Installation Guidelines

Specifications

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Installation Guidelines

Use a qualified stone, tile, or brick mason to do your installation!!

Materials needed

Setting buttons-- plastic shims 1/16", 1/8", 1/4". Usually sold at a glass supplier, granite supplier or a specialty materials hardware store.
Ties, Straps, Pins-- brick ties, Copper wire #8, 1/4" dowel pins, stainless steel straps, or dove tails etc. Usually sold at a hardware store, electrical supply, or specialty steel strap shop.
Sand -- masonry Sand not Bank sand - Sold at your local Masonry supply.
Cement -- type one portland cement - Sold at a Masonry supply, or Hardware store.
Note-- for certain installations a latex modified thin set adhesive should be used, as when setting hearths, floor tiles and other similar items - read manufactures label. Usually sold at a ceramic tile, or brick supplier.
Grout -- latex modified colored Grout ( for grouting the joints ) Usually sold at your local brick supply, or ceramic tile dealer - Brick mason may use the sand and cement mix.
Other Items -- certain installations will require relieving angles such as 1" x 1", or larger.
Cleaners -- cleaners for our product are Sure Clean Vana Trol manufactured by Prosoco, Inc. Call 1-800-255-4255 for the nearest source.

Tools and Equipment

To lift mantle-- use a rented motor lift, a rented HVAC lift, or a scaffold to 8' tall with chain hoist and straps. You can also use a chain hoist and straps to structure above, or six to seven strong workers .
To move mantle-- use a dolly that can handle the weight. Be sure and protect the floor from scratching.
Tools needed-- masonry saw, notch trowel at 3\4", grout float, margin trowel, sponge, rags, two 3 1/2 gal water buckets.
Note-- all installations are different and can require other tools and/or materials. You should use a qualified Stone or Brick Mason to do your installation.

The Installation

Study the piece numbers on the dimensioned drawing and locate the pieces.
Start at the bottom and install each piece with shims between the pieces. The shims will support the weight.
Attach the brick tie or strap at each joint to secure the pieces back to the structure.
Put the thin set adhesive at the back of the pieces and between the pieces at the brick ties. This will hold all pieces in place.
You can either grout as you go or grout all at one time after setting the pieces and after the thin set adhesive is dried.
After the grout has been washed back to the desired level and dried for 24hours, you should do a thorough cleaning with Vana Trol.
For mantles without self supporting legs you will need a relieving angle mounted at the bottom of the mantle piece and dowels back to the wall at the top of the piece.
Note: The hearth can be installed first or last. If installed first you will need to let it dry in place before the installation of the mantle. The weight of the mantel is too heavy to be installed on the hearth with fresh adhesive. If you install the hearth last you will need to cut around the legs. The hearth will add height to the mantle if the hearth is installed first!

Cast Limestone Specifications

PART 1 GENERAL

1.1 SECTION INCLUDES

A. Cast stone per: American Cast Limestone, 713 Lehman, Houston, TX 77018, 1-800-805-7865.

B. Accessories required for installation of all cast stone.

C. Mortar required for installation of cast stone.

1.2 SUBMITTALS

A. Shop drawings: Submit setting drawings showing details and sizes of stone, arrangement of joints, bonding, inserts, joints, connections to adjoining construction, reinforcing, and method of installation and anchoring per American Cast Limestone.

B. Samples: Submit two 3x3 inch size samples illustrating color, finish, and texture per American Cast Limestone 1-800-805-7865.

1.3 QUALITY ASSURANCE

A. Manufacturer Qualifications: Company specializing and providing shop fabricated cast stone products with minimum two years continuous experience.

1.4 DELIVERY, STORAGE, AND HANDLING

A. Coordinate delivery with scheduled installation date to allow minimum storage time at site.

B. Store units above ground on level platforms allowing air circulation under and around units. Protect from soiling, abuse, and moisture.

1.5 PROJECT CONDITIONS

A. Environmental Requirements: Lay no masonry when temperature is 45 degrees Fahrenheit or lower and falling. Lay no masonry when nearest NOAA weather service predicts 32 degrees Fahrenheit temperature locally within 24 hours.

B. Existing Conditions: Verify existing conditions and substrates before starting work. Correct any unsatisfactory conditions before proceeding.

PART 2 PRODUCTS

2.1 MATERIALS

A. Portland Cement: ASTM C150. Type I or III, white, single source and same manufacturer for all cast stone units. American Cast Limestone, 713 Lehman, Houston, Texas 77018, 1- 800-805-7865.

B. Aggregates: ASTM C33, single source for entire project.

1. Fine: To match American Cast Limestone Mix Design.

2. Coarse: To match American Cast Limestone Mix Design.

C. Water: Clean, potable.

D. Coloring: ASTM C979, non-fading, inorganic, iron oxide pigments, resistant to lime and other alkalis. Amount not to exceed 10% by weight of cement used.

E. Reinforcing Steel: Deformed billet steel bars, ASTM A615 grade 40 or 60, hot-dip galvanized ASTM A153 ( only if shown necessary ).

F. Anchors: Standard building stone anchors. Type 304 stainless steel.

G. Form work: AC1347, APA B-B Plyform. Class 1. fiber glass-lined. Seal corners to prevent leakage and/or as per American Cast Limestone.

H. Admixtures: Per American Cast Limestone Mix Design.

2.2 ACCESSORIES

A. Bonding Agent: Latex modified thin set by American Olean, Dal-Tile or similar approved.

B. Curing Compound: As per American Cast Limestone Sealer - Prosoco Natural Stone Treatment.

2.3 MIX

A. Maintain water content as constant as possible.

B. Maintain consistent quantities throughout job.

C. Maintain temperature during casting of no less than sixty degrees Fahrenheit and not to exceed eighty degrees Fahrenheit - 24 hours.

2.4 FABRICATION

A. Compressive strength at 28 days- 3900 pounds per square inch.

B. Absorption not to exceed 10% average at boiling. 5 hours.

C. Construct units according to ACI 304.

D. Provide suitable wash on all exterior seals, coping, projecting courses, and pieces with exposed top surfaces.

E. Window sills shall have raised fillets at back side unless shown otherwise.

F. All projecting pieces shall have drips under the outer edge.

2.5 FINISH

A. Finish at face and exposed edges: Per American Cast Limestone sample. Perform at plant.

B. Exposed surfaces to exhibit the fine grain texture of natural stone with no air pockets-“bug holes”.

2.6 FABRICATION TOLERANCES

A. Stone Dimensions: Plus or Minus 1/8".

B. Maximum out-of-square or out-of-alignment: Plus or Minus 1/8" in 10 feet.

C. Maximum bowing: Length of unit Plus or Minus 1/8" in 10 feet.

PART 3 EXECUTION

3.1 INSTALLATION

A. Set stones accurately, in accordance with approved shop drawings.

B. Clean stone prior to setting to achieve full bond with adhesive.

C. Set stones per manufacturer with all vertical joints full. Fill all anchor and dowel holes full with mortar.

D. Rake joints after setting to a depth of 3/4 inch. Sponge face of stone to remove mortar.

E. Pointing:

1. Dampen joints and point, tooling face to a smooth concave surface.

2. Pointing Mortar: 1 part non-staining cement, 1 part hydrated lime, 4 parts clean washed sand. Add color pigments as required.

F. Set partially or wholly horizontal stone with unfilled vertical joints. Apply sealant to vertical joints in accordance with section 07900.

3.2 CLEANING

A. Remove any mortar from face of stone. Scrub face of stone with fiber brush and soap and water prior to pointing. Thoroughly rinse with clear, clean water. Do not use acid or masonry cleaners.

B. Cast stone shall show no obvious repairs or imperfections other than minimal color variations when viewed from twenty (20) feet in daylight with unaided eye.

3.3 TOLERANCES

A. Setting: Plus or Minus 1/8 inch out of plane from adjacent unit.

END OF SECTION