RECOMMENDED TOOLS

• Screw Gun(s)
• Drill with bits
• 48" Level & 24" Level
• Snips or Linesman Pliers to cut out shims
• Circular Saw with dry cut diamond tipped blade
• Screw Drivers (to pry panels when shimming)
• Dead Blow Hammer
• Small Paint Brush to clean debris from ILC's

FRAMING CONSTRUCTION

Steel stud or furring must be designed and installed for maximum deflection limited to L/240, and not to exceed allowable stresses. Lateral support and bridging must be installed. This system does not provide lateral support for stud framing.

Framing must be erected plumb and true. The maximum variation from a true plan should not exceed 1/8 inch in 10 feet. Defects must be corrected prior to proceeding with panel installation.

Framing members must be located according to shop drawings prepared or approved by the stone panel-installing contractor. These drawings must account for panel joint locations in order to provide adequate attachment for each panel. The maximum variation from shop drawing dimensions locations should not exceed 1/8 inch in 10 feet.

JOBSITE STORAGE

Panels must be stored in a clean dry area, free from contamination. When removed from the packaging crate, they must be placed on a shock absorbent support such as expanded polystyrene for edge protection.

It is recommended that panels be placed so that identification numbers are easily readable when they are removed from the crates. This will minimize the amount of time required to search for panels, as they are needed for installing. Reduced handling will also reduce labor cost and the possibility of edge damage caused by bumping and dropping panels.

StoneLite^® Panels are durable and impact resistant. However, the natural stone facing is easily chipped at edges and softer stones can be face marred. Softer stones including limestone's and marbles can be stained by dirt, mud and other contaminates.

STAGING

Material handling is a most important factor in determining whether the project will be successful for the installer. The majority of installing labor hours is needed for moving panels from the delivered pallet/crate to the final location on the building.

The panels normally come crated by size to minimize damage during shipping. You may need to unpack several crates to get the correct panels for an elevation. A crating list will be provided to show what panels are in each crate.

It is strongly recommended that panels should be staged in advance and moved to the installing location in a manner that will reduce labor hours on the scaffold. The first panel needed should be located on the outside of an upright sloping rack, or on top of a flat stack. All panels should be arranged in the order needed for installing.

INSTALLING

NOTE: The following suggested instructions are intended for vertical wall panels only. If a horizontal soffit or sill is included, some modification to these instructions will be necessary.

NOTE: The location for interlocking Channel (ILC) extrusions will be specified on the shop drawings.

a) Following the shop drawings, measure the wall to determine exact panel locations and mark the positions of panel edges at the base of the wall. Check the vertical panel edge locations relative to framing locations for assurance that ILC sections will have framing support.

Use a laser or level to establish a fixed elevation for the total construction area. From that elevation, mark on the framing, or existing wall, the exact location of all bottom panel lower edges. The shop drawings will indicate the location of the ILC's from the bottom of the panel.

Using a transit or laser, check the elevation for alignment to find the most outward point(s). This will determine the installing "plane" and the amount of shimming required. Drop a string line (piano wire is recommended for this) from the top of the elevation to the bottom of the elevation. This string line should be set at least two inches from the most outward point of the elevation. This will be your reference line which you will measure back from to establish the plane for all of the ILC' sections and panel faces.

b) Drop a plumb line at the location where installing will begin. Position the vertical edge of the ILC section at the beginning vertical edge as indicated by shop drawings, flush with the line. Clamp the first ILC section in place, then screw attach the ILC sections to the framing, through the groove in the section, at each end and at 24" o.c. maximum or as specified by Stone Panels, Inc. shop drawings. Excess ILC length should be cut off and used where possible.

c) Once the first field ILC section has been installed, panel installation may proceed. Spray the field ILC sections on wall with soapy water or rub a small bar of soap over them for lubrication and ease in setting. Set panels above and against the ILC sections, then slide them down so that the section on the panel engages with the section on the wall. The channel hanging off the top of the panel may now be screw attached to the framing. Use levels and plumb lines to determine amount of shimming required. Shim as necessary to maintain a flat level plane. Once the necessary amount of shims are in place, screw attach the JT-ILC section to the framing, through the groove in the section, at each end and at 24" o.c.

d) Once the first horizontal row of panels has been set, place shims equal in size to the thickness of the joint, on top of the first row of panels. Now place the next panel above and against the JT-ILC section from the panel below, and then slide it down so that the section on the bottom of the panel engages with the section on the top of the panel below. The panel above should rest on the shims placed on the panel below to set the joint thickness. The ILC at the bottom of the panel should not fully engage with the JT-ILC. The channel hanging off the top of the panel may now be screw attached to the framing. Use levels and plumb lines to determine amount of shimming required. Shim as necessary to maintain a flat level plane. Once the necessary amount of shims are in place, screw attach the JT-ILC section to the framing, through the groove in the section, at each end and at 24" o.c.

Field ILC sections will be required where there is no panel below such as the first row of panels, above windows, openings, soffits, etc. Or where the panel height exceeds 30" (750 mm). It is strongly recommended to check that the panels are the correct vertical and horizontal location according to the shop drawings at a minimum of every floor to be sure you are staying level and your joints are falling the in the correct locations.

e) Installation may progress horizontally or vertically depending on how the panels have been staged. Continue applying a small amount of soap film onto sections for lubrication and ease in engagement. Careful attention should be paid to aligning panel joints as the panels are installed.

CAULKING EXTERIOR JOINTS

NOTE: It is recommended that test be conducted by the sealant manufacture for assurance that neither sealant nor primer will "bleed" into the stone to cause staining. Allow 8 to 12 weeks for this testing.

a) At caulk joints around panel perimeters push round open-cell polyurethane foam backer rod between panels well into the joint to expose the veneer stone edge plus approximately 3/16 inch width of honeycomb. This should provide for approximately 3/8 inch bond width of sealant to panel, and a 1/4 inch sealant thickness at the center of the joint width.

(CAUTION: Open cell backer rod must be used with stone panels. Closed cell backer rod can emit gas into the joint when the coating is scratched by the honeycomb causing the caulking to bubble at the surface.)

b) Apply primer if recommended by the sealant manufacturer. This primer attaches itself to the stone edge surface, and the sealant then adheres to the primer. Primer will not stick to a dirty surface and it is not a substitute for cleaning.

(CAUTION: Primers are moisture sensitive and will deteriorate quickly when exposed to moisture. They should be purchased in pint containers and stored with caps tightly closed. When exposed to moisture, they form a cloudy white precipitate and must be discarded.)

c) Pour only a ten-minute supply of primer into clean container, then replace the cap on the primer can. Dip a clean, dry, lint-free cloth into the primer and gently wipe a thin film onto the stone edge surface.

(CAUTION: Application of a thick layer of primer can cause severe loss of adhesion between the sealant and primer. A powdery white film will form on the surface if too much primer has been applied. This film must be removed with a clean, dry, lint free cloth.)

d) Allow primer to dry. The surface is now ready for application of sealant. If the sealant can not be applied immediately, the surface must be protected to avoid contamination.

e) Some sealant cannot be completely removed from some stone. It may be necessary for adjacent surfaces to be carefully masked or taped to prevent sealant from getting on the surface.

f) Sealant should be applied in a continuos operation from a caulking gun. A positive pressure, adequate to fill the entire joint width, should be used. This can be done by "pushing" the sealant bead ahead of the application nozzle. Within 10 minutes after application, tool sealant into the joint. This spreads the sealant against the back-up material and the joint surfaces to obtain compaction to the panel edges. This also fills voids in the aluminum honeycomb and provides a secure bond to the honeycomb.

Do not use liquid tooling aids such as water, soap or alcohol. These materials may interfere with the curing or adhesion of the sealant.

It is critical that the sealant fills the entire joint of cavity and that it firmly contacts the panel surfaces. If this is not done, poor adhesion will result and sealant performance will be weakened.

Avoid the technique of scraping off excess sealant, which pulls sealant out of the joint and prevents bond to the panel edges.

g) Masking or taping must be removed within ten minutes after tooling. If a solvent will be used for cleaning, consult Stone Panels, Inc. for recommendations to avoid staining the stone surface and/or adversely affecting the sealant.

To view pictures of this system, CLICK HERE

For additional details on any of our attachment systems or for custom details for your application, please contact our Technical Services Staff.

Disclaimer: By writing these instructions, Stone Panels, Inc. in no way makes any warranty nor takes any responsibility for the quality of the installation of the panels, joint sealant, or any other materials. Further, these instructions are merely our suggestions on how to install the panels and seal the joints. Use at your own risk. Any warranty, representation, statement or undertaking whatsoever that may be expressed or implied by statute, custom or otherwise is hereby expressly excluded. Under no circumstances shall Stone Panels, Inc. be liable for any costs, losses, expenses or damages (whether direct or indirect, consequential, special, economic or financial including any losses of profits) whatsoever that may be incurred through the use of any information contained in the Stone Panels, Inc. website or in any other website. This website may contain inaccurate information. Stone Panels, Inc. is under no responsibility to update or correct any such information or to even maintain this website.

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