Back-up framing and supporting structures include light gauge steel framing (min. 18 gauge), wood studs, steel furring (min. 18 gauge, i.e.: hat channels and “Z” sections), or treated wood furring.
A foam thermal break tape should be used on all framing members, whether steel or wood.
Panels may also be installed over framing covered by plywood, gypsum sheathing or cement board sheathing.
Vertical framing members should be placed at a maximum of 24” on center or 16” in high-impact or windload situations.
Stoneflex panels can withstand a wind load up to 40 lbs. per square foot when installed using the manufacturer’s approved systems.
The Stoneflex aggregate panel is directional in the long dimension and is marked on the back of each panel indicating the top and bottom.
JOINT TREATMENT
Illustrated is a typical detail using a caulking compound. A good grade sealant should be used in all cases when filling the joints between the panels.
Recommended Caulk Joint Width 3/8” (min. 1/4”)
All panel joints should be backed by a solid surface. The size of the joints will depend on the type of caulking used, but generally, width should be twice the depth. The recommended gap between panels is 3/8” and must never be less than 1/4”.
Joints and panel edges should be free from dust and, if recommended by the sealant manufacturer, the edges should first be primed. Special care should be taken to avoid primer from being applied on the face of the panel.
It is mandatory to provide a release at the back of each joint so that the caulking compound will only stick to either edge of the panel and allow for differential movement. To accomplish this release, a polyethylene or similar bond breaker tape must be used. Care should be taken to protect the stone surface from excess sealant and to leave finished work in a neat and clean condition. For best results, it is recommended that a recognized caulking contractor be used.
Color matched foam EPDM joint gaskets are also available. (See also Accessories)
Contact CEP Panels for samples and details.
FASTENING
Due to their texture, Stoneflex panels can be face fastened using painted screw heads that are readily concealed in the aggregate surface. Fasteners have a colored head to match the aggregate as closely as possible and are available from Stoneflex, Inc.
For steel and wood framing, use no. 6 or 8 Trim Head, stainless steel, flat head, Tek or Type A point screws to a length to suit the application.
All screw holes must be pre-drilled with a hole 1/16” larger than the screw shank diameter. It is important that the hole is drilled straight and the drill is kept perpendicular to the panel.
Maximum fastener spacing's are 8” on center around the perimeter of the panel, a maximum of 1/2” from panel edges and 12” on center for fasteners in the center of each panel.
See Diagram #1.
All panels should be fully supported at the perimeter. Fastening should start at the middle of the top edge of each panel and then down, proceeding left and right of the center thereafter.
FABRICATION
Factory Fabrication
Having panels fabricated before shipment saves labor on site, insures precision, and quality control providing material that is clean and ready to install. CEP Panels, Inc. offers a comprehensive fabrication service including:
- Cutting standard sheets to special sizes.
- Pre-drilling holes.
- Cutting special shapes and cut-outs.
- Rebating, beveling, or mitering edges.
- Grooving panel surfaces.
- Prefabricating inside and outside corners.
- Preparing curved/radiused panels.
- Coating the aggregate face.
Panels are often delivered already cut to size and pre-drilled, but it is usually necessary to fabricate some panels on the job, e.g.: corner panels cut to suit a site dimension.
When fabricating panels at the factory, shop drawings and/or a detailed description of the required procedures must be submitted and approved. It is the responsibility of the purchasing contractor/customer to provide all sizes, dimensions, details, etc. Any necessary field dimensions are supplied by others.
Cutting
Stoneflex panels may be sawn, drilled, or routed using the appropriate tools.
Cutting in a shop or onsite is usually carried out using an electric circular saw with either an abrasive cutting disc (for minimal cutting) or a dry-cut diamond blade (for more extensive cutting). Operators should always wear eye protection and a respiratory mask. The panels should be face side down, held down to a flat saw bed and a guide rail used to ensure true and straight cutting. Dust should be cleaned from all panels immediately after cutting.
Drilling
Normal drilling can be carried out from either the front or the back of the panel, using a portable hand-held pistol drill fitted with a masonry bit suitable for drilling at between speeds of 900 and 1200 rpm. The drill size should be 1/16” larger than the screw shank diameter. Dust should be cleaned from all panels immediately after drilling.
CLEANING
Stoneflex panels will retain atmospheric dirt as do other aggregate surfaces. Most of this can be removed with water or a mild detergent mix. To keep panels bright and clean, the building owner should include an inspection in his annual maintenance schedule. A high pressure wash or scrubbing with a mild detergent followed by a clean water rinse, at high pressure, from the top down, using standard commercial cleansing techniques is all that is normally required. During installation or subsequently during building alterations, building site dirt and dust can contaminate the surface. This should be removed immediately.
Certain dirt and stains induced by other trades onsite may be removed by a proprietary brand of cleaner. It is advisable to test the cleaner first on a small area.
Stoneflex panels damaged onsite can be repaired with the Stoneflex Repair Kit which normally includes color matched paste, catalyst, natural stone, and written instructions.
COLOR MATCHING/PANEL SEQUENCE
Only natural stone aggregates are used in the manufacture of Stoneflex panels. Care is taken when mining and crushing to select veins in which the color remains constant.
To match Stoneflex on an existing building, a sample of the original Stoneflex panel should be submitted. It should be noted that natural stone aggregates, when mined, can vary from one deposit to another. Every effort is made to maintain consistency, but it may not always be possible to match an existing or desired aggregate exactly.
RECEIVING
It is recommended that an inventory be taken upon delivery to be sure all panels and accessories are on hand. A separate packing list page will be supplied for each individual crate.
STORAGE AND HANDLING
Extreme care should be taken when handling Stoneflex panels onsite. Panels will normally be delivered to the site on wood pallets, face side up, wrapped in plastic sheets with protective side panels. Care should be taken when lifting the Stoneflex panel. Ropes or wires should not be allowed to damage the panel edges.
The pallets should be stored flat, clear of the ground and under cover in a ventilated space. Extreme care should be taken to avoid rain or standing water as migration of moisture between the panels can cause staining or bowing. Should wet material be suspected or discovered, it must be uncrated immediately and towel dried.
Panels should always be carried vertically and care taken not to damage the surface, edges or corners. One sheet should always be lifted completely off the next. They should not be temporarily stored outside of the original shipping crate unless completely supported and separated by the protective paper. If mechanical lifting equipment is used, panels should always be properly protected to avoid scuffing from ropes or chains.
If the panels are soiled or damaged, remedial treatment should be administered immediately for best results. It is much easier to clean before the panels are in place rather than after permanently installed when the panels are more difficult to access.
It should be noted that in the manufacturing process of Stoneflex panels, an excess amount of stones is applied. Some of these may become dislodged in transport, handling and/or installation, but will in no way affect the final appearance.
End of Installation Guide