Genesis Panel Systems LLC Dura-Max Brick Panel Siding Installation Instructions

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1 Genesis Panel Systems LLC Dura-Max Brick Panel Siding Installation Instructions Thank you for purchasing the Genesis Dura-Max Brick Panel system for your project. The system allows you to have the look and feel of real brick quickly, without the excessive weight and time expended, which is required with conventional brick installations. Our panels are installed similar to siding and utilize similar tools, along with a circular saw with and masonry blade for cutting / trimming the panels. Genesis Panel Systems 1 Siding Installation Instructions

2 Description of System Components The Genesis Panel System consists of multiple components. Not every project will use every component. Component ID Component Name Description A Corner Starter Piece The first panels installed to enable L-Brick to fill the leave-out voids at the ends of the panels and to wrap the corners properly. Left side is wider than the right side. MUST BE Properly Installed and vertically level. B J-Hook Starter Rail Metal strip used to level align bottom of first row. C Full Panel The main field panel of the Genesis System. The masonry components are bonded into this panel in the pattern desired. Leave-outs for brick to cross the panel gaps are at both ends. D Versa-Panel A field panel with a section of leave-out voids in the center. When cut on the line on the reverse side, used as the off-set panel to start the ends of alternating rows of panels. May be used as a field panel with all bricks installed. E Frame-All Panel A field panel of all voids, used for framing around windows and doors. F Soldier Course Panel A field panel with two rows of vertical brick installed over one row of horizontal brick. Cut it in half down its length to make two soldier course pieces. G Accent Panel A field panel with a special design or pattern. May be used alone or with other similar panels. H Field-Applied Brick Masonry component to fill the leave-outs in the panels. I Window / Door Edging J-Channel to match door and window trim to hide edges of the panels J Mortar Type S Mortar to fill gaps between masonry pieces. Covers all seams between panels and all fasteners. Genesis Panel Systems 2 Siding Installation Instructions

3 Tools and Materials Needed Measuring tape Exterior Deck Screws, at least 1-5/8 long Pencil Circular Saw with Diamond Fiber Board Blade Screw Gun / Drill with Tip to match screw heads Square / Carpenter s Square Cutting Surface / Saw Horses Corner Edging Window-Door Edging J-Hook Starter Rail Vapor Barrier Genesis Brick Panels to Cover Wall Area Staple Gun and ¼ ½ Staples SB 105 Adhesive Caulk / Caulk Gun Genesis Field-Applied Brick (4 / panel) Small Grinder / File or Rasp Dust mask Eye Protection Hearing Protection Straight Edge and Spring Clamps Tool Pouch Dremel-type Motor Tool with Masonry Bit / Blade Procedures Discussed General Wall Preparation Stud Spacing and Panel Attachment Wall Preparation Getting Started Installing the Starter Elements Installing the First Panel(s) Mounting the Panels Outside Corners Inside Corners Cutting End Panels to Fit Installing Around Windows and Doors Installing Around Electrical Outlets and Switches Installing Bricks in the Leave-Outs Mortaring the Joints Genesis Panel Systems 3 Siding Installation Instructions

4 General Wall Preparation Panel Description The Genesis Dura-Max panels are 48 inches wide by 21 inches tall (or 24 inches, depending on specific brick selected) and the corners are square. With the typical running bond pattern, vertical grout lines of each row are 8 apart and are staggered in alternating rows every 4 across the panel. The panels can therefore be attached directly to the 16 on-center or 24 on-center stud framework of your structure, through the grout lines. Additionally, fasteners may be installed in the leave-out void areas at the edges of each panel with the conventional running-bond pattern. ( Leave-outs are where brick will be installed across the gap between panels to complete the running bond pattern of full brick across the wall surface.) Panel Attachment The preferred method of attachment of Genesis Panels is over ½ or thicker sheathing installed over a stud framework. The sheathing may be OSB, plywood, or similar material. Fasteners may be installed through the grout line at an intersection of the horizontal and vertical grout lines on the panel. Attachment at the panel edges is preferred to be at least ½ ¾ away from the edge to prevent damage to the edge. (The grout lines between the bricks of the Genesis Panels are intended to be filled with mortar to complete the installation, covering all fasteners and the joints between adjacent panels.) Alternately, the panels may be installed directly to a stud framework or furring strips over a stud framework. Studs are not always located exactly on center. When installing the panels, DO NOT trim the panels to fit the underlying studs, as the brick pattern of the wall will be interrupted. It is recommended that additional stud material be scabbed to the stud(s) so that there is adequate material on which to fasten the panel. Alternately, the use of horizontal furring strips across the face of the studs, and small strips attached vertically between the horizontal strips, assures that there is ample surface on which to fasten, and to fully support, all edges of the panels. Preferably the edge of each panel falls in the center of the strips. The strips are optimally 2 3 wide and a minimum of ½ thick. If a panel edge falls short of the furring strip and does not extend to the next structural member, a piece of blocking (1 x 4 ) at least 36 long may be used for the joint. The blocking should be fastened to both adjacent panels at the joint and then to the panels above and below the joint, to fully support the end joint. Genesis Panel Systems 4 Siding Installation Instructions

5 Wall Preparation Prepare the wall surface by removing any nails, staples, or other fasteners that may be on the surface of the sheathing, furring, or studs. The attachment surface should be level and smooth. Genesis recommends an approved exterior vapor barrier over the sheathing or studs as a preventative of additional moisture and air infiltration. Measure the height of the wall to determine how many rows of Full Panels (C) will be used. If a Soldier Course (F) is to be used, subtract the height of the soldier course from the height of the full panels and Corner Starter Pieces (A) to be used. Soldier Course Panels are miter-cut at the corners. Establish a level line to locate the J-Hook Starter Rail (B) such that it hangs ½ 1 below the lowest portion of the wall plate. The first row of Full Panels will rest on this J-Hook. Align the Corner Starter Pieces with the bottom of the J-Hook Starter Rail such that the Full Panels will be square and level. Getting Started Installing the Starter Elements Once the grade is determined and the approved water proofing is installed, the starter elements can be applied. Install the brick frieze trim first. This trim runs the entire perimeter of the upper surface of the wall and covers the brick at the very top of the wall. The frieze is not part of the Genesis Panel System. The next pieces to install are the Window and Door Edging (I) around the doors and windows. Install the sides of windows and door jambs first, then the tops and bottoms of the windows, and then only the tops of the door jambs, so the parts can be notched and flashed properly. Install the J-Hook Starter Rail along the level line at the bottom of each wall. Install and level the Corner Starter Pieces (A) on all the outside corners, the bottom of the Corner Starter ½ above the bottom of the J-Hook Starter Rail.. Mounting the Panels General Instructions Dura-Max panels are attached with exterior deck screws that penetrate the underlying substrate (studs, sheathing, furring, etc.) by at least an inch. Screws are installed through the grout lines of the panel, preferably at the junction of the horizontal and vertical lines between the bricks. These intersections should line up with the studs in the wall as they are multiples of 4 from the edge of the panel. Screws at the panel s edges may be installed from about ½ from the edge so that they intersect Genesis Panel Systems 5 Siding Installation Instructions

6 with the underlying substrate securely. If installing the panels over sheathing, screws may be installed in the brick leave-out areas at each end of the panel rather than close to the edge. Install screws next to / in all of the leave-out areas at each end of the panel and at least three screws in each vertical stud or about every 16. The panel must be securely fastened to the underlying substrate. Note: Nails ARE NOT an approved fastener for this system. Installing the First Panel(s) The top of the Dura-Max Full Panel contains 6 full size bricks and half the width of a normal grout line on all edges of the panel. Install a Full Panel (C) flush against the Corner Starter Piece on the J-Hook Starter Rail on both the left and right side of the wall. Install screws through the grout lines into the underlying sheathing, furring, or studs. Be sure the bottom row is flat as you start installing the screws in the middle of the bottom row and work toward both ends and then up. Align and install a second Full Panel or part thereof adjacent to each installed panel and work toward the center of the wall. Test-fit a few of the Field-Applied Bricks (H) to assure that they fit properly before screwing down the panel. Adjust the alignment as required. Plan for an expansion joint at one edge of a door or window, or cut the panels to make one if there are no doors or windows in the wall. The expansion joint allows the brick patterns from each side to meet without matching. To start the second row, cut a Versa-Panel (D) along the line across the back of the panel to cut the panel in half. Align and install one half of the panel above the first panel adjacent to the left Corner Starter Piece. Check that the grout lines of the two panels line up properly and that the bottom row of the top panel is off-set one-half brick from the top row of the bottom panel. Once the second row panel is aligned, screw it in place. Repeat for the end half panel on the other end of the row. Align and install full panels toward the center of the wall (the expansion joint) from both sides. Check for level at the top of each second row installed. Align the expansion joint edges up the wall. The gap in the expansion joint should be 3/8 ½. Carefully cut the panels to fit the Window / Door Edging (I) around the windows and doors. If the area around windows and / or doors is tight or an odd shape, use the Frame-All Panel (E), as it is easier to handle, trim, and attach than a regular Full Panel. Once the panels are aligned and installed around the window or door, install Field-Applied Brick (H) in the leave-out voids. Whenever a panel s pattern is interrupted completely by a door opening or tall window, you must be aware to maintain the brick and mortar pattern as it picks back up over the window or door opening. Run a level line across the opening and across the tops of panels on each side of the opening to verify level. Adjust as needed to continue the originally-established panel layout as if the door or window cutout was not there. This step maintains the established brick and mortar line layout as the rest of the panels are installed across and up the wall. Genesis Panel Systems 6 Siding Installation Instructions

7 Start the third row at each end of the wall with a Full Panel, such that the gaps between adjacent panels align with the middle of the panels of the previous row. Adjust with the grout lines in the installed panels. When the rows of panels exceed the height of the Corner Starter Piece, the Full Panels will need to be cut along their length to match the top of the wall. If there is no Soldier Course to be installed, the Full Panels will need to be cut to fit under the brick frieze. Mark the panels on the back and cut with the back of the panel up. Slide under the brick frieze, align, and install the panels. If the Soldier Course Panels (F) are to be installed, check for level and then cut the top row of Full Panels level with the top of the Corner Starter Piece at each end. Install the modified top Full Panels. Measure and cut the full Soldier Course Panel (F) in half such that there is a single horizontal row of bricks under the vertical soldier bricks. Take the first piece of Soldier Course Panel and align it over the top of the top row of bricks in the uppermost panel and adjust left or right until the grout line of the horizontal bricks in the soldier course piece are in line with the grout lines of the second (NOT top) row of the uppermost panel AND there is a full brick or almost a full brick at the corner of the wall. Mark the vertical brick and miter-cut it at a 45 degree angle. Install the Soldier Course Panel, being careful to maintain the alignment. Repeat for the other end of the wall. Cut other Soldier Course Panels in half to finish the top of the wall, including the location of the expansion joint. Corners Outside Corners Outside corners of full brick may be finished in one of two ways: 1) a special L-brick corner wrap, or 2) a mitered joint. The Corner Starter Panel is an L-brick corner wrap that properly aligns all panels at each corner. The Corner Starter Panels are installed on each corner first. These panels are designed for the size and shape of the specially-cut L -shaped bricks to simulate the look of a full-size brick. Field panels are installed in both directions from the Corner Starter Panel. Once the L-brick are installed and mortared, the finished installation is identical in appearance to conventionally-applied brick. Mitered joints are panels that have the side edge cut on a 45 degree angle such that the brick from each side of the corner meet to give the appearance of a full-size cut brick at the corner. Tight, accurate miter cuts are difficult to distinguish from whole brick, especially when viewed from more than a few feet away from the joint. Soldier Course Panels are preferably miter cut. Genesis Panel Systems 7 Siding Installation Instructions

8 Inside Corners Inside corners may be finished in either of two ways: 1) butt-joint, or 2) mitered cut. For either inside corner method, install a piece of metal flashing in the corner to protect against water infiltration through the grout. Butt-joint panels are installed all the way to the end of the wall. The edge of the panel is cut the thickness of the panel plus 3/8 short of abutting the wall. The panel on the adjacent wall is also cut the thickness of the panel plus 3/8 short of abutting the wall. It is then aligned with the grout lines of the first panel and installed with a gap in the corner by the mounted panel. Mortar will be applied in the gap between the panels. Mitered cut joints have a reverse 45-degree cut at the corner. Cut the panels about 3/16 short of the actual length so that the miter has a gap of about 3/8 in the corner. This gap will be mortared later. Since walls are often not 100% square and true, a test cut with a piece of scrap panel is suggested to assure that the second wall s panels will fit snugly and are installed along the straight bottom line for that wall. Adjustments to the angle and direction of the cut on the panel to be installed can be made for the first cut. Cutting End Panels to Fit By starting at the corners and working toward an expansion joint in the center of the wall, cutting end panels is eliminated. In the installations where starting corner panels are not used or an expansion joint is not planned, it will be necessary to cut the end panels to finish out a row. The cut must contain the leave-out sections to mate with the adjacent panels. The remaining panel section may be saved to be used to fill in on the other end of the wall or by a door or window if there is enough useable material remaining. Measure from the edge of the mounted panel to the end of the wall. If the panel is to be cut on a taper (miter cut), measure the back side of the panel for interior corners and to the front side of the panel for exterior corners. Measure at the top edge of the panel and at the bottom edge of the panel at a minimum. Walls are often not square and taking only one measurement can result in either a tight fit or a large gap or both. Mark the back side of the panel, verify your measurements, and then cut the panel from the BACK side to minimize chipping of the brick by the saw blade. Genesis Panel Systems 8 Siding Installation Instructions

9 Installing Around Windows and Doors Most walls contain a window, a door, or both. Panels must be cut to fit. Your choice of the Window / Door Edging (I) to trim out the edge of the panel at the window or door will influence how accurate your panel cuts must be. Measure the area to be covered and transfer the dimensions to the back side of the panel to be cut. Verify that the dimensions are correct and then cut the panel from the back side. Windows and the tops of doors require a cut along the length of the panel in the middle of a panel. Carefully measure the dimensions for this cut as the horizontal surface of the window or door may not be parallel to the line of the panels being installed. Installing Around Electrical Outlets and Switches Prepare the panel to fit the space that contains an electrical switch or outlet. Test fit the panel above or below the switch or outlet to know where the grout lines will align. Turn off the electricity to the switch or outlet and then remove the cover plate. Measure carefully from a reference point on the wall to the edge of the electrical box. Transfer those measurements to the back side of the panel to be installed and draw the edges of the area to be cut out. Carefully re-check the measurements and hold the panel in its intended position on the wall to verify the location of the hole to be cut. Once confirmed, use a motor tool with a masonry bit or blade to remove the material from the measured location on the panel. Cut inside the lines you measured but not all the way to them. Hold the panel in place again and check if there is a need to adjust the final cuts to make a better fit. Once the location of the hole is confirmed, enlarge to the full size needed for the electrical box. Mount the panel over the electrical box and then re-install the receptacle or switch. The receptacle or switch will need to be adjusted to the additional thickness of the panel with longer screws and shims. Replace the cover plate before you restore power to the circuit. Installing Bricks in the Leave-Outs When all the panels are installed, the field-applied bricks must be installed in the leave-out areas between panels. Place a single brick in the leave-out area to see how it fits. If there is something that keeps the brick from fitting into the leave-out completely, it must be trimmed to fit. Carefully trim any flash or excess grout from the leave-out and re-test the fit of the brick. The brick may need to be filed down to fit. Flip the brick over and gently file or grind down the back edge of the brick at a 45-degree angle. Removing the back square edge of the brick is often the only adjustment needed to allow the brick to fit down in the leave-out area. If necessary, continue filing down the backside edges until the brick fits. Be careful to avoid damaging the front edge or surface of the brick. Also, check that the shade of the brick is appropriate for the leave-out location. Bricks vary in shade and appearance. Randomness in color and texture will help make the wall look more natural than installing a brick that is very similar to an adjacent brick. Genesis Panel Systems 9 Siding Installation Instructions

10 When the brick fits readily into the leave-out void, place three nickel-sized dots of SB 105 adhesive caulk on the back of the brick then install the brick in the leave-out void. Gently rock the brick to spread the adhesive, but do not press too hard or too fast, as the brick might crack. Gently pressing and rocking the brick evenly spreads the adhesive and fills any irregularities behind the brick. Make sure to align the brick so that the grout lines are straight with the surrounding brick. Repeat for all leave-outs. Mortaring the Joints Once all of the leave-out bricks have been installed, the grout lines between the bricks on all panels can be mortared to hide all of the fasteners and the joints between panels. The mortar unifies the surface of the panels and secures the installation of all leave-out bricks. The finished installation should be identical in appearance to a conventional brick installation. Genesis Panel Systems 10 Siding Installation Instructions