Modern in Minutes
Hourwall is a panelized wall system for interior, feature wall projects. Made of high-density polyurethane, hourwall is available in 3 different profiles: urbanCONCRETE, classicBRICK, and barnWOOD. To produce the most realistic product possible, hourwall panels are precisely cast from real concrete, brick, and wood materials by skilled artisans. The hourwall panels are affixed to a wall using screws and/or nails and without the need for structural reinforcement. Hourwall is durable and maintenance free. Within minutes, you can transform the feel of a room by easily installing these lightweight panels.
Detailed Installation Guidelines
Hourwall does not install panels or have control over the installation of the panels, therefore these Installation Instructions are to be used as guidelines. It is the responsibility of whomever does the installation to ensure all Hourwall products are installed in accordance to the Hourwall Installation Instructions. It is also the responsibility of the installer to ensure that all applicable building codes are being met or exceeded. InStone Distribution assumes no liability for improper installation or personal injury resulting from proper or improper use or installation.
RECOMMENDED TOOLS: Miter Saw and/or Table Saw Drill Measuring Tape Pencil Level 10 oz. Caulking Gun Metal Square / Ruler Drywall Saw Utility Knife Safety Glasses Earplugs Dust Mask Hourwall Detailed Installation Guidelines IMPORTANT The following installation instructions must be followed for warranty purposes and for optimal performance. The operator of any power tools or other tools should be skilled and familiar with the correct use of each tool. Always study and follow local Building Codes when applying Hourwall. Hourwall products are for interior use only. Exterior use may result in negative effects on the finish. Proper safety gear must be worn at all times. PRODUCT COLORING: Please ensure, wherever possible, that the production dates on all product being installed side-by-side are the same or compatible. This will help ensure consistent coloring. Most of the time product from different dates will match up, but the installer should check this before installing. Also, there is the possibility for a panel to be slightly off-colored in a batch. Again, the installer should check all panels match before installing. INSTALLATION – 1-2-3 1.
MEASURE and MARK: Products should be measured and marked from the backside. Using a measuring tape, mark the backside with a pencil or marker, and then use a straight edge to mark a cutting line.
CUT: The panels are easiest cut from the flat backside. Use a hand saw or miter saw to make the cut. For cutting panels lengthwise, a table saw is recommended for straighter cuts. To cut outlet and fixture holes, make markings on the backside of the panel, then use a hole saw or high speed drill (Dremel) tool to cut the opening. For precise cuts or for trimming, use a utility knife or drywall saw.
FASTEN: Fasten product to drywall or wood substrate using brad nails, heavy duty construction adhesive, 2” drywall or wood screws (must penetrate wood 1”). If adhesive is being used, the panels may need to be roughed up on the back for proper adhesion.
classicBRICK 1. Brad Nails – use a finishing nail, and try to apply to inconspicuous spots (existing indents, the grout lines, top and side shiplaps). Little or no touch up should be necessary. . 2. We recommend putting (4-6) screws, spaced roughly every 8 inches, into the top shiplap, and (4) screws into the right side where the adjoining panel will cover. In some cases where the shiplap or right wide has been cut off, all screws must be applied directly into the face of the panels. This should be done into the grout line, where caulking can be applied. Paintable caulking should be used to cover screw holes, and can be painted with the matching Hourwall Paint Kit.
urbanCONCRETE 1. Brad Nails – use a finishing nail, and try to apply to inconspicuous spots (existing indents, the 4 face circles, top and side shiplaps). Little or no touch up should be necessary. 2. We recommend putting (4-6) screws, spaced roughly every 8 inches, into the top shiplap, and (2-4) screws into the right side where the adjoining panel will cover. In some cases where the shiplap or right wide has been cut off, all screws must be applied directly into the face of the panels. This should be done into the 4 circles, where caulking can be applied. Paintable caulking should be used to cover screw holes, and can be painted with the matching Hourwall Paint Kit.
barnWOOD 1. Brad Nails – use a finishing nail, and try to apply to inconspicuous spots (existing indents, nail holes, cracks). Little or no touch up should be necessary. 2. We recommend putting (4-6) screws or nails into the same inconspicuous spots (existing indents, nail holes, cracks). Screws or nail heads may leave a desired look, and can be left exposed. Otherwise, paintable caulking can be used to cover screw holes, and can be painted with the matching Hourwall Paint Kit. 3. For an extra rustic look, use nails that are rusted, or longer nails that can be hammered in and then bent for that authentic aged look. For more information, please visit our website or contact us: www.hourwall.com
APPLYING PANELS: If installing barnWOOD, please pay attention to the different molded pieces as they come out of the box. barnWOOD has 4 different molds and 3 different plank thicknesses. It is best to try and keep similar pieces away from one another when applying to the wall to avoid a repetitive pattern. Before installing any of the Hourwall panels, the wall should first be measured and panels laid out. A level should be used to ensure the first row is level.
WALL TO WALL With urbanCONCRETE and classicBRICK it is ideal to start from the right side. Cut a straight line to fit snug against the wall, and work to the left from there. The final two pieces of classicBRICK may be easiest to fit together and then put in place.
CORNER TO WALL (or) WALL TO CORNER If installing urbanCONCRETE, it is better to begin at the corner to ensure a cut is not made through the face circles. If installing barnWOOD, a barnWOOD piece can be used vertically as a corner trim, or the pieces can be butt right to the corner. If installing urbanCONCRETE corner to corner, start installation on the most visible corner.
CORNER RETURNS Returns can be done in two ways. Butt - The panels can simply be butt together to create a finished corner. If any cut edges are exposed, the appropriate coordinating Hourwall Paint Kit should be used to color the ends. Miter – The panels can be mitered to create a more finished look. Cut the panel at a 45 degree angle, then use the same piece to continue on the return. If there is a gap, tighten screws or nails and fill unwanted gaps with the appropriate coordinating caulking and Hourwall Paint Kit.
WORKING AROUND ELECTRICAL PLUGS AND SWITCHES: If you are using any type of trim, the trims should be installed prior to installing Hourwall panels. If you are not using a trim, make markings on the backside of the panel, then use a hole saw or high speed drill (Dremel) tool to cut the opening. For precise cuts or for trimming, a utility knife or drywall saw can be used.
INSET Leaving the cover plate on, simply butt the panels to the edges of the cover plate for a clean look.
FLUSH MOUNT An electrical extension box may be used to extend the electrical outlet to be flush with panels. You must first measure the thickness of the Hourwall panel(s) and extend the electrical outlet out the appropriate amount to be flush with the panel. Ensuring a tight fit, install the panel(s) around the box and reinstall the cover plate on the face of the panel(s).
APPLICATION OVER CONCRETE/BRICK: Hourwall can be applied over concrete or brick according to the standard (drywall and wood) instructions above, with a couple of differences. A pilot hole can be drilled into the concrete with a masonry bit, and a special masonry screw should be used to fasten the product. In some cases, a wood or masonry screw can be applied directly into the concrete without pre-drilling a pilot hole. A second option is to fasten a sheet of 1/2” or 3/4” plywood to the concrete and then to continue with normal wood substrate installation. Adhesive (as per below) can be used in conjunction with the screws to ensure a solid installation. In some cases, adhesive will work on its own.
ADHESIVE: Products can be fastened to concrete, brick or other hard surfaces using the proper construction adhesive. Hourwall recommends high tack/grab heavy duty construction adhesive, or other polyurethane-friendly construction adhesives. All surface areas must be clean, dry and free of oily and loose materials. It is recommended to scuff or roughen the back of the panels prior to application. A utility knife, rasp, or sandpaper can be used for this.
EXPANSION AND CONTRACTION: Polyurethane panels will expand and contract much like many other building materials. It is recommended to install your Hourwall panels when they are cool (contracted state) and as tight as possible to minimize the visual appearance of expansion and contraction. Caulking and the Hourwall Paint Kits can be used to fill in any unwanted gaps for a seamless finish. MAINTENANCE: Dirt and scum can be washed off the product surface with water and a non-scuffing cloth or sponge. Mild, non-abrasive household cleaners or soap can be used carefully with water clean stubborn materials or stains. If any finish is compromised, the Hourwall Paint Kit can be used for all touch-ups and to re-finish.