AMERISTONE 100% Acrylic-Based Finish with Multi-Colored Quartz Aggregates

Transcription

1 AMERISTONE 100% Acrylic-Based Finish with Multi-Colored Quartz Aggregates Ameristone Spray Application Instructions

2 I. General Instructions The following instructions apply to any spray application equipment for Ameristone including hopper guns or Xlent pressure pot spray equipment. A. Mock-up 1. A minimum 2.4 m x 2.4 m (8 ft x 8 ft) area of actual project or mock-up wall must be sprayed with the Ameristone finish for the approval of the color and texture by the owner/architect. Additionally, the mock-up serves to allow the applicators to familiarize themselves with the product and determine specific coverage rates for the job. The individual who will be spraying the project should be the one to make the mock-up. The mock-up is a requirement and must be completed prior to ordering material for the job. B. Material Preparation 1. Ameristone a. Mix for approximately 1 minute with a "Twister" paddle or equivalent mixing blade powered by a 12.7 mm (1/2 in) drill at RPM, just prior to application. Add water only to allow the material to flow. See the Hopper Gun or Xlent section for water-add recommendations specific to each type of spray equipment. Mix all the pails the same length of time and make the same water-add to each pail for a particular batch. DO NOT OVERMIX. 2. Color Prime a. Mix with a "Twister" paddle or equivalent mixing blade, powered by a 12.7 mm (1/2 in) drill at RPM to a homogenous consistency. C. Surface Preparation 1. It is essential that the Ameristone finish be applied to a clean, smooth, flat and level base coat or approved substrate. A spray finish will not hide surface imperfections. Sometimes it may be necessary to skim out the wall with the Dryvit Primus, Genesis, TM Primus DM, Genesis DMR, Genesis DMS mixtures to obtain a flat and level surface. Refer to appropriate Dryvit Product Data Sheet for mixing instructions and application. 2. Apply an even coat of the specified color-coordinated Color Prime by brush, paint roller or spray equipment. Allow to dry at least four (4) hours or until completely dry. D. Application Conditions 1. Air and surface temperatures for application of Ameristone must be (10 C) 50 F or higher and must remain so for a minimum of 48 hours. Avoid spraying on windy days or airborne Ameristone material will mist unprotected areas. Also, on windy days there is a tendency to position the spray gun closer than 0.6 m (2 ft), which causes a milky, blotchy appearance. These areas will look different when compared to areas sprayed on calm days. Spray in the shade whenever possible. When spraying on areas exposed to direct sunlight, have someone shade the area being sprayed or work with the sun at a low angle. E. Air Pressure and Orifice Openings 1. Different textures are achieved by regulating the air pressure. The higher the air pressure; the finer the texture. By decreasing the air pressure, the texture will be heavier. See the Hopper Gun or Xlent section for recommended pressure level ranges specific to each type of equipment. Be sure to keep air pressure consistent throughout the project. The air compressor should maintain a constant air pressure without surging. Surging will cause texture variations. 2. The common orifice openings for Ameristone finish are 6.4 mm, 7.9 mm, or 9.5 mm (¼ in, 5/16 in or 3/8 in). The larger the opening, the heavier the spray texture, and the smaller the opening, the finer the spray texture. Orifice openings smaller or larger than those listed above should not be used. The orifice plate should be inspected after spraying each panel and cleaned if needed. Excess material obstructing the orifice plate can change the texture delivered to the surface. F. Spray Techniques 1. With the appropriate spray equipment, spray apply the Ameristone finish to the primed wall surface. Spray an initial pass left to right or up and down striving for a uniform coat covering the Color Prime. Small circular motions can be made with the spray unit while spraying. The spray unit, either hopper or wand, must stay perpendicular to the wall surface at all times and never be closer than 0.6 m (2 ft) to the wall surface. The individual spraying should focus their attention on the area of contact point of approximately 254 mm (10 in) in diameter where the material spray is highly concentrated. Follow this contact point closely when spraying. In doing so, the wall will be uniformly coated without a blotchy appearance. Spray a full panel or to a natural break or joint in the wall before doubling back with a second pass. 2. Double back with a lighter second pass perpendicular to the first. The second pass should be made while the material is still wet or tacky. Never allow the finish to be dry to the touch before spraying the second pass. On the second pass, hold the spray unit back from the wall a little farther, to 0.76 m to 0.91 m (2-1/2 to 3 ft). While spraying, look for the larger stones in the formulation to begin sticking consistently without bounce back. Once this begins to occur, the optimum thickness has been achieved. Strive for a uniform appearance, again focusing on the area of contact point as described above, and move on. Avoid spraying too thickly. All wall sections must be sprayed with the final pass in the same direction, either left to right or up and down. This is 2

3 essential in panel plants as well. The panels must be sprayed in a vertical position and laid out in the same position as they would be installed on the building so the finish can be applied in the same direction. 3. Since no two applicators will have the identical spraying technique, the most uniform results will be obtained, if one applicator can spray the entire project or elevation. If this is not possible, ensure that each mechanic is using the same type of equipment, pressure level, orifice opening and spray distance(s) from the wall. G. Achieving a Uniform Job 1. Whenever possible, utilize lift equipment that will allow a free range of motion for the sprayer and will eliminate the potential for scaffold lines. If scaffolding is used, it should be placed away from the wall so outriggers can be used to provide a free range of movement. 2. Enough material should be ordered to complete the entire project so it can be produced from the same production batch. Because of the natural aggregates used in the finish, slight color variations can occur from batch to batch. When project size requires more than one production batch of Ameristone, be sure adjacent wall surfaces are sprayed with the same batch. 3. Do not spray Ameristone on surfaces that will receive caulk/sealant. These surfaces shall be coated with color coordinated Color Prime. H. Coverage 1. The optimum coverage for Ameristone is 5.6 m 2 (60 ft 2 ) per pail, including over-spray waste. Determine the pails required to cover a particular section of wall as follows: Area of Wall (sq.ft.) 60 = Pails needed to cover Approximately 75% of the material should be used on the first pass and 25% on the second pass. Coverage rates can vary down to 5.1 m 2 (55 ft 2 ) per pail depending upon the texture and if there are difficult objects such as aesthetic joints, bands, trims and ornate cornice to spray. Coverage should not exceed 6.0 m 2 (65 ft 2 ) per pail. Greater coverage rates will result in background show through, mottling and inconsistent appearance. IMPORTANT: Ameristone must never be applied greater than 3.2 mm (1/8 in) thick including first and second passes. If applied greater than 3.2 mm (1/8 in), the Ameristone finish may form cracks or blisters resulting in localized delamination. I. Curing 1. The Ameristone finish must dry for a minimum of 48 hours under average drying conditions [21 C (70 F), 55% RH] in order to resist washoff, blistering or water whitening from rains. Cooler and/or more humid conditions will require a longer cure. Temperatures should remain above 10 C (50 F) during the cure period. Ameristone finish must be allowed to fully cure before being exposed to rain or freezing temperatures. II. Hopper Gun Instructions The following instructions are specific to the use of hopper guns. The above general instruction procedures together with these specifics should be followed when a job will be spray applied with hopper guns. A. Hopper Guns Recommended 1. All hopper guns are basically the same design and are gravity fed. Some have a dial orifice plate with various size openings, while others have individual plates with different size openings. Recommended brands are Goldblatt and Marshalltown. B. Compressor 1. A compressor capable of maintaining 7 cubic feet per minute (CFM) above working pressure or a minimum tank pressure of 552 kpa (80 PSI) is needed for spraying with hopper guns. A four horsepower compressor is usually adequate. C. Air Pressure 1. A working pressure range of 10 to 25 lbs. as determined by an air pressure gauge at the hopper gun is normally used. The applicator must find and maintain the pressure that produces the most desirable spray texture. The pressure should be noted so as to maintain it consistently throughout the job. An inline air regulator such as a Sears AirLine Regulator Model No is recommended. III. Xlent Equipment Instructions A. General Information The UltraAir spray equipment manufactured by Xlent Equipment Company is approved for spraying Ameristone finish. The equipment consists of a pressure pot, hoses, an applicator gun and attachments. Unlike hopper guns, which require frequent refilling, the UltraAir holds up to four pails of material and is especially suited for large jobs. Ameristone is transferred to the pot, the pot is sealed and air pressure forces the product through up to 22.8 m (75 ft) of hose to the applicator gun. Follow the general spray instruction procedures in the first section of this document augmented by the following. A Dryvit Field Service Manager must be contacted if Xlent equipment is to be used to provide guidance. 3

4 B. Models Recommended 1. The UltraAir SP or the UltraAir 3 sprayers from the Xlent Equipment Company are the only pressure pot sprayers approved for applying Ameristone finish. The latter houses a 13-CFM compressor. Refer to the owner s manuals from Xlent for step-by-step instructions for use of these models. Please note there may be some information in an Xlent manual that differs with the information in this document. The reason is that the Xlent machines are used to spray many other products besides Ameristone. Use this document and consult a Dryvit Field Service Manager on all points of information regarding spraying Ameristone with Xlent equipment. For information regarding the equipment itself, call the Xlent Equipment Company at C. Compressor 1. A compressor that supplies a minimum of 13 working CFM is needed when spraying through up to 15.2 m (50 ft) of hose length. A compressor that supplies a minimum of 18 working CFM is needed if spraying through 22.8 m (75 ft) of hose length, or if spraying walls more than 3 m (10 ft) above where the tank is positioned even if using shorter hose lengths. D. Recommended Water-Adds and Tank Pressures 1. Water-adds and tank pressures will vary depending upon the hose length used. Hoses come in 7.6 m (25 ft) lengths and should be transparent in order to monitor the material flow. A maximum of 22.8 m (75 ft) of hose can be used. The following is a table of recommended water-add and tank pressure ranges for spraying Ameristone. Hose Length Water Add Spray Pressure Meter Feet Ml/Pail (Ounces/Pail) kpa PSI The reason that water-adds are greater with Xlent equipment than with hopper guns is that moisture from the product is lost as it is pushed through the hose under high pressures. In hot/dry weather, the upper limit of the water-adds will likely be needed. It is recommended that Ameristone not be sprayed with Xlent equipment if the temperature exceeds 35 C (95 F). Do not mist or fog walls with water to cool them before spraying Ameristone. The water-add will make the material somewhat thinner than a troweled product. As with any spray method, the water-add must be consistent for each pail of a given batch. 3. The above spray pressure recommendations are based on testing done with the tank positioned on the same level as the wall being sprayed. Lower pressures will work when spraying on a level below where the tank is positioned. Higher pressures will be needed when spraying on a level above where the tank is positioned. A general rule of thumb is 34 kpa (5 PSI) difference for every 3 m (10 ft) of elevation, up or down. 4. The water-add and spray pressure combination allows for the material to flow properly through the hose. The above recommendations are general guidelines, which should cover most situations. The local Dryvit Field Service Manager must be contacted for help, especially if it is necessary to deviate from the above recommended ranges. E. Mixing/Application Instructions 1. After adding water to the Ameristone pails, and mixing them as described in the general instructions, add up to four (4) pails to the Xlent tank. Place the Ultra Stop follower plate on top of the material in the tank. Place the lid on the material, ensuring that the seal is clean and secure the lid by hand tightening the clamps. Attach the regulator hose. 2. The use of Flo-eze, a clear viscous liquid product supplied by Xlent, is approved for lubricating hoses when spraying Ameristone. Approximately 237 ml (8 oz) of Flo-eze per length of hose 7.6 m (25 ft) should be poured into the pump end of the hose. This will lubricate the hose and facilitate flow of the material. Connect the material hose with the valve closed and hook up the air line. 3. Turn on the compressor and open the regulator to pressurize the tank. Listen for air leaks through the seal. Tighten clamps by hand to eliminate, or relieve the tank pressure, remove the lid, clean the seal and try again. Adjust the pressure to within the recommended range. 4. Open the material outlet valve to let the material flow through the hose. Without the gun attached at this point, open the material valve at the end of the hose to check the material flow into a bucket. Adjust the tank pressure to the lowest possible air setting to achieve constant material flow. The material should flow slowly and steadily without dripping. 5. Shut off the material valve and rinse material from the cam-lock gasket and attach the gun. The gun should have a tip attachment with a 6.4 mm, 7.9 mm or 9.5 mm (¼ in, 5/16 in or 3/8 in) orifice. Attach the air line to the gun. With the air stem pulled back all the way, open the material flow valve on the gun. The material should flow through the orifice in a slow and steady stream. Point the gun toward a large scrap piece of cardboard or foam board, and turn on the air valve on the gun. Push the stem forward until the desired spray pattern is achieved. There is a fine adjustment on the nozzle of the gun as well to optimize the pattern. 4

5 6. While spraying, check the working pressure on the tank to ensure it is in the specified range for the hose length being used. Maintain constant pressure and do not adjust the settings if possible throughout the job to maintain consistency. Note: The follower plate does not always stop the flow of material from the tank. Surging may happen when the tank is nearly empty. To avoid this, be sure there is at least one pail of material left in the tank. Account for material in the hose as well [22.8 m (75 ft) of hose holds a full pail of materia IV. Troubleshooting Guide Problem: After spraying has begun, it is determined that the tank pressure is set too high. Recommendation: With the air valve on the gun turned off, pull the air stem back from the nozzle tip and open the material gun valve to let the material flow through. Adjust the tank pressure down until the material flow stops. At that point, adjust the tank pressure up, in small increments, until constant material flow is achieved. Problem: There is a need to make an adjustment in order to maintain the material flow while spraying. Recommendation: The tendency is to work the fine adjustment to increase the flow of material. This should not be done. The fine adjustment should only be used to adjust the spray pattern not assist material flow. The cause of the problem most likely is that the air stem is set too close to the nozzle. Adjust the air stem back and forth until a constant flow of material is obtained without the air pressure being turned on. Then spray a piece of scrap cardboard and work the fine adjustment to obtain a proper spray pattern. Problem: Spray is weak even though tank pressure is well up into the recommended range. Recommendation: Water may be added to the material in the tank. Relieve all pressure, remove the lid and estimate the number of pails remaining in the tank. Add no more than 59 ml (2 oz) of water per pail and mix in with Jiffler mixer DO NOT OVERMIX. Check the material with the squeeze test, then reassemble the Xlent equipment and without the gun, retest the material flow. Keep track of the total water-add per pail so as to make the same add to pails in subsequent fillings of the tank. Expect to need more water per pail if stepping up in hose length. Therefore, it is best to use only one hose length for a particular job. Problem: Material will not spray properly, even though upper limits of recommended water-add and tank pressure are being used. Recommendation: Check orifice for obstructions. If spraying on a level above where the tank is positioned, relocate the tank to be even or above the elevation being sprayed. If the problem persists, contact a Dryvit Field Service Manager. Problem: Tank pressure drops while spraying causing a weaker spray. There is a constant need to stop and repressurize the tank. Recommendation: Compressor may not be strong enough to support the length of hose being used and/or compressor may not be strong enough to pump to a higher elevation. Try a shorter hose length or reposition the tank to be at or above the level of the wall being sprayed. V. Clean Up 1. Refer to the UltraAir SP owner s manual for clean up instructions. These involve the use of an Ultra-Clean air tool that allows for flushing sponge balls through the hoses to clean them out. DISCLAIMER Information contained in these application instructions conforms to standard detail and product recommendations for the installation of the Ameristone Finish as of the date of publication of this document and is presented in good faith. Dryvit Systems Canada assumes no liability, expressed or implied, as to the architecture, engineering or workmanship of any project. To insure that you are using the latest, most complete information, contact Dryvit Systems Canada. Dryvit Systems Canada 129 Ringwood Drive Stouffville, Ontario Canada L4A 8A Printed in Canada R6: Dryvit Systems Canada 1996 Page 5 of 5