STONEWRAP MANUFACTURED STONE VENEER - LUXURY MANUFACTURED STONE
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1 STONEWRAP MANUFACTURED STONE VENEER - LUXURY MANUFACTURED STONE Stonewrap manufactured stone is produced by replicating natural stone. They are lighter in weight in comparison to natural stone. Due to the improvisational methods used in our production technology, each piece of stone looks different than the others in terms of geometrical shaping and color shading. This allows for walls covered with Stonewrap to have a unique look. This manual has been produced to present the methods that need to be followed in order to get the best results with installation of Stonewrap manufactured stone. Please read this manual carefully since you ll be installing these stone only once to use it for decades to come. Stonewrap manufactured stone is actually very easy to install, and if suggestions in this manual are followed, you ll obtain surfaces you ll take delight in looking at for years and years. 1 Necessary Tools Basic tools: Trowel, Masonry Trowel, Wooden or Plastic Stick, Whisk Broom, Soft Wire Brush, Grout Bag, Hammer, Horse Hoof Nippers Professional tools: Wheelbarrow, Lever, Circular Saw, Large Trowel, Dust Mask, Rubber Hammer, Paint Mixer, Grout Gun 2 Preparation of the installation area Appropriateness of the installation area is very important in order to provide better bonding! a - If wall is made of cement or brick, stone can directly be applied. However, for brick surfaces, coating with one layer of stucco and letting rest for one day will provide better bonding. Smooth concrete surfaces should be chipped and chemicals increasing adherence should be applied on the surface. Surface needs to be clean, flat, dry and free of grease. If there is paint on the surface, it needs to be scraped out before installation. b - If the wall consists of light structural elements such as aerated concrete, it needs to be coated with adherence increasing stucco specially produced for such light-weight structural elements. c - If wall consists of gypsum boards, it should be coated with one or two layers of adherence increaser before installation. On high walls made of gypsum board, an additional framework of galvanized wire mesh is necessary. d - If wall consists of wooden materials such as plywood, surface should be wrapped with a moisture barrier (such as membrane or asphalt felt). The membrane, then, should be covered with galvanized wire mesh. Wire mesh should be stabilized with nails or nutted bolts about 10 cm apart from each other. Afterwards wire mesh should be coated with stucco to make the surface ready for installation. Page 1
2 3 Adhesive Best choice for adhesive is readily mixed Stonewrap adhesive. Water added into the adhesive should be clean and in the exact amount suggested in instructions placed on package. Main point is to maximize the adherence properties of your mixture. Make sure not to install under frosty weather conditions, and never add glycose based chemicals into your mixture to fight frost. These additives limit the hydration of the adhesive leading to weak bonding. After working with the same adhesive mixture for a while, this mixture can get thickened. In this case, you can add some water into it to bring it back to the original state. However, applying this procedure several times on the same mixture will decrease its bonding properties significantly. Make sure that the adhesive does not get smeared on the visible surface of the stone. If it does happen, wait until it dries out, then brush away with a soft brush. Do not use a wire brush. Do not try to clean with water or wet sponge. Always install the corner pieces first, then continue onto the flat pieces using the same technique. Especially for irregularly shaped types such as Field Stone or River Rock, first install the larger pieces when working with flat pieces. Larger pieces will leave empty spaces in between one another. These spaces then can be filled using smaller pieces forming the joints in between. When exact sized stone for a particular space can t be found, you may cut existing pieces to help them fit. Try looking into the box first, for any already broken pieces during transport. In dry-stack installations and when working with modular types of stone such as Pratico or Urban, try to install stone pieces as close to one another as possible avoiding any space for joints. You ll get better results by coating broken faces of stone with mortar. Try to install the stone in a way to keep the broken faces in concealed angles. Additionally, try to avoid installing longer pieces vertically. Main idea is to have a look that replicates the looks of a wall made of natural stone. 4 Before Installation Open up several boxes and lay the stone on the ground randomly. This will allow to see the color variety better and help with finding the suitable stone for each space on the wall faster. If there are corners on the application area, you should start with the corners first. Corner stone pieces usually have one side longer than the other. Try to alternate them as you install them up and down the corner. If there are windows in the application area, install the window pieces (such as, window moldings & window sills, etc.) before flat stone pieces as well. Since modular types such as Pratico, Opus, and Urban are installed without joints, they are packaged to fill each sqmt accordingly. For all other types, sqmt packaging has been calculated to allow for joint spacing in 1cm thickness. For this reason, if you ll be doing a dry-stack application with non-modular types, you should increase the calculated amount of stone needed by 10-20%. 5 Starting the Installation You can prepare the adhesive mixture by adding water into it. Coat one layer of adhesive on the installation surface using a Masonry Trowel. Also apply a thin coat of adhesive on the back of the stone to be installed as well. Making sure that this coat covers the whole surface on the back will provide better bonding. Since Stonewrap manufactured stone are much lighter than natural stone, installation can start on top and go towards bottom as well as starting on the bottom and going upwards. Starting on the top will avoid spilling adhesive on the previously installed stone at the bottom. Especially in hot and dry climates, wetting the back of the stone before applying the adhesive will increase its adherence to the adhesive. In dry-stack applications, back face of each stone is to be dampened regardless of weather conditions. In extremely hot weather conditions, wall should be dampened as well. Install the stone with adhesive on the back side on the previously prepared wall. As you re pushing the stone towards the wall, move it slightly left & right to allow for some adhesive to surge from sides and hold for a couple of seconds. Using the tip of the trowel, clean excess adhesive from the sides still leaving some portion in the joint. This remaining portion of adhesive will help with better bonding especially in dry stack installations. You may knock on the stone with a rubber hammer to increase adherence. In especially dry-stack installations done outdoors, it s important to cover the complete back side of the stone with adhesive without leaving any space. Otherwise, humidity can collect up in these spaces and freeze under cold weather conditions causing the stone to be pushed out of its space! Page 2
3 6 Applying the Joint Mortar Right color of grout material suitable with the tones of the stone should be selected and applied with a grout bag or grout gun. Filling the grout bag only half-way will make it easier to use. Matching the color of grout with the color of stone is crucial in obtaining a natural look. Light gray grout is the most frequently used one, and it matches most colors of stone. If the color of grout is much lighter or much darker than the color of stone, joints will be more noticeable than the stone. After filling the joints, wait for some time for the grout to partially dehydrate. This time period can change depending on weather conditions. Wait until grout is tender enough not to smear on the stone surfaces. Once the grout becomes crispy, clean up the excess material using a Wooden or Plastic stick. After the grout has dried, do the final cleaning of joints by brushing with a Soft Wire Brush. Make sure you do not use a wire brush to clean the surface of the stone! For outdoor installations, if the weather is too hot, dampening the stone with clean water after the installation is over and the grout has dried will increase the quality of installation even more. General Suggestions and Alerts For outdoors installations, wait several days for the stone and the grout to dry out. It d be favorable to coat the surface with Stonewrap water repellent. These type of water insulators will avoid humidity in the wall by blocking water absorption on the surface. At the same time, they protect stone from freeze-thaw cycles in the winter time. Since they are transparent, they do not affect the natural look of the stone. For whatever reason, never apply acid based chemicals on stone. If cleaning is necessary, use a soft brush. You may wash the surface with water including minor amount of liquid soap. Salt or similar alkali materials will harm all sorts of concrete materials. Our warranty does not cover such damages. Chlorine or similar chemicals used in swimming pools may cause the color of stone to fade. Stonewrap manufactured stone veneer should not be used at swimming pools. Efflorescence and Claims This phenomenon might appear in some of our paving, stones and urban bricks for walls. Atlantis Inc. cannot be responsible for it, as it s a normal chemical reaction for good quality products with high cement content. This chemical reaction can appear. This phenomenon may be exhibited by an apparent loss of intensity of the color and the appearance of a milky white bloom on the face of the product. The effect generally disappears with time and is no way detrimental to the performance of the product. Atlantis will not take any responsibility for claims based on this phenomenon. Instructions in this manual is intended for information purposes only and do not constitute legal advice. Our Company is not responsible for any problems that occurs by erroneous installations. Our liability is limited to manufacturing defects only. Page 3
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