in cold conditions.
Chimneys and Fire Places require at least 2 weeks drying prior to lighting fire as mortar cracking is likely to occur.
Curing of Stone and Mortar - Once these have cured, they will develop their true colours. Curing time can take several weeks.
Before Rustic Stone's Reproduction Stone you would have to pay a lot of money for real stone to get your house looking identical to natural stone
Now with this Alternative stone product looking identical to natural stone, Rustic Stone is manufactured in moulds designed to reproduce and enhance the individual character and texture of selected natural stone.
Rustic Stone produces a wide range of reproduction bluestone and sandstone products designed specifically for the building industry.
Rustic Stone is a small family business that has been operating in Ballarat Vic (Australia), since 1993. It was conceived by Michael Thurlbeck, an Engineering Pattern Maker, who develops and produces all moulds used in the production of Rustic Stone.
Unlike natural stone, Rustic Stone cladding is manufactured using the latest technology providing huge savings in labour and transport. This ensures a highly economic product ideal for almost all wall situations, both inside and out.
The benefits of building in Rustic Stone cladding include: Increased resale value, Quick and easy to install, Reduces labour cost, economical - save $$$, Ideal for both new buildings and old,No expensive footings required,Suitable for the home handyman or our specialist craftsmen available,Increased insulation, Low waiting periods, Maintenance free, Will not rot