Day 19 - Westminster MD - "2 Steps - 7 To~Go"

The end of the day always comes so quickly when the sun is shining and I'm on a roll! I've completed 2 of the total of 9 steps to get to the upper landing. Each of the steps has rise of 7" +/- and a tread ranging from 15" - 22" on average I'm shooting for 17". I'm also doing me best to have them pitched out in order to have water run off them. The good news is they are all set in a 3/4" gravel so the will naturally drain. The step design is what I call a double stack. 2 stones to make the desired height. These stones are a called Blue stone sheet stock. I have them over hanging about 2"+. More or less I simply use my level to be my measuring device for each one. Each stone must be custom cut and grinded down in order to make such a tight fit. I'm also adding low voltage piping in the middle of each tread. This way I can either do a under light or several. The pipes will direct the wire to come out right between the joints under the overhang of each tread. Now on to my day pic by pic details. (if you're reading this and have not been following the daily updates on Facebook go there now to get caught up. At some point I'll be moving each day over to the blog)

I started off with the second step I had set on Saturday. The stone had a major bump in the middle. It would just sit there and spin in circles it was so bad. So I had to lift it up and grind it down. I like to use the Ditch Witch an a board to minimize the stone being lifted up from pushing out the lower stones. Never fun when that happens to you. ONLY has to happen once then you learn.

After getting the second step left completed. I then moved on to digging back the bank. More for the next step to the right. Along with the stone wall which would follow up the side of the steps. I only like to dig out as I go to minimize over excavating. It's wise to set all stones on good solid compacted soil. (with gravel as needed)

Then I picked out the next stone for the right side of the steps. I placed my pvc rollers in place under the stone setting. This allows me to move the stone around to see what it looks like. Now before I get to carried away this stone had 4x4 boards underneath it with the rollers on top of them. The reason for this is  so I could overlap it on the stone next to it. As seen in photo below. This allows me to line up the face on my marker line on lower steps. I make sure I have enough overlap then I cut it with the gas saw. When the saw cuts the top stone it then leaves the mark on the bottom stone. The bottom stone is really the left step. I then finish cutting to allow for a tight fit. 

Over lapped stone on right sitting over top stone on left. 14" gas saw with water ready to cut. 

You can see just how tight the cut was by doing this. I then had to grind of a another high spot on the bottom of this stone in order for it to sit lower and not rock. Of course that means lifting it up then setting it down to test it. Then repeat as needed. I'd guess these stone come in around 300 lbs. I'm using a 7" grinder with the 7" Dewalt Diamond double cup wheel. This works the best to really take down high spots. I'm also running a dust collector in order minimize airborne dust. You will also see in the photos several wood blocks. Left to right - 4x4 use 2 of these when setting down a stone, (middle) 6x6 with piece missing this is my digging bar block, (right) small door stops made out of 2x4 doubled up - used to make adjustments when setting caps or steps to be level or to just to get the rollers out without pinching my fingers. 

I did some grinding on the top of the back of this stone for the 3 step face to sit. I also put the board down in order to help when dig. This keeps the dirt from mixing into the gravel. The stone was longer then what I had excavated. 

Strapped in the next stone before calling it a day. 

Only issue with it was I had to dig out more of the back. So I placed it on the 1" PVC rollers to slide it around. I also used the digging bar to place it onto the line. This one is set 22" back on the left to help direct the steps to the right, as they go up the hill. The middle of this stone comes out to 17" for the tread.

Everything is now set and marked out. Next up the right side! To the left at bottom of white pole you can see my 4 rollers along with my collection of door stops. 

Next many of you have been seeing the Zip Level in many of my photos. I wanted to take a moment to explain how I'm using it with the steps. In this image the little square box is the digital readout. In the cord inside the carrying unit is fluid. This works a lot like a clear hose with water in it. Essentially its a water level. Where the box is sitting is the top of the patio. Next I ZERO IT OUT, I then can set it on any step or top of area by porch to see how I'm doing. I'm I on track with the sizes of each step. You don't want to get to the top only to find out you are to short or to tall. Hard to pull them all apart then start all over. 

ZERO - top of patio grade.

Second step at back

3rd under step 3, This means I need to find a stone which is -3" in order to be on target with a 7" rise per step. As you can see it really takes all the guesswork out. Easy to set up and easy to read. You can change the read out to multiple options, meters, feet,  etc....

Coming along 1 by 1. The space is really starting to look like something. One of the things I love about natural stone compared to pavers. They are not square. YOU have endless opportunities to create just about anything. I like to like to let the stone tell me what it wants. 

End of the day the empty oil tank with gravel now gets to go back to the farm for a refill. The tools head back to the job trailer. Everyone is happy.  

3 pallets and 1 oil tank off Richard's grass. Ready for road trip. 

Everything tucked in for the evening. 

WHY I DO WHAT I DO EVERY DAY! Myersville Straw Bale Home, Backyard Patio Systems Current 2019

Current - March 2019 5'ft now underway above 4'ft wall below

The back end work can take months and months of building and planning. To often when you see a finished project it is hard to image what really goes into a project of this size! Currently I believe I'm well over 200 tons of JUST back wall stone to build this out. To avoid settling over time and the cost difference. The plan to go with straight stone instead of compacted earth just made sense long term. I've included a few pictures to help tell the story along the project journey currently still on today. The process of this project with the stone has taught me so much everyday about myself. What I'm should I be doing, Where I'm at in my skills and speed, How I should be doing it, Who I am as I work in the, freezing temps, snow, rain, sick, dark and WHY I DO WHAT I DO EVERY DAY! THE LIFE OF A CERTIFIED PROFESSIONAL WALLER.

Let me tell you a bit about the project I first meet the clients back in 2015 when the home was first being built. Like anything it was so hard to image what was being created by Sigi Koko, WHO specializing in designing natural buildings, plans and hands on workshops. See more www.buildnaturally.com

As my part of the project started I encouraged the clients to reach out to a few artist to determine the best way to go about the railing system. They felt most comfortable with their builder and his ability to create amazing woodwork on the 3 inside steps and railings.  The felt he would be best fit to handle the job. When we meet he explained to me some of the requirements for the original clay model design. I soon realized a lot of things just didn't make sense. While I don't build rails and never have I quickly learned some new things. To start if you have more then a 2' ft drop you need a railing. If you have more then 2 steps you need a handrail. I also believe there is one in there if the span is to far a way say the steps you can't touch both sides you need a handrail on both sides. From county to county, state to state this can vary I'm no expert. For the most part many of these are just common sense. So when designing the retaining walls or stairs be sure to consider including the contractor if you can. So you can design around his/her needs to install properly without frustration. This is what I did and in the process I quickly realized a lot of things just wouldn't look right or made any sense. For example the seating wall on the clay model is the right lower wall. A 3' railing would have to be installed on top of this since the overall height would have exceeded over 7' ft. from the ground. Talking about blocking the view when you walk around the house to the backyard. Or just sitting on the wall with a railing behind you YUK! Ya that just wasn't going to work. So with a few hours sitting in the seat of my mini excavator, staring, thinking, thinking some more, imagining.  I came up with a rough quick sketch (seen below) where new design needed to go. 

The new plan simplified some things but also complicated a few others. The removal of the floating steps. To more master curved steps in the middle lower walls. The left lower wall would be dropped by 12" to match the right 4' wall. Which now added a smaller circle plan at the bottom of the upper strait steps (as seen in drawing above where you see the word DOOR) So much to think about so hard to see. Just like the first day I saw the home being built in 2015. I could have ever imagined what it looks like today. WOW! So while we had a clear path, we let the stream guide us down the the now river as we occasionally bummed a few rock on the way. Adapting to the space. I could go on on and on about every little thing which really is a big thing when it's all finished. Just like the saying the butterfly theory. To often I think of those large landscape firms that have a design team who come in, measure it all out, sit at a desk in front of computer using some software to create the perfect plan. Is there ever a perfect plan in life?  The crew sticks to it and when it's all said and done it looks planned. Just like it was. Life is full of surprises, everyday we make choices good ones bad ones but are they really either or just the river taking us on a new journey. Allowing to be open, listen, feeling, trusting your gut that's what living is all about. Follow what feels right. If you don't like something change. Have a plan just be open to letting in the light and making changes. It will always show in those who do. 

In the beginning - nothing but burlap on the walls to protect the lime plaster from drying to quickly.

This was my canvas when I started. Not much in the way of any compacted earth over the 5 years of home being built. The biggest challenge how to create a upper patio that you could walk out on but also get to the lower level master bedroom. ONLY 9'ft below. Wait and lets not forget there is the lower breezeway doors limiting how far you can really come out on the upper patio. Sure yes you could build a 9ft retaining wall. Most walls you would divided the height by 2 and get how wide your base is. Yes 4.5 ft wall at the bottom wide. I've ever heard from engineers about gravity walls add 1 ft to be safe 5.5 ft wide base. Thats alot of walling and stone. Thankfully nothing had to be dug out. There is nothing there to start really. Hardscape patios for future plans boulder back walls layered in reduced sizes of stone as I got closer to the top. 

The placing and setting of locally quarried limestone boulder set by a my mini excavator became a new process for me. I can't begin to tell you how much I enjoyed this back wall building with boulders. It was like a arcade game sitting on the mini excavator using the joysticks to set each large stone in place.  

I will say it goes quick - just like any placement of stone you have to look for similar sizes and be sure to break the joints as you go. A few safety tips particle board to avoid the 10' tall doors from being damaged. I can't image the replacement cost.  The $40 dollars wood and $4 for the pool noodles were a smart safe investment. This photo also shows the protruding foundation set on earth not gravel. The gravel is only outside the walls incase you don't know how much rain we have seen in the last year. Hard to work in mud with machines or walking safely with stones in your hand. You can also see the white pipe. This is perforated schedule 40 connected to the builders black corrugated french drain so it now has daylight out the wall but can handle any weight load if by chance the bridging of lintel stone settle. 

As I made progress on the job I had to consider daily the planning of the site to be sure to best optimise my time. For example the placement of the bulk stone, The banker table the generator, the stone splitter the job box with tools not in the job trailer around the front. Every step adds time. How best to save a step helps with time management when possible. Not all things are possible on every site. Always think about one's movements on your projects. 

With winter season at hand many of the stones were placed on pallets to avoid breezing to the ground.  Later more large gravel was put down to minimize the bulk pile from freezing to the earth. Now as seen the shape is starting to come together the first small onsite boulder was a hit with many more to follow as they kept getting bigger and bigger (as seen above in pic with mini) . The mini excavator was push to the limits but with a few little learned techniques it all come together nicely. Thank you mini for making my job easy except when you drop a boulder it breaks the wall and you have to repeat the steps twice to build a wall drop a boulder fix the wall, try to place the boulder - drop the boulder to fix the wall. Ok make that's 3 times the charm. NOT I know I used some words I never use. Like jungle gym or buttermilk. Ok maybe not those exact words might have sounded like that over the running engine of the mini excavator ...

The start of the master circular steps were next on the list to build. With a total of 30 stones all saw cut on the sides, natural faces, feather and wedge faces or dressed faces. Build time about 1 month. Nothing easy about making steps unless you pre-order them to size. Which can be the easier route to take when you get what you want. I don't like to have my design dictated by my opinions. This can really limit your creative ability. Each option has pro/cons. Just stick with what works for you and the client. This is always a win win solution. 

Hard to believe I started this build back in Sept 2018. When I meet again with the clients, Serge and Joan in Myersville MD. To come up with a patio system which would fit there needs and the homes style. As seen in this clay model as I began this blog. Little by little each new section was being created almost like a room in a house. It felt so great to have a section done. Giving that new sense of space. I'm sure this blog has really helped to give a bit of sense of the timeline involved with such a build. Walling is very quick when your just walling! It's everything else that adds up. Stating that fact I lost count (my invoices didn't) of how many 14" diamond saw blades I used. All adds up! 

8 Pound Hammer,  www.ziplevel.com,  Swanson Levels,  Analog Inclinometer in my hands, Gorilla Step Platform

Close up of the first wall and small boulder. Plus the schedule 40 french drain to daylight. As mentioned above the white pipe. 

Upper steps will have 5' retaining wall now started. This will be the upper patio to back doors. In this same pic you will see what I like to call mountain shadow the title for the walling around the large boulder on right with all native stones placed around to give a timeless feature in the wall. Notice that banker table and stone splitter keep finding new homes as I build. Why you forgot already... every step should be made into a small steps. Less movement saves you time and the client money. 

Second of 2 walls finished with built in stainless steel railing rods for the home builder to build on. I call them plug and play. 

Mark Jurus in Large Planter

Eamon Espey in Small Planter

The larger planter is about 4'x5' and the small planter is 30"x 36" this is for unknown planted shade vide on upper system as see in pictures with full house in view. 



Now in the home stretch as I've started the last of the 3 walls of which is the upper patio to the back door. I'm so excited to so you more. I have a great deal of Vblogs I've created and will show up on my YouTube channel to come. Please subscribe to stay tuned. I'm really excited about the Pro Series intend for those of you in the trades or learning the trade. My goal helping others as others have helped me. http://www.youtube.com/c/RockinWalls

Thank you for reading my blog. I hope you found information in the blog helpful to you. 

The clift note specs on this project:
2019 March, Myersville Straw Bale home, 2 of 3 retaining walls 4 ft + including many large local boulders from the property. 1:6 batter wall, flat caps, stainless steel railing rods built into wall 3 courses down, all tie stones plumbed with electrical pipes for future Low Voltage Led lighting. Protruding foundation below grade. Small planter built 3' x 30" at end of wall by house for above vine trellis system. Dollar store pool noodles just for the fun of it. To protect the stainless steel all thread rods which the home builder will be installing 3' Locust logs for post from property. Stainless steel rods to be installed 4" spacing for code and to tie in with upper vine trellis system. 7 custom cut onsite - feather wedge faces curved steps 7" rise w/ 16" tread 30 stones cut to fit singles with some double stacked. Railing rods also installed. Wall built on steps. Boulders built out from home including bridging of 2 french drains and 1 out of wall lintel. Wall to be built behind this patio 5' tall for upper patio to back door as seen on background.

How To - YouTube Building a Foundation for 2' high PA Field Stone Wall

This is something I shot earlier this year just to show how I build my Dry Laid Stone Foundations. The wall was a rebuild using the old and new PA Field stone. The wall had failed after 20 years. The wall was a typical landscaper/mason (not to stereo type 90% failed dry laid stone walls by this industry) style of single wall. The single wall was dependent on the earth behind it. This is not how any one should build a wall unless you have monster stones to build with.

To gain hands on come take a Workshop. This year I will be offering the only one workshops in the USA dedicated to building foundations. Every thing in life starts with a GREAT Foundation. Relationships, house..... and of course dry stack stone walls.

I'll put some more photos of this project up soon on this blog post.

FREE Fire Pit Workshop Oct 18th @ Balducci Stone Yard

Come Join me Mark Jurus at Rocktober Open House Event is this Saturday, Oct 18 at 12pm rain or shine @ Balducci Stone Yard! I'll be teach everyone how to construct their very own dry laid stone fire pit. 

I'll be on hand  to answer any questions regarding your hardscape projects! 

If our a professional in the industry please stop out to learn more about Dry Laid Stone workshops. I will also be bring my Sponsors: Bon Tool and Trow and Holden Hammers for folks to "Try Before You Buy" 

See you on Saturday!!

Balducci Stone Yard
18159 Susquehanna Trail South, New Freedom, PA 17349. 

Right on York Road about a block north from Maryland Fire Dept

BONUS!!!!!
Also be sure to ask for a Bon Tool $15 dollar off Rockin Walls Coupon on your purchase over $50.