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Light Weight Honeycomb Reinforced Stone Cladding System

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From <strong>Stone</strong> Panels, Inc. ®<br />

An AIA Continuing Education Program<br />

Credit for this course is 1 AIA HSW CE Hour<br />

OVER 35 YEARS OF<br />

INNOVATION IN NATURAL<br />

STONE CLADDING<br />

<strong>Light</strong> <strong>Weight</strong> <strong>Honeycomb</strong> <strong>Reinforced</strong><br />

<strong>Stone</strong> <strong>Cladding</strong> <strong>System</strong><br />

Course Sponsor<br />

100 S. Royal Lane<br />

Coppell, Texas 75019<br />

Ph. (469)635-5000<br />

Fax (469)635-5555<br />

E-mail<br />

dons@stonepanels.com<br />

Web<br />

www.<strong>Stone</strong>Panels.com<br />

Course Number<br />

sti04a<br />

Course Title<br />

<strong>Light</strong> <strong>Weight</strong><br />

<strong>Honeycomb</strong> <strong>Reinforced</strong><br />

<strong>Stone</strong> <strong>Cladding</strong> <strong>System</strong><br />

Please note: you will need to complete the conclusion<br />

quiz online at Ronblank.com to receive credit<br />

© Ron Blank & Associates, Inc. 2005


An American Institute of Architects (AIA)<br />

Continuing Education Program<br />

Approved Promotional Statement:<br />

Ron Blank & Associates, Inc. is a registered provider with The American Institute<br />

of Architects Continuing Education <strong>System</strong>. Credit earned upon completion of this<br />

program will be reported to CES Records for AIA members. Certificates of<br />

Completion are available for all course participants upon completion of the course<br />

conclusion quiz with +80%.<br />

Please view the following slide for more information on Certificates of Completion<br />

through RBA<br />

This program is registered with the AIA/CES for continuing professional<br />

education. As such, it does not include content that may be deemed or<br />

construed to be an approval or endorsement by the AIA or Ron Blank &<br />

Associates, Inc. of any material of construction or any method or manner<br />

of handling, using, distributing, or dealing in any material or product.


An American Institute of Architects (AIA)<br />

Continuing Education Program<br />

Course Format: This is a structured, web-based, self study course with a final<br />

exam.<br />

Course Credit: 1 AIA Health Safety & Welfare (HSW) CE Hour<br />

Completion Certificate: A confirmation is sent to you by email and you can<br />

print one upon successful completion of a course or from your RonBlank.com<br />

transcript. If you have any difficulties printing or receiving your Certificate<br />

please send requests to certificate@ronblank.com<br />

Design professionals, please remember to print your certificate of<br />

completion after successfully completing a course conclusion quiz. All AIA<br />

and non-AIA members will be sent a copy of their certificate to the email<br />

address they have provided in their RonBlank.com account.<br />

Please note: you will need to complete the conclusion<br />

quiz online at Ronblank.com to receive credit


Course Description<br />

Review composite wall panels made of thin natural stone veneer<br />

reinforced with an aluminum honeycomb backing. The stone<br />

veneer can be almost any stone including granite, marble, and<br />

limestone. Learn about the many aspects and benefits of a stone<br />

panel system.


Course Objectives<br />

Upon Completion of this course the Design Professional will be<br />

able to:<br />

‣ Define stone panel cladding systems and explain the need for<br />

reinforcing.<br />

‣ List the design decisions associated with reinforced stone cladding<br />

systems.<br />

‣ Describe the manufacturing process, product capabilities, and<br />

installation methodologies of stone panel systems.<br />

‣ Knowledgeably design and specify lightweight reinforced natural<br />

stone wall systems.


Why H/C <strong>Reinforced</strong> <strong>Light</strong>weight <strong>Stone</strong><br />

Here is an overview of the reasons why lightweight aluminum<br />

honeycomb-reinforced natural granite, marble, and limestone<br />

cladding is a great alternative with building owners, architects<br />

and contractors.<br />

‣ Lower installed cost<br />

‣ More design flexibility<br />

‣ Sizes – 4ft. or 5ft. wide x 8 ft. to 10 ft. long<br />

‣ 80% less weight than 3-cm thick typical slab granite panels<br />

‣ 60 times greater impact strength than 3cm thick traditional slab<br />

granite panels<br />

‣ Resists hurricane large missile impact force testing<br />

‣ Impervious to water penetration<br />

‣ High flexural strength, far superior to typical slab granite panels<br />

‣ Withstands seismic racking and shear movement<br />

‣ Proven performance in all climates<br />

‣ Green – use of stone veneer saves approximately 65% of natural<br />

stone resources.<br />

‣ <strong>Light</strong>weight, less fuel for transporting, and no heavy equipment<br />

needed for installing


What Is A <strong>Stone</strong> Panel<br />

This lightweight stone product is composed of a<br />

3/16” to 1/4” thick veneer of granite, marble,<br />

travertine, slate or limestone; bonded with high<br />

strength epoxy to a substrate of aircraft quality<br />

aluminum honeycomb. This is accomplished<br />

by placing a layer of epoxy reinforced glass<br />

cloth directly over the stone to provide crack<br />

and fracture resistance in addition to flexure<br />

and impact strength. For exterior construction,<br />

there is a second layer of epoxy-glass cloth<br />

applied and bonded to the stone for added<br />

strength and to render the stone panel totally<br />

impervious to moisture penetration. The<br />

honeycomb core has thin aluminum walled<br />

cells. It works like the web of a beam,<br />

separating the reinforced skin on the stone side<br />

and the skin on the backside. Although the<br />

thermal coefficient of expansion for aluminum<br />

is three (3) times greater than that of stone, a<br />

potential problem is eliminated because the<br />

aluminum walls are perpendicular to the plane<br />

of the stone.


<strong>Stone</strong> Panels The Manufacturing Process


Manufacturing <strong>Light</strong>weight <strong>Honeycomb</strong> <strong>Stone</strong> Panels<br />

The first step to manufacturing<br />

lightweight honeycomb stone is to quarry<br />

natural granite, marble or limestone.<br />

Large blocks are cut out in the quarry.<br />

The stone veneer is quarried from one of<br />

many locations throughout the world. Italy is<br />

a principle source for many architectural<br />

stones, but only a few types of marble,<br />

travertine and granites are actually quarried<br />

there. France is best known for its’ wide<br />

range of limestones. Marble, granite,<br />

travertine, limestone and slate are quarried in<br />

other European countries as well as in US<br />

locations, while Brazil is well known as a<br />

source for granite. Granite from China, while<br />

inexpensive, doesn’t present the color<br />

intensity of many other sources.


The Quarried Blocks Of <strong>Stone</strong> Are Transported To A<br />

Local Factory For Gang Sawing<br />

Blocks of stone are often in 5-ft. wide x 9-ft. long x 5-ft. high blocks.<br />

That size block weighs more than 40,000 lbs., or 20 tons. You really<br />

don’t want to meet that truck coming down a narrow winding<br />

mountain road.


Gang Saws Have About 50 Blades For Cutting The<br />

Desired Thickness Slabs<br />

When blocks of stone<br />

arrive at the factory, they<br />

are placed under a gang<br />

saw consisting of multiple<br />

blades that cut the block<br />

into several stone slabs.<br />

A lightweight honeycomb<br />

reinforced panel<br />

manufacturer usually<br />

prefers slabs that are cut to<br />

about 1-inch thickness.


Epoxy Glass Cloth Is Placed On Both Sides Of<br />

Expanded Aluminium <strong>Honeycomb</strong><br />

The honeycomb-reinforced<br />

substrate is fabricated from very<br />

thin sheets of aircraft quality<br />

aluminum which, when expanded<br />

to its cellular form, weighs only a<br />

few ounces per square feet.<br />

Here, a layer of epoxy preimpregnated<br />

glass cloth is placed<br />

on both the top and bottom of the<br />

aluminum honeycomb.


Platen Press Bonds Epoxy Glass Cloth to<br />

Expanded Aluminum<br />

The composite of aluminum and<br />

reinforcing glass is then placed into a<br />

platen press, operating at 300 degrees<br />

Fahrenheit. The epoxy within the preimpregnated<br />

glass melts while under<br />

extreme high pressure and it bonds the<br />

glass to the edges of the aluminum cells.<br />

A honeycomb reinforced stone panel<br />

manufacturer, using aircraft quality<br />

aluminum honeycomb components,<br />

produces stone panels in a similar<br />

fashion as the building of certain<br />

aircraft assemblies. And while this<br />

quality honeycomb is costly, the<br />

resulting bond strength is such that it<br />

would require more than 60,000 lbs. per<br />

sq. ft. to separate the glass from the<br />

aluminum honeycomb substrate. As a<br />

result of its strength to light weight<br />

characteristic, the time to install<br />

honeycomb reinforced stone panels is<br />

significantly reduced as compared to<br />

traditional solid stone slab stone and<br />

there’s no need for expensive lifting<br />

equipment or specialized labor.


<strong>Stone</strong> Slab Milling and Gauging Area<br />

Slabs of stone arrive at the factory,<br />

larger than necessary for panel<br />

production. The slabs are trimmed<br />

to the desired nominal size, milled<br />

flat, washed, and dried.


Saturation Process<br />

Epoxy Saturated Glass Cloth<br />

Between H/C & <strong>Stone</strong><br />

A sheet of honeycomb, up to 5-ft. wide<br />

and 10-ft. long, is placed on a bonding<br />

table. Then heavy glass cloth that has<br />

been saturated in high-strength epoxy is<br />

laid over the honeycomb sheet and<br />

rolled out for assurance of complete<br />

contact. From there, a slab of stone is<br />

set over the fresh epoxy and cloth,<br />

followed by another layer of epoxy<br />

saturated glass which is again covered<br />

with a top layer of honeycomb. In<br />

other words, there is a sandwich created<br />

with reinforcing on both the top and<br />

bottom of the stone slab, which is then<br />

moved to the press for assurance of<br />

complete bonding.


Radial Diamond Saw Cuts<br />

Through Center Of <strong>Stone</strong> Slab<br />

With 6-1/2 Ft. Diameter Blade<br />

After the epoxy is cured, the<br />

sandwich is moved to a saw room<br />

where it is split into two (2) pieces<br />

using large diamond tip radial<br />

saws or diamond studded wire<br />

saws.<br />

Cutting Process


The Largest <strong>Reinforced</strong> <strong>Stone</strong> Production<br />

Facility in The World<br />

Ten Radial Saws Plus Diamond<br />

Cable Saw<br />

Some lightweight honeycomb<br />

reinforced stone manufacturers<br />

bond a slab of stone to the<br />

reinforcing, then mill the stone<br />

thickness down to obtain a<br />

lightweight panel. Some have one<br />

saw for splitting the sandwich.<br />

The largest factory in the world<br />

has ten (10) saws simultaneously<br />

cutting through the center of the<br />

stone thickness.


Polishing Process<br />

16 Head Rotating Polisher Uses<br />

Diamond Bricks For Honed Or<br />

Polishing <strong>Stone</strong>.<br />

After cutting is complete, the panel is<br />

taken to one of several finishing<br />

machines where it is honed, polished or<br />

bush hammer finished. This picture<br />

shows how a honed or polished finish<br />

is accomplished on a panel, using<br />

rotating diamond-studded heads (or<br />

bricks as they are called) to grind away<br />

the rough sawn surface. The first few<br />

passes remove saw marks and smooth<br />

the surface, while additional passes<br />

give the stone a shiny reflective finish.<br />

One manufacturer also offers<br />

sandblasted, bush hammered, or flame<br />

finished stone.


Shop Drawings and Fabrication Tickets<br />

Shop Drawings Are Submitted And<br />

Approved, Then Fabrication Tickets<br />

Are Prepared Prior To Cutting<br />

A full-service lightweight stone<br />

manufacturer will prepare shop<br />

drawings immediately following the<br />

placement of an order allowing the<br />

designer, architect, and contractor to<br />

review exactly what is to be provided,<br />

and how it’s to be installed. Upon final<br />

approval, the manufacturer’s<br />

engineering staff then prepares detailed<br />

production tickets to be utilized during<br />

the manufacturing process.


Cutting Finish Panels into Desired Part Sizes<br />

The finished panels are then cut into<br />

final part sizes as determined by the<br />

shop drawings.


Bonding Finished Corners<br />

Jig Tables Used To Build<br />

Bonded Finish Corners<br />

The manufacturer may or may<br />

not have the capability to<br />

include the fabrication of<br />

finished returns to render an<br />

end product appearance as that<br />

of solid stone wherein the<br />

outside corner returns are<br />

miter cut and then bonded to<br />

the main panel using<br />

pigmented epoxy. Be sure to<br />

inquire as to the manufacturers<br />

capability to fabricate finished<br />

returns and cornices.


Interlocking Channels Are<br />

Anchored To Each Panel<br />

Connection materials are anchored<br />

to the backside of every panel at<br />

the factory, unless the panels will<br />

be adhesive attached which is<br />

sometimes done on interior walls.<br />

Anchoring to Each Panel


Shipped the Finished Product<br />

Finished Material Is Shipped In<br />

Pallet Crates (~2000 Lbs)<br />

Each completed panel is marked and<br />

numbered for position location on<br />

the building based on shop<br />

drawings, and then loaded into<br />

pallet crates. There is a layer of<br />

polystyrene insulation board and<br />

plywood placed around the entire<br />

perimeter of the product to protect<br />

the panels. The incidence of<br />

shipping damage is virtually zero if<br />

panels are properly crated and<br />

protected in this fashion.


Understanding<br />

Interlocking Channels & Installation


Interlocking Channels Are Attached<br />

Interlocking Channels Attached Over<br />

Water/Air Barrier<br />

And Or Over Exterior Sheathing<br />

Interlocking channels are one of the most<br />

popular attachment devices. Long lengths of<br />

aluminum-extruded channels are supplied<br />

for the installer to anchor over steel stud<br />

framing, furring or masonry backup.<br />

Exterior grade sheathing and/or an air/water<br />

barrier are quite often specified to go over<br />

steel framing for assurance that moisture<br />

will not reach the framing cavity.<br />

<strong>Light</strong>weight honeycomb reinforced stone<br />

panels, if properly manufactured, are<br />

impervious to water penetration, but an<br />

added barrier is often desired as additional<br />

assurance of water tightness in the event of a<br />

sealant caulk joint failure at some time in the<br />

future.


Interlocking Channels Are Factory-Anchored<br />

Interlocking Channels Are Factory-Anchored To The Backside Of<br />

Every Panel. The Regular Size Is Shown.<br />

Interlocking channels (ILC’s) are most often attached using selfdrilling,<br />

self-tapping TEK screws driven directly into the steel stud<br />

framing, or more often, screw attached through the exterior grade<br />

gypsum sheathing into the framing behind. The ILC’s can also be<br />

anchored directly to masonry with TAPCON screws.<br />

There are two (2) sizes of ILC’s, the larger of which provides a 2 ¼”<br />

dimension from the face of the attachment extrusion to the face of<br />

stone as shown on the following slide.


Interlocking Channels are Factory-Anchored


Screw Attach Interlocking Channels<br />

Screw Attach Interlocking<br />

Channels Direct Or Through<br />

Exterior Grade Sheathing<br />

A failing curtain wall was removed<br />

from this building and galvanized<br />

steel stud framing was installed over<br />

the masonry backup. Interlocking<br />

channels were then attached to the<br />

framing using neoprene washer-head<br />

TEK screws. The extruded aluminum<br />

interlocking channels had an<br />

anodized coating and were also<br />

painted to prevent electrolytic action<br />

between the aluminum and<br />

galvanized framing.


Case Studies<br />

Product Capabilities & Installation Methodologies


TIAX Headquarters, Reclad In 1994<br />

15 Acorn Park, Cambridge, MA<br />

Here is a picture of the building after<br />

exterior recladding with three<br />

different types of granite.<br />

The building is currently TIAX<br />

Headquarters building located in<br />

Cambridge, MA.


Narrow Interlocking Channels Anchored Through<br />

Exterior Grade Gypsum Sheathing<br />

This detail shows the narrow version<br />

of an interlocking channel being<br />

attached through sheathing to<br />

framing which provides a dimension<br />

of 1 ¾” from the face of the<br />

attachment to the face of the stone.<br />

Joints between panels are sealed with<br />

backer rod and silicone or a<br />

polyurethane sealant.


White Plains Metro Center<br />

White Plains, NY<br />

Large panels quickly installed<br />

with interlocking channel system<br />

The Reckson Metro-Center in White Plaines, NY was<br />

also renovated. A barrier was attached on all exterior<br />

walls after furring had been anchored over the existing<br />

brick and concrete. Then interlocking channels were<br />

attached through the framing behind. The lightweight<br />

stone panel system has interlocking channels which<br />

were factory anchored to the backside of each piece for<br />

installing. All pieces were numbered by location, as<br />

the stone was factory fabricated and cut to exact size.<br />

The large panel shown here at the right was easily<br />

handled and set by only two men.


The Reckson Metro<br />

Center at Hamilton and<br />

Church Streets in White<br />

Plaines, NY was re-clad<br />

in granite over the<br />

original hodge-podge of<br />

poured in place concrete<br />

and brick, as seen at the<br />

bottom left.<br />

White Plains Metro Center<br />

White Plains, NY


White Carrara Marble Panels Installed on Building<br />

in Genoa, Italy<br />

This 4-ft. x 8-ft. piece of<br />

stone weighed about 120<br />

lbs. That’s 80 % less<br />

than a traditional solid<br />

marble slab, so there’s<br />

neither riggers nor<br />

derrick men required to<br />

mechanically hoist the<br />

marble into place. In<br />

this case, the stone was<br />

quarried about 30 miles<br />

from this building in<br />

Genoa, Italy, but the<br />

slabs were shipped to<br />

the U.S. for honeycomb<br />

reinforcing and<br />

production of the<br />

lightweight stone panel<br />

product.<br />

4-ft. x 8-ft. piece of stone<br />

weighed about 120 lbs.


<strong>Honeycomb</strong> <strong>Reinforced</strong> Granite Clads<br />

Mercedes of Nashville<br />

Many luxury auto dealerships across North America utilize lightweight<br />

honeycomb reinforced stone panels. This Mercedes dealership in<br />

Nashville, TN has a limestone exterior.


Silver Star Cadillac – Thousand Oaks, CA<br />

Mocha Crème Limestone<br />

Cadillac, Lexus, Lamborghini, Hummer and Mercedes dealerships<br />

throughout the U.S. have incorporated lightweight honeycomb reinforced<br />

stone on their exteriors.


A Crew of Three will Typically Set 30 to 60 Pieces of<br />

<strong>Light</strong>weight <strong>Stone</strong> in an 8 hour Shift.<br />

This picture says it all about lightweight<br />

honeycomb reinforced panels! Here, a large<br />

corner piece of stone weighing only 45 lbs.<br />

is being set on the exterior of an auto<br />

dealership. It would not be possible to have<br />

a corner return such as this made from solid<br />

slab dimensional limestone. Furthermore,<br />

were a solid limestone panel possible, it<br />

would have been 3” thick and weighed well<br />

over 500 lbs. It would require a crane or<br />

hoist to set each piece in place. In the case<br />

of lightweight stone panels, a crew of 3 will<br />

typically set 30 to 60 pieces in an 8-hr. day.<br />

Conversely a solid dimensional stone crew<br />

will set only 3 to 6 pieces per day. So, in<br />

other words, it takes approximately ten (10)<br />

times longer to install a building with solid<br />

slab stone as compared to lightweight<br />

honeycomb-backed natural stone panels.


425 Broadhollow Rd. Granite Covering Old Brick<br />

The 425 Broadhollow Road Building in<br />

Melville, NY had Multicolor Red<br />

granite installed over a failing brick<br />

façade back in 1994. It was the first<br />

honeycomb reinforced stone project in<br />

Melville. Today, there are seven<br />

buildings in Melville, NY, within a 10-<br />

mile radius, clad with this exterior<br />

system and several more multi-story<br />

buildings scheduled for completion in<br />

early 2006 and 2007. All of these<br />

buildings also have lightweight<br />

honeycomb reinforced stone in place<br />

on interior walls, with many<br />

incorporating panels on elevator walls<br />

as well.


Testing and Proof of Performance<br />

The Specification Should Require Proof Of<br />

Performance, Including Flexure Testing<br />

Following 100 Cycles Of Acid Freeze-thaw<br />

Accelerated Aging.<br />

<strong>Light</strong>weight honeycomb reinforced natural stone<br />

panels were originally developed and initially<br />

patented in the 1960’s in Ireland, but the<br />

advantages were not truly recognized and<br />

commercially produced until 30 years later. It is<br />

recommended to require any prospective<br />

lightweight reinforced stone panel manufacturer<br />

to first provide proof that their product has been<br />

fully tested for long-term performance by<br />

independent laboratories. It is equally important<br />

the testing be required to include performance<br />

requirements addressing a proven capability of<br />

meeting or exceeding seismic racking shear<br />

requirements, air-water infiltration limits, and<br />

minimal flexural strength loss following sulfuric<br />

acid solution freeze-thaw accelerated aging.


Northern Project / Moscow Russia<br />

<strong>Reinforced</strong> lightweight granite on<br />

35-story International Business Ctr.<br />

On this project in Moscow, lightweight<br />

honeycomb reinforced granite was<br />

easily installed by a curtainwall<br />

contracting crew, over galvanized steel<br />

stud furring. Pallets of granite panels<br />

were taken up to the setting location<br />

using a material hoist, and then<br />

distributed around the building<br />

perimeter using a pallet jack. They were<br />

then passed through the window<br />

openings for installation where two (2)<br />

men easily handled the 5-ft. x 5-ft.<br />

pieces of granite with incorporated 8”<br />

top and bottom returns. Had these<br />

panels been produced in solid 3-cm.<br />

thick granite, they would have each<br />

weighed over 600 lbs.


The finished installation on the<br />

International Center, a building<br />

owned by the City of Moscow.<br />

<strong>Reinforced</strong> granite covers the<br />

spandrels, column covers, and<br />

shear walls on the tallest<br />

building in the Russia<br />

Federation, where there are<br />

relatively warm summers and<br />

extremely cold winters<br />

producing significant freezethaw<br />

conditions.<br />

International Business Center<br />

Moscow Russia


Anchorage Courthouse (Installed 1993)<br />

Anchorage, Alaska<br />

After extensive research, the architect<br />

said, “this was the only stone product<br />

we found that was light enough and<br />

strong enough to meet the severe<br />

seismic conditions”.<br />

<strong>Light</strong>weight honeycomb reinforced<br />

stone was also installed on this<br />

courthouse in Anchorage, Alaska in<br />

1994.


<strong>Light</strong>weight <strong>Honeycomb</strong> <strong>Reinforced</strong> Santa Cecilia<br />

Granite on the ARSC Building Anchorage, Alaska<br />

<strong>Light</strong>weight reinforced stone<br />

panels were also installed on<br />

the exterior of this 10-story<br />

building in Anchorage.


Fairbanks Courthouse / Alaska<br />

One of two building exteriors clad<br />

with reinforced granite in<br />

Fairbanks Alaska<br />

This courthouse is one of two<br />

buildings in Fairbanks having the<br />

exterior clad in lightweight reinforced<br />

granite. The other building was the<br />

Mission Support Facility. Fairbanks<br />

has the most severe temperature<br />

variation of any city on earth, ranging<br />

from –66 F to +99 F.


Roman Classic Travertine on Las Vegas City Hall<br />

<strong>Light</strong>weight natural stone panels<br />

have been installed on the exterior<br />

of buildings in hot climates,<br />

including the Justice Center in<br />

Indio, CA where the temperature<br />

often exceeds 120 F, and here on<br />

Las Vegas City Hall where<br />

temperatures frequently exceed 110<br />

F in July. We have included these<br />

projects as examples of installations<br />

in bitter cold to very hot climates to<br />

illustrate and emphasize that<br />

lightweight aluminum honeycombbacked<br />

panel systems stand-up to<br />

even the most extreme climatic<br />

conditions on earth.


<strong>Light</strong>weight <strong>Stone</strong> Shapes and Cornices are<br />

Economically Fabricated<br />

Heavy, solid dimensional stone<br />

can be cut to produce most<br />

shapes, but it is profoundly<br />

expensive to produce and install.<br />

On the other hand, lightweight<br />

reinforced stone panels can be<br />

fabricated and installed at a<br />

fraction of the cost for traditional<br />

stone.


Fabricated Shapes for Ann Taylor Flagship Store<br />

The cornice for the Ann Taylor Flagship store was<br />

factory assembled on galvanized steel stud<br />

framing, in lengths of 5-ft. each. Two carpenters<br />

installed 200 lineal ft. of cornice (40 pieces) in two<br />

7 ½-hour days from a scaffold. The alternative for<br />

Gensler Architects was traditional solid stone,<br />

which would have required heavy equipment for<br />

setting and man-weeks of time. Gensler was able<br />

to achieve their design<br />

intent, at an acceptable<br />

price by specifying<br />

lightweight<br />

honeycomb reinforced<br />

stone for this and<br />

numerous other buildings<br />

from coast to coast.


Ann Taylor Flagship Store / Midtown Manhattan<br />

Retail applications such as Ann<br />

Taylor at 60th and Madison in<br />

Manhattan, are common. The<br />

darker color limestone is flamefinished<br />

Rocheret, quarried near<br />

Leon, France. Iron oxide in that<br />

limestone brings out the reddish<br />

color. Only dense dolomitic<br />

limestones can be given a flamed<br />

or thermal finish.<br />

Architect: Gensler


Completed Assemblies were Shipped to the Jobsite for<br />

Economical and Speedy Installing<br />

Production of the Indiana<br />

limestone cornices at the roof, over<br />

entrances and at the drive-thru for<br />

the Bank of Elgin was done using<br />

fixtures to locate the pieces where<br />

they were then anchored to a<br />

galvanized steel stud frame.<br />

<strong>Reinforced</strong> lightweight panels were<br />

also installed on the tower walls,<br />

column covers and for upper floor<br />

balconies and roof cornices.


<strong>Light</strong>weight Cornice Set Using Small Winch<br />

This 5-ft. high x 8-ft. long<br />

fabricated cornice being<br />

installed on the Silver Star<br />

casino weighs only 500 lbs.,<br />

and can be lifted into place<br />

with a small winch.


Williams Sonoma 59th & Lexington<br />

Valders Limestone<br />

Williams Sonoma renovated a<br />

building on 59th St., just west of<br />

Lexington in Manhattan for their<br />

new store and they chose<br />

lightweight reinforced stone panels<br />

for the project.


Pottery Barn 59th & Lexington New York<br />

Rocheret Limestone<br />

The Pottery Barn, located next<br />

door to Williams Sonoma, utilized<br />

Rocheret limestone quarried near<br />

Leon, France for their lightweight<br />

panel system.


Radius Shape Limestone was Installed on the Exterior of<br />

Kimbrough Hall, Washington State University<br />

Did you know that real stone could be curved Well, lightweight aluminum<br />

reinforced stone panels can be! The thin veneer of stone, when fully bonded to reenforced<br />

aluminum honeycomb provides the flexing property that makes it<br />

possible. Limestone, for example can be formed to a 20-ft. radius, while granite<br />

and marble are usually limited to a 40-ft. radius. In this photo, you see radius shape<br />

limestone on the exterior wall at Washington State University.


<strong>Light</strong>weight Granite Truss-frame Assemblies Loaded<br />

for Transport to Jobsite<br />

Seen here, are lightweight honeycomb reinforced stone panels that were<br />

factory assembled and anchored to 30-ft. long by 7-ft. high truss frames.


The Factory Assembled Granite Clad Frames are<br />

Rigged for Lifting onto the Building<br />

These granite-clad trusses<br />

were loaded onto trailers in<br />

a pre-determined sequence<br />

for transport to the jobsite,<br />

then they were also rigged<br />

for lifting into place at the<br />

jobsite.


NBBJ Design Specified <strong>Light</strong>weight <strong>Honeycomb</strong><br />

<strong>Reinforced</strong> Granite for this 14-story Building<br />

NBBJ, one of the largest<br />

architectural firms in the<br />

world, specified this system<br />

for the 14-story Public<br />

Employees Retirement<br />

<strong>System</strong> in Columbus, OH.


Project in Melville, NY.<br />

Granite & backup framing weigh<br />

less than 7 lbs ./sq. ft.<br />

And weighing less than 7 lbs. per<br />

square foot, an average of 12 panels,<br />

totaling more than 2,500 sq. ft., were<br />

installed every day on this project in<br />

Melville, NY.


Completed Installation Expressway Corp Center<br />

Melville, NY<br />

Cannon Architects<br />

Reckson Associates, a Real<br />

Estate Investment Trust, has<br />

used lightweight honeycomb<br />

granite panels on eight of their<br />

buildings to date around the NY<br />

Tri-State area. Beyond the<br />

construction cost savings<br />

realized, Reckson also enjoys the<br />

“speed to market” contribution<br />

that lightweight reinforced stone<br />

panels provides as a key part of<br />

their business plan which is to<br />

totally pre-lease a property<br />

before they build the building<br />

and then bring it on line as fast<br />

as possible.


Rotunda US Courthouse & Federal Bldg.<br />

Sacramento, CA<br />

The U.S. Courthouse in Sacramento has it’s entire rotunda clad with lightweight<br />

limestone and granite. There were more than 10,000 different sized and shaped<br />

pieces in the rotunda, which is egg-shaped at the base, tapering to a symmetrical<br />

ellipse at the skylight. They also incorporated limestone in the elevators and<br />

granite in every lobby. The result was stunning.


Korean Supreme Court Building<br />

Seoul, Korea<br />

Pooshon granite was shipped from<br />

Korea to the US for production of<br />

lightweight honeycomb panels. The<br />

finished polished granite panels were<br />

then shipped back to Korea for<br />

installation on walls and ceiling of the<br />

South Korean Supreme Court Building


Embarcadero Center, San Francisco<br />

Lobby and Elevator Cab Renovation<br />

The Embarcadero Center in San<br />

Francisco consists of four hi-rise<br />

buildings. The lobbies at the ground<br />

floor, at the main lobby level, and at the<br />

mezzanine level were renovated by<br />

installing French limestone over the<br />

original fractured rib concrete.<br />

The limestone at each elevator<br />

entrance was factory fabricated into<br />

four pieces for ease of installing. All<br />

of the work was done at night,<br />

between 9 pm and 5 am, so the<br />

building occupants would not be<br />

disturbed. The lightweight stone was<br />

delivered and stored on a lower level<br />

parking floor, and brought up to the<br />

work area in one of the elevators. At<br />

the end of the shift, any pieces which<br />

had not been installed were returned<br />

to storage, and the lobby was cleaned<br />

for the morning arrival of people who<br />

worked in the building. It would have<br />

been impossible to accomplish this<br />

work with solid traditional stone<br />

panels. The walls of 80 elevator cabs<br />

were also covered with this limestone.


<strong>Light</strong>weight <strong>Stone</strong> Clad Elevator Cabs<br />

Elevator cabs are often clad or re-clad<br />

with a aluminum reinforced<br />

honeycombed-backed system, because<br />

the lightweight nature of the product<br />

reduces machinery requirements,<br />

and the high strength<br />

properties of reinforced stone<br />

will allow for the racking<br />

movement encountered in<br />

elevator cabs.


Caesars Palace Las Vegas<br />

Rosso Laguna Marble<br />

inlaid into White Carrara<br />

Marble<br />

Inlaid panels can also be produced for<br />

elevators using different types of stone, as<br />

was done when cabs at Caesars’ Palace were<br />

renovated. The finished panels weighed<br />

only 3-½ lbs. per sq. ft., about the same as<br />

plastic laminate.


Course Summary<br />

The Design Professional will now be able to:<br />

‣ Define stone panel cladding systems and explain the need for<br />

reinforcing.<br />

‣ List the design decisions associated with reinforced stone cladding<br />

systems.<br />

‣ Describe the manufacturing process, product capabilities, and<br />

installation methodologies of stone panel systems.<br />

‣ Knowledgeably design and specify lightweight reinforced natural<br />

stone wall systems.


From <strong>Stone</strong> Panels, Inc. ®<br />

An AIA Continuing Education Program<br />

Credit for this course is 1 AIA HSW CE Hour<br />

OVER 35 YEARS OF<br />

INNOVATION IN NATURAL<br />

STONE CLADDING<br />

<strong>Light</strong> <strong>Weight</strong> <strong>Honeycomb</strong> <strong>Reinforced</strong><br />

<strong>Stone</strong> <strong>Cladding</strong> <strong>System</strong><br />

Course Sponsor<br />

100 S. Royal Lane<br />

Coppell, Texas 75019<br />

Ph. (469)635-5000<br />

Fax (469)635-5555<br />

E-mail<br />

dons@stonepanels.com<br />

Web<br />

www.<strong>Stone</strong>Panels.com<br />

Course Number<br />

sti04a<br />

Course Title<br />

<strong>Light</strong> <strong>Weight</strong><br />

<strong>Honeycomb</strong> <strong>Reinforced</strong><br />

<strong>Stone</strong> <strong>Cladding</strong> <strong>System</strong><br />

Please note: you will need to complete the conclusion<br />

quiz online at Ronblank.com to receive credit<br />

© Ron Blank & Associates, Inc. 2005

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