1/22/2016 CPD302015:Useofstoneandfaiencecladding|OnlineFeatures|Building

CPD302015:Useofstoneandfaiencecladding
4December2015

ThisCPDfocusesontwotraditionalfacadematerialsincontemporaryarchitectureandrestorationprojects,
examiningtheirsustainabilitycredentialsandinstallationmethods.ItissponsoredbySzerelmey

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DEADLINE:29JANUARY2016

BarrattHomesCourthouseluxuryresidential
buildinginWestminster,designedbyHLM
Architects,iscladwithMoleanoslimestone,
installedbySzerelmey

ThismoduleissponsoredbySzerelmey

INTRODUCTION
Stoneandfaiencearebothtraditionalbuildingmaterialsstillincommonusetoday.Combinedwithmodern
constructiontechnology,theyofferawiderangeofdesignpossibilities,particularlyascladding.ThisCPDwill
provideanoverviewtotheiruseinmodernarchitecture,exploringdifferentstonetypes,sustainability,testingand
standards,fixingandinstallation,andrestorationmethods.

TYPESOFSTONE
Therearethreebasiccategoriesofstone,allformedinthelithosphere,whichistheoutermost200kmoftheEarths
crust.Theseareigneous,sedimentaryandmetamorphic.

Igneousrockismadefromhotmeltedmineralsthathavecrystallisedonorbelowthesurface.Intrusive
igneousrocks,suchasgranite,areformedfrommagmathatcoolsandsolidifieswithintheEarthscrustthe
magmacoolsslowlyand,asaresult,theserocksarecoarsegrained.Extrusiveigneousrocks,suchas
basalt,areformedbythecoolingofmoltenmagmaontheEarthssurface.Themagma,whichisbroughtto
thesurfacethroughfissuresorvolcaniceruptions,solidifiesatafasterratehencetherocksaresmooth,
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crystallineandfinegrained.
Sedimentaryrock,suchassandstoneorlimestone,iscreatedbythe
accumulationandcompactionofsediments.Theerosionofrockson
theEarthssurfaceproducessoliddebrisandsolublechemicalsthat
arecarriedbywater,wind,ice,massmovementorglaciers,and
depositedinlayerstoformthestrataofsedimentaryrock.IntheUK,
limestonespredominateinthesouth,sandstonesinthenorth.
Metamorphicrockcanbeanyprotolithrockthathasbeenheated,pressurisedandrecrystallisedatdepthsof
570kmbeneaththeEarthscrust,beforebeingexposedbyerosionoruplift.Sandstonesformrockscalled
gneissesandquartzites,whichresembletheirprecursorsbutareharder,whilelimestonesformmarbles,
whichareveryornateandcharacterful.

Oneadvantageofstoneasaconstructionmaterialisthatthereisawidevarietyofavailablefinishesand
performancecharacteristicstosuitarangeofapplications,includingexternalcladding,hardlandscaping,internal
wallingandflooring.Somebenefitsarecommontoalltypesofstone,suchasdurabilityandversatility.

Itisimportanttoseektheadviceofastonespecialistearlyinaproject.Theywillbeabletoadviseonthe
appropriatetypeofstonetomeetaesthetic,performanceandsustainabilityrequirements.Oncethetypeofstone
hasbeendetermined,quarryvisitsarerecommendedtounderstandtheextractionprocessesandtheproduction
capacityofthequarrytoensureconsistencyacrosstheprojectthisisparticularlyimportantonlargeprojects.Note
thatnotwoquarriesarealike,andthatthestonewillvarywithinthesamequarry.Aquarryvisitwillalsoenable
specifierstounderstandthegeologicallimitationsofthestonetheyarespecifying:bedheightsaredeterminedby
thegeologyandcannotbeincreased.Bedheightsinexcessof750mmneedtobediscussedwiththesupplier.

Itisalsoimportanttobeawareofleadtimes,asthequarrywillneedtimetoexcavate,workandsupplythematerial.
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SUSTAINABILITYOFSTONE
Althoughstoneisafiniteresource,itcanbeextractedtominimisewasteandpreserveexistingreserves.Themost
environmentallysensitivemethodusessawstocuttherockfaceratherthanblackpowdertoblastit.Thestoneis
thenmovedoffitsnaturalbedusinghydrobags.Thestoneisnotfracturedbytheblast,whichincreasestheyield
andreduceswaste.Anywastematerialproducedduringthemanufacturingprocesscanbealmostcompletely
recycledeithercrushedforaggregateorthefinesusedforpointingorrepairs.Forexample,limestonewasteis
pulverisedforlimemortar.

Inuse,stonehasanumberofsustainabilitybenefits:

Itcanbesourcedlocally.Britainhasawealthofdifferentstonesavailablewithawidearrayofcoloursand
performancecharacteristics.
Ithashighthermalmass,whichmeansitcanabsorbheatinwarmtemperaturesandreleaseitasthebuilding
cools.Thisisakeyelementofpassivelowenergydesign,asitmeansthatinternalclimatecanberegulated
naturally.
Itishighlydurableandhasanextremelylonglife,whichminimisestheneedforrepairandreplacement,
therebymakingtheoperationofstonebuildingshighlyefficient.

Oncladdingapplications,thereisapositiveenvironmentalimpacttousingthinnerstoneforexample,reducing
thicknessfrom75mmto50mm.Thisalsorepresentsacostsavingtotheclient.Testing(seebelow)willindicatethe
achievablestonethicknessfordifferentapplications.

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CrownEstatesStJamessGatewaybuildingincentralLondon,designedbyEricParryArchitects.TheJermyn
StreetfacadecomprisesnewPortlandstonecladding,sourced,designedandinstalledbySzerelmey

FAIENCEINCONSTRUCTION
Faienceisglazedterracotta,whichisfiredclay.Beforefiring,itisahighlymalleablematerialthatcanbeproduced
invirtuallyanyshapeandcolour,affordingarchitectsarangeofaestheticpossibilities.Faienceisextremelyeasyto
cleanandmaintainhenceitspopularityinsmogriddenVictorianLondonandithasexcellentfireresistance.

Thereareanumberofspecialisedmanufacturersoffaiencefortheconstructionindustry,witheachhavingstrengths
indifferentareassuchasvolumeofproduction,levelofglazing,qualityofshapesandleadintimes.Aswithstone
quarries,itisimportanttovisitthedifferentsupplierstounderstandthecomplicatedprocessesinvolvedinthe
productionofthisbuildingmaterial.Leadintimesforfaiencecanbesurprisinglylong,suchassixmonths.

SUSTAINABILITYOFFAIENCE
Clayisacompletelynaturalmaterial,itiseasilyextractedandrequireslittleinthewayofpostprocessing.Faience
hasgoodlongevity,durabilityandthermalperformance.Glazesaretypicallycreatedfromnaturallyoccurringraw
materials.Terracottaandfaienceareinertproductsanddonotreleaseanycompoundsintotheatmosphere.They
havethelowestradonexhalationrateofallbuildingproducts.

Thekilnfiringisoneoftheleastsustainableareasoffaienceproduction,asitisenergyintensive.Inlightofthis
thereiscontinualresearchintodevelopingmoreefficientkilnsthatmaximiseefficiency.Suppliersrecycleasmuch
oftheirwasteclayaspossibleinordertoreuseitintheproductionprocess.Inaddition,wasteterracottaiscrushed
andreusedashardcoreandaggregates.

TESTINGANDSTANDARDS
CEmarkingcertificatesandDeclarationsofPerformance(DoP)havebeenmandatoryfornaturalstoneapplications
sinceJuly2013.TheDoPistheformaldocumentthatsetsouttheoperatorscommitmenttosupplystonethat

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meetsthetechnicalpropertiesstated,whiletheCEcertificateprovidesthedesignerwithdetailsofthetechnical
propertiesofthestone.Theseprovidetestresultsrelevanttotheproposedapplicationofthestone.Theymaynot,
however,providealltestresults,andinsomecasesitisprudenttolookatawiderrangeoftests.Anindependent
consultantcanprovideadviceonthetestingrequiredandfurthertestingavailable.

Testingtypicallytakesfourtosixweeks(knownaspreproductiontesting)andcontinuesatintervalsthroughoutthe
productionperiod.

Allowtimetoretestincaseoffailure,andconsiderspecifyingstonemanufacturedfrompretestedblock.

TheBritishstandardforthedesignofnaturalstonecladdingisBS8298:2010.Thissetsoutthecriteriafor
calculatingtherequiredthicknessofstoneasfollows:

Stoneperformancevalues(strength,weatheringcharacteristics)
Sizeofpanel
Windloading
Typeoffixing
Distancebetweenfixings.

BS8298putstheresponsibilityonthespecialistcontractortoprovethatthethicknessofthestoneisfitforpurpose,
withcorrespondingtestdata.

Otherrelevantstandardsinclude:

BSEN1467:2012Naturalstone.Roughblocks.Requirements
BSEN1468:2012Naturalstone.Roughslabs.Requirements
BSEN1469:2015Naturalstoneproducts.Slabsforcladding.Requirements
BSEN12440:2008Naturalstone.Denominationcriteria

Thereiscurrentlynorequirednationalstandardforfaienceorterracottacladding,althoughthereareceramicscodes
fortiling.Thefacadeengineerorspecialistcontractorshouldsubjectthematerialtosimilartestingcriteriaasthose
usedonstoneandalsorefertocurrentceramicscodes.

At57StHelensPlaceintheCityofLondon,SzerelmeywasresponsibleforthefaiencefacadedesignedbyEric
ParryArchitects.Itiscomprisedof14,000elementsincorporating168differentshapesincludingcurvedpieces,
columnpieces,copingsandsoffits

CLADDINGAPPLICATIONS
Whenusingstoneorfaienceasacladdingmaterial,therearethreemaintypesofapplication:

HandsetcladdingThisisatraditionalapproachtocladdingwitheachstoneindividuallyrestrained,supported
onbracketsatslablevel,groutedandfixedbyskilledmasons.Itrequiresamasonsscaffoldfortheduration
ofthebuild.
StoneonprecastcladdingStoneisbondedtolargeprecastbackingpanelsatthefactory,oftencompletewith
theinsulation.Thepanelsarefixedusingcranes.Thereisalongleadinfordesignandmanufacturefor
relativelyfastconstructionusinglargepanels.
RainscreencladdingThisisanotherquickoptionandensuresearlyweathertightnessofthebuilding.Units
aresupportedandrestrainedindividuallytoapreinstalledstainlesssteelstructure.Thisistypicallyanopen
jointedsystemandhastheaddedadvantagethatindividualunitsareveryeasytoreplaceifnecessary.

Allthreeoftheabovemethodsaresuitableforstoneorfaienceinstallation.

FIXINGSANDINSTALLATION
Typicallybespokefixingsystemsaredevelopedforeachprojecttoaddressthespecificcomplexitiesofthebuilding.

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Movementjointswillneedtobeincludedasanyfoundationmovementthataffectsthestructuralframewillalso
affectthecladding.Compressionjointsaretypicallylocatedateveryfloorlevelandareaminimumof15mmthick.
Thepositioningandwidthcanvary,butanyvariationmustbesupportedbydetailedcalculation.Expansionjointsare
requiredatamaximumof6mintervalsandbetween1.5mand3mfromanycorner.Theyshouldbeaminimumof
10mmthickandareoftenconcealedbehindrainwaterpipes.Expansionjointsintheblockworkinfillpanelmustbe
carriedthroughtothestonework.

Fixingdesignmusttakeintoaccounttheimposedloads:allowforathreewayadjustmenttoenableproperfitwithin
holesormorticesinthestoneandtothesubstrate.Fixingsaremainlyproducedinstainlesssteel.Thenumber,type
andpositionoffixingsiscalculatedbasedonthestone(orfaience)tobeused,thethicknessandfaceareaofthe
units,thenatureofthesubstrateandtheloadappliedtoeachfixing.Typesoffixinginclude:

Loadbearingfixings,suchasacorbelplate.Theseusuallyrequireanexpansionanchortofixittothe
backingstructure(whichisnormallyconcrete).
Restraintfixing,withanexpandingboltfix.Theseareusedtoholdthestonetothebackingstructure
(normallyblockwork,concreteorsteel).

Aresinbondedanchorrequiresapredrilledholeintowhichtheresinissquirtedusingacartridgegun.Thestonehas
tobesupportedwhiletheresinhardens.Typicallyananchorcanbedeemedrestrainedin1520minutesinhot
weather.Thedisadvantageisthatitisslowtofixandweatherdependent.Inverycoldtemperatures,theresinmay
notevensetandtheuseofresinwouldbediscouragedinfavourofexpandinganchors.

SoffitfixingsTheseareusedtosuspendasoffitatjointsbetweenstones.
FacefixingsThesearerarethesedaysbuttheyaresometimesunavoidableforrestorationwork.Skilled
repairsareneededtocamouflagetheentryholeofthefixing.

Installationofstoneorfaiencefacadesorinternalcladdingshouldonlybeundertakenbyaspecialistcontractor,
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usinganappropriatelytrainedworkforce.

ThePiccadillyfacadeofStJamessGatewaywasdesignedinconjunctionwithartistRichardDeacon,andisclad
infaiencetileswithanunusualcornice

RESTORATION
Allcladdingmaterialswillbecomedirtyovertime,especiallythoseininnercityenvironments,andothersmight
sufferdamage.Cleaningandrestorationofstoneandfaiencefacadesshouldonlybeundertakenbyaspecialist
contractor.Inparticular,historicfacadesshouldbeapproachedwithgreatcare.Beforeanycleaningisundertaken,
testpanelsshouldbecarriedout.Itisimportanttothoroughlyinvestigatethebuildingfabricbeforecommencingwith
samples.

Therequiredleveloftemporaryprotectiontothefabric,andtomembersofthepublic,willvarydependingonthe
typeofcleaningtechniqueemployed.Thiswillalsoaffectbothcostandprogramme.Afullysheetedscaffoldwillbe
requiredifeitherchemicalorabrasivecleaningtechniquesareused.Heavygaugepolytheneshouldbesealed
aroundtheperimeterwithheavydutyadhesivetapetowindowsanddoors.

Howtotakethismodule
UBMsCPDdistancelearningprogrammeisopentoanyoneseekingtodeveloptheirknowledgeandskills.Each
modulealsooffersmembersofprofessionalinstitutionsanopportunitytoearnbetween30and90minutesof
creditstowardstheirannualCPDrequirement.

ThisarticleisaccreditedbytheCPDCertificationService.ToearnCPDcredits,readthearticleandthenclick

http://www.building.co.uk/professional/cpd/cpd302015useofstoneandfaiencecladding/5079074.article 7/9
1/22/2016 CPD302015:Useofstoneandfaiencecladding|OnlineFeatures|Building

thelinkbelowtocompleteyourdetailsandanswerthequestions.Youwillreceiveyourresults
instantly,andifallthequestionsarecorrectlyanswered,youwillbeabletodownloadyour
CPDcertificatestraightaway.

CPDCREDITS:60MINUTES

DEADLINE:29JANUARY2016

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GridArchitectsoriginallydesigntheCourthouseproject.HLMwerethedeliveryarchitects.

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