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Stone Artisans Services

How to Install Concrete Stone-Facing

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Concrete Stone Facing is a popular choice for homes. It’s durable and comes in four different styles with over 30 colors to choose from.

Concrete Stone Facing

Moisture will get past your stone veneer application and into the sheathing of the house, so it’s important that you have a game plan for moisture management. That includes a drainage mat or furring strips mounted to the sheathing.

Manufactured stone veneer is an increasingly popular way to add the look of natural stone to a building. Like any remodeling project, the success of a stone veneer installation is determined by careful preparation. Whether it’s concrete or cement board, there are several key steps that must be taken to ensure the final product performs as intended.

The first step in preparing the substrate is to wash away any dirt or oil residue from the wall surface. This helps to ensure a consistent color and texture of the finished product. It also removes any preservative chemicals that might have been added to the material to help extend its life and durability.

Once the wall is clean, a scratch coat of mortar should be applied. This can be mixed from scratch using a standard mix of one part type N or type S cement and 2.25 parts sand, or purchased as premixed scratch coat mortar. If using a premixed scratch coat, follow the manufacturer’s recommendations for application.

It is critical that the scratch coat is completely dry before applying the stone veneer. This helps to prevent moisture penetration that can lead to Efflorescence. Efflorescence is a white residue that forms when cementitious materials such as brick, CMU block, concrete, or thinset are exposed to moisture for extended periods of time. This can result in the release of volatile compounds that crystallize and leave a salt-like deposit on the face of the product.

When working with real stone veneer, it is also important to stagger the pieces. This prevents them from lining up and forming unsightly grout lines when the product is grouted. It is also a good idea to use a light colored mortar so that the joints are less noticeable.

Once all of the pieces are installed and have had a chance to set for 24 hours, a final joint finish should be applied with a pointing tool or a damp sponge. This helps to prevent moisture penetration and protects the stone from damage and stains.

In exterior applications, it is also a good idea to apply a waterproofing sealer. This will further enhance the longevity and beauty of the stone and help to minimize future maintenance needs.

Mixing

Stone masons have long relied on a mix of sand and other aggregate, cement (typically Portland cement) and chemical admixtures to create a strong and durable concrete structure. However, this process is laborious, time consuming and requires the use of hand tools. A revolutionary new adhesive has been developed that eliminates the need for mortar and greatly simplifies the process. This heavy-duty adhesive has proven to be extremely effective and is now the adhesive of choice for many professional masons.

Before applying the adhesive, it is important that all surfaces are free of dirt, waterproofing, paint, form oil and any other substance that could inhibit a strong bond. A rough texture is also necessary to ensure a good adhesion of the adhesive. The surface should have a minimum ICRI (International Concrete Repair Institute) rating of 2.

In order to make the process even easier, the contractor should use a type of mortar that is pre-mixed and ready for application. This is usually available at brick/masonry supply yards (where the pros buy their materials) and should be mixed according to the manufacturers instructions. The mixture should be like peanut butter consistency so that it can easily be spread with a masonry trowel.

If the masonry veneer is to be used for exterior applications, it is a good idea to apply a moisture barrier such as a peel and stick membrane or #30 felt paper to prevent any water penetration into the wall. This can be done before laying the veneer or after it has been installed. In either case, the moisture barrier will help to protect the stone from mold and mildew growth.

For new block or poured walls, the mason should make sure that the wall is plumb before attempting to lay the stone veneer. This will save both time and effort, as well as ensuring that the stones are set properly.

For existing block, poured or wood-frame walls, the mason should make sure that there is adequate support under the stone and that the wall is attached to the foundation with the proper wall ties. This is especially important when working with older walls, which may have shifted or settled over the years.

Pouring

Concrete stone veneer is a growing popular building material that gives homes and commercial structures a rich, upscale look. It is often installed over a concrete masonry or wood frame wall and a variety of construction methods are used. The success of a stone veneer system depends on proper installation and inspection. This TEK addresses key installation/inspection points to ensure an effective, long-lasting stone veneer system.

Manufactured stone veneer is fabricated by pouring a lightweight concrete mix into rubber forms of different styles and then using a coloring process to make the finished product resemble real stone. It is a less expensive alternative to natural stone and can be installed by the professional or do-it-yourselfer. It is important to keep in mind that manufactured stone is not as durable as natural rock and can be affected by moisture. It is a good idea to treat the stone with a silane-based, non-film-forming, breather-type masonry sealer. This will help extend the life of the stone, especially if it is located in moisture-prone areas like walls near swimming pools or hot tubs.

Roger starts his work on a clean concrete wall (any painted or stuccoed concrete must be stripped and roughed up with a power chipping hammer first) but stone veneer can also be applied over cement board or even directly to wood sheathing. Whatever substrate is chosen, it must be covered with a weather resistant barrier, galvanized metal lath and a half inch scratch coat before applying the stone veneer.

The next step is to bolt down a steel angle iron to the wall and then create a brick ledge to set the stones on. Using a level and a mason’s chisel, Roger sets the stones in an alternating pattern along the ledge. When the first row is complete, he ties in the inside corners with a piece of rebar. Roger then mortars the stones to the wall with a Type S mortar.

After 5-6 hours when the mortar has completely cured, Roger can begin laying his stone facing over the rest of the walls. He makes sure to check that the walls are plumb as he goes, this speeds up the installation and helps to avoid problems later. A mason’s hammer is also used to smooth the edges of the stones and make them fit together better.

Finishing

After the concrete is poured and rough floated, step away from your project for a day or two to allow it to cure. The surface of your concrete will dry and harden and this is the ideal environment for your stone veneer to begin bonding with it. Moisture control is the key to any stone installation. You will need a moisture barrier over your substrate (cement board, brick, or cast-in-place concrete), flashing around doors and windows, and gutters to direct water away from your stone application, not into it.

During the curing process, chemical admixtures in the concrete react with water to form strong bonds between the aggregate and other concrete elements. These chemical reactions create a strong material that is very durable and durable against impact. The water is also a natural de-icer, protecting the stone from cold temperatures and snow.

Before you begin installing the stone, a “dry layout” is recommended to determine how your design will work out and whether any adjustments need to be made. It is particularly important to verify that the wall is plumb so that you can lay the stone evenly. A level is the best tool for this.

If your concrete is going to be exposed to the weather, it should also be protected with a waterproofing membrane to prevent damage caused by rain water and sun exposure. This is especially true in wet climates.

Once you have a clear understanding of your layout, it is time to start applying the mortar. Be sure to use a masonry type mortar that has been specifically designed for your stone veneer application. Using the proper mortar will ensure long life and the proper strength to support your stone.

When using mortar, it is very important to scratch out any excess prior to laying your stones. Scratch-ing too early can smear cement on the edges of your stones and compromise the integral structure that is hidden within the mortar bed. This is why it is important to wait.

It is also a good idea to use a trowel with a fine point and to try to keep the joint widths consistent throughout your project. This will help to create a uniform appearance that is more pleasing to the eye.

Properly Cut Your Concrete
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Different Ways To Properly Cut Your Concrete

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Cutting concrete can be a difficult task. It is important to use the proper tools to avoid injury and ensure quality results.

For smaller projects, a hammer and chisel will work fine. For larger projects, consider using a walk behind concrete saw. It requires a bit of practice, but once you have it down, it will be easy to use.

1. Chisel and Hammer

If you’re looking to cut concrete block walls or a house slab, using a chisel and hammer is an effective method. This type of cutting allows you to use natural human power and is the oldest and most commonly used method. This is a slow process, but it can get the job done effectively. It’s recommended that you wear personal protection equipment and clear the area of any potential trip hazards or utilities. You should also put on safety glasses and a dust mask.

After marking the lines you want to cut on the concrete block, you should start chiseling. You should use a chisel that has a flat back and a sharp edge. You can choose a wooden chisel or one made of metal. Some chisels have concave backs, which make it easier to pare away the surface of wood. You can also purchase chisels that are designed to be inserted into pneumatic hammers, which eliminate the need for you to strike the tool yourself.

To begin the chiseling process, you should hold the chisel in one hand and a hammer in your other. Position the edge of the chisel against the concrete and begin striking it with the hammer in light blows. Keep striking the chisel in this way until you have a groove that runs along the line you marked. Once you have this, you can continue chiseling until you have broken through the block.

When you are using a chisel to break up the concrete, you should try to strike the center of the block to cause it to crack. You should avoid hitting the sides of the concrete, which could damage the chisel or weaken it. You should also avoid hitting a chisel repeatedly in the same spot, as this can chip the surface of the concrete and make it more difficult to break up.

A jackhammer is another tool that can be used to cut concrete, but it’s best used if you’re working with large slabs over a few inches thick. This tool is noisy and expensive, but it provides the power needed to break up thick concrete quickly.

2. Sledgehammer

A sledgehammer can be an excellent tool for breaking concrete. It is especially helpful when a project requires you to break concrete in awkward places where a saw just can’t reach. A heavy sledgehammer is usually constructed of steel and designed with an ergonomic handle grip. The handle’s design determines how easy it is to maneuver the head of the hammer and to direct its chipping action. A sledgehammer with a longer handle is also ideal for a demolition job because it provides more leverage and allows you to control the force of your blows.

When using a sledgehammer, be sure to follow the proper safety guidelines. Ensure that the area you’re working in is free from obstructions, and close all nearby windows. Using a sledgehammer on concrete can produce a lot of dust, so it’s important to run a trickle of water over the area as you work to keep the amount of airborne dust at a minimum. It’s also a good idea to wear protective equipment, including a mask.

Before you begin breaking your concrete, make a guideline with chalk line or spray paint on the surface of the concrete where you’re going to make your cut. This way, you can accurately locate the exact point where your cuts should be made. You’ll also want to protect any areas where you don’t want to damage with a drop cloth or plastic sheeting.

Using a sledgehammer, start at the corners of your guideline and gradually chip away at the concrete. Be careful not to hit the same spot too many times, as this will only create a hole instead of chipping it. Also, be sure to aim the sledgehammer head at an angle when hitting the concrete. This will help to separate the concrete more evenly.

If you have to cut through concrete and can’t reach the desired depth with a wet saw, you’ll need to switch to a sledgehammer. A sledgehammer has more power than a regular hammer and can be used to break through the toughest materials with relative ease.

3. Diamond Blade

Whether you’re putting in a new slab, sawing control joints or enhancing existing concrete with decorative scoring or removal, a top-quality diamond blade is the best tool to use. The reason is that, unlike abrasive blades, diamond blades will last much longer. The key is to choose the right blade for your job, and to make sure that it’s used correctly.

To achieve that, you’ll need to know what type of concrete you’re working with. For example, rebar-reinforced concrete requires a different type of blade than non-rebar-reinforced concrete. In addition, if you’re cutting aggregate-heavy mixes, it may be necessary to cut through the entire mix instead of just breaking up the surface. In such a case, you’ll need to use a wet-cutting blade, which works best with a walk-behind concrete-cutting saw (renting one of these is ideal, as it’s job-specific). This will help to disperse the hazardous airborne dust and cool the blade as it cuts, thus reducing wear on the blade.

Once you have the right blade, it’s important to follow the manufacturer’s directions for usage. This will ensure that the diamonds are distributed evenly and exposed properly, which can maximize the life of the blade. You’ll also need to wear high-grade respiratory equipment, safety glasses, a face mask, gloves, work boots and ear defenders, to avoid exposure to the dangerous abrasive particles released during cutting.

When using a diamond blade, you’ll want to mark your cut line with a piece of chalk. When you start to cut, be careful not to apply too much pressure at first – you only want to score the concrete along your marked line. Continue to make slow, controlled passes, reducing the pressure as you go. You can stop once you’ve reached the desired cut line or when your blade becomes dull.

Another important point to remember is that you’ll need to keep an eye on the blade regularly. If the diamond segments glaze over, you can remedy this by running it through a soft material like asphalt to expose fresh diamonds. Alternatively, you can purchase a “dressing stick” that has a rough surface and run it over the blade to help re-expose the diamonds.

4. Trencher

The trencher is a highly versatile machine that has many uses, including in construction, landscaping and agriculture. A trencher is capable of digging a ditch, and can be used to install pipes for water or gas, cables for electricity and telecommunications, and irrigation systems. Trenchers can also be used to make drainage channels, preventing flooding and facilitating efficient water management.

While many individuals may be tempted to use a spade when cutting concrete, this method is often ineffective and will most likely result in wasted time and energy as well as damaged equipment. When using a trencher, it is important to follow the manufacturer’s instructions and use proper safety procedures at all times.

When using a trencher to cut concrete, it is best to start with a shallow cut and work your way up. This method helps to prevent the saw from breaking or losing segments, and it also protects the blades from overheating and extending their life. It is also recommended to use a wet cutting process, which utilizes a diamond blade that is cooled by water as it cuts. This helps to reduce the risk of respiratory health issues, as well as reducing dust particles that can be harmful to the eye and lungs.

Before starting to cut, it is best to remove any furniture or vehicles from the area. This will help to contain the dust and debris, and it will make cleanup much easier. It is also a good idea to cover vents and turn off any mechanical systems that are in the area. It is also recommended to wear a face mask, thick gloves designed for heavy work, and steel-toed boots when operating the trencher.

Once the cutting is complete, it is a good idea to inspect the cut edge for any jagged edges that need to be smoothed out with a chisel and hammer. It is also a good idea to apply a sealant to the concrete slab, as this will protect it from water damage and extend its lifespan. The sealant should be a high-quality product that is specifically designed for concrete.