Historically, builders have achieved strength through bulk. The outer walls were armored with stone, brick and a lot of mortar to create an exterior that could withstand the real world. But times have changed. We have technology that enables us to create lighter materials that–when installed as part of a system–are just as strong. Bulk isn’t the only way to achieve durability anymore.
In this article, we challenge the perception that lighter exterior finishes are less durable. The weight alone of the exterior cladding or finish doesn’t determine performance; the system design does. And nobody does system design better than Sto. Get ready to rethink weight as a performance advantage.
The Problem with Traditional “Heavy Equals Durable” Thinking
As beautiful as some traditional cladding materials are, they come at a price and with tradeoffs. That’s why there’s a need for finishes that reduce weight without sacrificing resilience.
The tradeoffs of using masonry, brick and stone include:
- Structural load – The heavier the cladding, the stronger the structural framework needs to be which leads to more materials and increased costs
- Installation time and labor – Traditional cladding materials require skilled labor and take more time to install and set
- Cracking, efflorescence and long-term maintenance – Traditional materials are often not engineered for weather tightness and incur efflorescence, leading to more maintenance being required over time. Plus, rigid claddings can crack and fracture under impact.
There are situations where traditional cladding options make sense. But now more than ever, building owners are seeking durability by design, not mass.
Durability by Design, Not Mass
There’s more than one way to achieve durability. As we’ve already discussed, you can create a heavy-duty exterior using traditional, bulky materials. But now we can also achieve durability by design. Here are just a few of the ways we’re now doing that:
- Reinforced acrylic composition
- Flexibility that absorbs impact rather than transferring stress
- Integration with Sto’s reinforced basecoat and mesh assemblies
Sto’s products and systems are designed with considerations of the building process, use and maintenance of the structure over its lifecycle. The systemized approach reduces risks and improves the lifespan and durability of the building. By providing an engineered and tested system, our finishes and exterior claddings allow for seamless transitions that create a monolithic barrier against the elements.
StoCast: A Lightweight Finish Built for the Real World
StoCast is a family of prefabricated, flexible resin cast shapes that capture the natural beauty of traditional cladding in astonishing detail. This innovative cladding creates thin, lightweight profiles that offer flexible construction and adhesive application without mechanical fasteners. When integrated with StoTherm® ci (or one of Sto’s other cladding systems), StoCast delivers proven durability, reduced risk and long-term maintenance advantages over traditional claddings.
StoCast also offers sustainability benefits, including:
- Reduced material usage
- Lower transportation energy
- Reduced structural demands
- Silica-free handling
StoTherm® ci is an EIFS with Drainage continuous insulation wall system that integrates StoGuard® air and water-resistive barrier, GPS, EPS or mineral wool insulation. It can achieve a variety of aesthetic appearances using Sto textured finishes, Sto Specialty finishes, or StoCast surface components. When StoCast is engineered as part of this complete wall system, even lightweight finishes can outperform traditional claddings.
StoCast Brick Durability Demonstration
Anyone can claim that a thinner, lighter material is just as durable as traditional claddings. We’re willing to show you. Below is a link to a video where we absolutely punish StoCast Brick, which is installed over StoTherm® ci GPS with Sto Armor Mat XX mesh. (That’s our StoTherm complete wall system.)
To simulate real-world abuse scenarios, we conducted three different tests. These tests were:
- 20-foot steel weighted ball drop
- Baseball bat impact
- Hammer strike
So how did the StoCast Brick perform? The system remained undamaged with only minor, repairable aesthetic surface marks. This video clearly demonstrates StoCast Brick’s:
- Incredible impact resistance
- System integrity
- Repairability without replacement
It’s time for you to see for yourself. Watch this video to see StoCast Brick in action.
Durability in High-Risk and High-Traffic Applications
High-performance claddings and finishes are great anywhere, but they’re especially needed in high-risk and high-traffic applications. These include:
- Schools and campuses
- Multifamily and mixed-use buildings
- Renovation and recladding projects
- Areas prone to impact, vandalism or frequent contact
When used as part of a complete wall system, these cladding and finishes offer several advantages over traditional brick and wood:
- Reduced cracking and efflorescence
- Lower maintenance burden
- Faster repair when damage occurs
Design Flexibility Without Performance Compromise
Sto Corp. believes in developing products that deliver design freedom by providing architects, designers and contractors with a wide array of customizable, high-performance building materials and facade systems. StoCast Brick and Wood are perfect examples. Here are some of the ways they provide design flexibility without compromise:
StoCast Brick
- Traditional and custom brick aesthetics
- Flexible shapes and patterns
- Proven 20+ year project history
StoCast Wood
- Authentic wood grain without warping or fading
- Interior and exterior use
- Curved surfaces, soffits and ceilings
- Ideal for multi-cladding facades using one integrated Sto system.
Why System Integration Matters
An exterior cladding or finish is only as robust as its transitions and other wall components. Material-only approaches create a piecemeal solution that inevitably results in gaps between incompatible products.
Sto’s integrated approach includes proven technology such as StoGuard AWRBs, StoTherm ci EIFS with drainage, and StoVentec rainscreen systems. Plus, we offer continuous insulation, including noncombustible options. And our comprehensive, systematized approach means one manufacturer, coordinated responsibility and reduced risk.
Lightweight Doesn’t Mean Less Durable
Creating durability through material mass is the old way. The new way to achieve durability is as a function of system design. System design can endow a lightweight cladding or finish with super performance powers. StoCast is proof. It’s a lightweight finish that delivers resilience, repairability and long-term performance.
Sto is a trusted authority in building science focused on real-world performance. We invite you to collaborate with our experts early in your next project to help you select the right reinforcement and wall assembly for impact-resistant designs or learn more about StoCast finishes.
