Stone Inlay Techniques on Asheville School Crest Medallion

This is the site of our current project, a gathering space at Asheville School. The school crest will be located in the center of the patio.


Our current project has us building a gathering space at Asheville School. The patio will be the centerpiece of the Bement Garden. We are collaborating with Mardi Letson of Gardens By Mardi on this project.

The medallion is five feet across. The Sharpie lines indicate the inlay locations.


We are building a stone medallion that depicts the school’s crest for the center of the patio. There are symbols throughout the crest that will be inlaid into the patio stone. Some are fairly straightfoward- others are quite tricky.

The most challenging part of doing inlay in stone is removing the material where the inlay is supposed to go. The following video walks through the process and the tools I use.

Grinder lines cut into stone for major stock removal.


I used both of the grinders in the video to create the outer border of the design and cut a cross hatch pattern into the stone. This allows for easier stock removal.

Hand hammer and chisel to remove the vast majority of the stone. Must be careful to not damage edges doing this.


Hand hammer and chisel were used to get out the vast majority of the stock. This is very effective in wide open areas- like the center- but not wise near the edges or in tight spaces.

I’ve removed what I could by hand chisel and grinder. Ready to tackle it with the pneumatic chisel.


I use a pneumatic chisel- made by Trow and Holden Company of Barre, Vermont- to work close to the edges. This is not necessarily a delicate tool- it’s really just a mini jackhammer- but it is more efficient than doing it by hand. I can regulate the air flow to control the strength of the chisel blows. Really though, the key is in the angle of attack. Work away from the edges of the design and away from the top of the stone.

The tree pattern space after finishing up with the pneumatic chisel.

I try to take out a half an inch of stock when doing an inlay.

I try to take out about a half inch of depth. This allows room for a stone tile- generally 3/8″ thick- and a bed of thinset tile mortar.

A mosaic tree inlay in a piece of bluestone


It fits! Some detail work on the mosaic and it’s ready for thinset. A bunch more to do!

Magician’s Staff

I recently hosted a family at my shop as part of a mosaic design process. More on that later. While they were there, I gave the two daughters, aged five and eight, a couple of colorful scraps of stones I had. They liked the rich color of the Blue Macaubas marble from Brazil. I had some small diamonds of it left over from the Dragon Family mosaic. We tested the blue as a highlight to the green dragon scales, but decided it just didn’t quite work.

A couple days later, while on site to work on the project, the girls showed me the magician’s staff they had made with the blue diamond. This super cool piece reinforces my strong belief that if you give kids art supplies, they’ll make amazing things. They played in the yard with the staff the whole day while we worked.

A scrap of blue marble is transformed…

Stream Path Stone Mosaic

Stream Path Stone Mosaic

The North Carolina Arboretum commissioned Hammerhead to design and build a stone mosaic in their stream garden. The stream garden is located immediately adjacent to the Arboretum’s signature quilt garden. The Stream Path stone mosaic was fabricated at the shop and installed onsite.

 

For the rapids section of the mosaic, the branches are made of Tennessee sandstone and often correspond with drops in elevation in the stream, to create visual interest and to enhance the sound of the water moving. Kind of like a real branch or log fallen across a stream…

I used a Dremel rotary tool to engrave this mayfly into one of the background stones near the frog in the stream path.

A fun detail of me working under the bridge is that you can see the ‘map’ on the wall. It was a handy reference to have. It shows all the stones and their positions.

Stream Path Stone Mosaic

The map is also pictured here on the level across the stream while Jonathan works.

Process shots from the shop of stone crayfish and the trout chasing minnows.

After fabrication comes transportation. Here is the trout as well as part of the background stacked up in the back of the truck.

Top Ten Stonework Photos

Top Ten Stonework Photos

Photographs are an important part of my stonework. They are essential tools in sharing my work with others. A strong portfolio drives business.

Photographs are part of my process as well. I take pictures throughout a project. Studying them later- that same day, or months on- helps me troubleshoot problems and see where potential lies. They show flaws and places to grow as well as the tiny little details that make all the difference.

Photographs act as my memory. I don’t have any stonework of my own. Much of my work is hidden in backyards and hard to get to. My archives- a disorganized mess of over 20,000 images- help me see what I’ve done. This helps me keep things in perspective; in the depths of winter it’s a nice reminder that the weather will someday break and we can get back to making things.

What follows are my favorite ten images from the first ten years of Hammerhead Stoneworks. These are not the best pictures or the ones that make up the strongest portfolio. These are the photographs that speak to me of the process and the materials and why I love what I do. Click on the titles to read the story behind each of the top ten stonework photos.

John’s Exploded Mosaic

Top Ten Stonework Photos

This might be my favorite image of the last ten years. It’s a memorial mosaic I made, resting in the back of my truck ready to be brought to Riverside Cemetery for installation. There’s something about the exploded, expanded view that I really enjoy. It doesn’t hurt that it’s in the back of my favorite old truck, which now rests dead in the driveway. Residual bright blue spray paint pokes through seams. The name plate at the bottom was carved by me. It’s not at all expertly done done but I was proud of the accomplishment. The family decided to add the dates of John’s birth and death, which wouldn’t fit on this piece. I cut a new stone and had it engraved. I may still have that nameplate somewhere at the shop.

Feathers & Floors

Top Ten Stonework Photos

Twenty years ago Kristin I took an off-season trip to Italy. I had just started stone work and was mesmerized by the craft on display throughout the country. The floors in Venice, especially at Basilica San Marco, were breathtaking and completely changed the way I thought about stone. Their color palettes were bold and clashing, their patterns chaotic and busy, and yet the end result was endlessly fascinating and beautiful. My pursuit of mosaic goes back to the moment I first saw those floors. This small section of the Phoenix Rising mosaic reminds me of those floors. It is a thread- however modest it might be–that connects my humble pursuits to the master craftsman of that bygone age.

Textures

Top Ten Stonework Photos

When I take pictures of my work for my portfolio, I always have to be reminded to show the contacts surrounding the finished piece. Future customers want to see how the wall interacts with the landscape. They want to see how the patio looks with tables and chairs. But I am always drawn to the close-ups, to the images that explore the stone and the stone alone.

This particular image is from my first public art commission”The Blue Spiral” in Gainesville Florida. This shot was taken in the shop during the fabrication process. I love the textures in the tight lines. In this image I saw the potential of the idea being realized.

Frogger

I made a mosaic for the North Carolina Arboretum. It lines the floor of a water feature and includes native species like this bullfrog. As is often the case, my favorite photograph is early in the process, when I recognize that the idea will work. I love the colors here. Most of the stone is regional and in its natural state. The tympanic membrane is a highly polished scrap of marble salvaged from a company that makes countertops.

GreenMan at Rest
Top Ten Stonework Photos

There are so many better pictures of the GreenMan mosaic, Hammerhead’s first large scale wall piece, but this is a favorite. I took this picture at the shop, while we were fabricating. The whole face is there except the eyes, which went through several iterations before I got them right. Even without the eyes, I could tell that this was going to work. This was a crazy time for Hammerhead; GreenMan was built on top of the labyrinth at our shop.

Little Men

Top Ten Stonework Photos

This is a sentimental choice. I don’t love this wall- one of my first- but I do love those little dudes, who are not so little anymore.

Marbles Inlaid

Another shop shot, another moment when a weird idea came together. I had tried prototypes of this idea before, with limited success. Prototypes aren’t supposed to work, I guess. They’re give you the info you need for when you convince a customer to let you build something crazy, like a bench that’s supposed to look like it’s balanced on a bed of marbles.

Alien Landing Pad

Top Ten Stonework Photos

There’s not even any stone in this picture, but I still love it and wanted to include it in the top ten stonework photos. It’s the layout of a hexagonal folly that we built for clients in Biltmore Forest. When we were done, they were married there. I like the vivid colors. I discovered the secret to laying out a hexagon on Wikipedia. It involved aligning the centers of three circles with identical radii. The points where the circles kiss each other become the corners of the hexagon- whose sides will be the same as the radius used. This very simple and practical approach to geometry spurred an ongoing fascination with old school Islamic tile mosaics which are incredibly complex and are designed with only a compass and a straight line.

Labyrinth With Red Leaves

This one soothes me. It’s really the only portfolio-ish shot amongst the top ten stonework photos. It’s been my desktop wallpaper for months now.

Worshop Pegboard

Order is fleeting; chaos always wins. This was taken the day we hung pegboard in the shop. It’s been a mess ever since.

Bonus Image: Hovering Stone

Jonathan Frederick took this shot of me as we were installing 3000 pound chunks of granite at the entrance to the labyrinth. Bodie is running the crane as I escort the big guy to its new home.

Phoenix Rising: Photographs of the Finished Piece

Completed Stone Mosaic: Phoenix Rising

Huge thanks to photographer Dave Chance for getting these excellent photographs of the recently completed stone mosaic in a school in Norfolk, VA. Phoenix Rising is part of a series of six mosaics Hammerhead is making for schools in this area as part of a public art commission. You can peruse Dave’s portfolio here.

© 2018 Dave Chance

 

Completed Phoenix Stone Mosaic

© 2018 Dave Chance

Completed Phoenix Stone Mosaic

Head of the Phoenix © 2018 Dave Chance

Stone pattern © 2018 Dave Chance

Phoenix Stone Mosaic

Phoenix Stone Mosaic

Phoenix Stone Mosaic

Life Drawing: Phoenix Rising is a 9.5 feet by 17.5 feet natural stone mosaic. It was completed in late October after four long, long days. It is installed at Richard Bowling Elementary School in Norfolk, Virginia. The mosaic is located in the main hallway of the school, near the entrance to the cafeteria and the gym and not far from the main office. It is part of a series of mosaics we are making as part of a public art project for the city of Norfolk. I have so much appreciation and respect for my crew whose commitment and craftsmanship made this possible. Thanks be to Fred Lashley, Jonathan Frederick and Tony Costa.

Click here for other mosaics in this series. Enjoy the details of this piece in the photos below.

phoenix stone mosaic

Phoenix Stone Mosaic

 

Sacred Circle Fire Pit: Google Maps View

Hammerhead completed the Sacred Circle Fire Pit in January of 2014 for clients hoping to use the space for ceremonial gatherings. The photo below is of the fire pit after completion from down here on solid ground.

And here is a photo of the completed fire pit from Google Maps from up above.

This is the Google Maps photo from before the project was completed. Note the 7 small squares below the site. Those are pallets of stone we brought down to build with.

And back on the ground.

Phoenix Stone Mosaic: Coming Soon!

This phoenix stone mosaic is in progress as part of a public art installation in public schools in Norfolk, VA. The Hammerhead crew leaves this week to install it there.

The Phoenix Head

phoenix stone mosaic

The original concept for this artwork was a Great Blue Phoenix. Equally inspired by the rugged beauty of the great blue heron and the strength and persistent lives of the mythical Phoenix, the color theme was to be blue and gray. But I ran into a problem finding blue stone! Always expensive, there are very few types of truly blue stone that are made into tiles and sold in the United States. So I had to pivot…
Now the Phoenix is just a Phoenix. I think you can see the hint of the heron in this image of the Phoenix’s head.

The Workshop

phoenix stone mosaic

This table is my happy place. I have spent many hours here cutting templates and tracing patterns on to stone. Sometimes it’s hard to find a place to work because there’s so many tile choices on the table. A large map of the whole mosaic hangs over the table and is a useful reference. Hanging over the map is the phoenix tail, awaiting stone choices and cutting.

Design Reversal

phoenix stone mosaic

After we finished cutting the piece, we started laying it out. In a manner common to mosaics, we are laying it face down. Once we have established that we like the fits between stones, we are going to glue it to the paper. Then, we’re going to epoxy mesh to the back. Instead of 500 individual stones, we will have approximately 20 panels of stone to install.

Phoenix Detail

phoenix stone mosaic

By the nature of this process, we have never seen the completed mosaic all together in one place. I guess I can see how that would be a liability, but I prefer to think of it as a opportunity. It will be exciting to see it on the wall, for the first time, with the kids who it is for. It will be a surprise for all of us!

Phoenix Stone Mosaic: Feathers

phoenix stone mosaic

We have been calling these shapes scallops. They are a main element of the wing design. I made no effort to arrange the colors, preferring to let randomness take its course.

See some completed stone mosaics in this series in Norfolk, VA here and here.