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A-1 Stone Crafters, Inc. Products Installation Instructions are available separately from your dealer.
Building code requirements many very from area to area. Check with you local authorities for Building Code requirements in your area. Carefully read all installation instructions before with you A-1 Stone Crafters application. Observe safety precautions. A-1 Stone Crafters products are covered by a 30 year limited warranty when installed in accordance with the Manufacturer's Installation Instructions.
Estimating Stone Required
Determine the amount of A-1 Stone Crafters products needed by measuring the area to be covered. Measure the length times the height to arrive at the square footage of flat stone needed. Subtract square footage for window and door openings. Measure the linear feet of outside corners to determine the amount of corner pieces needed. One linear foot of corner pieces covers approximately 3/4 of a square foot of flat area. Subtract the flat area covered by the linear feet of corner pieces from the square footage of stone required. You may wish to obtain some extra stone to allow for cutting and trimming.Tools Required
Hammer or Staple Gun Wheelbarrow & Hoe Hock & Trowel Mason's Trowel Margin Trowel Masonry Circular, Table Saw or Grinder with Carborundum or Diamond Blade Wide Mouth Nippers or Hatchet Safety Glasses/Dust Mask Level Metal Join Tools or Wood Stick Grout Bag Whisk BroomSundry Material Requirements
A. Mortar Components
1. Premixed: Type N or S premixed mortar, or mortar mixed as per mixing instructions
2. Mortar Color: Iron outside color (if desired).B. Weather-Resistant Barrier
Depending on local building code requirement, barrier shall be equal to U.B.C. Standard No. 14-1 for Kraft waterproof building paper or asphalt saturated rag felt or ASTM D 226, Type 1, No 15 felt.
Note: Weather - resistant barrier must be used on all exterior and interior mortar applications except for those over masonry concrete or stucco.C. Fastening Components
1. Minimum 2.5 lb. Expanded metal lath (diamond mesh) galvanized. Black metal lath (rust inhibitive) my be used on interior application.
2. Or 18 gauge galvanized metal lath.
3. For metal buildings & open stud construction - minimum 3.4 lb. 3/8" rib expanded galanized metal lath.
4. Or other code accepted mesh or lath.D. Fasteners
1. Galvanized nails, staples, concrete nails.
2. Pancake Head screws (Used for installation to metal surfaces).E. Masonry Sealer
1. Silane based breather type sealer (Recommended).
Wall Surface Interior & Exterior Preparation Required Rigid Backwall
Wallboard
Plywood
Paneling
Wall Sheathing
Concrete Board
Polystyrene Insulation Board
Installed over a rigid blackballCover sheathing with a breather type weather resistant barrier, lap joints 4" shingle fashion. Then in accordance with local building code, lab and install lath or mesh using galvanized nails or staples 6" or center vertically, penetrating studs a minimum of 1" continuously wrap weather-resistant barrier and metal lath a minimum of 16" are all outside and inside corners
Clean & Untreated
Concrete
Masonry
Stucco
No preparation needed. Examine newly poured concrete closely to insure that its finished surface contains no release agents form oil). If it does contain form oil, etch surface with muratic acid, rinse thoroughly and/or scrub with a wire brush.
Dirty, Painter or Sealed
Concrete, Masonry or Stucco
Sandblast or water blast to original surface (remove sandblasting dust by washing or securely attach lath).
Metal Buildings
Lap and install paperbacked 3/8" rib expanded metal lath to metal cladding supports of 20 ga. to 12 ga, using Pancake Head Screws, Screws must penetrate 3/8" beyond the inside face of metal surface. Screws are to be installed on metal surfaces Screws must be installed on centers equal to 1 screw sq. ft. and shall not exceed 6" on center in one direction. Apply 1/2" to 3/4" scratch coat and allow to dry 48 hours.
Open Studs
Polystyrene Insulation Board Installed Over Open Studs
Lap and install paperbacked metal lath to studs using nails which penetrate a minimum of 1" to 4" on center. Apply 1/2" to 3/4" scratch out and allow to dry 48 hours.
Watertable/Sill Installations
Watertable/Sills provide a transition piece between a stone wainscot and other exterior finishes and for water runoff. They can also be used as a window sill.
Install using galvanized metal support brackets or support strip fastened with galvanized nails or screws penetrating stufs 1" at a mimimum of 16" O.O. Caulk and flash top of watertable as required.Prepare Your Work Area
Spread A-1 Stone Crafters wall veneer our at the job site so you have a good variety of sized and shapes and colors to choose from. Paln for some variety and contract in the overall design. Use small stones next to large ones, heavy textured pieces next to smooth, thick stones next to thiner ones. Mixing A-1 Stone Crafters wall veneer from different boxes during application will allow you to achieve a desirable balance of stones on your finished project.Mortar and Application
Notes: Weather Conditions
If stone is being applied in hot or dry weather, the back of each piece should e moistened with a fine spray of water or a wet brush to adequately prevent excessive absorption of moisture from the mortar. If being installed over concrete, masonry, or scratch coat substrate, the substrate surface area should be dampened before applying the mortar.Application should be protected from temperatures below freezing as mortar will not set up properly under such conditions. Do not use antifreeze compounds to lower the freezing point mortar.
A. Mixing Mortar/Grout
Using Premixed type N mortar or S Mortar, mix to a firm, moist consistency. Mortar that is too dry and crumbly will not bond properly. Mortar that is too wet will be weak and messy.B. Mortar Color
Tinting mortar complements the color of the stone being installed. Example: Use tan mortar with earthstone stones. This will greatly enhance the appearance of the finished installation. Regular mortars can be tinted to complement your A-1 Stone Crafters products using iron oxide pigments available from your dealer.C. Applying Mortar to Prepared Surface
Using a plasterer on a mason's trowel, apply mortar 1/2" to 3/4" thick to prepared surface area. Do not spread more than a workable area (5 to 10 sq. ft.) so that mortar will not "set up" before stone is applied.D. Starting Point
Apply mortar and stone working from the bottom up or most stones can also be applied from the top down. Working from the tope down may help avoid splicing previously applied stone with dripping mortar. Ledgestone types should be installed from the bottom up.E. Joint Width
In order to obtain the most natural look, joints should be as narrow as possible, average should not exceed 1/2" in width. An attractive look can also be achieved by fitting stone rightly together if desired.F. Setting the Stones
Press each stone into the mortar setting bed firmly enough to squeeze some mortar out around the stone's edges. Apply pressure to the stone to ensure a good bond. Ensure complete coverage between the mortar bed and back surface of the stone. Mortar may be also applied to the entire back of the stone.
Care must be taken to avoid smearing mortar on the surface of the of the stone, Accidental smears should be removed using a whisk broom only after mortar has become crumbly.G. Install Corner Pieces First
If your application requires corner pieces, apply these first, Notice that the corner pieces have long and short legs, Alternate these in opposite directions.H. Install Flat Pieces
After the corner pieces are in place, flat pieces are applied working toward the wall center.I. Keep your Mortar Joints Consistent
Place the individual stones close together creating uniform joints between them. Cut and trim as required to achieve consistent width in the mortar joints. Then trim and fit small pieces into any remain voids.J. Cutting and Trimming
Stones can be cut and shaped for a fit. Use wide mouth nippers or a hatchet. Some broken stones may be found in the box. These also may be used in filling gaps between large stones. For best finished appearance, coat cut or broken edges with mortar. If possible, position cut edges up when they are above eye level, down when below eye level. Always use safety glasses when cutting and trimming.Notes:
Level and Plumb Joint Lines
When applying castlestone, , Limestone, or Ledgestone, endeavor to maintain level and plumb joint lines. Also, long rectangular pieces will look most natural if applied horizontally.With Rock and Plumb Joint Lines
When applying ledgestone types keep joints as small as possible to maintain a natural look and install from the bottom up. Strike joints deeply being careful not to expose the back edge of the stones.Ledgestone Types
When applying Ledgestone types keep joints as small as possible to maintain a natural look and install from the bottom up. Strike joints deeply being careful not to expose the back edge of stones.Grounding and Finishing Joints
A. Grouting Joints
If additional mortar is required, use a grout bag to fill in the joints. Care bust be taken to avoid smearing mortar on surface of stone. Accidental smears should be removed only after mortar has become crumbly using a shisk broke or dry brush. Never use a wet brush or wire brush.B. Finishing Joints
When the mortar joints have become firm or thumb dry, setting time will vary depending on wall surface and climatic condition,they should be pointed up with a wood stick or metal jointing tool. Rake excess mortar, compact and seal edges around stones. Careful attention to proper and even jointing will result in a professional looking finish. The design simplicity of Ledger, Castlesone and Tumbled Rock and Ledger allows for easy installation of components and provides a finished mortar-less joint between the stones. This reduces the time required From the cutting, grouting and jointing.C. Cleaning Finished Job
At the End of the work day, or when the mortar is sufficiently set up, the finished job should be broomed or washed to remove loose mortar and clean the face of the stone. A wet brush should never be used to treat the mortar joints as this will cause staining that will be difficult, or impossible to remove. Do not use acid or acid base products. Care must be taken to avoid smearing mortar on the surface of components. Accidental smears should be removed with a Wisk broom or dry bristle brush only after the mortar has become crumbly. Do not use a wet brush or a wire brush, Careful attention to proper jointing will result in a professional looking finish. Do not use acid or acid base products.D. Cutting and Trimming
Cutting should be done outside as some dust will occur.
SAFETY GLASSES AND A DUST MASK SHOULD ALWAYS BE WORN WHEN CUTTING ANY A-1 STONE CRAFTERS PROJECTS. Stones can also be cut and shaped using wide mouth nippers or a hatchet.Installing Heathstones
Heathstones are not recommended or warranted for exteriors or as a surface area subject to foot traffic.
A. Place Mortar
Place mortar 3/4" deep in a 3-inch wide stripes - 1 inch apart on prepared surface.B. Install Heathstones
Place the first Hearthstone on to the mortar bed and level. Place adjacent Hearthstones, aligning and leveling with the first piece. If joint need additional mortar, fill joints following previous instructions under "Grouting and Finishing Joints" Ensure Hearthstones are set in a complete bed of mortar.Notes: Hearthstone Installation
Raised Hearth
Do not use cantilever or extend Hearthstones more that 1 1/2" beyond direct support. When grouting the extended portion or a centilevered Heartstone, bring the grout to the front edge. Push a long galvanized nail horizontally into the grout to add support, then cover the nail with mortar.Sealing Fireplaces/Hearths
If desired, sealing the A-1 Stone Crafters facing or hearth of a fireplace installation will assist in the removal of smoke and soot stains should this occur.General Information
Cleaning
Dirt etc. may be removed by using a strong solution of granulated soap or detergent and water with a bristle brush. Do not use a wire brush as it will cause damage to the surface. Rinse immediately with fresh water. For help with serious cleaning problems, contact your local dealer. Do not attempt to clean using acid or acid containing products. Do no clean with high pressure power washer.Salt and De-icing Chemicals
Because all concrete and masonry is vulnerable to damage by salt, A-1 Stone Crafter products are not warranted against damage incurred form salt or other chemicals on area immediately adjacent to an A-1 Stone Crafters application.Scuffing
Scuffing occurs on all natural stone. Occasionally some scuffing will occur on the surface of A-1 Stone Crafters products. This can enhance for the natural appearance of your A-1 Stone Crafters Installation. Some Scuff marks can be removed by cleaning as described above.Efflorescence
Efflorescence is a water-soluble salt that is deposited on the surface of stucco, concrete, brick and other masonry products by the evaporation of water that has penetrated the wall. On rare occasions effloresence will occur on A-1 Stone Crafters products. To remove efforescene, all the stone to dry thoroughly, then scrub vigorously with a stiff bristle brush and clean water. Rinse thoroughly - do not use a wire brush. For more difficult efflorscence problems, scrub thoroughly with a solution of 1 part white household vinegar to 5 parts water. Rinse thoroughly, For unusually difficult cleaning problems contact your local A-1 Stone Crafters dealer.Swimming Pools
A-1 Stone Crafters products should not be used below water level as in swimming pool lines. Chlorine and other chemicals may discolor the A-1 Stone Crafter Products and other masonry materials.Incorporate Good Building Practices
Building Code Requirements
Building Code Requirements vary from area to area. Check requirements in your area. Carefully read all Installation Instructions. Before proceeding with your A-1 Stone Crafters applications.Exterior Application
Make sure that the application of A-1 Stone Crafters products and the structure that they are being applied to incorporate good building practices. Rigid, corrosion-resistant flashing shall be installed at all wall penetrations. Flashing type and locations shall be in accordance with the requirements of the applicable building code. On exterior applications, the incorrect installation or absence of flashing surface areas. Masonry and other building products subjected to these conditions may develop staining, and when combined with sever freeze-thaw conditions, may eventually cause surface damage. This application of A-1 Stone Crafters products under these conditions is not recommended.Capping of the Exposed Tope of Exterior Walls
To achieve a finished architectural look on horizontal or sloping to areas of exterior walls, piers, retaining walls, or other surfaces, the use of A-1 Stone Crafters Capstones or a poured-in place concrete cap should extend approximately 1" to 2" beyond the finished Stone Crafters corner pieces or flat pieces must not be used to cap walls.Retaining Walls
All retaining walls must be water-proofed at the fill side. Wall constructions should incorporate proper use of granular back fill and provisions for good drainage. A continuous longitudinal drain along the back of the wall in drain rock is recommended.Chimney Cap
All Chimney Chases must be capped with a one piece cap that extends 1" - 2" beyond the finished stone surface to prevent water from entering the wall system. Chimney or chase construction should incorporate proper finishing.