SAU STONE VENEER INSTALLATION GUIDE
1. PREPARING THE SURFACE
Saujana Stone can be applied to any structure sound surface. Due to its light weight, no special foundation or structural alterations are necessary. On clean (unpainted, untreated and unsealed) brick, block, concrete or other masonry surfaces, install Saujana Stone directly to the surface. If necessary, roughen wall and apply a thin layer of mortar and allow to set prior to installing the Saujana Stone.
2. APPLYING THE STONE
Apply an even layer of mortar to the back of Saujana Stone and press it firmly into place on the wall surface so that the mortar behind the stone squeezes out around all the sides. Using a gentle wiggling action while applying the stone will insure a good bond.
To help keep the stone clean during construction, start installing Saujana 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 uniform as possible. And avoid long straight unbroken joints.
3. TRIMMING THE STONE
When necessary, Saujana Stone 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 the cut edges will not show. If the chosen profile is tight and close to every stone without leaving gaps please continue to step 6.
4. GROUTING THE JOINTS
After all of the Saujana 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.
5. 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.
Brush the mortar joints with a whisk broom to smooth them and clean away the loose mortar for profiles with gap. At the same time, brush off any mortar spots from the face of the stone. Loose mortar spots which have set for only a few hours can be clean up easily and should never be allowed to setup overnight
The use of high quality waterproofing sealer is recommended on any Saujana Stone surface (PBM Masonry Water Repellent 0012) , but expecially on those exposed to conditions which could discolor or stain the stone. A sealed surface is much easier to clean than an unsealed surface.