Carpenters laid out and cut the stone for this patterned
by Patricia McDaniel
1. The Arizona sandstone the author used came in
large, irregular slabs of varying
The project architect created the layout, a 6x6-foot
repeating square containing 11 rectangular pieces (Figure 2).
Because so much cutting was involved — and because the
soft sandstone cuts fairly easily — we decided to use our
own crew to cut and dry-fit the pieces, then bring the mason in
to set and grout the stone.
2. A repeating grid of 11 rectangles made a
pleasing floor layout.
Arizona sandstone is sold by the ton, in pallets of about 1
1/2 tons. The stone yard told us to expect 110 square feet of
coverage per ton. Since we were cutting the irregular slabs
into rectangles, we thought we'd need to add in about 20% for
waste, for a total of about 5 tons of stone for a
460-square-foot area. In fact, waste was quite a bit higher
than expected, and we ended up needing 8 tons. Fortunately,
we'll be able to use much of the sizable scrap pile elsewhere
on the project.
With the help of CAD, we superimposed the stone layout on
the floor plan. There were ten different sizes of stone,
ranging from 24x36 inches to 12x18 inches. Using colored
pencils, we marked and counted the number of each size, then
made full-size templates for each from scrap OSB (Figure
3. OSB templates assisted in getting the best
yield from the stone slabs.