ArcussStone on Windows, Columns and Arches Mixes Well with a Natural Stone Building Face.

Restore a building or make a new structure look like it has beautiful cut limestone—all with stone coating materials as thin as 3/8 inch from ArcusStone Products, Oakland, CA. It was Carol Kavalaris' fascination with old stone buildings that led to this "liquid stone" product. Kavalaris, a designer who lived in Europe for several years became fascinated with the preservation of historic structures. She watched building repairs, took lots of pictures and observed the workmen applying thick slurry mixes over stone. After returning to the U.S. and working with a French artisan who knew the basics – a mix of crushed limestone and cement, Kavalaris and her associates began a formulation process using modern technology that resulted in an easy-to-use one-bag blended mix. Now, ArcusStone Products, LLC. offers stone coating materials in 15 standard colors and 15 standard plasters. You can apply them vertically, horizontally, and in any imaginable shape. They weather well outdoors like natural limestone and are for interior walls, fireplace surrounds, flooring and more.

The ArcusStone Market The exciting thing is that by utilizing various polymers and bonding agents, a wide variety of substrates may be treated with ArcusStone® Coatings. Buildings can be retrofit with it. Use it over sheet rock, drywall, stone and cement. Apply ArcusStone to walkways, driveways and countertops. Use it over tile and inside showers—basically, anywhere that mesh and a basecoat can be applied. Pre-cast manufacturers, concrete contractors, the ornamental plaster trade, faux painters, and sculptors all use this material. With such versatility, ArcusStone is many places—high-end residential, commercial and public buildings.

To use ArcusStone as a floor product, apply it as you would a concrete overlay. You can imprint and even chemically stain it. Bob French, French's Custom Stamped Concrete, Arroyo Grande, CA imprinted a front porch with a 1/4 inch topping of ArcusStone. He used powdered release and Brickform Rafco stamps. He is very pleased to have one more upper end finish to present to customers. French adds, "The requirement for training by ArcusStone keeps quality control high."

Another flatwork application is for pool decks. It's durable in wet areas, tolerant to pool chemicals and remains cool underfoot. Its molding possibilities make it highly useful for pool copings and cantilevered edges.

Stone CoatingThe stone mix contains a blend of crushed limestone aggregate. It is usually applied 3/8 inch up to one inch. The stone mix has a compressive strength of 4600 PSI. In addition to the 15 colors available, ArcusStone does custom coloring from swatches provided by owners or designers. The mineral oxide color material is provided in easy to use soluble bags.

Six Pattern Possibilities Illustrated- Brick to Deep Cut Limestone

Different Textures and FinishesMany textures and edge designs are possible with ArcusStone. For a basic stone finish, vertical or horizontal, the product is trowel applied, flattened and textured with a polyurethane float and a texture grid float made of dense rubber. Texturing is further accomplished using hand stones and different power tools while the concrete is still in the initial set phase. The hand stones compact and compress the concrete. Compression almost self-textures the material by bringing up aggregate in the mix. After hand stoning, workers come back a day later for finishing. You can use a 150 grit and random orbital sander to polish, burn and buff. Diamond pads can be utilized for higher shine. Machine burnishes can be accomplished using different grinders, and angle grinders for burnishing and mottling. After texturing, and finishing, workers cut pattern.

Cutting Joints to Create PatternTo create the pattern, complete the finish process as described above and while concrete is still somewhat plastic, cut the pattern lines—sharp lines like a tile grid or those that emulate individual limestones, polished travertine or a tumbled marble. "Strike a line and fine tune as you go," says Bill Tott, the technical director for ArcusStone. "You can achieve a pattern so it does not repeat and the joints can be grouted if desired. Go back on kneeboards with a carbide tipped blade or an angle grinder doing the grouting as the joints are cut," Tott explains. Use sealer to complete exterior works in cold climates.

Random Limestone Around Windows and Facing, Cut with Trowel

ArcusStone Plaster TreatmentsArcusStone plaster has much finer aggregate that allows thinner application. After the brown coat, apply the plaster—the thickness averages 1/4 inch down to 1/8 inch. Plaster mixes are formulated to wear outdoors or inside. It may be sprayed-on or trowel applied. The final finish looks like wall stucco or cast limestone rather than a knock down or slick finish. Or use a stone mix inside and polish it by grinding. If you decide not to seal the work it mottles and ages with a traditional limestone patina.

Grinding Interior Wall Gives Polished and Mottled Finish.

Create Architectural Molding and ShapesTott is animated when he talks about the ability to create custom coated shapes. He says, "Cast it, carve it, or use it over Expanded Polystyrene (EPS). These are very cost-effective solutions for special details and coordinated designs. Cut EPS with hot wire to the shape required, cover with mesh, apply a base coat, and then ArcusStone material." Tott concludes, "Now you have a light architectural shape that can be a column, a window surround, a door surround or even surround a fireplace."

ArcusStone Distributors Florida/Caribbean, LLC, vice president Keith Hammel and president Glenn Davis say that cast stone manufacturers also use ArcusStone. They explain that you can cut a shape in foam with hot wire and use either the positive or the negative sides for casting possibilities. Or, a manufacturer can put their existing molds to use avoiding new mold-up costs that impact the bottom line.

Training PossibilitiesArcusStone provides training for new contractors and has a growing number of distributors across the country. Hammel and Davis conduct training seminars with people coming from many states. With so much material to cover, they offer one, two and three day sessions. Sometimes a company just wants one day devoted to vertical applications. Another time, it is a two-day workshop on foam cutting and coating or to learn stone casting techniques. They are willing to tailor fit their training programs to individual company needs.

Techniques for Curved Arch Application, Creating Old Stone with Grout, and New Polished Surfaces.

Typically training includes:

  • Information and hands on experience with both Stone and Plaster ArcusStone products
  • Learning about appropriate substrates and how to prepare them
  • Varied applications: thickness, amounts of water, using color
  • Finishing techniques to achieve the different rock textures and grouting
  • Polishing instructions and equipment
  • Learning how to shape stones
  • Casting with ArcusStone; Coating shapes with ArcusStone
  • Protection: protective clothing, handling dust, and providing good ventilation
  • Bidding jobs, coverage rates, labor costs. (Pricing runs about 60% of real stone installed.) Computerized bidding program

ArcusStone's Future Is Bright!Arcus is a Greek word meaning the first stone placed in an arch. With their continued innovation, ArcusStone wants more firsts. Several new stone coating products are currently planned. After having a booth at World of Concrete in 2004, interest is strong from concrete contractors. Inquiries are coming from as far away as Taiwan, Panama and Costa Rica. See them again in 2005 in Las Vegas. Find out more yourself about their products.

Visit www.arcusstone.com online or call:
Bill Tott, Technical Director
ArcusStone Products, LLC.
5601 San Leandro Street
Oakland, CA 94621
510-535-9300
info@ArcusStone.com