Veneer Plaster Systems - BuildSite

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12TH EDITION09 26 13/NGC09 26 13Veneer PlasterSystems 43

VENEER PLASTER SYSTEMSVeneer plasterexpands architecturaldesign limits as withthis curved vaultedceiling.DESCRIPTIONVeneer Plaster Systems consistof a 4' wide gypsumplastering base with aspecial, highly absorptivepaper surface that iscovered with thinlytroweled, special purposeplasters. Two basic typesof veneer plaster areavailable: Uni-Kal andX-KALibur, which areone-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 nailpop resistant than drywalland, when properlyinstalled, more crackresistant than conventionallath and plaster.ADVANTAGES - GENERALThe advantages of veneerplaster over othercommonly used partitionand ceiling systemsinclude:1. Rapid installation whichreduces overallconstruction time.2. Appearance and surface ofconventional plaster atlower cost than regularplastering.443. 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 plasteringmaterial on the job.2. Slightly lower in-place costthan two-coat system.3. Can be applied directly toconcrete block.4. X-KALibur is formulatedto have extended setcharacteristics beyondtraditional Uni-Kal settingtimes.ADVANTAGES - TWO-COATSYSTEM (KAL-KOTE)1. Kal-Kote System may beused 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 forexterior 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.NATIONAL GYPSUM VENEER PLASTER SYSTEMS3. 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.Kal-Kore boards are screwedto steel studs or nailed orscrewed to wood studs toform a base.Joints are reinforced withKal-Mesh fiberglass webbing.Steel corner and casing beadsprotect corners.Kal-Kote is applied in 2 coats,a base and a finish, to forma hard-surfaced, 1/8" totalthickness.

09 26 13/NGCVeneer Plaster System ComponentsTECHNICAL DATAGOLD BOND BRAND KAL-KORE PLASTER BASEKal-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 andX-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 BASEAbrasion-Resistant Uni-Kal Veneer PlasterEnhanced CorePcs.per Bdl.SizeThicknessEdge4'x8', 16'(1219 mm x 2438 mm,4877 mm)3/8" (9.5 mm)SquareorTapered24'x8', 16'(1219 mm x 2438 mm,4877 mm)1/2" (12.7 mm)1/2" (12.7 mm)FSK-CSquareorTapered24'x8', 16'(1219 mm x 2438 mm,4877 mm)5/8" (15.9 mm) FSKSquareorTapered24'x8', 12'(1219 mm x 2438 mm,3657 mm)1/2" (12.7 mm)Square5/8” (15.9 mm) FSKorHi-AbuseTapered209 26 13Gold Bond BRAND Hi-Abuse Kal-Kore Fire-Shield Type XPlaster Base boards consist of a fire resistive Type Xgypsum core encased in a heavy, blue absorptive facepaper designed to permit rapid trowel application andstrong bond of Uni-Kal veneer plaster and strong linerpaper on the back side. Gold Bond BRAND Hi-AbuseKal-Kore Fire-Shield Type X Plaster Base features aspecially formulated core to provide fire resistanceratings when used in tested systems as well as greaterresistance to surface indentation. Long edges of theboards are tapered to allow joints to be reinforced andconcealed with Kal-Mesh Tape and Uni-Kal Plaster.Gold Bond BRAND Hi-Abuse Kal-Kore Fire-ShieldType X Plaster Base is manufactured to conform toASTM Specification C 1396 and Federal SpecificationSS-L-30D Type VI Grade X (Fire-Shield).Heavy Liner PaperNATIONAL GYPSUM VENEER PLASTER SYSTEMS45

KAL-KOTE BRAND BASEPLASTERKal-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 tothose 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, 425475 sq. yds. per ton (150170 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 PLASTERKal-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 bag46Coverage (est.)*1/16" coat troweled on KalKote Base Plaster, 650-700sq. yds. per ton (145-160sq. ft. per bag).KAL-KOTE BRAND TEXTUREFINISH PLASTERKal-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 KalKote Base Plaster, 650-700sq. yds. per ton (145-160sq. ft. per bag).UNI-KAL AND X-KALIBURBRAND VENEER PLASTERUni-Kal and X-KALibur aresingle component veneerplasters for applicationover tapered edge 1/2”Regular or 5/8” Fire-ShieldKal-Kore, 5/8” Kal-KoreHi-Impact or as a finishcoat over Kal-Kote base.When applied in a thincoat 3/32" thick andtroweled to a smoothfinish, they provide adurable, abrasion-resistantsurface for furtherdecoration.X-KALibur has a longerextended working time.Uni-Kal and X-KALibur maybe worked to a variety oftextured 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 andX-KALibur provides asurface resistant toabrasion, cracking andnail-pops.Fire ResistanceFire ratings equivalent tothose of drywall systemscan be obtained byapplying the correspondingKal-Kore type andNATIONAL GYPSUM VENEER PLASTER SYSTEMSthickness over the sameframing member size andspacing with the samefasteners and 3/32" of UniKal 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, 600665 sq. yds. per ton (135150 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.

Veneer Plaster Accessories* Used in Both SystemsE-Z STRIP CONTROL JOINTDesigned for drywall or veneerplaster systems. A vinylextrusion used as anexpansion or control jointfor ceilings or partitions.EXPANDED VENEERCORNERBEADUsed as an alternate to theKal-Korner Bead forexterior corners. 1 1/4"flanges.KAL-MESH TAPEA coated non-adhesivefiberglass tape which isstapled to Kal-Kore toreinforce all joints andinterior angles.ARCH CORNERBEADCan be used straight forexterior corners or flanges,or may be snipped andbent to form arches.093 ZINC CONTROL JOINTDesigned as an expansion orcontrol joint for ceilingand partition areas forboth drywall or veneerplaster systems.VENEER J TRIM CASINGBEADUsed as a finished edge atdoor and window jambsby slipping over edge ofplaster base.1 1/2" DRYWALL FURRINGCHANNEL CLIPAttaches Screw FurringChannel to 1 1/2" coldrolled steel channel.VENEER L TRIM CASINGBEADUsed as a finished edge atdoor and window jambs.*Metal products are not manufactured by National Gypsum Company.NATIONAL GYPSUM VENEER PLASTER SYSTEMS4709 26 13KAL-KORNER BEADFormed of galvanized steel toprotect exterior cornerswith veneer plastering.Flange length 1 1/4" .09 26 13/NGC

FASTENERS FOR ATTACHING KAL-KOREFramingSteelStuds &FurringKal-KoreFastenerTABLE 1–SPACING OF FRAMING OR FURRINGFastener Spacing1/2" (12.7 mm) Type S Screws1" (25.4 mm) for single layer5/8" (15.9 mm) 1 5/8" (41.3 mm) for two-ply12" o.c. Max.(305 mm)Kal-KoreThicknessMaximumSpacingon centerWood3/8" (9.5 mm)1/2" (12.7 mm)5/8" (15.9 mm)*16" (406 mm)**24" (610 mm)24" (610 mm)***Metal3/8" (9.5 mm)1/2" (12.7 mm)5/8" (15.9 mm)N.A.16" (406 mm)24" (610 mm)3/8" (9.5 mm)WoodFraming1 1/4" (31.8 mm) annular or Ceiling 7" o.c.4d box nails**(178 mm) Max.1/2" (12.7 mm) 1 1/4" (31.8 mm) annular or Sidewall 8" o.c.5d box nails**(203 mm) Max.5/8" (15.9 mm) 1 3/8" (34.9 mm) annular or6d box nails**Type ofFraming orFurring**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).N.A.–Not Approved.* Bound edge of Kal-Kore must be at right angles to framing for ceiling orwalls.** 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 aresecured with flanges up (open side up) at spans not to exceed: 6' (1829mm) 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/240.48NATIONAL GYPSUM VENEER PLASTER SYSTEMS

09 26 13/NGCDETAILSWOOD STUDKAL-KOREKAL-MESHWOOD STUDSKAL-KOTEBASE & FINISHKAL-KORE JOINTKAL-KOREKAL-KORNERBEADKAL-MESHCORNER-WOOD STUDSJOINT DETAIL09215AScale: 2 1/4" 1'-0"09215CScale: 2 1/4" 1'-0"TRACK1/2"GAP5/8" FIRE-SHIELDKAL-KORE09 26 13KAL-KOTEBASE & FINISHE-Z STRIP VINYLEXPANSION JOINTKAL-MESHSTEEL STUD5/8" GAP2 1/2" STEELSTUDSKAL-KORE5/8" FIRE-SHIELDKAL-KORE STRIPSKAL-KORNERBEADKAL-KOTEBASE & FINISH1 5/8" DRYWALL SCREWS24" O.C.CORNER-STEEL STUDSONE HOUR FIRE RATED CONTROL JOINT DETAILBased on Warnock-Hersey Report No. WH-651-0318.1and Factory Mutual Design No. W1B-1 hr.09215BScale: 2 1/4" 1'-0"09215DScale: 2 1/4" 1'-0"1-1/2" C.R. CHANNELPIECE 16" LONG-NESTED(TWO WIRE TIES EACH SIDE)HANGER WIREFURRING CHANNELKAL-KORE1-1/2" C.R. CHANNELWIRE TIEE-Z STRIPEXPANSION JOINTKAL-KOTE BASE & FINISHSUSPENDED VENEER PLASTER CONTROL JOINT09215ENATIONAL GYPSUM VENEER PLASTER SYSTEMS49

RECOMMENDATIONSVENEER 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 KalKore 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. Fasteneach channel with concretestub nails or appropriatefasteners through channelflanges into the masonry orconcrete. Fasteners shall bespaced on alternate flangesnot over 24" o.c. ApplyKal-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 shallconform to ASTM C 844.1. Cut and position Kal-Koreaccurately. Bring all jointedges together but do notforce into place. Positionall end joints over framingmembers. To avoid ridging,minimize gaps betweenadjacent boards.2. Minimize the numberof 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.Uni-Kal orX-KALibur FinishKal-Kore Plaster Base50Avoid 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 usingappropriate fastenersspaced 12" apart.E-Z STRIP CONTROL JOINTAPPLICATIONInstall E-Z Strip Control Jointat 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 andfasteners in Kal-Kote andUni-Kal Plaster Systemswith Kal-Kote Base Plaster,Uni-Kal, X-KALibur or StaSmooth Joint Compound.Low humidity, hightemperatures and rapidlycirculating air can causecracking of plaster and jointbeading when Kal-Kore isapplied 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 BasePlaster, Uni-Kal orX-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.Kal-Kote Smooth FinishKal-Kote Texture FinishKal-Kote BaseKal-Kote BaseKal-Kore Plaster BaseKal-Kore Plaster BaseNATIONAL GYPSUM VENEER PLASTER SYSTEMS

STA-SMOOTH PAPER TAPETREATMENT METHOD1. Mix Sta-Smooth Compoundper 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 overtrowel 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-adheringmesh.1. Center and secure KalMesh 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-toceiling 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 thatit will lie flat against theKal-Kore.4. Pre-treat all joints and KalBeads with Kal-Kote, UniKal or X-KALibur Plaster.Tightly trowel over jointline in both directions toprevent voids, featheringto a maximum width ofabout 6".5. Allow the treated joints toset prior to general plasterapplication.PLASTERINGNote: Application shallconform to ASTM C 843.The same general jobconditions used in goodconventional plasteringpractice should bemaintained. However,because Veneer Plastercoats are thin, particularaction must be taken toguard 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 bedone 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: 1820 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 theproper 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 greaterthan 5 minutes will notbe 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 cleanup to avoid undue setacceleration.D. Avoid the practice ofmixing partial bags sincethis leads to difficulty inmaintaining uniformmaterial qualities.JOB S

plastering techniques. Apply not exceeding 1/16" over Kal-Kote Base. Requires the addition of water only. It may also be used as a finish for conventional basecoat plasters. Small amounts of commercial retarder may be cautiously used to slow the setting time when used over conventional basecoat plasters. Bag Weight 50 lbs. (22.7 kg) Water Ratio .

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