Submittal Package 565 Airport Drive Mansfield, TX 76063 817-477-5061 Office 817-473-4734 Fax

JCF Companies, LLC. Cast Stone Division

Submittal Package 565 Airport Drive Mansfield, TX 76063 817-477-5061 office 817-473-4734 fax www.jcfcompanies.com

Johnson County Foam, Inc. Cast Stone Division 565 Airport Drive Mansfield, TX 76063 817-477-5061

In our submittal package, you will find the following information. If you would like to know more about Johnson County Foam, Inc., please visit our website at www.jcfcomapnies.com.

1. Statement of Qualifications

2. JCF Portfolio

3. Independent Testing

a. Compressive Strength ASTM – C1194

b. Absorption Testing ASTM – C1195

c. Freeze Thaw Testing ASTM – C666

d. Particle Size Analysis ASTM – C136

4. Material Safety Data Sheet

5. Raw Material Product Data

a. Product Data for Johnson County Foam, Inc. - Cast Stone Division

b. Portland Cement ASTM – C150 / Mill Certificate

c. Reinforcement Inspection Certificate / Mill Certificate ASTM – A615/A615M

d. Inorganic Iron Oxide Pigment ASTM – C979

6. Technical Bulletins

a. Jobsite Handling & Installation

b. Cleaning: Care & Maintenance

c. LEEDS Information

7. Cast Stone Gallery

Please visit us at

www.JCFCompanies.com

Statement of Qualifications

Thank you for your time and consideration of Johnson County Foam, Inc. as your suppliers. We strive for excellence in customer service and the highest quality in our cast stone materials.

Our Cast Stone department is a one-stop shop that provides the following services;

· Estimating Services: Our estimating department uses your plans to identify all the places on your project that cast stone products might be used. Our estimating department will also make sure your cast stone is created in the most cost efficient and timely manner.

· Design Consultation: We will help you review and confirm the design details using AutoCAD, ReVu or other software tools to enhance your designs, reduce cost and increase speed of delivery. We will help in selecting and combining different materials for optimum design with seamless color matching.

· Drafting Services: Whether you need a quick simple drawing, a full set of submittal drawings or detailed setting plans. JCF has onsite draftsman available.

· Custom Color Matching: Choose from Standard JCF colors; Sugar Cane, Biscuit, Raw Hide, Canyon, Slate, or Lueders or JCF is able to develop any custom color with a control sample.

· Custom Shapes & Sizes: Choose from Standard JCF shapes or Let JCF help you customize any shape you can imagine.

· Pattern/Mold Making Services: Here at JCF, we have a large arsenal of tools that make even your most complex projects seem simple. We can digitally scan any object in 3D to a very precise model. Then scale the object to any size and have it cut using one of our two 5 axis machines or our 3 axis water jet. We can make any size, shape, or profile. Not only do we make all standard items, but also ANYTHING custom you can imagine.

· Shipping: Every stone is palletized on a hardwood pallet and protected with 3/4 ” sheets of foam in between each stone to cushion stress points. Each pallet is stacked in a manner to ensure weight balance and support normal impacts through shipping transit. Layers of stretch wrap are applied until the stone is completely wrapped and secure. This ensures your stone gets to the project site undamaged.

JCF Portfolio

We started Johnson County Foam 30 years in our backyard in a little building we called the bunkhouse. We are now a 60,000 square foot production powerhouse. We make literally TONS of residential and commercial foam trim, but that’s not all we do. We can make any standard or custom shape out of a variety of materials. We design and manufacture molds for precast stone, precast concrete, lightweight stone, fiberglass, rubber, and so much more. Our machinery allows us to be extremely precise.

We do 3D scanning, 3D printing and laser scanning. We have a 3-axis water jet that will cut rubber, paper, plastic, wood, fiberglass, and metal up to 2″ thick! We make stage props, statues, and sculptures in 3D. Lots of them. Any size. We machine them, plastic coat them, and get them ready for either end use or a mold.

We are fast, efficient, and affordable. We are experienced in large art projects with museums and set pieces. We have a full fab shop that allows us to build any kind of steel structure in house. We can then wrap that in foam and have it delivered and assembled at your location. We don’t waste anything at Johnson County Foam. We recycle it all. We love our planet and want to leave it better than we found it. This also helps keep your costs down.

Construction Testing Sciences 2978 Congressman LN. Dallas, TX 75220 Phone: 214.789.3472 www.ctsciences.com Report of Compressive Strength and Absorption

Client: Johnson County Cast Stone Report No.: 13448 Project: Quality Control Testing Date of Service: 07/17/19 Project No: 101390 Report Date: 07/18/19

Sample ID: JCF Manufacture Date: 6/19/2019 ASTM C 1194, Compressive Strength of Architectural Cast Stone

Width Width Area Compressive Strength Sample No. Load (lbf) (in.) (in.) (Sq. In.) (PSI) 1 2.00 2.02 4.04 53,620 13,270 2 2.01 1.99 4.00 51,270 12,820 3 2.01 2.00 4.02 50,480 12,560 Average 12,880

ASTM C 1195, Absorption of Architectural Cast Stone

Oven Dry SSD Absorption Sample ID Weight Weight (percent) (g) (g) A 291.85 305.65 4.73 B 289.93 304.70 5.09 C 292.63 307.22 4.99 Average 4.94

Technician: J.Halverson

Jack Gary, General Manager

LIMITATIONS: The test results presented herein were prepared based upon the specific samples provided for testing. We assume no responsibility for variation in quality (composition, appearance, performance, etc.) or any other feature of similar subject matter provided by persons or conditions over which we have no control. Our letters and reports are for the exclusive use of the clients to whom they are addressed and shall not be reproduced except in full without the written approval of Construction Testing Sciences, LLC. ASTM C666/C666M-15 Test Report Job No.: 18-386-1B Standard Test Method for Resistance of Report Date: 10/12/2018 Concrete to Rapid Freezing and Thawing

Client: Johnson County Foam Inc. Testing Agency: National Concrete Masonry Association Address: 565 Airport Dr. Research and Development Laboratory Mansfield, TX 76063 Address: 13750 Sunrise Valley Drive Herndon, VA 20171-4662

Unit Specification: ASTM C1364-17 Sampling Party: Cast Stone Institute

Unit Designation/Description: Date Samples Received: 6/27/2018 Architectural Cast Stone Date of Casting: 5/22/2018

Mark: 'ID # 52218-AG-1' Date Testing Began: 7/23/2018 Age of Specimen at Start of Testing: 62 days Test Specimen Dimensions: 3 x 4 x 16 in. Specimen Sample Location: Bottom molded horizontal surface of the test sample

The client delivered one 5 x 18 x 18 inch sample piece of architectural cast stone for testing. (3) - 3 x 4 x 16 inch freeze-thaw durability specimens were extracted for testing. Speciments were tested in accordance with Procedure A, outlined in ASTM C666/C666M-15. Reported values of cumulative percent weight loss are provided as modified by ASTM C1364-17.

Test Media: WATER Calculated Received Oven-Dry Unit Weight, Initial Wt. No. (g) (g) 1c 6992.5 6783.1 2c 6885.9 6686.9 Note: Initial weight calculated as sum of final oven-dry weight of 3c 6937.9 6731.9 specimen plus oven-dry weight of all collected residue.

Accumulative Residue Weight (g) Unit No. Cycle No.: 0 30 60 90 120 150 180 210 240 270 300 1c 0.0 2.5 4.5 5.7 7.7 9.4 11.4 13.0 15.4 18.6 21.5 2c 0.0 1.7 3.2 4.7 6.1 8.3 10.9 14.1 17.9 22.0 28.6 3c 0.0 2.1 3.9 5.5 7.6 9.6 11.9 14.8 18.6 22.5 26.4

Cumulative Percent Mass Loss (%) Unit No. Cycle No.: 0 30 60 90 120 150 180 210 240 270 300 1c 0 0.0 0.1 0.1 0.1 0.1 0.2 0.2 0.2 0.3 0.3 2c 0 0.0 0.0 0.1 0.1 0.1 0.2 0.2 0.3 0.3 0.4 3c 0 0.0 0.1 0.1 0.1 0.1 0.2 0.2 0.3 0.3 0.4

Weight Loss for Each Specimen

5 4.5 4 3.5 3 1c 2.5 2c 2 1.5 Weight Loss (%) Loss Weight 3c 1 0.5 0 0 50 100 150 200 250 300

Number of Freeze-Thaw Cycles

Comments: 1) These units comply with freeze thaw durability requirement of ASTM C1364-17 for architectural cast stone. That criterion requires that the cumulative percent mass loss (CPWL) is less that 5% after 300 cycles of freezing and thawing.

Douglas H. Ross Jason J. Thompson Manager, Research and Development Laboratory Vice President of Engineering

Form TR-C666-01 Revised 6/5/2018 Page 1 of 1 ASTM C426-16 Test Report Job No.: 18-386-1C Linear Drying Shrinkage of Concrete Masonry Units Report Date: 10/12/2018

Unit Specification: ASTM C1364-17 Sampling Party: Johnson County Foam Inc.

Unit Size and Description: Date Samples Received: 6/27/2018 Architectural Cast Stone Date Testing Started: 9/13/2018 Mark: 'ID # 52218-AG-1'

Shrinkage beams were saw-cut from submitted specimen for the purpose of testing in accordance with ASTM C426-16.

Each reported value represents an average of calculated shrinkage values from measurements taken on each of two sides of the three specimens.

Unit #1 Unit #2 Unit #3 Average Linear Linear Linear Linear Drying Drying Drying Drying Weight Shrinkage Weight Shrinkage Weight Shrinkage Weight Shrinkage (lbs) (%) (lbs) (%) (lbs) (%) (lbs) (%)

Saturated 6.45 --- 6.24 --- 6.57 --- 6.42 --- 5 Days 6.19 0.036 5.98 0.035 6.31 0.034 6.16 0.035 7 Days 6.17 0.043 5.96 0.021 6.29 0.040 6.14 0.035 9 Days 6.16 0.049 5.95 0.048 6.27 0.047 6.13 0.048 11 Days 6.15 0.054 5.95 0.052 6.26 0.052 6.12 0.053 13 Days 6.15 0.053 5.94 0.053 6.26 0.052 6.12 0.053 15 Days 6.15 0.057 5.94 0.055 6.26 0.056 6.12 0.056 17 Days 6.15 0.060 5.94 0.058 6.26 0.059 6.11 0.059 19 Days 6.15 0.061 5.94 0.059 6.26 0.060 6.11 0.060 21 Days 6.14 0.061 5.93 0.060 6.25 0.059 6.11 0.060 23 Days 6.14 0.060 5.94 0.060 6.25 0.059 6.11 0.060

Final Linear Drying Shrinkage, S (%) Unit #1 Unit #2 Unit #3 Average 0.061 0.060 0.059 0.060

Note: Final linear drying shrinkage, S, is calculated by averaging the final length measurement at equilibrium with the 0.080 previous two measurements for each 0.070 specimen. 0.060 0.050 0.040 0.030 0.020

Drying Drying Shrinkage(%) 0.010 0.000 0 5 10 15 20 Drying Time (days)

Douglas H. Ross Jason J. Thompson Manager, Research and Development Laboratory Vice President of Engineering

Form TR-C426-01 Revised 12/7/2017 Page 1 of 1 Johnson County Foam Cast Stone Division 565 Airport Drive Mansfield, TX 76063 817-477-5061

MATERIAL SAFETY DATA SHEET

The information provided within was obtained from authoritative sources and is believed to be accurate for the manner in which the product is intended to be used. Any other uses could result in consequences which are not considered within this document.

SECTION 1 – IDENTITY

Product Name: Cast Stone Architectural Products

Chemical Family: Does not apply Chemical Name: Does not apply

Trade Name & Synonyms: Cast Stone Architectural Products Architectural Precast Products Precast Concrete Products

Formula: Mixture of Coarse and Fine Aggregates, Portland Cement and Water.

SECTION 2 – HAZARDOUS INGREDIENTS

Hazardous Component CAS# % (wt) TLV PEL Sand (quartz) 14808-60-7 0.1 mg/m3 Portland Cement 65997-15-1 10 mg/m3 15 mg/m3 Limestone 1317-65-3 10 mg/m3

SECTION 3 – PHYSICAL DATA

Boiling Point: Specific Gravity (H2O=1): Vapor Pressure (mm mg): Does not apply 2.6-2.71 Does not apply Percent Volatile by Volume (%): Vapor Density (AIR = 1): Evaporation Rate (=1): 0 Does not apply Does not apply Solubility in Water: Reactivity in Water: Appearance and Odor: Will not evolve flammable or toxic Solid, Stone-like in appearance and Insoluble gases normally odorless

SECTION 4 – FIRE AND EXPLOSION DATA

Flash Point: Flammable Limits in Air (% by Volume): Lower: Does not apply Will not ignite Upper: Does not apply Extinguishing Media: Auto Ignition Temperature: Does not apply Does not apply Unusual Fire & Explosion Hazards: Special Fire Fighting Procedures: None None

SECTION 5 – HEALTH INFORMATION

Primary Routes of Exposure: Inhalation, Skin Contact

Signs and Symptons of Exposure:

1. Acute Overexposure: Dusts from this product may cause irritation of the skin, eyes, or nasal passages. Contact of skin or eyes with wet dusts may result in irrataion and/or alkali burns.

2. Chronic Overexposure: Excessive exposure to ducts by inhalation over an extended period of time may result in the development of pulmonary diseases including pneumoconiosis and silicosis. A significant incidence of carcinomas of the lung was induced in rats exposed to quartz dusts. Studies indicate lung cancer occurs more frequently amoung silicotics than in the general population.

Chemical/Component Listed as (Potential) Carcinogen: Quartz

NTP: _____ Yes __X__ No

IARC: __X__ Yes _____ No

OSHA: _____ Yes __X__ No

Other Exposure Limits: None

Emergency & First Aid Procedures:

1. Inhalation: Remove from exposure. If not breating, give artificial respiration. If breathing is difficult, give oxygen. Consult a physician.

2. Eye Contact: Immediately flush eyes with large amount of water for at least 15 minutes. Consult a physician.

3. Skin Contact: Immediately wash skin thoroughly with soap and water.

SECTION 6 – REACTIVITY DATA

Stability: Conditions to Avoid: Stable Does not apply Incompatibility (Materials to Avoid): Dust from product is highly alkaline. Contact with strong acids may produce a violent, exothermic reaction and may evolve toxic gases or vapors, depending on the acid involved. Hazardous Decomposition Products: Thermal decomposition may produce oxides of carbon, oxides of silica, and other toxic organic agents. Hazardous Polymerization: Conditions to Avoid: Will not occur Does not apply

SECTION 7 – SPILL OR LEAK PROCEDURES

Steps to be Taken in Case Material is Leaked or Spilled:

Clean-up of dust may require personal protective equipment to prevent dust exposure and protect against alkali burns or irrataion. See Section 8 for more information.

Waste Disposal Method:

If this material, as provided by the manufaturer, becomes a waste, it does not meet the criteria of a hazardous waste as defined by the Environmental Protection Agency under the authority of the Resource Conservation and Recovery Act (40 CFR 261). Dispose of in accorance with Federial, State, and Local Regulations.

SECTION 8 – PERSONAL PROTECTION INFORMATION

Respiratory Protection: NIOSH/MSHA approved dust respirators for conditions where dust levels exceed or are likely to exceed approximate exposure limits.

Ventilation: General or local exhaust to maintain exposure below TLV/PEL.

Protective Gloves: Rubber, PVC, Neoprene, or other impervious material.

Eye Protection: Goggles

Other Protective Clothing or Equipment: Rubber high top boots, arm sleeves and apron, when necessary to prevent skin contact with dusts from this product

SECTION 9 – SPECIAL PRECAUTIONS

Precautions to be Taken in Handling & Storing:

This product is included in the definition of an “Article” as described in the Hazard Communication Standard (29 CFR 1910.1200). Under conditions of normal use, the product does not release, or otherwise result in exposure to a hazardous chemical.

Other Precautions:

Cutting, grinding or sawing of this product is not considered normal use, and may result in the evolution of hazardous dust.

Johnson County Foam, Inc. Cast Stone Division 565 Airport Drive Mansfield, TX 76063 817-477-5061

Product Data for Johnson County Foam, Inc. - Cast Stone Division

1.) Product Name: Architectural Cast Stone

2.) Manufacturer: Johnson County Foam, Inc. 565 Airport Drive Mansfield, TX 76063 Office: 817-477-5061 Fax: 817-473-4734

3.) Product Information: Composition and Materials: Cast Stone is a building material manufactured from carefully controlled portions of Portland Cement and coarse and/or fine aggregates, molded into final shapes.

Basic Use: Cast Stone is a masonry product generally used as trim, facing and ornamentation. It is made to simulate natural cut stones such as limestone, brownstone, and sandstone.

Typical Use: Cast Stone is most often used for copings, wall caps, window sills, door and window surrounds, veneer, columns, balustrade systems, and other similar architectural features.

Vibrant Dry-Tamped (VDT): Johnson County Foam, Inc. manufactures cast stone using the dry tamped method. Ingredients are blended with the proper amount of water in the mixer to slimp of 0 inches. The mix is placed in the mold and tamped to produce a solid, smooth surface finish. This concerte case method produces a relatively dry product, so the pieceis removed from the mold immediately after tamping, finished, inspected, and water mist-cured while allowing it to harden.

Molds: Molds used for the production of cast stone shapes are typically fabricated from soft woods and high density overlay (HDO) or medium density overlay (MDO) plywood. Specialty items, with intricate detail, like fireplace surrounds, balusters, and column caps may require special fabricated rubber molds.

Approvals: Once an order has been placed, shop drawings, generally submitted through electronic email, will be submitted for approval. Fabrication of all cast stone shapes can commence once the shop drawings and color selections are approved by both the contractor/owner/ and/or architect.

Structural Limitations: VDT-produced cast stone pieces generally cannot be used as structural elements without additional reinforcing members such as steel lintels (provided by others). Cast stone is not designed to be load bearing therefore proper planning and architectural thought must be used for securing the elements to the structure.

Setting Materials and Accessories: Johnson County Foam, Inc. may or may not furnish setting hardware and accessories with the cast stone materials, depending on the projects conditions and drawing specifications. Regardless of the hardware and accessory requirements, mortar setting materials, caulking, sealants, and such, required fr installation, all are furnished by the installation contractors. Installation is to be provided by trained and experienced masonry personnel and not Johnson County Foam, Inc. employees.

4.) Installation: Preparation: Substrates must consist of materials that are compatible with cast stone members and structurally designed to permit anchoring and/support of cast stone members without failing. All anchors, dowels, and fastenings installed by others must be firmly attached to the elements supporting the cast stone members. Installation is not performed by Johnson County Foam, Inc. All cast stone materials should beinspected for any damage that may have occurred in shipping or storage on site location. Installation of cast stone elements deems acceptance.

Cleaning: All cast stone faces that remain exposed should be cleaned with water or a mild masonry cleaner that is applied with a soft, bristle brush designed for masonry work and intended ‘not’ to scratch the cast stone. Plastic, not metal, tools should be used to remove dried unwanted materials. Cast stone should remain moist during installation. A bucket of clean water should be kept nearby to imediately wash off the cast stone with a mild acid (unually 5 – 10%) will generally change the texture of the cast stone and roughen the finish, thus should be avoided unless the roughened texture is desired. Cast stone should never be cleaned with high pressure spray. If one inadvertently uses a high pressure spray, it is prudent to check the joints to make sure that they have not been compromised. Mortar re-pointing should be done before cleaning starts; caulking joints should be installed after cleaning is completed and approved.

Precautions: All normal care should be taken to prevent water from entering open joints and staining or discoloration of adjacent finished surfaces from cleaning liquids. Always rest your cleaning compound on a surface that is out of normal sute to ensure that it does not stain or discolor the elements.

5.) Availability and Cost: Availability: Cast stone can be delivered to any jobsite. Specification of need for lift gate, if no forklift is available, is very helpful as the driver may have to return on another day with the appropriate lift gate and pallet jack to unload, Delivery hours and directions are helpful. Delivery times depend on timely shop drawing and color approvals for JCF’s normal production lead times. Make sure that you have reviewed the color selections on the website or request color samples ahead of time to avoid additional waiting time on color approval.

Cost: Factors affecting the unit cost of cast stone include the quantity of cast stone to be produced, the complexity of the molds and the degree of ornamentation. Cast stone is most economical when standard colors are selected and the shapes and profiles are simple and / or repetitive. The fewer the molds required and the greater the quantity, the less the unit cost will be.

6.) Technical Services: Contact Johnson County Foam, Inc for additional information and assistance in detailing, specifying and preliminary pricing of cast stone elements. Additional information, standard product profiles, technical bulletins, care / maintenance bulletins and deisgn tops are available on www.jcfcompanies.com.

P.K.614 YENİTAŞKENT TEL : 324 454 00 60(12) ÇİMENTO SANAYİ ve TİCARET A.Ş FAX : 324 454 00 75 ( 2 ) 33013 MERSİN-TÜRKİYE MERSİN E.Mail:[email protected] CEMENT ANALYSIS REPORT

EC Certificate of Conformity Certificate No. 2404 - CPR - 0026 :WHITE PORTLAND CEMENT SAMPLE STANDARD : SUPER WHITE PORTLAND CEMENT (ÇİMSA SAMPLE) ACCORDING TO ASTM C 150 TYPE I DATE OF REPORT :09.07.2019

STANDART VALUES RESULT METHOD CHEMICAL REQUIREMENTS Min Max L.O.I % 3,33 - 3,50 ASTM Free Lime % 1,60 - - C-114 I.R % 0,14 - 1,50

SiO2 % 21,35 - -

Al2O3 % 4,12 - -

Fe2O3 % 0,27 - - CaO % 67,08 - - MgO % 1,40 - 6,00 XRF

SO3 % 3,03 - 3,50

Na2O % 0,14 - -

K2O % 0,59 - -

Na2O.Eq % 0,53 - 0,60

MINERALOGICAL COMPOSITION

C3S % >60 - -

C2S % <25 - - C A >10 3 % BOGUE - - FORMULA

C4AF % <1 - -

PHYSICAL REQUIREMENTS

Specific Surface m2/kg 460 260 - Residue on 0,045 mm Sieve % 1,0 - - Air Content % 8,0 - 12,0

Autoclave % 0,6 ASTM - 0,80

Initial Setting Time Minute 100 C-185,451,191 45 - Final Setting Time Minute 120 - 375

Whiteness (Y Value) 86,0 CIE % - - (L, a, b) 92,73 - 1,40 3,23 HUNTERLAB

STRENGTH TEST RESULTS

3 Days Compressive PSI 4976 1740 - 7 Days Compressive PSI 5904 ASTM C-109 2760 - 28 Days Compressive PSI 6701 4060 - Report shall not be reproduced except in full without the written approval of the testing laboratory.

Dok No:EYS-MRS-FR-KA-023 Tarih:15.12.2009/00

JOB SITE HANDLING AND INSTALLATION TECHNICAL BULLETIN #37

JOB SITE HANDLING AND INSTALLATION

The proper use of cast stone in the design of a project and the job site handling of the cast stone can affect the overall performance. On-site personnel should be familiar with the Cast Stone Institute® specifications and the project specification covering delivery, storage, setting, touch-up and repair, cleaning, pointing, caulking and sealing. In case of a conflict between the two specifications, the project specification should take precedent. Where the project specification may not include a particular issue, the industry standards should be followed.

The following checklist has been developed for the handling and installation of cast stone.

Prior to delivery there should be a set of the approved shop drawings and color and texture sample on file. All test reports specified should be submitted as required. Upon delivery, all cast stone should be checked for chips, cracks, stains, or broken pieces. Any damage should be noted on the delivery slips and communicated to the manufacturer. Color and texture should be inspected in accordance to approved color sample or mock-up panel set up at the job site. In general, the color and texture of the cast stone should be approximately equal to the approved sample when viewed in typical daylight conditions at a distance of twenty foot. (See Technical Bulletin #36 Inspection and Acceptance.) Storage of cast stone should be above the ground on non-staining planks or pallets. The storage site should be away from heavy construction traffic. Cast stone stored for an extended period of time should be kept on pallets or non-staining planking and covered with non-staining tarpaulins. Allow for air circulation. Prior to setting, ensure climatic conditions are within thermal limitations of mortar. Cast stone should not be set if the environmental conditions are not within the acceptable temperature range specified by the manufacturer’s recommendations. Mortar set retarders and set accelerators should be used according to manufacturer’s recommendations but not with touch-up and repair material. Set cast stone within size limitations in full mortar joints and fill in all dowel holes and anchor slots completely with project approved bonding material (usually Mortar, Non-Shrink Grout or Epoxy). Ensure uniform joint widths within specification tolerances. If shims are required in the mortar joints, mortar should be raked back and caulked to mitigate hairline cracking in the joints. Sealant joints may be sanded to give the appearance of mortar when desired. Ensure that all specified flashing and dampproofing is installed. Flashing pierced by stone anchors must be sealed either by metal thimble, grommet or approved sealant. Concrete should never be poured against unprotected cast stone. Where poured in place concrete is placed against cast stone sills, separate with an appropriate barrier material prior to pouring concrete. Cast stone anchors must meet specified standards and be non-corrosive. Cast stone slots to receive anchors should be completely filled with project approved material usually mortar, non-shrink grout or epoxy. Prior to setting, each surface to be set in mortar should be wetted before mortar is applied. This helps to secure the bond between the mortar and the cast stone and may help to prevent shrinkage and hairline cracking in the joints. Weep holes must be installed over windows, at relieving angles and at the bottom of walls. No mortar droppings shall be allowed in the wythe between back of stone and face of back-up structure. All joints in cast stone units, which are set using mechanical anchors and plastic bearing shims, should be sealed. All control joints and any floor line joints at relief angles should be sealed to allow for movement. Only the ends of load bearing lug sills shall be set in a full bed of mortar to prevent cracking from future wall settlement. After setting, prime the joints, insert properly sized backup rod and gun in sealant.

JOB SITE HANDLING AND INSTALLATION TECHNICAL BULLETIN #37

All trim items must align with control joints. Bridge parapet coping units over control joints to maximize their effectiveness. All coping should have a minimum ½” wash to control runoff. Do not bridge parapet coping over expansion joints. Cast stone should be handled to minimize chipping. Handle stones with the wide portion of the cross section in the vertical position to minimize breakage. After setting, columns, pilasters, entry jambs, window sills and all cast stone with projecting profiles should be protected during the remaining construction. During construction, cover the top of the walls when rain is anticipated. Chipped cast stone must be patched by skilled labor. A trial patch must be approved before general touch and repair is to commence. Planter coping, fountain coping, swimming pool coping, treads, risers, stone pieces above grade, and pavers may be treated with a silane or silane/siloxane blend water repellent coating after setting. A waterproof product may be applied to the back, sides and at and below grade surfaces. This will minimize the likelihood of dirt and groundwater entering the surface of the stone; a frequent cause of staining, efflorescence and enhancement of crazing. Check that the water repellent coating does not affect color or texture when dry. Load bearing cast stone units should be reinforced as necessary. They may not be designed to be handled in a different orientation than they will be installed in the structure. Lintels and large panels must be kept vertical. Any exposed reinforcement is to be cut back to a minimum depth of 1.5 inches. Apply a galvanized compound, zinc primer or other reinforcement protection to all exposed reinforcement. Fill recessed pocket containing coated reinforcement with repair material prior to setting the cast stone.

When installing in extreme weather conditions consult Cold Weather Setting Practices Technical Bulletin #41, and Hot Weather Setting Practices Technical Bulletin #48.

This Technical Bulletin addresses generally accepted practices, methods and general details for the use of Architectural Cast Stone. This document is designed only as a guide and is not intended for any specific application or project. It is the responsibility of design and construction professionals to determine the applicability and appropriate application of any detail to a specific project based on professional judgment, specific project conditions, manufacturer’s recommendations and solid understanding of product characteristics. The Cast Stone Institute makes no express or implied warranty or guarantee of the techniques or construction methods identified herein. Technical references shall be made to the edition of the International Building Codes for the location of the structure, the latest edition of the TMS 402/406 Masonry Standards document and TMS 404, 504, 604 Standards for Design, Fabrication and Installation of Architectural Cast Stone.

The Cast Stone Institute (CSI) is a not-for-profit organization created to advance the design, manufacture and use of Architectural Cast Stone. To further this goal, the CSI continually disseminates information to targeted construction industry audiences through presentations, programs and technical publications. (Page 2 of 2) © Cast Stone Institute Technical Manual Copyright 2019 Updated June2018

CLEANING TECHNICAL BULLETIN #39

CLEANING

Despite all efforts to prevent dirt and staining on new building construction, a final wash down is recommended. To minimize the severity of cleaning though, every effort should be taken to protect the cast stone during storage and installation. Storage of cast stone should be above ground on non-staining planks or pallets and away from heavy construction traffic. Cast stone stored for an extended period of time should be kept on pallets or non- staining planking and covered with non-staining tarps. After setting, columns, pilasters, entry jambs, windowsills and all stone with projecting profiles should be protected with non-staining materials during the remaining construction.

The most common stains due to construction are dirt, mortar smears and efflorescence. A general rule of thumb is to use the least aggressive cleaning material and method to clean the building. There are a variety of commercial cleaners available to remove mortar smears, dirt and efflorescence without altering the finish or causing damage to the cast stone. Most contain detergents combined with mild solutions of phosphoric and/or muriatic acids. Use only the commercial cleaner developed for the specific stain to be removed. Before Cleaning After Cleaning Dirt can be removed by scrubbing with a mild detergent and water and thorough rinsing. Extreme care should be taken when applying acidic based cleaners to areas where joints are left open or where joint sealant is used as jointing material. Hardened mortar stains are more tenacious and may require a more aggressive solution to remove. The manufacturers of adjacent building materials (clay brick, concrete block, windows, doors, sealant, etc…) should be consulted to determine compatibility with the cleaning materials.

Dunnage materials used in the packing and transport of cast stone can leave stains (or clean spots) after becoming wet. Wood packaging products can transfer resins to the surface, which may be easily removed. However, solid dunnage made from fresh timber can cause dunnage marks, which become difficult to remove. Packing and dunnage materials should always allow the exposed surfaces to breathe, especially when stones are palletized or placed into storage shortly after manufacture. This will avoid color differential due to moisture becoming trapped on the surface of the stone.

When unusual stains are encountered, the same procedures, which are recommended to clean concrete, will normally clean Cast Stone. The Portland Cement Association publishes a guide for the removal of stains in concrete.

The most important step to stain removal is identifying the stain and its cause. Manufacturers of cleaners should be contacted for guidance on removing particular stains. For the best result, follow the manufacturer’s recommendations for using their product. Any treatment should be tested in a small inconspicuous area prior to cleaning the main wall. Also, ensure that lower cast stone courses are frequently rinsed with water because as acid is rinsed down the wall it can gather strength when reapplied. Take necessary steps to protect windows door and grade materials. Cleaners not fully rinsed from the building may cause corrosion to embedded steel later.

(Page 1 of 2)

CLEANING TECHNICAL BULLETIN #39

Pressure Washing Wand Damage Direct high pressure power washing and sandblasting are not recommended procedures for cleaning cast stone. Furthermore, metal fiber brushes, rubbing stones and any tool or device that can scar the cast stone not to be used for cleaning cast stone.

The Cast Stone Institute (CSI) is a not-for-profit organization created to advance the design, manufacture and use of Architectural Cast Stone. To further this goal, the CSI continually disseminates information to targeted construction industry audiences through presentations, programs and technical publications. (Page 2 of 2) (Page 2 of 2) Updated October 2017 © Cast Stone Institute Technical Manual Copyright 2019

CAST STONE AND LEED® v4 TECHNICAL BULLETIN #53

CAST STONE AND LEED® v4

INTRODUCTION Sustainable design has become one of the most prominent trends in the building industry. Designers aiming for a more environmentally-friendly building design often turn to building rating systems and certification programs to help them assess the environmental impact of a building and its components. The most widely used system in the U.S. is the LEED® green building certification program.

The U.S. Green Building Council (USGBC) developed the LEED rating system; LEED stands for Leadership in Energy and Environmental Design. A separate entity, the Green Building Certification Institute (GBCI) administers LEED project certification and professional credentialing programs. The LEED certification program was developed to provide a method to define and measure what are commonly called “green buildings.” From its inception as a pilot program for new buildings in 1998 to the present, the LEED certification program has expanded and grown dramatically. There are numerous LEED rating systems organized by type of construction and end use, including: BD+C (Building Design and Construction): New Construction, Core & Shell, Schools, Retail, Hospitality, Data Centers, Warehouses & Distribution Centers, Healthcare ID+C (Interior Design and Construction): Commercial Interiors, Retail, Hospitality EB:O+M (Existing Buildings: Operations and Maintenance): Existing Buildings: Operations & Maintenance, Schools, Retail, Hospitality, Data Centers, Warehouses & Distribution Centers ND (Neighborhood Development): Neighborhood Development Plan, Neighborhood Development Homes: Homes, Mid-Rise

The most widely used rating system in the U.S. is currently LEED® BD+C: New Construction™ (LEED for New Construction) though LEED Existing Buildings: Operations and Maintenance is also widely used. While each rating system is distinct, most of the topics covered can be grouped into the same general categories. This Bulletin examines the requirements of LEED v4 for BD+C: New Construction and its relevance to cast stone.

THE USE OF CAST STONE Cast stone is used primarily on the exterior of buildings. Cast stone veneer may be used alone or as an integral part of a clay or concrete masonry veneer. Cast stone may also be used as an accent or trim material on the exterior of buildings sheathed with other materials such as synthetic stucco. Other opportunities for use of cast stone include caps and copings on building walls and landscape walls, stair treads, and column covers. Though not as common, cast stone can also be used as pavers and in interior applications. Many of these applications can be part of a strategy to earn points in the LEED rating systems.

LEED® v4 When LEED v4 was approved in July 2013 after a lengthy revision process, it contained significant changes from the previous version (LEED 2009) particularly in the area of materials and resources. LEED v4 is organized into six environmental categories plus credits for integrated design, innovation and regional priorities. In LEED v4 the credits related to the building site and location are split into two separate categories, Sustainable Sites and Location and Transportation. Each of the six credit categories may contain mandatory prerequisites as well as voluntary credits that are worth points toward a building project’s certification. Figure 1 shows the points allocated to each category.

CAST STONE AND LEED® v4 TECHNICAL BULLETIN #53

LEED v4 Points by Category

4 1 6 16 Location and Transportation Sustainable Sites 16 10 Water Efficiency Energy and Atmosphere Materials and Resources

11 Indoor Environmental Quality 13 Innovation Regional Priority Integrative Process 33

Figure 1: LEED v4 Points by Category

CERTIFICATION Under LEED for New Construction a building project must earn at least 40 points out of a possible 110 to be a LEED-certified project. In the LEED rating systems, the more points a building project earns, the “greener” the building. The USGBC recognizes four levels of LEED certification (Figure 2).

Total Possible 110

Platinum 80

Gold 60

Silver 50

Certified 40

0 20 40 60 80 100 Points Required for Certification

Figure 2: LEED for New Construction 2009 certification levels

CAST STONE AND LEED® v4 TECHNICAL BULLETIN #53

EARNING LEED POINTS Cast stone masonry can make a significant contribution toward earning LEED points on a project. While no product or material alone can earn LEED points, cast stone masonry can be used as part of a strategy to earn points in many credits. It is important to remember that the calculations for these credits require inclusion of the entire building project and materials to determine the percent of qualifying material.

LOCATION AND TRANSPORATION (LT) This category addresses issues related to the location of the project site and its connection to the surrounding community. A total of 16 points are available in this category with the majority given for locating the project in a densely developed area with a diverse array of businesses, residential areas, and services.

LT Credit 4 - Surrounding Density and Diverse Uses (1-5 points) – the intent of this credit is to encourage development in urban areas with existing infrastructure. Building products do not directly contribute to this credit. However, masonry materials are often used for urban infill development because of their appearance, size and scale, fire ratings, as well as for benefits in space required for construction. Cast stone masonry can often be installed without the use of a crane, thus helping to minimize the need for large equipment on site.

SUSTAINABLE SITES (SS) This category addresses issues associated with site preparation as well as impacts on surrounding areas after construction is complete. A total of 10 points are available in the Sustainable Sites category. Cast stone may play a role in strategies associated with SS credit 5.

SS Credit 5: Heat Island Reduction (2 points) – the intent of this credit is to reduce the retention of heat due to dark colored surfaces by providing shade, using materials that meet solar reflectance criteria, or other strategies for the roof and non-roof areas such that their weighted area exceeds the sum of the area of site paving and total roof area. Cast stone used as caps on landscaping walls, stair treads, and pavers on the site or on the building roof can meet the criteria for earning this point.

This credit requires that paving materials have a three-year aged solar reflectance (SR) value of at least 0.28. If three-year aged value information is not available, materials must have an initial SR of at least 0.33 at installation. A study [Ref. 1] by the Portland Cement Association of 135 concrete specimens all had a SR of at least 0.33. One specimen made with white Portland cement had a SR of at least 0.64. Cast stone elements typically meet the LEED requirements for solar reflectance, especially if white Portland cement is used.

ENERGY & ATMOSPHERE (EA) The Energy and Atmosphere category covers a variety of issues related to energy use associated with heating and cooling buildings including reduction in energy use, ozone reduction and use of renewable energy. There are four mandatory prerequisites and seven voluntary credits that have a total of 33 points associated with them. The thermal mass associated with cast stone and other masonry materials can help reduce the amount of energy used for heating and cooling a building. There is one prerequisite and one credit associated with this intent.

EA Prerequisite 2: Minimum Energy Performance (0 points) – as part of a masonry wall, cast stone can help mitigate temperature swings and achieve the required energy performance particularly when interior masonry is left exposed.

EA Credit 2: Optimize Energy Performance (up to 18 points) – as part of a masonry wall, cast stone can be used to help reduce the amount of energy consumed by the building. The benefit of thermal mass is best recognized when using energy modeling tools such as BLAST or EnergyPlus.

CAST STONE AND LEED® v4 TECHNICAL BULLETIN #53

MATERIALS & RESOURCES (MR) The intent of this category is to minimize the impact on the environment, encourage product transparency, and reduce construction waste. There are a total of 2 prerequisites and 13 points available in the Materials and Resources category. Several of the MR credits in LEED v4 are focused on specific manufacturer practices such as developing an environmental product declaration or disclosing material ingredients. As a result, achieving the credits in this category may vary widely depending upon the specific manufacturer. A brief overview of each of the MR credits is provided below.

MR Credit 1: Building Life-Cycle Impact Reduction (up to 5 points) – this credit incorporates the former Building Reuse and Material Reuse credits, and gives more weight (points) to reuse of whole buildings than the previous version of LEED. This credit contains four different paths, with the first three focused on building and material reuse and the last on new construction. Masonry buildings, many of which incorporate cast stone details, are good candidates for reuse. Cast stone features on the building interior such as columns, fireplace mantels and surrounds, stair treads, etc. are also good candidates for reuse. Anchoring details that allow for disassembly can facilitate this. Larger elements not set in mortar are especially suited for salvaging. In addition, cast stone can be repaired to conceal damage that may occur during disassembly and removal.

MR Credit 2: Building Product Disclosure and Optimization – Environmental Product Declarations (2 points), is a new credit in LEED v4. This credit has two options, worth one point each. The first option focuses on reporting of environmental impact data via an Environmental Product Declaration (EPD), while the second rewards improved performance in specified environmental impact categories through life cycle assessment. Cast stone elements produced by manufacturers having an EPD can count toward this credit.

MR Credit 3: Building Product Disclosure and Optimization – Sourcing of Raw Materials (up to 2 points) has two different options worth one point each. Option 1, Raw Material Source and Extraction Reporting, requires use of at least 20 different permanently installed products sourced from at least 5 different manufacturers that have publicly released a report from their raw material suppliers. Third-party verified corporate sustainability reports are counted in full. Self-declared reports count as only ½ value, so for example, if only self-declared reports are used, 40 products would be required instead of 20.

The second option incorporates aspects of the recycled content, rapidly renewable, certified wood and material reuse credits found in LEED 2009. Option 2, Leadership Extraction Practices, requires use of products that meet at least one of the responsible extraction criteria below for at least 25%, by cost, of the total value of permanently installed building products in the project. When calculating the value of the products, those demonstrating extended producer responsibility are valued only at 50% of their cost. Other extraction criteria are valued at the full amount.

Extended producer responsibility Bio-based materials: Sustainable Agriculture Standard Wood products: FSC certified Materials reuse Recycled content: post consumer + ½ pre-consumer USGBC approved program

Cast stone elements can help earn this credit when they incorporate recycled materials into their mix, most often as aggregates or supplementary cementitious materials. Pre-consumer (post-industrial) recycled materials that may be incorporated into cast stone include recycled aggregate or slag that can be used as an aggregate and supplementary cementitious materials like fly ash. Color may be affected by incorporation of certain recycled materials, so contacting the cast stone manufacturer is recommended.

CAST STONE AND LEED® v4 TECHNICAL BULLETIN #53

MR Credit 4: Building Product Disclosure and Optimization – Material Ingredients (up to 3 points) – This credit has three options worth 1 point each. All three options require documentation of the raw material ingredients for building products. Several chemical and ingredient screening programs are listed as compliance paths including the GreenScreenTM for Safer Chemicals, Cradle to Cradle certification, and the Health Product Declaration (for more information see Resources), but Material Safety Data Sheets (MSDS) are not considered compliant with this credit. Cast stone producers that provide the chemical inventory for their products using the Chemical Abstract Service Registry Numbers (CASRN) can count toward Option 1 of this credit.

MR Credit 5: Construction and Demolition Waste Management (up to 2 points) – The intent of this credit is to eliminate construction waste from landfills. Up to two points can be earned for recycling or salvaging specified amounts of construction waste, or two points can be earned if the project does not generate more than 2.5 lbs of construction waste/ft2 of the building's floor area. On-site waste from cast stone elements is limited primarily to packaging materials. Cast stone elements are carefully detailed and exact amounts are delivered to the site so that waste stone is nearly eliminated helping meet the reduction of total waste goal. Any waste cast stone elements that are present can be crushed and used as aggregate or fill.

INDOOR ENVIRONMENTAL QUALITY (IEQ) This category aims to ensure quality indoor air among other goals. One way to achieve this is by reduction or elimination of volatile organic compounds (VOCs) in materials used in the interior of a building.

IEQ Credit 2 – Low-Emitting Materials (up to 3 points) – This credit focuses on volitile organic compound (VOC) emissions, rather than content. It also explicitly lists stone, glass, concrete, and clay brick as “…inherently non- emitting and comply without any testing if they do not include integral organic-based surface coatings, binders, or sealants.” Thus cast stone elements without integral organic-based materials used on exposed interior walls or floors meet this credit without any testing required.

SUMMARY LEED v4 for BD+C: New Construction rating system is one of the most commonly used tools in the U.S. for assessing the impact of a building and its components on the environment. LEED covers six environmental credit categories each containing numerous credits. Cast stone, like other masonry materials, can play a role in strategies designed to achieve many of these credits, particularly in the Materials and Resources credit category.

Designers utilizing the LEED v4 for BD+C: New Construction rating system are encouraged to contact cast stone manufacturers to determine relevant practices for achieving LEED credits and to look for opportunities and the synergy that can occur when cast stone is chosen for use on a project.

REFERENCES 1. “Concrete Shines as Solar Reflectance Material,” http://www.cement.org/for-concrete-books-learning/concrete- technology/concrete-construction/concrete-as-solar-reflectance-material, accessed February 5, 2014.

2. LEED v4 User Guide (June 2013), U.S. Green Building Council, Washington, DC, http://www.usgbc.org/resources/leed-v4-user-guide.

CAST STONE AND LEED® v4 TECHNICAL BULLETIN #53

WRITTEN BY Christine A. Subasic, P.E., LEED A.P. is a consulting architectural engineer at C. Callista Subasic in Raleigh, NC, specializing in sustainable design and masonry.

Ms. Subasic has been a member of The Masonry Society (TMS) since 1992 and a member of the Board of Directors since 2002. She serves on the Design Practices committee and is a founding member of the Sustainability Committee. Ms. Subasic also represents the masonry industry on the ASHRAE 189.1 Standing Standard Project Committee for high-performing green buildings.

The Cast Stone Institute (CSI) is a not-for-profit organization created to advance the design, manufacture and use of Architectural Cast Stone. To further this goal, the CSI continually disseminates information to targeted construction industry audiences through presentations, programs and technical publications. (Page 6 of 6) Updated October 2017 © Cast Stone Institute Technical Manual Copyright 2019

Cast Stone Portfolio

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