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Designing Commercial Projects with Manufactured Stone Veneer Representative Name Representing Cultured Stone ® by Boral®, Boral ProStone ® and Boral Versetta Stone ®

Bucks County Dressed Fieldstone

®

Designing Commercial Projects with Manufactured Stone Veneer Boral is a Registered Provider with the American Institute of Architects Continuing Education Systems. Credit earned on completion of this program will be reported to CES Records for AIA members. Certificates of Completion for non-AIA members are available on request. This program is registered with the AIA/CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product. Questions related to specific materials, methods and services will be addressed at the conclusion of this presentation.

Designing Commercial Projects with Manufactured Stone Veneer Learning Objectives 

MSV Project Introduction

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What is Manufactured Stone Veneer

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Advancements in Manufactured Stone Veneer

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Project Tour

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Manufactured Stone Veneer Masonry Detailing

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Mechanically Attached Manufactured Stone Veneer

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Large Format Manufactured Limestone

History 50+ Years

Today this innovation is used in various construction applications throughout the world

Manufactured Stone Veneer (MSV)  Lightweight concrete  Cement, lightweight and normal aggregate with water and mineral oxide color pigments

Manufactured Stone Veneer (MSV) Master & Mold Creation

QRY MST Mold Batch PGM Paint Pour Cure Pull Pack Store Ship An experienced team of master craftsmen shape & set each stone

Natural Stone

Master

Production Mold

Manufactured Stone Veneer (MSV) Mold Creation

QRY MST Mold Batch PGM Paint Pour Cure Pull Pack Store Ship A unique mold creation process replicates even the slightest details of natural stone

Manufactured Stone Veneer (MSV) Advanced Batching System

QRY MST Mold Batch PGM Paint Pour Cure Pull Pack Store Ship Batch Delivery System 

On staff concrete scientist ensures batch consistency of color and performance  Raw materials are tested to ensure they fit the batch specification  Automated batch delivery system enables consistent delivery of raw materials into the batch  Core samples are tested for performance. 9

Manufactured Stone Veneer (MSV) Computerized Color Pigmentation

QRY MST Mold Batch PGM Paint Pour Cure Pull Pack Store Ship Use of advanced color technology techniques and equipment delivers consistent color

Manufactured Stone Veneer (MSV) Each Mold is Hand Colored

QRY MST Mold Batch PGM Paint Pour Cure Pull Pack Store Ship Thorough training and use of standard work procedures enable consistent color application

11

Manufactured Stone Veneer (MSV) Pouring Cement Mixture into Molds

QRY MST Mold Batch PGM Paint Pour Cure Pull Pack Store Ship Manual screeding and high frequency vibration of molds enhances color penetration and durability, and controls quality

12

Manufactured Stone Veneer (MSV) Curing

QRY MST Mold Batch PGM Paint Pour Cure Pull Pack Store Ship Temperature and time controlled cure lanes deliver proper strength and color absorption

Quality in Manufacturing  Include packaging as part of your specifications Material Qualifications  Ensure the stone arrives intact and remains protected at the job site  Specify small or large quantity packaging based on your job conditions  If you have an ESR number, you must put it on the side of each packaging

Quality in Manufacturing Rusting

RUSTING Causes Might Include 

Ferrous metals in the aggregate

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No aggregate quality control specification by the manufacturer

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As the metal rusts, it expands, causing spalling and discoloration

Solution 

Require ASTM C33, C330, C331 for Aggregates and a Quality Control Process

Quality in Manufacturing Air Bubbles

AIR BUBBLES Cause 

Inadequate vibration



Inadequate mix control

SOLUTION  

Ensure manufacturer employs a robust quality control program Check with the manufacturer to see if/how they vibrate their production molds

Quality in Manufacturing Low Quality Manufacturing = Duplicate Sizes and Textures

Do you see the “like” stones?

Number of Molds Per Texture and Coloring Processes are MAJOR differentiators of product in the marketplace.

Quality in Manufacturing Stone Duplication

STONE DUPLICATION Causes might include 

Manufacturer has too few masters to support its production

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Too many molds from the same master

Solution  Avoid placing duplicate stones in proximity, to one another  Request confirmation of the manufacturers mold and master fleet for the stone you have specified

Quality in Manufacturing High Quality Manufacturing = Innovating Matching Capabilities

Natural Stone

MVM Stone

Interiors

Interiors

Single Family

Single Family

Stucco, Stone and Brick

The design flexibility of MSV allows combinations with other exterior products like:    

Brick Natural Stone Stucco Siding

Multi-Family

Commercial

Medical



Fast Food

video

Hospitality

Signage

Retail

Retail

Outdoor Living

MSV Stone Types

System Stones Modular Stone

Individual Stones

MSV Stone Types Individual Stones

MSV Stone Types Individual Stones

MSV Stone Types Individual Stones

Benefit: Design Flexibility  Significant flexibility in application and grouting  Individual stones can be used to create custom blends and unique look

MSV Stone Types Individual Stones: On-Site Blending to Create a Custom Look

MSV Stone Types Individual Stones: Blending to Create a Custom Look

40 %

10 %

10 %

40 %

MSV: Modular Systems Key Features  Fast Installation  Very Productive  Clean Installation

Benefit: Fast, Tight-Fitted  Pieces come in a standard height and varying lengths  Multiple stones within each piece  Creates a stacked, tight-fitted look  Installs faster

MSV Stone Types Modular Systems

 Faster application than natural stone  Weighs about one-third less than natural stone  Packaging expedites job site setup

MSV Stone Types Modular Systems

Manufactured Stone = Lower Cost    

Costs less than natural stone on the wall Typically requires no additional structural backup Faster to install, which means higher job site productivity Lower scrap rate

Warranty and Building Code Compliance  Includes a manufacturer warranty  Should meet current building codes  It is the manufacturer's responsibility to have their products tested, provide proof of code compliance and a warranty

Building Codes  MSV is just now being addressed in building codes  Current requirements for MSV are pulled from sections of the code required for other materials  The International Council Code Evaluation Service (ICC-ES) compiled these requirements to generate Acceptance Criteria for Precast Stone Veneer (AC 51)  Criteria allows manufacturers to prove they meet the intent of a code

ICC-ES Evaluation Report

ES Report certifies that a manufacturer meets or exceeded the standards set forth in the Acceptance Criteria for Pre-Cast Stone Veneer (AC-51) And will indicate which codes and version (ie. 2003 ore 2006 IBC or IRC) the product has been evaluated against.

Acceptance Criteria for Precast Stone Veneer – AC51  Raw materials required  Product dimensions  Product performance requirements and test procedures  Installation instruction requirements  Quality control requirements

Acceptance Criteria for Precast Stone Veneer – AC51 AC-51 Tests the following attributes:  Density  Compressive Strength  Tensile Strength  Flexural Strength  Shear Bond  Absorption 9-19%  Freeze Thaw- Durability  Thermal Resistance  Weight- Less than 15lbs. Sq/Ft  Fire Resistance

AC51 Product Performance Requirements and Test Procedures C67 Standard Test Methods for Sampling and Testing Brick and Structural Clay Tile, Including freeze thaw requirements.

You want a stone that can withstand harsh freeze thaw conditions

AC51 Summary AC-51 criteria is important because the manufactured stone has been tested for: 

Durability

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Quality

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Reliability

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Safety

Design for Success 

Use a reputable, proven manufacturer who can provide an ICC-ES Evaluation Report

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Insist on stringent, consistent production standards

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Local representation by the manufacturer

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View previous projects

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Consult a set of good detail drawings from the manufacturer

Installation Best Practices Substrate Types  Wood/Metal Framed Construction  Masonry Construction

Installation Best Practices Wood/Metal Framed Construction

WOOD/METAL FRAMED CONSTRUCTION Installation in Accordance with Industry Guidelines 1. Sheathing 2. Layers of Weather-Resistant Barrier (WRB) 3. Galvanized Metal Lath 4. Mortar 5. Manufactured Stone Veneer 6. Mortar Joint

Installation Best Practices Special Corner Consideration

SPECIAL CORNER CONSTRUCTION  WRB and Galvanized Metal Lath MUST continuously lap a minimum of 16” beyond outside and inside corners and be fastened into framing  For WRB, lap joints 6" at vertical joints and 2" at horizontal joints in shingle fashion  For Metal Lath, lap vertical and horizontal joints a minimum 1"

Installation Best Practices Metal Lath

Metal lath must be installed horizontally

Installing metal lath vertically is NOT acceptable

NOTE: Expanded Metal Lath should feel smooth going down, rough going up.

Installation Best Practices Weather Considerations

Hot/Dry Weather  The scratch coat and back of each piece of stone should be moistened with a fine spray of water or a wet brush  Concrete, masonry substrates should also be damp  This will minimize risk of excessive absorption of moisture from the mortar

Cold Weather 

Applications should be protected from temperatures below 40°F as mortar will not cure properly under such conditions

Installation Best Practices Mortar

A full 1 /2- 3 /4" setting bed of mortar behind every stone

Press each stone firmly in place, allowing mortar to ooze out around all edges

Installation Best Practices Mortar  Use a grout bag to fill joints  Avoid smearing mortar on stone  When joints are thumb-print dry, use a wood stick or metal jointing tool to rake out excess mortar, compact and seal edges around stone

Installation Best Practices Mortar  This stone failure may be the result of insufficient mortar, possibly caused by a slick back, poor mortar prep, very hot or cold environmental conditions

Installation Best Practices Concrete Construction

In Sequence  Mortar can be applied directly to untreated, unpainted masonry, concrete or stucco.  If paint or oil are present, clean the surface or install metal lath  Install MSV  Mortar Joint

Innovations in MSV

March 2013 MSV is approved over Continuous Insulation! More details & testing available at the end of this presentation.

Innovations in MSV Installation Over Continuous Insulation

Design for Success

LEED Credit Category  Optimize Energy Performance  Recycled Content  Regional Material  Low Emitting Materials  Thermal Comfort

Planning the Project

Division 4 MSV Manufacturer with Contact Information, Product Texture and Color Name (include SKU number when available)  There is a huge variety, so every detail in the specification is important  Incorporate appropriate ratios if you have selected a blend

Planning the Project Joint Grouting Styles

Options include:  Tight-Fitted  Standard 1/2"  Wide joint  Wide with an Overgrout  Consider whether you would like mortar color/tint  Will additional material be required based on your grouting selection?

Planning the Project Stone Direction

Random Placement

Laid Horizontally

Planning the Project Mortar Specification  Specify mortar color that complements your stone  Proportion, mix and color per ASTM C 270  Select a mortar type with compatible compressive strength  Selecting a mortar that is stronger than the stone may cause MSV to crack  Weaker mortar may not meet durability requirements

ASTM C 270 (psi) Mortar Type

M

S

N

O

Compressive Strength

2,500

1,800

750

350

Planning the Project Importance of a Mock-Up  Division 1  Material Transitions  Termination  Other Considerations

Planning the Project Importance of a Mock-Up  Gives everyone on the job a reference point  Sets the expectation and ensures the final look you desire

Planning the Project Importance of a Mock-Up

Compare field install against your mock-up: 

Confirm mortar joint & mortar color meets your specification

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Level & plumb

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Vertical joints do not align

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Color blended well

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Various stone dimension sizes are blended well on the wall

Suggest a mock up of window, termination and penetration treatments.

Planning the Project Importance of a Mock-Up

Group of small ‘leftover’ stones Vertical joint

Planning the Project Mock-up

Planning the Project Mock-up: Multi Family Colorado

Planning the Project At Grade Detailing

Planning the Project At Grade Detailing

 • On exterior stud walls, weep screeds and other base flashings  should be held a minimum of 4” above grade or a minimum  of 2” above paved surfaces such as driveways, patios, etc. This  minimum can be reduced to 1/2” if the paved surface is a  walking surface supported by the same foundation supporting  the wall.   • On exterior stud walls where the ACMV continues down a  concrete or CMU foundation wall, and where a weep screed  is incorporated into the wall-to-foundation transition, at the  bottom maintain minimum 2” clearance from grade, or 1/2”  clearance from a paved surface.

 • On exterior stud walls where the ACMV continues down a  CMU foundation wall, with WRB and lath installed down to  the weep screed at bottom, maintain minimum 4” clearance  from grade, or 2” clearance from a paved surface.   • Where ACMV is applied over an exterior concrete or CMU  wall, maintain 2” clearance from grade or 1/2” from a paved  surface.   • Over an exterior concrete or CMU wall that is not enclosing  conditioned space (e.g. landscape walls, pillars, columns, etc)  maintain minimum 2” clearance from grade or 1/2” from a paved surface

Planning the Project De-icing Salts

At grade where de-icing salts are used.

Calcium chloride (CaCl2) is a chemical compound formed by calcium and chloride

Planning the Project Other Considerations: Material Transitions and Terminations

Where dissimilar materials meet:  Transition between alternate cladding material  Termination at foundation walls  Flashing/Moisture Management  Clearance at grade

Planning the Project Flashing/Moisture Management

It's also important to specify flashing at any wall penetration

Planning the Project Flashing/Moisture Management  Consult the manufacturer's details or industry association guidelines and contact your manufacturer’s rep for a review  Flash appropriately at termination of MSV using corrosion resistant rigid metal flashing or a flexible adhesive-type flashing  Carefully review the boundaries between two or more cladding materials  Keep the stone 12 inches back from running water  Review with trades at pre-construction meeting

Planning the Project Other Considerations  Sealing  Efflorescence  Installers  Maintenance

Planning the Project Other Considerations - Sealing

Sealing can:  Increase stain resistance  Darken the color

But it can also:  Slow water migration through the stone  Aggravate efflorescence problems because it increases the amount of time that water is in the stone  Ask the manufacturer if they require sealing and if so, what kind  Typically done according to region and project

Planning the Project Other Considerations - Efflorescence

Causes of efflorescence on the surface of masonry  Latent salts brought to the surface by migrating water  Poor concrete mix design at the plant or lack of process control  Improper detailing and poor moisture control

Planning the Project Other Considerations - Installation  Seek the most highly qualified installers. Your manufacturer's rep can recommend a qualified installer  Request to see previous projects of the mason and specify job-type (commercial vs. residential)  It's imperative that installers follow the manufacturer's installation instructions.  Review them often for modifications  Take advantage of the resources manufactures provide: videos, technical details and design aids

Planning the Project Other Considerations – Product Cleaning and Maintenance

Review the Manufacturer’s Installation Instructions:  Clean with stiff bristle brush  Water & mild soap detergent  Rinse with water

Accents and Details

Accents and Details

Accents and Details Trim Accessories

Walls, Coping and Pier Caps

Innovations in MSV Large Dimension Stone Veneer

Innovations in MSV Large Dimension Stone Veneer

Innovations in MSV Large Dimension Stone Veneer

Innovations in MSV Large Dimension Stone Veneer

Achieving Best Practices

 MSV is a beautiful way to add color, texture and character  The manufacturer's processes and support play a key role in product quality and the design of the finished project  Your specifications and knowledge of best practices also play a major role in the final appearance and success of the project

Designing Commercial Projects with Manufactured Stone Veneer This concludes the AIA portion of our presentation Thank you for attending our presentation today A program certificate will be delivered to you Please fill out the quality commitment questionnaire form. Please see more information at : www.culturedstone.com Questions?

Environmental Practices Sustainability is at the heart of how we do business Industry leading position in sustainable practices and products Manufacturing Processes for a Sustainable Future 

Implemented a closed-loop system that allows us to reuse water during manufacturing. As a result we have reduce water consumption by 50% per ton produced since 2006.



Implemented a regrind and reuse program that has reduced our landfill waste by 80% per ton of product produced since 2009

Products for a Sustainable Future 

We incorporate a minimum of 54% pre-consumer waste stream material into all of our products.

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Our products have demonstrated through 3rd party testing to meet the indoor air quality standards of the GREENGUARD Environmental Institute. In addition, we have met the even more stringent GREENGUARD Children & Schools standard, which represents the most rigorous building product emissions criteria to date.

Design for Success Sustainability is at the heart of how we do business

LEED Credit Category  Optimize Energy Performance  Recycled Content  Regional Material  Low Emitting Materials  Thermal Comfort

Design for Success

Design for Success

Manufacturer Resources Websites, CDs and Binders • Detail Drawings • Hatch Patterns • Images For Renderings • Green Building Design Info

Designing Commercial Projects with Manufactured Stone Veneer Copyright Materials This presentation is protected by US and International Copyright laws. Reproduction, distribution, display and use of the presentation without written permission of Boral Stone Products LLC is prohibited. ©2011 Boral Stone Products LLC

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Build something great™ Designing Commercial Projects with Manufactured Stone Veneer

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