2. MANUFACTURER
Thunderstone
3400 West O Street Lincoln, NE 68528
Phone: (402) 420-2322
FAX: (402) 420-2542

3. PRODUCT DESCRIPTION
Cast stone is used as a masonry product to provide architectural trim, ornamentation or functional features on buildings and other structures. It is a highly refined architectural precast concrete building stone manufactured to simulate natural cut stone. One of the oldest known types of concrete, it is the most aesthetically refined form of concrete known today.
The earliest known use of Cast Stone was in the year 1138. The product was first used extensively in London in the year 1900 and in America around 1920. Since the early 1920's, Cast Stone has earned widespread acceptance in the architectural community as a suitable replacement for many masonry materials (such as terra cotta) and for all types of natural cut building stone.

4. COMPOSITION & MATERIALS
Depending upon the desired color and texture, our product is made from different combinations of white &/or gray Portland Type I cement: washed and graded natural sand, silica sand, granite sand, limestone, marble and quartz aggregates, natural &/or synthetic mineral pigments, (not to exceed 10% by weight of cement), and a liquid polymer which enhances the curing process and the unit's overall durability. The selected ingredients are mixed with water and admixtures to allow the mix to flow into the molds and fill all undercuts and corners without compromising strength.

This casting process is known as a "wet cast" process, which produces a finish very close to that of natural stone, exhibiting a fine, tight grain and a smooth "saw cut" finish. Reinforcement: When necessary for handling, setting and structural stress, units shall be reinforced with new billet steel reinforcing bars, grade 40 or 60, and the size of the reinforcing shall be specified. If surfaces are to be exposed to weather, the reinforcement shall be galvanized or epoxy coated when covered with less than 1 1/2" of material for bars 5/8" or smaller, 2" for bars larger than 5/8".

5. MOLD CONSTRUCTION
The mold and pattern shop is the heart of our facility. The craftsmen in this department work from shop drawings previously approved by the architect or contractor to fabricate a pattern or model of the desired unit out of materials such as wood, plaster, fiberglass, clay, or sometimes from existing stone or terra cotta pieces. These finished patterns become the model for making the production molds used in the actual casting process. These molds are most often made using a polyurethane rubber "liner" supported by a wood or plaster "carrier".

6. LIMITATIONS
With today's available materials and the skills that each of our craftsman possess, there is literally no limitations to what can be produced. However, in the interest of economy, the one practical limitation to the profile of the piece is that the design of the profile must allow for one side to be unfinished, usually the back side which is inside the wall cavity or otherwise hidden from view.

Cast stone is not intended for structural use and should be generally considered only under compressive loads. Loose steel lintels are typically used to support cast stone above openings, however, under certain conditions cast stone can be used as a load bearing lintel, usually in an arched or deep cross sectional shape.

THUNDERSTONE does not furnish anchorage or setting materials. Depending upon the application, standard building stone anchors and fasteners in non-corrosive materials such as galvanized steel, stainless steel and carbon steel are required. A list of anchoring systems/components manufacturers are available upon request. As with any concrete product, direct contact with untreated wood frames or flashings should be avoided.

7. TECHNICAL DATA
Compressive Strength: 6500 psi @ 28 days, minimum. Absorbtion: 5% by dry weight, maximum.

8. DRAWINGS
Scale and/or full size drawings will be furnished where necessary by the Architect, and they shall be accurately followed in execution of this work. All shop drawings submitted by THUNDERSTONE must be approved by the Architect &/or masonry contractor before any manufacturing of cast stone units can begin.

Unless otherwise specified, shop drawings shall provide for the following: 1. Provide suitable wash on all exterior sills, copings, projecting courses and pieces with exposed top surfaces. 2. All projecting pieces and soffit stones shall have drips under the outer edge. 3. In most cases, the shop drawings shall show the setting mark of each stone and it's location on the structure. The stone when delivered shall bear the same corresponding setting mark on an unexposed surface.

9. INSTALLATION
Preliminary Work: Substrates must be of adequate strength to anchor and/or support the cast stone as required. All anchors and dowels are furnished by others and they must be firmly placed with holes filled completely with mortar.

Tolerances: See page titled "Tolerances", page I. Joint sizes at stone/brick - 3/8". Joint sizes at stone/stone in vertical position - 1/4" (3/8" optional). Stone/stone joints exposed on top side - 3/8". Setting: Cast stone must be set by experienced masons accurately and according to approved shop drawings. When setting with mortar, all stones must be thoroughly wet with clean water just prior to setting. Unless otherwise noted, every stone shall be set in a full bed of mortar with all vertical joints flushed full. After each stone has been set, all joints must raked to a depth of 3/4" from the face for pointing. Only the ends of lugged sills and similar stones shall be embedded in mortar. The balance of joint to be left open until pointing of stone work, then tuck points on face only to a depth of 3/4". Finishing Joints: All cornices, copings, projecting belt courses, and in general, all stone areas either partially or totally horizontal, shall be set with unfilled vertical joints.

After setting, insert properly sized backer rod to proper depth, prime the ends of the stone, and gun-in sealant. Re-pointing with mortar should be done prior to cleaning; gun-in of a sealant should be done after cleaning. Cleaning: The face of cast stone must be cleaned with a mild masonry cleaner such as "Vanatrol" or "600 Detergent", both by "Sure Klean". No acids or prepared cleaners should be used without manufacturer's approval. Care must be taken to prevent staining of adjacent surfaces by mortar and masonry cleaners. Patching: The repair of chipped or damaged cast stone can be successfully finished by a "mechanic" skilled in this type of work. Materials necessary for these repairs can be shipped via U.P.S. upon request.

10. AVAILABILITY:
Cast stone can be delivered to any jobsite, however, delivery dates are always subject to shop drawing and production lead times.

11. COST:
Some of the factors affecting the unit cost of cast stone are the quantity of stone produced, the quantity of molds required, (sometimes dictated by the timetable between the date ordered and the required shipping date), the degree of ornamentation, color, and shipping considerations such as distance and the size of the units. Cast stone can usually be kept in the lower range of cost by using standard or easily reproducible colors and by limiting the number of "custom" or non-standard shapes. The fewer the number of molds required, the greater the repetition of pieces, the less the job will cost.

12. WARRANTY:
THUNDERSTONE warrants all of it’s products to be free from defect within accepted industry standards and will be replaced if product is defective and manufacturer is notified of defect by purchaser within ten days of receipt of material. THUNDERSTONE will patch and repair or replace defective material at no additional cost.

THUNDERSTONE makes no other warranties with respect to this product, express or implied. Manufacturer’s liability shall be limited in all events to supplying sufficient product to repair or replace the specific defective units. Acceptance and use of this product absolves THUNDERSTONE LLC from any other liability, from whatever source, including liability for incidental, consequential or resultant damages whether due to breach of warranty or negligence. Product must be inspected by purchaser prior to installation. This warranty may not be modified or extended by representatives of THUNDERSTONE LLC, it’s distributors or dealers.

13. MAINTENANCE:
No maintenance of our product is required, however periodic inspection of caulked wash joints in copings and sills is advisable.

14. ENGINEERING:
Any engineering required for manufacturing THUNDERSTONE CAST STONE products are done prior to the manufacturing of said units. However, “applications” for THUNDERSTONE CAST STONE products may require engineering which is the sole responsibility of the user. THUNDERSTONE neither implies nor accepts responsibility for any engineering not directly related to the manufacturing of THUNDERSTONE CAST STONE products.