Here are six alternative techniques to use on outside wall corners:
1 - Butt Similar Stones Against Each Other at Corners: The lack of
outside corner molds should not really present much of a problem for
most customers and commercial producers of stone once they decide to use
one of the alternative methods proposed here. Our simple instructions
suggest that you pretty much do what professional stone masons do---
butt similar stones up against each other at corners. Depending on the
stone style, place them right ON the corners as they come out of the
mold. This is what many professionals do when installing a real natural
stone like a River Rock. Some other stone styles are thick enough to be
able to do that with as well, and without any cutting at all. In the
case of brick installations, it's even simpler. Since the color and
material are integral in concrete tile and brick, it is really difficult
to see any difference at the juncture. This is the least expensive way
to go. You may want to consider rounding the corner with a file slightly
to hide it even further from plain sight.
2.- The Picture Frame Method - Cut the Stone, Tile, or Brick Veneer at a
45 Degree Angle and Join: The best method for most styles of stone
being installed where detection is likely, is to lay a piece of the
veneer on its side, and cut it at a forty-five degree angle, as you
would a picture frame. An inexpensive composite masonry blade can be
used in a standard circular saw to accomplish this. Be sure to wear eye
protection and other protections as cutting stone and bricks will
result in a lot of dust. An appropriate face mask is suggested to
prevent breathing the dust created during cutting. To install, join the
two angles at the corners... again, as you would a picture frame. Rub
some colored mortar into the tiny crack where the two pieces meet. It
will be very difficult to find the joint - even close up. If you look
at many one-piece corner veneers very closely, you can usually still
tell that they are a veneer, since the corners are normally poured in
two phases. One side is poured with concrete, laid down to set up, and
once set the other side is poured joining the first side. There's
usually a very thin line where the two sides meet, no matter what you
do. This is the second least expensive way to go.
3 - DIY Corner Mold - Make a Corner Mold Yourself for Your Installation:
There are many companies on the Internet that sell products to make
poured or build-up rubber molds. The first method consists of a
two-part silicone rubber mix that is poured over the master to duplicate
and make a mold. The second method involves using a liquid
ammonia-based latex rubber that is brushed over the original in layers.
It is left to dry and then additional coats are applied to build up a
thicker rubber mold. These are very pliable, and usually require a
backing to help hold the original form and shape of the mold during
pouring the concrete. Complete instructions are available from most
suppliers, and there are videos on YouTube as well. This method is
great if you have time, patience, and a bit of talent. The rubber is
still fairly expensive, and may only make sense for larger projects.
These are the methods used to make the expensive molds that may be
available at retail for making corner stones and bricks.
4 - Purchase Manufactured Stone, Tile, or Brick Corner Pieces from a
Distributor: Depending on the size of your project, or more importantly,
how many outside corners you need to cover, this alternative may be
your best choice. Once you figure out about how many corners you will
need, you can purchase them already made from a distributer. You can
then contact your mold supplier that you plan to purchase your flat
molds from and get assistance matching the colors to the corner pieces
you've just purchased. You can then make the flat pieces of stone,
brick or tile for a fraction of what the same pieces would have cost you
to purchase. It is a good compromise if you feel you must have cut-out
corner pieces for your outside corners.
5 - Purchase Corner Molds to Make Stone, Bricks, or Tile Along with the
Flat Molds. This may not make financial sense for most homeowners and
do-it-yourselfers unless they are doing a very large project, or plan to
go into business making these concrete pieces for other homeowners,
do-it-yourselfers, and trades people to purchase. At around $75.00 or
more each, one could end up spending a lot of money on molds that could
possibly get very little use.
6 - A New Concept - LEASE A MOLD is being introduced soon by one of the
key concrete stone mold companies. This may be an option for the
perfectionist who wants to make his own outside corner stones with molds
to match his flat stones. This will work fine unless they need to make
thousands of the exact same corner stones. According to the preliminary
information released, the program has not been finalized yet, but is
close to being introduced. Basically, the company will lend a set of
corner molds to their customers for a time use fee. This fee would be
much less than if the customer purchased the rubber corner molds
outright, unless they go beyond the agreed amount of rental time. The
customer is only charged for the time they are using the molds... up to a
maximum of course.