The following guidelines are recommended by Revelstone as the manufacturers, as the correct way to install there cast stone products. However it must be understood that as Revelstone does not provide an installation service, the company cannot be held responsible for any defects which may arise from incorrect installation by contractors or clients. It is important that only experienced installers and contractors are used; do not use installers who are unfamiliar or inexperienced with cast stone products.

All installations are done at the users own risk.

It is important to understand that our Cladding is cement based and moulded from original Stone Masters to exactly simulate the appearance of natural stone, therefore sizes and thickness vary. This ensures that all our products resemble natural stone as closely as possible. Follow the procedure outlined below.

STORAGE & HANDLING

  • All Revelstone products must be handled carefully to avoid damaging edges and surface of the product.
  • Cladding should always be stored undercover on their edge not horizontally (stacked) prior to being laid. All Cladding is manufactured and stored undercover before delivering to site; this explains the darker colour sometimes apparent when you receive delivery. This occurs due to heat being created between the cladding on the pallet in its curing stage and will generally get lighter in time depending on the prevailing conditions.
  • Suitable lifting and handling equipment should be used. The correct safety gear and protective clothing must be worn at all times i.e. gloves, dust masks, safety boots etc.

SURFACE PREPARATION

On all newly built or plastered walls there is a minimum curing period for both brick and concrete.

  • New walls require 4 weeks curing time before cladding can begin.b
  • Newly plastered walls require another 2 weeks before cladding can commence.
  • Ensure that all brickwork, concrete and cement plasters are suitable, firm (no friability) and have moisture content of 5% or less before cladding commences. Remove and replace all defective cement plasters before cladding commences.
  • When cladding directly onto concrete, ensure that the surfaces are clean, free of all traces of laitance, curing agents or contaminants. This can be done by scarifying the surface. Do not use solvents as this may lead to contamination of the substrate and cause poor bonding of the tile adhesive or preparation material.
  • Post tensioned rib and block, hollow core or echo slabs require priming as below before cladding commences.
  • Most walls will need to be primed, chipped, brushed, scabbled or shot blastered to 80% prior to cladding. Alternately the surface must be primed with Permobond and Cement/ Sand mix or similar. Apply to a thickness of 1,5-2mm with a builders block brush. Allow 24 hours to dry before cladding commences.
  • All painted surfaces must be chipped 80% and then primed prior to tiling – as mentioned above.
  • Cladding must be clean, free of dust and contaminants. Cladding must be laid dry and must not be soaked before application. This can be easily done using a steel brush and clean water.

MOVEMENT JOINTS

  • Should there be any building structural/expansion joints in the structure of the walls, these joints width must be maintained and carried through the adhesive bed and the cladding, and filled with a suitable flexible filler or expansion joint profile.
  • Cladding movement joints must also be allowed for in vertical corners. Surface obstructions, pipes, fixed fittings, over all building material variances (brick and concrete beams).

PROCEDURE TO FOLLOW FOR ADHESIVE APPLICATION FOR REVELSTONE CLADDING

  • Ensure that the surface is not friable and that all laitance, dust is removed. Do not wet the surface before cladding commences.
  • Use Tylon WB11, Fastset WB114 or similar mixed only with clean cold water. Apply to the surface to a minimum bed thickness of 6mm. This can be achieved by using a 10mmx10mmx10mm notched floor trowel.
  • Spread only enough adhesive for each individual piece. Should a thin film (skin) appear on the surface of the adhesive, re agitate with trowel before bedded.
  • Press the dry Revelstone cladding firmly into wet adhesive with a twisting action. Product must be bedded with the aid of a rubber mallet.
  • Lift and replace random cladding to ensure that 100% contact is being achieved between the cladding and adhesive (no voids behind cladding).
  • Back buttering of Revelstone cladding is recommended where the back of the cladding product surface is irregular or when cladding in awkward locations.
  • Remove excess adhesive from joints and cladding product before drying has occurred. The minimum joint width for Revelstone cladding is 2mm. Please take extra care when you butt joint the cladding.
  • To cut the product it is necessary to use a Diamond Blade with an angle grinder. Be aware that some of the products have steel re-enforcing. The correct safety gear and protective clothing must be worn at all times i.e. gloves, dust masks, safety boots, etc.

PROCEDURE TO FOLLOW FOR MORTAR APPLICATION FOR REVELSTONE CLADDING

This is recommended when laying certain of our Random Cladding.

  • Ensure that the surface is not friable and that all laitance, dust is removed. Do not wet the surface before cladding commences.
  • Use a mortar mix (3 parts sand to 1 part PPC Cement) mixed only with clean cold water. Apply to the surface to a minimum bed thickness of 10mm.
  • Spread only enough adhesive for each individual piece. Should a thin film (skin) appear on the surface of the adhesive, re-agitate with trowel before bedded.
  • Press the dry Revelstone cladding firmly into wet mortar with a twisting action. Product must be bedded with the aid of a Rubber mallet.
  • Lift and replace random cladding to ensure that 100% contact is being achieved between the cladding and mortar (no voids behind cladding).
  • Back buttering of Revelstone cladding is recommended where the back of the cladding product surface is irregular or when cladding in awkward locations.
  • Remove excess mortar from joints and cladding product before drying has occurred. The minimum joint width for Revelstone cladding is 2mm. Please take extra care when you butt joint the cladding.
  • If and when required the cladding can now be grouted – using a mortar mix (3 parts sand to 1 part PPC Cement). Caulk the joints with the use of a sponge and a pointing tool depending on the desired finish. The use of a sponge with clean water is essential – please keep Cladding clean at all times during this process.
  • To cut the product it is necessary to use a Diamond Blade with an angle grinder. Be aware that some of the products have steel re-enforcing. The correct safety gear and protective clothing must be worn at all times i.e. gloves, dust masks, safety boots etc.

CLEANING OF CLADDING

  • It is vital to keep the cladding clean using a sponge and water whilst laying and especially when grouting(if required).
  • Should the product be badly soiled or stained use acidic cleaners sparingly to remove grout and cement stains. This is however done at your risk and must be supervised by the contractor or installer responsible.
  • A mix of water and pool acid – 10:1 doing small areas of less than 1m2 at a time with a medium to soft plastic bristle brush, rinsing off heavily with water/ soap solution to dilute so as not to damage the cladding surface.
  • A synthetic acid alternative – Nanoprufe Tile and Surface Cleaner – is recommended and is available from us.
  • This will clean off most adhering cement, grouting and efflorescence marks appearing on the newly installed product.
  • As it is a cement product it requires time after being laid to dry out to its original colour, etc. Often the stone has a wet patch in the middle after being laid, this is because the stone dries from the outside in. This drying out patch will disappear depending on how much moisture etc. has been trapped and how long this takes to move out through natural osmosis.