36C24419B0046-0003005.pdf

Erie VA Medical Center VA Project #562-17-309 Replace Legacy EPSS Bid Document Submission Erie, PA July 24, 2019

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SECTION 04 01 11

MAINTENANCE OF MASONRY

PART 1 - GENERAL

1.1 SUMMARY

A. Section Includes:

1. Alteration of existing masonry construction.

2. Installation of new masonry exterior walls.

1.2 APPLICABLE PUBLICATIONS

A. Comply with references to extent specified in this section.

B. ASTM International (ASTM):

1. C67-14 - Sampling and Testing Brick and Structural Clay Tile.

2. C144-11 - Aggregate for Masonry Mortar.

3. C150/C150M-15 - Portland Cement.

4. C207-06(2011) - Hydrated Lime for Masonry Purposes.

5. C216-15 - Facing Brick (Solid Masonry Units Made fr om Clay or

Shale).

6. C270-14a - Mortar for Unit Masonry.

7. C295/C295M-12 - Petrographic Examination of Aggrega tes for Concrete.

1.3 SUBMITTALS

A. Submittal shall be submitted in accordance with Sec tion 01 33 23, SHOP

DRAWINGS, PRODUCT DATA, AND SAMPLES.

B. Manufacturer's Literature and Data:

1. Description of each product.

1.4 QUALITY ASSURANCE

A. Installer Qualifications:

1. Documented experience in completion of work, simila r in design, material, and extent specified.

1.5 DELIVERY

A. Deliver products in manufacturer's original sealed packaging.

B. Mark packaging, legibly. Indicate manufacturer's na me or brand, type, color, production run number, and manufacture date.

C. Before installation, return or dispose of products within distorted, damaged, or opened packaging.

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1.6 STORAGE AND HANDLING

A. Store materials covered, protected from weather, an d elevated above grade.

1. Prevent contamination of aggregates.

B. Protect products from damage during handling and co nstruction operations.

1.7 FIELD CONDITIONS

A. Environment:

1. Cold Weather Requirements: Maintain mortar ingredie nts and substrate within temperature range between 4 degrees C (40 de grees F) and

49 degrees C (120 degrees F) when outside temperatu re is less than

4 degrees C (40 degrees F).

2. Hot Weather Requirements: Protect mortar-joint from evaporation of moisture from mortar material. When required, provi de adequately shaded work area.

1.8 WARRANTY

A. Construction Warranty: FAR clause 52.246-21, "Warra nty of

Construction."

PART 2 - PRODUCTS

2.1 MATERIALS

A. Mortar Components:

1. Hydrated Lime: ASTM C207, Type S.

2. Aggregate: ASTM C144.

3. Portland Cement: ASTM C150/C150M, Type I.

4. Pigments: ASTM C979/C979M; inorganic, inert, minera l pigments only, unaffected by atmospheric conditions, nonfading, al kali resistant, and water insoluble.

5. Water: Potable, free of substances that are detrime ntal to grout, masonry, and metal.

2.2 PRODUCTS - GENERAL

A. Provide each product from one manufacturer and from one production run.

2.3 REPLACEMENT MASONRY UNITS

A. Brick:

1. Face Brick:

a. ASTM C216, Grade SW, Type FBS.

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b. Brick when tested according to ASTM C67: Classified slightly efflorescent or better.

c. Size:

1) Modular.

B. Concrete Masonry Units (CMU):

1. Hollow and Solid Load-Bearing Concrete Masonry Unit s: ASTM C90.

a. Unit Weight: Medium weight.

2. Sizes: Modular, 200 mm by 400 mm (8 inches by 16 in ches) nominal face dimension; thickness as indicated on drawings.

C. Concrete Brick: ASTM C55.

D. Other Masonry Units: Match existing.

2.4 MIXES

A. Masonry Mortar: ASTM C270/C270M.

1. Admixtures:

a. Do not use mortar admixtures, and color admixtures unless approved by Contracting Officer's Representative.

b. Do not use antifreeze compounds.

B. Colored Mortar:

1. Maintain uniform mortar color for exposed work, thr oughout.

2. Match mortar color to existing adjacent.

C. Color Admixtures:

1. Use color admixture as required to match the existi ng adjacent

2. Proportion as specified by manufacturer.

2.5 GROUTING

A. Grout Components:

1. Hydrated Lime: ASTM C207, Type S.

2. Aggregate For Masonry Grout: ASTM C404, Size 8.

3. Blended Hydraulic Cement: ASTM C595, Type IS, IP.

4. Water: Potable, free of substances that are detrime ntal to grout, masonry, and metal.

B. Grout Mix: ASTM C476; fine grout and coarse grout.

C. Ready-Mixed Grout: ANSI A118.8.

2.6 ANCHORS, TIES, AND REINFORCEMENT

A. Steel Reinforcing Bars: ASTM A615/A615M; Grade 60, deformed bars.

B. Joint Reinforcement:

1. Form from wire complying with ASTM A951/A951M.

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2. Hot dipped galvanized after fabrication.

3. Width of joint reinforcement 40 mm (1.6 inches) les s than nominal thickness of masonry wall or partition.

4. Cross wires welded to longitudinal wires.

5. Joint reinforcement minimum 3000 mm (10 feet) long, factory cut.

6. Joint reinforcement with crimp formed drip is not a cceptable.

7. Maximum spacing of cross wires 400 mm (16 inch) to longitudinal wires.

8. Trussed Design:

a. Longitudinal and cross wires minimum 4 mm (0.16 inc h nominal) diameter.

b. Longitudinal wires deformed.

9. Multiple Wythes and Cavity Wall Ties:

a. Longitudinal wires 4 mm (0.16 inch), two in each wy the with ladder truss wires 4 mm (0.16 inch) overlay, welded to each longitudinal wire.

b. Longitudinal wires 4 mm (0.16 inch) with U shape 4 mm

(0.16 inch) rectangular ties extending into other w ythe minimum

75 mm (3 inches) spaced 400 mm on center (16 inches ). Adjustable type with U shape tie designed to receive 4 mm (0.1 6 inch) pintle projecting into other wythe 75 mm (3 inches min.).

2.7 ACCESSORIES

A. Weeps:

1. Weep Hole Wicks: Glass fiber ropes, 10 mm (3/8 inch ) minimum diameter, 300 mm (12 inches) long.

2. Weep Tubing: Round, polyethylene, 9 mm (3/8 inch) d iameter, 100 mm

(4 inches) long.

3. Weep Hole: Flexible PVC louvered configuration with rectangular closure strip at top.

B. Cavity Drain Material: Open mesh polyester sheets o r strips to prevent mortar droppings from clogging the cavity.

C. Preformed Compressible Joint Filler:

1. Thickness and depth to fill joint.

2. Closed Cell Neoprene: ASTM D1056, Type 2, Class A, Grade 1, B2F1.

3. Non-Combustible Type: ASTM C612, Class 5, 1800 degr ees F.

D. Box Board:

1. Mineral Fiber Board: ASTM C612, Class 1.

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2. 25 mm (1 inch) thickness.

3. Other spacing material having similar characteristi cs is acceptable subject to Contracting Officer's Representative's a pproval.

E. Masonry Cleaner:

1. Detergent type cleaner selected for each type mason ry.

2. Acid cleaners are not acceptable.

3. Use soapless type specially prepared for cleaning b rick or concrete masonry as appropriate.

F. Fasteners:

1. Concrete Nails: ASTM F1667, Type I, Style 11, 19 mm (3/4 inch) minimum length.

2. Masonry Nails: ASTM F1667, Type I, Style 17, 19 mm (3/4 inch) minimum length.

3. Screws: FS-FF-S-107, Type A, AB, SF thread forming or cutting.

G. Welding Materials: AWS D1.4/D1.4M, type to suit app lication.

PART 3 - EXECUTION

3.1 PREPARATION

A. Examine and verify substrate suitability for produc t installation.

B. Protect existing construction and completed work fr om damage.

1. Protect from mortar droppings and cleaning operatio ns.

C. Remove existing fixtures and fittings concealing ma sonry joints to permit repointing and repair.

3.2 MASONRY UNIT REPLACEMENT

A. Cut out mortar joints surrounding masonry units req uiring replacement.

1. Remove existing masonry units creating opening for replacement masonry unit installation.

2. Remove mortar, dust, and debris from opening perime ter surfaces.

3. Prevent debris from falling into cavity.

B. Dampen surfaces of surrounding existing masonry bef ore installing replacement masonry units.

1. Allow existing masonry to absorb surface moisture b efore installing replacement units.

2. Butter contact surfaces of existing masonry and rep lacement masonry units with mortar.

3. Center replacement masonry units in opening and pre ss into position.

4. Remove excess mortar.

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5. Tuck point replacement masonry units to ensure full head and bed joints.

3.3 INSTALLATION - BRICKWORK

A. Lay clay brick according to BIA TN 11B.

B. Laying:

1. Lay brick in one-half running bond with bonded corn ers, unless indicated otherwise. Match bond of existing buildin g on alterations and additions.

2. Maintain bond pattern throughout.

3. Do not use brick smaller than half-brick at any ang le, corner, break, and jamb.

4. Where length of cut brick is greater than one half length, maintain vertical joint location.

5. Lay exposed brickwork joints symmetrical about cent er lines of openings.

6. Do not structurally bond multi-wythe brick walls, u nless indicated on drawings.

7. Before starting work, lay facing brick on foundatio n wall and adjust bond to openings, angles, and corners.

8. Lay brick for sills with wash and drip.

9. Build solid brickwork as required for anchorage of items.

C. Joints:

1. Exterior And Interior Joint Widths: Lay for three e qual joints in

200 mm (8 inches) vertically, unless shown otherwis e.

2. Rake joints for pointing with colored mortar when c olored mortar is not full depth.

D. Weep Holes:

1. Install weep holes at spacing to match existing, 6 00 mm (24 inches) on center maximum, in bottom of vertical joints of exterior masonry veneer or cavity wall facing over foundations, bond beams, and other water stops in wall.

2. Form weep holes using wicks made of mineral fiber i nsulation strips turned up 200 mm (8 inches) in cavity. Anchor top o f strip to backup to securely hold in place.

3. Install sand or pea gravel in cavity approximately 75 mm (3 inches) high between weep holes.

E. Cavity Walls:

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1. Keep air space clean of mortar accumulations and de bris.

2. Lay the interior wythe of the masonry wall full hei ght where dampproofing is required on cavity face. Coordinate to install dampproofing before laying outer wythe.

3. Insulated Cavity Type Exterior Walls:

a. Install insulation against cavity face of inner mas onry wythe.

b. Place insulation between rows of ties or joint rein forcing.

Adhere insulation to masonry surface with a bonding agent as recommended by insulation manufacturer.

c. Lay outer masonry wythe up with air space between i nsulation and masonry units.

3.4 INSTALLATION - CONCRETE MASONRY UNITS

A. Types and Uses:

1. Provide special concrete masonry shapes as required , including lintel and bond beam units, sash units, and corner units. Provide solid concrete masonry units, where full units cann ot be installed, or where needed for anchorage of accessories.

2. Provide solid load-bearing concrete masonry units o r grout cell of hollow units at jambs of openings in walls, where s tructural members impose loads directly on concrete masonry, and wher e shown.

3. Provide rounded corner (bullnose) shapes at opening jambs in exposed work and at exterior corners.

4. Do not install brick jambs in exposed finish work.

5. Install concrete building brick only as filler in b ackup material where not exposed.

B. Laying:

1. Lay concrete masonry units with 9 mm (3/8 inch) joi nts, with a bond overlap of minimum 1/4 of unit length, except where stack bond is indicated on drawings.

2. Do not wet concrete masonry units before laying.

3. Bond external corners of partitions by overlapping alternate courses.

4. Lay first course in a full mortar bed.

5. Set anchorage items as work progress.

6. Where ends of anchors, bolts, and other embedded it ems, project into voids of units, completely fill voids with mortar o r grout.

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7. Provide 6 mm (1/4 inch) open joint for sealant betw een existing construction.

8. Lay concrete masonry units with full face shell mor tar beds and fill head joint beds for depth equivalent to face shell thickness.

9. Lay concrete masonry units so cores of units, that are to be filled with grout, are vertically continuous with joints o f cross webs of such cores completely filled with mortar. Unobstruc ted core openings minimum 50 mm (2 inches) by 75 mm (3 inches).

10. Do not wedge masonry against steel reinforcing. Min imum 13 mm

(1/2 inch) clear distance between reinforcing and m asonry units.

11. Install deformed reinforcing bars of sizes indicate d on drawings.

12. At time of placement, ensure steel reinforcement is free of loose rust, mud, oil, and other contamination capable of affecting bond.

13. Place steel reinforcement at spacing indicated on d rawings before grouting.

14. Minimum clear distance between parallel bars: One b ar diameter.

15. Hold vertical steel reinforcement in place vertical ly by centering clips, caging devices, tie wire, or other approved methods.

16. Support vertical bars near each end and at maximum 192 bar diameter on center.

17. Splice reinforcement or attach reinforcement to dow els by placing in contact and securing with wire ties.

18. Stagger splices in adjacent horizontal reinforcing bars. Lap reinforcing bars at splices a minimum of 40 bar dia meters.

19. Grout cells of concrete masonry units, containing r einforcing bars, solid as specified.

20. Install cavity and joint reinforcement as masonry w ork progresses.

21. Rake joints 6 to 10 mm (1/4 to 3/8 inch) deep for p ointing with colored mortar when colored mortar is not full dept h.

3.5 GROUTING

A. Preparation:

1. Clean grout space of mortar droppings before placin g grout.

2. Close cleanouts.

3. Install vertical solid masonry dams across grout sp ace for full height of wall at intervals of maximum 9000 mm (30 feet). Do not bond dam units into wythes as masonry headers.

4. Verify reinforcing bars are installed as indicated on drawings.

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B. Placing:

1. Place grout in grout space in lifts as specified.

2. Consolidate each grout lift after free water has di sappeared but before plasticity is lost.

3. Do not slush with mortar or use mortar with grout.

4. Interruptions:

a. When grouting must be stopped for more than an hour , top off grout 40 mm (1-1/2 inches) below top of last masonr y course.

b. Grout from dam to dam on high lift method.

c. Longitudinal run of masonry may be stopped off only by raking back one-half masonry unit length in each course an d stopping grout 100 mm (4 inches) back of rake on low lift me thod.

C. Puddling Method:

1. Consolidate by puddling with grout stick during and immediately after placing.

2. Grout cores of concrete masonry units containing re inforcing bars solid as masonry work progresses.

D. Low Lift Method:

1. Construct masonry to 1.5 m (5 feet) maximum height before grouting.

2. Grout in one continuous operation and consolidate g rout by mechanical vibration and reconsolidate after initia l water loss and settlement has occurred.

E. High Lift Method:

1. Do not pour grout until masonry wall has cured mini mum of 4 hours.

2. Place grout in 1.5 m (5 feet) maximum lifts.

3. Exception:

a. Where following conditions are met, place grout in 3.86 m

(12.67 feet) maximum lifts.

b. Masonry has cured minimum of 4 hours.

c. Grout slump is maintained between 250 and 275 mm (1 0 and

11 inches).

d. No intermediate reinforced bond beams are placed be tween top and bottom of grout lift.

4. When vibrating succeeding lifts, extend vibrator 30 0 to 450 mm (12 to 18 inches) into preceding lift.

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3.6 PLACING REINFORCEMENT

A. General: Clean reinforcement of loose rust, mill sc ale, earth, ice or other materials which will reduce bond to mortar or grout. Do not use reinforcement bars with kinks or bends not shown on drawings or approved submittal drawings, or bars with reduced c ross-section due to excessive rusting or other causes.

B. Position reinforcement accurately at spacing indica ted on drawings.

Support and secure vertical bars against displaceme nt. Install horizontal reinforcement as masonry work progresses . Where vertical bars are shown in close proximity, provide clear di stance between bars of minimum one bar diameter or 25 mm (1 inch), whic hever is greater.

C. Splice reinforcement bars only where indicated on d rawings, unless approved by Contracting Officer's Representative. P rovide lapped splices. In splicing vertical bars or attaching to dowels, lap ends, place in contact and wire tie.

D. Provide minimum lap as indicated on approved submit tal drawings, or if not indicated, minimum 48 bar diameters.

E. Embed metal ties in mortar joints as work progresse s, with minimum mortar cover of 15 mm (5/8 inch) on exterior face o f walls and 13 mm

(1/2 inch) at other locations.

F. Embed prefabricated horizontal joint reinforcement as work progresses, with minimum cover of 15 mm (5/8 inch) on exterior face of walls and

13 mm (1/2 inch) at other locations. Lap joint rein forcement minimum

150 mm (6 inches) at ends. Use prefabricated “L” an d “T” sections to provide continuity at corners and intersections. Cu t and bend joint reinforcement for continuity at returns, offsets, c olumn fireproofing, pipe enclosures and other special conditions.

G. Anchoring: Anchor reinforced masonry work to suppor ting structure as indicated on drawings.

H. Anchor reinforced masonry walls at intersections wi th non-reinforced masonry.

3.7 JOINT TOOLING

A. Tool new masonry joints when mortar becomes slightl y hardened.

B. Produce smooth, compacted, joint matching existing.

3.8 CLEANING AND REPAIR

A. General:

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1. Clean exposed masonry surfaces on completion.

2. Protect adjoining construction materials and landsc aping during cleaning operations.

3. Cut out defective exposed new joints to depth of ap proximately 19 mm

(3/4 inch) and repoint.

4. Remove mortar droppings and other foreign substance s from wall surfaces.

B. Brickwork:

1. First wet surfaces with clean water, then wash down with detergent solution. Do not use muriatic acid.

2. Brush with stiff fiber brushes while washing, and i mmediately wash with clean water.

3. Remove traces of detergent, foreign streaks, or sta ins of any nature.

C. Concrete Masonry Units:

1. Immediately following setting, brush exposed surfac es free of mortar or other foreign matter.

2. Allow mud to dry before brushing.

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