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Intallations

installations

Product delivery and storage

Delivery

  • Tick the boxes on the delivery note to show you have received the correct amounts.
  • Highlight any issues to Chelsea Stone.

Storage

  • All product should be stored in a dry and safe manner. Mortar should be covered at all times.
  • Ensure that cardboard boxes containing stone are kept as dry as possibl

Preparation of the surface

a) BLOCK OR BRICK SURFACES

No surface preparation is required although it would be advisable to apply scratch coat with a water sealer for chimney stacks to minimise water penetration. Check newly poured concrete surface for oils or release agents by spraying with water. A release agent can be detected if the water beads up or runs off the wall.

b) PLYWOOD OR OTHER RIGID WOOD RELATED SHEATHING

Cover the wall with a weather resistant barrier ( breather membrane) .The building paper should be applied horizontally with the upper layer lapped over the lower layer not less than 100 mm. Where vertical joints occur the paper should be lapped not less than 150 mm .Interior stud walls ( wood framing) should have a metal lath installed. Exterior applications will require a galvanised metal lath. Apply a 10mm/12mm thick base of mortar over the metal lath and allow to set for 48 hours.

Mixing mortar

  • Put water into container.
  • Mixing mortar powder in with the water and mix.
  • Add enough water to get right consistency.
  • A good test to see if mortar is at the right consistency is that the mortar should cling to the trowel when held vertically and should release with a shake.
  • Wet the back of stone if conditions are very hot or very dry.
  • To prevent waste use a small petrol or electric mixers.
  • Only mix mortar as required.

Laying out the stone

  • It is good practice to mix stones from different boxes.
  • This creates a balance between different colours, shapes, thickness and textures.
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Pointed stone installation

  • Mortar joints are better off narrow but should be consistent.
  • Fill large gaps with small stones.
  • Evaluate your work as you go along.

Cut and trim the stones if you need particular size stones to fill the gaps

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Use a pointing gun to fill joints, overfill the joints to avoid pitting

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Raking out

  • When mortar is firm to the touch, (thumbprint dry) it is ready to be raked out. Drying time will vary due to weather conditions.
  • It is important not to rake out joints until the mortar is powder dry to avoid staining the edge of the stones.
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Brushing off

  • Compress and rake out the excess mortar for a clean look. Don’t rake too deep, check your previous work as a reference for consistency and constant width joint.
  • If mortar accidentally gets on the stone when applying do not rub off, wait until the mortar has set and then brush off.

Joint finishes

1) Standard Raked

  • Set the stone one finger apart and use a pointing gun to fill in the gaps.

2) Dry Stack

  • The finished look will appear as if no mortar was applied but it is important to have joints sealed with mortar.

3) Flush finish

  • Overfill joints to start.
  • Rake back pointing flush with stone face.
  • Over grout can effectively hide any broken or cut edges.

Trimming

  • For best fit, stones can be cut or shaped using a hatchet, wide mouth nippers or a mason’s trowel edge. Straight lines can be cut with a water saw or grinder.
  • Cut edge should be turned down when below eye level and up when above eye level to ensure that they cannot be seen.

Good practice

  • It is important to divert water run off from the stone surfaces by gutters and flashing as this may cause staining. Retaining walls should be waterproofed at the fill side and incorporate provisions for adequate drainage.
  • Tick the boxes on the delivery note to show you have received the correct amounts.
  • Fit cornerstones first and work from the corners inward.
  • Corner pieces have long and short legs which should be placed alternatively.
  • If the application is being done in very hot /dry climate spray the wall surface and the stones with water.
  • When using brick it is important to keep the work level.
  • Chalk marks should be marked every 100 mm to 200mm, it is also important to stagger the joint lines both vertically and horizontally.
  • Building code requirements vary from country to country.
  • Check with your local authorities for building control regulations.
  • Read your instruction leaflet before you commence work.
  • The preferred method of installation is not to cover the surface with mortar but to apply it to the stone. Ensure complete cover between mortar bed and the stone.

Do Not !

  • Use acid or acid based products as this will damage the stone.
  • Use a wire brush as this will damage the stone face.
  • A high pressure power washer.
  • Let loose mortar dry overnight.
  • Use a wet brush as this may leave permanent staining.
  • Sandblast.
  • Use Corner stones or flat stones in exterior horizontal planes or to cap walls in high freeze thaw area’s.
  • Use our stone below water level as in swimming pools.
  • Chlorine and other chemicals may discolour product and other masonry materials.

    • Housekeeping, Responsibilities for waste & Scaffolding

    Housekeeping

    • Ensure the site is kept tidy and safe at all times, this includes securing nylon banding, cardboard boxes, mortar bags etc. Foam should be secured to prevent from blowing away. Taking these precautions will help minimise waste, keep control on products and prevent accidents.

    Responsibilities for waste

    • Unless stated in the contract, all waste is the responsibility of the client/contractor.

    Scaffolding

    • Ensure a qualified scaffolder has fitted the scaffolding. All stone should be at ground level and not be left on the scaffolds overnight .Any unused stone should be stored and not left around possibly causing an accident or posing a risk.