Manufactured stone veneer is an aesthetically pleasing veneer system that continues to gain popularity. Ensuring proper performance in service depends on proper detailing and construction. This guide focuses on installation of Adhered Manufactured Stone Veneer (AMSV) systems onto a variety of structural backup systems.
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Now that you know which stone veneer product you want to use, you may be asking yourself: "How do I install stone veneer?" Don't worry! We've got you covered. Below are our step by step guide to help you learn how to traditional stone veneer istallation and also a tight-stack stone installation. The following is a broad outline for installing Cast Natural Stone.
The metal lath/scratch coating may be applied over structurally sound wall surfaces of plywood, OSB, concrete board or gypsum sheathing, supported by wood or steel studs, and over concrete or masonry walls.
Do not wash off with clear water. This will result in a milky residue. Brush off any mortar spots from the face of the stone veneer. If desired, use a mild vinegar and water solution to remove any remaining mortar spots. Loose mortar and mortar spots should not be allowed to dry overnight.
Corners are measured by the lineal foot. This is measured as the actual height of the corner requiring coverage. Since corners will cover some of the surface area of the wall, it is recommended to subtract 0.5 square foot from the quantity of flats for each lineal foot of corners. This is a only a general guideline, and the exact square footage coverage will vary with each box. Some stones may cover more or less than 0.5 square foot.
Prepare 2 layers of a Weather Resistive Barrier (WRB). WRB should be a #15 felt conforming with ASTM D226 or a Grade D 60 minute building paper (Super JumboTex is a popular Grade D 60 minute building paper). The first layer of WRB may be either traditional house wrap or a WRB meeting the above requirements. Various liquid WRB are also available. Consult the manufacturer of the WRB to ensure that it is suitable for use with natural thin stone veneer and to obtain installation instructions.
When installing over OSB, it is important to ensure that the OSB sheets have been adhered with an appropriate gap between the pieces. This allows for expansion should the OSB swell. If OSB swells, it may cause cracking on the wall. For interior applications, a WRB is typically not required.
Install cement board according to the manufacture's recommendations. Tape all joints with a tape approved by the cement board manufacturer. Install WRB according to cement board manufacturer's instructions. If using a liquid WRB, consult the manufacturer of the WRB to ensure that it is suitable for use with natural thin stone veneer. For interior applications, a WRB is typically not required. Ensure cement board complies with ASTM C1325 & ICC-ES AC3769.
Over clean CMU block or poured concrete walls (CMU block or concrete that has not been sealed, painted, or otherwise coated), thin stone veneer may be installed without a WRB. While not required, liquid applied WRBs are often advantageous to prevent moisture from wicking through the wall. Natural stone veneers and manufactured concrete products are often porous, and without a liquid WRB, it may be possible for a small amount of moisture to wick through the wall in extreme conditions. Liquid applied WRBs provide a good protection again this wicking. See part 3 for more information on preparing poured concrete walls to receive material.
Certain products may qualify as WRBs that are outside the scope of this installation guide. Consult with the manufacturer of these items to ensure that they qualify as a WRB when used for the installation of natural thin stone veneer.
No wire lath is required with cement board applications, provided proper mortars are used for bonding the stone veneer to the cement board. Type S mortar is not suitable for bonding to cement board. See part 4 of this guide for more information.
When attaching wire lath to CMU block or poured concrete walls, a power or powder actuated fastener is recommended at the corners as well as the long dimensional midpoint of the wire lath. Additional fasteners (either power or powder actuated or stub nails) should be fastened in rows no more than 16" on center and spaced no more than 7" vertically. They should be a minimum of 0.75" with a head size of at least 0.375".
Wire Lath should be installed horizontally with the cups facing up. All joints should overlap a minimum of 1" horizontally and vertically. Wire Lath should always be attached to studs and never to sheathing. Refer to ASTM C1063 for additional information. There may be other commercially available products that may be used in place of 2.5 or 3.4 lbs./sq. yd. self-furring wire lath. Consult the manufacturer of these products to ensure that they are appropriate for natural thin stone veneer installation. Ensure that the product used allows for the scratch coat to be adequately thick.
A scratch coat is not necessary for installation over clean CMU or poured concrete walls. If the surface is not clean and wire lath is required, follow the preparation steps for a scratch coat over wire lath. If wire lath is not being used, it is extremely important that all sealers, release agents, etc. have been removed from the wall before starting the installation of stone veneer. This may be achievable by simply cleaning the wall with a water or sand blasting technique, but if the wall cannot be completely cleaned, the installation of wire lath may be required. It is recommended in all instances to clean the wall before starting the installation even if the wall appears visually clean. A liquid applied WRB may be beneficial to use in these applications, but is not required.
When adhering directly to a poured concrete wall without a scratch coat or wire lath, it is extremely important to ensure that the bonding mortar being used is compatible with installation over these substrates. Consult the mortar manufacturer to confirm compatibility. Additionally, these mortars will likely require a certain Concrete Surface Profile (a standardized measurement of a concrete's texture/roughness) for the mortar to bond. This roughness is typically achieved by some sort of blasting (shot, bead, or high pressure water).
Polymer modified mortars that adhere to ANSI A118.4 or A118.15 should be used. Because natural thin stone veneer pieces have smooth backs, Type S or N mortars should not be used for bonding the stone to the scratch coat. When bonding to cement board, directly to CMU, or directly to poured concrete walls, a polymer modified mortar that is designed to adhere to these substrates MUST be used. Additionally, certain more sensitive products require that premium mortars be used for bonding to maintain durability. Modified thinsets are popular for these applications; ARDEX and Laticrete are two well-known companies that produce mortars that meet these standards and are designed to work for these applications.
The method for applying the mortar to bond the stone veneer to the wall varies depending on the brand and type of mortar used. Consult the mortar's manufacturer for specific installation recommendations. Following are general guidelines for the 2 most common installation methods. For both methods, it is important to ensure that the entire back of each piece of stone is being covered and that there are no voids in the mortar between the stones and the wall.
Fully coat the entire back of the piece of the stone, ensuring no voids are left on the surface of the stone. Typically 0.375" to 0.5" of mortar will be required on the back of each stone. Firmly press the stone onto the wall and gently shift it on the wall back and forth approximately 1" to 2" to ensure that the mortar is fully and evenly distributed on the back of the stone. After the stone is adhered to the wall, the mortar behind the stone should typically be 0.25" to 0.375" thick. For dry-stacked applications, no scratch coat should be visible between the stones after they are installed.
Using a notch tooth trowel (typically 0.5"), work mortar vertically on the wall, creating vertical grooves. Apply a thin layer of mortar to the back of the stone. Place the stone on the wall and shift the stone right to left approximately 1" to 2" creating a full bond. Typically, an area of several square feet is skimmed on the wall at a time to reduce labor; however, care must be taken to avoid skimming too large an area. The skimmed area must not start to harden before stone can be applied.
In this application, the stones should not grind against the scratch coat when they are being pressed and shifted onto the wall. If the stone contacts the scratch coat during this process, it should be removed, and more more mortar should be added.
A large selection of stone should be laid out prior to installing to create the proper mix. A minimum of 25 to 50 square feet should be laid out to work from at all times. Blending stones from multiple crates or boxes is also strongly recommended. Failure to do so may create color inconsistencies on the wall.
Important Note: Once the stones have been adhered to the wall and the mortar begins to harden, the bond should not be disturbed. Any disturbance could create a weak bond that may cause the stone to loosen from the wall in the future. If a bond is disturbed after the mortar has started to harden, it is best to remove and reattach the stone with fresh mortar.
Type S or Type N mortar may be used for grouting. Other mortars may be commercially available for the specific use of grouting stone veneer or natural thin stone veneer. Consult with the manufacturer of these mortars to make sure they are suitable for natural thin stone veneer installation. Iron oxide pigments may be added to the mortar if a colored mortar joint is required. The weight of pigments added should be no more than 10% of the total cement weight.
On a wood or steel framed wall, base flashing (such as weep screed) should be at least 4" above grade. Over paved or finished surfaces, this can be reduced to 2". When the stone meets grade on a CMU or concrete wall, maintain a clearance of 2" above grade. Regardless of substrate, clearance can be reduced to 0.5" when installing stone above a paved walking surface supported by the same foundation that supports the wall. When a CMU or concrete wall requires a WRB and wire lath, maintain a clearance of 4" above grade or 2" above paved or finished surfaces. These clearances allow proper water drainage and prevent water from wicking up the base of the installation area. 2ff7e9595c
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