1. Preparing the surface for manufactured stone

Our manufactured stone products can be applied to any structurally sound surface. Due to its light weight, no special foundation or structural alterations are necessary. On masonry walls (block, poured concrete, full brick) install 2.5 galvanized mesh directly to surface using concrete fasteners with a minimum of 3/4″ length and a minimum 3/8″ diameter head. For all wood or steel stud construction, all exterior sheatings should be covered with weather resistant barriers with an ASTM E1677 Type 1 such as Tyvek®. Apply a minimum of 15 lb. Felt Paper as well. Then 2.5 galvanized metal lath should be attached with galvanized nails or staples penetrating 1″ into stud, 16″ on center, with nails 6″ apart. Lath to metal studs should be done with non-corrosive self tapping screws having a minimum of 1″ in length and minimum of 3/8″ diameter head. Metal lath must overlap 4″ at horizontal and vertical joints. Vertical joints must overlap on a stud.

2. Applying the Scratch Coat

As a rule, lathed surface should be covered with a thin coat mortar (Type 5 ASTM C720) and allowed to set prior to installing the manufactured stone. Mortar can be mixed with enough water to achieve a workable (not too wet, or dry) consistency. The same can be used for scratch coating, for applying the manufactured stone and for grouting the joints.

3. Mortaring the manufactured stone

Before starting to install manufactured stone, it is best to lay out the manufactured stone near your working area to give you a better choice of stone. Select a stone and apply a 1″ thick, even layer of mortar to the back of the stone.

4. Applying the manufactured stone

Press the manufactured stone firmly into place on the wall surface so that mortar behind the stone squeezes out around all sides. Using a gentle wiggling action while applying the stone will insure a good bond.

In warm weather, masonry surfaces may need to be dampened prior to installing the stone so that the moisture will not be drawn from the mortar to rapidly. To keep the stone clean during construction, start installing manufactured stone at the top of the wall surface and work down. Install the corner stones first for easiest fitting. When selecting stones, try to achieve a balanced pattern of shapes, sizes, colors, thickness and textures. Keep the mortar joints between the stones as tight and as uniform as possible. Avoid long straight unbroken lines.

5. Trimming the manufactured stone

When necessary, manufactured stones can be cut and shaped with a hatchet, brick trowel or nippers to form special sizes and shapes for better fitting. Always try to position the trimmed stones on the wall surface so that the cut edges will not show.

6. Grouting the Joints

After all of the manufactured stone has been applied to the wall surface, fill a grout bag with mortar, and in the manner of decorating a cake, partially fill the joints between the stones with mortar. Be sure, while grouting, to cover any noticeable broken stone edges with mortar. If you prefer colored mortar joints, oxide colors can be mixed with your mortar prior to grouting. All J & N Stone must have grout between each stone. We DO NOT WARRANTY a dry stacking installation.

7. Striking the Joints

When the mortar joints become firm, use a wooden or metal striking tool to rake out the excess mortar to the desired depth and at the same time to force the mortar into the joints to thoroughly seal the joint edges. Be careful not to work the joints too soon or the mortar will smear.

8. Brooming

Brush the mortar joints with a whiskbroom or soft brush to smooth them and clean away the loose mortar. At the same time, broom off any mortar spots from the face of the stone. Loose mortar and mortar spots which have set for only a few hours clean up easily and should never be allowed to set overnight.

9. Completion

Manufactured stones do not require a sealer to warrant its guarantee. J & N Stone does not cover damage to its product from building settlement, excessive contact with salt or de-icing chemicals, paint or airborne contaminants. ACID should NOT be used for clean up. Consult your dealer or call J & N Stone, Inc. for more details.