12TH EDITION 09 26 13/NGC Veneer Systems 09 26 13

®

43 VENEER PLASTER SYSTEMS

Veneer plaster expands architectural design limits as with Kal-Kore boards are screwed this curved vaulted to steel studs or nailed or ceiling. screwed to wood studs to form a base. DESCRIPTION 3. High resistance to cracking, 3. Provides less rigidity than nail-popping, impact and similar standard plaster abrasion failure. systems. Veneer Plaster Systems consist 4. Mill-mixed plaster 4. When Uni-Kal/X-KALibur of a 4' wide components help ensure will be applied, do not plastering base with a uniform installation install Kal-Kore too far in special, highly absorptive performance and finished advance of plastering since paper surface that is job quality. Uni-Kal/X-KALibur bond covered with thinly ADVANTAGES - ONE-COAT can be adversely affected if troweled, special purpose SYSTEM (UNI-KAL/X-KALIBUR) face of Kal-Kore has . Two basic types become faded from light. If of veneer plaster are 1. Requires only one plastering Kal-Kore has been faded, available: Uni-Kal and material on the job. apply Kal-Kote Base Plaster X-KALibur, which are 2. Slightly lower in-place cost or a bonding agent to one-coat plaster system than two-coat system. obtain good bond. products; and Kal-Kote, a 5. All are designed for trowel two-coat plaster system. 3. Can be applied directly to block. application. Gold Bond The gypsum plaster base, Veneer Plasters are not Kal-Kore, is erected in the 4. X-KALibur is formulated suitable for conveyance or same manner for both to have extended set application by characteristics beyond systems. Both veneer conventional plastering Joints are reinforced with plaster systems can be traditional Uni-Kal setting machines. specified for virtually all times. Kal-Mesh fiberglass webbing. types of partition and 6. Compared to conventional Steel corner and casing beads ADVANTAGES - TWO-COAT plasters, Veneer Plaster protect corners. ceiling constructions SYSTEM (KAL-KOTE) including wood or steel Systems are more subject to framing or furring and 1. Kal-Kote System may be beading (ridging) and . For both used for plaster-embedded cracking at the joints under residential and commercial electric radiant heating rapid drying conditions buildings, either type of cable systems. such as those caused by veneer plaster system 2. Same application low humidity, high produces a wall more nail- techniques as for temperature and/or high pop resistant than conventional plaster. draft exposure. and, when properly 3. Greater crack resistance 7. All provide a base over installed, more crack than one-coat systems. which paints or other resistant than conventional finishes should be applied. and plaster. 4. Can be applied directly to concrete block. 8. Do not use a polyethylene ADVANTAGES - GENERAL vapor retarder unless LIMITATIONS structure is ventilated The advantages of veneer adequately during plaster over other 1. Not recommended for exterior use or where application of veneer commonly used partition plasters. and ceiling systems subject to weathering, include: direct water contact or 9. A bonding agent must be temperature exceeding applied to monolithic 1. Rapid installation which 125˚F (52˚C) for extended concrete prior to reduces overall periods of time. application of either construction time. system. Kal-Kote is applied in 2 coats, 2. Framing spacing is limited a base and a finish, to form 2. Appearance and surface of and partition heights are 10. Mix only full bags of conventional plaster at a hard-surfaced, 1/8" total reduced in comparison plaster for proper set. thickness. lower cost than regular with some standard plastering. 11. Do not use self- constructions. mesh tape.

44 NATIONAL GYPSUM VENEER PLASTER SYSTEMS Veneer Plaster System Components 09 26 13/NGC

TECHNICAL DATA

GOLD BOND® BRAND KAL-KORE PLASTER BASE Kal-Kore is a tapered edge gypsum plaster base having a blue absorptive face paper surface designed to permit rapid trowel application and strong bond of Kal-Kote, Uni-Kal and X-KALibur plasters. Also available foil backed or Fire-Shield (type X). Kal-Kore is manufactured to conform to ASTM Specification C 1396 and CSA A82.27.

GOLD BOND® BRAND HI-ABUSE KAL-KORE PLASTER BASE

Gold Bond BRAND Hi-Abuse Kal-Kore Fire-Shield Type X Plaster Base boards consist of a fire resistive Type X gypsum core encased in a heavy, blue absorptive face paper designed to permit rapid trowel application and strong bond of Uni-Kal veneer plaster and strong liner paper on the back side. Gold Bond BRAND Hi-Abuse Kal-Kore Fire-Shield Type X Plaster Base features a specially formulated core to provide fire resistance Pcs. ratings when used in tested systems as well as greater Size Thickness Edge per Bdl. resistance to surface indentation. Long edges of the 4'x8', 16' 3/8" (9.5 mm) Square 2 boards are tapered to allow joints to be reinforced and (1219 mm x 2438 mm, or concealed with Kal-Mesh Tape and Uni-Kal Plaster. 4877 mm) Tapered Gold Bond BRAND Hi-Abuse Kal-Kore Fire-Shield Type X Plaster Base is manufactured to conform to 4'x8', 16' 1/2" (12.7 mm) Square 2

ASTM Specification C 1396 and Federal Specification 09 26 13 SS-L-30D Type VI Grade X (Fire-Shield). (1219 mm x 2438 mm, 1/2" (12.7 mm) or 4877 mm) FSK-C Tapered

4'x8', 16' 5/8" (15.9 mm) FSK Square 2 (1219 mm x 2438 mm, or 4877 mm) Tapered

4'x8', 12' 1/2" (12.7 mm) Square 2 Abrasion-Resistant Uni-Kal Veneer Plaster (1219 mm x 2438 mm, 5/8” (15.9 mm) FSK or 3657 mm) Hi-Abuse Tapered

Heavy Liner Paper Enhanced Core

NATIONAL GYPSUM VENEER PLASTER SYSTEMS 45 KAL-KOTE BRAND BASE Coverage (est.)* thickness over the same PLASTER 1/16" coat troweled on Kal- framing member size and Kal-Kote Base Plaster is a Kote Base Plaster, 650-700 spacing with the same specially designed high sq. yds. per ton (145-160 fasteners and 3/32" of Uni- strength basecoat plaster sq. ft. per bag). Kal or X-KALibur. for application 1/16" Specification Reference minimum thickness over Kal-Kore, masonry or KAL-KOTE BRAND TEXTURE ASTM Designation C 587. monolithic concrete that FINISH PLASTER Bag Weight has been treated with a Kal-Kote Texture Finish is 50 lbs. (22.7 kg) bonding agent. designed to provide a Water Ratio Strength of Kal-Kote Base is variety of decorative substantially greater than surfaces using common 13-15 quarts per bag plastering techniques. that exhibited by typical Coverage (est.)* sanded basecoat plaster. Applied as a 1/16" finish coat over Kal-Kote Base. It 3/32" on Kal-Kore Base, 600- Fire Resistance requires the addition of 665 sq. yds. per ton (135- Fire ratings equivalent to water only. 150 sq. ft. per bag). One coat to level over masonry, those of drywall systems Bag Weight can be obtained by 300-350 sq. yds. per ton applying the 50 lbs. (22.7 kg) (70-80 sq. ft. per bag). corresponding Kal-Kore Water Ratio type and thickness over the 11-12 quarts per bag *Coverage estimates are same framing member size Coverage (est.)* approximately the same as and spacing, with the same over Kal-Kore Base Board fasteners. The total plaster 1/16" coat troweled on Kal- for conventional plasters. thickness should be a Kote Base Plaster, 650-700 minimum of 1/8". The sq. yds. per ton (145-160 minimum 1/8" thickness is sq. ft. per bag). achieved by applying a finish not exceeding 1/16" over 3/32" of Kal-Kote UNI-KAL AND X-KALIBUR Base Plaster. BRAND VENEER PLASTER Specification Reference Uni-Kal and X-KALibur are single component veneer ASTM Designation C 587. plasters for application Bag Weight over tapered edge 1/2” 80 lbs. (36.3 kg) Regular or 5/8” Fire-Shield Kal-Kore, 5/8” Kal-Kore Water Ratio Hi-Impact or as a finish 10-12 quarts per bag coat over Kal-Kote base. Coverage (est.) When applied in a thin coat 3/32" thick and 1/16" on Kal-Kore Base, 425- troweled to a smooth 475 sq. yds. per ton (150- finish, they provide a 170 sq. ft. per bag). One durable, abrasion-resistant coat to level over masonry, surface for further 225-275 sq. yds. per ton decoration. (80-100 sq. ft. per bag). X-KALibur has a longer KAL-KOTE BRAND SMOOTH extended working time. FINISH PLASTER Uni-Kal and X-KALibur may Kal-Kote Smooth Finish is be worked to a variety of designed to provide a textured finishes. white smooth trowel finish Uni-Kal and X-KALibur using conventional applied not exceeding plastering techniques. 1/16" may be used as a Apply not exceeding 1/16" finish coat over a 3/32" over Kal-Kote Base. coat of Kal-Kote Base Requires the addition of water Plaster for a total minimum only. It may also be used thickness of 1/8". as a finish for conventional Strength of Uni-Kal and basecoat plasters. Small X-KALibur provides a amounts of commercial surface resistant to retarder may be cautiously abrasion, cracking and used to slow the setting nail-pops. time when used over conventional basecoat Fire Resistance plasters. Fire ratings equivalent to Bag Weight those of drywall systems can be obtained by 50 lbs. (22.7 kg) applying the corresponding Water Ratio Kal-Kore type and 18-20 quarts per bag

46 NATIONAL GYPSUM VENEER PLASTER SYSTEMS Veneer Plaster Accessories* Used in Both Systems 09 26 13/NGC

KAL-KORNER BEAD E-Z STRIP® CONTROL JOINT Formed of galvanized steel to Designed for drywall or veneer protect exterior corners plaster systems. A vinyl with veneer plastering. extrusion used as an Flange length 1 1/4" . expansion or control joint for ceilings or partitions.

EXPANDED VENEER KAL-MESH TAPE CORNERBEAD A coated non-adhesive Used as an alternate to the fiberglass tape which is Kal-Korner Bead for stapled to Kal-Kore to exterior corners. 1 1/4" reinforce all joints and flanges. interior angles. 09 26 13 ARCH CORNERBEAD .093 ZINC CONTROL JOINT Can be used straight for Designed as an expansion or exterior corners or flanges, control joint for ceiling or may be snipped and and partition areas for bent to form arches. both drywall or veneer plaster systems.

VENEER J TRIM CASING 1 1/2" DRYWALL FURRING BEAD CHANNEL CLIP Used as a finished edge at Attaches Screw Furring door and window jambs Channel to 1 1/2" cold by slipping over edge of rolled steel channel. plaster base.

VENEER L TRIM CASING *Metal products are not manufactured by National Gypsum Company. BEAD Used as a finished edge at door and window jambs.

NATIONAL GYPSUM VENEER PLASTER SYSTEMS 47 FASTENERS FOR ATTACHING KAL-KORE TABLE 1–SPACING OF FRAMING OR FURRING Framing Kal-Kore Fastener Fastener Spacing Type of Maximum Steel 1/2" (12.7 mm) Type S Screws 12" o.c. Max. Framing or Kal-Kore Spacing Studs & 1" (25.4 mm) for single layer (305 mm) Furring Thickness on center Furring 5/8" (15.9 mm) 1 5/8" (41.3 mm) for two-ply Wood 3/8" (9.5 mm) *16" (406 mm) 3/8" (9.5 mm) 1 1/4" (31.8 mm) annular or Ceiling 7" o.c. 1/2" (12.7 mm) **24" (610 mm) 4d box nails** (178 mm) Max. 5/8" (15.9 mm) 24" (610 mm) Wood 1/2" (12.7 mm) 1 1/4" (31.8 mm) annular or Sidewall 8" o.c. ***Metal 3/8" (9.5 mm) N.A. Framing 5d box nails** (203 mm) Max. 1/2" (12.7 mm) 16" (406 mm) 5/8" (15.9 mm) 1 3/8" (34.9 mm) annular or 5/8" (15.9 mm) 24" (610 mm) 6d box nails** N.A.–Not Approved. **Alternate: On walls, 1 1/4" (31.8 mm) Type W screws are spaced 12" * Bound edge of Kal-Kore must be at right angles to framing for ceiling or (305 mm) when framing is 24" o.c. (610 mm) or 16" o.c. (406 mm). walls. ** Bound edge of Kal-Kore must be at right angles to joists. 16" (406 mm) maximum spacing for bound edge of Kal-Kore parallel to joists. *** On ceilings, furring channel [7/8" (22.2 mm) depth] shall span 48" (1219 mm) maximum. Resilient furring channel [1/2" (12.7 mm) depth] shall span 24" (610 mm) maximum. For greater spans, 1 5/8" (41.3 mm) Steel Studs may be used as Ceiling Furring Channels provided they are secured with flanges up (open side up) at spans not to exceed: 6' (1829 mm) at 12" o.c. (305 mm) spacing, 5'6" (1676 mm) at 16" o.c. (406 mm) spacing and 5' (1524 mm) at 24" o.c. (610 mm) spacing. Note: Veneer Plaster Systems are to be installed with maximum deflection criteria of L/240.

48 NATIONAL GYPSUM VENEER PLASTER SYSTEMS DETAILS 09 26 13/NGC

KAL-KORE WOOD STUD

KAL-MESH

WOOD STUDS

KAL-KORE KAL-KORE JOINT KAL-KOTE BASE & FINISH

KAL-KOTE KAL-KORNER BASE & FINISH BEAD KAL-MESH

CORNER-WOOD STUDS JOINT DETAIL 09215A 09215C Scale: 2 1/4" = 1'-0" Scale: 2 1/4" = 1'-0"

TRACK 5/8" FIRE-SHIELD 1/2" E-Z STRIP VINYL KAL-KORE GAP EXPANSION JOINT KAL-MESH

STEEL STUD 09 26 13

5/8" GAP

2 1/2" STEEL 1 5/8" DRYWALL SCREWS STUDS 24" O.C.

5/8" FIRE-SHIELD KAL-KORNER KAL-KORE STRIPS BEAD KAL-KORE KAL-KOTE BASE & FINISH ONE HOUR FIRE RATED CONTROL JOINT DETAIL Based on Warnock-Hersey Report No. WH-651-0318.1 CORNER-STEEL STUDS and Factory Mutual Design No. W1B-1 hr. 09215B 09215D Scale: 2 1/4" = 1'-0" Scale: 2 1/4" = 1'-0"

1-1/2" C.R. CHANNEL HANGER WIRE PIECE 16" LONG-NESTED (TWO WIRE TIES EACH SIDE)

FURRING CHANNEL 1-1/2" C.R. CHANNEL

E-Z STRIP KAL-KOTE BASE & FINISH KAL-KORE WIRE TIE EXPANSION JOINT

SUSPENDED VENEER PLASTER CONTROL JOINT 09215E

NATIONAL GYPSUM VENEER PLASTER SYSTEMS 49 RECOMMENDATIONS

VENEER PLASTER FOR each channel with concrete Avoid joining Kal-Kore at applied to metal framing. METAL AND WOOD stub nails or appropriate corners of doors, window To minimize this during FRAMING fasteners through channel frames, and other openings, these conditions, joints 1. Wood Studs or Joists. flanges into the masonry or unless control joints are may be pre-treated using Wood members shall meet concrete. Fasteners shall be created using E-Z Strip paper tape. the minimum requirements spaced on alternate flanges Control Joints. Three acceptable methods of of local building codes. not over 24" o.c. Apply 4. Fasten Kal-Kore to framing treating Kal-Kore joints are: Framing shall not exceed Kal-Kore vertically or members with face out, horizontally in maximum DRYWALL PAPER TAPE spacing shown in Table 1 using the proper type and TREATMENT METHOD on page 46. Most partition lengths to minimize end spacing of fasteners shown fire ratings require that Kal- joints. under types of fasteners. 1. Trowel Kal-Kote Base Plaster, Uni-Kal or Kore be applied vertically. 4. Furred Ceilings with Bar 5. Draw Kal-Kore tight to When such ratings are not Joists. Attach regular furring X-KALibur over joint line framing. Drive fasteners filling the channel formed required, horizontal channel 16" o.c. to bar straight and dimple the application may be used to joists spaced up to 4' o.c. by the tapered edges of the surface without breaking Kal-Kore board in an even minimize joints. For Resilient Furring Channel the paper face. ceilings, application at right (wire-tied only) shall span a . angles to framing is maximum of 24". Wire tie KAL-KORNER BEAD 2. Center drywall paper tape preferred. Furring Channel to joists or APPLICATION over the joint line and 2. Metal Studs. Align floor use 1 1/2" Drywall Furring Install Kal-Korner Bead using embed the tape into the and ceiling tracks to ensure Channel Clip for 1 1/2" appropriate fasteners soft plaster using a trowel plumb partition. Secure carrying channel. Apply spaced 12" apart. and level the joint. Tape track with appropriate Kal-Kore with paper bound the full length of the joint. edges at right angles to the E-Z STRIP CONTROL JOINT fasteners at a maximum of APPLICATION 3. Allow the treated joints to 24" o.c. Position studs in furring channel. set prior to general plaster track on specified centers ® Install E-Z Strip Control Joint KAL-KORE AND HI-ABUSE at 30' max. spacing on application. by rotating into place for a KAL-KORE APPLICATION friction fit. Secure studs walls and 50' max. spacing Note: Application shall in either direction on located adjacent to door conform to ASTM C 844. and window frames, ceilings. Apply the control partition intersections and 1. Cut and position Kal-Kore joint with staples spaced 6" corners by self-drilling accurately. Bring all joint along each side of the sheet metal screws through edges together but do not flanges. both flanges of studs and force into place. Position TREATMENT OF KAL-KORE tracks or by use of steel all end joints over framing JOINTS members. To avoid ridging, stud clinching tool. Apply Pre-treat all joints and Kal-Kore vertically for most minimize gaps between adjacent boards. fasteners in Kal-Kote and fire ratings. When ratings Uni-Kal Plaster Systems are not required, horizontal 2. Minimize the number with Kal-Kote Base Plaster, application may be used to of end joints by using Uni-Kal, X-KALibur or Sta- minimize joints. maximum practical lengths Smooth . with proper positioning. 3. Masonry Wall Furring with Low humidity, high Screw Furring Channel. 3. Stagger joints so that they temperatures and rapidly Attach furring channel occur on different framing circulating air can cause vertically spaced not to members and will not be cracking of plaster and joint exceed spacing shown in directly opposite one beading when Kal-Kore is Table 1 on page 44. Fasten another on partitions.

Uni-Kal or Kal-Kote Smooth Finish Kal-Kote Texture Finish X-KALibur Finish

Kal-Kote Base Kal-Kote Base

Kal-Kore Plaster Base Kal-Kore Plaster Base Kal-Kore Plaster Base

50 NATIONAL GYPSUM VENEER PLASTER SYSTEMS 09 26 13/NGC

STA-SMOOTH PAPER TAPE guard against dryouts TREATMENT METHOD (primarily avoiding direct 1. Mix Sta-Smooth Compound exposure to concentrated per instructions on sources of heat and drafts.) package. Do not Special attention should also contaminate the compound be given to temperature with other materials, dirty conditions under which the water or previous mixes. system is installed. Both Do not retemper. “in-place” and application 2. Apply the Sta-Smooth performance of individual Compound to the joint by Veneer System components hand or machine tool. The will be greatly enhanced if drywall paper tape must be all construction areas and centered over the joint line materials are at a suitable and embedded into the soft temperature equilibrium compound. Do not over- before, during and after installations. During cold C. Caution is advised against for the finish plaster when trowel to a slick surface. mixing more than two necessary. Leave the surface rough to weather, maintain a temperature 55˚F (13˚C) to successive batches without Smooth Finish Over Basecoat provide mechanical keying thorough equipment clean- of the plaster. 70˚F (21˚C) before, during 1. Apply only over properly and after installation of all up to avoid undue set 3. Allow the treated joints to acceleration. prepared Kal-Kote basecoat system components until plaster. Scratch-in tightly, set and dry prior to general veneer plaster has dried. D. Avoid the practice of plastering. then double back with MIXING mixing partial bags since material from the same KAL-MESH TREATMENT this leads to difficulty in Equipment: Mixing should be batch immediately to METHOD maintaining uniform create a uniform coat not done with a high-speed material qualities. Do not use self-adhering mechanical mixer. A exceeding 1/16" in average mesh. paddle-type agitator fitted JOB SETTING ADJUSTMENT thickness. 1. Center and secure Kal- to a 500-600 RPM heavy 1. Basecoat and Finish 2. Remove trowel marks, “cat Mesh over all joints and duty, 1/2" electric drill and Plasters: Small amounts of faces,” and other major interior angles with 1/4" or a clean, smooth-sided commercial retarder or surface imperfections by 09 26 13 5/16" staples. drum of convenient size commercial gypsum type “drawing-up” or “laying 2. Position staples a maximum are recommended for accelerator may be down” the surface with of 24" apart as follows: rapid, efficient mixing of all cautiously used to adjust light trowel pressure when Kal-Kote Plaster types. setting time when extreme plaster has stiffened. A. Joints: at alternate edges conditions demand. When for the run from end to end Water Ratios: Use only clean, Use water sparingly if needed, fresh water suitable for commercial retarder or but do not over-trowel or and directly opposite one accelerator is used, add to another at either end. human consumption. over-water because this Basecoat: 10-12 qts. per 80 mixing water directly, or in aggravates any normal B. Angles: along ceiling lb. bag. Smooth Finish: 18- previously prepared water tendency for blistering edge only for wall-to- 20 qts. per 50 lb. bag. solution form to obtain the when working over low ceiling angles. Along one Texture Finish: 11-12 qts. most uniform effect. suction bases. Such edge for wall-to-wall per 50 lb. bag. Uni-Kal and 2. Never use gauging or blistering will be eliminated angles. X-KALibur: 13-15 qts. per moulding plasters in place by the final water-troweling 3. After the first staples are 50 lb. bag. of commercial accelerator operations. placed at the end of a joint PROCEDURE since they can adversely 3. Water-trowel to densify or angle, pull unstapled affect working qualities. and polish the surface to Kal-Mesh as stapling 1. Put all but 1 to 2 qts. of the the desired degree when proceeds to ensure that proper water volume in a KAL-KOTE APPLICATION OVER KAL-KORE plaster has set, eliminating it will lie flat against the suitable mixing drum. any blistering if present. Kal-Kore. Note: Starting with an Basecoat Over Kal-Kore Never use a felt “blister 4. Pre-treat all joints and Kal- insufficient amount of 1. Tightly scratch material into brush” as a substitute for Beads with Kal-Kote, Uni- mixing water will seriously previously treated joints water troweling! Kal or X-KALibur Plaster. degrade mixing and and cornerbeads, then 4. Uni-Kal and X-KALibur Tightly trowel over joint application performance. immediately scratch-in Plaster may be substituted line in both directions to 2. Add plaster and allow to tightly over the wall and/or for Kal-Kote Smooth Finish. prevent voids, feathering ceiling area. soak for about 1 minute or Texture Finish Over Basecoat to a maximum width of add plaster as mixer is 2. Double back over the area about 6". turning, then mix until just troweled with material 1. Apply per (1) under Smooth 5. Allow the treated joints to uniformly wetted. from the same batch, Finish. set prior to general plaster 3. Add remaining water and bringing total thickness up 2. When plaster has stiffened, application. mix sufficiently to obtain to 1/16" minimum. float its surface to any desired finish. PLASTERING desired lump-free material 3. When plaster has “taken fluidity. up,” eliminate excessive Do not float the soft surface Note: Application shall Note: trowel marks and fill all of plaster which has conform to ASTM C 843. surface voids and already set. A. Mixing periods greater The same general job imperfections to obtain a Up to equal parts by weight of conditions used in good than 5 minutes will not reasonably uniform surface. be required if proper clean, graded silica sand conventional plastering Do not over-trowel to a may be added to Uni-Kal practice should be equipment and procedure slick surface. Roughen the are used. and X-KALibur to aid maintained. However, unset basecoat plaster texturing. because Veneer Plaster B. Mix no more than two bags surface with a serrated coats are thin, particular per batch to avoid mixing darby or lightly wire rake to action must be taken to too far in advance of provide mechanical keying application. NATIONAL GYPSUM VENEER PLASTER SYSTEMS 51 APPLICATION PROCEDURES Smooth or Textured Finishes Note: Application shall Apply finishes to the Kal-Kote conform to ASTM C 843. Plaster as outlined under Kal-Kote Base Application the regular Kal-Kote System Over Bonding Agent as described on page 49. 1. First straighten any major Uni-Kal or X-KALibur surface irregularities, such Application Over Bonding as holes, ridges, wavy Agent sections, etc. Scratch 1. First straighten any major plaster in tightly by trowel surface irregularities such and fill out to any adjacent as holes, ridges, wavy level area. sections, etc. Scratch 2. After the straightening plaster in tightly by trowel material has set, trowel in a and fill out to any adjacent tight scratch coat over the level area. entire area to be plastered; 2. Allow the straightening then immediately double material to set. back with material from the 3. Tightly scratch material in same batch to minimum over the wall and/or ceiling thickness of 1/16" or as area. This application required to achieve a level should be about 1/16" surface. Use a rod or thick. Double back over feather edge if needed. the area just troweled with 3. When plaster has “taken material from the same up,” eliminate excessive batch, bringing total trowel marks and fill all thickness up to 3/32" surface voids and minimum. imperfections to obtain a 4. Begin finish troweling at reasonably uniform surface. time of initial set, using Do not trowel to a slick water sparingly. Final surface. Roughen the unset UNI-KAL OR X-KALIBUR VENEER PLASTERS DIRECT troweling must be basecoat plaster surface accomplished before APPLICATION OVER TO BOND-COATED with a serrated darby or KAL-KORE MONOLITHIC CONCRETE complete set takes place, as lightly wire rake to provide evidenced by darkening of 1. Tightly scratch material into DESCRIPTION mechanical keying for the the surface. previously treated joints finish plaster when The Kal-Kote System, necessary. and cornerbeads, then consisting of a basecoat immediately scratch-in plaster and a finish coat tightly over the wall and/or plaster, Uni-Kal or ceiling area. X-KALibur may be applied 2. Double back over the area directly to monolithic just troweled with material concrete treated with a from the same batch bonding agent. bringing total thickness up to 3/32" minimum. LIMITATIONS 3. Begin finish troweling at 1. Surface to be plastered shall time of initial set, using be treated with a bonding water sparingly. Final agent applied according to troweling must be manufacturer’s directions. accomplished before The performance of this complete set takes place, as system is the sole evidenced by darkening of responsibility of the the surface. bonding agent manufacturer. Note: Uni-Kal or X-KALibur may be applied to produce 2. Concrete should be aged a textured finish. at least one month prior to plastering. A. When Uni-Kal or X-KALibur is mixed, add 3. Kal-Kote Smooth or up to but not exceeding Texture Finishes are not 50 lbs. of silica sand, designed for direct texturing grade, per application to concrete, 50 lb. bag of plaster. but must first have Kal- Kote Base Plaster applied B. The sanded Uni-Kal or to fill and level surface. X-KALibur mix should be scratched-in tightly 4. Do not apply system to the over the plastering base. interior side of exterior Immediately double walls below grade. To use back over the area just above grade these walls troweled with material shall be kept dry and shall from the same batch. have been properly waterproofed on the Veneer plaster performs well C. When plaster is well exterior side to prevent in high traffic areas such as taken up, float to the water penetration. stairways and halls. desired texture finish.

52 NATIONAL GYPSUM VENEER PLASTER SYSTEMS 09 26 13/NGC

Veneer plaster walls are particularly suited to accommodate The Veneer plaster wall system is particularly suited to wall situations where light conditions require smooth, even residential and commercial construction in areas which need expanses of wall. strength for special architectural details, and unusual design elements.

VENEER PLASTERS DIRECT KAL-KOTE APPLICATION and Uni-Kal or X-KALibur 09 26 13 TO UNIT MASONRY Note: Application shall Veneer Plaster Systems. DESCRIPTION conform to ASTM C 843. The Z Furring Channel is manufactured from The Kal-Kote System, Proceed with the full field of galvanized steel (.0179" consisting of a basecoat the wall by scratching-in min. base steel) and is plaster and a finish coat tightly, then double back produced with web depths plaster, Uni-Kal or immediately with material of 1", 1 1/2" and 2". The X-KALibur, the one-coat from the same batch to a furring channel which is system, may be applied minimum thickness of applied to a masonry wall directly to masonry surfaces 1/16" over the block holds the insulation in providing the following surface, or as required to place and the wide flange recommendations are level. serves as framing for the followed. Kal-Kote Finishes should be application of the Kal-Kore RECOMMENDATIONS kept as thin as possible and plastering base. applied as described on 1. Surface must be free from page 44 and 51. LIMITATIONS dirt, grease, oil, mold, 1. Since the interior wall parting agents, or any UNI-KAL OR X-KALIBUR surface will take the material which will prevent APPLICATION general configuration of the plaster adhesion. Proceed with full field of the masonry wall, it may be 2. When erecting masonry, wall by scratching-in necessary when applying strike joints flush. If tightly, then double back the system to unit masonry masonry has recessed immediately with same to use joints, fill joints flush to batch of material to a plaster to bring the wall to masonry surface with minimum thickness of a plane surface. basecoat plaster, Uni-Kal or 3/32" over the block 2. This system is mainly for X-KALibur and allow to set. surface. new masonry construction. EXTERIOR CORNERS Caution: Since Uni-Kal On well-cured concrete or or X-KALibur is a one-coat masonry, it may be difficult Install cornerbead with material system, exercise to properly drive fasteners. adhesive at least 4 and care in leveling the wall to preferably 16 hours before 3. Power-driven fasteners compensate for the uneven shall be used only for plastering. Apply a suction. continuous bead of attachment to monolithic adhesive approximately VENEER SYSTEMS APPLIED concrete surfaces. 1/4" x 1/4" along the inside TO MASONRY WITH Z 4. Kal-Kore should be applied of both cornerbead flanges. FURRING CHANNEL within 24 hours of foam Press the bead firmly over SYSTEM application. the corner so that adhesive DESCRIPTION is in continuous contact with masonry surface. This system consists of a Align bead and allow to Z Furring Channel, rigid stand undisturbed at least insulation and the 4 hours. components of the Kal-Kote

NATIONAL GYPSUM VENEER PLASTER SYSTEMS 53 Design flexibility is achieved with veneer plaster systems.

APPLICATION PROCEDURES to-ceiling insulation, wider PLASTER STORAGE 1. Begin application of than insulation thickness, Various job conditions such as Gypsum plaster must be kept Z Furring members by but not exceeding 3". suction differences, wet or dry before use. Storage positioning first channel Continue application of only partially dry walls, and conditions vary with vertically at a corner, furring and insulation reactions between paint and location and seasonal locating it on the wall progressively as described may cause unsatisfactory changes, which may affect adjacent to the wall being above. paint finishes, particularly storage life. These insulated first. At windows, doors and trim on new construction. conditions may affect The insulation thickness areas, use wood nailers, Alkali-resistant primers product characteristics such determines the distance of nominal 2" wide x specifically formulated for as setting time, working Z Furring web from wall insulation thickness plus use over new plaster will qualities, component being insulated. At the 1/32". Use the nailers also permit decorating with oil separation, or lumping, etc. appropriate distance, with at wall-floor angles to or latex type paints. Quality Such aging is normally a wide flange pointing support trim and provide paint products should be function of exposure to toward applicator, secure backing for base. used and manufacturers’ humid air, temperature, Z Channel with appropriate 2. Apply Kal-Kore to the recommendations and physical support in fasteners, spaced 24" o.c. flanges of Z Channel with followed. Finished plaster warehousing. Adverse driven through short flange. 1" Type S screws spaced should be painted or storage conditions or (Note: Power-driven 12" o.c. Normally, vertical covered to conceal prolonged storage may fasteners are not application of Kal-Kore is possible discoloration. The affect the working qualities recommended for use recommended; however, paint system should be of the product. Rotate with masonry block.) for installations 8' or less in suitable for use over plaster inventory frequently for best results. Install 24" wide floor-to- height, horizontal surfaces that contain lime, ceiling insulation board, application may be which has a high pH of 10- pressed snugly against web preferred since the number 13. of first Z. Install next Z with of joints would be reduced. It is essential that plaster be the wide flange 3. Apply Kal-Mesh and Kal- sound and completely dry overlapping the edge of the Korner Bead according to before painting. Under first insulation board. procedures described on good drying conditions, Fasten Z to wall through page 50 and 51. veneer plaster may be narrow flange. Continue in 4. Mix and trowel on Kal-Kote painted 48 hours after this manner with Z Furring Base and Finish Plaster or application. member 24" o.c. to end of Uni-Kal Plaster as High build, heavy duty and wall. Locate last Z so that described on pages 46, 51 special purpose coatings web is located a distance and 52. such as Epoxy are not equal to insulation recommended over veneer thickness from adjoining or job gauged lime putty wall. Cut last insulation finishes. board to fit remaining space. In all cases, the paint manufacturer should be At exterior corner, attach the Z consulted and approve through its wide flange with paint system suitability for narrow flange extending use with gypsum/lime beyond the corner. Begin finish plaster. with a narrow strip of floor-

54 NATIONAL GYPSUM VENEER PLASTER SYSTEMS 09 26 13/NGC INSTALLATION KAL-KORNER BEAD

KAL-MESH KAL-MESH

KAL-KOTE FINISH (Smooth or Texture)

KAL-KOTE BASE

KAL-MESH 09 26 13

KAL-KORE FOR USE WITH WOOD STUDS KAL-KORNER OR METAL STEEL STUDS BEAD

1" X 4" T& G FINISH FLOOR OR 5/8" T& G PLYWOOD 1" X 6" SUBFLOOR OR 1/2” PLYWOOD 1" X 4" BRIDGING

2" X 10" WOOD JOISTS 16" O.C.

KAL-MESH

1" TYPE S SCREWS R.F. CHANNEL 24" O.C. 12" O.C.

KAL-KOTE BASE

1/2" FIRE-SHIELD C KAL-KORE KAL-KOTE FINISH (Smooth or Texture) U.L. DESIGN L515

NATIONAL GYPSUM VENEER PLASTER SYSTEMS 55 SPECIFICATIONS

SECTION 09 26 13 VENEER PLASTER THE FOLLOWING PARAGRAPHS ARE FOR INSERTION INTO SECTIONS OF GENERIC SPECIFICATIONS OR GENERIC/PROPRIETARY SPECIFICATIONS COVERING VENEER PLASTER PRODUCTS. THE NATIONAL GYPSUM COMPANY PRODUCT NAME FOLLOWS THE GENERIC DESCRIPTION IN PARENTHESES. PART 1 GENERAL 5. Fire Resistant, Abuse Resistant: A gypsum core lathing board 1.02 REFERENCES with additives to enhance fire and impact resistance and surfaced with absorptive paper on front and long edges with A. American Society for Testing and Materials (ASTM): heavy liner paper bonded to the back side; and complying 1. C 587, Specification for Gypsum Veneer Plaster. with ASTM C 1396, Type X (Hi-Abuse BRAND Kal-Kore Fire- 2. C 1396, Specification for Gypsum Board (Gypsum Shield Plaster Base). Base for Veneer Plaster). a. Thickness: 5/8" 3. C 843, Specification for Application of Gypsum Veneer b. Width: 4' Plaster. c. Length: 8' through 12' d. Edges: Tapered 4. C 844, Specification for Application of Gypsum Base to Receive Gypsum Veneer Plaster. B. Gypsum Plaster: 1. Base Plaster: High strength gypsum plaster complying with ASTM C 587 (Kal-Kote BRAND Base Coat Plaster). PART 2 PRODUCTS 2. Finish Plaster: Gypsum plaster for smooth finish 2.01 MANUFACTURER complying with ASTM C 587 (Kal-Kote BRAND Smooth A. National Gypsum Company Finish Plaster). 2.02 MATERIALS 3. Finish Plaster: Gypsum plaster for textured finish A. Veneer Plaster Base: complying with ASTM C 587 (Kal-Kote BRAND Texture Finish Plaster). 1. Regular: A gypsum core lathing board surfaced with absorptive paper on front, and long edges and IF TEXTURED FINISH IS SPECIFIED FOR BELOW, SAND MAY BE REQUIRED. complying with ASTM C 1396 (Gold Bond BRAND 4. One Coat Plaster: Gypsum plaster for single component Kal-Kore Plaster Base). application complying with ASTM C 587 (Uni-Kal BRAND a. Thickness: 3/8" or 1/2" Veneer Plaster). b. Width: 4' 5. One Coat Plaster: Extended set gypsum plaster for single c. Length: 8' through 16' component application complying with ASTM C 587 d. Edges: Tapered (X-KALibur BRAND Veneer Plaster). 2. Fire-Resistant: A gypsum core lathing board with additives to enhance the fire resistance of the core and PART 3 EXECUTION surfaced with absorptive paper on front, and long edges and complying with ASTM C 1396, Type X. 3.01 INSTALLATION A. In accordance with the manufacturer’s recommendations, a. Thickness: 1/2" (Gold Bond BRAND Kal-Kore Fire- National Gypsum Company “Gypsum Construction Shield C Plaster Base) or 5/8" (Gold Bond BRAND Kal- Kore Fire-Shield and Fire Shield C Plaster Base). Guide,” and the following standards: b. Width: 4' 1. Gypsum plaster base and accessories in accordance c. Length: 8' through 16' with ASTM C 844. d. Edges: Tapered 2. Gypsum veneer plaster in accordance with ASTM 3. Regular, Foil-Backed: A gypsum core lathing board C 843. surfaced with absorptive paper on front, and long edges; B. Tolerances: For flatness of surface, do not exceed 1/4" in backed with aluminum foil; and complying with ASTM 8' for bow or warp of surface and for plumb and level. C 1396 (Gold Bond BRAND Kal-Kore Foil-Back Plaster Base). a. Thickness: 1/2" b. Width: 4' c. Length: 8' through 16' d. Edges: Tapered 4. Regular, Abuse-Resistance: A gypsum core lathing board with additives to enhance impact resistance and surfaced with absorptive paper on front and long edges with heavy liner paper bonded to the back side; and complying with ASTM C 1396 (Gold Bond BRAND Hi- Abuse Kal-Kore Plaster Base). a. Thickness: 1/2" b. Width: 4' c. Length: 8' through 12' d. Edges: Tapered

56 NATIONAL GYPSUM VENEER PLASTER SYSTEMS