2013 - Volume #37, Issue #3, Page #34
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Concrete Logs Look Like The Real Thing
Joe discovered Walt Smith, inventor of the patented design for Old Kentucky Logs on the Internet and decided to become a distributor in the Pennsylvania/East Coast area. The O’Harahs also make concrete statues.
“We have always liked the old hand-hewn logs, but they take so much maintenance,” Susan O’Harah says. Concrete eliminates problems associated with wood such as warping, settling, twisting, rotting and holes dug by bugs and birds.
With several realistic wood grain molds, Old Kentucky concrete logs are 2 by 10 in. and 8 ft. long with rebar inside to prevent the logs from cracking. Logs weigh just 80 lbs. so two people can handle them. There are also special molds to make dovetail corners and sills, trim and other siding accents.
“It goes on like veneer stone with metal tabs and screws,” O’Harah says. Walls are prepared with at least 1/2-in. thick plywood or OSB, covered with felt paper or plastic moisture barrier and topped with wire mesh. Spread mortar on the back of the log, level it on the wall and screw it in place. Stack the siding pieces up the wall, leaving a gap (usually between 1 1/2 and 2 in.), and cut gable pieces to fit using a saw with a concrete blade.
Once all the logs are in place, the siding is ready for staining.
“We use a concrete acid stain sprayed with a cheap garden sprayer,” O’Harah says. Once it’s dry, use a bag or applicator to smooth grout between the logs. Paint or spray a good sealer over everything.
The O’Harahs have their own molds under a royalty agreement with Old Kentucky Logs to make the logs in Pennsylvania, which saves customers shipping costs. With a small model cabin at their business, they’ve had a good response since they started in June 2012.
For example, one customer is beefing up his log restaurant after a car ran into it. He purchased concrete logs for both the interior and exterior. A homeowner with a two-story brick farmhouse plans to side his house with the concrete logs – which can be mortared directly to the brick.
“We mainly just make and sell the product,” O’Hara says. “But we go and show customers how to get started. We want to make sure they’re doing it right.”
Installation goes fairly quickly, she says, especially when compared to veneer stone siding.
The cost for the concrete logs is $7.50 per sq. ft. That’s similar to the cost of lower priced veneer stone and much less than using real logs – especially factoring in the cost of maintenance.
The O’Harahs have been busy making logs and storing them for the upcoming season. They’ve heard from potential customers as far away as Maine and New York.
Contact: FARM SHOW Followup, O’Harah Concrete Inc., 4679 Rt. 310, Reynoldsville, Penn. 15851 (ph 814 653-8791; www.oldkentuckylogs.com).
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