Wall dry hanging stone construction technology standard

[Students' Questions] Wall construction technology for dry hanging stone?

[Answer] A. Working Conditions

1. The structural framework has been inspected and approved, with all necessary pre-inspection procedures completed. Electrical, plumbing, and mechanical systems have been fully installed and tested.

2. The stone has been selected and prepared according to the design specifications, including type, quality, physical and mechanical properties, and quantity. Each stone is protected on all six sides to prevent damage during handling.

3. All exterior doors and windows are in place and have passed inspection, meeting the required quality standards.

4. Essential materials such as stainless steel anchors, adhesive, sealant, foam strips, and power tools have been gathered and ready for use.

5. All workers involved in the installation have received technical briefings, emphasizing safety, quality standards, and protection of finished surfaces.

6. A trial installation was conducted first. After internal quality checks, it was reviewed by the client and designer before full-scale construction began.

B. Construction Process

1. Stone Inspection: A dedicated person is responsible for inspecting the stones. They must match the design specifications, including size, model, and color. If any stone shows a significant color mismatch, it should be set aside and returned to the manufacturer.

2. Scaffolding Setup: Steel pipe scaffolding is erected with double rows, ensuring a minimum 500mm distance from the wall. Crossbars should be at least 300mm away from the wall. The structure is securely anchored, and the platform is fully covered with planks. Safety nets are also installed around the perimeter.

3. Layout and Measurement: Vertical lines are marked using a plumb bob or theodolite, starting from the top to the bottom. The thickness of the stone and the spacing between the stone and the wall (typically 60–80mm) are considered. Horizontal lines are then marked based on the stone height, usually 6–10mm apart. Elastic lines are placed symmetrically and evenly spaced.

4. Drilling and Grooving: Before installation, exact positions are measured, and holes are drilled. For concrete or brick walls, drill a hole 80–100mm from the center of the slab, about 20–25mm deep, then drill a 8–10mm hole where the slate will be attached. Insert one end of the stainless steel expansion bolt into the hole and secure the other end. On reinforced concrete columns, avoid drilling near rebar to ensure stability. Once the anchor is fixed, drill and groove the corresponding position on the stone.

5. Installing the Bottom Slab: The bottom slab is positioned according to the stainless steel anchor points. The slab’s hole aligns with the anchor pin, and the rectangular bolt hole is used for adjustment. Ensure the slab is level and square. Secure it with the anchor and fill the hole with embedded glue.

6. Installing Upper Slabs: Apply embedded glue into the next row of bolt holes, wipe off excess, and install the upper slabs following the same method. Check the alignment and fix them according to design specifications. For hard-to-reach areas, side fixing can be used.

7. Sealing and Caulking: After the stone is in place, clean the surface and remove dust from the joints. Insert 8–10mm diameter foam strips into the joint, leaving a 5–6mm gap. Apply a 10–15mm wide plastic tape along both sides to prevent sealant from staining the stone. Then apply the sealant using a caulking gun. If any sealant gets on the stone, wipe it off immediately. Finally, remove the tape, clean the stone, and polish it to meet quality standards before removing the scaffolding.

C. Installation Methods

1. Stone Preparation: Select and classify the stone by color using a colorimeter. Stones on the same side should have consistent color, and each piece should be numbered according to the design layout.

2. Base Layer Preparation: Clean the structural surface and mark vertical and horizontal lines based on the design. Pop up the installation lines and block lines accordingly.

3. Hanging Lines: Use a theodolite to mark vertical control lines on both sides of the corner. Position the line about 20cm away from the corner for accurate vertical alignment. Mark the control line up and down for smooth installation.

4. Support Brackets: Place support brackets on the upper slab according to the top line. Ensure they are firmly connected and aligned. Lay 50mm thick wooden boards in the direction of the supports, keeping the top and bottom of the stone level.

5. Fixing Metal Parts: Attach angle iron and flat steel plates to the structure using stainless steel bolts as specified. Adjust the flat steel plate so that its small hole aligns with the stone’s insertion hole. Secure it tightly with a wrench.

6. Installing the Bottom Slab: Place the bottom slab on the corner of the connecting metal parts.

7. Adjustment and Fixing: Temporarily fix the panel and adjust its level. If the surface is uneven, place a copper wire mat on the lower part of the flat steel plate. Adjust the verticality and spacing of the connectors until the panel is perfectly aligned.

8. Top Panel Installation: Install the final layer of panels with special attention to alignment. Place a 20mm thick wooden strip in the gap between the structure and the stone, and lift it using a connection point. Hang the wooden strip with aluminum wire. Fill the gap with packing material to prevent leakage during grouting.

9. Cleaning the Surface: Remove anti-stain films from marble and granite, and wipe the stone with a cotton cloth to ensure a clean finish.

D. Finished Product Protection

1. Plan the construction sequence carefully. Water, electricity, HVAC, and equipment installation should be done early to avoid damaging or polluting the stone cladding.

2. Regularly clean any residue like sealant, dust, glue, oil, fingerprints, or water from door frames, glass, and metal surfaces. Apply protective film to prevent stains and rust.

3. Avoid bumping or damaging the dry-hung stone during disassembly or loading.

4. Protect the corners of vulnerable areas with wooden boards. Prevent painting or other work from affecting the stone surface.

5. Do not pour garbage or debris onto the stone surface while the coating is still wet.

6. Assign someone to monitor the finished stone cladding to prevent vandalism or graffiti.

E. Construction Precautions

7.1 Color Consistency: To avoid color variation, select and test stones before installation.

7.2 Straight Lines and Even Joints: Measure the actual dimensions of the structure and ensure precise segmentation. Regularly check with horizontal and vertical lines for accuracy.

7.3 Temporary Fix: Marble glue can be used temporarily during dry-hanging, but it must be replaced with AB glue once the stone is properly positioned.

F. Quality Standards

(1) Main Control Items

1. All materials used in the stone wall project must comply with design requirements and current national standards.

2. The shape, appearance, color, gloss, and pattern of the stone wall should meet the design specifications.

3. The number, depth, position, and size of the stone holes and grooves must meet the design requirements.

4. The connection nodes at the corners must conform to design and technical standards.

(2) General Items

1. The stone wall surface should be clean, smooth, and free of stains, cracks, or defects. The color and pattern should be uniform, with no visible differences or scratches.

2. The joints between stones should be even and straight. The edge of the stone should be neat, and the embossed lines should be consistent. The cut edges of the stone should be precise and well-fitted.

3. The allowable deviation in the installation of the stone cladding must follow the provisions of Table 8.2.9 in the "Code for the Acceptance of Quality of Building Decoration Engineering."

This content is compiled based on real-world challenges faced by students in their projects. It is provided for reference only. If you find any errors or have questions, feel free to communicate and correct them promptly.

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