The StoneDeks Story:
Where Dreams Meet Decks
From Food Stamps to Stone Decks: An American Dream Realized
Picture this: A young boy and his single mom, living in a rust belt town. Despite the obstacles, he’s washing dishes at 13, hauling trash with a one-ton dump truck in high school, and working 12 years of night school to earn his business degree.
This isn’t just another rags-to-riches story—it’s the foundation of an innovation that would revolutionize how we think about outdoor living spaces.
Meet Bart Stuchell, a machinist by trade with an inventor’s heart, who grew up on welfare but refused to let circumstances define his future. “I went to use food stamps one time in my life,” Bart recalls, “and something in my bloodstream said I’d rather get three jobs than use that food stamp.”
That spirit of self-reliance and determination would later drive him to create something the world had never seen: Stone on a Deck.
The “Aha!” Moment That Changed Everything
The year was 2007. Bart’s contractor friend called him up for what seemed like an ordinary ride. But when they arrived at the friend’s deck, Bart saw something that would spark a revolution. His buddy had laid a concrete sidewalk right down the middle of his wooden deck using swimming pool liner—a solution that was destined to fail in just three years.”Bart, you need to invent something that makes this a whole lot easier,” his friend said.
As a machinist with 15 years of R&D experience and owner of a plastic injection molding operation, Bart’s wheels started turning. The breakthrough came at a plastic show in Chicago, where he spotted a simple 12×12-inch grate designed to hold heavy injection molds.
“It was an ‘aha’ moment,” Bart remembers. “I thought, ‘Man, if I could just adapt this…’ and because I knew basic construction—16 inches on center—I knew exactly what size we had to build.”
That moment of inspiration led to the iconic SilcaGrate™ honeycomb design—a masterpiece inspired by nature itself. Just as bees have perfected the honeycomb structure over millions of years to create maximum strength with minimal material, Bart’s SilcaGrate™ harnesses this same natural engineering principle.
Weighing just a few pounds each, these lightweight grates can support incredible loads thanks to their biomimetic design that distributes weight with remarkable efficiency. But turning this nature-inspired innovation into reality? That was about to become the challenge of a lifetime.
The Leap of Faith
“I was looking to buy equipment for our injection molding operation anyway,” Bart explains, “so I tagged the mold on top of that purchase. We went out on that proverbial limb.”
Here’s where the story gets real. Bart needed expensive injection molding tooling, but he’d never made a single sale. Most people would have stopped there. Instead, he made a gutsy decision that would define his company’s future.
It was a calculated risk born from deep conviction. Bart wasn’t just creating a product—he was solving a problem that he knew existed for countless homeowners who dreamed of something more elegant, more durable, more luxurious than traditional deck surfaces.
Breaking Barriers, One Contractor at a Time
The biggest challenge wasn’t technical—it was psychological. For years, the construction industry had operated in silos. Wood people worked with wood. Stone people worked with stone. Never the two shall meet.
“People who cut wood can cut stone, and people who cut stone can cut wood,” Bart would tell anyone who’d listen. It sounds simple now, but convincing an entire industry to think differently? That was an uphill battle that lasted over a decade.
“What used to happen was everyone would say, ‘This is a good idea, but get someone else interested first.” Manufacturers would say get dealers interested. Dealers would say get contractors interested. Contractors wanted homeowners asking for it.”
It was a classic chicken-and-egg problem that required a completely different approach.
Here’s where the story gets real. Bart needed expensive injection molding tooling, but he’d never made a single sale. Most people would have stopped there. Instead, he made a gutsy decision that would define his company’s future.
“I was looking to buy equipment for our injection molding operation anyway,” Bart explains, “so I tagged the mold on top of that purchase. We went out on that proverbial limb.”
It was a calculated risk born from deep conviction. Bart wasn’t just creating a product—he was solving a problem that he knew existed for countless homeowners who dreamed of something more elegant, more durable, more luxurious than traditional deck surfaces.
The Breakthrough: When Innovation Meets Acceptance
The turning point came from an unexpected direction. While StoneDeks initially targeted the deck industry, it was the hardscape contractors who embraced the innovation first.
“They could suddenly sell more of their products in a whole different market they couldn’t reach before,” Bart explains. “Now they could put pavers on elevated systems—decks, docks, bridges, gazebos. We opened up entirely new revenue streams for them.”
This early adoption by hardscapers created the proof of concept that eventually convinced deck builders. The transformation was remarkable: “It went from ‘this is a good idea’ to ‘this is a plausible thing’ to ‘this is actually what I want on my deck. Make it happen.'”
Award-Winning Innovation
The proof is in the projects. Today, StoneDeks boasts nearly 2 million square feet installed across North America, with licensing extending to New Zealand, Australia, and the Pacific Islands. The system has earned ICC certification, meeting all residential building codes and giving contractors and homeowners complete confidence in its safety and reliability. Each SilcaGrate™ undergoes rigorous testing—supporting the equivalent of 1,000 pounds per square foot when commercial code only requires 100 pounds—proving that nature’s engineering wisdom, when properly applied, creates solutions that far exceed industry standards.
The recognition reached its peak at the prestigious Deck Summit awards in Florida, where StoneDeks-enhanced projects took home multiple honors:
- First Place: Decks Unlimited’s innovative fire pit inlay using porcelain pavers with composite decking
- Second Place: Holloway Company’s stunning elevated deck featuring travertine pavers
These weren’t just awards for StoneDeks—they were recognition of contractors who dared to think differently, to offer their clients something extraordinary.
More Than Just a Product: A Gateway to Luxury Living
Here’s what makes StoneDeks special: it’s not really about the technical specifications (though they’re impressive). The SilcaGrate™ honeycomb design, inspired by nature’s most efficient structural pattern, weighs just a few pounds yet can handle loads that would challenge much heavier systems. It’s about the moment a homeowner steps onto their deck and feels something different.
Imagine walking barefoot across cool travertine on a summer evening, hosting friends around a fire pit inlaid with beautiful porcelain, or simply enjoying your morning coffee on a surface that feels more like a luxury resort than a backyard deck.
“The name of the game for contractors is differentiation.” Bart notes. “There are tons of deck builders and tons of hardscapers out there. Our product allows contractors to offer both worlds and bring the best of both together.”
The Ripple Effect: Safety, Innovation, and Opportunity
The impact extends beyond aesthetics. StoneDeks has found unexpected applications in rooftop safety systems, where the grates provide crucial backup support for porcelain installations. “If the porcelain should fail from shock load, somebody doesn’t fall and get hurt,” Bart explains.
For young people entering the trades, StoneDeks represents a unique opportunity. The system is so user-friendly that newcomers can start by subcontracting deck framing while learning to install the StoneDeks system and pavers themselves.
“It’s a great way for young people to get their feet wet in both deck building and hardscaping,” Bart emphasizes. “They’re building experience in the field while working with a product that’s tried and true.”
A Family Business with Heart
At its core, StoneDeks remains a tight-knit operation of just six employees in Alliance, Ohio. But don’t let the size fool you—this team has created something that resonates across continents.
The family aspect runs deep. It represents the personal investment and genuine care that goes into every aspect of the business.
“We’re here eight to five every day, and we welcome phone calls,” Bart says. “Phones aren’t antiquated. We’ll be glad to talk to people and help them through whatever challenges they’re facing.”
Paying It Forward: The Innovation Mentorship
Perhaps most remarkably, Bart has made helping other inventors a personal mission. “I welcome anyone who has questions about polymers, how to make a product, how to invent a product,” he offers. “My passion is to take someone with an idea and educate them about the patent process, the manufacturing process, and the investment process of bringing a product to market.”
This isn’t just lip service. Bart regularly meets with inventors, sharing the hard-won wisdom from his journey. “Just had somebody in my office two days ago with one of the coolest things I’ve seen in a long time,” he says with genuine excitement.
It’s this spirit—the belief that innovation thrives when knowledge is shared—that makes StoneDeks more than just a product company. It’s a testament to what’s possible when determination meets opportunity.
Looking Forward: Where Dreams Continue to Build
Today, StoneDeks sales grow every day, driven by homeowners who refuse to settle for ordinary outdoor spaces and contractors who understand that differentiation leads to premium margins and lasting client relationships.
The future holds expanding applications, new markets, and countless opportunities for contractors to offer something truly special to their clients. But at its heart, StoneDeks will always be about one simple truth: everyone deserves to feel a little luxury when they step outside their back door.
The StoneDeks Difference: Where Your Outdoor Dreams Come Home
Whether you’re a homeowner envisioning your perfect outdoor retreat or a contractor looking to offer something extraordinary, StoneDeks represents more than just a building product. It’s a gateway to possibilities you didn’t know existed.
Because sometimes the best innovations come not from trying to reinvent everything, but from asking a simple question: “What if we could do this better?”
That question, asked on a wooden deck in Ohio over a decade ago, has transformed millions of square feet of ordinary outdoor spaces into something extraordinary. And the best part? We’re just getting started.
Want to hear the full story in Bart’s own words? Listen to the complete interview on The Trades Podcast for more insights about innovation, perseverance, and building something meaningful.
Ready to explore what StoneDeks can do for your project? Contact us or call us at (330) 821-1585. We’re here to help turn your outdoor dreams into reality—one deck at a time.
