AirStone is a lightweight, realistic stone wall covering that offers an aesthetically pleasing and durable alternative to traditional masonry. Designed for both interior and exterior applications, AirStone is easy to install and adaptable to a wide range of surfaces. This guide provides a detailed breakdown of the installation process, material requirements, and best practices based on manufacturer documentation, user experiences, and technical specifications.
Overview of AirStone Products and Materials
AirStone is available in multiple product types, each designed to suit specific installation needs. The three primary product lines include:
- AirStone® Primary Wall Stone: These are the main flat stones used to cover the majority of a surface. One carton of Primary Wall Stone typically covers 8 square feet and includes four variations of color and texture.
- AirStone® Corner/Finished End Stone: These are used for corners and edges. One carton covers 6 linear feet and 7.5 square feet, also containing four color and texture variations.
- Adhesive Options: For interior applications, AirStone Interior Adhesive is recommended. One gallon bucket covers 30 square feet. For exterior projects, Loctite construction adhesive is used, with one tub covering approximately 10 square feet.
Additional materials such as construction adhesive, putty knife, and cutting tools (e.g., hacksaw, tile saw, masonry blade) are commonly used during installation. The product is sold at major retailers like Lowe’s, though online ordering is available if local stock is limited.
Surface Preparation and Compatibility
Before beginning installation, it is essential to prepare the surface and ensure it is compatible with AirStone. The manufacturer specifies that the surface must be:
- Rigid and stable, with no likelihood of expansion, contraction, flexing, or bowing due to environmental or humidity changes.
- Clean, dry, and free of dirt, dust, grease, oil, and residue from prior adhesives or coatings.
- Structurally sound, particularly if installing over tile, brick, or stone. Existing tile must be well-secured to its original substrate, and painted surfaces must be in good condition (no peeling or chipping).
For exterior applications, a ½-inch gap should be left between the bottom row of AirStone and any hard ground surface to accommodate ground swell or settlement. This prevents cracking and ensures long-term durability.
Step-by-Step Installation Process
The installation of AirStone involves a straightforward, two-step process: surface preparation and stone application. The following steps are derived from verified installation instructions and user experiences.
1. Clean and Prepare the Surface
Before applying any adhesive, the surface must be thoroughly cleaned. This includes removing:
- Dirt, dust, and debris
- Loose paint, wallpaper, or residue from previous adhesives
- Grease or oil using a degreaser if necessary
For surfaces like concrete, brick, or cinder blocks, it is recommended to remove any loose tile or existing finishes. A clean surface ensures strong adhesion and minimizes the risk of peeling or detachment over time.
2. Create a Layout Template
To achieve a natural, non-patterned appearance, it is beneficial to create a layout template before applying adhesive. This can be done by:
- Taping off an area on a drop cloth that matches the dimensions of the wall or surface to be covered.
- Laying out the AirStone pieces to visualize the placement, ensuring a mix of colors and shapes for a balanced look.
- Staggering the seams and joints to mimic the randomness of natural stone.
Each box of AirStone contains four color variations, which are labeled for easy identification. A well-planned layout helps avoid color clustering and ensures visual consistency across the project.
3. Apply Adhesive and Install the Stone
Once the layout is finalized, adhesive can be applied. The method varies slightly depending on the type of adhesive used:
- For interior projects, use AirStone Interior Adhesive. Apply a thick, even layer using a putty knife.
- For exterior projects, use Loctite construction adhesive, which is applied in a similar manner.
Once the adhesive is in place, press the AirStone pieces into the wall or surface. It is important to press firmly to ensure proper adhesion and to avoid shifting or repositioning after the stone is in place.
4. Cutting and Fitting Stones
AirStone is designed to be easily cut, even by hand. A hacksaw is the most commonly used tool for cutting, and it allows for precise shaping to fit around fixtures, corners, or irregular surfaces. For larger or more complex cuts, a tile saw or masonry blade can be used to save time.
When cutting, it is recommended to start from the front or textured side of the stone for a cleaner cut. For tight spaces or around electrical boxes, gas meters, or other obstructions, it is possible to cut the stones to size and fit them into place.
5. Finishing and Securing Fixtures
After installation, AirStone can be finished by installing fixtures, covers, or vent systems directly on top of the stone. The material is compatible with drilling and screwing, allowing for the attachment of items such as:
- Dryer vent covers
- Electrical boxes
- Wall-mounted fixtures
- Artwork or shelves (after the adhesive has fully cured)
For example, in an exterior foundation wall project, a dryer vent cover was installed over the AirStone after it had fully cured. The stone was drilled using pilot holes, and the cover was secured with screws.
Best Practices for Installation
Based on the provided documentation and user experiences, the following best practices are recommended:
- Plan the layout in advance to avoid visible patterns and ensure a natural appearance.
- Use a drop cloth or temporary layout area to sort and arrange stones before installation.
- Work in manageable sections to maintain control and prevent adhesive from drying before installation.
- Allow sufficient curing time before installing fixtures or attaching objects to the surface.
- Leave a gap at the base for exterior projects to accommodate ground movement.
Troubleshooting and Common Issues
Although AirStone is generally easy to install, users may encounter some common issues:
- Adhesive not adhering properly: This can occur if the surface is not clean or if the wrong type of adhesive is used. Always follow the manufacturer’s recommended adhesive types.
- Stone shifting during installation: To prevent this, ensure the adhesive is applied evenly and the stones are pressed firmly into place without repositioning.
- Difficulty cutting around fixtures: Using a hacksaw and starting from the textured side of the stone can help achieve clean, precise cuts.
Compatibility with Fireplaces and Heat Sources
AirStone is safe to use around fireplaces and other heat sources, provided that the underlying surface is suitable and the stone is applied correctly. The material is heat-resistant and does not emit harmful fumes when exposed to normal fireplace temperatures. However, it is not designed for direct flame contact or extremely high-temperature environments.
Color Options and Design Considerations
AirStone offers three distinct color collections:
- Birch Bluff: A neutral palette of grays, tans, and whites, ideal for traditional and modern interiors.
- Autumn Mountain: A warmer palette with earthy tones, suitable for rustic or cozy spaces.
- Spring Creek: A mix of grays, shale, and charcoal, offering a more contemporary and bold look.
The choice of color depends on the desired aesthetic and the existing design elements in the space. Larger, more natural stone sizes are available compared to traditional stone panels made from scrap pieces, offering a more refined and classic appearance.
Tools and Equipment
The following tools are commonly used during AirStone installation:
- Putty knife: For spreading adhesive evenly.
- Hacksaw or tile saw: For cutting stones to size.
- Masonry blade: Optional, for faster or more complex cuts.
- Drop cloth and painter’s tape: For layout planning and surface protection.
- Measuring tape and level: For accurate placement and alignment.
For interior projects, basic tools are sufficient. Exterior projects may require additional equipment such as gloves and a caulk gun for handling adhesive and working in open environments.
Safety and Compliance
AirStone is designed to meet standard safety and building codes for interior and exterior wall applications. When used as specified, it is safe for both residential and commercial settings. However, it is important to:
- Follow manufacturer installation guidelines
- Use approved adhesives
- Ensure proper ventilation during installation
- Wear protective gloves and eyewear when cutting or handling tools
Conclusion
AirStone offers a lightweight, realistic, and easy-to-install alternative to traditional stone. With the right tools, materials, and preparation, it can be applied to a wide range of surfaces for both interior and exterior projects. The installation process is straightforward, and the final result provides a durable, aesthetically pleasing finish that mimics natural stone.
Whether used for fireplace surrounds, foundation walls, or decorative accents, AirStone is a versatile solution that combines style, functionality, and ease of use. By following the outlined steps and best practices, users can achieve professional-quality results with minimal effort.