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Masterguide - norstone Wall and Facade - Natural Stone Panels
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Masterguide - norstone Wall and Facade - Natural Stone Panels

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  • 1. europe norstone panel masterguide Norstone is a manufacturer and supplier of premium natural stone products for designer residential and commercial world Markets. Established in 2002, norstone has forged its name by maintaining the highest standards in the industry for quality control, product design, and customer service. We’re as passionate about your project as you are. Internet: www.norstone.eu T: +45 20484997 Email: sales@norstone.eu © 2009 norstone europe 1/10/2009
  • 2. norstone europe norstone global europe moelvangvej 94 po box 824 7300 Jelling narrabeen denmark sydney, nsw, 2101 +45 2048 4997 +614 1238 7817 fredi@norstone.eu sales@norstone.com.au norstone.eu norstone.com.au Table of Contents Introduction to the Norstone Panel .................................................................... 3 Tools and Material needed ................................................................................. 3 Preparing your substrate for installation ............................................................. 3 Installing over open stud walls ........................................................................... 4 Installing over block, brick, cmu, or poured concrete ........................................ 4 Installing over steel ............................................................................................. 4 Installing the Norstone Panels ............................................................................ 4 How to address corners ...................................................................................... 5 Special Note on moisture rich environments and freeze thaw climates ............. 5 Post Installation Guidelines ................................................................................ 5 Cleaning ............................................................................................................. 5 Sealing ................................................................................................................ 5 Ongoing Maintenance ....................................................................................... 5 Appendix A – Substrate Detail ........................................................................... 6 Appendix A details proper installation procedures over various substrates in both interior and exterior applications. Please direct all questions to: norstone europe at 0045 20 48 49 97. Open Stud – Cement Board – Exterior………………………………………...…... 6 Open Stud – Lathe and Mortar – Exterior………………………………………..... 7 Open Stud – Interior………………………………………………………………….. 8 Concrete...……………………………………………………………………………... 9 Steel – Epoxy Adhesive…………………………………………………………….... 10 Steel – Lathe and Mortar…………………………………………………………….. 11 © 2009 norstone europe 1/10/2009
  • 3. norstone europe norstone global europe moelvangvej 94 po box 824 7300 Jelling narrabeen denmark sydney, nsw, 2101 +45 2048 4997 +614 1238 7817 fredi@norstone.eu sales@norstone.com.au norstone.eu norstone.com.au Introduction to the Norstone Panel Tools and material needed Norstone Natural Stone Panels are produced by norstone Pty Ltd., [1] For cutting and modifying Norstone Panels, a quality brick or of Sydney Australia. For information not contained in this docu- tile water saw with a continuous rim diamond blade is required ment, contact Norstone Europe at 0045 20 48 49 97. The Norstone and should tilt if miter cuts are necessary; these are usually availa- Panel concept is aimed at providing the look and feel of stacked ble for hire on a daily basis from large equipment hire firms in your natural stone at the low cost installation and speed of tile. Norsto- area. If pre-fabricated corner units are to be used, or if the mitering ne Panels strictly adhere to the following physical properties: of corners is not required, a tilting wet saw is not necessary. Classification: Quartzite-based sedimentary stone. [2] An angle grinder may be used for around small protrusions in the wall such as pipes, steelwork etc. Color: Ochre Blend, Charcoal, White, Ivory, or Chalk [3] Steel trowel, 13mm round notched trowel Size: 152mm Tall by 610mm. Thickness varies between approx 15mm to 30mm. [4] scraper [5] stiff wire brush [6] masonry brush [7] large sponge [8] selected Norstone Panels [9] recommended tile thinset adhesive, (see laticrete short term specification). Optional materials that may be required, depending on the sub- strate and application include: Metal Lath Thick Bed Mortar Waterproofing Membrane Natural Stone Sealer Weight: approx 5.5kg per panel. Packaging: 4 panels per box; 48 boxes per crate = 17.5sqm per crate. Professional Installation Recommended Preparing your substrate for installation Norstone Panels can be installed by most home handyman with It is mandatory that local building codes be followed in the instal- a limited knowledge of building and construction; however we lation of Norstone Panels. Please consult your building authority strongly recommend they be installed by professional licensed with any specific questions relating to the local building codes. tradesmen. Norstone panels weigh approximately 64kg sqm; therefore it is critical that they are fixed to an appropriate substrate to en- sure a successful installation. Norstone Panels may be applied over any masonry surface, concrete block, brick, cement, etc. Painted surfaces must be sandblasted, or otherwise stripped of paint. If a new wall needs to be built of a thinner and lighter sub- strate, then there is only one product suitable - cement board. Norstone Panels SHOULD NOT be installed over drywall or sheetrock. © 2009 norstone europe 1/10/2009
  • 4. norstone europe norstone global europe moelvangvej 94 po box 824 7300 Jelling narrabeen denmark sydney, nsw, 2101 +45 2048 4997 +614 1238 7817 fredi@norstone.eu sales@norstone.com.au norstone.eu norstone.com.au Installing over open stud walls Installing over steel Norstone panels can be installed over open stud walls using either First ensure that the surface is clean and free of any surface cement board or a combination of plyboard, lath, and scratch contamination, such as rust, dirt, paint, and manufacturing oils. Re- coat. First ensure the wood or steel frame is structurally capable of fer to the steel manufacturer’s guidelines for adequately removing supporting the weight of the norstone panels. all manufacturing oils as to not interfere with the bond between If using cement board, it must be a minimum of 15mm thick to Norstone Panel and substrate. support the weight of the rock panels and must be securely fixed If the project is either exterior or will be exposed to moisture, a wa- to the framework of either wood or steel. We suggest that the terproofing / anti fracture membrane, to comply with ANSI 118.10 board be glued and screwed to the frame. First, cover the entire will be required between the mortar bed and the setting material. frame, where contact with the cement board is made, with a good quality mastic type adhesive and then fix the cement board to the Alternatively, Norstone Panels can be adhered directly to a conta- frame, screwing at 250mm centers using screws that are a mini- minant-free steel substrate using an epoxy tile adhesive,(see lati- mum of 60mm long. To ensure safety, strength and permanent crete short term specification). fixing, this work should only be done by a qualified and licensed Please refer to Appendix A for detailed substrate drawings over builder. If project is either exterior or will be exposed to moisture, steel. a waterproofing / anti fracture membrane will be required, (see laticrete short term specification) between the cement board and the setting material. If using plyboard, it must be exterior grade . If project is either Installing the Norstone Panels exterior or will be exposed to moisture, a waterproofing / anti frac- ture membrane will be required between the scratch coat and the Make certain the back of each panel is free of dirt, sand, or loose setting material. particles. When necessary, wash them completely. If the back of Please refer to Appendix A for detailed substrate drawings over the panel is dry, dampen it first with a wet sponge, but do not sa- open stud walls. turate. This prevents the panel from pulling the moisture from the adhesive, allowing it to cure naturally and with a stronger bond. Select a tile adhesive that meets or exceeds local standards stan- dard, and mix per the manufacturer’s instructions (see laticrete Installing over block, brick, cmu, or pou- short term specification). When laying rock panels it is necessary to start the bottom row on a level line in order to maintain con- red concrete sistent levels in each row as you work up the wall. Always start First ensure that the surface is clean and free of any foreign agents, installing Norstone Panels at the bottom row, and start each row including paint that may interfere with the bond between stone at an outside corner if one exists. It is also important that they rest and substrate. This may require light sandblasting or waterbla- on a secure base such as a concrete floor or footing to help carry sting. the weight until the thinset has fully set. The panels should be laid in a randomized, staggered fashion, in an effort to minimize any ** Special note for pre-fabricated concrete tilt up construction – all vertical seams lining up from one course to the next. The panels release agents must be removed from concrete surfaces prior to should not be ”stacked” one on top of the other in a single line Norstone up the wall, nor laid in a running or brick bond pattern as this in- Panel installation. creases the likelihood of patterned or vertical seams being visible from the wall. Next, in all installations over brick, or over other concrete substra- tes with uneven surfaces, a thick bed mortar mix, is troweled onto When fixing the stone panels use a generous amount of re- the substrate to even out any inconsistencies in the substrate and commended tile adhesive and apply it to the back of each panel provide a mortar base with which to adhere the setting material and to the wall. It is important to screed the tile adhesive on to the to. If the project is either exterior or will be exposed to moisture, a wall as would normally be the application method used for laying waterproofing / anti fracture membrane will be required between tiles. By applying the adhesive to the back of each panel and to the mortar bed and the setting material. the wall, this ensures the maximum possible adhesion to your wall surface, as all the gaps, voids and cracks are filled. Please refer to Appendix A for detailed substrate drawings over concrete substrates. Press each panel into the adhesive, rotating slightly, forcing some of the adhesive to squeeze out freely. Any adhesive forced out beyond the finished joint or on the panel surface itself must be removed before the adhesive is allowed to set. Tight joints will provide a neat appearance. Be sure not to allow any adhesive to harden on the face of the panels as this will help in the cleanup process. © 2009 norstone europe 1/10/2009
  • 5. norstone europe norstone global europe moelvangvej 94 po box 824 7300 Jelling narrabeen denmark sydney, nsw, 2101 +45 2048 4997 +614 1238 7817 fredi@norstone.eu sales@norstone.com.au norstone.eu norstone.com.au How to address corners Moisture Rich Environments – It is critical that a waterproofing membrane be applied between the substrate and tile adhesive to Outside 90 degree corners can be handled either by [1] using form a waterproof barrier. This will ensure moisture will not reach Norstone pre-fabricated finger jointed corner units or [2] miter- the substrate material and potentially degrade its ability to sup- cutting individual flat panels. Corner units provide for a smooth, port the Norstone Panels. finished look, and are easier to install, but are appropriate for 90 degree corners only. Mitering provides for a nice clean edge at Freeze / Thaw Climates – Norstone Panels will not be affected the corner, however do require a higher level of skill to fabricate at all by the normal freezing and thawing of the climate which on site. Miter-cuts should be used in all off-angle (45°, 60°, etc) they are exposed to, however, the same cannot be said about the corner applications. substrate to which they are applied. It is critical that a waterproof / anti-fracture membrane meeting or exceeding be applied bet- Corner Units are installed by forming the corner on site, cutting ween the substrate and tile adhesive to form a water and fracture the returns down to size as necessary, and adhering the stone proof barrier, capable of resisting substrate movement during fre- to the substrate in the same manner as a flat panel. Corner units eze thaw cycles. stand 152mm tall, and are comprised of two sides: one approxim- ately 200mm, and the other approximately 410mm. Special care should be made to alternate the returns as the installation pro- gresses up the corner so as to prevent any patterns forming in the Post Installation Guidelines wall which may lead to the appearance of vertical seams. Cleaning. Excess dirt and film may be removed using clean water and a stiff brush, it is important not to allow adhesive to dry on face of the stone panels. Remove it prior to it hardening. Acidic cleaning agents should not be used as these could activate iron content in the stone causing rusting or leaching. Sealing. Natural Stone may be sealed with a good quality pene- trating sealer only after thoroughly curing which usually takes 4 weeks on inside work. Follow the manufacturer’s instructions on the application of sealer. Sealed stone may be easier to keep clean than unsealed stone and certain sealers also repel stains. However, sealers must be periodically reapplied, especially on exterior ap- plications, and could alter the natural coloring of the stone. Ongoing Maintenance. Though natural stone will last many life- times, routine maintenance may be required from time to time. Depending on the application – as with any wall finish - various types of scaling or build-up may occur. Should you experience a need to clean your Norstone Panels please adhere to the follo- wing recommendations: • Regular dusting for interior applications and hose washing for To use a miter cut for an outside corner, select one panel and exterior applications is recommended. mark the point where the join should be, which is determined by • In the event that cleaning agents are needed, please select the position of the adjoining norstone panels. Once you have mar- a natural detergent that is non-corrosive and non-acidic to ked where to make your cut, make a straight cut to separate the remove build-up in problem areas. Test your detergent in an panel into two pieces; once the panel has been cut into two sepa- inconspicuous place to verify compatibility and results. rate pieces, cut each on a 45 degree miter to form a right angle. NOT making a straight cut (or separating the panel) prior to the • In some cases, a low grade pressure wash may be used. mitered cut could render the thicker pieces on the opposing panel However, the stone should never be exposed to a direct angle vulnerable to direct attack from the saw blade, so it is important to of attack from the nozzle. Note that up-close attack from a designate and separate the panel prior to mitering it. pressure washer may corrode the stone, so please stand a minimum of 1.5 meters away when pressure washing. Once cut, check the panel to make sure it forms a perfect 90° cor- ner. The color, the width and thickness of the stone pieces should WARNING match to form a continuous look that seems to ”flow” around the corner. Never use 2 different panels to form a corner. Every Please DO NOT: Norstone Panel is unique so the results would be very disappoin- • Acid wash the stone. ting, because nothing matches. • High-Pressure Wash the stone (directly or indirectly). Special Note on moisture rich environments and freeze thaw cli- mates Natural stone is an excellent choice of building material for • Use any sharp object, such as a steel scraper, knife, or screw- any environment and climate, be it interior or exterior, adjacent driver, to remove stubborn deposits from the face of the sto- or completely submerged in water, desert hot or polar cold. Cer- ne. This can result in damage to the natural texture of the tain products should be used and procedures followed in some of product. these environments, as noted: © 2009 norstone europe 1/10/2009
  • 6. norstone europe norstone global europe moelvangvej 94 po box 824 7300 Jelling narrabeen denmark sydney, nsw, 2101 +45 2048 4997 +614 1238 7817 fredi@norstone.eu sales@norstone.com.au norstone.eu norstone.com.au Open Stud – Cement Board – Exterior Open stud wall Exterior grade plyboard Exterior sheathing Cement board Norstone Panels Anti fracture / water proofing membrane Polymer modified thinset © 2009 norstone europe 1/10/2009
  • 7. norstone europe norstone global europe moelvangvej 94 po box 824 7300 Jelling narrabeen denmark sydney, nsw, 2101 +45 2048 4997 +614 1238 7817 fredi@norstone.eu sales@norstone.com.au norstone.eu norstone.com.au Open Stud – Lathe and Mortar – Exterior Open stud wall Exterior grade plyboard Exterior sheathing Wire lathe Thick bed mortar Norstone Panels Anti fracture / water proofing membrane Polymer modified thinset © 2009 norstone europe 1/10/2009
  • 8. norstone europe norstone global europe moelvangvej 94 po box 824 7300 Jelling narrabeen denmark sydney, nsw, 2101 +45 2048 4997 +614 1238 7817 fredi@norstone.eu sales@norstone.com.au norstone.eu norstone.com.au Open Stud – Interior Open stud wall Cement board Norstone Panels Polymer modified thinset © 2009 norstone europe 1/10/2009
  • 9. norstone europe norstone global europe moelvangvej 94 po box 824 7300 Jelling narrabeen denmark sydney, nsw, 2101 +45 2048 4997 +614 1238 7817 fredi@norstone.eu sales@norstone.com.au norstone.eu norstone.com.au Concrete Brick, block, cmu or poured concrete Note: Scratch coat should be applied to poured concrete if surface is uneven. Norstone Panels Anti fracture / water proofing membrane Polymer modified thinset © 2009 norstone europe 1/10/2009
  • 10. norstone europe norstone global europe moelvangvej 94 po box 824 7300 Jelling narrabeen denmark sydney, nsw, 2101 +45 2048 4997 +614 1238 7817 fredi@norstone.eu sales@norstone.com.au norstone.eu norstone.com.au Steel – Epoxy Adhesive Metal/steel stud wall Steel sheathing Tack welded wire lathe Thick bed mortar Norstone Panels Anti fracture / water proofing membrane Polymer modified thinset © 2009 norstone europe 1/10/2009
  • 11. norstone europe norstone global europe moelvangvej 94 po box 824 7300 Jelling narrabeen denmark sydney, nsw, 2101 +45 2048 4997 +614 1238 7817 fredi@norstone.eu sales@norstone.com.au norstone.eu norstone.com.au Steel – Lathe and Mortar Metal/steel stud wall Steel sheathing Norstone Panels Epoxy tile adhesive © 2009 norstone europe 1/10/2009