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SECTION 04 42 00
STONE CLADDING PANELS
 
 
Copyright 2014 - 2017 ARCAT, Inc. - All rights reserved
** NOTE TO SPECIFIER ** TerraCORE Panels; Natural Stone Wall Cladding Panel products.
.
This section is based on the products of TerraCORE Panels, which is located at:
2030 Irving Blvd.
Dallas, TX 75207
Toll Free Tel: 877-503-2062
Tel: 214-749-0999
Fax: 214-742-2804
Email: request info (info@terracorepanels.com)
Web: www.terracorepanels.com
[ Click Here ] for additional information.
The TerraCORE brand is an internationally recognized, state-of-the-art reinforced wall panel cladding system that incorporates the natural beauty of Granite, Marble, Limestone, Travertine, Onyx and Sandstones with an aluminum honeycomb backing. The various substrates provide enhanced durability, unparalleled impact resistance, water impenetrability, significant weight reduction and lower project costs. As such, TerraCORE and its natural stone surfacing system is the stone cladding product of choice by many architects, general contractors, engineers, interior designers and developers throughout the world.
Headquartered in Dallas, Texas, TerraCORE Panels's corporate office manages Marketing, Engineering, Customer Service/Support and Project Management. TerraCORE Panels' state-of-the-art production facility is located in Foshan, China, overseen by a full-time Quality Control engineer. Strategically assigned independent representatives located throughout the United States and the world handle both domestic and international sales and support.
 
PART 1 GENERAL
 
1.1
SECTION INCLUDES
 
** NOTE TO SPECIFIER ** Delete items below not required for project.
 
A.
Exterior stone cladding system.
B.
Metal framing support system.
C.
Flashing and trim integral stone cladding system.
1.2
RELATED SECTIONS
 
** NOTE TO SPECIFIER ** Delete any sections below not relevant to this project; add others as required.
 
A.
Section 05 10 00 - Structural Metal Framing.
B.
Section 05 40 00 - Cold-Formed Metal Framing.
C.
Section 07 26 23 - Below-Grade Gas Retarders .
D.
Section 07 27 26 - Fluid-Applied Membrane Air Barriers .
E.
Section 06 10 00 - Rough Carpentry.
F.
Section 07 25 00 - WeatherBarriers.
G.
Section 07 60 00 - Flashing and Sheet Metal.
H.
Section 07 91 23 - Backer Rods.
I.
Section 08 41 13 - Aluminum-Framed Entrances and Storefronts.
J.
Section 08 44 13 - Glazed Aluminum Curtain Walls.
K.
Section 09 25 23 - Lime Based Plastering.
1.3
REFERENCES
 
** NOTE TO SPECIFIER ** Delete references from the list below that are not actually required by the text of the edited section.
 
A.
ASTM B 221 - Standard Specification for Aluminum-Alloy Extruded Bars, Rods, Wires, Shapes and Tubes.
B.
ASTM D 897 - Standard Test Method for Tensile Properties of Adhesive Bonds.
C.
ASTM D 1761 - Standard Test Method for Mechanical Fasteners in Wood.
D.
ASTM E 84 - Standard Test Method for Surface Burning Characteristics of Building Materials.
E.
ASTM E 283 - Standard Test Method for Rate of Air Leakage through Exterior Windows, Curtain Walls, and Doors.
F.
ASTM E 330 - Standard Test Method for Structural Performance of Exterior Windows, Curtain Walls, and Doors under the Influence of Wind Loads.
G.
ASTM E 331 - Standard Test Method for Water Penetration of Exterior Windows, Curtain Walls, and Doors by Uniform Static Air Pressure Difference.
H.
ASTM E 1996 - Standard Specification for Performance of Exterior Windows, Curtain Walls, Doors, and Impact Protective Systems Impacted by Windborne Debris in Hurricanes
1.4
PERFORMANCE REQUIREMENTS
A.
Design Requirements; design exterior stone cladding system to withstand:
1.
Positive and negative design wind loads acting normal to wall plane in accordance with Building Code and ASCE 7 with deflection of any member not to exceed L/175,as tested to ASTM E 330.
2.
Movement caused by an ambient temperature range of 120 degrees F and a surface temperature range of 160 degrees F.
B.
Performance Requirements:
1.
Air infiltration: Maximum 0.01 CFM per square foot, tested to ASTM E 283 at pressure differential across assembly of 6.24 PSF.
2.
Water resistance: No leakage, tested to ASTM E 331 at 12.0 PSF.
3.
Uniform load deflection:
a.
Two panel specimen: No damage, tested to ASTM E 330 at 65 PSF positive and negative.
b.
Single panel specimen: No damage, tested to ASTM E 330 at 260 PSF positive and negative.
4.
Uniform load structural:
a.
Two panel specimen: No damage and maximum 0.07 inch permanent set, tested to ASTM E 330 at 97.5 PSF positive and negative.
b.
Single panel specimen: No damage and maximum 0.150 inch permanent set, tested to ASTM E 330 at 390 PSF positive and negative.
5.
Impact resistance: No penetration, tested to ASTM E 1996 at 50 FPS.
6.
Freeze/thaw resistance: No delamination, cracking, chipping, or visible distortion; tested to GB/T 9966.1 at 25 cycles.
7.
Adhesive bond: Average bond strength of 284 PSI, tested to ASTM D 897.
8.
Tensile bond strength for adhesive: Average of 358 PSI, tested to ASTM D 897 after 25 thermocycles.
9.
Shear load strength for riveted brackets: Average of 172 PSI, tested to ASTM D 1761.
10.
Fire hazard classification: Maximum flame spread/smoke developed rating of 10/155, tested to ASTM E 84.
1.5
SUBMITTALS
A.
Submit under provisions of Section 01 30 00 - Administrative Requirements.
B.
Product Data: Manufacturer's data sheets on each product to be used, including:
1.
Preparation instructions and recommendations.
2.
Storage and handling requirements and recommendations.
3.
Installation methods.
C.
Shop Drawings: Include plans, elevations, and details, size and layout of panels, trim, accessories, supports, and attachments.
1.
Show locations, mounting details and details of joints both within honeycomb-backed stone cladding assembly and between stone panel cladding assembly and other construction.
2.
Include details of all varying joints, anchorage, corners, direction changes and connection to other materials.
3.
Show locations and details of channel system.
4.
Show direction of veining, grain, or other directional pattern.
5.
Include large-scale elevations of each building elevation with each panel numbered and dimensioned
 
** NOTE TO SPECIFIER ** Delete selection samples if colors have already been selected.
 
D.
Selection Samples: For each finish product specified, two complete sets of color chips representing manufacturer's full range of available colors and patterns.
E.
Verification Samples: For each finish product specified, two sets of samples, minimum size 6 inches (152 mm) square, representing actual product, color, and patterns and exhibiting the extremes range of color and other visual characteristics to be expected for the project.
F.
Manufacturer's Certificates: Certify products meet or exceed specified requirements.
G.
Closeout Submittals: Provide manufacturer's maintenance instructions that include recommendations for cleaning and maintenance of cladding.
1.6
QUALITY ASSURANCE
A.
Manufacturer/Fabricator Qualifications: Minimum of 5 years experience in the manufacturing of the panel product specified and meeting the following:
1.
Manufacturing facilities utilized in production ISO-9001 certified.
2.
Panels shall be tested in a dedicated and certified on-site lab using approved ASTM testing standards and conducted for every 10,000 SF of panels.
B.
Installer Qualifications: Minimum 3 years documented experience in work of this Section and the type of panel products specified.
 
** NOTE TO SPECIFIER ** Include a mock-up if the project size and/or quality warrant taking such a precaution. The following is one example of how a mock-up on a large project might be specified. When deciding on the extent of the mock-up, consider all the major different types of work on the project.
 
C.
Mock-Up: Provide a 4 foot high by 8 foot wide mock-up for evaluation of surface preparation techniques and application workmanship.
1.
Finish areas designated by Architect.
2.
Do not proceed with remaining work until color and workmanship is approved by Architect.
3.
Refinish mock-up area as required to produce acceptable work.
4.
Approved mockup may remain as part of the Work.
D.
Pre-Installation Conference:
1.
Convene at site 2 weeks prior to beginning work of this Section.
2.
Attendance: Architect, Owner, Contractor, panel manufacturer's representative, panel installer, and related trades.
3.
Review and discuss: Project conditions, scheduling, related work and other matters affecting erection.
1.7
DELIVERY, STORAGE, AND HANDLING
A.
Schedule delivery and installation of stone panel cladding with all parties involved to avoid extended on-site storage and coordinate with work adjacent to stone panel cladding. Ship panels by elevation in a pre-determined priority sequence to be determined prior to production.
B.
Store products in manufacturer's properly labeled, unopened packaging until ready for installation.
C.
Store panels off ground; prevent contact with materials that could cause staining or damage.
D.
Store and handle stone and related materials to prevent deterioration or damage due to moisture, temperature changes, contaminates, corrosion, breaking, chipping, and other causes.
E.
Mark stone units, on surface that will be concealed after installation, with designations used on Shop Drawings to identify individual stone units. Orient markings on vertical panels so that they are right side up when units are installed.
F.
Lay out and arrange panels on the ground in the order of the elevation sequence for inspection of color consistency and panel alignment.
G.
Perform detailed quality control check on every panel prior to packaging.
H.
Package all panels in custom plywood crates using protective covers on all of the panel edges and fill the gaps between panels with expandable foam for maximum protection.
1.8
PROJECT CONDITIONS
A.
Field Measurements: Verify locations of structural members and wall opening dimensions by field measurements before stone wall panel fabrication, as the project schedule permits.
B.
Maintain environmental conditions (temperature, humidity, and ventilation) within limits recommended by manufacturer for optimum results. Do not install products under environmental conditions outside manufacturer's absolute limits.
1.
Cold-Weather Requirements: Comply with cold-weather construction and protections requirements for masonry contained in ACI 530.1/ASCE6/TMS 602. Remove and replace honeycomb-backed stone panels damaged by frost or freeing conditions.
2.
Hot-Weather Requirements: Comply with hot-weather construction and protection requirements for masonry contained in ACI 530.1/ASCE 6/TMS 602.
1.9
WARRANTY
A.
Provide manufacturer's limited 10 year limited warranty against delamination and separation of panel components
1.10
MAINTENANCE MATERIAL
A.
Furnish ____ SF of extra materials of each product and color installed packaged with protective covering for storage and identified with labels describing contents.
PART 2 PRODUCTS
 
2.1
MANUFACTURERS
A.
Acceptable Manufacturer: TerraCORE Panels, which is located at: 2030 Irving Blvd.; Dallas, TX 75207; Toll Free Tel: 877-503-2062; Tel: 214-749-0999; Fax: 214-742-2804; Email: request info (info@terracorepanels.com); Web: www.terracorepanels.com
 
** NOTE TO SPECIFIER ** Delete one of the following two paragraphs; coordinate with requirements of Division 1 section on product options and substitutions.
 
B.
Substitutions: Not permitted.
C.
Requests for substitutions will be considered in accordance with provisions of Section 01 60 00 - Product Requirements.
 
** NOTE TO SPECIFIER ** Edit the following paragraphs as required and applicable to project. Delete the paragraphs that are not applicable.
 
2.2
EXTERIOR STONE CLADDING
A.
TerraCORE Stone Panels: TerraCORE aluminum "T"honeycomb substrate with a Fire Retardant Filler bonded to a natural thin stone veneer.
1.
Panel Size: Provide maximum lengths and widths available that will minimize joints in each area that correspond with the support system indicated.
2.
Weight: Weight including stone facing.
a.
4 to 5 lbs/sf (19.53 to 24.41 kg / sq.M).
3.
Reinforcing: 3/4 inch (19 mm) honeycomb backing bonded to stone by high strength adhesive impregnated by reinforced fiberglass sheet.
a.
Fiberglass Top Sheet: 1 mm.
 
b.Honeycomb Core: 17 mm
 
b.
Aluminum backing sheet: 1 mm.
 
** NOTE TO SPECIFIER ** Edit the following to indicate overall panel thickness. Coordinate with stone, core, and backing thicknesses specified above.
 
c.
Overall panel thickness: 1 inch (25.4 mm).
4.
Stone Facing Type/Color: 1/14 inch (6 mm) plus or minus 1/16 inch (1.6 mm) natural stone.
 
** NOTE TO SPECIFIER ** Edit the following paragraph to indicate stone type(s) and color group required. Refer to current TerraCORE Panels LLC product data or contact TerraCORE Panels LLC for available stone types/colors. Note also that custom stone types can be also accommodated.
 
d.
Granite,
1)
Group Budget
2)
Group 1A
3)
Group 1B
4)
Group 2
5)
Group 3
6)
Group 4
7)
Group 5
8)
Group 6
e.
Marble
1)
Group 2
2)
Group 3
3)
Group 4
4)
Group 5
5)
Group 6
f.
Limestone
1)
Group 3
2)
Group 4
g.
Travertine
1)
Group 3
2)
Group 4
3)
Group 5
h.
Onyx
1)
Group 3
2)
Group 5
i.
Sandstone
1)
Group _
 
** NOTE TO SPECIFIER ** The finish(es) required from the following and delete those not required. Refer to current TerraCORE Panels LLC product data for available stone finishes on each type of stone.
 
4.
Surface Finish:
a.
Honed.
b.
Flamed.
c.
Polished.
d.
Antiqued.
e.
Sandblasted.
f.
Acid washed.
g.
Bushhammered.
5.
Panel Edges: Apply FRF (Fire Retardant Fill) to all edges of the aluminum honeycomb (exposed or not) to fill voids in honeycomb. Edges to be smooth and filled. Use FRF with color similar to stone.
6.
Corners and returns: Provide prefabricated panel units with mitered corners, bonded with epoxy and finished exposed surfaces.
B.
Hanging Channels: Continuous extruded aluminum rails.
1.
Channel Material: ASTM B 221, 6063-T5ORT6 alloy and temper.
2.
Finish: Flat black painted finish where exposed.
3.
Water weepage: Allow water to pass between channel and substrate.
4.
Connection and anchorage hardware, including interlocking channels, anchor plates, structural silicone and threaded inserts shall be of sufficient size, thickness and strength to properly support panels and applied loads. Panel fastening shall be completely concealed.
C.
Accessories:
1.
Fasteners: Concealed type except where unavoidable and suited to application, stainless or corrosion resistant coated steel.
2.
Joint Sealers: Type recommended by panel manufacturer as specified in Section 07 91 23 - Backer Rods.
2.3
FABRlCATlON
 
** NOTE TO SPECIFIER ** Edit the following to indicate desired type of channel system.
 
A.
Fabricate manufacturer's standard interlocking channel system. System shall allow for the free and noiseless vertical and horizontal thermal movement due to expansion and contraction. Buckling of panels, opening of joints, undue stress on fasteners, failure of sealants or any other detrimental effects due to thermal movement will not be permitted
B.
Attach channels to back of panels in factory.
 
** NOTE TO SPECIFIER ** Include the following for factory-fabricated panel returns.
 
C.
Where indicated shop fabricate panel returns in factory with hairline joints to appear as monolithic stone.
 
** NOTE TO SPECIFIER ** Edit the following to indicate whether a factory-applied clear sealer is required. Delete if not required.
 
D.
Apply clear sealer to exposed stone surfaces at factory.
PART 3 EXECUTION
 
3.1
EXAMINATION
A.
Examine surfaces to receive stone panels and conditions under which they will be installed for compliance with installation tolerances and other conditions affecting performance of panels.
B.
Do not begin installation until substrates have been properly prepared.
C.
If substrate preparation is the responsibility of another installer, notify Architect of unsatisfactory preparation before proceeding.
3.2
PREPARATION
A.
Clean surfaces thoroughly prior to installation.
B.
Before setting panels, clean surfaces that are dirty or stained by removing soil, stains and foreign materials. Clean stone by thoroughly scrubbing with fiber brushes and then drenching with clear water. Use only mild cleaning compounds that contain no caustic or harsh materials or abrasives.
C.
Prepare surfaces using the methods recommended by the manufacturer for achieving the best result for the substrate under the project conditions.
3.3
INSTALLATION
A.
Install in accordance with manufacturer's instructions and approved Shop Drawings.
B.
Install interlocking channel system properly aligned for the panel installation.
C.
Set panels aligned, level, and plumb. Shim as required with hard plastic shims up to a maximum of 1/2 inch thick.
D.
Fasten receiving channels to supports. Snap panels into receiving channels. Use silicone sealant in bed of channel if recommended by the manufacturer.
E.
Seal panel joints with joint sealer as specified in Section 07 91 23 - Backer Rods.
F.
Allowable Tolerances:
1.
Variation from Plumb: For vertical lines, external comers and surfaces of walls, do not exceed 1/8 inch in 10 feet, 3/16 inch in 20 feet, or 1/4 inch in 40 feet or more.
2.
Variation from Level: For lintels, sills, water tables, parapets, horizontal bands, horizontal grooves, and other conspicuous lines, do not exceed 1/16 inch in 10 feet, 1/8 inch in 20 feet or 3/16 inc maximum.
3.
Variation of Linear Building Line: For positions shown in plan and related portions of walls and partitions, do not exceed 1/8 inch in 20 feet or 1/4 inch in 40 feet or more.
4.
Variation in Cross-Sectional Dimensions: For thickness of walls from dimensions indicated, do not exceed plus or minus 1/8 inch.
5.
Variation in Joint Width: Do not vary from average joint width more than plus or minus 1/16 inch or a quarter of nominal joint width, whichever is less. For joints within 60 inches of each other, do not vary more than 1/16 inch or a quarter of nominal joint width, whichever is less from one to the other.
6.
Variation in plane between adjacent stone units (lipping): Do not exceed 1/16 inch difference between planes of adjacent units.
G.
Separate dissimilar metals and use gasket fasteners where needed to eliminate the possibility of corrosive or electrolytic action between metals.
3.4
ADJUSTING AND CLEANING
A.
Remove and replace broken, chipped, stained, or otherwise damaged stone, defective joints, and honeycomb-backed stone panel cladding that does not match approved samples.
B.
Repair panels with minor damage as acceptable to the Architect.
C.
Clean stone panel cladding as work progresses. Remove excess sealant and smears as sealant is installed.
D.
Clean stone panel cladding no fewer than six days after completion of pointing and sealing. Clean using clean water and stiff-bristle fiber brushes. Do not use wire brushes, acid-type cleaning agents, cleaning agents containing caustic compounds or abrasives, or other materials or methods that could damage stone.
3.5
PROTECTION
A.
Protect installed products until completion of project.
B.
Prevent staining of stone from mortar, grout, sealants, and other sources. Immediately remove such materials from stone without damage to the stonework.
C.
Protect base of walls from rain-splashed mud and mortar splatter by means of coverings spread on ground and over wall surface.
D.
Touch-up, repair or replace damaged products before Substantial Completion.
END OF SECTION