Joseph Aspdin

Plaster describes the earliest interior coatings. It is a Greek term meaning to “daub on” and it dates back to 500 BCE. It was not until the invention of Portland Cement that exterior plastering, then called Stucco, was developed that could withstand the elements. A man named Joseph Aspdin, a bricklayer in Leeds, England, invented Portland Cement in his kitchen in 1824, when he cooked a mixture of lime and clay together. He named the product Portland cement because it looked similar to a stone he had seen on the Isle of Portland off the British Coast.

Stucco is essentially vertical cement on a building. It is strong and lasts a very long time. Stucco is prone to cracking from many reasons but is patchable and repairable. According to the Stucco Manufacturers Association, who has a statement on stucco cracking they are a normal part of the process. That being said, cracks are the most common failure we see. In our dry climate this rarely causes issues. When we do find problems, it is from water seeping behind the stucco and causing all sorts of moisture related issues.

New & Old

While remodeling in Boise Idaho we have run into many situations where stucco was either present and required patching or adding on. That which has never been painted is easier to work with. Achieving an identical look is nearly impossible but we are not afraid to try. Bottom line is that once the entire project is put back together, patches are rarely the focus of attention and blend into the big picture. In any regard, patching requires the skill and attention of a specialist. This is where our Stucco Contractor Roger Purcell comes into the picture.

Turns out there are several types of stucco products. The system we use is the cementitious one that is not much different than what Mr. Aspdin invented. We start with a well attached sheathing and attach a water resistant barrier, in this case a 60 minute Plaster Craft tar paper with staples was used. Metal lath and chicken wire are applied with pneumatic staples too. The mesh is pulled away from the structure slightly so it will be in the middle of the first coat AKA Scratch Coat. The edges are treated with all sorts of specialty webbed metal pieces until the process is ready to be coated.

Scratch Coat & Metal

Then a mixture of Lime, Portland Cement, and Sand which is carefully blended on site is applied with trowels that clings to the house and the metal. This is called a scratch coat. It is roughed up and left to dry and crack as much as possible.  In some areas a three coat system, the second being the Brown Coat is used but this takes additional time and is essentially an extra step that they can skip. According to Rodger the three layer process is rarely used any longer .

The next coat is the Top Coat, this is also where the texture is added. It is also a mixture of Lime, Portland Cement, Sand and possibly other materials to achieve a look. In our case we are adding paint color in it to finish out the process. In most situations the stucco is painted after the top coat has time to dry. The art is in the application and blending. Much of the texture is provided in the top coat product but it still requires the masters touch to make it right.

The other stucco looking product is known as Exterior Insulating Finishing System or EIFS. It is often refereed to as Synthetic Stucco and can have that look but it is not Portland Cement Plaster. It was developed in post world war II Europe and involves cladding with foam sheets that are reinforced with mesh (often fiberglass impregnated), then coated with a top coat that mimics stucco. In our area this system is used frequently on commercial buildings. It has had issues with moisture penetration and failures over the years which the manufacturers blame on the contractors. Roger agrees with the manufacturers of EFIS who say their product is superior and says “Since the horrific failures of EFIS in several parts of the country, insurance companies won’t insure contractors to install it”. “Rather they will but it is cost prohibitive” Roger installed EFIS for years without any issues.

Dryvit is a name brand of a material manufacturer they are also involved in the EIFS system. They boasts about the Green aspects of added exterior insulation system. I have not seen a residential application but I am told that they are out there.

We can handle your stucco home and anything that you might need to repair stucco problems. Whether creating an addition or or replacing windows in a stucco home, Levco has you covered. Here is an industry link to more information than you  ever wanted to know about stucco.

The Mess

Stucco is not the cleanest or easiest or fastest product to install, in fact it has been the cause of a cluttered disorganized building site for several weeks. Stucco takes time to dry properly prior to the top coat being installed. Lots of hairline cracks appeared in the base coat, Worried I reached out to the manufacturers representatives and Rodger Purcell our installer who says, “I want it to do all the cracking it is going to do prior to installing the top coat” So we finally got the top coat installed and it looks remarkably good.

The clean up is going to be a real job. I often ask potential clients to visit a job site to see how neat the job looks. I used to think that seeing the project in action will give a decent representation of the contractors organizational skills. I am eating my words now, if this is as good as it gets we flunk. With any luck the disappointing aspects of a messy job site will wear off long before the positive aspects of a great stucco finished product.

Top Coat With Arches

Gutters were also installed on the same day to protect the finish. Paint will be applied to the entire structure soon and we ought to have a nice harmonious finished product.

Here in Boise Idaho remodeling older homes like in any other part of the country is a dynamic challenging process that has it’s ups and downs.

Having the project neat and tidy is the ultimate goal, but occasionally a difficult one to achieve on a daily basis. On a side note I have recently given sneak peaks to the neighbors and it is extremely rewarding to show what we have accomplished in such a short period of time.

These next few weeks will be filled with activity as painting, flooring, cabinets and counter tops as well as tiling slide into place.

Green Siding

We are using an Engineered Lumber designed to replicate real wood siding of old because the description of work specified harmonizing with existing conditions. The style we are matching this time is called  cottage lap and is made of at least 25% recycled material.  The siding also come pre-primed, an extra bonus for us. In speaking with Don Barnes a salesman for the manufacturer, the Collins company has been around since 1855 and is the manufacturer of True Wood this product also uses forest tree trimmings and rather than have them burned in slash piles they are broken down the the fibers and combined to make siding. So in reality it is a more green product than it takes credit for.

Lap Siding

The Collins Company has a rich history and Levco is especially proud to be using their products in our projects. As you can see we caulk each nail head in anticipation of paint we also added vertical pieces, one to disguise the seam and one to add symmetry. I’m not telling which one is which. In this case we also added gutters to harmonize.

Dried in with chicken wire

Stucco is being used as siding in this case to harmonize with the existing structure. Stucco is a cementitious coating with lime and sand that is mixed and hand applied over a semipermeable layer of tar paper with wire mesh nailed and stapled to it. We are using a material that has fiberglass particles in it to improve the strength. This system will consist of a brown coat and a finish coat. The weather has not been cooperating with us much. Having a humid climate to allow the brown coat to dry slowly and remain hydrated is preferable.

Brown Coat installed

The finish coat will be a LaHabra brand base 200 proprietary mix that will be applied with a hawk, trowel, and a rubber float to harmonize texture with the existing home. The entire home will be repainted too. Challenges include blending textures, attaching new to old, the weather, and the window wraps that add character to the home. Roger Purcell  is our stucco contractor and is a 20 year veteran of the trade.