Thin Brick and Thin-Cut Stone Take on Full-Dimension Masonry Products

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Installation Concerns

Generally, failure of thin stone or thin brick veneer in the field is the result of poor installation. Veneer that has not been properly adhered to the substrate, or water that has infiltrated the application are typical reasons for breakdown of the installation.

Code Compliance

When installing thin masonry veneer as an adhered veneer application, several model building codes offer guidance. For standards on weather resistant barriers, metal lath and fasteners, mortar and stone dimensions and area, the following codes should be consulted:

  • 2006 International Building Code (IBC) (Section 1405.9)
  • 2006 International Residential Code (IRC) (Table R703.4 Note Z)
  • 2005 Building Code Requirements for Masonry Structures,Masonry Standards Joint Committee Code, ACI-530-05/ASCE 5-05/TMS 402-05 (Sections 6.1 and 6.3)
  • 1999 Standard Building Code (SBC)
  • 1997 Uniform Building Code (UBC)

As building codes vary by region, it is important to check local building codes for proper installation guidelines. Particularly in areas with frequent seismic activity, code requirements may be more stringent.

Design Control

Thin brick veneer may be installed right out of the box, and while it is possible to do this with thin rock veneer, many masons prefer to lay out the product on the ground or floor to facilitate planning and to ensure an easier installation and design control. Prior to actual installation, masons should complete necessary trimming of stones or bricks. "Thin veneer works well around windows or any penetrations," says Kazenske. "It's easy to crack on the spot and notch it around the opening. You'd have trouble doing that with full-dimension masonry."

Mortar color selection will have a significant effect on the overall product appearance. Mortar joint dimension or elimination of the mortar joint (dry stacking) will affect the overall product appearance and the amount of material needed per square foot.

Veneers can be installed in a straightforward design or in a random pattern that is eyed and set by the mason. That is why care in selecting a qualified mason will be well worth the effort: an experienced mason that can jigsaw irregularly shaped stones into a coherent design will assure the project has a pleasing aesthetic.

There are many ways to install thin veneer materials, and the installation method depends on the wall or foundation to which the product is being applied.

Applications

There are many ways to install thin veneer materials, and the installation method depends on the wall or foundation to which the product is being applied. Generally, installation of natural thin stone veneer is uncomplicated. The veneer may be applied directly over any clean masonry surface such as concrete block, brick or cement. "Thin natural stone veneer installs just like thin synthetic stone," says Robinson Brick's Hambleton. "People have a pre-conceived notion that natural rock is heavier and it is harder to install. But a smooth-backed natural stone sticks better than the rough backs of synthetic stone because manufactured stone can absorb the moisture out of the mortar prior to curing, resulting in a weaker bond."

Adhered natural thin stone veneer is supported by the wall to which it is attached, with the structural backup resisting any loads. Wood framing, metal framing, concrete block or poured-in-place concrete structural backups are all available. For all applications, Type S mortar conforming to ASTM C270 is recommended. Composed of 1 part cement, ½ part lime, and 4½ parts sand, Type S is a general-purpose mortar used in above-grade exteriors with exposure to severe weather conditions. Type S is also used in interiors and all load-bearing structures unless otherwise specified.

 

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Originally published in Architectural Record
Originally published in December 2007

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