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INSTALLATION

1. Installation

To maintain quality control and ensure that the application methods meet Council requirements all Eldorado Stone (with the exception of landscaping installations) must be completed by a licensed applicator.

Eldorado Stone is a decorative, artificial stone veneer classified under the New Zealand Building Code  as a medium-weight slip. Its veneer style installation allows it to be used in new and existing buildings and applied to any timber framed building covered by NZS 3604 (Timber Frame Building) in conjunction with E2.
There is no need for special foundations or framing strengthening, this also enables the product to be used extensively above windows and roof lines and on second floor applications where the weight of real stone would be restrictive. Eldorado is also believed to be the only known stone veneer to have undertaken extensive UV testing - a must under New Zealand’s harsh UV conditions. Eldorado Stone offers a 50 year limited manufacturers warranty and stands behind 39 years of history and reputation. This product can be confidently specified as it has stood the test of time - Be sure to specify Eldorado Stone.

Eldorado Stone is generally applied as a decorative slip over an approved fibre cement board system but can also be applied over brick, concrete blocks and even some plaster applications. The veneer is fixed to the wall using specialty mortar mixes or tile adhesives that carry flexibility, waterproofing and bonding capabilities.

Where possible we encourage the use of corner stones, trim and a few simple rules of application to best replicate depth, dimension and believability of stone usage - the difference between pasting stone on to a surface, and working with the stone so that it becomes an integral component of a structure. It doesn’t take a trained professional to notice the difference.

2. Substrates

2.1 Fibre Cement Board
The most common and cost-effective form of application is over an approved fibre cement board substrate. We use and recommend BGC Stonesheet 7.5mm and 9mm sheets. Please refer to the manufacturers specifications for all sheet cutting, layout and fixing requirements.

Special attention should be paid to fulfill all E2 and building code requirements including flashings, control joints and uPVC jointing options. Please see the attached recommended details (Pages 10 & 11).

2.2 Concrete Masonry/Brickwork or Concrete Panels

The Surface must be totally free of oil, grease, paint, curing compounds, sealers, mould release agents, dust or other loose contaminating materials. If any of these materials are present the surface must be cleaned back to the original surface by sandblasting, water blasting, acid etching or wire brushing.

Prior to applying the bonding mortar, dampen the surface, then prime with a slurry coat, brushed or rolled on to a depth of not more than 2mm.

3. Waterproofing

It is critical that the substrate is fully waterproofed prior to stone application. We use and recommend FEBond SBR Waterproofing and Bonding Agent. Ensure that all relevant fibre cement board flashing and joints have been installed correctly.

FEBond SBR is a liquid bonding compound and waterproofer.
The use of FEBond SBR provides excellent bonding and waterproofing characteristics, improving overall strength.

4. Waterproofing Slurry

FEBond SBR is used both in the form of a waterproofing and bonding slurry applied to the surface and is also added to the adhesive mix for stone application.

5. Bonding Mortar

To give Eldorado Stone a realistic ‘laid-in-mortar’ look we use a traditional sand and cement based mortar with added FEBond SBR for all of the following properties:

• Improved flexibility.
• Greatly reduced shrinkage.
• Prevents bleeding.
 Earlier hardening.
• Lower water-cement ratio.
• Increased durability and toughness.
• High resistance to water penetration.
• Good frost resistance and resistance to salt permeation. 
• Excellent adhesion to steel, concrete and many building products.
• Prolonged corrosion protection.
• Similar thermal expansion and modulus properties to concrete (unlike resin mortars and primers).
• Non-toxic. Can be used with potable water.

Stone Application

Enough mortar is applied to the back of the stone (approximately 30mm) so that when the stone is pushed onto the substrate this provides a 10mm blanket coverage over the entire substrate as well as filling in between the stones. Excess mortar between the stones is raked or brushed out when the mortar becomes part-dry - different depth mortar joints can be achieved by scraping out more or less mortar depending on the desired finish. While providing increased strength and waterproofing, the mortar also creates a pointed look between the stone adding to the overall realism and 'laid-in-mortar' look. Application methods can be obtained from Hard as Rocks Ltd for building consent purposes if needed.

6. Clean Up

Use a brush or whisk broom to clean away any loose and dry mortar from the joints and stone face. Loose mortar and mortar spots which have set for only a few hours clean up easily and should never be allowed to set overnight.
Caution: Do not use wet brushed or sponges to wipe the joints or clean mortar off the face the stone as it will smear and stain. Also, never use wire brushes or acid on the stone surfaces.

7. Key Notes

• Eldorado Stone should only be installed on substrates that are structurally sound and conform to local building codes and E2 requirements.
• Eldorado Stone will be installed by trained, licensed applicators with the exception of stand alone pillars, landscaping applications and interior installations where a capable handyman or other tradesman may carry out the installation.
• Retaining walls must be waterproofed on the fill side and incorporate provisions for adequate drainage.

8. Maintenance

To clean dirt or other particles from the stone, use a granulated type detergent mixed with water and a soft bristle brush. If efflorescence occurs, as it does with most masonry products, it is usually caused by moisture migration through the masonry substrate when the stone is saturated. Once the moisture is on the masonry surface, it evaporates, depositing the dissolved salts in the form of efflorescence. The efflorescence will disappear gradually with time. To clean the efflorescence right away, scrub the surface with a soft bristle brush and a solution of 1 part white household vinegar mixed with 5 parts water.

 

© 2009 Hard as Rocks