Masonry Magazine January 2008 Page. 36
THIN STONE
Installation
Thin stone from Delaware Quames comes with an image of the stone on the box along with step-by-step installation instructions. Natural thin stone veneer can be applied over any masonry surface, concrete block, brick, cement, etc. Painted surfaces must be sandblasted or stripped of paint. If it is difficult to remove paint, or if the surface is frame construction, an 18-gauge metal lath should be nailed to the wall securely, six inches on center. If it's an exterior wall, a vapor barrier should be applied first, and then the metal lath. Next, a scratch coat is applied to the lath, assuring the lath is covered completely with a thin coat (1/2- to 3/4-inch thick). The mason should use a metal scraper or small scrap of lath to lightly rake horizontal grooves into the scratch coat, and allow it to set or cure. At this point in the process, the surface is ready for the thin stone veneer to be applied. From this point, the mason follows a basic application of the thin stone using Type S mortar spread 1/2-inch thick.
The thin veneers usually are shipped on pallets, though New Hope, Pa-based Delaware Quarries packages its TruStone product in boxes made of corrugated polypropylene to protect from the elements, according to George Cannell, director of the company.
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Something to think about: Consider the term "concrete stone." Can the word "concrete" describe a pre-existing, natural material such as stone?
"The containers also have stacking cleats for added safety," Cannell says. "To make things easier for the thin stone 'mechanics' who will lay the material, installation instructions are included on the outside of the box in both English and Spanish. The installer can start applying the thin stone to the top of the wall and work his way down."
Thin vs. full-bed stone veneer
FOR THOUSANDS OF YEARS, stone has been the building material of choice. Castles and monuments were constructed of stone blocks a few feet in thickness, because their builders wanted them to last forever. That endurance has translated into a symbol of lasting beauty today, as stone is a part of any project that commands a high-class appearance. Natural stone is thought to be simply a timeless building material.
Though natural stone is loved by many, it was, for a long time, afforded only by some. Thin stone makes a natural stone product a possibility for many reasons. The material is less costly to ship, usually about one-quarter the price of shipping a load of full-bed stone veneer. Stone is often quarried on one continent, sometimes fabricated on another, and used in construction on a third, meaning transportation costs cannot be ignored. Depending on the distance, this could mean tens of thousands of dollars and more in savings when shipping a thin stone veneer.
Labor costs are considerably less for two reasons: ease of installation and time involved. Lifting and applying a product that weights much less is going to speed up the installation process, plain and simple. The amount of time saved is about 50 percent. Since the product is easier to install, shop drawings are not necessary. Structural support is not necessary; builders can install thin stone on a frame or block structure.
The intensity of a considerably heavy stone product is reduced through the use of thin stone, which is much kinder to the backs and other body parts of mason and bricklayers. It is safe to assume that with fewer workman's comp claims, the cost of workman's comp insurance in this particular industry might decrease over time. This insurance is costly as any mason