TM
PAT PEND
Installation
Guide
Warranty
2
Product Mix and Packaging
3
Estimating Sq.ft. and Tools
4
Wall Types
5
Applying the Stone
6
®
“Poz-E-Flo ” and Corners
7
Phoenix Bond Pattern
8
Trimming Stone
9
Working around Openings
10
Watertable/Sill Installation
11
Keystone, Mortar and Grouting 12
60025011
Mortar Joint Styles
13
Finishing Touch
14
Completed Jobs
15
Completed Jobs
16
Family Tradition with Family Pride
“Fusion Stone” marks a new dimension in Stone Veneers at Shouldice
Designer Stone with aesthetic beauty, ease of installation, extensive
spectrums of choice and cost efficiency. Unique and individual expression
are guaranteed when “Fusion Stone” is incorporated in construction
design.
Shouldice Designer Stone was founded in 1947 as a manufacturing facility
for an extensive spectrum of Stone Profiles. Shouldice today is a third
generation family business supplying projects of distinction on all modes
of construction throughout North America.
Backed by Family Values with a commitment to quality and innovation, we
have grown to become today’s leading manufacturer of Stone Products
and Veneers on the market.
TM
We strive to stay in touch with the world of design by having a clear vision
ensuring our mix of products reflect the evolving desires and needs with
our customers.
Recognized as the leader in the Industry we continue to build on our
reputation as an innovator for a third generation family business. Steve,
Mark & Brad Shouldice are hands on in day to day operations and work
shoulder to shoulder with skilled Craftsmen in their Stone creation roles.
Thank-you for your consideration. We would love the opportunity to prove
our worth and value for you.
Rob Shouldice
Fusion Stone Warranty and Guarantee
The strongest attribute Shouldice products possess is The Lifetime
Guarantee. Your complete satisfaction is very important and that
commitment is reflected in our Guarantee. Shouldice Guarantees For Life
the structural, aesthetic and performance integrity of their products, and
any product that proves defective before, during or after installation will be
replaced or repaired without cost.
A Guarantee of Strength and Performance on all “Fusion Stone”
products is provided to the original purchaser when used on structures
that conform to local building codes and when installed as per the
manufacturers requirements. Products installed in accordance to
installation guidelines that prove defective will be replaced without cost
(excluding labour). Proof of purchase is required.
The Warranty does not cover what we have no control over, namely
building settlement, wall movement, contact with chemicals and airborne
contaminants that may cause staining or colour changes to the product.
Fusion Stone Product Mix
Phoenix Stone
and Corners
Starter Strip
Architectural Stone
and Corner
Poz-E_-Flow
Watertable/Sill
and Corner
Brick
and Corner
Keystone
Packaging
Fusion Stone Products are packaged in two container sizes. The small
size or “Small-Pak” weighs less than 60 lbs and contains 5 sq.ft. of
product. The large size or “Bulk-Pak” contains between 100 to 160 sq.ft./
container depending on Stone size and the two container sizes can be
used to match exact material needs. Fusion Stone is packaged to allow
outdoor storage keeping product clean and dry until needed.
Fusion Stone…The Package System
New and Exclusive to Fusion Stone is the way it’s installed. The Patented
Fusion Stone system is simple, easy, and large or small your project is
guaranteed to offer a lifetime of performance with unmatched beauty.
Small-Pak
Bulk-Pak
Fusion Stone comes with the following components packed on every skid:
• The Fusion Stone of your choice
• Stainless steel clips (quantity matches square feet per container)
• Stainless Steel screws
• Robertson Power Drivers
• “Poz-E-Flo” Drainage Panels are sold separately, by the piece or
in 100 sq.ft. boxes (8 sheets).
Starter Strips come in 4’ lengths and are sold separately. Starter strips
may be purchased individually or in bundles of 15 pcs (60 linear ft.)
“Bulk-Pak”
“Poz-E-Flo” Drainage Panel
(Sold Separately)
Starter Strips
(Sold Separately)
Clips & Screws
(Included with all
Fusion Stone Products
“Bulk-Pak” and “Small-Pak”)
Estimating Square Footage
Fusion Stone consists of two key components called Flats and
Corners that are used in almost all installations. Flats are applied
to the entire flat wall surface in the work area and are measured
in square feet. Fusion Stone corners are applied to all outside
8’
corners and are ordered in vertical feet. Using corners around
window and door openings will add distinguished finishing touches
for individual expression.
3’
+ 3’ 3’
Step #1: Calculate the total project square footage; multiply the
length by the height of each surface area to be covered. Deduct
the area of all openings such as windows and doors from the total.
Step #2: Calculate the total vertical feet of all outside Corners
required.
Note: Window and Door openings may or may not require corner
pieces depending on individual design and preference.
Step #3: To determine the square feet of Flat Stones required, the
area covered by the Corner Stones needs to be subtracted from
the total wall area. Calculate the Corner Stone area by multiplying
the vertical feet of each corner by the Corner Stone coverage
listed below. Subtract this figure from your total wall area for the
required square feet of Flat Stones. Some extra quantity of Flats
are desirable for cutting and trimming.
Phoenix Stone & Brick: 1 vertical ft. of corner = 1 sq.ft. of flat stone
Architectural Stone:
1 vertical ft. of corner = 3 sq.ft. of flat stone
8’
7’
+
-
20’
20’
Typical Phoenix or Brick Take-Off
(Example based on Building shown above)
Wall Area: 8’ x 20’ + 8’ x 20’ = 320sq.ft.
Opening Area: 3’ x 3’ + 3’ x 7’= 30sq.ft.
Corner Area: 8’ x 3 corners = 24 sq.ft.
Wall Area - Opening Area – Corners Area
Equals Total Flat Stones Required
320 sq.ft. - 30 sq.ft.- 24 sq.ft. = 266 sq.ft.
Total Starter Strip required:
20’+20’+3’+3’= 46 linear feet
Tools Required
For Fusion Stone installation the
following tools will get the job done
right. We want you to enjoy your
completed project so please ensure
a safety first attitude is maintained
during installation of your project
Hawk
Mask and
Safety Glasses
Angle Grinder
with Diamond or
Masonry Blade
Wheel Barrow
Jointer
Chalk Line
Tape Measure
Utility Knife
Level
Tin Snips
Stapler & 1/2”
Staples
String & Level
Cordless Drill/
Screw Gun
Hammer
Masonry Chisel
Slicker
Wisk
Tools Optional
Power Grouter
Grouting Bag
8’
Power Saw
w diamond/masonry
blade
Laser Level
Stud Wall (Wood or Steel Studs)
Wall Types
Fusion Stone installations are PreEngineered to a maximum height of
30 feet. Heights may be increased
when approved by Building Officials
and specified by a Structural
Engineer.
Stud Wall
Plywood or OSB
Board
Weather Resistant
Barrier
“Poz-E-Flo ”
Fusion Stone is unique and may be
Fusion Brick
installed on above grade or at grade
applications (the starter
Fusion Watertable/Sill
strip must be installed a minimum
Stainless Steel Clip
1/4” clearance below to allow for
and Screw
drainage). Fusion Stone can be
Fusion Architectural
installed in above freezing or below
Stone
freezing conditions and in dry
conditions or wet weather.
No wall ties are required as the
“Fusion Clip” does the job of a Brick
tie.
®
Ensure substrate is a minimum 7/16”
OSB or 1/2” Plywood, and covered
in a code approved, breathable
weather-resistant barrier. Fusion
Stone should only be installed
to structurally sound surfaces
incorporating sound building
practices.
Masonry Block or Concrete Wall
Masonry Block
Strapping
Plywood or OSB should be fastened
to the stud with the following
minimums, spiral or ringed nails
with a 1 3/4” penetration or screws
with a 1” penetration and a vertical
spacing of eight inches.
Exterior Insulation
When Rigid Foam Insulation is
applied simply use longer fasteners
to anchor Plywood or OSB to the
wall assembly.
Rigid Foam Insulation
Rigid Foam
Fusion Stone
Poz-E-Flo®
Plywood or OSB
Fusion Clip
Starter Strip
Weather Resistant
Barrier
Flashing as
per code
Flashing and Moisture
Barriers
To maintain weatherresistance of the exterior wall on
which Fusion Stone products are
installed, a rigid, corrosion-resistant
flashing and a means of drainage
shall be installed at all penetrations
and terminations of the Stone
Cladding.
1
2
Building codes vary from area to
area so check your Local Building
Code Specifications.
The installation of water proofing,
caulking, flashing around doors
and windows, gutters and down
spouts must be installed correctly
to prevent water infiltration and
damage in later years.
Install flashing under the weather resistant
barrier
Starter Strip
Level and install Stainless
Steel Starter Strips using
Stainless Steel Screws provided.
All Starter Strips are made of
Stainless Steel for Permanent
Performance.
3
Install with stainless steel screws provided
Install Starter Strip over top of window and
door openings.
Install “Poz-E-Flo®” Drainage Panels over
top of Starter Strip
Staple “Poz-E-Flo®” Panels with staple gun
with no overlap, just butt panels together
Install “Poz-E-Flo®” over top of Starter Strip
Drainage Panels
Install “Poz-E-Flo®”
Drainage Panels using a
staple gun. “Poz-E-Flo®” Drainage
Panels must over lap the Starter
Strip. They are supplied in 40” x 48”
sheets and “Poz-E-Flo®” Drainage
Panels can easily be cut to fit with
a utility knife. See “Poz-E-Flo®”
information on the next page.
4
Level starter strip. Allow a minimum 1/4”
clearance above grade for drainage.
Keeping it Level
Snap a horizontal chalk
line every 24” on the wall
(Starting from Starter Strip). This line
can be used as a visual reference that
the Stones are maintaining a level
installation. The Fusion Stone Clip will
maintain an exact 3/8” mortar joint
spacing between Stones and if the
Stone is not sitting level then simply
spread the clip by hand or pinch bar to
achieve level installation. This leveling
technique should seldom have to be
used but works if need be.
Chalk Lines
24”
Snap a horizontal chalk line every 24” on the
wall to use as a level reference line.
If required spread clip by hand
or pinch bar to achieve level
installation (use gloves).
“Poz-E-Flo®” Drainage Panels
The Fusion Stone “Poz‑E‑Flo®”
Drainage Panels are exclusively
manufactured for ease of
handling and installation.
They are supplied in 40” x 48”
sheets, not in a large roll that
is difficult to handle and move.
“Poz‑E‑Flo®” is the best water
drainage system on the market
today.
Can walls leak??…Yes! And
if they don’t leak today they
may leak tomorrow. Walls
may shift or move, caulking
ages and can separate from
wall component areas, mortar
joints can leak when they
crack, foundations shift from
Mother Nature extremes etc.
5
The Fusion Stone “Poz‑E‑Flo®”
Drainage Panel System guarantees
what gets through the exterior wall
get trapped and vertically drained
back outside, not inside where real
harm and moisture damage can
occur. In addition the Fusion Stone
“Poz‑E‑Flo®” Drainage Panel has
a felt covering on one side to keep
mortar and other contaminating
materials from plugging the
drainage performance over time.
No weepers are required as
“Poz‑E‑Flo®” Drainage Panels
provide positive vertical drainage
and ventilation and there is no need
to over lap panels, just butt the
edges together.
“Poz‑E‑Flo®” with felt covering cut away to
show drainage grid.
Start with the Corners
Install Corners onto the
Starter Strip using 3 Clips and
Screws. Install a Flat Piece on
either side of the Corner. then
place the second Corner on top
alternating long and short sides.
6
Place Corner piece on both Starter Strips
Secure using 2 screws on the long side and
1 on the short side
Place Flat Stone next to the short side of the
Corner Piece
Place the next Corner Piece alternating the
long and short side to overlap the Stone
Work toward the centre
Install Flat Stones working
toward the centre of the
wall while consistantly maintaining
a 3/8” space for the mortar joint
between Stones. Refer to bond
patterns on the next page for
correct overlap and Clip placement.
Typical Fusion Stone
Phoenix Bond
The two Stone heights
need to be evenly mixed
throughout the wall for the best
natural Stone appearance. The 8”
high pieces should be placed to
break up long horizontal mortar
joints and spaced so they don’t lay
next to each other.
Overlap stones a minimum of
2” and always try to maintain a
maximum 8” vertical mortar joint.
7
Start by installing a single course of 4 and 8” Stones ensuring that the 8” Stones do not
touch each other and are spaced evenly. Place Clips as shown.
Add the second course using both 4” and 8” Stones again making sure the 8” Stones do not
touch.
Continue up the wall one course at a time using both 4” and 8” Stones as this ensures the 8”
Stones break up long horizontal mortar joints.
Stainless Steel Clips, Screws and Robertson
Power Drivers included.
Keep vertical mortar joints to a maximum of
8 inches.
Fusion Clips
Architectural Bond
Red markers indicate correct Clip
locations for Architectural Stone.
Each Clip is placed an equal distance between the vertical mortar
joints. Notice the Clips on top of
the Watertable/Sill are placed to
suit the next course of the Fusion
Architectural Stone as well as the
Watertable/Sill.
Phoenix Stone
Overlap Stone a MINIMUM of 2”
Watertable
Architectural Stone
Brick Bond
Each row is offset by half the width
of the Brick (which is called half
bond or running bond). Clips are
placed at each end on the bottom
and the centre on the top. The
space in the Clip must line up with
the mortar joint.
Mortar Space
Stainless Steel
Brick Clip, Screws and
Robertson Power Driver
included
8
Place Clips as shown for running bond
Trimming Stones
Stones may be cut to
length using an angle grinder
or power saw with a diamond
or masonry blade to score the
backside. Phoenix Stone may then
be split using a masonry chisel.
This method leaves a natural edge
and the antique finish may be
restored by rubbing the cut edge
firmly with a waste piece of Fusion
Stone.
Trimming for Custom Corners
Score backside first (angle grinder shown)
Finish with a chisel to break off piece
Use a power saw to cut custom
angles for areas such as bay
windows.
Cut this Stone to
match required angle
Maintain 3/8 mortor joint between pieces
Rub a waste Stone over the edge to restore
the antique texture.
Power saw with a masonry blade (optional).
Cutting Fusion Slots
Check to see if the blade of the
angle grinder is equal to the
height of the slot on your Fusion
Stone. If required adjust the
blade using shims (flat washers).
With the the angle grinder guard
on a firm flat surface cut a new
slot where required.
Working around
Windows and Doors
Sometimes Fusion Stone
will not course out even with the
top or bottom of windows and
doors. This can be resolved with
horizontal trimming or Soldier
coursing.
When trimming Fusion Stone
horizontally to the required height
cut two slots, one at each end, for
the Fusion Clips using an angle
grinder.
Use spacers (flat washers) to adjust height
of cut.
Cut slot in the Stone on a firm flat
surface, bracing the Stone securely.
Horizontal cut Stone to fit under and
over windows/doors to restore bond
Restore slot only where Clips are required
9
Use the same technique when the top of a window or door does not line up with the bond
Soldier Coursing Fusion Stone
Fusion Stone may be installed as
soldier coursing above windows
or doors and creates a pleasant
look while allowing custom height
stones to course out with the
existing bond. Note: Clips may
be installed in vertical grooves
the same the as in the horizontal
grooves.
Soldier coursing can also be used to restore
bond when the base of a window does not
line up with the bond
Cut Clip slots in the end of Stones for
soldier coursing
The base of the Soldier Stone Piece is
secured in the Starter Strip and then Cliped
as shown
Some Clip adjustment may be required to
suit the next course.
When soldier coursing centre
the Stone spacing to achieve a
balanced look around windows and
doors.
10
Wall Watertable/Sill
Installation
The Fusion Watertable/
Sill provides an attractive and
professional transition from Fusion
Stone to other wall assembly
materials such as siding, brick or
stucco.
Place the Watertable/Sill Firmly on
lower Clips and install two Clips 2”
in from each end. If a Fusion Stone
product is to be used above the
Watertable/Sill more Clips may be
needed so place Clips according to
the products spacing requirement.
10
When installing Watertable/Sill a minimum of two Clips on top should be used. If Fusion Stone
is to be installed above the Watertable/Sill place the Clips as required for the style used.
Watertable/Sill used as a transition from
Fusion Stone Phoenix to siding.
Window Watertable/Sill
Installation
Window openings smaller
than 20” may be installed using a
single 24” Watertable/Sill. Position
the Watertable/Sill on lower Clips
and attach one Clip on top at each
end of the Watertable/Sill.
11
Watertable/Sills should extend a
minimum of 2” past the opening
width for best appearance and to
provide an area for Clip mounting.
Window openings wider then 20”
require two or more Watertable/Sill
Units that can be trimmed to fit.
For the best appearance of multiple
unit Watertable/Sills, trim left and
right sides equally to balance
mortar joint spacing. Watertable/
Sills are fastened at each end using
slots cut with an angle grinder.
Watertable/Sill used as a transition from
Fusion Architectural to Fusion Brick.
Clip
Place upper Clips as shown. See
photo below
Cut both Watertable/Sills equally for best appearance when
two Watertable/Sills are used. Place upper Clips as shown.
For multiple piece Watertable/Sills place cut piece in the centre or cut all pieces equally to
balance appearance. Place upper Clips as shown.
Extend Watertable/Sills 2” past the edge of
the window and place Clip as shown.
If Watertable/Sill does not extend past the
window edge or to join multiple Watertable/
Sills use Clips on ends.
Cut slots on the end to attach
Watertable/Sills tight to window bottom.
Mutiple 24” Watertable/Sills can be
joined this way for wider windows
11
Keystone installation
Fusion Stone Keystones
are manufactured with
slots on the top and bottom to
provide rock solid fastening with
hidden Clips and Screws.
12
Trim surrounding stones to match
Keystone angle allowing for a 3/8
mortar joint.
Mortar Tips
Keep the Stones Dry
Fusion Stone is manufactured
using an integral water repellant
agent that reduces water
absorption and efflorescence.
This low absorption rate may
affect set up time of the mortar
joints. A slow set up time will
be an advantage in warm dry
weather but it is important to
keep all material covered and
dry in wet or cold conditions to
ensure tooling of the joint can be
done at the proper time.
13
Mortar Type
With Fusion Stone we recommend
a Pre-mix, Type “N” mortar.
Pre‑mix mortar is the simplest and
easiest to use (just add water) and
provides consistency from start to
finish.
Mixing Mortar
Follow directions on the bag
working in small batches. If
colouring is used, measure ratio
carefully to ensure consistent
colour from batch to batch.
Mortar Colour
Don’t forget with Mortar being 10%
of your wall area that colouring
plain mortar from ordinary grey to a
shading of brown, black or a colour
of your choice will always add
Definition, Depth and Richness to
any wall assembly.
Grouting Mortar Joints
The last phase of
installation is the filling in
(grouting) of the mortar joints. You
will require one of the following
tools to fill the mortar joints.
· Hawk or Trowel
· Grout Bag (Icing type)
· Power Trowel or Grout pump
· Jointer
Grouting the Joints with Trowel and Jointer
Grouting the Joints with Grout Bag
All techinques of grouting work
fine but the more automated it is
the easier it will be. Use consistent
batching procedures when mixing
Mortar and read instuctions on bag.
Avoid installing mortar in joints
with air pockets as this can
cause mortar failure. Make sure
joints are filled completely to the
“Poz‑E‑Flo®” Drainage Panels.
Grouting the Joints with Power Trowel
Power Trowel detail
12
Mortar Joint Styles
There are many mortar joint
options including concave,
tooled and bagged.
The “concave” joint leaves a
rounded mortar joint.
The “tooled” joint must not have a
depth greater than 1/8” back from
the stone face to avoid exposing
the clips.
The “Bagged” joint is an
increasingly popular way to achieve
an old-world, rustic look. When
the joint type is selected weather
resistance and appearance must be
considered.
Concave Joint
Tooled Joint
Bagged Joint
14
Finish mortar joints
You will need a jointer to
“strike” off the mortar to
your desired style. Tool the joint
after the Mortar has begun to
stiffen slightly (normally 30-60
minutes).
15
Should a joint be tooled too soon
(in a wet condition) a light joint
results and conversely if a joint is
allowed to become too stiff a dark
joint will result. Remember that
jointing is the final step so care
should be taken for professional
results.
For a Concave Joint use a
round jointer.
Tool only a shallow Tooled Joint (maximum 1/8 Deep) to
avoid exposing Fusion Stone Clips.
Use a wisk broom to sweep away
excess crumbs of mortar after
jointing. The broom will also take
the shine off the mortar joint for a
non-slick mortar appearance. Care
must be taken to avoid smearing of
mortar on the Stone surface.
Accidental smears should be
removed only after mortar has
become crumbly using a wisk
broom or dry brush. Never use a
wet brush or broom.
For a Bagged Joint install mortar flush or
slightly over the stone surface.
Lightly flatten the high points of the Bagged
Joint with a piece of carpet or bag.
Use a DRY wisk broom to
remove loose mortar.
13
Freeze board and Soffit
Details to Add the Finishing
Touch
Freeze board covers union
Stone goes behind Soffit
Stone meets Soffit
Soldier Coursing may be used to ensure the Stone meets the Soffit
and adds a great finishing detail.
Replacing Existing Siding
Remove the existing siding and
make sure the wall is sound and
not degraded due to wet or dry
rot. If this is the case, install a
new substrate before installing the
Fusion Stone system.
Existing Siding
Weather
Resistant Barrier
overlaps flashing
Flashing
Modified Clip
Fusion
Watertable/Sill
To allow tight fit where the siding meets the Watertable/Sill,
modify the Clips used to install the Watertable/Sill by cutting
off the top wing as shown above.
14
Fusion Brick,
Stone or
Architectural
Top wing of Clip removed
Cleaning Stones
Fusion Solutions
Removing Excess Mortar
If cleaning is required, use a mild
masonry detergent and follow
manufactures instructions. Pressure
washers should not be used as a
means for removing excess mortar
or splatters.
Efflorescence
If efflorescence occurs, it is caused
by moisture migration through the
masonry. Once the moisture is on
the masonry surface it evaporates
and can leave dissolved salts in
the form of efflorescence that
will disappear naturally with time.
To clean the efflorescence right
away scrub the surface with a soft
bristle brush and solution of 1 part
household vinegar with 5 parts
water. Wash off with a flood coat of
water from a garden hose, DO NOT
use high pressure washers.
Fusion Brick
Fusion Stone to Brick with Watertable/Sills
Fusion Architectural and Watertable/Sill to Brick
Fusion Stone with Window Details
Fusion Stone
15
Fusion Stone to Siding
16
Fusion Stone
Fusion Stone to Stucco
Fusion Stone to Brick
Fusion Brick
Fusion Stone to Wooden Shakes
TM
PAT PEND
Fusion Stone products are proudly hand crafted in modern manufacturing
facilities by some of the most talented craftsmen available. For additional
information on beautiful and maintenance free Fusion Stone products and
services please visit us at www.fusionstone.ca or call 1-800-265-3174.
800-265-3174 • Fax: 800-211-6060
www.shouldice.ca
Established 1947
16
THE DESIGNER STONE COLLECTION IS EXCLUSIVELY MANUFACTURED AND PROCESSED UNDER PATENT PROTECTION U.S PATENT 4,335,549 AND CANADIAN PATENTS 1,169,265 & 2,127,191.
PRINTED IN CANADA
305002