A couple of weekends ago, I led a workshop at the NC Arboretum on building stone benches. First thing in the morning we studied images of various benches, stone-cutting techniques and ways to move heavy objects safely and with relative ease. Safety was a recurring theme throughout the day. After the classroom presentation, we went outside and built a free-standing bench, a style I call castle-block for the big chunks of stone that make up the supports. The bench we built is now a permanent fixture at the Arboretum, a rest station along one of the trails.
To facilitate ease of movement, we cut the big stone down in the back of my truck. In this image, Ronnie is using a star bit chisel to notch shallow guide holes in the top of the stone. This gives the drill bit a place to sit, reducing the likelihood of the bit bouncing around and scarring the stone.
Everyone got a chance to use the drill and work at cutting stone. Here Judy leans into the drill to get the proper placement.
Since our cut edges were going to be exposed, we took some time to clean up the drill holes. Here Carol is using a handset chisel to knock off the cut edge of the bench stone. We put the cut edge to the back of the bench, less visible to passers-by.
We spent some time doing bench math, designing everything so that it would be the proper height and balanced as a structure and as an aesthetic object. Here Carol measures the thickness of the slab, the starting point for figuring out the math. I handed out the following worksheet to guide the design and layout process.
By cutting it in the back of truck, we made the stone more manageable, but it was still a heavy chunk. Jason uses a rock bar to move the stone from the pallet onto the ramps we have set up. Using 2″ by 12″ pressured treated lumber as ramps, we slid the stone down to waiting blocks and from there into place.
We used mortar to set the bench. This design can be done dry, but the mortar reduces the risk of movement, particularly since the bench is in a public place.
We all felt good as we finished up. The bench looked great and we had built it efficiently and safely. It felt good to be leaving something cool and useful for everyone to enjoy. Tre and Ronnie test drive the bench and pronounce it good.