Cultured Stone SUBMITTAL PACKET Installation Manual

 CULTURED

TECHNICAL SUBMITTAL PACKET 2020

SUBMITTAL PACKET

WELCOME

COMPANY NAME:

CONTACT NAME:

PROJECT TITLE:

STREET ADDRESS:

CITY, STATE, ZIP:

We would like to congratulate you on your upcoming project which incorporates adhered concrete masonry veneer products. Enclosed in this packet are the required Cultured Stone submittal forms and technical documents. We have also enclosed additional support materials and installation details commonly requested by architects and contractors.

Visit culturedstone.com/resources to view all digital materials available for download.

SUBMITTAL FORM

TECHNICAL DATA SHEET

50-YEAR WARRANTY

CERTIFICATE OF QUALITY

STONE INSTALLATION

As part of our commitment to service, we would like to recommend that you take advantage of our consulting services.

We have trained Technical Field Service representatives that will walk through your project with you prior to installation. This can help prevent improper installations and in some cases identify where additional stone or accessories may be needed.

Thank you again for choosing Cultured Stone. Should you have any questions, please do not hesitate in contacting us. We are grateful for the opportunity to be a part of your project needs.

Sincereley,

BRICK INSTALLATION

3-PART SPEC

ICC-ES EVALUATION REPORT

SAFETY DATA SHEET

Sales Representative Cultured Stone

1.800.255.1727 | culturedstone.com

SUBMITTAL PACKET

SUBMITTAL FORM

Cultured Stone Representative:

PROJECT DETAILS CULTURED STONE

PROJECT NAME:

PROJECT ADDRESS:

CITY, STATE, ZIP:

Please ﬁll in all known information:

OWNER ARCHITECT BUILDER MASON

COMPANY NAME:

CITY, STATE:

CONTACT NAME:

CONTACT PHONE:

COMPANY NAME:

CITY, STATE:

CONTACT NAME:

CONTACT PHONE:

PROJECT NOTES:

PROFILE: COLOR:

APPROX SQ FOOTAGE:

MANUFACTURING LOCATION:

COMPANY NAME:

CITY, STATE:

CONTACT NAME:

CONTACT PHONE:

COMPANY NAME:

CITY, STATE:

CONTACT NAME:

CONTACT PHONE:

Pre-Installation Project Team Meeting Scheduled? Y N Date Scheduled:

Your signature below acknowledges receipt of Cultured Stone’s “Submittal Packet” and the above information is accurate to the best of your knowledge.

Received By: Date:

Company: Phone:

Cultured Stone Representative: Date:

Email completed form to: BoralStoneAnswers@Boral.com

1.800.255.1727 | culturedstone.com

TECHNICAL DATA

The Cultured Stone® collection of manufactured stone veneers is engineered to meet or exceed speciﬁcations for all major code approvals. Manufacturers who oer ”just like” or a so-called “equivalent” to Cultured Stone manufactured stone veneer products should be asked to document claims of test results and research reports.

Complete copies of these Cultured Stone manufactured stone veneer building code evaluation reports, research reports, approvals and listings are available upon request:

• ICC-ES ESR-1364 • Florida Product Approval FL15047

• Tested and listed by Underwriters Laboratories, Inc. • HUD Materials Release No. 1316

• Texas Department of Insurance– • BMEC Authorization Product Evaluation Report, EC-21

Note: Local building codes may vary; always check with your local building code authority prior to installation.

Results of tests conducted by an independent testing agency conﬁrm that the Cultured Stone collection of manufactured stone veneers conforms to or exceeds the following test requirements as speciﬁed in ICC Evaluation Service Acceptance Criteria 51 for Precast Stone Veneer:

MATERIALS

CEMENT ASTM C 150 or ACI 318 Section 3.2.1

SAND ASTM C 144 or C 33

AGGREGATE ASTM C 33 or C 330 (except gradation), C 331

TESTING

SHEAR BOND TEST (ADHESION)

WATER ABSORPTION Tested in accordance with UBC 15-5 9%–22% depending on texture

FREEZE/THAW CHARACTERISTICS

COMPRESSIVE STRENGTH

UNIT WEIGHT

TENSILE STRENGTH Tested in accordance with ASTM C 190 Reported

FLEXURAL STRENGTH Tested in accordance with ASTM C 348 Reported

THERMAL PROPERTIES

NONCOMBUSTIBLE

Tested in accordance with ASTM C 482 > 50 psi

Testing procedures follow those outlined in ASTM C 67

Tested in accordance with ASTM C 39 > 1800 psi @ 28 days

Density is determined in accordance with ASTM C 567

Tested in accordance with ASTM C 177-71

Tested and listed by Underwriters Laboratories, Inc.

< 3% mass loss

< 15 lbs. per square foot

R-value is .620 based on a 1.75" thick sample. Average thickness may vary on dierent Cultured Stone veneer products, and the R-value will vary accordingly.

Cultured Stone brand products showed zero ﬂame spread and zero smoke development.

052918

1.800.255.1727 | culturedstone.com

50-YEAR TRANSFERABLE LIMITED WARRANTY

LIMITATIONS ON THE TRANSFERABILITY OF THIS WARRANTY ARE SET FORTH HEREIN

INTRODUCTION

Thank you for your recent purchase of Cultured Stone® by Boral® manufactured stone veneer products (“Product(s)”). This express limited warranty (“Warranty”) only covers Cultured Stone manufactured stone veneer products manufactured by Boral Stone Products LLC (“Boral”).

WHO IS COVERED & FOR HOW LONG

Subject to the following terms, Boral warrants its Products for fi fty (50) years to the original purchaser (the “Purchaser”) (based upon the date of retail purchase, date of substantial completion of the installation if professionally installed, or date of settlement of the purchase of a newly constructed building, whichever is applicable). This Warranty is personal to you; however, the Warranty may be transferred to any subsequent purchaser(s) of your home or building during the fi rst fi fteen (15) years after the original purchase date (as described above), but the warranty period as to such subsequent owners is limited to fi fteen (15) years from the original purchase date (as described above).

WHAT BORAL WARRANTS

Boral, subject to the conditions and limitations listed herein, warrants its Products to be manufactured in compliance with the International Code Council Acceptance Criteria 51 (“ICC AC 51) for Precast Stone Veneer; however, Products that are accessories and Products that are not wall veneer shall not meet the weight, density and dimension parameters of ICC AC 51.

WHAT IS NOT COVERED

We do not cover damage to the Product due to any cause not expressly covered herein. This Warranty does not cover any problems with non-defective material caused by conditions or handling beyond our control.

Some examples of conditions not covered by this Warranty include:

1. Improper application, use of accessories which do not properly receive and/or secure our Products, or installation not in strict adherence to the applicable installation instructions or installation not in accordance with local building code requirements.

2. Damage resulting from accident, misuse, neglect, casualty, fi re, vandalism, plant growth, impact of foreign objects,

salt or de-icing chemicals, excessive exposure to water due to things such as standing water, water backups, improper fl ashing, leaks, seepage or irrigation systems, failure of or damage to the wall substrate on which the Product was applied caused by movement, distortion, cracking, or settling of such wall or the foundation of the building, surface discoloration due to airborne stains, pollutants, algae, fungi, lichens or cyanobacteria, exposure to harmful chemicals, external heat sources (including, but not limited to, a barbecue grill, fi re, or refl ection from windows and doors), acts of God, or other such occurrences beyond the control of Boral;

3. Product or material that has been painted, varnished, sealed with non-breathable sealer, or similarly coated over the

manufacturer’s original fi nish; and

4. The use of sandblasting, power washing, silicone treatments, or any other form of chemical wash.

Products shall not be in breach of this Warranty if they contain or exhibit (i) minor chipping, as defi ned under ASTM C1364, Section 8.2; or (ii) minor cracks, as defi ned under ASTM C 90-05, Section 7.2.1, incidental to the usual methods or materials of manufacture or minor chipping resulting from customary methods of handling in shipment and delivery which do not a˛ ect the proper placement of the unit or signifi cantly impair the strength or permanence of the construction.

Products are not warranted against discoloration caused by air pollution, exposure to harmful chemicals, or “normal weathering” resulting from exposure to the elements. “Normal weathering” is defi ned as the damaging e˛ ects of sunlight and extremes of weather and atmosphere that may cause any colored surface to oxidize, fade, or become soiled or stained over time.

Boral strives to accurately reproduce the colors of its masonry stone veneer Products in its marketing literature and sample boards. The Product colors that you see are as accurate as technology allows. Boral makes no warranty with respect to any real or perceived color di˛ erences between those depicted in its marketing literature and sample boards and those of the actual Products that will be installed on or within the home or building. Boral recommends that you look at actual Product samples before making a color selection for your home or building.

50˜YEAR TRANSFERABLE LIMITED WARRANTY

WHAT IS YOUR REMEDY

If the Products are not in conformance with our Warranty, Boral will, in its sole discretion, either (i) repair or replace the nonconforming Products at no charge to you, or (ii) refund the price paid for the Products. Labor costs for removal or installation are not covered. Any Products repaired or replaced hereunder will continue to be covered under the terms of this Warranty for the remainder of the original warranty period.

SUBMITTING A WARRANTY CLAIM

To obtain performance under this Warranty, the Purchaser(s) shall notify Boral of the claim promptly following its discovery, and shall submit with such notifi cation proof of date of purchase and/or installation, and proof of property ownership, in order to provide Boral an opportunity to investigate the claim and examine the material claimed to be defective. All notifi cations shall be provided to Boral at Boral Stone Products Warranty Department, 2256 Centennial Road, Toledo, Ohio 43617 or call 1-800-255-1727. Shortly after we receive your communication, we will contact you regarding your claim. To fully evaluate your claim, we may ask you to provide pictures of your Products or samples for us to test. If you have any questions, do not hesitate to write us at the address above or call 1-800-255-1727.

REPLACEMENT & PRODUCT VARIATIONS

As a result of our ongoing e˛ orts to improve and enhance our product line, we reserve the right to discontinue or modify our Products, including their colors, without notice to the Purchaser(s) and shall not be liable to the Purchaser(s) as a result of such discontinuance or modifi cation. We are not liable to you if you make a warranty claim in the future and any replacement Products you receive vary in color or fi nish because of normal weathering or changes in our product line. You should understand that if we replace any Products under this Warranty, we reserve the right to provide you with substitute Products that are comparable only in quality and price to your original Products.

LIMITATIONS

EXCEPT AS SET FORTH ABOVE, BORAL MAKES NO EXPRESS OR IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO ANY PRODUCT SOLD. ORAL STATEMENTS CONCERNING THE PRODUCT˝S˙ COVERED BY THIS WARRANTY, OR STATEMENTS CONTAINED IN BORAL’S GENERAL ADVERTISING, PAMPHLETS OR OTHER PRINTED MATERIALS DO NOT CONSTITUTE WARRANTIES, AND PURCHASER ACKNOWLEDGES THAT IT HAS NO RIGHT TO RELY UPON SAME. BORAL, WHETHER AS A MANUFACTURER OR CARRIER, SHALL NOT BE LIABLE FOR ANY COMMERCIAL LOSSES, SPECIAL, INCIDENTAL, CONSEQUENTIAL, PUNITIVE OR EXEMPLARY DAMAGES, OR FOR ANY LOSS, DAMAGE OR EXPENSE ARISING UNDER OR IN CONNECTION WITH ANY SALE OF PRODUCT. BORAL’S LIABILITY FOR DAMAGES OF ANY KIND SHALL IN NO EVENT EXCEED THE ORIGINAL PURCHASE PRICE OF THE PARTICULAR ORDER, LOT OR SHIPMENT ˝OR THE ORIGINAL PURCHASE PRICE OF THAT PORTION THEREOF WHICH IS NOT REPAIRED OR REPLACED˙ WITH RESPECT TO WHICH A CLAIM IS ASSERTED. IN PARTICULAR, BORAL SHALL NOT BE LIABLE FOR LOSS OF SALES, REVENUES OR PROFITS OR CLAIMS OF ANY THIRD PARTIES.

LEGAL RIGHTS

Some states do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you. Some states do not allow the exclusion or limitation on incidental or consequential damages, so the above limitation or exclusion may not apply to you. This Warranty gives you specifi c legal rights, and you may also have other rights which vary from state to state. If the laws of a particular state require terms other than or in addition to those contained in this Warranty, this Warranty shall be deemed modifi ed so as to comply with the appropriate laws of such state, but only to the extent necessary to prevent the invalidity of this Warranty or any provision of this Warranty or to prevent the imposition of any fi nes, penalties or any liability.

Certiﬁcate of Quality

DATE:

ATTN:

PROJECT TITLE:

PROJECT CITY+STATE:

PRODUCT/STONE COLOR+PROFILE (1):

PRODUCT/STONE COLOR+PROFILE (2):

ARCHITECT:

GENERAL CONTRACTOR:

MASONRY CONTRACTOR:

This document certiﬁes that the product manufactured by Cultured Stone, for the project listed above, meets the Acceptance Criteria AC-51 for Precast Stone Veneer established by ICC Evaluation Service and as speciﬁed in the Evaluation Report No. ESR-1364.

Sincerely,

Rick Garagliano Director of Quality, Cultured Stone

MANUFACTURER’S

STONE INSTALLATION INSTRUCTIONS

METHODS TO COMPLY WITH ASTM C1780

Cultured Stone® and Cultured Brick® Installation Instructions are available separately from your dealer and can

also be found at www.culturedstone.com.

Building code requirements vary from area to area. Check with local authorities for building code requirements in your area. Carefully read all Installation Instructions before proceeding with your Cultured Stone products application. Observe safety precautions. Cultured Stone products are covered by a 50-Year Limited Warranty when installed in accordance with the manufacturer’s Installation Instructions. See the complete warranty on our website at www.culturedstone.com.

STEP ONE:

DETERMINE BACK-UP WALL & SURFACE PREPARATION REQUIREMENTS

Typical back-up systems include:

WOOD FRAME

UNIT MASONRY/CONCRETE

In sequence: (1) sheathing, (2) two layers of water resistive barrier (WRB), (3) galvanized metal lath, (4) scratch coat, (5) mortar setting bed, (6) Cultured Stone manufactured stone veneer, (7) mortar joint.

In sequence: (1) mortar applied directly to untreated, unpainted masonry, concrete or stucco, (2) Cultured Stone manufactured stone veneer, (3) mortar joint.

Note: Painted, sealed, dirty & smooth surfaces/ walls will require additional preparation to address these conditions.

RIGID FOAM INSULATION METAL BUILDINGS

METAL FRAME

In sequence: (1) sheathing, (2) two layers of water resistive barrier (WRB), (3) galvanized metal lath, (4) scratch coat, (5) mortar setting bed (6) Cultured Stone manufactured stone veneer, (7) mortar joint.

CEMENT BOARD

In sequence: (1) rigid foam insulation, (2) two layers of water resistive barrier (WRB), (3) galvanized metal lath (Ribbed Lath shown), (4) scratch coat, (5) mortar setting bed, (6) Cultured Stone manufactured stone veneer, (7) mortar joint.

See the special Technical Evaluation Report regarding installation over continuous insulation for more information.

In sequence: (1) sheathing, (2) two layers of water resistive barrier (WRB), (3) cement board, (4) mortar setting bed, (5) Cultured Stone manufactured stone veneer, (6) mortar joint.

STONE INSTALLATION INSTRUCTIONS

WALL SYSTEM/BACK UP

SURFACE PREPARATION TABLE 1

PREPARATION REQUIREMENTS

CLEANING

2 LAYERS

WRB

LATH

SCRATCH

COAT

ROUGHEN/

TEXTURE

NOTES

WOOD FRAME 16"oc

METAL FRAME 16"oc

UNIT MASONRY

(BRICK OR BLOCK)

SHEATHING

PLYWOOD

OSB

CEMENT BOARD

WALLBOARD

½" FOA M BOARD

SHEATHING

EXTERIOR GYPSUM

OSB

PLYWOOD

½" FOA M BOARD

✓

✓ ✓ ✓

✓

OPTIONAL OPTIONAL N/A

✓ ✓ ✓

✓

✓ ✓

✓ ✓ ✓

✓

OPTIONAL OPTIONAL OPTIONAL

✓ ✓

N/A

SITE

EVALUATION

Requires modiﬁed mortar to bond units. Proprietary coatings between bonding mortar & cement board may compromise warranty.

Engineer review recommended for existing unit masonry.

POURED CONCRETE OR “TILT UP” CONSTRUCTION

OPEN STUD CONSTRUCTION

METAL BUILDING

INTERIOR INSTALLATION

CONTINUOUS INSULATION

STUCCO

Notes: Designer must consider and detail movement joints. Do not bridge movement joints with stone units. Optional surface preparation utilizing a rainscreen may be added. See General Information (page 8) for more information. Designer must consider a detail movement joint. Do not bridge movement joints with stone units

Some foam products may qualify as WRB. See foam manufacturer instructions.

Cleaning can be as simple as rinsing dust o the surface with clear water or as involved as bead blasting. You are

removing form release agents, dirt, paint, sealers or anything that may inhibit bond. This process may also be the method to roughen the surface to create bond ready texture. See ASTM C1780 for more information.

See cement board section for option to eliminate scratch coat application

***

✓

OPTIONAL OPTIONAL OPTIONAL

✓ ✓ ✓

SPECIAL CONDITIONS

1 LAYER

✓

✓ ✓ ✓

✓ ✓

✓

N/A

See ASTM C1780 for roughness evaluation.

48 hour scratch coat cure. Use paper backed 3.4 lb rib lath.

See TER for lath fastener selection available for framed or masonry applications.

Engineer review recommended for existing stucco.

Spacing per ASTM C1063

STEP TWO:

WALL SURFACE PREPARATION

EXTERIOR APPLICATIONS

Make sure that the application of Cultured Stone products and the structure they are being applied to incorporate good building practices. Corrosion-resistant ﬂashing shall be installed at all wall penetrations. Flashing type and locations shall be in accordance with the requirements of the applicable building code. On exterior applications, the incorrect installation or absence of ﬂashing, cant strips, gutters, kick out ﬂashing and downspouts may result in diversion of water run-o onto ﬁnished surface areas. Masonry and other building products subjected to these conditions may develop staining and, when combined with severe freeze-thaw conditions, may eventually cause damage. The application of Cultured Stone products under these conditions is not recommended.

Flashing

1. To maintain the weather-resistance of the exterior wall on which stone products are installed,

corrosion-resistant ﬂashing/weep screed and a means of drainage shall be installed at all penetrations and terminations of the stone cladding. Flashing type and locations shall be in accordance with the requirements of the applicable building code.

2. For additional recommendations regarding ﬂashing, refer to the following trade associations, standards, organizations and resources:

a. National Concrete Masonry Association - Manufactured Stone Veneer (NCMA-MSV) installation

guide for adhered concrete masonry veneer, available at www.ncma.org b. Architect or engineer c. ASTM E 2112 d. Asphalt Roofing Manufacturers Association (ARMA) e. Brick Institute of America (BIA)

f. The American Plywood Association (APA) g. Local building department h. Consult window manufacturer warranty as a perimeter soft joint/gap may be required

Clearance

Maintain a 4" clearance between Cultured Stone and grade or 2" clearance above a paved surface. Most building codes require the use of a weep screed in framed applications. In framed applications, this distance is measured from the “beak” of the weep screed. When a weep screed is not required— application over masonry as an example—a 2" × 4" leveling/ledger board may be used as a temporary level straight edge to start your installation. See the NCMA Installation Guide for conditions that allow a reduction in clearance requirements.

WATER RESISTIVE BARRIER (WRB) INSTALLATION

Where a WRB is required, it should be installed as two separate layers, in shingle fashion. Fasteners, fastening schedule, vertical and horizontal lap requirements should follow the manufacturer’s installation instructions. The WRB layers must be continuous through inside and outside corners, typically extending 16" to the next framing member. See Material Selection (page 4) for speciﬁc WRB material requirements. Example for building paper: 2" horizontal lap, 6" vertical lap.

Interior Gypsum Board

Batt Insulation

Wood Framing

Exterior Grade Sheathing

2 Layers Of WRB

Lath

Lath Fasteners–Type &

Mortar Scratch Coat

Mortar Setting Bed

Manufactured Stone Veneer

Mortar Joint

WRB Lapped Over Weep Screed

Weep Screed

CORNER CONSTRUCTION

Water resistive barrier & lath must continuously wrap a minimum of 16" at outside and inside corners and fasten at a framing member. In sequence: (1) wall substrate, (2) two layers of water resistive barrier, (3) metal lath

STONE INSTALLATION INSTRUCTIONS

LATH INSTALLATION

Where lath is required, it shall be installed in accordance with ASTM C1063. Typically this will require corrosion resistant fasteners every 6" on center vertically, and 16" on center horizontally, fastened to framing. If an alternative lath is used, install it in accordance with the manufacturer’s installation instructions and evaluation report. See the following Material Selection section for more speciﬁc lath requirements.

Note: Fasteners installed between framing should be limited as they may extend into the wall’s insulation cavity.

SCRATCH COAT

Using a trowel or spray application, install mortar scratch coat of minimum thickness of ½" up to ¾." Use sucient material and pressure to fully engage and encapsulate the lath. No lath material should be visible after scratch coat installation.

Note: Proper encapsulation and scratch coat thickness are key aspects to lath corrosion resistance and physical performance characteristics.

STEP THREE:

MATERIAL SELECTION

WATER RESISTIVE BARRIER (WRB)

Select a material meeting one or more of the following standards:

• ASTM D226 Type 1 No.15 Asphalt Felt, intended for wall application

• ASTM E2556/E2556M

• ICC ES AC-38. Current Evaluation Report, by an ANSI accredited evaluation service, showing compliance to ICC ES Acceptance Criteria #38

• ILiquid WRB/Air Barrier–Current Evaluation Report by an ANSI accredited evaluation service showing compliance to code requirements for WRB

LATH

Select a material meeting one or more of the following standards:

• ASTM C847, minimum 2.5 lb/yard expanded metal lath

• ASTM C847, minimum 3.4 lb/yard, 3⁄8" rib, expanded metal lath

• Non-metallic lath, with a current evaluation report, conﬁrming compliance to ICC-ES AC 275 by an ANSI accredited evaluation service, conﬁrming alternative to one of the above lath products

• Liquid WRB/Air Barrier–Current Evaluation Report by an ANSI accredited evaluation service showing compliance to code requirements for WRB

• Alternate lath products showing compliance with ICC-ES AC 275, or equivalent. Drain-N-Dry best in class ventilated rainscreen and superior integral Alkali Resistant glass lath combined meeting AC

275. For more information visit www.DrainNDryLath.com

All lath products must be self-furred, or use furring fasteners, to provide ¼" clearance between lath and substrate, for the purposes of mortar embedded encapsulating lath.

LATH FASTENERS

Select fasteners that meet the requirements of the following standard:

• ASTM C1063

1. Galvanized nails, staples, concrete nails. Penetration depth into wood framing is ¾" minimum.

2. Corrosion-resistant, self-drilling, self-tapping pancake-head screw with 7⁄16" head, of 1¼" length or suitable to obtain 3⁄8" penetration beyond inside surface of metal. (Used for installing to metal surfaces such as metal studs or metal building siding.)

Applications over continuous insulation, refer to Technical Evaluation Reports 1312-02 or 1302-01 available at www.culturedstone.com.

• ASTM C1032, minimum 18 gauge, woven wire mesh

• ASTM C933, welded wire lath

™

Lath is a

MORTAR

Select a material meeting one or more of the following standards:

• ASTM C270 Type N or Type S

• ASTM C1714 Type N or Type S

• ANSI 118.4 and 115.15

MORTAR (CONTINUED)

Mortar Admixtures: Comply with ASTM C1384 Bonding Agents: Comply with ASTM C1059 or C932 Coloring Pigment: Comply with ASTM C979

All mortar, additives, bonding agents and pigments must be stored, mixed and used in strict accordance with the manufacturer’s instructions and appropriate standards referenced above.

Notes: Refer to NCMA Installation Guide (www.ncma.org) for additional guidance with mortar selection by application. Under mixing, over mixing, tempering and open times of mortar can impact bond. Follow mortar manufacturer’s instructions.

STEP FOUR:

ESTIMATING THE STONE REQUIRED

Determine the amount of Cultured Stone products needed by measuring the area to be covered. Measure the length times the height to arrive at the gross square footage of ﬂat stone needed. Subtract square footage for window, door and other openings. Measure the linear feet of outside corners to determine the amount of corner pieces needed. One linear foot of corner pieces covers approximately 3⁄4 of a square foot of ﬂat area. Subtract the ﬂat area covered by the linear feet of corner pieces from the square footage of ﬂat stone required. You may wish to obtain some extra stone to allow for cutting and trimming, or tighter joints. In addition, be sure to verify whether the texture chosen is sold based on coverage with a ⁄" mortar joint or tight-ﬁtted. Most texture coverages are listed for a 1⁄2" joint, the exceptions being dry-stack Ledgestone, European Castle Stone, Pro-Fit

Pro-Fit Hewn Stone

Alpine Ledgestone, Pro-Fit® Terrain™ Ledgestone, Pro-Fit® Modera™ Ledgestone,

™

, and Cast-Fit®.

Ledgestone,

TOOLS REQUIRED

Choose the tools required for your installation:

• Safety Glasses and other personal protective equipment

• Staple Gun or Hammer

• Wheelbarrow & Hoe

• Hock & Trowel

• Mason’s Trowel

• Margin Trowel

• Masonry, Circular, Table, Wet Saw or Grinder with Carborundum or Diamond Blade Wide-Mouth Nippers or Hatchet

• Dust Mask

(1)

• Level

• Metal Jointing Tool or Wood Stick

• Grout Bag

• Whisk Broom

Note: Cutting dust mitigation steps include but are not limited to: wet saw, dust vac system and respirator systems. OSHA may be required due to speciﬁc site conditions.

(1) Caution: Product contains Crystalline Silica. Dust from

cutting or sawing may create possible cancer hazard. Dust may cause irritation of the nose, throat and respiratory tract. Avoid prolonged or repeated inhalation of dust. A properly ﬁtted, particulate-ﬁltering disposable NIOSH approved N-95 series face piece respirator (“dust mask”) should be used when mechanically altering this product (e.g., sawing, cutting, drilling or similar dust generating processes). Wear a long-sleeved shirt, long pants, gloves and safety glasses with side shields when handling and installing material. Wash hands and face with soap and warm water immediately after handling.

TOOLS REQUIRED

Staple Gun/Hammer

(Applying water-resistive barrier

and/or metal lath)

Mason’s Trowel

(Applying mortar)

Wheelbarrow & Hoe

(Mixing mortar)

Masonry, Circular, Table, Wet Cut Saw or Grinder

with Carborundum or Diamond Blade

Wide-Mouth Nippers/Hatchet

(Trimming stone)

(Applying masonry adhesive)

Margin Trowel

Dust Mask

Metal Jointing Tool/Wood Stick

(Finishing joints)

Grout Bag

Hock & Trowel

Level

Whisk Broom

(Cleaning finished work)

(1)

Safety Glasses

(1)

STONE INSTALLATION INSTRUCTIONS

STEP FIVE:

APPLICATION OF CULTURED STONE UNITS

PREPARE YOUR WORK AREA

Spread Cultured Stone wall veneer out at the job site so you have a good variety of sizes, shapes and colors to choose from. Plan for some variety and contrast in the overall design. Use small stones next to large ones, heavytextured pieces next to smooth, thick stones next to thinner ones. Mixing Cultured Stone wall veneer from dierent boxes during application will allow you to achieve a desirable balance of stones on your ﬁnished project.

LEVEL & PLUMB JOINT LINES

When applying Cobbleﬁeld Ledgestone, endeavor to maintain level and plumb joint lines. Also, long rectangular pieces will look most natural if

applied horizontally.

INSTALL CORNER PIECES FIRST

If your application requires corner pieces, apply these ﬁrst. Notice that the corner pieces have a long and a short leg. Alternate these in opposite directions (Fig. 1).

INSTALL FLAT PIECES

After the corner pieces are in place, ﬂat pieces are applied working toward the wall center (Fig. 2).

STARTING POINT

Apply mortar and stone working from the bottom up, or most stones can also be applied from the top down. Working from the top down may help avoid splashing previously applied stone with dripping mortar. Ledgestone types should be installed from the bottom up.

manufactured stone veneer, European Castle Stone, Limestone, Rockface, Coral or

FIG. 1

FIG. 2

JOINT WIDTH

In order to obtain the most natural look, joints should be as narrow as possible. The average should not exceed 1⁄2" in width. An attractive look can also be achieved by ﬁtting stones tightly together if desired. If using tight ﬁt/ dry-stack method, ﬁgure in additional stone material. It is important to make sure scratch coat/backing has been covered completely by the setting bed of mortar. This will conceal the scratch coat/backing and prevent pockets from forming behind stones that could trap water.

SETTING UNITS

Units shall be installed using Method A or Method B or a combination of both to achieve setting bed with complete coverage of the back of the unit and full contact between the mortar setting bed, unit and prepared backing surface.

Method A

Back butter the unit, using sucient mortar and pressure to ﬁll texture and voids in the back of unit. While 1⁄2" to 3⁄4"

setting bed mortar is wet, press and work the unit onto the prepared backing with enough pressure to force mortar to squeeze out around the entire perimeter of the unit.

Method B

The mortar setting bed shall be installed by trowel application 1⁄2" to 3⁄4" thick directly to the prepared surface. Plus back butter the unit using sucient mortar and pressure to ﬁll texture on and voids in the back of the unit. While the setting bed on the prepared backing surface is plastic, press and work the unit into the setting bed with enough pressure to force mortar to squeeze out around the entire perimeter of the unit. Limit mortar setting bed open time and work only an area that can be covered before the mortar skins over. Time and area will depend on mortar and weather conditions.

Note: Method B is recommended for tight ﬁt applications to ensure full setting bed of mortar. In tight ﬁt applications, before placing next unit, compact or remove the squeezed out mortar to allow adjoining unit to butt tightly. There shall be mortar between the units but the joint will be less than 3/8."

CUTTING & TRIMMING

Stones can be cut and shaped for ﬁt. Use wide-mouth nippers or a hatchet (Fig. 3 & 4). (Refer to page 5, Tools Required section.) Some broken stones may be found in the box. These also may be used in

FIG. 3

TRIM WITH

WIDEMOUTH NIPPERS

FIG. 4

TRIM WITH A HATCHET

ﬁlling gaps between large stones. For best ﬁnished appearance, coat cut or broken edges with mortar. If possible, position cut edges up when they are above eye level, down when below eye level. Placing a cut edge next to a thick/larger stone will also help conceal the cut.

Safety glasses and a dust mask

(1)

should always be worn when

cutting any Cultured Stone product.

MORTAR & WEATHER CONDITIONS

If stone is being applied in hot or dry weather, the back of each piece should be moistened with a ﬁne spray of water or a wet brush to adequately prevent excessive absorption of moisture from the mortar. If being installed over concrete, masonry or scratch coat substrate, the substrate surface area should also be dampened before applying mortar. Surfaces should appear damp but free of surface water. Applications should be protected from temperatures below 40°F as mortar will not cure properly under such conditions. See ASTM C1780 for Hot & Cold Weather Requirements.

If using a modiﬁed mortar, follow mortar manufacturer’s recommendations regarding wetting of stone and scratch coat.

ADDITIONAL INSTRUCTIONS FOR PRO-FIT PRO-FIT

ALPINE LEDGESTONE & EUROPEAN CASTLE STONE

LEDGESTONE,

Fit the Joints Tightly

Install all these products with tight-ﬁtted joints. Generally, components should be placed butting each other and aligned for level and plumb. When installing, the backs of all these components must be wet.* They should be noticeably damp, but free from surface water. Mortar may be tinted to match the color of the stone you are installing to help conceal the joint lines. If while setting a stone, a previously installed stone is disturbed, that stone must be removed, cleaned and re-installed.

* If using a modiﬁed mortar, follow mortar manufacturer’s recommendations regarding wetting of

stone and scratch coat. Consider using Method B for mortar setting bed application of tight ﬁtted installations

Starting Point

Products are applied starting from the bottom and working up. Start each ProFit Ledgestone course level and continue horizontally completing each course before starting the next. European Castle Stone is done in a similar sequence to achieve a random ashlar pattern. If required, cut the appropriate size component to ﬁt at the end or top of the ﬁnish area. Frequently check the installation for level and alignment.

STEP SIX:

GROUTING & FINISHING JOINTS

GROUTING JOINTS

When additional mortar is required, use a grout bag to ﬁll in joints completely. Care must be taken to avoid smearing mortar on surface of stone. Accidental smears or mortar droppings should be removed only after mortar has become crumbly using a whisk broom or dry bristle brush. Never use a wet brush or wire brush.

FINISHING JOINTS

When the mortar joints have become ﬁrm or “thumb-print” dry (setting time will vary depending on wall surface and climatic conditions), they should be pointed up with a wood stick or metal jointing tool. Rake out excess mortar, compact and seal edges around stones (Fig. 6). Careful attention to proper and even jointing will result in a professional looking ﬁnish.

FIG. 5

GROUT JOINTS

FIG. 6

FINISHING THE JOB

STONE INSTALLATION INSTRUCTIONS

CLEANING FINISHED JOB

When the mortar is suciently set up, the ﬁnished job should be broomed or brushed to remove loose mortar and to clean the face of the stone. A wet brush or sponge should never be used to treat the mortar joints as this will cause staining that will be dicult, or impossible, to remove. Do not use acid or acid-based products.

MORTAR COLOR

Tinting mortar complements the color of the stone being installed. Example: Use tan mortar with earth-tone stones. This will greatly enhance the appearance of the ﬁnished installation. Regular mortars can be tinted to complement your Cultured Stone product using iron oxide pigments available from your dealer.

GENERAL INFORMATION

CLEANING

Dirt, etc., may be removed by using a solution of granulated soap or detergent and water with a bristle brush. Do not use a wire brush as it will cause damage to the surface. Rinse immediately with fresh water. Do not attempt to clean using acid or acid-containing products, power-washing, sandblasting or wire-brush cleaning.

ENHANCED BOND

Refer to NCMA Installation Guide for application speciﬁc mortar recommendations. Pre-blended modiﬁed mortars, bonding agents and enhancers may provide greater bond strength. Enhanced bond strength capability

may be desired for tight ﬁt applications, tilt up construction or where code jurisdictions require higher bond

strength. These products must be compatible with manufactured stone and used in strict accordance with manufacturer’s instructions. These products may also have speciﬁc requirements regarding hot or cold weather, exposure to rain/water while curing or water used to dampen the stone units prior to installation.

SALT & DE-ICING CHEMICALS

Because concrete and masonry are vulnerable to damage by salt, Cultured Stone products are not warranted against damage incurred from salt or other chemicals used to remove snow or ice. Do not use de-icing chemicals on areas immediately adjacent to a Cultured Stone manufactured stone veneer application.

SCUFFING

Scung occurs on all natural stone. Occasionally some scung will occur on the surface of Cultured Stone products. This can enhance the natural appearance of your Cultured Stone manufactured stone veneer installation. Some scu marks can be removed by cleaning as described above.

EFFLORESCENCE

Eorescence is a water-soluble salt that is deposited on the surface of stucco, concrete, brick and other masonry products by the evaporation of water from the wall. On rare occasions eorescence will occur on Cultured Stone products. To remove eorescence, allow the stone to dry thoroughly, then scrub vigorously with a sti bristle brush and clean water. Rinse thoroughly—do not use a wire brush. For more dicult eorescence problems, scrub thoroughly with a solution of 1 part white household vinegar to 5 parts water. Rinse thoroughly.

WATER REPELLENT TREATMENTS/SEALERS

Sealers are not necessary on Cultured Stone products. However, some customers use sealers to help prevent staining in applications prone to smoke, soot, dirt or water splashing. If you choose to use a sealer, make sure it is a Silane, Siloxane or Silane-Siloxane blend breathable sealer. Take note that sealers may darken the color of the stone. A sealer may also slow the natural movement of moisture out of the stone and increase the possibility of eorescence and/or spalling. For information regarding actual performance or application of sealers, contact the manufacturer of the sealer directly. Craftshield beauty of the installation while safeguarding the surface from the elements.

™

is a protective treatment that preserves the intended artistry and

RAINSCREEN STATEMENT

Some building codes require a rainscreen behind cladding materials, including manufactured stone veneer. If you are installing manufactured stone/brick veneer in one of these jurisdictions, or are concerned about extreme weather conditions, it is recommended that you choose a rainscreen system that can achieve the following:

• The system should create a space with a minimum depth of 3/16" (5 mm) & max depth of ¾" (19 mm).

• The materials should be corrosion and rot resistant.

+ 35 hidden pages