Remember, safety first. Notice: StonePly can not anticipate every possible potential hazard during the installation of our products. Warnings and instructions in the guide are therefore not all-inclusive. The installer should satisfy themselves that the tool procedure or system they are using for the installation is safe and meets all building codes and safety requirements. Because each home or building is different, installation will vary slightly from unit to unit.
Warning: To avoid personal injury, product damage or possibly even death, carefully read and understand the instructions in this installation guide. Proper use of tools and products is your responsibility. It’s the responsibility of the person who installs this product to understand and follow the installation instructions and maintenance procedures. Installer should be a competent individual who’s aware of the inherent dangers in using power tools. Please read and understand all cautions, warnings, and notices.
Use proper tools: Always use the proper tools that are in good working condition during the installation of the products.
Inspect before cutting: If installation requires cutting into your wall, make sure that no plumbing or electrical wiring is present in the wall before you cut.
Wall Conditions
If you are installing these panels on existing shower bath application, inspect the walls before beginning the installation. Never install panels over walls that have existing mold or are damp.
Lifting Hazard
While StonePly panels are much lighter than solid slab stone, they can still be heavy. Keep in mind the National Institute of Occupational Safety and Health recommends maximum safe-lifting weight of 51 pounds when all lifting conditions are perfect. In order to avoid injuring yourself, always use proper lifting techniques and use two people to move cartons and panels that weigh more than 51 pounds. Always carry panels on edge.
Slipping Hazard
Do not attempt to install this product if the floor or the surfaces are wet. You should dry all surfaces prior to installation.
Personal Protection
Be sure to use all appropriate personal protective equipment such as work boots, preferably steel-toed boots, gloves, and a hard hat, if necessary. Always wear eye protection when using power tools.
Sharp Edge Hazard
After cutting the edge of StonePly panels, they can be sharp. You should wear protective gloves to prevent injury, and any rough exposed edges should be lightly sanded to round them.
Acclimatizing the Panels
When you receive the panels, they should be allowed to adjust to the room temperature for at least six hours before installation. Panels should not be installed when room temperatures are below 60 degrees Fahrenheit and should not be installed in areas where the temperature may get down to freezing or below within the next few hours.
Grab Bars
Grab bars are recommended, and when installed, they should comply with ANSI-A117.1 requirements. Grab bars must be anchored to the wall structure behind the panels. Never attach grab bars to the panels themselves or rely on the panels for support of the grab bars.
Fire and Solvent Hazard
If you’re using cleaners and solvents, be aware that they can pose a potential fire hazard. They can also give off vapors that could be harmful to your health. Work in a clean, well-ventilated area.
Dust Hazard
When cutting or drilling the StonePly panels, use a dust collection method which will prevent dust from going into the air. Always work at a well-ventilated area. It’s best to take the panels outside for cutting, drilling or sanding. Some stones, especially granites, contain silica. During cutting or grinding operations, silica can become respirable silica dust which, if inhaled, can lead to a condition known as silicosis.
When Cutting
- Take panels outdoors if possible or, if you must cut indoors only cut in a well-ventilated area.
- Position cutting location so that wind will blow dust away from user and others in working area.
- Use a wet blade stone saw or use a dust reducing circular saw equipped with a diamond blade and HEPA vacuum extraction.
NIOSH- approved respirators can be used in conjunction with above cutting practices to further reduce dust exposures. If concern still exists about exposure levels or you do not comply with the above practices, you should always consult a qualified industrial hygienist.
Shock Hazard
Contact with electrical wires from power tools can cause injury or death. Be sure to turn off the power at the electrical breakers before working on existing bathrooms. Never use electric power tools in damp or wet conditions and keep away from liquids. They could cause shorts in electrical cords in power tools.
General Information
Required Tools for Installation
Tools required for installation include, a wet saw with a diamond blade, grinder with a diamond cutting blade, a drill with three-eighth-inch drill bit, a hole saw in the size needed for your faucet, bathtub spout or your shower head, a tape measure, masking tape – the 2-inch-wide blue masking tape seems to work best – a level, medium grit and fine grit sandpaper, a caulking gun, clean shop towels or paper towels. Lumber is required for bracing, and denatured alcohol for cleaning.
Bathtub Wall Kit Contents
Depending on which wall kit you order or bathtub kit you order, one or more panels may be included. Check to see that the panels you have are sufficient for the job at hand.
Unpacking the Cartons
Before we ship the product to you, they were carefully inspected and everything was found to be in perfect order. Carefully unpack and inspect the product. If anything is damaged, something happened in transit. If damage is found, report it immediately to the shipping company. Use care when opening the cartons so that you do not damage the StonePly panels. The panels should be stored in a flat area to avoid warpage until they’re installed. Do not store the panels outside in their original packaging. Cardboard can stain if it’s wet.
Helpful Hints
There are many ways that these panels can be installed, and some of the ways may not be shown or described in this guide.
Ensure your construction is the right size, straight and square. Allow enough time for the parts in the kit to adjust to room temperature. Always carry the panels vertically or up on edge. Be careful when you lay the panels flat to prevent flexing. This is especially true if you’ve cut into the panels.
Preparing to Install Your Shower Surround
Measure the width of the back wall with the green board installed. Measurement of this wall cannot exceed the width of the StonePly panels. Measure the height of the wall. If this measurement is less than the height of the panels, then the panels must be cut to fit. Turn off your hot and cold water supply. Remove faucet handles, filler spouts or anything mounted to the wall such as towel bars or soap dishes. Measure the location of the plumbing cutouts. Make a cardboard template to fit the plumbing cutouts and test fit the cardboard template prior to cutting your StonePly panels.
StonePly panels can be installed over a variety of substrates. You can install it over sheet rock, cement board or green board or wood, plaster, concrete, old tile, wallpaper or Masonite panels. When installing over a sheet rock green board or cement board, the surface must be dry, free from dust, smooth and clean from soap scum or other contaminants. To ensure proper adhesion of the panels, the surface should be sealed with water or oil-based primer sealer. Allow the primer sealer to completely dry before installing.
Plaster
On plaster surfaces, prep depends on the condition of the existing plaster wall surface. If the wall is irregular, additional silicone may be needed to ensure contact between the plaster substrate and StonePly panel.
Textured plaster finishes should be sanded smooth. The wall surface should be cleaned with a damp cloth to remove soap scum, dust, or other contaminants. Before installation, the wall surface must be dry and smooth. To ensure proper adhesion, the wall surface should be sealed with a primer sealer. The primer sealer should be allowed to completely dry before installation proceeds.
Cement
When installing StonePly over concrete or cement walls, additional silicone may be required to ensure contact between the substrate and the back of the StonePly panel. To ensure proper adhesion, the complete area should be sealed with two coats of primer sealer.
Tile
When installing over old tile, much depends on the condition of the existing wall surface. As long as the tiles are solidly adhered, they may not need to be removed. Do not install over plastic tiles. Plastic tiles must be removed. When installing over ceramic tiles, remove or reattach any tiles that are loose. Any tile accessory such as soap dishes, etc., should be removed from the walls. Surface should be dry, smooth and free from dust or contaminants.
Wallpaper
When installing over wallpaper, all wallpaper needs to be removed from the area being covered by the StonePly panels. Once the wallpaper is removed, clean the wall surface to remove any dust, soap scum or contaminants. The entire wall surface should be sealed with two coats of quality primer sealer.
Masonite
When installing over Masonite, clean the wall surface to remove dust, soap scum or any other contaminants. Allow the wall surface to dry. The wall can then be primed with quality primer sealer before installation proceeds.
Filler
If your existing wall covering is shorter than the height that you want your new StonePly panels to be, it will become necessary to install a filler board at that height. The filler board is equal to the thickness of the existing wall covering, which is typically tile. For example, if your StonePly panels extend up 6 feet but you only have 5 feet of tile, then above the 5 feet of tile, you will need to install a piece of filler material, typically a quarter-inch Masonite, so that your substrate is smooth all the way to the top of the area to be installed.
Installation in New Construction
- Measure and cut out openings for the faucets, bathtub spout and/or showerhead. This is done by creating a paper template of the existing locations of the spouts and shower heads. The cardboard template can then be used to transfer the measurements and information to the StonePly panels. Take into consideration the coefficient of thermal expansion and allow a minimum 1/4″ silicone sealant joint between panels.
- Cut the panels with the diamond blade saw (see cutting instructions above). Test fit the cut panels.
- Clean the back of the panel to remove dust and residue. This can be done with a dry cloth or by the use of denatured alcohol. Be sure not to use any oily cleaners such as mineral spirits. These leave behind an oil film that will prevent proper adhesion.
- Apply silicone to the back of the panel in 1″ diameter dots every 8 to 10 inches. Be sure to follow the silicone manufacturer’s instructions and installation precautions.
- Press the panel into place and press firmly to the wall. Be sure to keep the top edge of the panel aligned when you’re installing adjacent panels. Use even pressure from top to bottom and side to side to ensure a solid wall contact.
- Brace the panel as necessary until the silicone sets (typically 24 hours).
- Apply silicone to the joints. Follow manufacturer’s instructions.
- Seal stone with a quality sealer. Follow manufacturer’s instructions.
- Install plumbing fixtures, knobs, spouts and shower heads.
