Cultured Stone® Installation Instructions.
Cultured Stone® Installation Instructions.
Cultured Stone® Installation Instructions.
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Boral stone ProDUCts llC<br />
Build something great <br />
<strong>Cultured</strong> Stone ®<br />
manufacturer’s installation instructions<br />
<strong>Cultured</strong> Stone ® and <strong>Cultured</strong> Brick ® Product <strong>Installation</strong> <strong>Instructions</strong> are available separately<br />
from your Dealer and can also be found at www.culturedstone.com<br />
Building code requirements vary from area to area. Check with local authorities for building code requirements in your area.<br />
Carefully read all <strong>Installation</strong> <strong>Instructions</strong> before proceeding with your <strong>Cultured</strong> Stone ® products application. Observe safety<br />
precautions. <strong>Cultured</strong> Stone ® products are covered by a 50-Year Limited Warranty when installed in accordance with the<br />
manufacturer’s <strong>Installation</strong> <strong>Instructions</strong>. See complete warranty on our website at www.culturedstone.com.<br />
Estimating thE stonE REquiREd<br />
Determine the amount of <strong>Cultured</strong> Stone ® products needed<br />
by measuring the area to be covered. Measure the length<br />
times the height to arrive at the gross square footage of<br />
flat stone needed. Subtract square footage for window,<br />
door and other openings. Measure the linear feet of outside<br />
corners to determine the amount of corner pieces needed.<br />
One linear foot of corner pieces covers approximately 3 ⁄4<br />
of a square foot of flat area. Subtract the flat area covered<br />
by the linear feet of corner pieces from the square footage<br />
of flat stone required. You may wish to obtain some extra<br />
stone to allow for cutting and trimming. In addition, be<br />
sure to verify whether the texture chosen is sold based<br />
on coverage with a 1 ⁄2" mortar joint or tight-fitted. Most<br />
texture coverages are listed for a 1 ⁄2" joint, the exceptions<br />
being Drystack Ledgestone, European Castle Stone, Pro-<br />
Fit ® Ledgestone and Pro-Fit ® Alpine Ledgestone. If you are<br />
installing a texture, which states coverage is for 1 ⁄2" mortar<br />
joint, in a tightfit application, increase stone by 10-22%.<br />
Formula:<br />
Length x Height = Wall Area<br />
Window Width x Window Height = Window Area<br />
Lineal Feet of Corners Required x .75 = Wall Area<br />
Covered by Corners<br />
Wall Area – Window Area – Wall Area Covered by<br />
Corners = Square Ft. Flats Required<br />
tools REquiREd<br />
Choose the tools required for your installation—see page 7<br />
for illustrations and appropriate use.<br />
• Safety Glasses and other personal protective equipment<br />
• Staple Gun or Hammer • Wheelbarrow & Hoe • Hock<br />
& Trowel • Mason’s Trowel • Margin Trowel • Masonry,<br />
Circular, Table, Wet Saw or Grinder with Carborundum or<br />
Diamond Blade • Wide-Mouth Nippers or Hatchet • Dust<br />
Mask (1) • Level • Metal Jointing Tool or Wood Stick • Grout<br />
Bag • Whisk Broom<br />
1<br />
sundRy matERial REquiREmEnts<br />
A. Mortar Components<br />
1. Premixed: Type N or Type S mortar, meeting<br />
ASTM C 270<br />
a. Mortar mixed as per Table #2 on page #3<br />
b. Mortar color: iron oxide color meeting ASTM<br />
C 979 (if desired)<br />
c. Water: Potable water meeting ASTM<br />
C 1602/1602M<br />
2. Premixed, Polymer Modified meeting ANSI 118.4<br />
and compatible with Adhered Lightweight Concrete<br />
Masonry Veneer.<br />
a. Mortar mixed: Strictly per mortar manufacturer’s<br />
instructions to insure compliance with ANSI 118.4<br />
b. Water (when required): Potable water meeting<br />
ASTM C 1602/1602M<br />
c. Mortar color: iron oxide color meeting ASTM<br />
C 979(if desired)<br />
3. Polymer Modifiers/Bonding Agents<br />
a. Polymer modifiers and/or bonding agents must<br />
comply with ASTM C 270, ASTM C 1059, ASTM<br />
C 1384 or CSA A179<br />
b. Polymer modifiers and/or bonding agents must be<br />
used in strict accordance with the manufacturers’s<br />
instructions for Adhered Lightweight Concrete<br />
Masonry Veneer and must satisfy the sheer bond<br />
requirements of ANSI 118.4<br />
c. Polymer bonding agents must accommodate<br />
rewetting to avoid potential bond compromise<br />
B. Water Resistive Barrier<br />
Depending on local building code requirements, barrier<br />
shall meet the requirements of ICC Acceptance Criteria 38<br />
“Acceptance Criteria for Water Resistive Barriers.”<br />
Note: Water-resistive barrier must be used on all<br />
exterior and interior mortar applications. Waterresistive<br />
barrier is not required for application over<br />
masonry or concrete.
C. Flashing<br />
1. To maintain the weather-resistance of the exterior<br />
wall on which stone products are installed, corrosionresistant<br />
flashing, weep screed and a means of<br />
drainage shall be installed at all penetrations and<br />
terminations of the stone cladding. Flashing type and<br />
locations shall be in accordance with the requirements<br />
of the applicable building code.<br />
2. For additional recommendations regarding flashing,<br />
refer to the following trade associations, standards,<br />
organizations and resources:<br />
a. ASTM E 2112<br />
b. Asphalt Roofing Manufacturers Association (ARMA)<br />
c. Brick Institute of America (BIA)<br />
d. The American Plywood Association (APA)<br />
e. Local building department<br />
f. Architect or engineer<br />
g. Masonry Veneer Manufacturers Association (MVMA)<br />
installation guide for adhered concrete masonry<br />
veneer, available at www.masonryveneer.org<br />
D. Metal Lath<br />
1. Minimum 2.5-lb. galvanized self-furring expanded<br />
metal lath (diamond mesh) meeting the requirements<br />
of ASTM C 847, or min. 18-gauge galvanized selffurring<br />
woven wire mesh meeting the requirements of<br />
ASTM C 1032.<br />
2. For metal buildings and open stud construction—<br />
minimum 3.4-lb. 3⁄8" rib, paper-backed, expanded<br />
galvanized metal lath.<br />
3. Or other code accepted mesh or lath.<br />
E. Fasteners<br />
1. Galvanized nails, staples, concrete nails.<br />
2. Corrosion-resistant, self-drilling, self-tapping pancakehead<br />
screw with 7⁄16" head, of 11⁄4" length or suitable to<br />
obtain 3⁄8" penetration beyond inside surface of metal.<br />
(Used for installing to metal surfaces such as metal<br />
studs or metal building siding.)<br />
F. Masonry Sealer<br />
1. Silane-based breather-type sealer (if required).<br />
See “Sealers” in General Information section (page 6).<br />
suRfacE PREPaRation foR moRtaR installations<br />
Using Table 1, determine the correct surface preparation for<br />
your installation<br />
Rigid Backwal l<br />
Two (2) Layers of<br />
Water-Resistive<br />
Barrier<br />
Metal Lath<br />
Scratch Coat/Mortar<br />
®<br />
<strong>Cultured</strong> Stone<br />
Product<br />
Open Studs<br />
Two (2) Layers of<br />
Water-Resistive<br />
Barrier (Paper-<br />
Backed Metal Lath)<br />
Metal Lath<br />
Scratch Coat<br />
Mortar<br />
Figure 1 1<br />
Figure 2 2<br />
Metal Building<br />
Concrete or<br />
Two (2) Layers of<br />
Masonry Surface<br />
Water-Resistive<br />
Barrier (Paper-<br />
Backed Metal Lath)<br />
Metal Lath<br />
Scratch Coat<br />
Mortar Mortar<br />
<strong>Cultured</strong> Stone ®<br />
Product<br />
®<br />
<strong>Cultured</strong> Stone<br />
Product<br />
<strong>Cultured</strong> Stone ®<br />
Product<br />
Figure 3 Figure 4<br />
Figure 3<br />
Figure 4<br />
2<br />
WALL SURFACE<br />
Rigid Backwall<br />
Wallboard<br />
Plywood<br />
Paneling<br />
OSB<br />
Concrete Board<br />
Polystyrene Insulation<br />
Board<br />
installed over a Rigid<br />
Backwall<br />
Clean & Untreated<br />
Concrete<br />
Masonry<br />
Stucco*<br />
Dirty, Painted or Sealed<br />
Concrete, Masonry or<br />
Stucco<br />
Metal Buildings<br />
Insulation Board or<br />
Open Studs<br />
Polystyrene Foam Board<br />
Please see <strong>Installation</strong> Over<br />
Thick Foam note page 7<br />
Table 1<br />
INTERIOR & EXTERIOR<br />
PREPARATION REQUIRED<br />
Cover sheathing with a two (2) layers of breather-type water<br />
resistive barrier, lap joints minimum 6" at vertical joints and<br />
minimum 2" at horizontal joints in shingle fashion. Then, in<br />
accordance with local building code, lap and install lath or<br />
mesh using galvanized nails or staples 6" on center vertically,<br />
penetrating studs a minimum of 1". Continuously wrap water<br />
resistive barrier and metal lath a minimum of 16" to next<br />
framing member around all outside and inside corners (Fig.<br />
1). Apply 3 ⁄8" to 3 ⁄4" scratch coat.<br />
Examine newly poured concrete closely to ensure that its<br />
finished surface contains no release agents (form oil). If it<br />
does contain form oil, etch surface with muriatic acid, rinse<br />
thoroughly and/or score with a wire brush, beadblast or<br />
sandblast (Fig. 3). No further preparation needed.<br />
Sandblast, beadblast or waterblast to original surface (remove<br />
sandblasting dust by washing) or securely attach lath.<br />
Install primary water resistive barrier.<br />
Lap and install 3.4-lb. 3 ⁄8" rib, paper-backed, expanded metal<br />
lath to metal cladding supports of 20 ga. to 12 ga. using<br />
corrosion-resistant, self-drilling, self-tapping pancake-head<br />
screw with 7 ⁄16" head, of 1 1 ⁄4" length or suitable to obtain 3 ⁄8"<br />
penetration beyond inside surface metal. Screws are to be<br />
installed on center equal to 1 screw/sq. ft. and shall not<br />
exceed 6" on center in one direction. Apply 1 ⁄2" to 3 ⁄4" scratch<br />
coat and allow to dry 48 hours (Fig. 4).<br />
Install primary water resistive barrier. Lap and install 3.4-lb.<br />
3 ⁄8" rib, paper-backed, expanded metal lath to studs using<br />
nails which penetrate a minimum of 1" at 4" on center. Apply<br />
1 ⁄2" to 3 ⁄4" scratch coat and allow to dry 48 hours (Fig. 2).<br />
*Stucco cement plaster meeting requirements of ASTM C926, or other building code<br />
approved stucco. EIFS systems are not an approved backing for <strong>Cultured</strong> Stone ® .<br />
WatER REsistivE BaRRiER (WRB)<br />
When installing manufactured stone veneer, in an exterior<br />
application requiring a WRB, two separate layers of<br />
WRB shall be used. Each layer of WRB should meet the<br />
requirements for Water Resistive Barrier (Grade D) as defined<br />
by ICC Acceptance Criteria AC-38, or ASTM E 2556/E<br />
2556M. <strong>Installation</strong> of the WRB should follow instructions<br />
provided by specific manufacturer. When installing<br />
manufactured stone veneer in an interior application, a<br />
single layer of WRB is recommended.<br />
WatERtaBlE/sill installations<br />
Watertables/sills provide a transition piece between a stone<br />
wainscot and other exterior finishes and for water runoff.<br />
They can also be used as a windowsill. Install using<br />
galvanized metal support brackets (Simpson Strong Tie<br />
A-21 or other galvanized right angle bracket with holding<br />
capacity minimum 5 lbs./LF) fastened with galvanized<br />
nails or screws penetrating studs 1" at a minimum of 16"<br />
on center. Two brackets per sill is preferred if blocking<br />
is present. Use construction adhesive to bond stone<br />
at bracket locations. Caulk and flash as required at<br />
Watertable/Sill locations using an approved corrosionresistive<br />
flashing that extends to the surface of exterior wall<br />
finish and is installed to prevent water from re-entering the<br />
exterior wall envelope.
Windowsill Windowsill Cross Section Cross Section<br />
Caulk/Flashing Caulk/Flashing<br />
as Required* as Required*<br />
Galvanized Galvanized Wood Wood<br />
Screw Screw<br />
Watertable/Sill Watertable/Sill Stone Stone<br />
Construction Construction<br />
Adhesive (Bracket Adhesive (Bracket<br />
Locations Locations Only) Only)<br />
Galvanized Galvanized Metal Metal<br />
Bracket, Holding Bracket, Holding<br />
Capacity 5 Capacity Lbs/LF 5 Lbs/LF<br />
Mortar Setting Bed<br />
Lath<br />
<strong>Cultured</strong> Stone ®<br />
Mortar Setting Bed<br />
Lath<br />
<strong>Cultured</strong> Stone<br />
Product<br />
Water-Resistive<br />
Barrier<br />
®<br />
Product<br />
Water-Resistive<br />
Barrier<br />
* Failure to properly caulk/flash as described in these installation directions may<br />
result in water damage to the structure.<br />
installing stonE at gRound lEvEl<br />
Keep the finished edge of the <strong>Cultured</strong> Stone ® product a<br />
minimum of 4" above grade if earth or 2" above pavement.<br />
Use a 2" x 4" leveling strip (straightedge) or weep screed/<br />
flashing. Framed (wood or metal) applications are required<br />
by code in many jurisdictions to have weep screed or a<br />
weeped casing bead, at the base of the wall or foundation<br />
transition. This will:<br />
• Provide drainage as required by applicable building code.<br />
• Avoid possible staining of the stone by soils containing<br />
alkali or other minerals.<br />
PREPaRE youR WoRk aREa<br />
Spread <strong>Cultured</strong> Stone ® wall veneer out at the job site<br />
so you have a good variety of sizes, shapes and colors<br />
to choose from. Plan for some variety and contrast in<br />
the overall design. Use small stones next to large ones,<br />
heavy-textured pieces next to smooth, thick stones next<br />
to thinner ones. Mixing <strong>Cultured</strong> Stone ® wall veneer from<br />
different boxes during application will allow you to achieve a<br />
desirable balance of stones on your finished project.<br />
moRtaR<br />
NOTE: Weather Conditions<br />
If stone is being applied in hot or dry weather, the back of<br />
each piece should be moistened with a fine spray of water<br />
or a wet brush to adequately prevent excessive absorption<br />
of moisture from the mortar. If being installed over concrete,<br />
masonry or scratch coat substrate, the substrate surface<br />
area should also be dampened before applying mortar.<br />
Surfaces should appear damp but free of surface water.<br />
Applications should be protected from temperatures below<br />
40°F as mortar will not cure properly under such conditions.<br />
Do not use antifreeze compounds to lower the freezing point<br />
of mortar. See International Building Code Section 2104.3 for<br />
cold weather construction requirements.<br />
A. Mixing Mortar/Grout<br />
Using Premixed Type N or Type S mortar or components<br />
from Table 2, mix to a firm, moist consistency. Mortar that<br />
is too dry and crumbly will not provide proper bond. Mortar<br />
that is too wet will be weak and messy.<br />
Interior Finish per<br />
Schedule<br />
2 x 4 Stud Wall<br />
(Insulated)<br />
Sheathing<br />
Water-Resistive<br />
Barrier<br />
Exterior Finish per<br />
Schedule<br />
Caulk/Flashing<br />
as Required*<br />
Watertable/Sill Stone<br />
Galvanized Metal<br />
Bracket, Holding<br />
Capacity 5 Lbs/LF<br />
Lath<br />
Mortar Setting Bed<br />
<strong>Cultured</strong> Stone ®<br />
Wainscot Cross Section<br />
Interior Finish per<br />
Schedule<br />
2 x 4 Stud Wall<br />
(Insulated)<br />
Sheathing<br />
Water-Resistive<br />
Barrier<br />
Exterior Finish per<br />
Schedule<br />
Caulk/Flashing<br />
as Required*<br />
Construction<br />
Adhesive (Bracket<br />
Locations Only)<br />
Watertable/Sill Stone<br />
Galvanized Metal<br />
Bracket, Holding<br />
Capacity 5 Lbs/LF<br />
Galvanized Wood<br />
Screw<br />
Lath<br />
Mortar Setting Bed<br />
<strong>Cultured</strong> Stone<br />
Product<br />
®<br />
Wainscot Cross Section<br />
Table 2 – Proportions for Mortar<br />
Parts By Volume<br />
Portland Cement<br />
Mortar<br />
Masonry Masonry Hydrated Lime<br />
or Blended<br />
Aggregate<br />
type<br />
Cement Type N Cement Type S or Lime Putty<br />
Cement<br />
N 1 I 4<br />
Construction<br />
Adhesive (Bracket<br />
Locations Only)<br />
Galvanized Wood<br />
Screw<br />
Product<br />
1 ⁄2 to 6<br />
N I 21 ⁄4 to 3<br />
S I 21 ⁄4 to 3<br />
B. Mortar Color<br />
Tinting mortar complements the color of the stone being<br />
installed. Example: Use tan mortar with earth-tone stones.<br />
This will greatly enhance the appearance of the finished<br />
installation. Regular mortars can be tinted to complement<br />
your <strong>Cultured</strong> Stone ® product using iron oxide pigments<br />
available from your dealer.<br />
C. Applying Mortar to Prepared Surface Area<br />
Using a plasterer’s or mason’s trowel (Fig. 5 and 6), apply<br />
mortar 1⁄2" to 3⁄4" thick to prepared surface area. Do not<br />
spread more than a workable area (5 to 10 sq. ft.) so that<br />
mortar will not “set up” before stone is applied.<br />
3<br />
Figure 5<br />
Scratch Coat<br />
Mortar<br />
Apply mortar using a<br />
plasterer’s trowel.<br />
Mortar<br />
Figure 6<br />
Apply mortar using a<br />
mason’s trowel.<br />
aPPlying cultuREd stonE ® PRoducts<br />
See page 4 for additional instructions concerning Pro-Fit ®<br />
Ledge-stone, Pro-Fit ® Alpine Ledgestone and European<br />
Castle Stone.<br />
A. Starting Point<br />
Apply mortar and stone working from the bottom up,<br />
or most stones can also be applied from the top down.<br />
Working from the top down may help avoid splashing<br />
previously applied stone with dripping mortar. Ledgestone<br />
types should be installed from the bottom up.<br />
B. Joint Width<br />
In order to obtain the most natural look, joints should be as<br />
narrow as possible. The average should not exceed 1⁄2" in<br />
width. An attractive look can also be achieved by fitting<br />
stones tightly together if desired. If using tight fit/drystack<br />
method, it is important to make sure scratch coat/backing<br />
has been covered completely by the setting bed of mortar.<br />
This will conceal the scratch coat/backing and prevent<br />
pockets from forming behind stones that could trap water.<br />
C. Setting the Stones<br />
Press each stone into the mortar setting bed firmly enough<br />
to squeeze some mortar out around the stone’s edges. Apply<br />
pressure to the stone to ensure a good bond. Ensure<br />
complete coverage between the mortar bed and<br />
back surface of the stone. Mortar may also be applied<br />
to the entire back of the stone (Fig. 7). When stone is<br />
installed correctly, lath will not be visible. The mortar setting<br />
bed shall be between 3 ⁄8” minimum and 1 ⁄8” maximum.<br />
Care must be taken to avoid smearing Figure 7<br />
mortar on surface of stone. Accidental<br />
smears or mortar droppings should be<br />
removed using a whisk broom only<br />
after mortar has become crumbly.<br />
Mortar applied to the<br />
entire back<br />
of the stone.
D. Install Corner Pieces First Figure 8<br />
If your application requires corner<br />
pieces, apply these first. Notice<br />
that the corner pieces have a long<br />
and a short leg. Alternate these in<br />
opposite directions (Fig. 8).<br />
Apply corners—<br />
alternating long<br />
and short legs<br />
in the opposite<br />
directions.<br />
E. Install Flat Pieces Figure 9<br />
Apply flat pieces.<br />
After the corner pieces are in place,<br />
flat pieces are applied working toward<br />
the wall center (Fig. 9).<br />
F. Keep Your Mortar Joints<br />
Consistent<br />
Place the individual stones<br />
close together, creating<br />
uniform joints between them.<br />
Cut and trim as required to<br />
achieve consistent width in the<br />
mortar joints. Then trim and fit<br />
Figure 10<br />
Position large pieces<br />
first, then trim and fit<br />
in smaller pieces.<br />
small pieces into any remaining voids (Fig. 10).<br />
G. Cutting and Trimming<br />
Stones can be cut and shaped for fit. Use wide-mouth<br />
nippers or a hatchet (Fig. 11 and 12). (Refer to page 7–<br />
Tools Required.) Some broken stones may be found in<br />
the box. These also may be used in filling gaps between<br />
large stones. For best finished appearance, coat cut or<br />
broken edges with mortar. If possible, position cut edges<br />
up when they are above eye level, down when below eye<br />
level. SAFETY GLASSES AND A DUST MASK (1) SHOULD<br />
ALWAYS BE WORN WHEN CUTTING ANY CULTURED<br />
STONE ® PRODUCTS.<br />
Figure 11<br />
Trim with widemouth<br />
nippers.<br />
Figure 12<br />
Trim with<br />
a hatchet.<br />
NOTES:<br />
Level and Plumb Joint Lines<br />
When applying Cobblefield ® manufactured stone veneer,<br />
European Castle Stone, Limestone, Rockface, Coral or<br />
Ledgestone, endeavor to maintain level and plumb joint<br />
lines. Also, long rectangular pieces will look most natural if<br />
applied horizontally.<br />
River Rock and Stream Stone<br />
When applying River Rock or Stream Stone, plan the<br />
placement of stones to minimize trimming and cutting to<br />
maintain the natural look of the rounded shapes.<br />
Ledgestone Types<br />
When applying ledgestone types, keep joints as small as<br />
possible to maintain a natural look, and install from the<br />
bottom up. Strike joints deeply, being careful not to expose<br />
the back edge of stones or scratch coat/backing. See page<br />
4 for additional instructions regarding Pro-Fit ® Ledgestone,<br />
Pro-Fit ® Alpine Ledgestone and European Castle Stone.<br />
4<br />
tyPical installations:<br />
Wood Frame:<br />
In sequence: (1) sheathing, (2) two layers of water resistive barrier,<br />
(3) galvanized metal lath, (4) mortar/scratch coat/setting bed<br />
(5) <strong>Cultured</strong> Stone ® manufactured stone veneer, (6) mortar joint.<br />
Rigid Foam Insulation:<br />
In sequence: (1) rigid foam insulation, (2) two layers of water resistive<br />
barrier, (3) galvanized metal lath, (4) scratch coat, (5) mortar setting bed,<br />
(6) <strong>Cultured</strong> Stone ® manufactured stone veneer, (7) mortar joint.<br />
Masonry or Concrete:<br />
In sequence: (1) mortar applied directly to untreated, unpainted masonry,<br />
concrete or stucco, (2) <strong>Cultured</strong> Stone ® manufactured stone veneer,<br />
(3) mortar joint.<br />
Corner Preparation:<br />
1<br />
1<br />
1<br />
2<br />
2<br />
3<br />
2<br />
3<br />
4<br />
1<br />
4<br />
5<br />
2<br />
Water resistive barrier and lath must continuously wrap a minimum of<br />
16” at outside and inside corners and fasten at a framing member. Lap<br />
water resistive barrier a minimum of 4” at vertical and 2” at horizontal<br />
lap joints. Lap lath a minimum of 1” at vertical and horizontal seams.<br />
(1) wall substrate, (2) two layers of water resistive barrier, (3) metal lath.<br />
3<br />
6<br />
3<br />
5<br />
7<br />
6
gRouting and finishing Joints<br />
A. Grouting Joints<br />
Figure 13<br />
If additional mortar is required, Grout joints.<br />
use a grout bag to fill in joints (Fig.<br />
13). Care must be taken to avoid<br />
smearing mortar on surface of stone. Accidental smears or<br />
mortar droppings should be removed only after mortar has<br />
become crumbly using a whisk broom or dry bristle brush.<br />
Never use a wet brush or wire brush.<br />
B. Finishing Joints<br />
Figure 14<br />
Finishing the job.<br />
When the mortar joints have become<br />
firm or “thumb-print” dry (setting time<br />
will vary depending on wall surface<br />
and climatic conditions), they should<br />
be pointed up with a wood stick or<br />
metal jointing tool. Rake out excess<br />
mortar, compact and seal edges around stones (Fig. 14).<br />
Careful attention to proper and even jointing will result in a<br />
professional looking finish.<br />
C. Cleaning Finished Job<br />
At the end of the work day, or when mortar is sufficiently<br />
set up, the finished job should be broomed or brushed to<br />
remove loose mortar and to clean the face of the stone. A<br />
wet brush or sponge should never be used to treat the<br />
mortar joints as this will cause staining that will be difficult,<br />
or impossible, to remove. Do not use acid or acid-based<br />
products.<br />
additional instRuctions foR PRo-fit ®<br />
lEdgEstonE, PRo-fit ® alPinE lEdgEstonE<br />
and EuRoPEan castlE stonE<br />
Fit the Joints Tightly<br />
Install all these products with tight-fitted joints. Generally,<br />
components should be placed butting each other and<br />
aligned for level and plumb. When installing, the backs of all<br />
these components must be wet. They should be noticeably<br />
damp, but free from surface water. Mortar must be tinted<br />
to match the color of the stone you are installing to help<br />
conceal the joint lines.<br />
A. Starting Point<br />
Products are applied starting from the bottom and<br />
working up. Start each ProFit ® Ledgestone course level<br />
and continue horizontally completing each course before<br />
starting the next. European Castle Stone is done in a similar<br />
sequence to achieve a random ashlar pattern. If required,<br />
cut the appropriate size component to fit at the end or top<br />
of the finish area (Fig. 18). Frequently check the installation<br />
for level and alignment.<br />
B. Install Corner Pieces First<br />
If your application requires corner pieces, start by installing<br />
a corner piece first, followed by the adjoining flat pieces.<br />
Notice that the corner pieces have a long and short leg.<br />
Alternate these in opposite directions.<br />
C. Setting the Stones<br />
Press each stone into the mortar setting bed firmly enough<br />
to squeeze some mortar out around the mortar groove<br />
at the back edge of component. Apply pressure to the<br />
component to ensure a good bond. Ensure complete<br />
coverage between the mortar bed and back surface<br />
5<br />
of stone. Mortar may also be applied to the entire back of<br />
the stone. Check for level and plumb.<br />
D. Install Flat Pieces<br />
Figure 15<br />
Strike off extruded mortar<br />
from edge before placing<br />
next component. (ProFit ®<br />
Ledgestone shown)<br />
After the first corner<br />
piece is in place, the<br />
adjoining flat pieces<br />
of each course or<br />
pattern are applied.<br />
Using a trowel, strike<br />
off the excess mortar<br />
around the edges of<br />
the component prior<br />
to placing the next component. This will allow the next<br />
adjacent component to fit tightly (see Fig. 15). Choose<br />
the correct length component to ensure that vertical<br />
joints do not line up.<br />
E. Cutting and Trimming<br />
Vertical or horizontal cuts can be made using a table saw,<br />
circular saw or small grinder equipped with a dry cutting<br />
diamond or carborundum blade.<br />
CUTTING SHOULD BE DONE OUTSIDE AS SOME<br />
DUST WILL OCCUR. SAFETY GLASSES AND A DUST<br />
MASK (1) SHOULD ALWAYS BE WORN WHEN CUTTING<br />
ANY CULTURED STONE ® PRODUCTS. Stones can also<br />
be cut and shaped using wide-mouth nippers or a hatchet.<br />
Additional Information on Cutting and Fitting<br />
Finished Edges—Place finished edges at exposed areas.<br />
Cut Edges—Place cut edges within courses.<br />
Finishing Joints<br />
The design simplicity of Pro-Fit ® Ledgestone, Pro-Fit ® Alpine<br />
Ledgestone and European Castle Stone allows for easy<br />
installation of components and provides a finished, tightfit<br />
joint between the stones. This reduces the time required for<br />
cutting, grouting and jointing.<br />
Surface Cleaning<br />
Care must be taken to avoid smearing mortar on the<br />
surface of components. Accidental smears or mortar<br />
droppings should be removed with a whisk broom or dry<br />
bristle brush only after mortar has become crumbly. Do<br />
not use a wet brush, sponge or a wire brush. Do not<br />
use acid or acid-based products, power-washing,<br />
sandblasting or wire-brush cleaning.<br />
additional instRuctions foR installing cast-fit ®<br />
The Cast-Fit ® product has been designed for the best<br />
appearance and performance when installed with a 3/8”<br />
mortar joint. Starting with a level line for your first course,<br />
maintain level and plumb courses as you proceed up<br />
the wall. Starting with thicker stones to set face plane,<br />
use mortar setting bed thickness to even face plane of<br />
thinner stones and accommodate variations in substrate<br />
surface. Application of a uniform and true scratch coat will<br />
also accommodate variations in the substrate surface. It<br />
is recommended that 3/8” dowel pins or shims be used<br />
to maintain a uniform head and bed joint space during<br />
installation. The mortar joint should be tooled to a concave<br />
shape, just below the surface of the stone. To obtain the
coverage stated on packaging and literature this mortar<br />
joint spacing must be maintained. If you choose to install<br />
Cast-Fit ® in a tight-fit or mortar-less joint application<br />
you must achieve complete mortar setting bed<br />
coverage and full perimeter squeeze out. To achieve<br />
this, with stones of this size, it may be necessary to<br />
use a mortar application method in which mortar is<br />
toweled onto the scratch coat and back buttered on<br />
the stone.<br />
installing finishing touchEs<br />
Hearthstone <strong>Installation</strong> <strong>Instructions</strong><br />
Hearthstones are not recommended or warranted<br />
for exterior use or as a surface area subject to foot<br />
traffic. TERRA CRAFT ® Pavers are available from your<br />
dealer for use as a hearthstone or for patios and walkways.<br />
Consult surface preparation table 1 for requirements prior<br />
to installing Hearthstone.<br />
Figure 16<br />
A. Place Mortar<br />
Place mortar for<br />
Hearthstone installation.<br />
Place mortar 3⁄4” deep in 3-inch<br />
wide strips 1 inch apart on<br />
prepared surface (Fig. 16).<br />
B. Install Hearthstones<br />
Figure 17<br />
Place the first Hearthstone onto the<br />
Place<br />
mortar bed and level (Fig. 17). Place Hearthstone.<br />
adjacent Hearthstones, aligning and<br />
leveling with the first piece.<br />
If joints need additional mortar, fill<br />
joints using a grout bag. Tool and<br />
finish joints following previous instructions under “Grouting<br />
and Finishing Joints.” Ensure Hearthstones are set in a<br />
complete bed of mortar.<br />
C. Cutting and Trimming Hearthstones<br />
Hearthstones can be cut as required using a circular saw<br />
fitted with a carborundum or diamond blade or using a<br />
mason’s brick or tile saw. Place finished edges at exposed<br />
areas. SAFETY GLASSES AND A DUST MASK (1)<br />
SHOULD ALWAYS BE WORN WHEN CUTTING ANY<br />
CULTURED STONE ® PRODUCTS.<br />
NOTES: Hearthstone <strong>Installation</strong> UL Listed<br />
<strong>Cultured</strong> Stone ® manufactured stone veneer and hearth<br />
products are made from non-combustible materials. Mortar<br />
joints must not exceed 1 ⁄2” in width and the mortar must be<br />
even with the top of the hearth surface.<br />
Raised Hearth<br />
Do not cantilever or extend Hearthstones more than 1 ⁄2”<br />
beyond direct support. When grouting the extended portion<br />
of a cantilevered Hearthstone, bring the grout to the front<br />
edge. Push a long galvanized nail horizontally into the grout<br />
to add support, then cover the nail with mortar.<br />
Sealing Fireplaces/Hearths<br />
If desired, sealing the <strong>Cultured</strong> Stone ® facing or hearth of a<br />
fireplace installation will assist in the removal of smoke and<br />
soot stains should they occur. See “Sealers” in General<br />
Information section for more information (page 6).<br />
6<br />
<strong>Cultured</strong> Stone ® Electrical Box Stones<br />
<strong>Installation</strong> <strong>Instructions</strong><br />
NOTES: Electrical Box Stones <strong>Installation</strong><br />
Attach UL-listed extension box to prewired<br />
and mounted electrical box.<br />
Center Electrical Box Stone over the<br />
extension box. Level and plumb. Use<br />
removable shims if required.<br />
1 2<br />
3<br />
Apply mortar to back of Electrical Box Stone<br />
or prepared substrate.<br />
Complete placement of <strong>Cultured</strong> Stone ®<br />
veneer or other exterior material<br />
around Electrical Box Stone.<br />
• Electrical Box Stones must be installed in accordance<br />
with <strong>Cultured</strong> Stone ® <strong>Installation</strong> <strong>Instructions</strong>.<br />
• Extension box, light fixture or receptacle plate must be<br />
attached in accordance with manufacturer’s instructions<br />
and local building codes.<br />
Tuscan Lintel <strong>Installation</strong> <strong>Instructions</strong><br />
Method One<br />
On installations where the top of the opening provides no<br />
support for the bottom edge of the Tuscan Lintel: Install<br />
metal support brackets as per <strong>Cultured</strong> Stone ® <strong>Installation</strong><br />
<strong>Instructions</strong> for Watertables/Sills. Then install Lintel stones in a<br />
full setting bed of mortar in accordance with <strong>Cultured</strong> Stone ®<br />
<strong>Installation</strong> <strong>Instructions</strong>.<br />
Method Two<br />
On installations where the bottom edge of the Tuscan Lintel<br />
will be supported by a window or door frame’s molding or<br />
profile: Install lintel stones in a full setting bed of mortar in<br />
accordance with <strong>Cultured</strong> Stone ® <strong>Installation</strong> <strong>Instructions</strong>.<br />
Make sure you do not cause deflection to window with<br />
weight of Lintel. If there is any question, use method one.<br />
gEnERal infoRmation<br />
Cleaning<br />
Dirt, etc., may be removed by using a strong solution of<br />
granulated soap or detergent and water with a bristle<br />
brush. Do not use a wire brush as it will cause damage<br />
to the surface. Rinse immediately with fresh water. For<br />
help with serious cleaning problems, contact your local<br />
dealer. Do not attempt to clean using acid or acidcontaining<br />
products, power-washing, sandblasting<br />
or wire-brush cleaning.<br />
4
Enhanced Bond<br />
Pre-Blended Polymer modified mortars, bonding agents/<br />
enhancers may provide greater bond strength. Enhanced<br />
bond strength capability may be desired for: tight fit<br />
applications, tilt up construction or where code jurisdictions<br />
require higher bond strength. These products must be<br />
compatible with manufactured stone and used in strict<br />
accordance with manufacturer’s instructions. These<br />
products may also have specific requirements regarding:<br />
hot or cold weather, exposure to rain/water while curing or<br />
water used to dampen the stone units prior to installation.<br />
Salt and De-Icing Chemicals<br />
Because all concrete and masonry are vulnerable to<br />
damage by salt, <strong>Cultured</strong> Stone ® products are not<br />
warranted against damage incurred from salt or other<br />
chemicals used to remove snow or ice. Do not use de-icing<br />
chemicals on areas immediately adjacent to a <strong>Cultured</strong><br />
Stone ® manufactured stone veneer application.<br />
Scuffing<br />
Scuffing occurs on all natural stone. Occasionally some<br />
scuffing will occur on the surface of <strong>Cultured</strong> Stone ®<br />
products. This can enhance the natural appearance of your<br />
<strong>Cultured</strong> Stone ® manufactured stone veneer installation.<br />
Some scuff marks can be removed by cleaning as<br />
described above.<br />
Efflorescence<br />
Efflorescence is a water-soluble salt that is deposited on<br />
the surface of stucco, concrete, brick and other masonry<br />
products by the evaporation of water from the wall. On<br />
rare occasions efflorescence will occur on <strong>Cultured</strong> Stone ®<br />
products. To remove efflorescence, allow the stone to dry<br />
thoroughly, then scrub vigorously with a stiff bristle brush and<br />
clean water. Rinse thoroughly—do not use a wire brush. For<br />
more difficult efflorescence problems, scrub thoroughly with<br />
a solution of 1 part white household vinegar to 5 parts water.<br />
Rinse thoroughly. For unusually difficult cleaning problems,<br />
contact your local <strong>Cultured</strong> Stone ® dealer.<br />
Sealers<br />
Sealers are not necessary on <strong>Cultured</strong> Stone ® products.<br />
However, some customers use sealers to help prevent<br />
staining in applications prone to smoke, soot, dirt or water<br />
splashing. If you choose to use a sealer, make sure it is<br />
a silane-based, breathable sealer. Take note that sealers<br />
may darken the color of the stone. A sealer may also slow<br />
the natural movement of moisture out of the stone and<br />
increase the possibility of efflorescence and/or spalling. For<br />
information regarding actual performance or application of<br />
sealers, contact the manufacturer of the sealer directly.<br />
(1) CAUTION: Contains Crystalline Silica. Dusts from cutting or sawing may create<br />
possible cancer hazard. Dusts of this product may cause irritation of the nose,<br />
throat and respiratory tract. Avoid prolonged or repeated inhalation of dusts from<br />
this product.<br />
A properly fitted NIOSH approved N-95 series disposable particulate filtering<br />
facepiece respirator (formerly referred to as “dust masks”) should be used when<br />
mechanically altering this product (e.g., sawing, cutting, drilling or similar dust<br />
generating processes). Wear long-sleeved shirt, long pants, gloves and safety<br />
glasses with side shields when handling and installing material. Wash hands and<br />
face with soap and warm water immediately after handling this product.<br />
7<br />
Staple Gun/Hammer<br />
(Applying water-resistive barrier<br />
and/or metal lath)<br />
Mason’s Trowel<br />
(Applying mortar)<br />
Wheelbarrow and Hoe<br />
(Mixing mortar)<br />
Wide-Mouth Nippers/Hatchet<br />
(Trimming stone)<br />
tools Required<br />
Margin Trowel<br />
(Applying masonry adhesive)<br />
Masonry, Circular, Table, Wet Cut Saw or Grinder<br />
with Carborundum or Diamond Blade<br />
Metal Jointing Tool/Wood Stick<br />
(Finishing joints)<br />
Hock and Trowel<br />
Level<br />
Grout Bag<br />
Whisk Broom<br />
(Cleaning finished work)<br />
Dust Mask (1) Safety Glasses (1)<br />
Use of <strong>Cultured</strong> Stone ® Below Water Levels<br />
<strong>Cultured</strong> Stone ® veneer is a lightweight concrete material<br />
and will not deteriorate from exposure to fresh liquid water.<br />
The use of <strong>Cultured</strong> Stone ® veneer below water level, in<br />
which the water is chlorinated, treated with chemicals or dirty<br />
will likely cause discoloration as it would on any concrete,<br />
natural stone or other materials. Pool chemicals which<br />
contain acid, such as muriatic acid, may cause damage<br />
to <strong>Cultured</strong> Stone ® products, which would not be covered<br />
by the <strong>Cultured</strong> Stone ® 50 Year Limited Warranty. <strong>Cultured</strong><br />
Stone ® veneer, concrete and many natural stone materials<br />
are subject to potential damage from adverse freeze thaw<br />
conditions. For that reason, water should be drained below<br />
susceptible materials prior to freezing temperatures. Pressure<br />
and abrasion from constant fast flowing water may cause<br />
some surface deterioration as it would on other concrete<br />
materials. The surfaces of concrete and many other materials<br />
may be affected by exposure to extensive salt-water<br />
conditions. <strong>Cultured</strong> Stone ® veneer should not be considered<br />
a waterproof material.
incoRPoRatE good Building PRacticEs<br />
Building Code Requirements<br />
Building code requirements vary from area to area. Check<br />
with local authorities for building code requirements in<br />
your area. Carefully read all <strong>Installation</strong> <strong>Instructions</strong> before<br />
proceeding with your <strong>Cultured</strong> Stone ® manufactured stone<br />
veneer application.<br />
Exterior Applications<br />
Make sure that the application of <strong>Cultured</strong> Stone ® products<br />
and the structure they are being applied to incorporate<br />
good building practices. Rigid, corrosion-resistant flashing<br />
shall be installed at all wall penetrations. Flashing type and<br />
locations shall be in accordance with the requirements<br />
of the applicable building code. On exterior applications,<br />
the incorrect installation or absence of flashing, cant<br />
strips, gutters and downspouts may result in diversion of<br />
water run-off onto finished surface areas. Masonry and<br />
other building products subjected to these conditions<br />
may develop staining and, when combined with severe<br />
freeze-thaw conditions, may eventually cause damage.<br />
The application of <strong>Cultured</strong> Stone ® products under these<br />
conditions is not recommended.<br />
Rainscreen Statement<br />
Some building codes require a rainscreen behind cladding<br />
materials, including manufactured stone veneer. If you are<br />
installing manufactured stone/brick veneer in one of these<br />
jurisdictions, or are concerned about extreme weather<br />
conditions, it is recommended that you choose a rainscreen<br />
system that can achieve the following:<br />
• The system should create a space with a minimum depth<br />
of 3 /16” (10mm) and maximum depth of ¾” (19mm).<br />
• The materials should be corrosion and rot resistant.<br />
• Unless otherwise designed to manage moisture vapor, the<br />
system should be vapor open.<br />
• If rainscreen space is created with a material other than<br />
solid strapping/ furring attached directly to framing, the<br />
following must be considered. Lath fasteners must be<br />
capable of supporting the weight of the finished wall<br />
cladding system considering the unsupported/cantilevered<br />
portion of fastener that is equal to the thickness of the<br />
rainscreen materials.<br />
Overhead Application<br />
Overhead, horizontal or sloped applications are not included<br />
in our building code evaluation reports or acceptances.<br />
These applications often require special approval/<br />
inspections by local building code inspectors. Contact<br />
your architect or engineer for assistance designing these<br />
installations.<br />
<strong>Installation</strong> Over Thick Foam<br />
<strong>Installation</strong> over foam board thicker than 1 ⁄2” may require<br />
special fasteners. Consult your architect or engineer for<br />
assistance designing a thick foam installation.<br />
Capping Off the Exposed Top of Exterior Walls<br />
To achieve a finished architectural look on horizontal or<br />
sloping top areas of exterior walls, piers, retaining walls or<br />
8<br />
other surfaces, <strong>Cultured</strong> Stone ® Capstones or a pouredin-place<br />
concrete cap must be used to provide adequate<br />
run-off protection to the wall areas. Caps should extend<br />
approximately 1”–2” beyond the finished stone surface.<br />
<strong>Cultured</strong> Stone ® corner pieces, flat pieces, or<br />
hearthstones should not be used to cap walls.<br />
Retaining Walls. All retaining walls must be waterproofed<br />
at the fill side. Wall construction should incorporate proper<br />
use of granular backfill and provisions for good drainage.<br />
A continuous longitudinal drain along the back of the wall<br />
set in drain rock is recommended.<br />
Chimney Cap<br />
All chimney chases must be capped with a one-piece cap<br />
that extends 1”–2” beyond the finished stone surface to<br />
prevent water from entering the wall system. Chimney or<br />
chase construction should incorporate proper flashing.<br />
cultured stone ® 50-year limited Warranty<br />
<strong>Cultured</strong> Stone ® products are covered for a period of 50<br />
years from the date of purchase when used on a structure<br />
which conforms to local building codes and when installed<br />
in accordance with the manufacturer’s instructions. <strong>Cultured</strong><br />
Stone ® will repair or provide, free of charge, new materials<br />
to replace any determined to be defective pursuant to<br />
our express limited warranty. This warranty is limited to<br />
the original purchaser and may not be transferred to any<br />
subsequent owner.<br />
This warranty does not cover damage resulting from:<br />
• Settlement of the building or other wall movement<br />
• Contact with chemicals or paint<br />
• Discoloration due to airborne contaminants<br />
• Staining or oxidation<br />
Our warranty does not cover labor costs incurred in removal<br />
and replacement of defective products. For complete details<br />
of our <strong>Cultured</strong> Stone ® 50-year limited warranty please visit<br />
our website at www.culturedstone.com. Hearthstones are<br />
not warranted for use on the ground or as a surface area<br />
subject to foot traffic.<br />
codE comPliancE Evaluation and listings<br />
ICC-ES ESR-1364. Tested or listed by Underwriters<br />
Laboratories, Inc., HUD Materials Release<br />
No.1316, Texas Dept. of Insurance Product Evaluation<br />
EC-21.<br />
ICC-Evaluation<br />
Service ES ESR -1364<br />
Underwriters<br />
Laboratories<br />
✓ Recycled content<br />
Minimum of 54 percent recycled content on all<br />
<strong>Cultured</strong> <strong>Stone®</strong> veneer products.<br />
The GREENGUARD Indoor Air Quality Certified mark is a registered certification<br />
mark used under license through the GREENGUARD Envronmental Institute.
Build something great with Boral<br />
Roof tiles<br />
Roof Accessories<br />
Bricks<br />
Pavers<br />
Stone<br />
Explore the product range online<br />
www.boralna.com<br />
Pub. No. 62433-E. Printed in U.S.A. June 2012.<br />
©2012 Boral Stone Products LLC<br />
To learn more about <strong>Cultured</strong> Stone ® products<br />
visit www.culturedstone.com<br />
or call 1-800-255-1727