Real stone made simple

Midland Large Signs 1200mm x 300mm .indd 3
Real stone made simple
TECHNICAL MANUAL
17/06/13 10:48 AM
Contents
1.0 General Overview
1.1TechnicalDetailsPage2
1.2LimitationsPage2
1.3AcceptableSolutionPage2
1.4ProductSpecificsPage2
1.5ColourVariationPage2
1.6ProductVolumesandColoursPage2
2.0 Schist Brick Dimension Details
2.1DataSummarySheetPage3
2.2SinglePieceDimensionsPage3
2.3ManufacturingSpecificationPage5
3.0 Handling, Installation and Maintenance Instructions
3.1HandlingPage6
3.2ProductPreparationPage6
3.3LayingofProductPage6
3.4CleaningPage7
3.5MaintenancePage7
3.6LichenandMossPage7
3.7AcidWashingInformationPage7
4.0 Technical Details
Fig1StandardDesignaSchistVeneerPage8
Fig2FlatSoffitPage9
Fig3FlatSoffitwithBrickMouldPage9
Fig4FlatSoffitwithFriezeBoardPage9
Fig5DoorSillPage9
Fig6WindowHead–Aluminium–Option1Page10
Fig7WindowHead–Aluminium–Option2Page10
Fig8WindowSill–AluminiumPage10
Fig9WindowJamb–AluminiumPage10
Fig10DeepReveal–Jamb–UsingPackerPage11
Fig11DeepReveal–Jamb–DoublestudframingPage11
Fig12ControlJointsPage12
Fig13ColumnOptions500mm&700mmPage13
Fig13AExampleofColumnConstructionPage14
Fig14CornerConstructionPage14
‘Specific Design’
The Designa Schist is a concrete masonry product, installed as a normal veneer attached to a timber or metal
structural supporting frame. As such, it is covered by the general requirements of External Moisture-Acceptable
Solution 1 (E2/AS1 Masonry –Dec.2011). However, due to the nature and configuration of the product, some
details and installation aspects have been subject to ‘Specific Design’.
John Oliver
Specialist in Masonry Veneers
Lifetime Promotions Ltd
www.brickconsultant.co.nz
Designa Schist - Page 1
1.0 General Overview
Thisdocumentistoprovideaguidelineforthebuildingindustryandassociatedtradesandauthoritiesontheinstallationofthe
DesignaSchistproductandsystem.
1.1 Technical Details
1.5 Colour Variation
Theinformationandtechnicaldetailsprovidedinthismanual
correlatewithalllegislativerequirementsandgenerally
acceptedgoodtradepractice.Althoughprovidedasaguide
only,commonsenseandjobspecificdetailingcanbeadded
byqualifieddesigners.
Schistisanaturalstonewhichvariesintextureand
colour.Thisvarietyprovidestheruggedbeautysoughtby
customersworldwide.Thefullrangeofpossiblecolours
withineachbatchcannotbefullycapturedbyoneorafew
photographs.Thesecanprovideagoodindicationofwhat
tonesandshadeswillbepresentintheschiststock,aswill
physicalsamples.
1.2 Limitations
TheDesignaSchistcladdingproductislimitedinitsuse
bytherestraintsthatapplyinNZS3604,TimberFrame
Buildings,NZS4229,ConcreteMasonryBuildings(not
requiringSpecificDesign),andNZS4210,MasonryMaterials
andWorkmanshipinregardtotheinstallationofmasonry
veneer.
1.3 Acceptable Solution
TheDesignaSchistproductmeetstherequirementsof
NZBCClauseB2,basedontheinservicehistoryofother
masonryunitsandveneersconstructedusingadrainedand
ventilatedcavity.
Theschistbrickunitsthemselveshavebeenmanufactured
toAS/NZS4455andcanbeusedforprovidingadequate
meansofweathertightnessasacladdingtobothresidential
andcommercialbuildingsinNewZealand.
1.4 Product Specifics
Toenableacosteffectiveandaestheticallypleasingresult,it
isimportanttoconsiderthedimensionsoftheschistbricks
whendesigningtheproject.Thiswillavoidunnecessary
cuttingofpiecestofitavailablespaces.
Consistencyofcolourisahighpriorityduringthe
manufacturingprocess,butbeinganaturalproduct,this
canvary.Anyquestionsregardingthecolourorqualityof
theschistproductshouldberaisedatthetimeofdelivery.
TherelevantdistributoroftheDesignaSchistshouldbe
contactedimmediately.
Abricklaidisabrickaccepted.
1.6 Product Volumes and Colours
Itisrecommendedthatonceafinalplanisavailablefora
projectusingDesignaSchist,acopybegiventoyourclosest
DesignaSchistdistributorfortakingofftheoptimumbrick
piecesandquantities.Afullquotationcanthenbeprovided
forthespecificjob.
DesignaSchistbricksaresoldbythesquaremetre,whilesill
cappingandsquarecolumncapsaresoldperpiece.
PricesareuniformforallcolouroptionswithintheDesigna
Schistrange,whichcurrentlyincludes:
1.AutumnHue
Designsusingfullmoduleswherepossiblewillavoid
wastage,extracuttingtime,andmaximisethenaturallook
withoutexcessivemortarjoins.
Buildersneedtobeawareoftheoptimumdimensions
duringtheconstructionphase(foundationpreparation),and
bricklayersneedtobefullyawareofthemodulesizeswhen
settingoutandlaying.
Allpeopleinvolvedinthewholeprocessshouldbemade
awareofthedetailsandinstructionsprovidedinthis
document.
2.GreyAlps
Morecolouroptionsarebeingdevelopedforfuturerelease.
PleaseconsultwithyourlocalDesignaSchistdistributorfor
updates.
Designa Schist - Page 2
2.0 Schist Brick Dimension Details
2.1 Data Summary Sheet
Designa Schist Product
Product thickness: 80mm Nominal
Item
Weight per Square Meter: 140Kg/m2 approx.
Unit Weight
Dimension
Units Per Pallet
1
FullSizeZBricks
14Kgs
500x200x80
104
2
FullSizeEndBricks
14Kgs
550x200x80
96
3
HalfSizeEndBricks
7Kgs
300x200x80
160
4
SmallCorner/500mmColumnBlock
14Kgs
150/350x200x80
72
5
LargeCorner/700mmColumnBlock
19Kgs
150/550x200x80
54
6
SillCaps-40mm
10Kgs
500x140x40
-
7
ColumnCapfor550mmColumns
38Kgs
550x550x40
-
8
ColumnCapfor750mmColumns
55Kgs
750x750x40
-
2.2 Single Piece Dimensions
Type 1 - Full Size Z Brick
Type 2 - Full Size End Brick
Stoneonfaceonly
Stoneonfaceandoneendonly
Designa Schist - Page 3
2.0 Schist Brick Dimension Details
2.2 Single Piece Dimensions - cont
Type 3 - Half Size End Brick
Stoneonfaceandoneend
Type 4 - Small Corners
500mm Column Block
Stoneonbothfacesshownonly
Type 5 - Large Corners
700mm Column Block
Type 6 - Sill Cap
Stoneonbothfacesshownonly
Designa Schist - Page 4
2.0 Schist Brick Dimension Details
2.2 Single Piece Dimensions - cont
Type 7 - 550mm Column Caps
Type 8 - 750mm Column Caps
2.3 Unit Size & Tolerance
DimensionalTolerances
•
•
•
Eachcomponenttotherangewillbe+/-5mmfromthe
stated‘nominalsize’withtheexceptionofthefrontface
width(80mm).
Theconcretecomponentshallnotbelessthan50mm
thickaroundtheperimeterofeachunit,withthe
combinedfrontfacethicknessnotbeinglessthan
80mm.
TheZbrickshaveamouldedadhesiontrenchonthe
topconcretesectionto3mmdeep.Thisenablesdeeper
bondingandathickermortarjointofthebrick.
•
•
Somestonepiecesmayprotrudefromthebrickface.
Thecombinedconcreteandstonedimensioncangoup
to88mm.
AllDesignaSchistbrickshaveamortaredlook,witha
7mm-9mmmin.mortaredgapbetweenstones.To
constituteafirstgradeproduct,90%ofthefaceshould
complywiththisaspect.
Designa Schist - Page 5
3.0 Handling, Installation and
Maintenance Instructions
3.1 Handling
•
Duetotheweightoftheschistbrickunitsbeingheavier
thannormalveneerproducts,itisimportantthatthe
mortarisquitefirmascoursesarelaid.Thiswillprevent
themortarbeingsquasheddownandoutofthejoints.
Itisimportantthatthemortarjointdoesnotgodown
below7mminthickness.Itisstronglyrecommended
that120mls/mixofCemix‘Multibond’beaddedtothe
mortar.
•
Ensuretheareawherethebricksarebeingset-outis
cleananddry(andideallyeven).
•
Useglovesandavoidusingallmetalcarryingdevices
movebricks
•
Carrythebricksbytheconcreteportion,notbygripping
thestoneface
•
Ifrequired,install‘ControlJoints’.ReferTechnical
Details.
•
Keepthebricksaparttoavoiddamagewhenmoving
andplacingthebricks
•
•
Itispreferablethatbricksbeingset-outforlayingare
placedontheirbackstoprotectthestonefaceand
edges.
Oftentherearesituationswherefullbrickmodulesdo
notperfectlyfitthespaceallowed(see1.4Product
Specifics).Forexample,betweenwindows/doorsand
thenearestcorner.Wherethisoccurs,schistunitscan
becutbyabricksawtofittherequireddimension.
TheseneedtoremaininthesameZpatternasthefull
unit.
•
Usecleanwaterandbrushtopromptlyremoveany
freshmortarthatsplashesontothebrickwork.
3.2 Product Preparation
•
Bricksshouldbedryandclean.
•
Removeanyresidualpackagingusedtoprotectthe
bricksintransit.
•
Examinebrickstoensuretherearenocracksordamage
priortolaying.
•
Somesmallstonepiecesmaycomelooseduringtransit.
•
Ifkeptwiththebricktheycamefrom,thesecanoftenbe
gluedormortaredonandstillbeused.
•
ContactyourlocalDesignaSchistdistributorwithany
concernsyoumayhavepriortolaying.
Brick Ties
•
BricktiesaretobeaminimumofEarthquakeMedium
(EM)galvanisedscrew-fixedties.UseStainlessSteelties
inasea-sprayzone.
•
Tiesaretobeinstalledeverycoursevertically(200mm)
andintostudsatamaximumof600mmcentres
horizontally.
•
Thebricktiemustbeaminimumof40mmintothe
mortarbed–checkthecavitywidthtoensurethe
correctlengthoftieisused.
3.3 Laying of Product
Veneer Cavity
•
•
•
Bricksshouldbelaidinatradesmanlikemanner.In
mostcases,thiswillneedtobedonebyaLicenced
BuildingPractitioner(LBP).
Mortarjointsshouldbe9mm+/-2mm.
•
Theminimumcavitywidthpermittedis40mmtoa
maximumof75mm.
Astandard85mmlongbricktiecannotbeused
onacavitythatexceeds45mmtocomplywiththe
requirementthatthetieis50%intothebedmortar.In
thiscase,Longbrickties(110mm)shouldbeused.
Designa Schist - Page 6
3.0 Handling, Installation and
Maintenance Instructions
3.4 Cleaning
•
Usecleanwaterpromptlyandremoveanyfreshmortar
splashesusingastiffbristlebrush.
•
Oncompletionwashallsurfaceswithcleanwater.
•
Alightacidwashcanbeusedifcement/mortarstains
aretooheavyforwatertoremove.Refertoinstructions
ontheuseofacidforcleaning(3.7).
•
Thefinishedappearanceofthestonecanbe
permanentlyspoiled,andimpossibletorectify,by
leavingmortarresidueonthesurfacetoolong.
3.5 Maintenance
•
1:20(onepartacidand20partswater)maybestrong
enoughtoremovemostlightcasesofmortarstains,but
youcangoupto1:10forstubbornorheavystains.
•
ThemostcommonacidtouseisHydrochloricAcid,or
SpiritofSalts.Otherproductscandothisjob,butcheck
manufacturer’sinstructionscarefullypriortouse.
Procedure:
•
Wettheareaconcernedpriortoapplyingtheacid
•
Usesafetyequipment(thickrubbergloves,boots,flesh
coveredetc)
•
DesignaSchistisvirtuallymaintenancefree.
•
Chooseaninconspicuousareatotestthestrengthof
theacidtoremovethemortar.
•
Anannualcheckshouldbemadetocleanouttheweep
holes,brushthesurfaceusingasoftbristlebrushand
hoseoffwithwater.
•
Useamediumbristlebrush(toostiffandtheacidwill
notstayonthebristlesandtoosoftandthebrushwill
notremovethemortar).
•
Ifusingacidonwallorcolumnareasabovefinished
sealedsurfaces,keeparunninghoseontheareathe
bricksarebeingwasheddownonto.
•
Oncompletionwashtheareawithplentyofwater.
3.6 Lichen and Moss
•
Thegrowthoflichensandmossescanoccurwhen
stoneworkiscontinuallydamp.Theycanbetreated
usinganapplicationofcopperorammoniumsulphate
oralternatively,aproprietyproductdesignedforthis
purpose.Ifthestoneveneerissubjecttocontinual
moistureissues,considerationshouldbegivento
waterproofingtheveneerwithSurfaporeCavailable
fromLifetimePromotionsLtd(096244045).
3.7 Acid Washing Information
•
Note:Afterthebubblinghasstopped,donotlettheacid
scumdryonthesurface,cleanoffimmediatelyasitmay
provedifficulttoremoveonceithasbeguntodry.
Ifacidcleaningisrequired,refertothemanufacturer’s
instructions.Acidattacksthemortarfirst.Thismeans
themortarinthejointsaswellasanymortarsmeared
onthesurface.Removeasmuchmortaraspossible
first.Itisrecommendedthatallchemicalsaddedtothe
surfacebewashedoffwithlargevolumesofwateras
soonaspractical.
Designa Schist - Page 7
4.0 Technical Details
Fig.1 - Standard Designa Schist Veneer
Designa Schist - Page 8
4.0 Technical Details
Fig.2 - Flat Soffit
Fig.4 - Flat Soffit and 150mm frieze board
Fig.3 - Flat Soffit with brick mould
Fig.5 - Door Sill
Designa Schist - Page 9
4.0 Technical Details
Fig.6 - Window Head Aluminium Option 1
Fig.8 - Window Sill Aluminium
Fig.7 - Window Head Aluminium Option 2
Fig.9 - Window Jamb Aluminium
Designa Schist - Page 10
4.0 Technical Details
Fig.10 - Deep Reveal Window - Jamb - Using Packer
Fig.11 - Deep Reveal Window - Jamb - Double Stud Framing
Designa Schist - Page 11
4.0 Technical Details
Fig.12 Example of Control Joints
ControlJoints
Designa Schist - Page 12
4.0 Technical Details
Fig.13 - Column Options
500&700mm
Designa Schist - Page 13
4.0 Technical Details
Fig.13A - Example of Column Construction
Fig.14 - Corner Construction
Designa Schist - Page 14
Midland Large Signs 1200mm x 300mm .indd 3
contact us
Toll Free: 0800 MIDLAND (0800 643 5263)
Email: [email protected]
or visit our website at
17/06/13 10:48 AM
Proudly 100%
NZ Owned &
Operated
www.midlandbrick.co.nz or www.designaschist.co.nz
Head Office:
Midland Brick NZ
NZ Brick & Stone
8 Cowley Place, Rosedale,
Albany Auckland, New Zealand
Ph: 09 414 1075
Fax: 09 414 1073
Lower North Island:
Creative Brick & Stone
102 Kapiti Rd, Paraparaumu
New Zealand
Chris Marshall: 021 854 811
Fax: 04 234 6646
South Island:
Brick & Stone SI
35 Edmonton Rd, Hornby South
Christchurch, New Zealand
Ph: 03 343 6620
Fax: 03 343 6629