04 20 00 - Unit Masonry.pdf

04 20 00 – UNIT MASONRY

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SECTION 04 20 00 – UNIT MASONRY

PART 1 - GENERAL

1.1 SUMMARY

A. Section Includes:

1. Concrete masonry units.

B. Related Requirements:

1. Section 03 20 00 – Concrete Reinforcing: Product requirements for steel reinforcing in masonry cavities and cores for installation by this Section.

1.2 REFERENCE STANDARDS

A. ASTM International:

1. ASTM A82 - Standard Specification for Steel Wire, Plain, for Concrete

Reinforcement.

2. ASTM A153- Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel

Hardware.

3. ASTM A240 - Standard Specification for Chromium and Chromium-Nickel

Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General Applications.

4. ASTM A307 - Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile Strength.

5. ASTM A580 - Standard Specification for Stainless Steel Wire.

6. ASTM A615 - Standard Specification for Deformed and Plain Carbon Steel Bars for

Concrete Reinforcement.

7. ASTM A653 - Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or

Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process.

8. ASTM A951 - Standard Specification for Steel Wire for Masonry Joint

Reinforcement.

9. ASTM B370 - Standard Specification for Copper Sheet and Strip for Building

Construction.

10. ASTM B695 - Standard Specification for Coatings of Zinc Mechanically Deposited on Iron and Steel.

11. ASTM C27 - Standard Classification of Fireclay and High-Alumina Refractory Brick.

12. ASTM C34 - Standard Specification for Structural Clay Load-Bearing Wall Tile.

13. ASTM C55 - Standard Specification for Concrete Building Brick.

14. ASTM C56 - Standard Specification for Structural Clay Nonloadbearing Tile.

15. ASTM C62 - Standard Specification for Building Brick (Solid Masonry Units Made

From Clay or Shale).

16. ASTM C67 - Standard Test Methods for Sampling and Testing Brick and Structural

Clay Tile.

17. ASTM C73 - Standard Specification for Calcium Silicate Brick (Sand-Lime Brick).

18. ASTM C90 - Standard Specification for Loadbearing Concrete Masonry Units.

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19. ASTM C126 - Standard Specification for Ceramic Glazed Structural Clay Facing Tile, Facing Brick, and Solid Masonry Units.

20. ASTM C129 - Standard Specification for Nonloadbearing Concrete Masonry Units.

21. ASTM C140 - Standard Test Methods for Sampling and Testing Concrete Masonry

Units and Related Units.

22. ASTM C212 - Standard Specification for Structural Clay Facing Tile.

23. ASTM C216 - Standard Specification for Facing Brick (Solid Masonry Units Made from Clay or Shale).

24. ASTM C315 - Standard Specification for Clay Flue Liners and Chimney Pots.

25. ASTM C530 - Standard Specification for Structural Clay Nonloadbearing Screen

Tile.

26. ASTM C578 - Standard Specification for Rigid, Cellular Polystyrene Thermal

Insulation.

27. ASTM C652 - Standard Specification for Hollow Brick (Hollow Masonry Units Made

From Clay or Shale).

28. ASTM C744 - Standard Specification for Prefaced Concrete and Calcium Silicate

Masonry Units.

29. ASTM C1261 - Standard Specification for Firebox Brick for Residential Fireplaces.

30. ASTM C1283 - Standard Practice for Installing Clay Flue Lining.

31. ASTM C1314 - Standard Test Method for Compressive Strength of Masonry

Prisms.

32. ASTM C1405 - Standard Specification for Glazed Brick (Single Fired, Brick Units).

33. ASTM D226 - Standard Specification for Asphalt-Saturated Organic Felt Used in

Roofing and Waterproofing.

34. ASTM E84 - Standard Test Method for Surface Burning Characteristics of Building

Materials.

35. ASTM E119 - Standard Test Methods for Fire Tests of Building Construction and

Materials.

B. The Masonry Society:

1. TMS 402/602 - Building Code Requirements and Specification for Masonry

Structures and Related Commentaries.

1.3 COORDINATION

A. Section 01 31 13 – Project Coordination: Requirements for coordination.

B. Convene minimum one week prior to commencing Work of this Section.

1.4 SUBMITTALS

A. Section 01 33 00 – Submittal Procedures: Requirements for submittals.

B. Product Data:

1. Submit data for masonry units masonry wire reinforcement and other accessories.

C. Samples:

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1. Submit two full-size samples of CMU units to illustrate color, texture, and extremes of color range.

D. Manufacturer's Certificate: Certify that products meet or exceed specified requirements.

E. Source Quality-Control Submittals: Indicate results of factory tests and inspections.

F. Field Quality-Control Submittals: Indicate results of Contractor-furnished tests and inspections.

G. Qualifications Statements:

1. Submit qualifications for installer.

1.5 MAINTENANCE MATERIAL SUBMITTALS

A. Section 01 73 00 – Execution Requirements: Requirements for maintenance materials.

B. Extra Stock Materials:

1. Furnish 4 of each size, color, and type of CMU units.

1.6 QUALITY ASSURANCE

A. Perform Work according to TMS 402/602.

1.7 QUALIFICATIONS

A. Installer: Company specializing in performing Work of this Section with minimum three years' documented experience.

1.8 MOCKUPS

A. Section 01 40 00 – Quality Requirements: Requirements for mockups.

B. Size: Construct masonry wall mockup, 4 feet long by 4 feet high, including masonry, mortar and accessories.

C. Locate where directed by Engineer.

1.9 DELIVERY, STORAGE, AND HANDLING

A. Section 01 61 00 – Product Requirements: Requirements for transporting, handling, storing, and protecting products.

B. Inspection: Accept CMU units on-Site. Inspect for damage.

1.10 AMBIENT CONDITIONS

A. Section 01 50 00 – Temporary Facilities and Controls: Requirements for ambient condition control facilities for product storage and installation.

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B. Do not store reinforcing material directly on ground. Utilize blocking and other methods to prevent rust on accessories prior to installation.

C. Cold Weather Requirements: According to TMS 402/602 when ambient temperature or temperature of masonry units is less than 40 degrees F.

D. Hot Weather Requirements: According to TMS 402/602 when ambient temperature is greater than 100 degrees F or ambient temperature is greater than 90 degrees F with wind velocity greater than 8 mph.

1.11 EXISTING CONDITIONS

A. Field Measurements: Verify elevations, dimensions, and alignment of foundations prior to beginning Work. Indicate field measurements on Shop Drawings.

PART 2 - PRODUCTS

2.1 PERFORMANCE AND DESIGN CRITERIA

A. Concrete Masonry Compressive Strength (f'm): 2,000 psi for all exterior walls, below grade walls and all interior load bearing walls, 2,000 psi for all non-load bearing interior walls; determined by unit strength method.

1. Concrete Masonry Units (CMU):

a. 2,000 psi minimum net area compressive strength for all exterior wall, below grade walls, and all interior 12” CMU load bearing walls.

b. 2,000 psi minimum net area compressive strength for all interior 8” walls and 12” non-load bearing walls.

2.2 UNIT MASONRY ASSEMBLIES

A. Masonry Unit

1. Manufacturers:

a. Fizzano Brothers, 1776 Chester Pike, Crum Lynne, PA, 19022

b. Oberfields LLC, 528 London Road, Delaware, OH 43015

c. A. Jandris & Sons, 202 High Street, Gardner, MA 01440

d. York Building Products.

e. Substitutions: Section 01 61 00 – Product Requirements.

2.3 MATERIALS

A. Hollow Load-Bearing CMU: ASTM C90; normal weight – Interior walls and below grade walls.

B. Decorative CMU: ASTM C90; normal weight – at grade and above grade exterior walls;

color as selected by Owner to the following design:

1. CMU – 4” units and other sizes as needed for transitions at corners, openings, columns, and masonry control joints - w/ integral waterproofing – Dry-Block as manufactured by Grace Construction Products.

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C. Concrete Brick Units: ASTM C55, same weight as block units.

D. Plain CMU Size: Nominal modular size of 8 by 8 by 16 inches and 12 by 8 by 16 inches.

E. Special CMU Shape: Furnish special units for 90 degree corners; surface texture on sides and ends for outside wall corners.

2.4 ACCESSORIES

A. Single-Wythe Joint Reinforcement: ASTM A951; ladder type; steel; 0.188-inch-diameter side rods with 0.148-inch-diameter cross ties; hot-dip galvanized.

B. Reinforcing Steel: ASTM A615, 60 ksi yield grade, deformed billet bars, uncoated finish.

C. Partition “Z” strap anchors: Bent steel strap, 16 inch long by 3/16 inch thick with 2 inch bent legs at each end; ASTM A153, hot-dip galvanized.

D. Anchor Rods: ASTM A307; Grade C; J- or L-shaped; complete with washers and heavy hex nuts; sized for minimum 6-inch embedment; galvanized finish.

1. Hot-Dip Galvanizing: ASTM A153.

2. Mechanical Galvanizing: ASTM B695, Class 55.

E. Mortar and Grout: As specified in Section 04 05 13 – Masonry Mortaring and Section 040516 - Masonry Grouting.

F. Cavity Drain Material: Open polyethylene mesh thickness required to fill cavity space and shaped to ensure moisture drainage to cavity weeps.

1. Manufacturers:

a. Advanced Building Products, Inc, “Mortar Break”, Springvale, ME, www.advancedflashing.com 800-252-2306.

b. Dayton Superior Corporation, “Mortar Stop”, Dayton, OH, www.daytonsuperior.com 888-977-9600.

c. Mortar Net Solutions, 6575 Daniel Burnham Drive, Suite G, Portage, IN 46368, 800-664-6638, www.mortarnet.com

d. Substitutions: Section 01 61 00 – Product Requirements.

G. Drainage System: BlockFlash – single wythe flashing system – use on exterior walls.

1. Manufacturer: Mortar Net Solutions, 6575 Daniel Burnham Drive, Suite G, Portage, IN 46368, 800-664-6638, www.mortarnet.com.

H. Weeps: Honeycomb rectangular plastic weep hole material, 1-1/2” x 3-1/2”.

1. Manufacturer: Hohmann and Barnard, Inc. 631-234-0600, www.h-b.com

2. Substitutions: Section 01 61 00 – Product Requirements.

I. Cleaning Solution: Non-acidic, not harmful to masonry Work or adjacent materials.

J. Steel Lintels: Sizes as indicated on Drawing; hot-dip galvanized, 36 ksi minimum yield strength.

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K. Masonry Lintels: Sizes & reinforced as indicated on Drawings, 3,000 psi concrete compressive strength, ASTM A615 Grade 60 reinforcement.

2.5 SOURCE QUALITY CONTROL

A. Section 01 40 00 – Quality Requirements: Requirements for testing, inspection, and analysis.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Section 01 73 00 – Execution Requirements: Requirements for installation examination.

B. Verify that field conditions are acceptable and ready to receive Work.

C. Verify that items provided by other Sections of Work are properly sized and located.

D. Verify that built-in items are in proper location and ready for roughing into masonry Work.

3.2 PREPARATION

A. Section 01 73 00 – Execution Requirements: Requirements for installation preparation.

B. Direct and coordinate placement of metal anchors supplied to other Sections.

C. Furnish temporary bracing during installation of masonry Work. Maintain in place until building structure provides permanent support.

D. Wet clay and shale brick before laying when initial rate of absorption is greater than 30 g per min./30 sq. in. when tested according to ASTM C67.

3.3 INSTALLATION

A. Establish lines, levels, and coursing indicated. Protect from displacement.

B. Maintain masonry courses to uniform dimension. Form bed and head joints of uniform thickness.

C. Coursing of CMU:

1. Bond: Running.

2. Coursing: One unit and one mortar joint to equal 8 inches.

3. Mortar Joints: Concave.

D. Placing and Bonding:

1. Lay solid masonry units in full bed of mortar, with full head joints.

2. Lay hollow masonry units with face shell bedding on head and bed joints.

3. Buttering corners of joints or excessive furrowing of mortar joints are not permitted.

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4. Remove excess mortar as Work progresses.

5. Interlock intersections and external corners.

6. Reinforce intersections with Z-strap anchors at 16 inches o.c.

7. Do not shift or tap masonry units after mortar has achieved initial set. Where adjustment is required, remove mortar and replace.

8. Perform Project Site cutting of masonry units with proper tools to assure straight, clean, unchipped edges. Prevent broken masonry unit corners or edges.

E. Weeps and Vents: Furnish weeps and vents in outer wythe at 32 inches o.c. horizontally above shelf angles and lintels.

F. Drainage System: Install BlockFlash system at bottom of exterior wall CMU except at solid grouted cores.

G. Joint Reinforcement and Anchorage - Single-Wythe Masonry:

1. Install horizontal joint reinforcement 16 inches o.c. vertically.

2. Place masonry joint reinforcement in first two horizontal joints above and below openings. Extend minimum 16 inches each side of opening.

3. Lap joint reinforcement ends minimum 6 inches.

H. Masonry Flashings:

1. Extend Drainage System horizontally through outer face of CMU at first CMU joint above grade.

I. Lintels:

1. Install loose steel, precast concrete, and concrete masonry bond beam lintels over openings.

2. Install reinforced unit masonry lintels over miscellaneous openings more than 12 inches wide where lintels are not scheduled or indicated.

3. Do not splice reinforcing bars.

4. Support and secure reinforcing bars from displacement.

5. Place and consolidate grout fill without displacing reinforcing.

6. Maintain temporary support under masonry lintels for a minimum of seven days.

Do not apply floor, roof, equipment, or similar loads to masonry lintels for twenty-eight days unless temporary supports are maintained in place or the loads are approved by the Engineer.

7. Maintain minimum 8-inch bearing on each side of opening for masonry lintels and 4-inch minimum for steel angles or as noted on drawings.

J. Grouted Components:

1. Reinforce bond beams as indicated on Drawings. Maintain minimum of 1 inch rebar clearance from bottom web.

2. Lap splices bar diameters as required by code.

3. Support and secure reinforcing bars from displacement.

4. Place and consolidate grout fill without displacing reinforcing.

5. At bearing locations, fill masonry cores with grout for minimum 12 inches both sides of opening.

6. All cores occupied by reinforcement, dowels, or anchors must be grouted full.

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K. Reinforced Masonry:

1. Lay masonry units with cells vertically aligned and clear of mortar and unobstructed.

2. Place reinforcement bars at locations indicated on Drawings and vertical bars midway between wall faces unless noted otherwise.

3. Splice reinforcement as indicated on Drawings.

4. Support and secure reinforcement from displacement.

5. Place and consolidate grout fill without displacing reinforcing.

6. Place grout according to TMS 402/602.

L. Control Joints:

1. Install control joints at the following maximum spacings, unless otherwise indicated on Drawings:

a. Exterior Walls: 20 feet o.c. and within 48 inches on one side of each interior and exterior corner.

b. Interior Walls: 30 feet o.c.

c. At changes in wall height.

2. Do not continue horizontal joint reinforcement through control joints. (Install bond beam reinforcement continuous through control joints U.N.O.)

3. Install preformed control joint device in continuous lengths. Seal butt and corner joints.

M. Built-in Work:

1. As Work progresses, install built-in metal door frames and other items to be built in the Work and furnished by other Sections.

2. Install built-in items plumb and level.

3. Bed anchors of metal door frames in adjacent mortar joints. Fill frame voids solid with grout or mortar. Fill adjacent masonry cores with grout minimum 8 inches from framed openings.

4. Do not build in materials subject to deterioration.

N. Cutting and Fitting:

1. Cut and fit for pipes, conduit, and miscellaneous penetrations. Coordinate with other Sections of Work to provide correct size, shape, and location.

2. Obtain Engineer's approval prior to cutting or fitting masonry Work not indicated or where appearance or strength of masonry Work may be impaired.

3.4 TOLERANCES

A. Section 01 40 00 – Quality Requirements: Requirements for tolerances.

B. Maximum Variation from Unit to Adjacent Unit: 1/16 inch on exterior of wall.

C. Maximum Variation from Plane of Wall: 1/4 inch in 10 feet and 1/2 inch in 20 feet or more.

D. Maximum Variation from Plumb: 1/4 inch per story non-cumulative; 1/2 inch in two stories or more.

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E. Maximum Variation from Level Coursing: 1/8 inch in 3 feet and 1/4 inch in 10 feet; 1/2 inch in 30 feet.

F. Maximum Variation of Joint Thickness: 1/8 inch in 3 feet.

G. Maximum Variation from Cross Sectional Thickness of Walls: 1/4 inch.

H. Maximum Variation for Steel Reinforcement:

1. Install reinforcement within the tolerances specified in TMS 402/602 for foundation walls.

2. Plus or minus 1/2 inch when distance from centerline of steel to opposite face of masonry is 8 inches or less.

3. Plus or minus 1 inch when distance is between 8 and 24 inches.

4. Plus or minus 1-1/4 inch when distance is greater than 24 inches.

5. Plus or minus 2 inches from location along face of wall.

3.5 FIELD QUALITY CONTROL

A. Section 01 40 00 – Quality Requirements: Requirements for inspecting and testing.

B. CMU: Test each type according to ASTM C140.

1. Unit Strength Method – provide certifications that the masonry units, grout, and mortar meet the specified requirements.

C. Prism Tests: Test compressive strength of completed reinforced masonry according to

ASTM C1314.

D. Mortar: Submit certifications for materials demonstrating compliance with specifications.

Special Inspections of site-prepared mortar.

3.6 CLEANING

A. Section 01 73 00 – Execution Requirements: Requirements for cleaning.

B. Section 04 01 20 – Masonry Cleaning.

C. Remove excess mortar and mortar smears as Work progresses.

D. Replace defective mortar. Match adjacent Work.

E. Clean soiled surfaces with cleaning solution. [Coordinate with Work of specified water-repellent or surface coating.]

F. Use non-metallic tools in cleaning operations.

3.7 PROTECTION

A. Section 01 73 00 – Execution Requirements: Requirements for protecting finished Work.

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B. Protect exposed external corners subject to damage.

C. Protect base of walls from mud and mortar splatter.

D. Protect masonry and other items built into masonry walls from mortar droppings and staining caused by mortar.

E. Protect tops of masonry Work with waterproof coverings secured in place without damaging masonry. Provide coverings where masonry is exposed to weather when Work is not in progress. Maintain protection on tops of completed exterior walls until installation of permanent waterproof cap materials.

3.8 SCHEDULE

A. Refer to the Room Finish Schedule on Drawing 00A-11 for colors of the exterior decorative masonry. The Architectural drawings define the textures of the decorative masonry.

END OF SECTION 04 20 00