⟁ cover painted for this edition — the source module carried no illustrations
Complete Masonry and Stone Construction: From Quarry to Cathedral
Stone outlasts all other building materials. This campaign covers stone selection, quarrying, cutting, mortar making, and construction of walls, arches, and buildings.
Chapter 1: Stone Types and Selection
Stone
Hardness
Workability
Durability
Best Uses
Weight (lb/ft³)
Granite
Very hard
Difficult
Excellent
Foundations, monuments
165
Limestone
Medium
Good
Good
Walls, carving, lime production
150
Sandstone
Soft-medium
Easy
Moderate
Walls, paving, carving
140
Slate
Medium
Splits easily (layers)
Excellent
Roofing, flooring, writing
170
Marble
Medium
Good
Good (interior)
Sculpture, flooring, decoration
160
Basalt
Very hard
Difficult
Excellent
Foundations, paving
180
Fieldstone
Variable
None (use as found)
Variable
Walls, foundations
Variable
River stone
Variable
None (use as found)
Good
Foundations, drainage
Variable
Chapter 2: Quarrying and Shaping
Method
Tools
Stone Types
Output
Difficulty
Splitting (wedge and feather)
Drill, wedges, feathers
All
Rough blocks
Moderate
Splitting (fire and water)
Fire, cold water
Granite, hard stone
Rough pieces
Low (slow)
Sawing
Stone saw + sand/water
Soft-medium stone
Smooth slabs
Moderate
Chiseling (point chisel)
Point chisel, hammer
All
Rough shaping
Moderate
Chiseling (flat chisel)
Flat chisel, hammer
All
Smooth faces
Moderate-high
Grinding/polishing
Abrasive stones + water
All
Smooth/polished surface
Low (time-intensive)
Chapter 3: Mortar and Cement
Type
Ingredients
Mixing
Set Time
Strength
Best For
Mud mortar
Clay + sand + straw
Mix with water to paste
1-3 days (dry)
Low
Temporary, interior
Lime mortar
Lime putty + sand (1:3)
Mix thoroughly
1-7 days initial, months full
Moderate
Traditional masonry
Hydraulic lime
Hydraulic lime + sand
Mix with water
Hours-days
Good
Wet conditions, foundations
Portland cement
Cement + sand + gravel
Mix with water
Hours
Very high
Modern construction
Roman concrete
Lime + volcanic ash + aggregate
Mix with water
Days
Excellent (underwater)
Foundations, underwater
Lime production: 1) Gather limestone (calcium carbonate). 2) Build lime kiln (stone chamber). 3) Fire at 900°C+ for 24-48 hours (produces quickite/calcium oxide). 4) Slake: add water carefully (violent reaction, very hot — produces calcium hydroxide/lime putty). 5) Age lime putty (months improve workability). 6) Mix with sand 1:3 for mortar. Lime mortar is self-healing (reabsorbs CO2, re-crystallizes). It has lasted 2,000+ years in Roman buildings.
Chapter 4: Wall Construction
Wall Type
Thickness
Mortar
Skill Level
Load-Bearing
Best For
Dry stone (no mortar)
18-36 inches
None
High
Yes (if thick)
Field walls, retaining
Rubble (random stone + mortar)
12-24 inches
Lime or cement
Moderate
Yes
General walls
Coursed stone (uniform layers)
12-18 inches
Lime or cement
High
Yes
Quality buildings
Ashlar (cut blocks)
8-12 inches
Thin lime bed
Very high
Yes
Fine buildings, facades
Stone veneer
4-6 inches
Cement + ties
Moderate
No (decorative)
Over frame construction
Dry stone wall principles: 1) Foundation: dig trench to solid ground, largest stones on bottom. 2) Batter: walls taper inward (wider at base). 3) Two faces: build two outer faces, fill center with rubble. 4) Through-stones: long stones spanning full width (every 3-4 courses) tie faces together. 5) Hearting: small stones packed tightly in center. 6) Capstones: heavy flat stones on top (lock everything). 7) No running joints: offset every course (like brickwork). 8) Each stone rests on two below (never stack directly).
Chapter 5: Arches and Vaults
Type
Span
Difficulty
Load Capacity
Uses
Flat arch (lintel)
3-6 ft
Low
Moderate
Doors, windows
Round arch (Roman)
4-20 ft
Moderate
High
Doors, bridges, aqueducts
Pointed arch (Gothic)
4-40 ft
High
Very high
Cathedrals, large spans
Barrel vault
6-30 ft wide
High
High
Roofing, tunnels
Groin vault
6-30 ft square
Very high
High
Large rooms, intersections
Dome
10-100+ ft
Very high
Very high
Large spaces, monuments
Arch construction: 1) Build centering (temporary wood frame in arch shape). 2) Lay voussoirs (wedge-shaped stones) from both sides simultaneously. 3) Place keystone (center top stone) last. 4) Allow mortar to cure fully. 5) Remove centering (arch is now self-supporting). 6) The arch converts downward force into outward thrust — buttresses or thick walls must resist this thrust.
Reference Card
Foundation on solid ground (below frost line). 2. Batter walls (wider at base). 3. Through-stones tie walls together. 4. Offset joints every course. 5. Lime mortar for traditional (self-healing, flexible). 6. Arches are strongest shape (convert load to compression). 7. Let mortar cure fully before loading. 8. Stone lasts forever if foundation is sound and water is managed (drainage, caps, pointing).
