36C78619Q0211-003.pdf

04 01 20 - 1

SECTION 04 01 20

MAINTENANCE OF UNIT MASONRY

PART 1 - GENERAL

1.1 SUMMARY

A. Section includes maintenance of unit masonry consisting of brick clay masonry restoration and cleaning as follows:

1. Repairing unit masonry, including replacing units.

2. Painting steel uncovered during the work.

3. Repointing joints.

4. Preliminary cleaning, including removing plant growth.

5. Cleaning exposed unit masonry surfaces.

B. Related Sections:

1. Section 04 05 13, MASONRY MORTARING.

2. Section 04 20 00, UNIT MASONRY for new clay masonry construction.

1.2 DEFINITIONS

A. Very Low-Pressure Spray: Under 100 psi.

B. Low-Pressure Spray: 100 to 400 psi; 4 to 6 gpm.

C. Saturation Coefficient: Ratio of the weight of water absorbed during immersion in cold water to weight absorbed during immersion in boiling water; used as an indication of resistance of masonry units to freezing and thawing.

D. Restoration Bricklayers or Stone Masons: Individual workers who have demonstrable experience in historic masonry restoration and have been approved by the COR to perform the Work. The approval shall not be transferrable either to their company of employ or to other individuals.

E. Lead Restoration Bricklayer or Stone Mason: An individual Restoration

Bricklayer or Stone Mason with exemplary skills in historic restoration who has been approved by the COR to serve as crew leader, shall be present at all times during masonry restoration, and shall personally direct the work.

F. Masonry Crew Members: Restoration Bricklayers or Stone Masons, Lead

Restoration Bricklayer or Stone Mason, and Masonry Tenders.

1.3 PRECONSTRUCTION TESTING

A. Preconstruction Testing Service: Engage a qualified testing agency to perform preconstruction testing on masonry units as follows.

1. Provide test specimens as indicated and representative of proposed materials and construction.

SPECIFICATIONS

REPAIR BRICK WALL AND INSTALL GUARDRAILS

BATON ROUGE NATIONAL CEMETERY, BATON ROUGE, LOUISIANA

TABLE OF CONTENTS

Section Title Page

04 01 20 MAINTENANCE OF UNIT MASONRY……………………… 2

04 05 13 MASONRY MORTARING…………………………………… 16

04 20 00 UNIT MASONRY………………………………………………20

04 72 00 CAST STONE MASONRY…………………………………… 25

09 25 00 LIME-BASED PLASTERING………………………………… 32

09 91 00 PAINTING………………………………………………………35

09 97 26 SOL SILICATE COATINGS…………………………………. 41

34 71 13.16 VEHICLE CRASH BARRIERS………………………………. 47

04 01 20 - 2

2. Existing Brick: Test each type of existing masonry unit indicated for replacement, according to testing methods in ASTM C 67 for compressive strength, 24-hour cold-water absorption, 5-hour boil absorption, saturation coefficient, and initial rate of absorption

(suction).

3. Existing Mortar: Existing mortar has been tested by the VA under a separate contract. The results of this test can be found in specification Section 04 05 13, MASONRY MORTARING.

4. Replacement Brick: Test each proposed type of replacement masonry unit, according to sampling and testing methods in ASTM C 67 for compressive strength, 24-hour cold-water absorption, 5-hour boil absorption, saturation coefficient, and initial rate of absorption

(suction).

1.4 ACTION SUBMITTALS

A. Product Data: For each type of product indicated. Include recommendations for application and use. Include test data substantiating that products comply with requirements.

B. Samples for Initial Selection: For the following:

1. Pointing Mortar: Submit sets of mortar for pointing in the form of sample mortar strips, 6 inches long by 1/4 inch wide, set in aluminum or plastic channels.

a. Have each set contain a close color range of at least three

Samples of different mixes of colored sands and cements that produce a mortar matching the cleaned masonry when cured and dry.

b. Submit with precise measurements on ingredients, proportions, gradations, and sources of colored sands from which each Sample was made.

C. Samples for Verification: For the following:

1. Each type of masonry unit to be used for replacing existing units.

Include sets of Samples as necessary to show the full range of shape, color, and texture to be expected.

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a. For each brick type, provide straps or panels containing at least four bricks. Include multiple straps for brick with a wide range.

2. Each type of sand used for pointing mortar; minimum 1 lb. of each in plastic screw-top jars.

a. For blended sands, provide Samples of each component and blend.

b. Identify sources, both supplier and quarry, of each type of sand.

3. Each type, color, and texture of pointing mortar in the form of sample mortar strips, 6 inches long by 1/4 inch wide, set in aluminum or plastic channels.

a. Include with each Sample a list of ingredients with proportions of each. Identify sources, both supplier and quarry, of each type of sand and brand names of cementitious materials and pigments if any.

1.5 INFORMATIONAL SUBMITTALS

A. Qualification Data: For restoration specialists, including field supervisors and restoration workers, chemical-cleaner manufacturer and testing service.

B. Preconstruction Test Reports: For existing and replacement masonry units.

C. Quality-Control Program.

D. Restoration Program.

E. Cleaning Program.

1.6 APPLICABLE PUBLICATIONS

A. Publications listed below form a part of this specification to extent referenced. Publications are referenced in text by basic designation only.

B. American Society for Testing And Materials (ASTM):

C62 - 10 ...............Standard Specification for Building Brick

(Solid Masonry Units Made From Clay or Shale)

C67 - 11 ...............Standard Test Methods for Sampling and Testing

Brick and Structural Clay Tile

C216 - 11 ..............Standard Specification for Facing Brick (Solid

Masonry Units Made from Clay or Shale)

04 01 20 - 4

1.7 QUALITY ASSURANCE

A. Restoration Specialist Qualifications: Engage an experienced masonry restoration firm to perform work of this Section. Firms shall have completed work similar in material, design, and extent to that indicated for this Project with a record of successful in-service performance. Experience installing standard unit masonry is not sufficient experience for masonry restoration work.

1. Field Supervision: Restoration specialist firms shall maintain experienced full-time supervisors on Project site during times that clay masonry restoration and cleaning work is in progress.

Supervisors shall not be changed during Project except for causes beyond the control of restoration specialist firm.

2. Restoration Worker Qualifications: Persons who are experienced and specialize in restoration work of types they will be performing.

B. Restoration Bricklayers or Stone Masons:

1. Deteriorated material removal, material salvage, absorption control, mixing, re-pointing, curing, and finishing operations shall be performed Restoration Bricklayers or Stone Masons.

2. Before project start-up, every Restoration Bricklayer or Stone Mason shall perform mock-ups.

3. All members of the Masonry Crew shall be trained in procedures for handling historic and salvaged materials. During the progress of the project, if additional Masonry Crew Members are required due to personnel rotation and attrition or changes in the project schedule or the need to increase rate of production, the Subcontractor will be permitted to arrange for training of replacement or additional

Masonry Crew members providing, however, that at no time shall the number of approved Masonry Crew Members fall below seventy-five percent, nor two-thirds on any given crew of three, nor one-half of any given crew of two.

4. Replacement Crew Members must be approved by the COR via the submittal process and shall perform mock-ups.

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C. Source Limitations: Obtain each type of material for masonry restoration (face brick, mortar, sand, etc.) from one source with resources to provide materials of consistent quality in appearance and physical properties.

D. Quality-Control Program: Prepare a written quality-control program for this Project to systematically demonstrate the ability of personnel to properly follow methods and use materials and tools without damaging masonry. Include provisions for supervising performance and preventing damage due to worker fatigue.

E. Restoration Program: Prepare a written, detailed description of materials, methods, equipment, and sequence of operations to be used for each phase of restoration work including protection of surrounding materials and Project site.

1. Include methods for keeping pointing mortar damp during curing period.

2. If materials and methods other than those indicated are proposed for any phase of restoration work, add to the Quality-Control Program a written description of such materials and methods, including evidence of successful use on comparable projects, and demonstrations to show their effectiveness for this Project and worker's ability to use such materials and methods properly.

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F. Preinstallation Conference: Conduct conference at Project site.

1. Review methods and procedures related to masonry restoration and cleaning including, but not limited to, the following:

a. Construction schedule. Verify availability of materials, Restoration Specialist's personnel, equipment, and facilities needed to make progress and avoid delays.

b. Materials, material application, sequencing, tolerances, and required clearances.

1.8 DELIVERY, STORAGE, AND HANDLING

A. Deliver masonry units to Project site strapped together in suitable packs or pallets or in heavy-duty cartons.

B. Deliver other materials to Project site in manufacturer's original and unopened containers, labeled with manufacturer's name and type of products.

C. Store all materials on elevated platforms, under cover, and in a dry location.

D. Store hydrated lime in manufacturer's original and unopened containers.

Discard lime if containers have been damaged or have been opened for more than two days.

E. Store sand where grading and other required characteristics can be maintained and contamination avoided.

1.9 PROJECT CONDITIONS

A. Weather Limitations: Proceed with installation only when existing and forecasted weather conditions permit masonry restoration and cleaning work to be performed according to manufacturers' written instructions and specified requirements.

B. Repair masonry units and repoint mortar joints only when air temperature is between 40 and 90 deg F and is predicted to remain so for at least 7 days after completion of the Work unless otherwise indicated.

C. Cold-Weather Requirements: Comply with the following procedures for masonry repair and mortar-joint pointing unless otherwise indicated:

1. When air temperature is below 40 deg F, heat mortar ingredients, masonry repair materials, and existing masonry walls to produce temperatures between 40 and 120 deg F.

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2. When mean daily air temperature is below 40 deg F, provide enclosure and heat to maintain temperatures above 32 deg F within the enclosure for 7 days after repair and pointing.

D. Hot-Weather Requirements: Protect masonry repair and mortar-joint pointing when temperature and humidity conditions produce excessive evaporation of water from mortar and repair materials. Provide artificial shade and wind breaks and use cooled materials as required to minimize evaporation. Do not apply mortar to substrates with temperatures of 90 deg F and above unless otherwise indicated.

E. For manufactured repair materials, perform work within the environmental limits set by each manufacturer.

F. Clean masonry surfaces only when air temperature is 40 deg F and above and is predicted to remain so for at least 7 days after completion of cleaning.

1.10 COORDINATION

A. Coordinate masonry restoration and cleaning with public circulation patterns at Project site. Some work is near public circulation patterns and adjoining public and private property. Public circulation patterns cannot be closed off entirely, and in places can be only temporarily redirected around small areas of work. Plan and execute the

Work accordingly.

1.11 SEQUENCING AND SCHEDULING

A. Order replacement materials at earliest possible date to avoid delaying completion of the Work.

B. Order sand and portland cement for pointing mortar immediately after approval of Samples and mockups. Take delivery of and store at

Project site a sufficient quantity to complete Project.

C. Perform masonry restoration work in the following sequence:

1. Remove plant growth.

2. Rake out mortar from joints surrounding masonry to be replaced and from joints adjacent to masonry repairs along joints.

3. Repair masonry, including replacing existing masonry with new masonry materials.

4. Rake out mortar from all joints where plastering is exposed or scheduled to be removed.

5. Point mortar joints.

6. After repairs and repointing have been completed and cured, install lime based plastering.

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7. Inspect for open mortar joints and repair before cleaning to prevent the intrusion of water and other cleaning materials into the wall.

8. Clean all wall surfaces.

9. Install sol silicate coatings to all wall surfaces.

PART 2 - PRODUCTS

2.1 MASONRY MATERIALS

A. Face Brick: Provide face brick, including specially molded, ground, cut, or sawed shapes where required to complete masonry restoration work.

1. Provide units with colors, color variation within units, surface texture, size, and shape to match existing brickwork and with physical properties within 10 percent of those determined from preconstruction testing of selected existing units.

a. For existing brickwork that exhibits a range of colors or color variation within units, provide brick that proportionally matches that range and variation rather than brick that matches an individual color within that range.

2. Special Shapes:

a. Provide specially molded, 100 percent solid shapes for applications where core holes or "frogs" could be exposed to view or weather when in final position and where shapes produced by sawing would result in sawed surfaces being exposed to view.

b. Mechanical chopping or breaking brick, or bonding pieces of brick together by adhesive, are not acceptable procedures for fabricating special shapes.

3. Tolerances as Fabricated: Comply with tolerance requirements in

ASTM C 216, Type FBS.

B. Building Brick: Provide building brick complying with ASTM C 62, of same vertical dimension as face brick, for masonry work concealed from view.

1. Grade SW where in contact with earth.

2. Grade SW, MW, or NW for concealed backup.

C. Salvaged Brick: Salvaged brick from areas of wall demolition can be used. Clean off residual mortar.

2.2 MORTAR MATERIALS

A. Masonry mortaring materials shall be in accordance with Section 04 05

13, MASONRY MORTARTING.

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2.3 PAINT REMOVERS

A. Solvent-Type Paint Remover: Manufacturer's standard water-rinsable, solvent-type gel formulation for removing paint coatings from masonry.

B. Low-Odor, Solvent-Type Paint Remover: Manufacturer's standard low-odor, water-rinsable solvent-type gel formulation, containing no methanol or methylene chloride, for removing paint coatings from masonry.

2.4 CLEANING MATERIALS

A. Water: Potable.

B. Hot Water: Water heated to a temperature of 140 to 160 deg F.

C. Nonacidic Liquid Cleaner: Manufacturer's standard mildly alkaline liquid cleaner formulated for removing mold, mildew, and other organic soiling from ordinary building materials, including stone, brick, aluminum, plastics, and wood.

2.5 ACCESSORY MATERIALS

A. Miscellaneous Products: Select materials and methods of use based on the following, subject to approval of a mockup:

1. Previous effectiveness in performing the work involved.

2. Little possibility of damaging exposed surfaces.

3. Consistency of each application.

4. Uniformity of the resulting overall appearance.

5. Do not use products or tools that could do the following:

a. Remove, alter, or in any way harm the present condition or future preservation of existing surfaces, including surrounding surfaces not in contract.

b. Leave a residue on surfaces.

2.6 MORTAR MIXES

A. Provide mortar mixes as indicated in specification Section 04 05 13, MASONRY MORTARING.

1. Mixing Pointing Mortar: Thoroughly mix cementitious materials and sand together before adding any water. Then mix again adding only enough water to produce a damp, unworkable mix that will retain its form when pressed into a ball. Maintain mortar in this dampened condition for 15 to 30 minutes. Add remaining water in small portions until mortar reaches desired consistency. Use mortar within one hour of final mixing; do not retemper or use partially hardened material.

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2.7 CHEMICAL CLEANING SOLUTIONS

A. Dilute chemical cleaners with water to produce solutions not exceeding concentration recommended by chemical-cleaner manufacturer.

PART 3 - EXECUTION

3.1 RESTORATION SPECIALISTS

A. Restoration Specialist Firms: Subject to compliance with requirements, provide masonry restoration to oversee the work.

3.2 PROTECTION

A. Protect persons, motor vehicles, surrounding surfaces of cemetery wall being restored, building site, plants, surrounding buildings and memorial markers from harm resulting from masonry restoration work.

B. Comply with chemical-cleaner manufacturer's written instructions for protecting building and other surfaces against damage from exposure to its products. Prevent chemical-cleaning solutions from coming into contact with people, motor vehicles, landscaping, buildings, and other surfaces that could be harmed by such contact.

1. Cover adjacent surfaces with materials that are proven to resist chemical cleaners used unless chemical cleaners being used will not damage adjacent surfaces. Use materials that contain only waterproof, UV-resistant adhesives. Apply masking agents to comply with manufacturer's written instructions. Do not apply liquid masking agent to painted or porous surfaces. When no longer needed, promptly remove masking to prevent adhesive staining.

2. Keep wall wet below area being cleaned to prevent streaking from runoff.

3. Do not clean masonry during winds of sufficient force to spread cleaning solutions to unprotected surfaces.

4. Neutralize and collect alkaline and acid wastes for disposal off

Owner's property.

5. Dispose of runoff from cleaning operations by legal means and in a manner that prevents soil erosion, undermining of paving and foundations, damage to landscaping, and water penetration into building interiors.

C. Prevent mortar from staining face of surrounding masonry and other surfaces.

1. Cover wall, ledges, and projections to protect from mortar droppings.

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2. Keep wall area wet below rebuilding and pointing work to discourage mortar from adhering.

3. Immediately remove mortar in contact with exposed masonry and other surfaces.

3.3 TEMPORARY SHIM SUPPORT

A. Provide temporary supports where necessary to prevent displacement of masonry during re-pointing and until mortar has achieved sufficient strength.

B. Notify COR of need for temporary support and provide mock-up of temporary support.

3.4 BRICK REMOVAL AND REPLACEMENT

A. At locations indicated, remove bricks that are damaged, spalled, or deteriorated or are to be reused. Carefully demolish or remove entire units from joint to joint, without damaging surrounding masonry, in a manner that permits replacement with full-size units.

1. When removing single bricks, remove material from center of brick and work toward outside edges.

B. Support and protect remaining masonry that surrounds removal area.

Maintain flashing, reinforcement, lintels, and adjoining construction in an undamaged condition.

C. Remove in an undamaged condition as many whole bricks as possible.

1. Remove mortar, loose particles, and soil from brick by cleaning with hand chisels, brushes, and water.

2. Store brick for reuse. Store off ground, on skids, and protected from weather.

3. Deliver cleaned brick not required for reuse to COR unless otherwise indicated.

D. Clean bricks surrounding removal areas by removing mortar, dust, and loose particles in preparation for replacement.

E. Replace removed damaged brick with other removed brick and salvaged brick in good quality, where possible, or with new brick matching existing brick, including size. Do not use broken units unless they can be cut to usable size.

F. Install replacement brick into bonding and coursing pattern of existing brick. If cutting is required, use a motor-driven saw designed to cut masonry with clean, sharp, unchipped edges.

1. Maintain joint width for replacement units to match existing joints.

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2. Use setting buttons or shims to set units accurately spaced with uniform joints.

G. Lay replacement brick with completely filled bed, head, and collar joints. Butter ends with sufficient mortar to fill head joints and shove into place. Wet both replacement and surrounding bricks that have ASTM C 67 initial rates of absorption (suction) of more than

30 g/30 sq. in. per min.. Use wetting methods that ensure that units are nearly saturated but surface is dry when laid.

1. Tool exposed mortar joints in repaired areas to match joints of surrounding existing brickwork.

2. Rake out mortar used for laying brick before mortar sets and point new mortar joints in repaired area to comply with requirements for repointing existing masonry, and at same time as repointing of surrounding area.

3. When mortar is sufficiently hard to support units, remove shims and other devices interfering with pointing of joints.

3.5 PAINTING STEEL UNCOVERED DURING THE WORK

A. Inspect steel exposed during masonry removal. Where COR determines that it is structural, or for other reasons cannot be totally removed, prepare and paint it as follows:

1. Remove paint, rust, and other contaminants according to SSPC-SP 2, "Hand Tool Cleaning" or SSPC-SP 3, "Power Tool Cleaning", as applicable to meet paint manufacturer's recommended preparation.

2. Immediately paint exposed steel with two coats of antirust coating, following coating manufacturer's written instructions and without exceeding manufacturer's recommended rate of application (dry film thickness per coat).

B. If on inspection and rust removal, the cross section of a steel member is found to be reduced from rust by more than 1/16 inch, notify

Architect before proceeding.

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3.6 REPOINTING MASONRY

A. Rake out and repoint joints existing exposed and joints exposed by the removal of plastering. All existing cement mortar must be carefully removed by skilled Restoration Bricklayers or Stone Masons. Existing historic lime-based mortar shall be removed by hand. Use only hand or pneumatic stone carving chisels that are no wider than one half the width of the existing masonry joints.

B. Do not rake out and repoint joints where not required.

C. Rake out joints as follows, according to procedures demonstrated in approved mockup:

1. Remove mortar from joints to depth of joint width plus 1/8 inch, but not less than 1/2 inch or not less than that required to expose sound, unweathered mortar.

2. Remove mortar from masonry surfaces within raked-out joints to provide reveals with square backs and to expose masonry for contact with pointing mortar. Brush, vacuum, or flush joints to remove dirt and loose debris.

3. Do not spall edges of masonry units or widen joints. Replace or patch damaged masonry units as directed by COR and as indicated on the drawings.

a. Cut out center of mortar bed joints using angle grinders with diamond-impregnated metal blades. Remove remaining mortar by hand with chisel and resilient mallet. Strictly adhere to approved quality-control program. Do not grind mortar from any surface of the host masonry.

D. Notify COR of unforeseen detrimental conditions including voids in mortar joints, cracks, loose masonry units, and other deteriorated items.

E. Pointing with Mortar:

1. Rinse joint surfaces with water to remove dust and mortar particles.

Time rinsing application so, at time of pointing, joint surfaces are damp but free of standing water. If rinse water dries, dampen joint surfaces before pointing. Do not rinse when temperature is below freezing.

2. Apply pointing mortar first to areas where existing mortar was removed to depths greater than surrounding areas. Apply in layers not greater than 3/8 inch until a uniform depth is formed. Fully

04 01 20 - 14 compact each layer thoroughly and allow it to become thumbprint hard before applying next layer.

3. After low areas have been filled to same depth as remaining joints, point all joints by placing mortar in layers not greater than 3/8 inch. Fully compact each layer and allow to become thumbprint hard before applying next layer. Where existing masonry units have worn or rounded edges, slightly recess finished mortar surface below face of masonry to avoid widened joint faces. Take care not to spread mortar beyond joint edges onto exposed masonry surfaces or to featheredge the mortar.

4. When mortar is thumbprint hard, tool joints to match original appearance of joints as demonstrated in approved mockup. Remove excess mortar from edge of joint by brushing.

5. Cure mortar by maintaining in thoroughly damp condition for at least

72 consecutive hours including weekends and holidays.

a. Acceptable curing methods include covering with wet burlap and plastic sheeting, periodic hand misting, and periodic mist spraying using system of pipes, mist heads, and timers.

b. Adjust curing methods to ensure that pointing mortar is damp throughout its depth without eroding surface mortar.

6. Hairline cracking within the mortar or mortar separation at edge of a joint is unacceptable. Completely remove such mortar and repoint.

F. Where repointing work precedes cleaning of existing masonry, allow mortar to harden at least 30 days before beginning cleaning work.

3.7 FINAL CLEANING

A. After mortar has fully hardened, thoroughly clean exposed masonry surfaces of excess mortar and foreign matter; use wood scrapers, stiff-nylon or -fiber brushes, and clean water, spray applied at low pressure.

1. Do not use metal scrapers or brushes.

2. Do not use acidic or alkaline cleaners.

B. Sweep and rake adjacent pavement and grounds to remove mortar and debris. Where necessary, pressure wash pavement surfaces to remove mortar, dust, dirt, and stains.

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06-01-14

04 05 13- 1

SECTION 04 05 13

MASONRY MORTARING

PART 1 - GENERAL

1.1 DESCRIPTION:

A. Section specifies mortar materials and mixes required for repairs to historic masonry walls. Historic mixes shall be used to minimize damage to existing and historic unit masonry.

1.2 RELATED WORK:

A. Mortar Color: Match existing. Submit to COR for approval.

B. Section 01 45 29: TESTING LABORATORY SERVICES.

C. Section 04 20 00: UNIT MASONRY.

1.3 TESTING LABORATORY-CONTRACTOR RETAINED

A. Engage a commercial testing laboratory approved by Project Engineer and

COR to perform tests specified.

B. Submit information regarding testing laboratory's facilities and qualifications of technical personnel to Project Engineer.

1.4 TESTS

A. Test materials proposed for use for compliance with specifications in accordance with test methods contained in referenced specifications and as follows:

B. Mortar:

1. Test for compressive strength and water retention; ASTM C270.

2. Mortar compressive strengths as follows:

a. At 7 days: Minimum 250psi, maximum 400psi.

b. At 28 days: Minimum 275psi, maximum 500psi.

c. At 180 days: Minimum 800psi, maximum 1300psi.

d. At 365 days: Minimum 1200psi, maximum 1800psi.

C. Cement:

1. Test for water soluble alkali (nonstaining) when nonstaining cement is specified.

2. Nonstaining cement shall contain not more than 0.03 percent water soluble alkali.

D. Sand: Test for deleterious substances, organic impurities, soundness and grading.

1.5 SUBMITTALS

A. Submit in accordance with Section 01 33 23, SHOP DRAWINGS, PRODUCT

DATA, AND SAMPLES.

04 05 13- 2

B. Certificates:

1. Testing laboratory's facilities and qualifications of its technical personnel.

2. Indicating that following items meet specifications:

a. Portland cement.

b. Masonry cement.

c. Mortar cement.

d. Natural Hydraulic lime.

e. Fine aggregate (sand).

f. Color admixture.

C. Laboratory Test Reports:

1. Mortar, each type.

2. Admixtures.

D. Manufacturer's Literature and Data:

1. Cement, each kind.

2. Hydraulic lime.

3. Admixtures.

4. Liquid acrylic resin.

1.6 PRODUCT DELIVERY, STORAGE AND HANDLING

A. Deliver masonry materials in original sealed containers marked with name of manufacturer and identification of contents.

B. Store masonry materials under waterproof covers on planking clear of ground, and protect damage from handling, dirt, stain, water and wind.

1.7 APPLICABLE PUBLICATIONS

A. Publications listed below form a part of specification to extent referenced. Publications are referenced in text by basic designation only.

B. American Society for Testing and Materials (ASTM):

C40-11..................Organic Impurities in Fine Aggregates for

Concrete

C91-12..................Masonry Cement

C109-11.................Compressive Strength of Hydraulic Cement

Mortars (Using 2-in. or 50-MM Cube Specimens)

C141/C141M..............Standard Specification for Hydrated Hydraulic

Lime for Structural Purposes

C144-04.................Aggregate for Masonry Mortar

C150-12.................Portland Cement

04 05 13- 3

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

C270-12.................Mortar for Unit Masonry

C595-13.................Blended Hydraulic Cement

C780-10.................Preconstruction and Construction Evaluation of

Mortars for Plain and Reinforced Unit Masonry

C979-10.................Pigments for Integrally Colored Concrete

C1329-12................Mortar Cement

PART 2 - PRODUCTS

2.1 HYDRAULIC LIME

A. Pure and natural hydraulic lime. Shall confirm to ASTM C141/C141M.

Shall conform to European Norm (EN 459) and French Norm NFP 15.311.

Strength factor of 5 (Eminently hydraulic).

2.2 AGGREGATE FOR MASONRY MORTAR

A. ASTM C144 and as follows:

1. Light colored sand for mortar for laying face brick.

2. White plastering sand meeting sieve analysis for mortar joints for pointing and laying of structural facing tile units except that 100 percent passes No. 8 sieve, and not more than 5 percent retained on

No. 16 sieve. As stated below in C., well graded “play” sand (3mm to 75microns) shall be used.

B. Test sand for color value in accordance with ASTM C40. Sand producing color darker than specified standard is unacceptable.

C. Well graded “play” sand shall be used for all historic wall repairs: #6

(3mm) to #200 (75 microns).

2.3 BLENDED HYDRAULIC CEMENT

A. ASTM C595, Type IS, IP.

2.6 PORTLAND CEMENT

A. ASTM C150, Type I.

B. Use white Portland cement wherever white mortar is needed to match existing.

2.7 LIQUID ACRYLIC RESIN

A. A formulation of acrylic polymers and modifiers in liquid form designed for use as an additive for mortar to improve physical properties.

2.8 WATER

B. Potable, free of substances that are detrimental to mortar, masonry, and metal.

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2.9 COLOR ADMIXTURE

A. Pigments: ASTM C979.

B. Use mineral pigments only. Organic pigments are not acceptable.

C. Pigments inert, stable to atmospheric conditions, nonfading, alkali resistant and water insoluble.

PART 3 - EXECUTION

3.1 MIXING

A. Mix in a mechanically operated mortar mixer.

1. Mix mortar for at least three minutes but not more than five minutes.

B. Measure ingredients by volume. Measure by the use of a container of known capacity.

C. Mix water with dry ingredients in sufficient amount to provide a workable mixture which will adhere to vertical surfaces of masonry units.

D. Mortar that has stiffened because of loss of water through evaporations:

1. Re-tempered by adding water to restore to proper consistency and workability.

2. Discard mortar that has reached its initial set or has not been used within two hours.

E. Pointing Mortar:

1. Mix dry ingredients with enough water to produce a damp mixture of workable consistency which will retain its shape when formed into a ball.

2. Allow mortar to stand in dampened condition for one to 1-1/2 hours.

3. Add water to bring mortar to a workable consistency prior to application.

04 20 00 - 1

SECTION 04 20 00

UNIT MASONRY

PART 1 - GENERAL

1.1 DESCRIPTION

This section specifies requirements for replacement of masonry unit within walls.

1.2 RELATED WORK

A. Mortars and grouts: Section 04 05 13, MASONRY MORTARING.

B. Section 04 01 20, MAINTENANCE OF UNIT MASONRY.

1.3 SUBMITTALS

A. Submit in accordance with Section 01 33 23, SHOP DRAWINGS, PRODUCT DATA

AND SAMPLES.

B. Samples:

1. Face brick, sample panel, 200 mm by 400 mm (8 inches by 16 inches,) showing full color range and texture of bricks, bond, and proposed mortar joints.

2. Anchors, and ties, one each and joint reinforcing 305 mm (12 inches) long.

C. Certificates:

1. Certificates signed by manufacturer, including name and address of contractor, project location, and the quantity, and date or dates of shipment of delivery to which certificate applies.

2. Indicating that the following items meet specification requirements:

a. Face brick.

3. Testing laboratories facilities and qualifications of its principals and key personnel to perform tests specified.

D. Manufacturer's Literature and Data:

1. Anchors, ties, and reinforcement.

1.4 APPLICABLE PUBLICATIONS

A. Publications listed below form a part of this specification to the extent referenced. Publications are referenced in the text by the basic designation only.

B. American Society for Testing and Materials (ASTM):

C67-08..................Sampling and Testing Brick and Structural Clay

Tile

C216-07a................Facing Brick (Solid Masonry Units Made From Clay or Shale)

C. Masonry Industry Council:

Hot and Cold Weather Masonry Construction Manual,1999.

04 20 00 - 2

D. Brick Industry Association - Technical Notes on Brick Construction

(BIA):

11-2001.................Guide Specifications for Brick Masonry, Part I

11A–1988................Guide Specifications for Brick Masonry, Part II

11B–1988................Guide Specifications for Brick Masonry, Part III

Execution

11C-1998................Guide Specification for Brick Masonry Engineered

Brick Masonry, Part IV

11D-1988................Guide Specifications for Brick Masonry

Engineered Brick Masonry, Part IV continued

11E-1991................Guide Specifications for Brick Masonry, Part V

E. Masonry Standards Joint Committee; Specifications for Masonry Structures

(ACI 530.1-08/ASCE 6-05/TMS 602-05) (MSJC).

PART 2 - PRODUCTS

2.1 BRICK

A. Face Brick:

1. ASTM C216, Grade SW, Type FBS.

2. Brick when tested in accordance with ASTM C67: Classified slightly efflorescent or better.

3. Size:

a. Modular

b. Size of brick shall match existing.

4. Color and texture of brick shall match existing, where color of existing historic brick varies, provide brick having a full color range to match existing conditions.

5. Provide solid (non-cored) brick where existing wall configuration/brick layout cores will expose brick cores.

2.2 ACCESSORIES

A. Masonry Cleaner:

1. Detergent type cleaner selected for each type masonry used.

2. Acid cleaners are not acceptable.

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

PART 3 - EXECUTION

3.1 JOB CONDITIONS

A. Protection:

1. Cover tops of walls with nonstaining waterproof covering, when work is not in progress. Secure to prevent wind blow off.

04 20 00 - 3

2. On new work protect base of wall from mud, dirt, mortar droppings, and other materials that will stain face, until final landscaping or other site work is completed.

B. Cold Weather Protection:

1. Masonry may be laid in freezing weather when methods of protection are utilized.

2. Comply with MSJC and “Hot and Cold Weather Masonry Construction

Manual”.

3.2 CONSTRUCTION TOLERANCES

A. Lay masonry units plumb, level and true to line within the tolerances as per MSJC requirements and as follows:

B. Maximum variation from plumb:

1. In 3,000 mm (10 feet) - 6 mm (1/4 inch).

2. In 6,000 mm (20 feet) - 10 mm (3/8 inch).

C. Maximum variation from level:

1. In any bay or up to 6,000 mm (20 feet) - 6 mm (1/4 inch).

2. In 12,000 mm (40 feet) or more - 13 mm (1/2 inch).

D. Maximum variation in cross-sectional dimensions of piers and thickness of walls from dimensions shown:

1. Minus 6 mm (1/4 inch).

2. Plus 13 mm (1/2 inch).

3.3 INSTALLATION GENERAL

A. Keep finish work free from mortar smears or spatters, and leave neat and clean.

B. Anchor masonry as specified in Paragraph, ANCHORAGE.

C. Tooling Joints:

1. Do not tool until mortar has stiffened enough to retain thumb print when thumb is pressed against mortar.

2. Tool while mortar is soft enough to be compressed into joints and not raked out.

3. Finish joints in exterior face masonry work with a jointing tool, and provide smooth, water-tight concave joint unless specified otherwise.

4. Tool Exposed interior joints in finish work concave unless specified otherwise.

D. Before connecting new masonry with previously laid, remove loosened masonry or mortar, and clean and wet work in place as specified under wetting.

E. Wetting and Wetting Test:

1. Test and wet brick in accordance with BIA 11B.

2. Do not wet concrete masonry units before laying.

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3.4 BRICKWORK

A. Lay clay replacement brick in accordance with BIA Technical Note 11 series.

B. Laying:

1. Lay brick in running bond with course of masonry bonded at corners unless shown otherwise. Match bond of existing adjacent walls on alterations and additions.

2. Maintain bond pattern throughout.

3. Do not use brick smaller than half-brick at any angle, corner, or break.

4. Where length of cut brick is greater than one half but less than a whole brick, maintain the vertical joint location of such units.

C. Joints:

1. Joint widths: Lay for three equal joints in 200 mm (eight inches) vertically, unless existing wall construction differs otherwise.

3.5 PLACING REINFORCEMENT

A. General: Clean reinforcement of loose rust, mill scale, earth, ice or other materials which will reduce bond to mortar or grout.

B. Embed prefabricated horizontal joint reinforcement as the work progresses, with a minimum cover of 15 mm (5/8 inch) on exterior face of walls and 13 mm (1/2 inch) at other locations. Lap joint reinforcement not less than 150 mm (6 inches) at ends. Use prefabricated “L” and “T” sections to provide continuity at corners and intersections. Cut and bend joint reinforcement as recommended by manufacturer for continuity at returns, offsets, and other special conditions.

3.6 CLEANING AND REPAIR

A. General:

1. Clean exposed masonry surfaces on completion.

2. Protect adjoining construction materials and landscaping during cleaning operations.

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

(3/4 inch) and repoint. See Section 04 01 20, MAINTENANCE OF UNIT

MASONRY for additional requirements on repointing masonry.

4. Remove mortar droppings and other foreign substances from wall surfaces.

B. Brickwork:

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

04 20 00 - 5

2. Brush with stiff fiber brushes while washing, and immediately thereafter hose down with clean water.

3. Free clean surfaces of traces of detergent, foreign streaks, or stains of any nature which may affect the installation of the

Portland cement plastering.

04 72 00 - 1

SECTION 04 72 00

CAST STONE MASONRY

PART 1 - GENERAL

1.1 DESCRIPTION

A. This sections specifies manufactured concrete units to simulate a natural stone.

B. Installation of cast stone units.

1.2 RELATED WORK

A. Setting and pointing mortar: Section 04 05 13, MASONRY MORTARING.

1.3 SUBMITTALS

A. Submit in accordance with Section 01 33 23, SHOP DRAWINGS, PRODUCT DATA, AND SAMPLES.

B. Samples:

1. Cast stone, sample panel, size 100 by 300 by 300 mm (4 by 12 by 12 inches) each color and finish.

2. Show finish on two 100 mm (4-inch) edges and 300 by 300 mm (12 by 12 inch) surface.

C. Shop Drawings:

1. Cast stone showing exposed faces, profiles, cross sections, anchorage, reinforcing, jointing and sizes.

2. Setting drawings with setting mark.

D. Certificates: Test results indicating that the cast stone meets specification requirements and proof of plant certification.

E. Submit manufacturers test results of cast stone previously made by manufacturer.

F. Laboratory Data: Description of testing laboratories facilities and qualifications of its principals and key personnel.

G. List of jobs furnished by the manufacturer, which were similar in scope and at least three (3) years of age.

1.4 PRODUCT DELIVERY, STORAGE AND HANDLING

A. Store cast stone under waterproof covers on planking clear of ground.

B. Protect from handling, dirt, stain, and water damage.

C. Mark production units with the identification marks as shown on the shop drawings.

D. Package units and protect them from staining or damage during shipping and storage.

E. Provide an itemized list of product to support the bill of lading.

04 72 00 - 2

1.5 WARRANTY

Warranty exterior masonry walls against moisture leaks, any defects and subject to terms of "Warranty of Construction", FAR clause 52.246-21, except that warranty period shall be two years.

1.6 APPLICABLE PUBLICATIONS

A. Publications listed below form a part of this specification to extent referenced. Publications are referenced in text by the basic designation only. Comply with applicable provisions and recommendations of the following, except as otherwise shown or specified.

B. Cast Stone Institute Technical Manual and Cast Stone Institute standard specifications.

C. American Society for Testing and Materials (ASTM):

A167-99 (2004)..........Stainless and Heat Resisting Chromium-Nickel

Steel Plate, Sheet, and Strip

A185-07.................Steel, Welded Wire Fabric, Plain for Concrete

A615/A615M-09...........Deformed and Plain Billet-Steel Bars for

Concrete Reinforcement

C33-07..................Concrete Aggregates

C150-07.................Portland Cement

C173 / C173M - 10b .....Standard Test Method for Air Content of Freshly

Mixed Concrete by the Volumetric Method

C231 / C231M - 10 ......Standard Test Method for Air Content of Freshly

Mixed Concrete by the Pressure Method

C260 / C260M - 10a .....Standard Specification for Air-Entraining

Admixtures for Concrete

C426 - 10 ..............Standard Test Method for Linear Drying Shrinkage of Concrete Masonry Units

C494 / C494M - 11 ......Standard Specification for Chemical Admixtures for Concrete

C503-08.................Marble Dimension Stone (Exterior)

C568-08.................Limestone Dimension Stone

C615-03.................Granite Dimension Stone

C616-08.................Quartz-Based Dimension Stone

C618 - 08a .............Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete

C979-05.................Pigments for Integrally Colored Concrete

C989 / C989M - 11 ......Standard Specification for Slag Cement for Use in Concrete and Mortars

C1194-03................Compressive Strength of Architectural Cast Stone

C1195-03................Absorption of Architectural Cast Stone

04 72 00 - 3

C1364-07................Architectural Cast Stone.

D2244-07................Calculation of Color Differences from

Instrumentally Measured Color Coordinates.

1.7 QUALITY ASSURANCE

A. The Manufacturer:

1. Must have ten (5) years minimum continuous operating experience and have facilities for manufacturing cast stone as described herein.

Manufacturer shall have sufficient plant facilities to produce the shapes, quantities and size of cast stone required in accordance with the project schedule.

2. Must be a member of the Cast Stone Institute.

3. Must have a certified plant (certification by the Cast Stone

Institute).

B. Stone setter: Must have ten (5) years experience setting cast or natural building stone.

C. Testing: One (1) sample from production units may be selected at random from the field for each 500 cubic feet (14 m3) delivered to the job:

1. Three (3) field cut cube specimens from each of these sample shall have an average minimum compressive strength of not less than 85% with no single specimen testing less than 75% of design strength as specified.

2. Three (3) field cut cube specimens from each of these samples shall have an average maximum cold-water absorption of 6%.

3. Field specimens shall be tested in accordance with ASTMC 1194 and C

1195.

4. Manufacturer shall submit a written list of projects similar and at least three (3) years of age, along with owner, architect and contractor references.

1.8 MANUFACTURING TOLERANCES

A. Cross section dimensions shall not deviate by more than + 1/8 in. (3 mm) from approved dimension.

B. Length of units shall not deviate by more than length /360 or + 1/8 in.

(3mm), whichever is greater, not to exceed + 1/4 in (6 mm). Maximum length of any unit shall not exceed 15 times the average thickness of such unit unless otherwise agreed by the manufacturer.

C. Warp bow or twist of units shall not exceed length/360 or + 1/8 in. (3 mm), whichever is greater.

04 72 00 - 4

D. Location of dowel holes, anchor slots, and similar features – On formed sides of unit, 1/8 in (3 mm), on unformed sides of unit, 3/8 in (9 mm) maximum deviation.

PART 2 - PRODUCTS

2.1 ARCHITECTURAL CAST STONE

A. Comply with ASTM C 1364

B. Physical properties: Provide the following:

1. Compressive Strength – ASTM C 1194: 6,500 psi (45 Mpa) minimum for products at 28 days.

2. Absorption – ASTM C 1195: 6% maximum by the cold water method, or 10% maximum by the boiling method for products as 28 days.

3. Air Content – ASTM C173 or C231, for wet cast product shall be 4-8% for units exposed to freeze-thaw environments. Air entrainment is not required for vibrant dry tamp (VDT) products.

4. Freeze thaw - ASTM C 1364L The cumulative percent weight loss (CPWL) shall be less than 5% after 300 cycles of freezing and thawing.

5. Linear Shrinkage - ASTM C 426L Shrinkage shall not exceed 0.065%.

C. Job site testing – One (1) sample from production units may be selected at random from the field for each 500 cubic feet (14m3) delivered to the job site:

1. Three (3) field cut cube specimens from each of these samples shall have an average minimum compressive strength of not less than 85% with no single specimen testing less than 75% of design strength as allowed by ACI 318.

2. Three (3) field cut cube specimens from each of these samples shall have an average maximum cold-water absorption of 6%.

3. Field specimens shall be tested in accordance with ASTM C 1194 and C

1195.

2.2 RAW MATERIALS

A. Portland cement – Type I or Type III, white and/or grey, ASTM C 150.

B. Coarse aggregates – Granite, quartz or limestone, ASTM C 33, except for gradation, and are optional for the vibrant dry tamp (VDT) casting method.

C. Fine aggregates – Manufactured or natural sands, ASTM C 33, except for gradation.

D. Colors – Inorganic iron oxide pigments, ASTM C 979 except that carbon black pigments shall not be used.

E. Admixtures- Comply with the following:

1. ASTM C 260 for air-entraining admixtures.

04 72 00 - 5

3. Other admixtures: integral water repellents and other chemicals, for which no ASTM Standard exists, shall be previously established as suitable for use in concrete by proven field performance or through laboratory testing.

4. ASTM C 618 mineral admixtures of dark and variable colors shall not be used in surfaces intended to be exposed to view.

5. ASTM C 989 granulated blast furnace slag may be used to improve physical properties. Tests are required to verify these features.

F. Water – Potable

G. Reinforcing bars:

1. ASTM A 615/A 615M. Grade 40 or 60 steel galvanized or epoxy coated when cover is less than 1.5 in. (37 mm).

2. Welded Wire Fabric: ASTM A 185 where applicable for wet cast units.

H. All anchors, dowels and other anchoring devices and shims shall be standard building stone anchors commercially available in a non-corrosive material such as brass, or stainless steel Type 302 or 304.

2.3 COLOR AND FINISH

A. Match sample to existing pier and/or wall cap.

B. All surfaces intended to be exposed to view shall have a fine-grained texture similar to natural stone, with no air voids in excess of 1/32

in. (0.8 mm) and the density of such voids shall be less than 3 occurrences per any 1 in2 (25mm2) and not obvious under direct daylight illumination at a 5 ft. (1.5m)distance.

C. Units shall exhibit a texture approximately equal to the approved sample when viewed under direct daylight illumination at a 10 ft (3m) distance.

D. ASTM D 2244 permissible variation in color between units of comparable age subjected to similar weathering exposure.

1. Total color difference – not greater than 6 units.

2. Total hue difference-not greater than 2 units.

2.4 REINFORCING

A. Reinforce the units as required and for safe handling and structural stress.

1. Minimum reinforcing shall be 0.25 percent of the cross section area.

B. Reinforcement shall be non-corrosive where faces exposed to weather are covered with less than 1.5in. (38 mm) of concrete material. All reinforcement shall have minimum coverage of twice the diameter of the bars.

2. ASTM C 494/C 495 M Types A-G for water reducing, retarding, accelerating and high range admixtures.

04 72 00 - 6

C. Minor chipping resulting from shipment and delivery shall not be grounds for rejection. Minor chips shall not be obvious under direct daylight illumination from a 20-ft (6m) distance.

D. The occurrence of crazing or efflorescence shall not constitute a cause for rejection.

E. Remove cement film, if required, from exposed surface prior to packaging for shipment.

2.5 CURING

Cure units in a warm curing chamber 1000 F (537.8 C) at 95 percent relative humidity for approximately 12hours, or cure in a 95 percent moist environment at a minimum 700F (371.1 C) for 16 hours after casting. Additional yard curing at 95 percent relative humidity shall be

350-degree-days (i.e. 7 days @ 500F (260.0 C) or 5 days @ 700F (371.1 C) prior to shipping. Form cured units shall be protected from moisture evaporation with curing blankets or curing compounds after casting.

PART 3 - EXECUTION

3.1 EXAMINATION

Installing contractor shall check cast stone materials for fit and finish prior to installation. Do not set unacceptable units.

3.2 SETTING TOLERANCES

A. Comply with Cast Stone Institute SM Technical Manual.

B. Set stones 1/8 in. (3 mm) or less, within the plane of adjacent units.

C. Joints, plus – 1/6 in. (1.5 mm), minus – 1/8 in. (3 mm).

3.3 JOINTING

A. Joint size:

1. At stone/brick joints 3/8 in. (9.5 cm).

2. Stone/stone joint exposed on top 3/8 in. (9.5 mm).

B. Joint Materials:

1. Mortar, Provide…