SculptStone™ Specifications

SECTION 04720

Part 1 • GENERAL

1.1 Description:
This section covers all material, labor, accessories and appliances necessary for the complete installation of Architectural Grilles as indicated on the drawings and specified herein.

1.2 Manufacturer:
All Architectural Grilles used in this work shall be manufactured by Pineapple Grove Designs, Palm Beach County, FL 33425, (800) 771-4595, and shall meet the specifications as indicated in the manufacturer’s Tech Data sheets.

1.3 Submittals:
A) Shop Drawings: Submit in accordance with Architect’s Section. Indicate materials, construction, dimensions, locations, connections and installation details.
B) Custom Work: Furnish dimensioned camera-ready line art of proposed custom designs to manufacturer.
C) Product Data: Submit manufacturer’s descriptive literature and installation instructions.
D) Samples: Submit samples of material to architect for approval of color, shade, finish and material.

1.4 ORDERING:
All Medallions & Friezes used in this work will be manufactured specifically for this project. Material order shall be placed with Pineapple Grove Designs immediately to prevent delays.

PART 2 • PRODUCTS

2.1 SculptStone™ Composition:
All SculptStone™ cast stone Medallions & Friezes shall be a matrix of proprietary ingredients including cement, crushed and graded stone, virgin polypropylene fiber, iron oxide pigment, and admixtures necessary to achieve required physical properties.
Ingredients Include:
A) Cement: Type 1 White meeting ASTM C150.
B) Aggregate: Graded and washed natural sands and crushed grated stone Meeting ASTM C33, except that gradation may vary to achieve desired finish and texture; ± Post Consumer Glass and Aggregate.
C) Fiber: Virgin homopolymer polypropylene non-fibrillated fibers.
D) Coloring: Inorganic synthetic iron oxide pigments meeting ASTM C979 dispersed integrally throughout the mix.

E) Admixtures: Proprietary list of ingredients necessary to achieve required air entrainment, low permeability, accelerated cure, increased flexural and compressive strength and freeze-thaw resistance.

2.2 SculptStone™ Related Materials:
A) Mechanical Fasteners (Lugs): ¼" x 20 female stainless steel threaded imbed anchors shall be cast in the rear of each medallion by Pineapple Grove Designs. Pineapple Grove Designs shall provide ¼" x 20 stainless steel studs to be threaded into anchors at job site. Studs shall project from rear of cast stone ornament a minimum of 1" into hole drilled in the structural substrate of the mounting wall.
B) Adhesive: Solvent based construction adhesive or cement thinset mortar manufactured by others specifically for vertical tile or masonry bonding and incorporating bonding agent in cement mix.
C) Joint Finishing: Caulked joints and perimeter shall be caulking sealant type and color recommended by caulking manufacturer and approved by architect. Grouting or pointing mortar shall be composed of one part non-staining cement (ASTM C91), one part hydrate lime (ASTM C207 Type S) and four parts clean, washed sand (ASTM C144). Coloring pigments may be added as required. The architect shall approve color of mortar before proceeding with grouting or pointing.

2.3 SculptMetal™ Composition:
All SculptMetal&trade metal matrix polymer composite Medallions ™ Friezes shall be a matrix of proprietary ingredients including ground metal powders, fire suppressant materials, ground pigments, polymer binders, catalyzed urethane sealers and admixtures necessary to achieve required physical properties. Composition is reinforced with Kevlar™, carbon, glass and recycled cotton reinforced fiber.
A) Metal Powder: Bronze, Nickel or Iron metal powders and ±30% post consumer powdered Aluminum filler (specific metal to achieve desired finish and texture) meeting ASTM B923-02.
B) Kevlar™ Fiber: Continuous fiber strand bundles interwoven with other ingredients in matrix composition, meeting ASTM D629.
C) Carbon Fiber: Continuous fiber strand bundles interwoven with other ingredients in matrix composition, meeting ASTM F988-86.
D) Glass Fiber: Continuous fiber strand bundles interwoven with other ingredients in matrix composition, mix of virgin and ±15% post consumer recycled glass meeting ASTM D578-00.
E) Lignin Fiber: ±5% post consumer recycled cotton fiber reinforcing particulate.
F) Polymer inder: Unsaturated polyester and isophthalic resins meeting ASTM D1201.
G) Coloring: Inorganic synthetic iron oxide pigments meeting ASTM C979 dispersed integrally throughout the mix.
H) Admixtures: Proprietary list of ingredients necessary to achieve required low permeability, accelerated cure, increased flexural and compressive strength, freeze-thaw resistance and flame suppression.
I) Sealer: Catalyzed two part urethane topcoat meeting ASTM D1544-98.

2.4 SculptMetal™ Related Materials:
A) Mechanical Fasteners (Lugs): ¼" x 20 female stainless steel threaded imbed anchors shall be cast in the rear of each medallion by Pineapple Grove Designs. Pineapple Grove Designs shall provide ¼" x 20 stainless steel studs to be threaded into anchors at job site. Studs shall project from rear of ornament a minimum of 1" into hole drilled in the structural substrate of the mounting wall.
B) Adhesive: Solvent based construction adhesive or epoxy cement manufactured by others specifically for vertical tile or composite bonding and incorporating sufficient bonding strength for the intended purpose.
C) Joint Finishing: Caulked joints in perimeter shall be caulking sealant manufactured by others; type and color recommended by caulking manufacturer and approved by architect.

2.5 Fabrication:
Medallions & Friezes shall be manufactured in accordance with manufacturer’s strict guidelines for ingredient ratios, material mixing and consolidation, mold surface integrity, color and finish uniformity and curing methods for maximum strength achievement.

2.6 Shipping:
All Medallions & Friezes shall be carefully loaded and packed for transportation exercising customary and reasonable precaution against damage while in transit. All products shall be released to freight carrier in a sound, unblemished and unbroken condition.

PART 3 • EXECUTION:

3.1 Inspection:
A) Inspect adjacent construction for conditions that would prevent proper installation of Medallions & Friezes. Inspect substrate for soundness and surface adhesion quality.
B) Inspect product in crates for any damage from shipping. Notify manufacturer of any hidden damage. Inspect product for any variations in color, finish, tolerance or design as shown on manufacturer’s shop drawings or architect’s plans. Report any discrepancy to manufacturer.

3.2 SculptStone™ Installation:
Install SculptStone™ cast stone Medallions & Friezes true, plumb and level in accordance with manufacturer’s installation instructions and Tech Data sheet. All pieces shall be set by experienced and qualified stone masons or tile setters in accordance with the shop drawings.
A)Installer shall use necessary personal safety equipment to protect against hazards associated with stone and mortar fabrication, assembly and installation.
B)All SculptStone™ medallions & friezes shall be installed according to specifications included here in. Additional specifications shall apply if requested. Ultimate connection design is the responsibility of Building Design Engineer, Architect, or otherwise responsible person charged with the design connection.
C)All substrate to receive SculptStone™ Medallions & Friezes shall be prepared as indicated in manufacturer’s Tech Data sheet. Substrate shall be clean of any oil, paint, dust or debris. Surface shall be smooth, level sound and capable of a successful and permanent adhesion to the setting material.
D) When setting with mortar all pieces not thoroughly wet shall be drenched with clear potable water and excess water removed just prior to setting.
E) Unless otherwise noted, every piece shall be set in a full bed of mortar with all vertical joints flushed full. All anchors shall be firmly in place and all anchor holes and similar holes filled completely with mortar.
F) After setting, if required, each piece shall be braced with a diagonal support to the face and rest on a previously installed temporary horizontal ledger to be removed after full cure of setting material. The face of each piece shall then be sponged off to remove any splashed mortar or mortar smears.
G) All pieces shall be protected from splashing mortar or damage by other trades. Any foreign matter splashed or rubbed on the pieces shall be removed immediately.
H) A foam or wood "plug" ½" larger than the intended piece shall be temporarily installed on the substrate in applications where SculptStone™ cast stone Medallions & Friezes are not immediately available or construction conditions prohibit a timely installation. This plug shall be removed and typical installation shall proceed according to this section.
I) ½" minimum tolerance required in surrounding opening dimensions (i.e. 24" sq. medallion requires a 24 ½" x 24 ½" opening).

3.3 SculptStone™ Patching:
A) The repair of chipped or damaged SculptStone™ shall be done only by mechanics skilled in his work with materials furnished by the manufacturer and according to his direction.
B) SculptStone™ shall show no obvious repairs or imperfections other than the minimal color variations when viewed with the unaided eye under good typical lighting.

3.4 SculptStone™ Cleaning:
The face of all SculptStone™ cast stone Medallions & Friezes shall be cleaned where necessary by scrubbing with a bristle fiber brush, using soap powder and water and shall be rinsed thoroughly with clean running water. No acid or prepared cleaners shall be used without the approval of the SculptStone™ manufacturer.

3.5 SculptStone™ Sealing:
After cleaning and drying and full cure of any cementatious grouts (approximately 30 days), SculptStone™ cast stone Medallions & Friezes may be sealed with a silicone stearate solution. Follow sealer manufacturer’s instructions and apply to inconspicuous test area to determine job specific results.

3.6 SculptMetal™ Installation:
Install SculptMetal™ Medallions & Friezes true, plumb and level in accordance with manufacturer’s installation instructions (below) and Tech Data sheet. All pieces shall be set by experienced and qualified construction personnel familiar with construction trade practices and in accordance with the shop drawings and manufacturer’s installation instructions.
A) Installer shall use necessary personal safety equipment to protect against hazard associated with fabrication,assembly and installation.
B) All SculptMetal™ metal matrix polymer composite Medallions & Friezes shall be installed according to the specifications included herein. Additional specifications shall apply if required. Ultimate connection design is the responsibility of Building Design Engineer, Architect or otherwise responsible person charged with the design connection.
C) All substrate to receive SculptMetal™ items shall be prepared as indicated in manufacturer’s Tech Data sheet. Substrate shall be clean of any oil, dust, debris or other material that may interfere with the successfulinstallation of the item. Surface shall be smooth, level sound and capable of a successful and permanent adhesion to the setting material.
D) Adhesive material shall be prepared as per adhesive manufacturer’s instructions.Generally, surface must be scarified to insure optimum bonding of adhesive to the substrate. SculptMetal™surface to be bonded to adhesive must be treated similarly to substrate.
E) Unless otherwise noted, every piece shall be set in a full bed of adhesive with all vertical joints flushed full. All anchors shall be firmly in place and all anchor holes and similar holes filled completely with adhesvie.
F) After setting, all pieces shall be protected from damage by other trades. Any foreign matter splashed or rubbed on the pieces shall be removed immediately.

3.7 SculptMetal™ Patching:
A) The repair of chipped or damaged SculptMetal™ shall be done only by mechanics skilled in his work. Contact the manufacturer for instructions.
B) SculptMetal™ shall show no obvious repairs or imperfections other than the minimal color variations when viewed with the unaided eye under good typical lighting.

3.8 SculptMetal™ Cleaning:
SculptMetal™ metal matrix polymer composite Medallions & Friezes shall be cleaned where necessary with a pH balanced mild detergent cleaner and a soft cloth and shall be rinsed thoroughly with clean running water. No acid or prepared cleaners shall be used without the approval of the SculptMetal™ manufacturer.

3.9 SculptMetal™ Sealing:
SculptMetal&trade metal matrix polymer composite Medallions & Friezes are sealed at the factory during manufacture. No additional sealing is required.

PART 4 • HANDLING AND STORAGE

4.1 Handling:
All Medallions & Friezes shall be received and unloaded at the project site by competent workmen with the necessary care and handling to avoid damage and soiling.

4.2 Storage:
The Medallions & Friezes shall be stored on the job site in the same crating and packaging used for shipment. The packages and/or crates shall be stored on a level area clear of the ground and protected from the weather and other trades. If pieces are to be stored after uncrating, they should be placed carefully on edge and secured on non-staining supports. Pieces shall be stacked a maximum of one row high and protected from the weather and damage.