Do It Yourself

CAST VENEER STONE by EP HENRY

PRODUCT AND INSTALLATION GUIDELINES

 PRODUCT DESCRIPTION

 EP Henry’s Cast Veneer Stone is designed to provide a non-structural, lightweight veneer facing for both interior and exterior applications. The product provides a quality architectural finish with all the colors, textures, sizes and shapes of quarried natural stone.

 PRODUCT PACKAGING 

All Cast Veneer Stone by EP Henry products are packaged with an anti-scuffing material between each layer of stone.  This protects the product during packaging and shipping and protects against scuffing common with other veneer stone product lines.

            Each Crate of EP Henry Cast Veneer Stone flats contains                    100 sf  

Each EP Small Pak of EP Henry Cast Veneer Stone flats contains     12 sf

Each Crate of EP Henry Cast Veneer Stone corners contains      75 lf

            Each EP Small Pak of EP Henry Cast Veneer Stone corners contains  8 lf

            FITTINGS       All fittings are packaged in EP Small Paks as follows:

                                                Keystones                    18 pieces

                                                Electrical Fittings           20 pieces

                                                Trimstones                    24 pieces         

Unit weight per SF:       Maximum 15 psf (pounds per square foot)

PRODUCT WARRANTY 

EP Henry provides a 50 year warranty to the original purchaser for Cast Veneer Stone when installed in accordance with the manufacturer’s installation specifications. The warranty applies to Cast Veneer Stone units only and does not cover installation labor or damages resulting from improper installation or misuse of product.

 PRODUCT GENERAL INFORMATION  

Cast Veneer Stone should be applied only to structurally sound surfaces.

Cast Veneer Stone should not be used on exterior horizontal surfaces or as wall caps. Water collection on the units combined with freeze-thaw conditions can result in surface damage.

Product applications:

·        New construction: interior or exterior walls

·        Retro-fitting of existing interior and exterior walls

·        Fireplace openings, hearths and surrounds

·        Chimneys

·        Exterior Hardscaping masonry applications such as kitchens, bath houses and pre-cast fireplaces and seat parapet wall applications.

Do not install product below grade or in a water environment.

Do not install in applications that expose the product to chlorine or chemicals, as discoloration may result.  In fireplace and chimney applications, product should be kept at least 18” away from direct flame.

ESTIMATING STONE QUANTITIES 

1. Determine the total square footage of the project (length times height of each area). Remember to subtract the square foot area of all openings (doors, windows, etc.)
2. Calculate the linear footage of corner stones for the project. Remember to add all openings that require corner units. Convert the linear footage into square feet by multiplying by ½ (.5).
3. If using Architectural Trim or Detail pieces or electrical outlet fittings, calculate the number of pieces required and the square footage.  
4. Subtract square footage for corners and trim/detail pieces from total square footage to determine the amount of flats required.
5. It is recommended that an extra quantity of flats (approximately 5%) be factored into the estimated materials to allow for cutting, trimming and to achieve the   best fit.

TYPES OF MORTAR 

EP Henry recommends the use of a Type S mortar for Cast Veneer Stone installations.

           Type S Mortar: 1 bag Type S mortar cement: 2 ½ to 3 ft³ mason’s sand

INSTALLATION  

NOTE:  In accordance with good building practices, maintain materials and ambient air temperature in the work area at a minimum of 40 degrees F during installation and for 48 hours following the completion of work.   

Preparing the surface

For clean masonry surfaces that have not been painted or treated in any way, Cast Veneer Stone can be applied directly to the surface. It is recommended that a bonding agent be applied to the masonry surface as well as a scratch coat to help strengthen the bond and minimize cracking.

For all other surfaces and on painted or treated masonry, metal lath (galvanized for exterior use) must be applied first followed by a scratch coat. (See installation diagrams). Most building codes and best building practices require that any nails, staples or screws that are used be galvanized.

 Scratch Coat

An even, ½” thick coat of Type S mortar is applied to the metal lath or clean masonry surface to help insure proper bonding of Cast Veneer Stone.  The scratch coat should be allowed to set-up for 48 hours before installing the Cast Veneer Stone.

 Starting the Installation

Lay out a quantity of Cast Veneer Stone prior to installing. Make sure to select stones from as many boxes as possible to achieve the best possible mix of shapes, sizes, colors and textures. Continue this practice throughout the installation. Begin installing the stone from the top down. Start installing the corner units first. The corners have a long and short return which should be alternated in opposite directions as you go down the wall corner.

Try to maintain a uniform joint width (1/2”) around the stones. Avoid long, unbroken joint lines. The stones can be trimmed using a brick hammer, nippers or the side of a mason’s trowel. Stones can be cut when needed using a diamond or carborundum saw blade. Be sure to place the cut edges in unobtrusive places and touch up the cut with mortar when finishing the joints.

 Setting the Stones

Apply an even layer of Type S mortar, approximately ½” thick, to the entire back of the stone. Press the stone firmly into place on the wall surface. Press hard enough to squeeze the mortar out around the edges. To insure a good bond, gently wiggle the stone while pressing it in place. If any mortar gets on the stone face, DO NOT try to wipe it off. Allow the mortar to set and dry, then use a coarse brush to remove it.

If working in hot, dry weather it may be necessary to wet the scratch coat and stone to prevent the mortar from drying too quickly and losing strength. The surface and back of the stone can be dampened with a hose but do not wet to excess. If too much water is applied and runoff occurs, allow a few minutes for the surface to dry before proceeding with the installation.

Do not allow construction on the opposite side of the Cast Veneer Stone wall to take place until the stones have bonded and the mortar has cured properly (minimum of 48 hours).

Grouting and Finishing the Joints

Once all of the Cast Veneer Stone has been installed on the wall surface, use a grout bag and fill the joints between the stones with mortar making sure to fill all voids. It is recommended that a Type S or N mortar be used. The grouting mortar can be colored if desired.

When the mortar joints have begun to set and become firm to the touch, use a jointing tool and rake out the excess mortar to the desired depth. Make sure that all the edges of the stones are thoroughly sealed with mortar by pressing the mortar into place. Once the mortar joints have been worked, use a soft, hand whisk broom or paint brush and smooth the joints while cleaning away any loose mortar from the stones.

DRYSTACK INSTALLATION

 Dry stack installation follows the same guidelines as normal installation with a few key

differences as addressed below. 

1. Install from the bottom up.
2. Stones should be wetted regardless of air temperatures, bearing in mind that work should not be conducted in temperature below 40 degrees F.  If the scratch coat is dry, wet the wall as you go.
3. Use a chalk line and 4’ level to keep your Cast Veneer Stone level.
4. As there will be no mortar joint strengthening the bond, it is important that ample mortar is applied to the back of each stone to ensure it squeezes out around the edges.  Mortar should not be stiff to allow the joint to seal to the next stone. After setting stone, use a trowel to remove excess mortar and fill any voids along the stones’ edges. 

 CLEANING

It is always recommended that a test of the cleaning method be done in an inconspicuous location prior to proceeding with the overall cleaning.  Cleaning materials and methods appropriate for other masonry surfaces may not be suitable for Cast Veneer Stone.   

General Maintenance:

·        To clean dirt or dust, use a garden hose and a soft bristle brush

·        Mild detergents can be used but should be rinsed immediately

·        DO NOT use a wire brush

·        DO NOT use acid based products or a pressure washer to clean stone

Efflorescence Removal:

·        Allow Cast Veneer Stone to dry completely

·        Scrub with a stiff bristle brush and rinse thoroughly with clean water