Stone FrontLower-cost manufactured-stone veneers mimic the real deal.

  • By Stephanie Herzfeld
  • Source: BUILDING PRODUCTS Magazine
  • Publication date: 2003-03-25
By Stephanie Herzfeld.

As the popularity of manufactured stone grows, even homeowners who can afford the real thing are taking a second look at this impressive impostor.

Stonemason Jon O'Day says many clients who buy custom houses are dressing the facades with manufactured stone because it offers great looks and durability at a fraction of the cost of real stone. "People are watching their budgets even on $1-million homes," says O'Day, president of Cotati, Calif.-based O'Day Masonry.

Manufactured-stone veneers can be installed in the same applications as real stone -- exterior walls and entrances, fireplaces, patios, sidewalks, and much more. The products are made of portland cement, aggregate, and iron-oxide dyes that manufacturers guarantee not to fade. And they're as resilient as genuine stone, makers claim.

The big difference is that the synthetic replica is about half the price of real stone installed, because it offers many money-saving advantages. For one, manufactured stone is about 25 percent lighter than genuine stone, weighing 8 to 12 pounds per square foot. That makes it easier and quicker to put up over large areas, manufacturers say.

"[The veneers] install much faster. You can start from the top and work your way down -- lick 'em and stick 'em," says O'Day.

Also, because manufactured stone is an adhered veneer, it doesn't require the same structural supports that the real McCoy does, and it can be applied directly to walls with mortar. A mason can install two to six times as much manufactured stone as the real thing in any given time period, estimates Bob Heath, vice president of marketing for Cultured Stone.

"Real stone has to be chiseled and dressed to meet size requirements, which is why labor is so much more expensive," says Mike Grace, president of Bradstone, another manufactured-stone maker. Grace estimates that manufactured stone costs $12 to $14 per square foot installed, while natural stone costs $20 to $45 per square foot installed.

What's more, there's less waste associated with the synthetic stuff because it comes in numerous standard sizes and is uniform throughout.

"You have the luxury of choosing any size, any color, any shape. We can continually reproduce textures in any color scheme," says Heath. The extensive selection allows pros to specify patterns and colors not found locally in nature.

"Picking out a veneer is very personal. Manufactured stone allows you to achieve an exact look anywhere you live," says John Baugh, vice president of marketing for Centurion, a synthetic-stone manufacturer.

If installed properly, manufactured stone creates a sense of permanence and strength that's indistinguishable from the real thing, contractors claim. "The trick is to use the same joint-spacing techniques and procedures as you would for real stone for the right look," says O'Day.

Not for Everyone

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On Retainer
Despite the numerous accolades, manufactured stone doesn't suit every construction project. Although the product can look as good as its hefty counterpart, it can't be used in load-bearing or support applications because it's just a veneer. Real stone measures 8 to 10 inches thick, compared with manufactured stone's 1- to 3-inch thickness, so the latter is appropriate only for decorative purposes.

Additionally, faux stone's thinness may make it more brittle than genuine stone and susceptible to cracking. It's easily repaired, however. "You can touch up or remove a section because it's a veneer," Heath says.

Hard Facts: If you're looking for resources on natural stone, check out www.natural-stone.com. It provides distributor directories, news, links, and even forums for discussing stone-related questions.
Even though minor problems can be fixed easily, some builders are concerned about the ill effects of improper installation. "If water gets behind the veneer, it can freeze and pop it off," says Bill Mavrakis, of Canton, Ohio-based Mavrakis Construction, who notes that would never happen with genuine stone.

O'Day also advises against installing manufactured stone around pools, because the chlorine in the water could bleach or discolor the veneers.

Finally, there are simply some people who want only what Mother Nature has to offer, no matter the cost. "I just prefer the look and feel of real stone. It's more luxurious," says Glenda Urmacher, CEO of Rolling Hills, Calif.-based Glen Realty and Con-struction, a remodeling firm that works on $1-million-plus homes.

Although manufactured stone accounts for less than 10 percent of all U.S. exterior siding materials sales, manufacturers predict the product will continue to grow because of its good looks, easy installation, and lower price tag.

Bradstone. Created from Indiana limestone molds, Terra Walling manufactured stone comes in five colors. Masonry Walling, which has a random rubble look, and Traditional Walling, which has the chiseled look of quarried stone, are the two other stone styles the firm manufactures. Numerous accessories are available. 866-798-7809. www.wintergreenstone.com.

Eldorado Stone. Shown in veneto, a warm brown-and-tan color, this manufactured stone is a blend of two product lines. It is 60 percent Fieldledge and 40 percent Hillstone and is applied in an Old World style to create the look of an Italian villa, says the maker. More than a hundred profiles and color combinations are available. 808-254-3496. www.eldoradostone.com.

Arriscraft. Laurier building stone is available in eight colors and is one of three styles the firm manufactures. The product can be precut or fabricated by an on-site mason. Quoins, lintels, keystones, window- and doorsills, and slabs for hearths and mantels and stair treads and risers are available too. 800-265-8123. www.arriscraft.com.

Centurion. The Splitface pattern has a rough-hewn appearance that coordinates with any setting, says the firm. It measures 2 to 3 inches thick, is available in heights and widths from 6 to 10 inches, and comes in four color schemes. Other patterns are available as well. 800-786-6352. www.centurionstone.com.

Boral Bricks. Measuring 3 inches thick, Liberty Classic manufactured stone can be laid by masons in the same manner as brick, says the firm. The product weighs 18 pounds per square foot, can be used in interior and exterior applications, and comes in six colors. 800-526-7255. www.boralbricks.com.