For thousands of years, stone has been a much-lauded ingredient in building design and construction. And with good reason. Stone has many appealing qualities. Not only is it durable, but there is an unmatched aesthetic to stone that comes not only from its natural beauty, but its ubiquity throughout history as the choice construction material of mankind. Design choices know no bounds with stone’s wide-ranging variety of colors, types, patterns, and textures. Used over the centuries for everything from mighty ancient Greek and Roman structures, the Egyptian pyramids, and graceful churches and temples around the globe, stone has stood the test of time as a premier material choice.

Image courtesy of StonePly

Stone veneer panels on aluminum honeycomb provide an innovative alternative to traditional stone cladding.

Traditional, heavy stone masonry is rarely used in modern buildings; its main drawbacks have been its unwieldy weight, high labor costs, and quarry, cut, and transport challenges in getting stone from point A to point B. Today however, architects looking for innovative ways to incorporate stone's many benefits into their current projects no longer need to dismiss stone as an option. A lighter, cost-effective, sustainable, and proven product is available: lightweight aluminum honeycomb-backed stone panels.

The Basics of Thin stone on Aluminum Honeycomb Backing

Natural stone veneer on aluminum honeycomb panels are composite panels consisting of a thin layer of natural stone (such as granite, marble, travertine, or limestone), typically ¹/₄ inch thick, bonded with high-strength epoxy to a lightweight, yet extremely durable aluminum honeycomb backing. The total panel thickness including stone and aluminum honeycomb is typically either ³/₄ inch or 1 inch combined with the increased strength and light weight of aluminum. The panels are typically custom made to the size and shape required for the specific project. Corners, sills, and special shapes can be factory fabricated.

Natural stone is attached to the aluminum honeycomb backing with an extremely durable aerospace-grade epoxy.

The Process: How Does It Work?

The panels are custom fabricated in the stone type, color, finish, size, and shape selected by the designer. The first steps involve providing stone samples and shop drawings to ensure the designer’s vision is being expressed. Once shop drawings and submittals are approved, the manufacturing process begins.

The manufacturing process starts at the stone quarry, where large blocks of stone are extracted. The blocks are then taken to giant saws where they are cut into slabs, typically 1¹/₄ inches thick. The aluminum honeycomb panels are prefabricated with high-quality aluminum, which are then bonded with aerospace-strength epoxy to each face of the stone slab. The aluminum backing increases the strength and impact resistance of the stone and makes installation much easier and more secure than with traditional veneers. Panels weigh just 3.5 pounds per square foot but offer impact resistance up to 60 times greater than stone slabs.

At this point, the panel is a sandwich of aluminum honeycomb on both faces with the stone in the middle. The panel is then sawn down the middle of the stone slab to produce two panels with stone veneers roughly ⁵/₈ inch thick before the finish is done. Next, the panels go to the finishing process where they receive a final finish and texture, decreasing the thickness of the stone to about ¹/₄ inch. Depending on the project and the designer’s preference, the finish can be polished, honed, flamed, sandblasted, or tooled. Other options include carving or laser engraving. The panels then go to the fabrication area, where they are cut to the specific dimensions required for the project and corner pieces and any special shapes are custom fabricated. Finally, the panels are packaged along with installation drawings and instructions and shipped to the jobsite.

Pictured here, the process of how the stone panel is cut, ground, and polished.

Finally, the panels go to the jobsite for installation.

Corners & Finished Edges

The panels are custom fabricated in the stone type, color, finish, size, and shape selected by the designer. The first steps involve providing stone samples and shop drawings to ensure the designer’s vision is being expressed. Once shop drawings and submittals are approved, the manufacturing process begins.

See https://m.stoneply.com/documents/FCD1.pdf

Types of Corners:

In the images above, you are able to see the different types of corners that can be made.

Quirk Miter Edges & Corners:

• An external corner formed by two stone panels at an angle, with meeting edges mitered and with visible portions finished.

Factory Bonded Corners & Finished Edges:

• Factory bonded corners and finished edges give you the appearance of solid stone without the added weight.
• These corners save time and cost with an easier onsite installation.
• Factory bonded corners and finished edges help to eliminate some of the additional onsite work.

Truman Library – Front Entrance & Banner Wall

Feature Wall Drawings – Truman Library

 

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