Veneer Plaster Systems - National Gypsum Company NATIONAL GYPSUM VENEER PLASTER SYSTEMS VENEER...

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®

Veneer PlasterSystems

12TH EDITION

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44 NATIONAL GYPSUM VENEER PLASTER SYSTEMS

VENEER PLASTER SYSTEMS

DESCRIPTION

Kal-Kore boards are screwed to steel studs or nailed orscrewed to wood studs toform a base.

Veneer plasterexpands architecturaldesign limits as withthis curved vaultedceiling.

Joints are reinforced with Kal-Mesh fiberglass webbing.Steel corner and casing beadsprotect corners.

Kal-Kote is applied in 2 coats, a base and a finish, to form a hard-surfaced, 1/8" total thickness.

Veneer Plaster Systems consistof a 4' wide gypsumplastering base with aspecial, highly absorptivepaper surface that iscovered with thinlytroweled, special purposeplasters. Two basic types of veneer plaster areavailable: Uni-Kal and X-KALibur, which are one-coat plaster systemproducts; and Kal-Kote, atwo-coat plaster system.The gypsum plaster base,Kal-Kore, is erected in thesame manner for bothsystems. Both veneerplaster systems can bespecified for virtually alltypes of partition andceiling constructionsincluding wood or steelframing or furring andmasonry. For bothresidential and commercialbuildings, either type ofveneer plaster systemproduces a wall more nail-pop resistant than drywalland, when properlyinstalled, more crackresistant than conventionallath and plaster.

ADVANTAGES - GENERALThe advantages of veneer

plaster over othercommonly used partitionand ceiling systemsinclude:

1. Rapid installation whichreduces overallconstruction time.

2. Appearance and surface ofconventional plaster atlower cost than regularplastering.

3. High resistance to cracking,nail-popping, impact andabrasion failure.

4. Mill-mixed plastercomponents help ensureuniform installationperformance and finishedjob quality.

ADVANTAGES - ONE-COATSYSTEM (UNI-KAL/X-KALIBUR)1. Requires only one plastering

material on the job.2. Slightly lower in-place cost

than two-coat system.3. Can be applied directly to

concrete block.4. X-KALibur is formulated

to have extended setcharacteristics beyondtraditional Uni-Kal settingtimes.

ADVANTAGES - TWO-COATSYSTEM (KAL-KOTE)1. Kal-Kote System may be

used for plaster-embeddedelectric radiant heatingcable systems.

2. Same applicationtechniques as forconventional plaster.

3. Greater crack resistancethan one-coat systems.

4. Can be applied directly toconcrete block.

LIMITATIONS1. Not recommended for

exterior use or wheresubject to weathering,direct water contact ortemperature exceeding125˚F (52˚C) for extendedperiods of time.

2. Framing spacing is limitedand partition heights arereduced in comparisonwith some standardconstructions.

3. Provides less rigidity thansimilar standard plastersystems.

4. When Uni-Kal/X-KALiburwill be applied, do notinstall Kal-Kore too far inadvance of plastering sinceUni-Kal/X-KALibur bondcan be adversely affected ifface of Kal-Kore hasbecome faded from light. IfKal-Kore has been faded,apply Kal-Kote Base Plasteror a bonding agent toobtain good bond.

5. All are designed for trowelapplication. Gold BondVeneer Plasters are notsuitable for conveyance orapplication byconventional plasteringmachines.

6. Compared to conventionalplasters, Veneer PlasterSystems are more subject tobeading (ridging) andcracking at the joints underrapid drying conditionssuch as those caused bylow humidity, hightemperature and/or highdraft exposure.

7. All provide a base overwhich paints or otherfinishes should be applied.

8. Do not use a polyethylenevapor retarder unlessstructure is ventilatedadequately duringapplication of veneerplasters.

9. A bonding agent must beapplied to monolithicconcrete prior toapplication of eithersystem.

10. Mix only full bags ofplaster for proper set.

11. Do not use self-adhesivemesh tape.

45NATIONAL GYPSUM VENEER PLASTER SYSTEMS

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09 26 13/NGCVeneer Plaster System Components

TECHNICAL DATA

Pcs.Size Thickness Edge per Bdl.

4'x8', 16' 3/8" (9.5 mm) Square 2(1219 mm x 2438 mm, or

4877 mm) Tapered

4'x8', 16' 1/2" (12.7 mm) Square 2(1219 mm x 2438 mm, 1/2" (12.7 mm) or

4877 mm) FSK-C Tapered

4'x8', 16' 5/8" (15.9 mm) FSK Square 2(1219 mm x 2438 mm, or

4877 mm) Tapered

4'x8', 12' 1/2" (12.7 mm) Square 2(1219 mm x 2438 mm, 5/8” (15.9 mm) FSK or

3657 mm) Hi-Abuse Tapered

GOLD BOND® BRAND KAL-KORE PLASTER BASE

Kal-Kore is a tapered edge gypsum plaster base having a blueabsorptive face paper surface designed to permit rapid trowelapplication and strong bond of Kal-Kote, Uni-Kal and X-KALibur plasters. Also available foil backed or Fire-Shield(type X). Kal-Kore is manufactured to conform to ASTMSpecification C 1396 and CSA A82.27.

GOLD BOND® BRAND HI-ABUSE KAL-KORE PLASTER BASE

Gold Bond BRAND Hi-Abuse Kal-Kore Fire-Shield Type X Plaster Base boards consist of a fire resistive Type X gypsum core encased in a heavy, blue absorptive face paper designed to permit rapid trowel application and strong bond of Uni-Kal veneer plaster and strong liner paper on the back side. Gold Bond BRAND Hi-Abuse Kal-Kore Fire-Shield Type X Plaster Base features a specially formulated core to provide fire resistance ratings when used in tested systems as well as greater resistance to surface indentation. Long edges of the boards are tapered to allow joints to be reinforced and concealed with Kal-Mesh Tape and Uni-Kal Plaster. Gold Bond BRAND Hi-Abuse Kal-Kore Fire-Shield Type X Plaster Base is manufactured to conform to ASTM Specification C 1396 and Federal Specification SS-L-30D Type VI Grade X (Fire-Shield).

Abrasion-Resistant Uni-Kal Veneer Plaster

Enhanced Core Heavy Liner Paper


KAL-KOTE BRAND BASEPLASTER

Kal-Kote Base Plaster is aspecially designed highstrength basecoat plasterfor application 1/16"minimum thickness overKal-Kore, masonry ormonolithic concrete thathas been treated with abonding agent.

Strength of Kal-Kote Base issubstantially greater thanthat exhibited by typicalsanded basecoat plaster.

Fire ResistanceFire ratings equivalent to

those of drywall systemscan be obtained byapplying thecorresponding Kal-Koretype and thickness over thesame framing member sizeand spacing, with the samefasteners. The total plasterthickness should be aminimum of 1/8". Theminimum 1/8" thickness isachieved by applying afinish not exceeding 1/16"over 3/32" of Kal-KoteBase Plaster.

Specification ReferenceASTM Designation C 587.Bag Weight80 lbs. (36.3 kg)Water Ratio10-12 quarts per bagCoverage (est.)1/16" on Kal-Kore Base, 425-

475 sq. yds. per ton (150-170 sq. ft. per bag). Onecoat to level over masonry,225-275 sq. yds. per ton(80-100 sq. ft. per bag).

KAL-KOTE BRAND SMOOTHFINISH PLASTER

Kal-Kote Smooth Finish isdesigned to provide awhite smooth trowel finishusing conventionalplastering techniques.Apply not exceeding 1/16"over Kal-Kote Base.

Requires the addition of wateronly. It may also be usedas a finish for conventionalbasecoat plasters. Smallamounts of commercialretarder may be cautiouslyused to slow the settingtime when used overconventional basecoatplasters.

Bag Weight50 lbs. (22.7 kg)Water Ratio18-20 quarts per bag

Coverage (est.)*1/16" coat troweled on Kal-

Kote Base Plaster, 650-700sq. yds. per ton (145-160sq. ft. per bag).

KAL-KOTE BRAND TEXTUREFINISH PLASTER

Kal-Kote Texture Finish isdesigned to provide avariety of decorativesurfaces using commonplastering techniques.Applied as a 1/16" finishcoat over Kal-Kote Base. Itrequires the addition ofwater only.

Bag Weight50 lbs. (22.7 kg)Water Ratio11-12 quarts per bagCoverage (est.)*1/16" coat troweled on Kal-

Kote Base Plaster, 650-700sq. yds. per ton (145-160sq. ft. per bag).

UNI-KAL AND X-KALIBUR BRAND VENEER PLASTER

Uni-Kal and X-KALibur are single component veneer plasters for application over tapered edge 1/2” Regular or 5/8” Fire-Shield Kal-Kore, 5/8” Kal-Kore Hi-Impact or as a finish coat over Kal-Kote base. When applied in a thin coat 3/32" thick and troweled to a smooth finish, they provide a durable, abrasion-resistant surface for further decoration. X-KALibur has a longer extended working time.

Uni-Kal and X-KALibur may be worked to a variety of textured finishes.

Uni-Kal and X-KALiburapplied not exceeding1/16" may be used as afinish coat over a 3/32"coat of Kal-Kote BasePlaster for a total minimumthickness of 1/8".

Strength of Uni-Kal and X-KALibur provides asurface resistant toabrasion, cracking and nail-pops.

Fire ResistanceFire ratings equivalent to

those of drywall systemscan be obtained byapplying the correspondingKal-Kore type and

thickness over the sameframing member size andspacing with the samefasteners and 3/32" of Uni-Kal or X-KALibur.

Specification ReferenceASTM Designation C 587.Bag Weight50 lbs. (22.7 kg)Water Ratio13-15 quarts per bagCoverage (est.)*3/32" on Kal-Kore Base, 600-

665 sq. yds. per ton (135-150 sq. ft. per bag). Onecoat to level over masonry,300-350 sq. yds. per ton(70-80 sq. ft. per bag).

*Coverage estimates areapproximately the same asover Kal-Kore Base Boardfor conventional plasters.


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09 26 13/NGCVeneer Plaster Accessories* Used in Both Systems

KAL-KORNER BEAD Formed of galvanized steel to

protect exterior cornerswith veneer plastering.Flange length 1 1/4" .

VENEER J TRIM CASINGBEADUsed as a finished edge at

door and window jambsby slipping over edge ofplaster base.

EXPANDED VENEERCORNERBEADUsed as an alternate to the

Kal-Korner Bead forexterior corners. 1 1/4"flanges.

ARCH CORNERBEAD Can be used straight for

exterior corners or flanges,or may be snipped andbent to form arches.

VENEER L TRIM CASINGBEADUsed as a finished edge at

door and window jambs.

1 1/2" DRYWALL FURRINGCHANNEL CLIPAttaches Screw Furring

Channel to 1 1/2" coldrolled steel channel.

.093 ZINC CONTROL JOINTDesigned as an expansion or

control joint for ceilingand partition areas forboth drywall or veneerplaster systems.

E-Z STRIP® CONTROL JOINTDesigned for drywall or veneer

plaster systems. A vinylextrusion used as anexpansion or control jointfor ceilings or partitions.

KAL-MESH TAPEA coated non-adhesive

fiberglass tape which isstapled to Kal-Kore toreinforce all joints andinterior angles.

*Metal products are not manufactured by National Gypsum Company.


FASTENERS FOR ATTACHING KAL-KORE

Framing Kal-Kore Fastener Fastener Spacing

Steel 1/2" (12.7 mm) Type S Screws 12" o.c. Max.Studs & 1" (25.4 mm) for single layer (305 mm)Furring 5/8" (15.9 mm) 1 5/8" (41.3 mm) for two-ply

3/8" (9.5 mm) 1 1/4" (31.8 mm) annular or Ceiling 7" o.c. 4d box nails** (178 mm) Max.

Wood 1/2" (12.7 mm) 1 1/4" (31.8 mm) annular or Sidewall 8" o.c. Framing 5d box nails** (203 mm) Max.

5/8" (15.9 mm) 1 3/8" (34.9 mm) annular or6d box nails**

**Alternate: On walls, 1 1/4" (31.8 mm) Type W screws are spaced 12" (305 mm) when framing is 24" o.c. (610 mm) or 16" o.c. (406 mm).

TABLE 1–SPACING OF FRAMING OR FURRING

Type of MaximumFraming or Kal-Kore Spacing

Furring Thickness on center

Wood 3/8" (9.5 mm) *16" (406 mm)1/2" (12.7 mm) **24" (610 mm)5/8" (15.9 mm) 24" (610 mm)

***Metal 3/8" (9.5 mm) N.A.1/2" (12.7 mm) 16" (406 mm)5/8" (15.9 mm) 24" (610 mm)

N.A.–Not Approved.* Bound edge of Kal-Kore must be at right angles to framing for ceiling or walls.

** Bound edge of Kal-Kore must be at right angles to joists. 16" (406 mm) maximum spacing for bound edge of Kal-Kore parallel to joists.

*** On ceilings, furring channel [7/8" (22.2 mm) depth] shall span 48" (1219 mm) maximum. Resilient furring channel [1/2" (12.7 mm) depth] shall span 24" (610 mm) maximum. For greater spans, 1 5/8" (41.3 mm) Steel Studs may be used as Ceiling Furring Channels provided they are secured with flanges up (open side up) at spans not to exceed: 6' (1829 mm) at 12" o.c. (305 mm) spacing, 5'6" (1676 mm) at 16" o.c. (406 mm) spacing and 5' (1524 mm) at 24" o.c. (610 mm) spacing.

Note: Veneer Plaster Systems are to be installed with maximum deflection criteriaof L/240.


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09 26 13/NGCDETAILS

KAL-MESH

KAL-KOTEBASE & FINISH

WOOD STUDS

KAL-KORNERBEAD

KAL-KORE

CORNER-WOOD STUDS09215A

Scale: 2 1/4" = 1'-0"

KAL-KORE KAL-KOTEBASE & FINISH

STEEL STUD

KAL-MESH

TRACK

CORNER-STEEL STUDS09215B

Scale: 2 1/4" = 1'-0"

KAL-KORNERBEAD

KAL-KORE JOINT

KAL-MESH

KAL-KOTEBASE & FINISH

JOINT DETAIL09215C

Scale: 2 1/4" = 1'-0"

KAL-KORE WOOD STUD

5/8" GAP

E-Z STRIP VINYLEXPANSION JOINT

1/2"GAP

5/8" FIRE-SHIELDKAL-KORE

2 1/2" STEELSTUDS

5/8" FIRE-SHIELDKAL-KORE STRIPS

ONE HOUR FIRE RATED CONTROL JOINT DETAILBased on Warnock-Hersey Report No. WH-651-0318.1

and Factory Mutual Design No. W1B-1 hr.09215D

Scale: 2 1/4" = 1'-0"

1 5/8" DRYWALL SCREWS24" O.C.

FURRING CHANNEL

KAL-KORE WIRE TIEE-Z STRIPEXPANSION JOINT

KAL-KOTE BASE & FINISH

HANGER WIRE

1-1/2" C.R. CHANNEL

PIECE 16" LONG-NESTED(TWO WIRE TIES EACH SIDE)

1-1/2" C.R. CHANNEL

SUSPENDED VENEER PLASTER CONTROL JOINT09215E


RECOMMENDATIONS

Kal-Kore Plaster Base

Uni-Kal orX-KALibur Finish


Kal-Kote Base

Kal-Kote Smooth Finish


Kal-Kote Base

Kal-Kote Texture Finish

VENEER PLASTER FORMETAL AND WOODFRAMING1. Wood Studs or Joists.

Wood members shall meetthe minimum requirementsof local building codes.Framing shall not exceedspacing shown in Table 1on page 46. Most partitionfire ratings require that Kal-Kore be applied vertically.When such ratings are notrequired, horizontalapplication may be used tominimize joints. Forceilings, application at rightangles to framing ispreferred.

2. Metal Studs. Align floorand ceiling tracks to ensureplumb partition. Securetrack with appropriatefasteners at a maximum of24" o.c. Position studs intrack on specified centersby rotating into place for afriction fit. Secure studslocated adjacent to doorand window frames,partition intersections andcorners by self-drillingsheet metal screws throughboth flanges of studs andtracks or by use of steelstud clinching tool. ApplyKal-Kore vertically for mostfire ratings. When ratingsare not required, horizontalapplication may be used tominimize joints.

3. Masonry Wall Furring withScrew Furring Channel.Attach furring channelvertically spaced not toexceed spacing shown inTable 1 on page 44. Fasten

each channel with concretestub nails or appropriatefasteners through channelflanges into the masonry orconcrete. Fasteners shall bespaced on alternate flangesnot over 24" o.c. Apply Kal-Kore vertically orhorizontally in maximumlengths to minimize endjoints.

4. Furred Ceilings with BarJoists. Attach regular furringchannel 16" o.c. to barjoists spaced up to 4' o.c.Resilient Furring Channel(wire-tied only) shall span amaximum of 24". Wire tieFurring Channel to joists oruse 1 1/2" Drywall FurringChannel Clip for 1 1/2"carrying channel. ApplyKal-Kore with paper boundedges at right angles to thefurring channel.

KAL-KORE AND HI-ABUSE®

KAL-KORE APPLICATIONNote: Application shall

conform to ASTM C 844.1. Cut and position Kal-Kore

accurately. Bring all jointedges together but do notforce into place. Positionall end joints over framingmembers. To avoid ridging,minimize gaps betweenadjacent boards.

2. Minimize the number of end joints by usingmaximum practical lengthswith proper positioning.

3. Stagger joints so that theyoccur on different framingmembers and will not bedirectly opposite oneanother on partitions.

Avoid joining Kal-Kore atcorners of doors, windowframes, and other openings,unless control joints arecreated using E-Z StripControl Joints.

4. Fasten Kal-Kore to framingmembers with face out,using the proper type andspacing of fasteners shownunder types of fasteners.

5. Draw Kal-Kore tight toframing. Drive fastenersstraight and dimple thesurface without breakingthe paper face.

KAL-KORNER BEADAPPLICATIONInstall Kal-Korner Bead using

appropriate fastenersspaced 12" apart.

E-Z STRIP CONTROL JOINTAPPLICATIONInstall E-Z Strip Control Joint

at 30' max. spacing onwalls and 50' max. spacingin either direction onceilings. Apply the controljoint with staples spaced 6"along each side of theflanges.

TREATMENT OF KAL-KOREJOINTSPre-treat all joints and

fasteners in Kal-Kote andUni-Kal Plaster Systemswith Kal-Kote Base Plaster,Uni-Kal, X-KALibur or Sta-Smooth Joint Compound.

Low humidity, hightemperatures and rapidlycirculating air can causecracking of plaster and jointbeading when Kal-Kore is

applied to metal framing.To minimize this duringthese conditions, jointsmay be pre-treated usingpaper tape.

Three acceptable methods oftreating Kal-Kore joints are:

DRYWALL PAPER TAPETREATMENT METHOD1. Trowel Kal-Kote Base

Plaster, Uni-Kal or X-KALibur over joint linefilling the channel formedby the tapered edges of theKal-Kore board in an evenfashion.

2. Center drywall paper tapeover the joint line andembed the tape into thesoft plaster using a troweland level the joint. Tapethe full length of the joint.

3. Allow the treated joints toset prior to general plasterapplication.


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STA-SMOOTH PAPER TAPETREATMENT METHOD1. Mix Sta-Smooth Compound

per instructions onpackage. Do notcontaminate the compoundwith other materials, dirtywater or previous mixes.Do not retemper.

2. Apply the Sta-SmoothCompound to the joint byhand or machine tool. Thedrywall paper tape must becentered over the joint lineand embedded into the softcompound. Do not over-trowel to a slick surface.Leave the surface rough toprovide mechanical keyingof the plaster.

3. Allow the treated joints toset and dry prior to generalplastering.

KAL-MESH TREATMENTMETHODDo not use self-adhering

mesh.1. Center and secure Kal-

Mesh over all joints andinterior angles with 1/4" or5/16" staples.

2. Position staples a maximumof 24" apart as follows:A. Joints: at alternate edgesfor the run from end to endand directly opposite oneanother at either end.B. Angles: along ceilingedge only for wall-to-ceiling angles. Along oneedge for wall-to-wallangles.

3. After the first staples areplaced at the end of a jointor angle, pull unstapledKal-Mesh as staplingproceeds to ensure that it will lie flat against theKal-Kore.

4. Pre-treat all joints and Kal-Beads with Kal-Kote, Uni-Kal or X-KALibur Plaster.Tightly trowel over jointline in both directions toprevent voids, feathering to a maximum width ofabout 6".

5. Allow the treated joints toset prior to general plasterapplication.

PLASTERINGNote: Application shall

conform to ASTM C 843.The same general job

conditions used in goodconventional plasteringpractice should bemaintained. However,because Veneer Plastercoats are thin, particularaction must be taken to

guard against dryouts(primarily avoiding directexposure to concentratedsources of heat and drafts.)

Special attention should alsobe given to temperatureconditions under which thesystem is installed. Both“in-place” and applicationperformance of individualVeneer System componentswill be greatly enhanced ifall construction areas andmaterials are at a suitabletemperature equilibriumbefore, during and afterinstallations. During coldweather, maintain atemperature 55˚F (13˚C) to70˚F (21˚C) before, duringand after installation of allsystem components untilveneer plaster has dried.

MIXINGEquipment: Mixing should be

done with a high-speedmechanical mixer. Apaddle-type agitator fittedto a 500-600 RPM heavyduty, 1/2" electric drill anda clean, smooth-sideddrum of convenient sizeare recommended forrapid, efficient mixing of allKal-Kote Plaster types.

Water Ratios: Use only clean,fresh water suitable forhuman consumption.Basecoat: 10-12 qts. per 80lb. bag. Smooth Finish: 18-20 qts. per 50 lb. bag.Texture Finish: 11-12 qts.per 50 lb. bag. Uni-Kal andX-KALibur: 13-15 qts. per50 lb. bag.

PROCEDURE1. Put all but 1 to 2 qts. of the

proper water volume in asuitable mixing drum.

Note: Starting with aninsufficient amount ofmixing water will seriouslydegrade mixing andapplication performance.

2. Add plaster and allow tosoak for about 1 minute oradd plaster as mixer isturning, then mix untiluniformly wetted.

3. Add remaining water andmix sufficiently to obtaindesired lump-free materialfluidity.

Note:A. Mixing periods greater

than 5 minutes will not be required if properequipment and procedureare used.

B. Mix no more than two bagsper batch to avoid mixingtoo far in advance ofapplication.

C. Caution is advised againstmixing more than twosuccessive batches withoutthorough equipment clean-up to avoid undue setacceleration.

D. Avoid the practice ofmixing partial bags sincethis leads to difficulty inmaintaining uniformmaterial qualities.

JOB SETTING ADJUSTMENT1. Basecoat and Finish

Plasters: Small amounts ofcommercial retarder orcommercial gypsum typeaccelerator may becautiously used to adjustsetting time when extremeconditions demand. Whencommercial retarder oraccelerator is used, add tomixing water directly, or inpreviously prepared watersolution form to obtain themost uniform effect.

2. Never use gauging ormoulding plasters in placeof commercial acceleratorsince they can adverselyaffect working qualities.

KAL-KOTE APPLICATIONOVER KAL-KOREBasecoat Over Kal-Kore1. Tightly scratch material into

previously treated jointsand cornerbeads, thenimmediately scratch-intightly over the wall and/orceiling area.

2. Double back over the areajust troweled with materialfrom the same batch,bringing total thickness upto 1/16" minimum.

3. When plaster has “takenup,” eliminate excessivetrowel marks and fill allsurface voids andimperfections to obtain areasonably uniform surface.Do not over-trowel to aslick surface. Roughen theunset basecoat plastersurface with a serrateddarby or lightly wire rake toprovide mechanical keying

for the finish plaster when necessary.

Smooth Finish Over Basecoat1. Apply only over properly

prepared Kal-Kote basecoatplaster. Scratch-in tightly,then double back withmaterial from the samebatch immediately tocreate a uniform coat notexceeding 1/16" in averagethickness.

2. Remove trowel marks, “catfaces,” and other majorsurface imperfections by“drawing-up” or “layingdown” the surface withlight trowel pressure whenplaster has stiffened.

Use water sparingly if needed,but do not over-trowel orover-water because thisaggravates any normaltendency for blisteringwhen working over lowsuction bases. Suchblistering will be eliminatedby the final water-trowelingoperations.

3. Water-trowel to densifyand polish the surface tothe desired degree whenplaster has set, eliminatingany blistering if present.Never use a felt “blisterbrush” as a substitute forwater troweling!

4. Uni-Kal and X-KALiburPlaster may be substitutedfor Kal-Kote Smooth Finish.

Texture Finish Over Basecoat1. Apply per (1) under Smooth

Finish.2. When plaster has stiffened,

float its surface to anydesired finish.

Do not float the soft surface of plaster which hasalready set.

Up to equal parts by weight ofclean, graded silica sandmay be added to Uni-Kaland X-KALibur to aidtexturing.

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Veneer plaster performs wellin high traffic areas such as

stairways and halls.

UNI-KAL OR X-KALIBURAPPLICATION OVER KAL-KORE1. Tightly scratch material into

previously treated jointsand cornerbeads, thenimmediately scratch-intightly over the wall and/orceiling area.

2. Double back over the areajust troweled with materialfrom the same batchbringing total thickness upto 3/32" minimum.

3. Begin finish troweling attime of initial set, usingwater sparingly. Finaltroweling must beaccomplished beforecomplete set takes place, asevidenced by darkening ofthe surface.

Note: Uni-Kal or X-KALiburmay be applied to producea textured finish.A. When Uni-Kal or

X-KALibur is mixed, addup to but not exceeding50 lbs. of silica sand,texturing grade, per50 lb. bag of plaster.

B. The sanded Uni-Kal orX-KALibur mix shouldbe scratched-in tightlyover the plastering base.Immediately doubleback over the area justtroweled with materialfrom the same batch.

C. When plaster is welltaken up, float to thedesired texture finish.

VENEER PLASTERS DIRECT TO BOND-COATEDMONOLITHIC CONCRETEDESCRIPTIONThe Kal-Kote System,

consisting of a basecoatplaster and a finish coatplaster, Uni-Kal or X-KALibur may be applieddirectly to monolithicconcrete treated with abonding agent.

LIMITATIONS1. Surface to be plastered shall

be treated with a bondingagent applied according tomanufacturer’s directions.The performance of thissystem is the soleresponsibility of thebonding agentmanufacturer.

2. Concrete should be agedat least one month prior toplastering.

3. Kal-Kote Smooth orTexture Finishes are notdesigned for directapplication to concrete,but must first have Kal-Kote Base Plaster appliedto fill and level surface.

4. Do not apply system to theinterior side of exteriorwalls below grade. To useabove grade these wallsshall be kept dry and shallhave been properlywaterproofed on theexterior side to preventwater penetration.

APPLICATION PROCEDURESNote: Application shall

conform to ASTM C 843.Kal-Kote Base Application

Over Bonding Agent1. First straighten any major

surface irregularities, suchas holes, ridges, wavysections, etc. Scratchplaster in tightly by troweland fill out to any adjacentlevel area.

2. After the straighteningmaterial has set, trowel in atight scratch coat over theentire area to be plastered;then immediately doubleback with material from thesame batch to minimumthickness of 1/16" or asrequired to achieve a levelsurface. Use a rod orfeather edge if needed.

3. When plaster has “takenup,” eliminate excessivetrowel marks and fill allsurface voids andimperfections to obtain areasonably uniform surface.Do not trowel to a slicksurface. Roughen the unsetbasecoat plaster surfacewith a serrated darby orlightly wire rake to providemechanical keying for thefinish plaster whennecessary.

Smooth or Textured FinishesApply finishes to the Kal-Kote

Plaster as outlined underthe regular Kal-Kote Systemas described on page 49.

Uni-Kal or X-KALiburApplication Over BondingAgent

1. First straighten any majorsurface irregularities suchas holes, ridges, wavysections, etc. Scratchplaster in tightly by troweland fill out to any adjacentlevel area.

2. Allow the straighteningmaterial to set.

3. Tightly scratch material inover the wall and/or ceilingarea. This applicationshould be about 1/16"thick. Double back overthe area just troweled withmaterial from the samebatch, bringing totalthickness up to 3/32"minimum.

4. Begin finish troweling attime of initial set, usingwater sparingly. Finaltroweling must beaccomplished beforecomplete set takes place, asevidenced by darkening ofthe surface.


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Veneer plaster walls are particularly suited to accommodatewall situations where light conditions require smooth, evenexpanses of wall.

The Veneer plaster wall system is particularly suited toresidential and commercial construction in areas which needstrength for special architectural details, and unusual design elements.

VENEER PLASTERS DIRECTTO UNIT MASONRY DESCRIPTIONThe Kal-Kote System,

consisting of a basecoatplaster and a finish coatplaster, Uni-Kal or X-KALibur, the one-coatsystem, may be applieddirectly to masonry surfacesproviding the followingrecommendations arefollowed.

RECOMMENDATIONS1. Surface must be free from

dirt, grease, oil, mold,parting agents, or anymaterial which will preventplaster adhesion.

2. When erecting masonry,strike joints flush. Ifmasonry has recessedjoints, fill joints flush tomasonry surface withbasecoat plaster, Uni-Kal orX-KALibur and allow to set.

EXTERIOR CORNERSInstall cornerbead with

adhesive at least 4 andpreferably 16 hours beforeplastering. Apply acontinuous bead ofadhesive approximately1/4" x 1/4" along the insideof both cornerbead flanges.Press the bead firmly overthe corner so that adhesiveis in continuous contactwith masonry surface.Align bead and allow tostand undisturbed at least 4 hours.

KAL-KOTE APPLICATIONNote: Application shall

conform to ASTM C 843.Proceed with the full field of

the wall by scratching-intightly, then double backimmediately with materialfrom the same batch to aminimum thickness of1/16" over the blocksurface, or as required tolevel.

Kal-Kote Finishes should bekept as thin as possible andapplied as described on page 44 and 51.

UNI-KAL OR X-KALIBURAPPLICATIONProceed with full field of the

wall by scratching-intightly, then double backimmediately with samebatch of material to aminimum thickness of3/32" over the blocksurface.

Caution: Since Uni-Kal or X-KALibur is a one-coatmaterial system, exercisecare in leveling the wall tocompensate for the unevensuction.

VENEER SYSTEMS APPLIEDTO MASONRY WITH ZFURRING CHANNELSYSTEMDESCRIPTIONThis system consists of a

Z Furring Channel, rigidinsulation and thecomponents of the Kal-Kote

and Uni-Kal or X-KALiburVeneer Plaster Systems.The Z Furring Channel ismanufactured fromgalvanized steel (.0179"min. base steel) and isproduced with web depthsof 1", 1 1/2" and 2". Thefurring channel which isapplied to a masonry wallholds the insulation inplace and the wide flangeserves as framing for theapplication of the Kal-Koreplastering base.

LIMITATIONS1. Since the interior wall

surface will take thegeneral configuration of themasonry wall, it may benecessary when applyingthe system to unit masonryto use portland cementplaster to bring the wall toa plane surface.

2. This system is mainly fornew masonry construction.On well-cured concrete ormasonry, it may be difficultto properly drive fasteners.

3. Power-driven fastenersshall be used only forattachment to monolithicconcrete surfaces.

4. Kal-Kore should be appliedwithin 24 hours of foamapplication.

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Design flexibility is achieved with veneer plaster systems.

APPLICATION PROCEDURES1. Begin application of

Z Furring members bypositioning first channelvertically at a corner,locating it on the walladjacent to the wall beinginsulated first.

The insulation thicknessdetermines the distance ofZ Furring web from wallbeing insulated. At theappropriate distance, withwide flange pointingtoward applicator, secure Z Channel with appropriatefasteners, spaced 24" o.c.driven through short flange.(Note: Power-drivenfasteners are notrecommended for use with masonry block.)

Install 24" wide floor-to-ceiling insulation board,pressed snugly against webof first Z. Install next Z withthe wide flangeoverlapping the edge of thefirst insulation board.Fasten Z to wall throughnarrow flange. Continue inthis manner with Z Furringmember 24" o.c. to end ofwall. Locate last Z so thatweb is located a distanceequal to insulationthickness from adjoiningwall. Cut last insulationboard to fit remainingspace.

At exterior corner, attach the Zthrough its wide flange withnarrow flange extendingbeyond the corner. Beginwith a narrow strip of floor-

to-ceiling insulation, widerthan insulation thickness,but not exceeding 3".Continue application offurring and insulationprogressively as describedabove.

At windows, doors and trimareas, use wood nailers,nominal 2" wide xinsulation thickness plus1/32". Use the nailers alsoat wall-floor angles tosupport trim and providebacking for base.

2. Apply Kal-Kore to theflanges of Z Channel with1" Type S screws spaced12" o.c. Normally, verticalapplication of Kal-Kore isrecommended; however,for installations 8' or less inheight, horizontalapplication may bepreferred since the numberof joints would be reduced.

3. Apply Kal-Mesh and Kal-Korner Bead according toprocedures described onpage 50 and 51.

4. Mix and trowel on Kal-KoteBase and Finish Plaster orUni-Kal Plaster asdescribed on pages 46, 51and 52.

PAINTING PLASTERVarious job conditions such as

suction differences, wet oronly partially dry walls, andreactions between paint andlime may cause unsatisfactorypaint finishes, particularlyon new construction.

Alkali-resistant primersspecifically formulated foruse over new plaster willpermit decorating with oilor latex type paints. Qualitypaint products should beused and manufacturers’recommendationsfollowed. Finished plastershould be painted orcovered to concealpossible discoloration. Thepaint system should besuitable for use over plastersurfaces that contain lime,which has a high pH of 10-13.

It is essential that plaster besound and completely drybefore painting. Undergood drying conditions,veneer plaster may bepainted 48 hours afterapplication.

High build, heavy duty andspecial purpose coatingssuch as Epoxy are notrecommended over veneeror job gauged lime puttyfinishes.

In all cases, the paintmanufacturer should beconsulted and approvepaint system suitability foruse with gypsum/limefinish plaster.

STORAGEGypsum plaster must be kept

dry before use. Storageconditions vary withlocation and seasonalchanges, which may affectstorage life. Theseconditions may affectproduct characteristics suchas setting time, workingqualities, componentseparation, or lumping, etc.Such aging is normally afunction of exposure tohumid air, temperature,and physical support inwarehousing. Adversestorage conditions orprolonged storage mayaffect the working qualitiesof the product. Rotateinventory frequently forbest results.


09

26

13

INSTALLATION

KAL-MESH

KAL-KORE

KAL-MESH

KAL-KOTE FINISH(Smooth or Texture)

KAL-KOTE BASE

KAL-KORNERBEAD

FOR USE WITH WOOD STUDSOR METAL STEEL STUDS

1" X 4" T& G FINISH FLOOR OR 5/8" T& G PLYWOOD

1" X 4" BRIDGING

1" TYPE S SCREWS 12" O.C.

KAL-MESH

1/2" FIRE-SHIELD CKAL-KORE KAL-KOTE FINISH

(Smooth or Texture)

KAL-KOTE BASE

R.F. CHANNEL 24" O.C.

2" X 10" WOOD JOISTS 16" O.C.

1" X 6" SUBFLOOR OR 1/2”PLYWOOD

KAL-MESH

KAL-KORNER BEAD

U.L. DESIGN L515

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SPECIFICATIONS

SECTION 09 26 13VENEER PLASTERTHE FOLLOWING PARAGRAPHS ARE FOR INSERTION INTO SECTIONS OF GENERIC SPECIFICATIONS OR GENERIC/PROPRIETARY SPECIFICATIONS COVERINGVENEER PLASTER PRODUCTS. THE NATIONAL GYPSUM COMPANY PRODUCT NAME FOLLOWS THE GENERIC DESCRIPTION IN PARENTHESES.

PART 1 GENERAL1.02 REFERENCES

A. American Society for Testing and Materials (ASTM):1. C 587, Specification for Gypsum Veneer Plaster.2. C 1396, Specification for Gypsum Board (Gypsum

Base for Veneer Plaster).3. C 843, Specification for Application of Gypsum Veneer

Plaster.4. C 844, Specification for Application of Gypsum Base to

Receive Gypsum Veneer Plaster.

PART 2 PRODUCTS2.01 MANUFACTURER

A. National Gypsum Company2.02 MATERIALS

A. Veneer Plaster Base:1. Regular: A gypsum core lathing board surfaced with

absorptive paper on front, and long edges andcomplying with ASTM C 1396 (Gold Bond BRANDKal-Kore Plaster Base).a. Thickness: 3/8" or 1/2"b. Width: 4'c. Length: 8' through 16'd. Edges: Tapered

2. Fire-Resistant: A gypsum core lathing board withadditives to enhance the fire resistance of the core andsurfaced with absorptive paper on front, and long edgesand complying with ASTM C 1396, Type X.a. Thickness: 1/2" (Gold Bond BRAND Kal-Kore Fire-

Shield C Plaster Base) or 5/8" (Gold Bond BRAND Kal-Kore Fire-Shield and Fire Shield C Plaster Base).

b. Width: 4'c. Length: 8' through 16'd. Edges: Tapered

3. Regular, Foil-Backed: A gypsum core lathing boardsurfaced with absorptive paper on front, and long edges;backed with aluminum foil; and complying with ASTMC 1396 (Gold Bond BRAND Kal-Kore Foil-Back PlasterBase).a. Thickness: 1/2"b. Width: 4'c. Length: 8' through 16'd. Edges: Tapered

4. Regular, Abuse-Resistance: A gypsum core lathing boardwith additives to enhance impact resistance andsurfaced with absorptive paper on front and long edgeswith heavy liner paper bonded to the back side; andcomplying with ASTM C 1396 (Gold Bond BRAND Hi-Abuse Kal-Kore Plaster Base).a. Thickness: 1/2"b. Width: 4'c. Length: 8' through 12'd. Edges: Tapered

5. Fire Resistant, Abuse Resistant: A gypsum core lathing boardwith additives to enhance fire and impact resistance andsurfaced with absorptive paper on front and long edges withheavy liner paper bonded to the back side; and complyingwith ASTM C 1396, Type X (Hi-Abuse BRAND Kal-Kore Fire-Shield Plaster Base).

a. Thickness: 5/8"b. Width: 4'c. Length: 8' through 12'd. Edges: Tapered

B. Gypsum Plaster:1. Base Plaster: High strength gypsum plaster complying

with ASTM C 587 (Kal-Kote BRAND Base Coat Plaster).2. Finish Plaster: Gypsum plaster for smooth finish

complying with ASTM C 587 (Kal-Kote BRAND SmoothFinish Plaster).

3. Finish Plaster: Gypsum plaster for textured finishcomplying with ASTM C 587 (Kal-Kote BRAND TextureFinish Plaster).

IF TEXTURED FINISH IS SPECIFIED FOR BELOW, SAND MAY BE REQUIRED.4. One Coat Plaster: Gypsum plaster for single component

application complying with ASTM C 587 (Uni-Kal BRANDVeneer Plaster).

5. One Coat Plaster: Extended set gypsum plaster for singlecomponent application complying with ASTM C 587 (X-KALibur BRAND Veneer Plaster).

PART 3 EXECUTION3.01 INSTALLATION

A. In accordance with the manufacturer’s recommendations, National Gypsum Company “Gypsum Construction Guide,” and the following standards:1. Gypsum plaster base and accessories in accordance

with ASTM C 844.2. Gypsum veneer plaster in accordance with ASTM

C 843.B. Tolerances: For flatness of surface, do not exceed 1/4" in

8' for bow or warp of surface and for plumb and level.

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