MOUNTAIN STONE® Products
PRODUCT USERS GUIDE
Mountain Stone® Products P.O. Box 20308 42102 4301 Industrial Road Bowling Green, KY. 42101
(270) 796-6123 (270) 796-6131 (800) 781-0277 Local Fax Nationwide
Product Users Guide 1
STONE TEST RESULTS
BY Mountain Stone® Products 4301 Industrial Road Bowling Green, KY. 42101
Product Testing Results
The following tests were performed by: ATEC Associates (The American Testing and Engineering Corporation) located in Nashville, Tennessee.
Absorption Test- ASTM C-67 Flexural Strength - ATSM C-348 Absorption Percentage Average=3.3% Flexural Strength ( psi) –average - 117
Compressive Strength – ASTM C- 67 Freeze -Thaw - ASTM C- 67-83 Compressive Strength Average = 3260 psi *No noticeable cracking occurred.
Thermal Properties Efflorescence Test - ATSM C-67 sec.10 Thickness (inches) = 1.587 *Not efflorescenced Density (pcf) = 63.17 R-factor ** = 1.38
**R factor is based on the thickness in accordance with ASTM C 177-71. Average thickness may vary, which will result in R-factors varying. The insulative quality is equal to 6” of common brick.
Other Tests •= Non-combustible stone, showed zero flame spread and no smoke developed. •= Colorfastness: During testing of stone no undesirable change in color was noted.
Installation Procedures
1. PREPARING THE SURFACE
Due to its light weight, Mountain Stone can be applied to any structurally sound surface, (except Sheet Rock) and needs no special structural foundation alteration or additions.
Apply Mountain Stone directly to the surface of concrete, block, brick, and other masonry surfaces only if the surfaces are clean, unpainted, unsealed, and untreated. All other surfaces must be covered with a 2.5# Galvanized Diamond metal lath. Product Users Guide 2
Lath is to be laid horizontally across wall, as you run your hand down the wall, starting at the top, seems smooth. Running your hand upward, starting from the bottom, seems rough, overlap lath 2”. Always work from the bottom to the top when attaching lath. On wood, nailing is to be 6” apart down each stud, using 1-3/4” roofing nails or 1”x 2” staples used with air pressure of 90 lbs. Minimum. Over metal studs or metal buildings (18 gauge min.), use No. 8 self tapping screws to penetrate or on painted masonry surfaces use 1” masonry nails same distance as above. Nailhead may have to have a small washer adapted to help hold mesh. A 15 lb. Felt paper or paper backed lath available from Mountain Stone must be placed under all outside applications except on clean masonry surface. (If applying stone over clean masonry surface, please skip step 1 and go to step 2).
2. APPLYING THE BED COAT OVER LATH
Mix thoroughly 1 part Type “S” mortar to 1-1/2 parts clean brick sand (12 gallons). Add clean potable water to achieve a trowelable mixture, use a 12” trowel and spread mixture over metal lath, enough to cover lath approx. 3/8” thick. After drying, this will provide a rigid backing and assure firm bonding on the stone veneer.
3. APPLYING THE STONE
Using the same mixture as the bed coat, apply approximately ½” of mortar to back of stone, covering the entire stone. By using gentle pressure, and a slight wiggling action while applying the stone to the bed coat, will assure a good bond. During warm weather, the bed coat may have to be dampened with water to prevent water being drawn too rapidly from the applying mortar. During cold weather, follow all the guidelines set forth by the Construction Masonry Institute concerning cold weather masonry. To keep stones clean, start at top and work down. If corner pieces are used set them first for easy fitting. (Tip: Avoid getting mortar on the face of the stone during installation.)
Installation Procedures (continued)
4. Grouting Joints
Grouting mixture shall consist of 1 part Type “N” mortar to 2 parts sand, and clean water. This mixture is to be thoroughly mixed to provide a heavy cream like consistency. This mixture is then placed in a grout bag. Fill the bag ½ full, twist the top and hold tight. With slight pressure from the other hand, and twisting from the top, place opening in joint somewhat like using a caulking gun, and fill the joint flush with the stone. Do not get mortar on any other parts of the stone by the joint area. Let mortar set until firm but workable before finishing joint. (It may be necessary to snip the opening of the grout bag to allow for easier dispensing of the mortar.)
5. FINISH JOINT PROCEDURE
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When mortar joints become firm, use of a wooden striking tool carved just a little smaller than the joint width may be used. Press gently and smoothly as to fill grout voids and remove excess mortar to desired depth. Note: The mortar should be firm enough not to stain stone.
6. BRUSHING JOINTS
This should be done within 2 hours after tooling of joints. The best way is with a clean whisk broom or a plastic bristle brush. Do not use a brush made of metal. Do not let it set over night before tooling and brushing. Do not brush wet mortar, it will smear and leave brush marks.
7. CLEANING
Never use acid for cleaning. If mortar dripping occur, use a clean wet sponge immediately to clean.
8. SEALING
Sealing is unnecessary and optional on most jobs.
Specification Guide
Use this specification guide for each Furnish Mountain Stone stone veneer as individual project. And be sure to omit specified on drawings and specified portions not applicable to single projects and installation procedures. actual needs. 1.4 SUBMITTALS 1.1 PRODUCT NAME Submit a 4’x 4’ grouted sample of Mountain Stone so that accepted stone veneer to be Manufactured stone veneer for exterior and used falls within accepted range of sizes, interior wall covering by Mountain Stone. color, texture, and grouted joint style. Type______Color______Sample shall remain on job until project is completed. 1.2 MANUFACTURER Mountain Stone Products 1.5 MATERIAL COMPOSITION 4301 Industrial Road Stone veneer to be produced of Type 1 Bowling Green, KY. 42101 Portland cement, expanded aggregate, and (270) 796-6123 additives to meet or exceed the following specifications: 1.3 DESCRIPTION OF WORK Water Absorption: 3.3% Compressive Strength: 3,260 psi. + Thermal Conductivity: 1.38 R-Factor Product Users Guide 4
Reinforcement wire-mesh, Galv. 2.5# 1.6 PRODUCT PACKAGING AND Joint color- pure iron oxide colors or HANDLING Mortar Type N. Mountain Stone is packaged on 40x 48 pallets with 24 boxes per pallet. 2.2 METAL LATH Each box contains 10 square feet of the A. WoodFrame Construction: For exterior stone. Corners are 10 lin. feet per box. application cover area with15 lb. felt paper Pallets can be stacked 3 high for easy or paper backed lath available from space saving, storage and inventory Mountain Stone. Joint overlaps require 2” control. on horizontal and vertical joints. 2.5# Boxes weigh approx. 65lbs. each. Galvanized Metal Lath is then nailed every 6” on centers into studs. INSTALLATION MATERIALS 2.1 MATERIALS B. To Masonry: Stone may be applied All equipment and materials are to be directly to masonry wall provided the clean and free of chemicals that may cause walls surface is clean. Sealed masonry or efflorescence. Materials shall conform to: painted surfaces should be sand blasted or Type 1 Portland cement - ASTM C150 covered with metal lath using 1” masonry Sand – ASTM- C-144 nails. Use clean potable water
SPECIFICATION GUIDE size of a penny. Grout shall set after C. Metal studs or metal buildings: 2.5# Galv. grouting so that so that when tooled it metal lath is backed with 15 lb. paper, then will not smear and stain stone. secured to the studs or metal high rib with B. Colored Joints: Colors shall be selected no.8 self-tapping metal screws no less than from standard colors available from ¼”penetration into metal. approved manufacturers of iron oxide.
2.3 BONDING MORTARS EXECUTION Use Type “S” mortar with clean brick sand. 3.1 SURFACE CONDITIONS Mixture will be 1-1/2 parts sand and 1 part A. Examine the areas and conditions under Type ”S” mortar. This mixture shall be used which work will be performed. If or covering metal lath and adhering stone problems are found, do not proceed until only. Mixture to be mixed thoroughly and unsatisfactory conditions are corrected. evenly. B. Coordinate with other trades as needed to assure that proper substrate is 2.4 GROUTING MORTARS provided to receive the stone veneer. A. Shall be 1 part Type N Mortar to 1-1/2 C. Condition of surfaces to receive stone to 1-3/4 part clean brick sand. Mixture veneer. to be thin enough to be squeezed easily 1. Verify that surface to receive mortar from a Grout bag with a hole about the setting bed and stone are firm, dry, Product Users Guide 5
and clean, and free from substances 100% coverage of mortar on the back that may not let product bond of each unit. Remove excessive properly. mortar from around the stone.
2. Verify that all electrical – plumbing, 3.3 GROUTING etc., in or behind the stone have been A. Do not begin grouting stone until stones installed before proceeding with are firmly set. installation of the stone work. B. Force the maximum amount of grout into joints using a grout bag filling all gaps and 3.2 INSTALLATION OF STONE VENEER skips. A. Maintain minimum temperature limits 1. Do not permit grout on stone face. on job site and installation practices 2. Remove surplus grout from joints by recommended by materials Mfg. raking and tooling. Sweep all areas to remove excessive material. 1. Prepare the surfaces, set, fit, group, 3. Remove mortar and haze from the and clean the work of this section in face of the stone within two hours of strict accordance with the placing. manufacturer's recommendations. 2. Spread mortar on stone's back a 3.4 CLEANING minimum of 1/2" thick. After completion of setting and grouting, 3. Press and set the stone in place using thoroughly clean stone face by sweeping. a back and forth motion to obtain Do not use acid or any cleaners.
Miscellaneous Specifications and Rule of Thumb Estimates
Stone Packaging and Ordering
1. 10 square feet of stone per box.
2. 10 lineal feet of stone corners per box.
3. Pallet size for shipping is 40"x 48"
4. 24 boxes of stone per pallet
5. Approximate weight per box is 65-70 lbs.
6. Full truckload is 24 pallets (576 boxes or 5,760 S.F.)
Sand, Mortar and Lath for Every 100 Sq. Ft.
1. Order 1 bag of Type “S” mortar for every 100 sq. ft. for scratch coat and applying stone.
Product Users Guide 6
2. Order one bag of Type “N” mortar for grouting every 100 sq. ft.
3. Each piece of metal lathe is 18 sq. feet (Each piece will cover 17 sq. feet because of overlap)
4. Order 200lbs. of sand for each bag of mortar (For mixing purposes, use 140 to 150 lbs./ per bag.)
5. One average round point shovel-full of sand is approxiamently ten pounds (These quantities are for estimating purposes only.)
TOOLS NEEDED
1. Staple Gun for attaching felt.
2. Hammer for attaching lath.
3. 12" x 4" concrete finishing trowel and mud hawk
4. 6 Cubic Foot wheel barrow for mixing mortar
5. Shovel for shoveling sand into mortar mix
6. Masonry trowel for sticking stone
7. Grout bag for filling joints
8. Tuckpointer for striking the join
9. Whisk broom for cleaning off stone
10. Mortar Hoe
11. 4' Level
12. Chalk line
Product Users Guide 7
MATERIALS REQUIRED
1. 15 LB Felt or use Paper Backed lath available from Mountain Stone (If you use Paper Backed Lath you do not need item # 3.)
2. Felt Staples
3. 2-1/2LB Galvanized Metal Lath
4. 1-3/4" roofing nails or 1" x 2" staples
5. Type “S” Mortar (scatch coat & bedding)
6. Masonry Sand
7. Clean Water
8. Type “N” Mortar (grout joints)
9. Mountain Stone
1. DETERMINING AND PREPARING THE SURFACE
Due to its light weight, Mountain Stone can be applied to any structurally sound surface (except Sheet Rock) and needs no special structural foundation alteration or additions.
Apply Mountain Stone directly to the surface of concrete, block brick, and other masonry surfaces only if the surfaces are clean and unpainted. All other surfaces must be covered with a 2.5 # Galvanized Metal Lath.
Product Users Guide 8
2. APPLYING THE BED COAT OVER LATH
(If applying stone over clean masonry surface, please skip step 2 and go to step 3.)
Mix thoroughly 1 part Type “S” mortar 1-1/2 parts clean brick sand (Approx. 12 gallons) in a 6-cubic foot wheelbarrow using your pointed shovel. Add clean water (approx. 2-1/2 gallons) to a achieve a trowelable mixture.
Use a concrete finishing trowel and spread mixture over metal lath, enough to cover lath approx. 3/8" thick. Allow to dry for 12 hours. This will provide a good backing and assure firm bonding of the stone veneer.
HELPFUL HINTS
A. WHEN USED WITH VINYL SIDING 1. Bring J channel out 1" to 1-1/2" (depending on the style of stone used) toward the face of the stone. Then install stone to within 1/2" of channel for mortar joint.
2. Corners: Install J channel back 3 inches on vinyl side of corner and cut stone corners as a return.
3. Transition piece: Use the Marietta Sill to accommodate transition from a wainscot of Stone to a vinyl siding. Set J channel directly on top of tip and caulk joint.
B. WINDOWS AND DOORS Install stone around windows first to insure proper fit. Then install stone as you normally would on the wall. (Certain applications may require flashing)
C. OUTSIDE LIGHTS 1. Mount rough-in boxes directly to wall or if box is already mounted flush, install box extensions to bring out flush with stone.
2. Outside Receptacle: Mount approved weatherproof box directly to wall where stone is to be applied. Install stone upto 1/2" from box (grout).
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3. APPLYING THE STONE
To keep the stone clean, start at top and work down. If corner pieces are used set them first for easy fitting. Keep lines level and stone level (use 4' level to check.) Stone may be trimmed by brick hammer, brick trowel, or a dry concrete blade in an electric circular saw. Using the same mixture as the bed coat, apply approx. 1/2" of mortar to the back of the stone using your point trowel, covering the entire stone. By using gentle pressure, and a slight wiggling action while applying the stone to the bed coat, you will assure a good bond. During warm weather, the bed coat may have to be sprayed with water to prevent water from being drawn too rapidly from the applying mortar; dry mortar doesn't stick well. During cold weather, follow all guidelines set forth by the Construction Masonry Institute concerning cold weather masonry. (Tip: Chalk horizontal lines every 16-24” on the scratch coat to keep joint lines & stone level.)
GROUTING JOINTS
Grouting mixture shall consist of one part Type “N” mortar to 2 parts sand, and clean water. This mixture is to be thoroughly mixed to provide a heavy cream-like consistency. This mixture is then placed in a grout bag. Snip the end to create a hole about the size of a penny. Fill the bag about half-full, twist the top and hold tight. With slight pressure from the other hand, and twisting from the top, place opening in joint and fill the joint flush with the stone. Rinse grout bag with water occasionally to keep in good working condition. Do not get mortar on any other parts of the stone. Let mortar set until firm yet workable.
FINISHING JOINT PROCEDURE
When mortar joints became firm, the use of a wooden striking tool carved just a little smaller than the joint width may be used. Press gently and smoothly as to fill grout voids and remove excess mortar to desired depth. The mortar should be firm enough not to stain stone. If the mortar is struck too quickly the joint will appear creamy – if this happens, allow some additional drying time.
BRUSHING JOINTS This should be done within 2 hours after tooling of joints. The best way is with a clean whiskbroom. Do not brush mortar wet, as it will smear and leave brush marks.
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CLEANING Never use acid or steel brush for cleaning. If mortar dripping occurs, use a clean wet sponge immediately. If severe staining occurs ask your dealer or call Mountain Stone for assistance.
SEALING Sealing is unnecessary and optional on most jobs. Ask your dealer or call our Technical Department at (270) 796-6123, for any questions about sealing.
Product Users Guide 11