New construction technologies have emerged over the past decade to redefine the way we construct buildings, all while maintaining the warm, traditional looks we are all familiar with. These products increase a building's durability (it's life cycle), while reducing the impact on the environment from the manufacturing process and simultaneously reducing the cost of construction. Stucco exterior columns are one such relatively new construction technologies. Unlike wood columns, stucco columns are not susceptible to warping, rot or infestation. In addition, they look like upscale concrete columns at a fraction of the cost and weight.
They are manufactured from a shaped core that is cut from lightweight expanded polystyrene (EPS) then layered with alkali-resistant fiberglass mesh and run through an extruding machine - leaving a thin, yet resilient coating that looks identical to precast concrete. This manufacturing method actually makes the columns closer to Exterior Insulation Finish Systems (EIFS) in construction, but are more frequently referred to as stucco columns. It is important to be aware that not all supposed stucco column manufacturers make their products the same - some substituting cheaper materials to drive the price down, at the unfortunate cost of quality and longevity.
The key features one wants to ensure when selecting a manufacturer is as follows:
1. The styrofoam is made from Type I (1 pound per cubic foot), virgin (not recycled) polystyrene that is oven cured.
2. The mesh is alkali-resistant (a special coating that prevents it from being broken down by the cement).
3. The cementitious coating is extruded in 2 layers, in separate runs so that the first layer is allowed to dry before the second is applied. An "acrylic binder" - a type of glue - should be mixed with the cement which increases the impact resistance of the coating, while making it more flexible to prevent cracking of the protective layer.
It is unfortunate that most home owners do not know the ins and outs of the manufacturing process, as the 3 specifics above can literally make the difference between whether a column lasts for 3 years before falling apart in a harsh exterior climate, or 25+ years in immaculate condition.
Exterior stucco columns have become popular on home renovations due to the ease of installation around existing posts or columns. Supplied in halves, the column cores can be cut to any size required to be placed around unsightly supporting posts to retrofit the look of the house. The two halves can be glued together using a construction adhesive suitable for styrofoam (such as PL Premium) or a cementitious adhesive product from a local EIFS distributor - use of a rope or similar binding method is recommended to ensure a solid fit until the adhesives dry, typically 24 hours.
That is not to say that these styrofoam columns are load bearing. If the columns themselves are required to support a structure then other materials such as fiberglass or glass-fiber reinforced concrete (GFRC) would be better suited. This point is easily worked around by using a structural post made of either wood or metal at the required load bearing points, and simply wrapping the column halves around it. Comparable load-bearing concrete columns cost thousands of dollars, making stucco columns an ideal alternative.
Far from just supplying a column, many suppliers also carry basic caps and bases, as well as elaborate corinthian, ionic and doric caps and bases. These caps and bases are installed in the same manner as the columns themselves - by placing the two halves around a center pole, and having the column sit on top in the case of a base and below in the case of a cap.
Color options are limitless, allowing the home owner to match the exterior column to the exterior of their home or make the columns stand out as an architectural feature. Stucco columns are supplied in the standard cement-color of the coating, and are painted using an exterior-grade masonry paint found at a local hardware store or EIFS manufacturer. 2 coats is typically recommended to ensure full saturation of the color, and to protect the cementitious coating from the elements. If the right supplier is selected, the paint is actually partially absorbed into the cementitious coating, creating a seamless coating that will not peel and flake off over time.
When it comes to the exterior, stucco columns are superior in every way to competing products. They will not degrade due to exposure to the elements or insects like wood. They do not cost a fortunate (to manufacture, and transport!) like comparable precast concrete columns. On top of all that, stucco columns are also ideal for renovations, because existing posts/poles/columns can be left in place and the two halves simply wrapped around - drastically changing the look without requiring an engineer's approval to remove load bearing members.
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