MOUNTAIN STONE Products

Transcription

1 MOUNTAIN STONE Products PRODUCT USERS GUIDE Mountain Stone Products P.O. Box Industrial Road Bowling Green, KY (270) (270) (800) Local Fax Nationwide Product Users Guide 1

2 STONE TEST RESULTS BY Mountain Stone Products 4301 Industrial Road Bowling Green, KY Product Testing Results The following tests were performed by: ATEC Associates (The American Testing and Engineering Corporation) located in Nashville, Tennessee. Absorption Test- ASTM C-67 Flexural Strength - ATSM C-348 Absorption Percentage Average=3.3% Flexural Strength ( psi) average Compressive Strength ASTM C- 67 Freeze -Thaw - ASTM C Compressive Strength Average = 3260 psi *No noticeable cracking occurred. Thermal Properties Thickness (inches) = Density (pcf) = R-factor ** = 1.38 Efflorescence Test - ATSM C-67 sec.10 *Not efflorescenced **R factor is based on the thickness in accordance with ASTM C Average thickness may vary, which will result in R-factors varying. The insulative quality is equal to 6 of common brick. Other Tests = Non-combustible stone, showed zero flame spread and no smoke developed. = Colorfastness: During testing of stone no undesirable change in color was noted. 1. PREPARING THE SURFACE Installation Procedures Due to its light weight, Mountain Stone can be applied to any structurally sound surface, (except Sheet Rock) and needs no special structural foundation alteration or additions. Apply Mountain Stone directly to the surface of concrete, block, brick, and other masonry surfaces only if the surfaces are clean, unpainted, unsealed, and untreated. All other surfaces must be covered with a 2.5# Galvanized Diamond metal lath. Product Users Guide 2

3 Lath is to be laid horizontally across wall, as you run your hand down the wall, starting at the top, seems smooth. Running your hand upward, starting from the bottom, seems rough, overlap lath 2. Always work from the bottom to the top when attaching lath. On wood, nailing is to be 6 apart down each stud, using 1-3/4 roofing nails or 1 x 2 staples used with air pressure of 90 lbs. Minimum. Over metal studs or metal buildings (18 gauge min.), use No. 8 self tapping screws to penetrate or on painted masonry surfaces use 1 masonry nails same distance as above. Nailhead may have to have a small washer adapted to help hold mesh. A 15 lb. Felt paper or paper backed lath available from Mountain Stone must be placed under all outside applications except on clean masonry surface. (If applying stone over clean masonry surface, please skip step 1 and go to step 2). 2. APPLYING THE BED COAT OVER LATH Mix thoroughly 1 part Type S mortar to 1-1/2 parts clean brick sand (12 gallons). Add clean potable water to achieve a trowelable mixture, use a 12 trowel and spread mixture over metal lath, enough to cover lath approx. 3/8 thick. After drying, this will provide a rigid backing and assure firm bonding on the stone veneer. 3. APPLYING THE STONE Using the same mixture as the bed coat, apply approximately ½ of mortar to back of stone, covering the entire stone. By using gentle pressure, and a slight wiggling action while applying the stone to the bed coat, will assure a good bond. During warm weather, the bed coat may have to be dampened with water to prevent water being drawn too rapidly from the applying mortar. During cold weather, follow all the guidelines set forth by the Construction Masonry Institute concerning cold weather masonry. To keep stones clean, start at top and work down. If corner pieces are used set them first for easy fitting. (Tip: Avoid getting mortar on the face of the stone during installation.) 4. Grouting Joints Installation Procedures (continued) Grouting mixture shall consist of 1 part Type N mortar to 2 parts sand, and clean water. This mixture is to be thoroughly mixed to provide a heavy cream like consistency. This mixture is then placed in a grout bag. Fill the bag ½ full, twist the top and hold tight. With slight pressure from the other hand, and twisting from the top, place opening in joint somewhat like using a caulking gun, and fill the joint flush with the stone. Do not get mortar on any other parts of the stone by the joint area. Let mortar set until firm but workable before finishing joint. (It may be necessary to snip the opening of the grout bag to allow for easier dispensing of the mortar.) 5. FINISH JOINT PROCEDURE Product Users Guide 3

4 When mortar joints become firm, use of a wooden striking tool carved just a little smaller than the joint width may be used. Press gently and smoothly as to fill grout voids and remove excess mortar to desired depth. Note: The mortar should be firm enough not to stain stone. 6. BRUSHING JOINTS This should be done within 2 hours after tooling of joints. The best way is with a clean whisk broom or a plastic bristle brush. Do not use a brush made of metal. Do not let it set over night before tooling and brushing. Do not brush wet mortar, it will smear and leave brush marks. 7. CLEANING Never use acid for cleaning. If mortar dripping occur, use a clean wet sponge immediately to clean. 8. SEALING Sealing is unnecessary and optional on most jobs. Use this specification guide for each individual project. And be sure to omit portions not applicable to single projects and actual needs. 1.1 PRODUCT NAME Manufactured stone veneer for exterior and interior wall covering by Mountain Stone. Type Color 1.2 MANUFACTURER Mountain Stone Products 4301 Industrial Road Bowling Green, KY (270) DESCRIPTION OF WORK Specification Guide Furnish Mountain Stone stone veneer as specified on drawings and specified installation procedures. Product Users Guide SUBMITTALS Submit a 4 x 4 grouted sample of Mountain Stone so that accepted stone veneer to be used falls within accepted range of sizes, color, texture, and grouted joint style. Sample shall remain on job until project is completed. 1.5 MATERIAL COMPOSITION Stone veneer to be produced of Type 1 Portland cement, expanded aggregate, and additives to meet or exceed the following specifications: Water Absorption: 3.3% Compressive Strength: 3,260 psi. + Thermal Conductivity: 1.38 R-Factor

5 1.6 PRODUCT PACKAGING AND HANDLING Mountain Stone is packaged on 40x 48 pallets with 24 boxes per pallet. Each box contains 10 square feet of the stone. Corners are 10 lin. feet per box. Pallets can be stacked 3 high for easy space saving, storage and inventory control. Boxes weigh approx. 65lbs. each. INSTALLATION MATERIALS 2.1 MATERIALS All equipment and materials are to be clean and free of chemicals that may cause efflorescence. Materials shall conform to: Type 1 Portland cement - ASTM C150 Sand ASTM- C-144 Use clean potable water Reinforcement wire-mesh, Galv. 2.5# Joint color- pure iron oxide colors or Mortar Type N. 2.2 METAL LATH A. WoodFrame Construction: For exterior application cover area with15 lb. felt paper or paper backed lath available from Mountain Stone. Joint overlaps require 2 on horizontal and vertical joints. 2.5# Galvanized Metal Lath is then nailed every 6 on centers into studs. B. To Masonry: Stone may be applied directly to masonry wall provided the walls surface is clean. Sealed masonry or painted surfaces should be sand blasted or covered with metal lath using 1 masonry nails. SPECIFICATION GUIDE C. Metal studs or metal buildings: 2.5# Galv. metal lath is backed with 15 lb. paper, then secured to the studs or metal high rib with no.8 self-tapping metal screws no less than ¼ penetration into metal. size of a penny. Grout shall set after grouting so that so that when tooled it will not smear and stain stone. B. Colored Joints: Colors shall be selected from standard colors available from approved manufacturers of iron oxide. 2.3 BONDING MORTARS Use Type S mortar with clean brick sand. Mixture will be 1-1/2 parts sand and 1 part Type S mortar. This mixture shall be used or covering metal lath and adhering stone only. Mixture to be mixed thoroughly and evenly. 2.4 GROUTING MORTARS A. Shall be 1 part Type N Mortar to 1-1/2 to 1-3/4 part clean brick sand. Mixture to be thin enough to be squeezed easily from a Grout bag with a hole about the Product Users Guide 5 EXECUTION 3.1 SURFACE CONDITIONS A. Examine the areas and conditions under which work will be performed. If problems are found, do not proceed until unsatisfactory conditions are corrected. B. Coordinate with other trades as needed to assure that proper substrate is provided to receive the stone veneer. C. Condition of surfaces to receive stone veneer. 1. Verify that surface to receive mortar setting bed and stone are firm, dry,

6 and clean, and free from substances that may not let product bond properly. 2. Verify that all electrical plumbing, etc., in or behind the stone have been installed before proceeding with installation of the stone work. 3.2 INSTALLATION OF STONE VENEER A. Maintain minimum temperature limits on job site and installation practices recommended by materials Mfg. 1. Prepare the surfaces, set, fit, group, and clean the work of this section in strict accordance with the manufacturer's recommendations. 2. Spread mortar on stone's back a minimum of 1/2" thick. 3. Press and set the stone in place using a back and forth motion to obtain 100% coverage of mortar on the back of each unit. Remove excessive mortar from around the stone. 3.3 GROUTING A. Do not begin grouting stone until stones are firmly set. B. Force the maximum amount of grout into joints using a grout bag filling all gaps and skips. 1. Do not permit grout on stone face. 2. Remove surplus grout from joints by raking and tooling. Sweep all areas to remove excessive material. 3. Remove mortar and haze from the face of the stone within two hours of placing. 3.4 CLEANING After completion of setting and grouting, thoroughly clean stone face by sweeping. Do not use acid or any cleaners. Miscellaneous Specifications and Rule of Thumb Estimates Stone Packaging and Ordering square feet of stone per box lineal feet of stone corners per box. 3. Pallet size for shipping is 40"x 48" boxes of stone per pallet 5. Approximate weight per box is lbs. 6. Full truckload is 24 pallets (576 boxes or 5,760 S.F.) Sand, Mortar and Lath for Every 100 Sq. Ft. 1. Order 1 bag of Type S mortar for every 100 sq. ft. for scratch coat and applying stone. Product Users Guide 6

7 2. Order one bag of Type N mortar for grouting every 100 sq. ft. 3. Each piece of metal lathe is 18 sq. feet (Each piece will cover 17 sq. feet because of overlap) 4. Order 200lbs. of sand for each bag of mortar (For mixing purposes, use 140 to 150 lbs./ per bag.) 5. One average round point shovel-full of sand is approxiamently ten pounds (These quantities are for estimating purposes only.) TOOLS NEEDED 1. Staple Gun for attaching felt. 2. Hammer for attaching lath " x 4" concrete finishing trowel and mud hawk 4. 6 Cubic Foot wheel barrow for mixing mortar 5. Shovel for shoveling sand into mortar mix 6. Masonry trowel for sticking stone 7. Grout bag for filling joints 8. Tuckpointer for striking the join 9. Whisk broom for cleaning off stone 10. Mortar Hoe 11. 4' Level 12. Chalk line Product Users Guide 7

8 MATERIALS REQUIRED LB Felt or use Paper Backed lath available from Mountain Stone (If you use Paper Backed Lath you do not need item # 3.) 2. Felt Staples /2LB Galvanized Metal Lath /4" roofing nails or 1" x 2" staples 5. Type S Mortar (scatch coat & bedding) 6. Masonry Sand 7. Clean Water 8. Type N Mortar (grout joints) 9. Mountain Stone 1. DETERMINING AND PREPARING THE SURFACE Due to its light weight, Mountain Stone can be applied to any structurally sound surface (except Sheet Rock) and needs no special structural foundation alteration or additions. Apply Mountain Stone directly to the surface of concrete, block brick, and other masonry surfaces only if the surfaces are clean and unpainted. All other surfaces must be covered with a 2.5 # Galvanized Metal Lath. Product Users Guide 8

9 2. APPLYING THE BED COAT OVER LATH (If applying stone over clean masonry surface, please skip step 2 and go to step 3.) Mix thoroughly 1 part Type S mortar 1-1/2 parts clean brick sand (Approx. 12 gallons) in a 6-cubic foot wheelbarrow using your pointed shovel. Add clean water (approx. 2-1/2 gallons) to a achieve a trowelable mixture. Use a concrete finishing trowel and spread mixture over metal lath, enough to cover lath approx. 3/8" thick. Allow to dry for 12 hours. This will provide a good backing and assure firm bonding of the stone veneer. HELPFUL HINTS A. WHEN USED WITH VINYL SIDING 1. Bring J channel out 1" to 1-1/2" (depending on the style of stone used) toward the face of the stone. Then install stone to within 1/2" of channel for mortar joint. 2. Corners: Install J channel back 3 inches on vinyl side of corner and cut stone corners as a return. 3. Transition piece: Use the Marietta Sill to accommodate transition from a wainscot of Stone to a vinyl siding. Set J channel directly on top of tip and caulk joint. B. WINDOWS AND DOORS Install stone around windows first to insure proper fit. Then install stone as you normally would on the wall. (Certain applications may require flashing) C. OUTSIDE LIGHTS 1. Mount rough-in boxes directly to wall or if box is already mounted flush, install box extensions to bring out flush with stone. 2. Outside Receptacle: Mount approved weatherproof box directly to wall where stone is to be applied. Install stone upto 1/2" from box (grout). Product Users Guide 9

10 3. APPLYING THE STONE To keep the stone clean, start at top and work down. If corner pieces are used set them first for easy fitting. Keep lines level and stone level (use 4' level to check.) Stone may be trimmed by brick hammer, brick trowel, or a dry concrete blade in an electric circular saw. Using the same mixture as the bed coat, apply approx. 1/2" of mortar to the back of the stone using your point trowel, covering the entire stone. By using gentle pressure, and a slight wiggling action while applying the stone to the bed coat, you will assure a good bond. During warm weather, the bed coat may have to be sprayed with water to prevent water from being drawn too rapidly from the applying mortar; dry mortar doesn't stick well. During cold weather, follow all guidelines set forth by the Construction Masonry Institute concerning cold weather masonry. (Tip: Chalk horizontal lines every on the scratch coat to keep joint lines & stone level.) GROUTING JOINTS Grouting mixture shall consist of one part Type N mortar to 2 parts sand, and clean water. This mixture is to be thoroughly mixed to provide a heavy cream-like consistency. This mixture is then placed in a grout bag. Snip the end to create a hole about the size of a penny. Fill the bag about half-full, twist the top and hold tight. With slight pressure from the other hand, and twisting from the top, place opening in joint and fill the joint flush with the stone. Rinse grout bag with water occasionally to keep in good working condition. Do not get mortar on any other parts of the stone. Let mortar set until firm yet workable. FINISHING JOINT PROCEDURE When mortar joints became firm, the use of a wooden striking tool carved just a little smaller than the joint width may be used. Press gently and smoothly as to fill grout voids and remove excess mortar to desired depth. The mortar should be firm enough not to stain stone. If the mortar is struck too quickly the joint will appear creamy if this happens, allow some additional drying time. BRUSHING JOINTS This should be done within 2 hours after tooling of joints. The best way is with a clean whiskbroom. Do not brush mortar wet, as it will smear and leave brush marks. Product Users Guide 10

11 CLEANING Never use acid or steel brush for cleaning. If mortar dripping occurs, use a clean wet sponge immediately. If severe staining occurs ask your dealer or call Mountain Stone for assistance. SEALING Sealing is unnecessary and optional on most jobs. Ask your dealer or call our Technical Department at (270) , for any questions about sealing. Product Users Guide 11