I have had stone veneer and siding installed on my house from these guys. after the stone started falling from my house and the contractor wanted to accept zero responsiblity i had an Engineer investigate. Here is the response of the engineer. At your request I visited the above noted site to inspect the installation of a natural stone masonry veneer product manufactured by Realstone Systems. We understand the product is a Shadowstone panel in a charcoal colour. In attendance were you, the homeowner, a representative of Realstone Systems, and a representative of the installer. The inspection was carried out on July 20, 2011 at 9:00am. The installation is principally comprised of corners and key architectural highlights on a two storey residential structure. The masonry veneer elements are two stories in height on the sides and back of the building. The balance of the exterior cladding is EIFS. We understand the installation took place last year and panel failure occurred prior to the first freezing and thawing cycle. These panels were replaced using a construction adhesive. Further panel failure occurred following the winter season. The following observations were made; 1. The bedding mortar was not completely applied to the back of the panel in all areas where the panels had been removed or fallen off. In many areas the bedding mortar was not bonded to the scratch coat. In visible areas the profile on the scratch coat was not aggressive enough to promote bonding of the bedding mortar. In my estimation on average only 75% of the back panel was buttered with the bedding mortar. 2. The bedding mortar was not adhered well to the scratch coat and contained many air bubbles. In some areas the bedding mortar also fell off the scratch coat. It is reported that a type S mortar was used with a latex bonding agent. Large inconsistencies in colour and texture were noted at adjacent panels suggesting the addition of water or poor mixing practice between panel installation. 3. To improve the bond it is reported that Weld-Crete® by Larsen Products was applied to the back of each panel. This product requires that it be applied in a thin uniform coat and allowed to dry for one hour. It is apparent that the blue coloured residue from this product remained on the bedding mortar. This typically results when either the coating is too thick or has not dried sufficiently prior to installation of the panel. Applied too soon, this product can contribute to bond failure. 4. Voids behind the bedding mortar and scratch coat are a common deficiency in this installation and could be identified by tapping with a medium sized rubber hammer. This deficiency also makes it difficult to determine if the bond has failed at the panel to bedding mortar or at the bedding mortar to scratch coat. It was suggested that some areas had 100% mortar coverage. Accordingly, unlike the picture to the left where almost no bedding mortar extended to the edge of the panel, we investigated panels where it appeared the bedding mortar was complete and to the edge. During removal of this panel by tapping with a rubber hammer and applying hand pressure, several panels fell from above. The degree of vibration introduced during this removal does not warrant the failure of the upper panels. 5. Large areas of tile have failed in a progressive manner. Voids behind the bedding mortar indicate that the panel was not pressed well with a slight rotating action on to the scratch coat. All exposed areas had similar deficiencies described above that would contribute to bond failure. Accordingly, it is our opinion that these areas are representative of the whole installation. The last image shows all conditions and in this area panels could be removed by hand. Given the height of the installation this is a real safety concern. We do note that the joints are tight and the quality of the cutting and joint placement is good. However; it is our opinion that the bond failure is directly related to improper installation of the panels. Based on our assessment we recommend that the entire installation be removed down to the scratch coat. The scratch coat should be scored with a grinder to provide a more aggressive profile. Dependent on conditions it should be pre-dampened 24 hours in advance of application of the bedding mortar and stone veneer panel. Unless stringent conformance with the Weld-Crete® application requirements is followed, we do not recommend its use. With careful removal most of the panels can be salvaged. The back of each panel should be cleaned and be free of dust or materials that would negatively impact bond. Caution during the removal should be exercised to avoid falling panels. This is best achieved by starting from the top and working downward. Damage to panels will be reduced in this manner. If you have any further questions please contact the undersigned directly. Respectfully submitted, Paul R. Walkington, CET, rcca, LEED®AP Principal – Buildings Engineering STANTEC CONSULTING LTD. 2781 Lancaster Road, Suite 200 Ottawa ON, K1B 1A7 Direct Phone: (613) 738 6088 Fax: (613) 738 0721 Email: paul.walkington@stantec.com
- Approximate cost of services:
- $85,000.00
- Company Response
The unfortunate thing about the Internet is that anyone can say anything they like on it. We did do work for this gentleman, in fact quite allot of work. The work looks amazing and the transformation is really something. We do our best to always do good and honest work. Through the years we have worked with many different homeowners and we have hundreds of happy clients. Unfortunately from time to time mistakes can be made. After the engineer suggested that the stones should be repaired we agreed that it was appropriate for us to carry out the repairs. We also agreed to a mutually satisfactory amount of time that would be devoted to the repairs each week. We followed through with this arrangement for 6 weeks at great expense. During that time the working conditions eventually deteriorated so severely that it became impossible to continue. We pride ourselves on being "easy to work with" and reasonable. However repeated aggressive and abusive treatment toward any of our employees is taken very seriously. For the first time in 11 years of working on peoples homes I was forced to walk away. This is something we do not take lightly. We are extremely confident in our team and our reputation.