PAT PEND. Installation Guide

Transcription

1 TM PAT PEND Installation Guide Warranty 2 Product Mix and Packaging 3 Estimating Sq.ft. and Tools 4 Wall Types 5 Applying the Stone 6 Poz-E-Flo and Corners 7 Phoenix Bond Pattern 8 Trimming Stone 9 Working around Openings 10 Watertable/Sill Installation 11 Keystone, Mortar and Grouting 12 Mortar Joint Styles 13 Finishing Touch 14 Completed Jobs 15 Completed Jobs

2 Family Tradition with Family Pride Fusion Stone marks a new dimension in Stone Veneers at Shouldice Designer Stone with aesthetic beauty, ease of installation, extensive spectrums of choice and cost efficiency. Unique and individual expression are guaranteed when Fusion Stone is incorporated in construction design. Shouldice Designer Stone was founded in 1947 as a manufacturing facility for an extensive spectrum of Stone Profiles. Shouldice today is a third generation family business supplying projects of distinction on all modes of construction throughout North America. Backed by Family Values with a commitment to quality and innovation, we have grown to become today s leading manufacturer of Stone Products and Veneers on the market. TM We strive to stay in touch with the world of design by having a clear vision ensuring our mix of products reflect the evolving desires and needs with our customers. Recognized as the leader in the Industry we continue to build on our reputation as an innovator for a third generation family business. Steve, Mark & Brad Shouldice are hands on in day to day operations and work shoulder to shoulder with skilled Craftsmen in their Stone creation roles. Thank-you for your consideration. We would love the opportunity to prove our worth and value for you. Rob Shouldice Fusion Stone Warranty and Guarantee The strongest attribute Shouldice products possess is The Lifetime Guarantee. Your complete satisfaction is very important and that commitment is reflected in our Guarantee. Shouldice Guarantees For Life the structural, aesthetic and performance integrity of their products, and any product that proves defective before, during or after installation will be replaced or repaired without cost. A Guarantee of Strength and Performance on all Fusion Stone products is provided to the original purchaser when used on structures that conform to local building codes and when installed as per the manufacturers requirements. Products installed in accordance to installation guidelines that prove defective will be replaced without cost (excluding labour). Proof of purchase is required. The Warranty does not cover what we have no control over, namely building settlement, wall movement, contact with chemicals and airborne contaminants that may cause staining or colour changes to the product. 2

3 Fusion Stone Product Mix Phoenix Stone and Corners Architectural Stone and Corner Watertable/Sill and Corner Brick and Corner Keystone Starter Strip Poz-E_-Flow Packaging Fusion Stone Products are packaged in two container sizes. The small size or Small-Pak weighs less than 60 lbs and contains 5 sq.ft. of product. The large size or Bulk-Pak contains between 100 to 160 sq.ft./ container depending on Stone size and the two container sizes can be used to match exact material needs. Fusion Stone is packaged to allow outdoor storage keeping product clean and dry until needed. Small-Pak Bulk-Pak Fusion Stone The Package System New and Exclusive to Fusion Stone is the way it s installed. The Patented Fusion Stone system is simple, easy, and large or small your project is guaranteed to offer a lifetime of performance with unmatched beauty. Fusion Stone comes with the following components packed on every skid: The Fusion Stone of your choice Stainless steel clips (quantity matches square feet per container) Stainless Steel screws Robertson Power Drivers Poz-E-Flo Drainage Panels are sold separately, by the piece or in 100 sq.ft. boxes (8 sheets). Starter Strips come in 4 lengths and are sold separately. Starter strips may be purchased individually or in bundles of 15 pcs (60 linear ft.) Bulk-Pak Poz-E-Flo Drainage Panel (Sold Separately) Starter Strips (Sold Separately) Clips & Screws (Included with all Fusion Stone Products Bulk-Pak and Small-Pak )

4 Estimating Square Footage Fusion Stone consists of two key components called Flats and Corners that are used in almost all installations. Flats are applied to the entire flat wall surface in the work area and are measured in square feet. Fusion Stone corners are applied to all outside corners and are ordered in vertical feet. Using corners around window and door openings will add distinguished finishing touches for individual expression. Step #1: Calculate the total project square footage; multiply the length by the height of each surface area to be covered. Deduct the area of all openings such as windows and doors from the total. Step #2: Calculate the total vertical feet of all outside Corners required. Note: Window and Door openings may or may not require corner pieces depending on individual design and preference. Step #3: To determine the square feet of Flat Stones required, the area covered by the Corner Stones needs to be subtracted from the total wall area. Calculate the Corner Stone area by multiplying the vertical feet of each corner by the Corner Stone coverage listed below. Subtract this figure from your total wall area for the required square feet of Flat Stones. Some extra quantity of Flats are desirable for cutting and trimming. Phoenix Stone & Brick: 1 vertical ft. of corner = 1 sq.ft. of flat stone Architectural Stone: 1 vertical ft. of corner = 3 sq.ft. of flat stone Typical Phoenix or Brick Take-Off (Example based on Building shown above) Wall Area: 8 x x 20 = 320sq.ft. Opening Area: 3 x x 7 = 30sq.ft. Corner Area: 8 x 3 corners = 24 sq.ft. Wall Area - Opening Area Corners Area Equals Total Flat Stones Required 320 sq.ft sq.ft.- 24 sq.ft. = 266 sq.ft Total Starter Strip required: = 46 linear feet 8 Tools Required For Fusion Stone installation the following tools will get the job done right. We want you to enjoy your completed project so please ensure a safety first attitude is maintained during installation of your project Mask and Safety Glasses Angle Grinder with Diamond or Masonry Blade Wheel Barrow Hawk Jointer Tape Measure Tin Snips Chalk Line Level Hammer Slicker Utility Knife Stapler & 1/2 Staples String & Level Cordless Drill/ Screw Gun Masonry Chisel Wisk Tools Optional 4 Power Grouter Grouting Bag Power Saw w diamond/masonry blade Laser Level

5 Wall Types Fusion Stone installations are Pre- Engineered to a maximum height of 30 feet. Heights may be increased when approved by Building Officials and specified by a Structural Engineer. Fusion Stone is unique and may be installed on above grade or at grade applications (the starter strip must be installed a minimum 1/4 clearance below to allow for drainage). Fusion Stone can be installed in above freezing or below freezing conditions and in dry conditions or wet weather. No wall ties are required as the Fusion Clip does the job of a Brick tie. Ensure substrate is a minimum 7/16 OSB or 1/2 Plywood, and covered in a code approved, breathable weather-resistant barrier. Fusion Stone should only be installed to structurally sound surfaces incorporating sound building practices. Plywood or OSB should be fastened to the stud with the following minimums, spiral or ringed nails with a 1 3/4 penetration or screws with a 1 penetration and a vertical spacing of eight inches. Exterior Insulation When Rigid Foam Insulation is applied simply use longer fasteners to anchor Plywood or OSB to the wall assembly. Stud Wall Plywood or OSB Board Weather Resistant Barrier Poz-E-Flo Fusion Brick Fusion Watertable/Sill Stainless Steel Clip and Screw Fusion Architectural Stone Masonry Block Strapping Stud Wall (Wood or Steel Studs) Masonry Block or Concrete Wall Rigid Foam Insulation Fusion Clip Rigid Foam Plywood or OSB Poz-E-Flo Fusion Stone Starter Strip Weather Resistant Barrier Flashing as per code 5

6 Flashing and Moisture 1 Barriers To maintain weatherresistance of the exterior wall on which Fusion Stone products are installed, a rigid, corrosion-resistant flashing and a means of drainage shall be installed at all penetrations and terminations of the Stone Cladding. 2 Starter Strip Level and install Stainless Steel Starter Strips using Stainless Steel Screws provided. All Starter Strips are made of Stainless Steel for Permanent Performance. Building codes vary from area to area so check your Local Building Code Specifications. The installation of water proofing, caulking, flashing around doors and windows, gutters and down spouts must be installed correctly to prevent water infiltration and damage in later years. Install flashing under the weather resistant barrier Level starter strip. Allow a minimum 1/4 clearance above grade for drainage. Install with stainless steel screws provided Install Starter Strip over top of window and door openings. Install Poz-E-Flo Drainage Panels over top of Starter Strip 3 Drainage Panels Install Poz-E-Flo Drainage Panels using a staple gun. Poz-E-Flo Drainage Panels must over lap the Starter Strip. They are supplied in 40 x 48 sheets and Poz-E-Flo Drainage Panels can easily be cut to fit with a utility knife. See Poz-E-Flo information on the next page. Staple Poz-E-Flo Panels with staple gun with no overlap, just butt panels together Install Poz-E-Flo over top of Starter Strip 4 Keeping it Level Snap a horizontal chalk line every 24 on the wall (Starting from Starter Strip). This line can be used as a visual reference that the Stones are maintaining a level installation. The Fusion Stone Clip will maintain an exact 3/8 mortar joint spacing between Stones and if the Stone is not sitting level then simply spread the clip by hand or pinch bar to achieve level installation. This leveling technique should seldom have to be used but works if need be. Chalk Lines 24 Snap a horizontal chalk line every 24 on the wall to use as a level reference line. If required spread clip by hand or pinch bar to achieve level installation (use gloves). 6

7 Poz-E-Flo Drainage Panels The Fusion Stone Poz E Flo Drainage Panels are exclusively manufactured for ease of handling and installation. They are supplied in 40 x 48 sheets, not in a large roll that is difficult to handle and move. Poz E Flo is the best water drainage system on the market today. Can walls leak?? Yes! And if they don t leak today they may leak tomorrow. Walls may shift or move, caulking ages and can separate from wall component areas, mortar joints can leak when they crack, foundations shift from Mother Nature extremes etc. The Fusion Stone Poz E Flo Drainage Panel System guarantees what gets through the exterior wall get trapped and vertically drained back outside, not inside where real harm and moisture damage can occur. In addition the Fusion Stone Poz E Flo Drainage Panel has a felt covering on one side to keep mortar and other contaminating materials from plugging the drainage performance over time. No weepers are required as Poz E Flo Drainage Panels provide positive vertical drainage and ventilation and there is no need to over lap panels, just butt the edges together. Poz E Flo with felt covering cut away to show drainage grid. 5 Start with the Corners Install Corners onto the Starter Strip using 3 Clips and Screws. Install a Flat Piece on either side of the Corner. then place the second Corner on top alternating long and short sides. Place Corner piece on both Starter Strips Secure using 2 screws on the long side and 1 on the short side Place Flat Stone next to the short side of the Corner Piece Place the next Corner Piece alternating the long and short side to overlap the Stone Work toward the centre 6 Install Flat Stones working toward the centre of the wall while consistantly maintaining a 3/8 space for the mortar joint between Stones. Refer to bond patterns on the next page for correct overlap and Clip placement. 7

8 Typical Fusion Stone 7 Phoenix Bond The two Stone heights need to be evenly mixed throughout the wall for the best natural Stone appearance. The 8 high pieces should be placed to break up long horizontal mortar joints and spaced so they don t lay next to each other. Overlap stones a minimum of 2 and always try to maintain a maximum 8 vertical mortar joint. Start by installing a single course of 4 and 8 Stones ensuring that the 8 Stones do not touch each other and are spaced evenly. Place Clips as shown. Add the second course using both 4 and 8 Stones again making sure the 8 Stones do not touch. Continue up the wall one course at a time using both 4 and 8 Stones as this ensures the 8 Stones break up long horizontal mortar joints. Stainless Steel Clips, Screws and Robertson Power Drivers included. Keep vertical mortar joints to a maximum of 8 inches. Overlap Stone a MINIMUM of 2 Fusion Clips Phoenix Stone Watertable Architectural Bond Red markers indicate correct Clip locations for Architectural Stone. Each Clip is placed an equal distance between the vertical mortar joints. Notice the Clips on top of the Watertable/Sill are placed to suit the next course of the Fusion Architectural Stone as well as the Watertable/Sill. Architectural Stone 8

9 Brick Bond Each row is offset by half the width of the Brick (which is called half bond or running bond). Clips are placed at each end on the bottom and the centre on the top. The space in the Clip must line up with the mortar joint. Mortar Space Stainless Steel Brick Clip, Screws and Robertson Power Driver included Place Clips as shown for running bond 8 Trimming Stones Stones may be cut to length using an angle grinder or power saw with a diamond or masonry blade to score the backside. Phoenix Stone may then be split using a masonry chisel. This method leaves a natural edge and the antique finish may be restored by rubbing the cut edge firmly with a waste piece of Fusion Stone. Trimming for Custom Corners Use a power saw to cut custom angles for areas such as bay windows. Score backside first (angle grinder shown) Finish with a chisel to break off piece Cut this Stone to match required angle Maintain 3/8 mortor joint between pieces Power saw with a masonry blade (optional). Rub a waste Stone over the edge to restore the antique texture. 9

10 Cutting Fusion Slots Check to see if the blade of the angle grinder is equal to the height of the slot on your Fusion Stone. If required adjust the blade using shims (flat washers). With the the angle grinder guard on a firm flat surface cut a new slot where required. Use spacers (flat washers) to adjust height of cut. Cut slot in the Stone on a firm flat surface, bracing the Stone securely. Working around 9 Windows and Doors Sometimes Fusion Stone will not course out even with the top or bottom of windows and doors. This can be resolved with horizontal trimming or Soldier coursing. When trimming Fusion Stone horizontally to the required height cut two slots, one at each end, for the Fusion Clips using an angle grinder. Horizontal cut Stone to fit under and over windows/doors to restore bond Restore slot only where Clips are required Use the same technique when the top of a window or door does not line up with the bond Soldier Coursing Fusion Stone Fusion Stone may be installed as soldier coursing above windows or doors and creates a pleasant look while allowing custom height stones to course out with the existing bond. Note: Clips may be installed in vertical grooves the same the as in the horizontal grooves. When soldier coursing centre the Stone spacing to achieve a balanced look around windows and doors. Soldier coursing can also be used to restore bond when the base of a window does not line up with the bond Cut Clip slots in the end of Stones for soldier coursing 10 The base of the Soldier Stone Piece is secured in the Starter Strip and then Cliped as shown Some Clip adjustment may be required to suit the next course.

11 Wall Watertable/Sill 10 Installation The Fusion Watertable/ Sill provides an attractive and professional transition from Fusion Stone to other wall assembly materials such as siding, brick or stucco. Place the Watertable/Sill Firmly on lower Clips and install two Clips 2 in from each end. If a Fusion Stone product is to be used above the Watertable/Sill more Clips may be needed so place Clips according to the products spacing requirement. When installing Watertable/Sill a minimum of two Clips on top should be used. If Fusion Stone is to be installed above the Watertable/Sill place the Clips as required for the style used. Watertable/Sill used as a transition from Fusion Stone Phoenix to siding. Watertable/Sill used as a transition from Fusion Architectural to Fusion Brick. Window Watertable/Sill 11 Installation Window openings smaller than 20 may be installed using a single 24 Watertable/Sill. Position the Watertable/Sill on lower Clips and attach one Clip on top at each end of the Watertable/Sill. Watertable/Sills should extend a minimum of 2 past the opening width for best appearance and to provide an area for Clip mounting. Place upper Clips as shown. See photo below Clip Cut both Watertable/Sills equally for best appearance when two Watertable/Sills are used. Place upper Clips as shown. For multiple piece Watertable/Sills place cut piece in the centre or cut all pieces equally to balance appearance. Place upper Clips as shown. Window openings wider then 20 require two or more Watertable/Sill Units that can be trimmed to fit. For the best appearance of multiple unit Watertable/Sills, trim left and right sides equally to balance mortar joint spacing. Watertable/ Sills are fastened at each end using slots cut with an angle grinder. Extend Watertable/Sills 2 past the edge of the window and place Clip as shown. If Watertable/Sill does not extend past the window edge or to join multiple Watertable/ Sills use Clips on ends. Cut slots on the end to attach Watertable/Sills tight to window bottom. Mutiple 24 Watertable/Sills can be joined this way for wider windows 11

12 Keystone installation 12 Fusion Stone Keystones are manufactured with slots on the top and bottom to provide rock solid fastening with hidden Clips and Screws. Trim surrounding stones to match Keystone angle allowing for a 3/8 mortar joint. Mortar Tips Keep the Stones Dry Fusion Stone is manufactured using an integral water repellant agent that reduces water absorption and efflorescence. This low absorption rate may affect set up time of the mortar joints. A slow set up time will be an advantage in warm dry weather but it is important to keep all material covered and dry in wet or cold conditions to ensure tooling of the joint can be done at the proper time. Mortar Type With Fusion Stone we recommend a Pre-mix, Type N mortar. Pre mix mortar is the simplest and easiest to use (just add water) and provides consistency from start to finish. Mortar Colour Don t forget with Mortar being 10% of your wall area that colouring plain mortar from ordinary grey to a shading of brown, black or a colour of your choice will always add Definition, Depth and Richness to any wall assembly. Mixing Mortar Follow directions on the bag working in small batches. If colouring is used, measure ratio carefully to ensure consistent colour from batch to batch. Grouting Mortar Joints 13 The last phase of installation is the filling in (grouting) of the mortar joints. You will require one of the following tools to fill the mortar joints. Hawk or Trowel Grout Bag (Icing type) Power Trowel or Grout pump Jointer All techinques of grouting work fine but the more automated it is the easier it will be. Use consistent batching procedures when mixing Mortar and read instuctions on bag. Avoid installing mortar in joints with air pockets as this can cause mortar failure. Make sure joints are filled completely to the Poz E Flo Drainage Panels. 12 Grouting the Joints with Trowel and Jointer Grouting the Joints with Power Trowel Grouting the Joints with Grout Bag Power Trowel detail

13 Mortar Joint Styles 14 There are many mortar joint options including concave, tooled and bagged. The concave joint leaves a rounded mortar joint. The tooled joint must not have a depth greater than 1/8 back from the stone face to avoid exposing the clips. The Bagged joint is an increasingly popular way to achieve an old-world, rustic look. When the joint type is selected weather resistance and appearance must be considered. Concave Joint Tooled Joint Bagged Joint Finish mortar joints 15 You will need a jointer to strike off the mortar to your desired style. Tool the joint after the Mortar has begun to stiffen slightly (normally minutes). Should a joint be tooled too soon (in a wet condition) a light joint results and conversely if a joint is allowed to become too stiff a dark joint will result. Remember that jointing is the final step so care should be taken for professional results. Use a wisk broom to sweep away excess crumbs of mortar after jointing. The broom will also take the shine off the mortar joint for a non-slick mortar appearance. Care must be taken to avoid smearing of mortar on the Stone surface. For a Concave Joint use a round jointer. Tool only a shallow Tooled Joint (maximum 1/8 Deep) to avoid exposing Fusion Stone Clips. Accidental smears should be removed only after mortar has become crumbly using a wisk broom or dry brush. Never use a wet brush or broom. For a Bagged Joint install mortar flush or slightly over the stone surface. Lightly flatten the high points of the Bagged Joint with a piece of carpet or bag. Use a DRY wisk broom to remove loose mortar. 13

14 Freeze board and Soffit Details to Add the Finishing Touch Freeze board covers union Stone goes behind Soffit Stone meets Soffit Soldier Coursing may be used to ensure the Stone meets the Soffit and adds a great finishing detail. Replacing Existing Siding Remove the existing siding and make sure the wall is sound and not degraded due to wet or dry rot. If this is the case, install a new substrate before installing the Fusion Stone system. Existing Siding Weather Resistant Barrier overlaps flashing Flashing Modified Clip Top wing of Clip removed Fusion Watertable/Sill To allow tight fit where the siding meets the Watertable/Sill, modify the Clips used to install the Watertable/Sill by cutting off the top wing as shown above. Fusion Brick, Stone or Architectural 14

15 Cleaning Stones Fusion Solutions Removing Excess Mortar If cleaning is required, use a mild masonry detergent and follow manufactures instructions. Pressure washers should not be used as a means for removing excess mortar or splatters. Efflorescence If efflorescence occurs, it is caused by moisture migration through the masonry. Once the moisture is on the masonry surface it evaporates and can leave dissolved salts in the form of efflorescence that will disappear naturally with time. To clean the efflorescence right away scrub the surface with a soft bristle brush and solution of 1 part household vinegar with 5 parts water. Wash off with a flood coat of water from a garden hose, DO NOT use high pressure washers. Fusion Architectural and Watertable/Sill to Brick Fusion Brick Fusion Stone with Window Details Fusion Stone to Brick with Watertable/Sills Fusion Stone 15

16 Fusion Stone to Siding 16 Fusion Stone Fusion Stone to Stucco Fusion Stone to Brick Fusion Brick Fusion Stone to Wooden Shakes PAT PEND TM Fusion Stone products are proudly hand crafted in modern manufacturing facilities by some of the most talented craftsmen available. For additional information on beautiful and maintenance free Fusion Stone products and services please visit us at or call Fax: Established 1947 THE DESIGNER STONE COLLECTION IS EXCLUSIVELY MANUFACTURED AND PROCESSED UNDER PATENT PROTECTION U.S PATENT 4,335,549 AND CANADIAN PATENTS 1,169,265 & 2,127,191. PRINTED IN CANADA