Dimensions
London Street Flags, Yorkstone and Antique French Limestone are each available in eleven different sizes. To reduce the chance of repetitions, there are a minimum of ten different patterns in each size. Antique French Rectangles and Tuscan Courtyard Brick come in only one size each, but with numerous patterns.

All dimensions given are subject to manufacturing tolerances. The dimensions are those normally attained when the stones are arranged with the correct spacing. The sizes shown include the joints which are approximately 1/2 inches. This allows you to simply plan the area covered and quantities required without having to calculate a separate allowance for joint widths.

Color Variation
Monarch Stone is manufactured utilizing naturally occurring aggregates, therefore no guarantee can be given that stone manufactured at different times will be identical in color shade. It should be understood that as with natural stone, location, weathering and natural curing can cause color variation to appear over the surface of the products.

Efflorescence
Monarch Stone cannot take responsibility for the phenomenon called efflorescence which may occur. Proprietary chemicals are used in the manufacturing to create a moisture barrier. Tests have shown this virtually eliminates efflorescence. The extreme high density of the concrete and the additives make it extremely unlikely that efflorescence will occur.

De-icing Salts
Salt should not be used on Monarch Stone to remove ice. Only use de-icing products specifically formulated for use on concrete.

Cleaning
For routine cleaning, use a neutral cleaner (pH 7.0).  Follow product label instructions for best results.  Sweep or vacuum floor frequently to remove dirt and loose soil.  Promptly wipe up any spills to minimize risk of staining.  Place protective felt pads on legs of moveable furniture.  For routine cleaning minimize the amount of solution used on floor, damp mop and dry promptly for best results.

For periodic heavy duty cleaning, use an alkaline cleaner (high pH).  A scrub brush will aid in this process.  Always sample a small section first.

INSTALLATION INSTRUCTIONS

Required Tools
Some of the tools you will require are: Rake, shovel, tape measure, bricklayer's trowel, tamper, spirit level, wheelbarrow, string lines, soft brush, timber straight edge, mixing board, rubber mallet and a bucket. Any tools you do not have can be obtained from any rental outlet.

General
Monarch Stone Inc. is a product design and manufacturing company and does no installation. The selection of an installer for our products is up to the customer. We recommend that when you make that selection, you place knowledge, experience and reputation high on your list of considerations and that you choose a professional who specializes in wetcast concrete. Compliance with local building codes is essential when installing the products, as well as when designing the project.

Planning and Design
Our flagstone ranges look most authentic when laid in a random pattern.

When planning small or irregular areas, it is best to draw the area to scale in squared paper and draw a combination of slab sizes to suit that setting. It may be helpful to cut paper templates of the different slab sizes to try various combinations. Where possible, adjust the dimensions of the area to reduce the need to cut flags.

For larger areas you may find it easier to use the Monarch Stone Layout Planner. The planner will lay out any size area you desire and give you a printed map and a list of materials required for the job. There are really no fixed rules. If a piece looks out of place, use it later and try a different size. For best effect avoid long unbroken jointing lines and having several flags of the same size next to each other.

For very large areas a higher proportion of the larger sizes will give a more pleasing effect, saving the smallest sizes as fillers.

Preparation
Before you start, correct site preparation is essential. When building a patio or path up against a house, it is essential that the finished paving level be below the damp proof course. Allow for a "fall" of around 1" in 36" away from buildings to allow surface water to drain off. How to prepare the site depends entirely on ground conditions and the intended use for the finished area.

If the ground is firm, you need only remove topsoil to accommodate the 3-4" sand bed plus mortar and flag thicknesses. Where the ground is wet or spongy you will need to excavate further to put in a 4" bed of well compacted hardcore, as well as the 2-3" of sand and mortar/flag thicknesses.

Where the site is not level, you may need to excavate some areas while building up others. Always build up with hardcore -- this gives a more stable base and allows extra drainage.

PLEASE NOTE: Poor drainage will result in water retention. This may alter the way flags weather and can affect flag color. Sub-base water retention is more common in areas that are left unjointed or where the joints are filled with sand or gravel. For best results, a fall to allow run-off and full mortar joints are recommended.

Suitable Sub-Base for Your Site
The correct sub-base is essential to ensure that you continue to enjoy your Monarch Flagstones for many years to come, and will vary depending on your intended use:

Monarch Stone cannot be held liable for damage to products caused by incorrect installation. If in doubt over the suitability of your ground conditions please consult a professional installer familiar with local conditions.

Starting the Job
Store your flags as close as you can to where you will be working.

Having decided the most suitable sub-base for your site, mark out the area with wooden stakes and string and excavate to the required level and depth. Then mark out the finished paving surface levels with further wooden stakes, allowing for a 1 in 36 fall away from buildings or fences. To establish a fall, use a spirit level taped to a straight edge supported by 2 stakes 6 feet apart. Place a 2' block between the straight edge and the stake, and then tap the stake down until a level reading is shown. The fall between the two stakes with the 2' block removed is 1 in 36.

Infill the area with sand, or hardcore and sand, and remove stakes prior to laying flags. The sand should be compacted initially by treading thoroughly or, for larger areas, a mechanical compacter can be obtained from a rental store.

Laying the Flags (Mortar Set)

Mortar is available in bags premixed dry or can be mixed on job sites.  When mixed on site, use 2-1/2 to 3 parts washed plaster sand to 1 part Portland cement.  Use of latex and acrylic concrete additives is strongly recommended.  Mortar too rich with cement has a tendancy to shrink and crack.  The mortar can be used at a minimum of 1/2" thick to a mazimum of 2" thick.  Do not allow mortar to lose plasticity  and become stiff, as that will inhibit bonding of the paver.  Extreme hot and cold weather affects the mortar's open time.  Consider both the air and slabs' temperature and do not spread too much at one time, as heat affects open time.  It is recommended to slurry coat (backbutter) the back of each individual slab for all applications, however, on exterior applications with pavers larger than 15"X15", it is mandatory.  This assures ultimate boonding through wet to wet mortar contact. Mix no more than you can use in around 20 minutes. After the  first slab is in place, tap it gently to the correct level using a rubber mallet.

After laying the first flag, repeat the process and also lay a strip of mortar around where the edges of the next flag will be. Lay the next flag and draw this strip up the side to minimise jointing afterwards. Tap each flag down to the required level. You should regularly check levels and falls throughout the laying process using a long straight edge across the faces of a number of flags.

To adjust the spacing between flags, a twist of a trowel between flags will enable you to shuffle them into position. Aim for a gap of 1/2" to 3/4", but do not worry if this varies. Monarch Stone flagstones are cast from genuine historic stone, therefore actual dimensions will vary slightly from flag to flag.

After completion, do not walk on the paving for at least 24 hours. Jointing should be completed as soon as possible after this time.

Jointing
It is wise at this point to apply a penetrating sealer to all the flagstones. This will make it easier to remove any mortar that might be accidentally spilled on the stone. Jointing should be carried out with a damp 5:1 mortar mix to give a permanent waterproof finish. You should take care not to use too wet a mix, and any spillage or residue, including concrete dust occuring from cutting stone, should be removed at once with a clean damp cloth and clean water. Similarly mortar should not be brushed into the joints. Cement left on the faces of the flags will cause unsightly staining, which is difficult to remove once dry. Joints may be raked out with a rounded piece of wood to a depth of around 1/4" below the surface of the flags or, for a more professional finish, may be "ridge" jointed with a trowel.

Jointing should only take place when flags are dry. Jointing in wet conditions may cause staining. Never leave a cement haze on the slabs surface overnight which is often done when installing ceramic tiles, because you will be unable to remove it the next day.  NEVER USE ACIDS when cleaning concrete tiles or grout as they will detrimentally affect the colors and finish forever.

Cutting Flags
Careful planning of your project will minimize the need for flags to be cut. Where cuts do need to be made, this can be done by scoring a line across the back with a bolster. If larger quantities are required to be cut we would recommend you rent a high-powered cutting tool fitted with a stone cutting disc or a diamond tipped blade. Cutting should be done away from the project site to avoid cutting dust from getting on the finished work surface.  If any dust gets on the surface of the stone, it should be cleaned off with a clean damp cloth.  Please ensure that the store that rents you the tool issues you with full instructions, and refer to our health & safety instructions.

HEALTH AND SAFETY INSTRUCTIONS

Mixing Cement/Mortar
Cement dust and wet mortar can cause irritation and burns to the eyes and skin. Suitable eye protectionand waterproof gloves should be worn when handling cement or mixing mortar. If either come into contact with the skin, wash off with plenty of water. If cement or mortar comes into contact with the eyes, irrigate with plenty of water. If irritation persists, seek medical attention.

Cutting
Cutting concrete with disc cutters produces a lot of dust. Inhalation of excessive amounts of this dust over long periods of time may cause long-term health problems. Suitable eye protection and dust masks should always be worn.

Manual Handling
Monarch Stone products are made from high strength concrete and can consequently be heavy, with pieces weighing up to 110lbs. It is strongly recommended that units weighing over 50 pounds are handled by two persons. Suitable gloves should always be worn to protect hands from abrasion.

FOR ADDITIONAL INFORMATION

CTMA

Concrete Tile Manufacturerr's Association

P.O. Box 6226

Buena Park, CA  90622

800 970-2862

www.concretetile.org