044010 CutStoneAssemblies.pdf

TALLAHASSEE NATIONAL CEMETERY PROJECT NO. 937CM3002

GRAVESITE EXPANSION SEPTEMBER 7, 2023

BID DOCUMENTS – RFI RESPONSE

CUT STONE ASSEMBLIES

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SECTION 04 40 10

CUT STONE ASSEMBLIES

PART - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract include Section 01

00 00, GENERAL REQUIREMENTS, apply to this Section.

1.2 SUMMARY

A. Section includes work for furnishing and installing all cut stone for the project. This section includes, but is not limited to, the following applications and basis of design for the cut stone masonry for the following assemblies:

1. Granite (polished): Service Emblem walls at Committal Service

Shelters.

B. Related Sections:

1. Section 07 92 00, JOINT SEALANTS for joining cut stone assemblies to various adjoining materials as indicated.

1.3 SUBMITTALS

A. Product Data: For each type of product indicated.

1. For stone varieties proposed for use on Project, include test data indicating compliance with physical properties specified or as required by applicable referenced ASTM standards.

B. Samples for Initial Selection: For mortar color and other items involving color selection.

C. Samples for Verification:

1. For each stone type indicated. Include at least three samples in each set for each type of stone, exhibiting extremes of the full range of color and other visual characteristics expected in completed work. Samples will establish the standard by which stone provided will be judged.

2. For each color of mortar required. Label Samples to indicate types and amounts of pigments used.

D. Qualification Data: For Qualified Installer as indicated herein below.

1.4 QUALITY ASSURANCE

A. Installer Qualifications: Cut stone installer(s) shall have been regularly engaged for at least three years in installation of cut stones similar to those for this project. The installer company as

04 40 10 - 2 well as the individual tradesman (stone masons and stone fitters) performing the actual installation shall meet the minimum three-year experience criteria. The Contractor shall submit written documentation as a submittal item, demonstrating compliance with these quality requirements.

B. Source Limitations for Stone: Obtain each variety of stone, regardless of finish, from one quarry with resources to provide materials of consistent quality in appearance and physical properties.

C. Source Limitations for Mortar Materials: Obtain mortar ingredients of a uniform quality, including color for exposed masonry, from single manufacturer for each cementitious component and from single source or producer for each aggregate.

D. Pre-installation Conference: Conduct conference at Project site prior to initiating the work for these elements with the COR, Contractor and all of the sub-contractors that will be working on the elements and if possible, the appropriate design A/E team member(s).

1.5 DELIVERY, STORAGE, AND HANDLING

A. Store cementitious materials on elevated platforms, under cover, and in a dry location. Do not use cementitious materials that have become damp.

B. Store aggregates where grading and other required characteristics can be maintained, and contamination avoided.

C. Deliver pre-blended, dry mortar mix in moisture-resistant containers designed for lifting and emptying into dispensing silo. Store pre-blended, dry mortar mix in delivery containers on elevated platforms, under cover, and in a dry location or in a metal dispensing silo with weatherproof cover.

D. Store masonry accessories, including metal items, to prevent corrosion and accumulation of dirt and oil.

1.6 PROJECT CONDITIONS

A. Protection of Stone Masonry: During construction, cover tops of walls, projections, and sills with waterproof sheeting at end of each day's work. Cover partially completed stone masonry when construction is not in progress.

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1. Extend cover a minimum of 24 inches down both sides and hold cover securely in place.

B. Stain Prevention: Immediately remove mortar and soil to prevent them from staining the face of stone masonry.

1. Protect base of walls from rain-splashed mud and mortar splatter by coverings spread on the ground and over the wall surface.

2. Protect sills, ledges, and projections from mortar droppings.

C. Cold-Weather Requirements: Do not use frozen materials or materials mixed or coated with ice or frost. Do not build on frozen substrates. Remove and replace stone masonry damaged by frost or freezing conditions. Comply with cold-weather construction requirements contained in ACI 530.1/ASCE 6/TMS 602.

1. Cold-Weather Cleaning: Use liquid cleaning methods only when air temperature is 40 deg. F and above and will remain so until masonry has dried, but not less than 7 days after completing cleaning.

D. Hot-Weather Requirements: Comply with hot-weather construction requirements contained in ACI 530.1/ASCE 6/TMS 602.

1.7 COORDINATION

A. Advise installers of other work about specific requirements for placement of reinforcement, anchors, flashing, and similar items to be built into stone masonry.

1.8 APPLICABLE PUBLICATIONS

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

B. American Concrete Institute (ACI) Publications:

530.1-92/ASCE 6/TMS 602.Specifications for Masonry Structures

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

C150/C150M-09...........Portland Cement

E. American Welding Society (AWS) Publications:

AWS D1.1-90.............Structural Welding Code

AWS D1.4-98.............Welding Reinforcing Steel

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PART 2 - PRODUCTS

2.1 STONE GENERAL

A. Varieties and Sources: Subject to compliance with requirements, provide stone of varieties and from single sources, for the various stone types, complying with Section 04 40 10 CUT STONE ASSEMBLIES.

B. The granite shall match the existing granite at the current

Cemetery. The location to be used for comparison with the existing conditions is the stone at the Columbarium Wall A. Specific location or locations to be used for comparison of the installation to match the existing Columbarium Wall are to be designated herein, or at the time of the pre-bid meeting and subsequent Addendum.

Contractor shall observe the existing conditions at the Columbarium

Wall, and by submission of his bid, acknowledges that he has observed the existing conditions that are to be matched and that his bid incorporates all requirements associated therewith.

C. Products to be used for the cut stonework for this project shall come from the same single source manufacturer.

2.2 STONE PRODUCTS

A. The products specified herein above establishes the minimum acceptable standard for the quality, finish, and color for the Cut

Stone Assemblies for this project.

B. Products: Submit samples for review that come closest to matching the existing conditions for various uses at the location indicated.

C. Stone products are subject to compliance with detailed requirements.

D. Basis of Design: The products specified below herein establishes the minimum acceptable standard for the quality, manufacturing, finish, and color for the cut stone utilized in this project.

1. Granite:

a. Description:

Absorption by weight ASTM C97 0.05%

Density ASTM C97 175.5 lb/ft3

Compressive strength ASTM C170 17,250 Psi

Flexural strength ASTM C880 1,040 Psi

b. Color: To match existing at columbarium.

c. Finishes: Polished finish.

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2.3 MORTAR MATERIALS

A. Portland Cement: ASTM C 150, Type I or II, except Type III may be used for cold-weather construction. Provide color to match existing.

1. Low-Alkali Cement: Not more than 0.60 percent total alkali when tested according to ASTM C 114.

B. Hydrated Lime: ASTM C 207, Type S.

C. Portland Cement-Lime Mix: Packaged blend of Portland cement complying with ASTM C 150, Type I or III, and hydrated lime complying with ASTM C 207.

D. Mortar Cement: ASTM C 1329.

E. Masonry Cement: ASTM C 91.

F. Mortar Pigments: Natural and synthetic iron oxides and chromium oxides, compounded for use in mortar mixes. Use only pigments with a record of satisfactory performance in stone masonry mortar.

G. Colored Cement Product: Packaged blend made from cement and mortar pigments, all complying with specified requirements, and containing no other ingredients.

1. Formulate blend as required to produce color indicated or, if not indicated, as selected from manufacturer's standard colors.

2. Pigments shall not exceed 10 percent of Portland cement by weight.

3. Pigments shall not exceed 5 percent of masonry cement or mortar cement by weight.

H. Aggregate: ASTM C 144 and as follows:

1. For pointing mortar, use aggregate graded with 100 percent passing No. 16 sieve.

2. White Aggregates: Natural white sand or ground white stone.

3. Colored Aggregates: Natural-colored sand or ground marble, granite, or other sound stone; of color necessary to produce required mortar color.

I. Cold-Weather Admixture: Non-chloride, noncorrosive, accelerating admixture complying with ASTM C 494/C 494M, Type C, and recommended by manufacturer for use in masonry mortar of composition indicated.

J. Water: Potable.

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2.4 STONE TRIM ANCHORS

A. Stone Trim Anchors: Units fabricated with tabs or dowels designed to engage kerfs or holes in stone trim units and holes for fasteners or post installed anchor bolts for fastening to substrates or framing.

B. Materials: Fabricate anchors from stainless steel, ASTM A 240/A

240M, Type 304. Fabricate dowels from stainless steel, ASTM A 276, Type 304.

C. Fasteners for Stone Trim Anchors: Annealed stainless-steel bolts, nuts, and washers; ASTM F 593 for bolts and ASTM F 594 for nuts, Alloy Group 1 (A1).

D. Post installed Anchor Bolts for Fastening Stone Trim Anchors:

torque-controlled expansion anchors made from stainless-steel components complying with ASTM F 593 and ASTM F 594, Alloy Group 1 or 2 for bolts and nuts; ASTM A 666 or ASTM A 276, Type 304, for anchors.

2.5 MASONRY CLEANERS

A. Proprietary Acidic Cleaner: Manufacturer's standard-strength cleaner designed for removing mortar and grout stains, efflorescence, and other new construction stains from stone masonry surfaces without discoloring or damaging masonry surfaces; expressly approved for intended use by cleaner manufacturer and stone producer.

2.6 MORTAR MIXES

A. General: Do not use admixtures, including pigments, air-entraining agents, accelerators, retarders, water-repellent agents, antifreeze compounds, or other admixtures, unless otherwise indicated.

1. Do not use calcium chloride.

2. Limit cementitious materials in mortar to Portland cement and lime.

3. Add cold-weather admixture (if used) at same rate for all mortar that will be exposed to view, regardless of weather conditions, to ensure that mortar color is consistent.

4. Mixing Pointing Mortar: Thoroughly mix cementitious and aggregate materials together before adding 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

04 40 10 - 7 mortar in this dampened condition for one to two hours. Add remaining water in small portions until mortar reaches desired consistency. Use mortar within 30 minutes of final mixing; do not re-temper or use partially hardened material.

B. Pre-blended, Dry Mortar Mix: Furnish dry mortar ingredients in the form of a pre-blended mix. Measure quantities by weight to ensure accurate proportions, and thoroughly blend ingredients before delivering to Project site.

C. Mortar for Stone Masonry: Comply with ASTM C 270, Specification and use highest quality for the intended purpose according to industry standards for the longest life installation.

D. Colored-Aggregate Mortar: Produce required mortar color by using colored aggregates and natural color or white cement as necessary to produce required mortar color.

2.7 FABRICATION

A. Fabricate stone to comply with sizes, shapes, and tolerances recommended by applicable stone association or, if none, by stone source, for faces, edges, beds, and backs.

B. Cut, at manufacturing facility, stone to produce pieces of thickness, size, and shape indicated. Dress joints (bed and vertical) straight and at right angle to face unless otherwise indicated.

C. Carefully inspect stone at quarry or fabrication plant for compliance with requirements for appearance, material, and fabrication. Replace defective units before shipment.

1. Clean sawed backs of stone to remove rust stains and iron particles.

D. Finish exposed faces and edges of stone to comply with requirements indicated for finish and to match approved samples based upon the designated match existing conditions.

PART – 3 EXECUTION

3.1 PRE-INSTALLATION CONFERENCE

A. Convene a meeting on site, after submittals are received and approved but before any work, to: review drawings and specifications; submittals; schedule; manufacturer instructions;

site logistics and pertinent matters of coordination; details, methodology, timing and responsibilities for construction of the

04 40 10 - 8 mock-up(s); temporary protection, governing regulations, tests and inspections; participants to include RE/COR and all parties whose work is effected or related to the work of this section.

3.2 EXAMINATION

A. Examine surfaces indicated to receive stone masonry, with Installer present, for compliance with requirements for installation tolerances and other conditions affecting performance.

B. Examine substrate to verify that dovetail slots, inserts, reinforcement, veneer anchors, flashing, and other items installed in substrates and required for or extending into stone masonry are correctly installed.

C. Proceed with installation only after unsatisfactory conditions have been corrected.

D. Determine the jointing method for securing the individual cut stone assemblies. Refer to the drawings for details on where the various cut stone assemblies are to be installed in the various project elements being constructed.

1. Full mortar bed, and mortar on sides of units.

2. Setting on shims, secured to substrate

a. Stainless Steel Pins

b. Adhesive applied to grooves in the cut stone assemblies, and substrate to which it is attached.

3. Backer rod and sealant (caulking) at joint between the cut stone assembly and a concrete substrate or adjoining material.

4. Backer rod and sealant (caulking) at joints between adjoining cut stone assemblies.

3.3 PREPARATION

A. Clean dirty or stained stone surfaces by removing soil, stains, and foreign materials before setting. Clean stone by thoroughly scrubbing with fiber brushes and then drenching with clear water.

Use only mild cleaning compounds that contain no caustic or harsh materials or abrasives.

3.4 SETTING OF STONE MASONRY, GENERAL

A. Generally, field cutting, and trimming should not be required as stones are to be cut after field measurements and submittal approval. Field cutting shall only be allowed if approved in advance for specific stones or unusual conditions and following an

04 40 10 - 9 acceptable demonstration of the methods to be performed and acceptance of the resulting products.

1. The use power saws to cut stone shall only be allowed as indicated above. Cut lines straight and true, with edges eased slightly to prevent snipping. Cut edges, if allowed shall be in accordance with the accepted established standards and samples.

B. Set stone to comply with location indicated on Drawings. Install supports, fasteners, and other attachments indicated or necessary to secure stone masonry in place. Set stone accurately in locations indicated with edges and faces aligned according to established relationships and indicated tolerances. Before setting, the existing surfaces of concrete or stone, or adjoining stones shall be protected from damage during the setting process.

C. Maintain uniform joint widths as indicated on the contract drawings within established construction tolerances. If construction tolerances are not indicated on the drawings, then the allowable tolerances shall be as established in shop drawings or as agreed to by the COR after consultation with the A/E.

D. Provide sealant joints between existing masonry and proposed granite.

1. Keep sealant joints free of mortar and other rigid materials.

3.5 CONSTRUCTION TOLERANCES

A. Variation from Level: For horizontal exposed lines for the stone surfaces, do not exceed plus or minus 1/8 inch from the true level plane established by the design drawings, unless specific tolerances differing these exist elsewhere in the drawings or specifications, and have been accepted by the COR following consultation with the design A/E.

B. Variation in Mortar-Joint Thickness: Do not vary from joint size range indicated.

3.6 INSTALLATION OF ANCHORED STONE MASONRY

A. Anchor stone trim with stone trim anchors where indicated in shop drawings. Install anchors by fastening to substrate and inserting tabs and dowels into kerfs and holes in stone units. Provide compressible filler in ends of dowel holes and bottoms of kerfs to prevent end bearing of dowels and anchor tabs on stone. Fill remainder of anchor holes and kerfs with mortar.

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B. Provide 1-inch cavity between stone masonry and backup construction unless otherwise indicated. Keep cavity free of mortar droppings and debris and use and install rain screen and weeps as indicated as accepted in the mock-up.

3.7 POINTING

A. Pointing shall match the existing.

B. Prepare stone-joint surfaces for pointing with mortar by removing dust and mortar particles. Where setting mortar was removed to depths greater than surrounding areas, apply pointing mortar in layers not more than 3/8 inch deep until a uniform depth is formed.

C. Point stone joints by placing and compacting pointing mortar in layers not more than 3/8 inch deep. Compact each layer thoroughly and allow to become thumbprint hard before applying next layer.

D. Tool joints, when pointing mortar is thumbprint hard, with a smooth jointing tool to produce joint profile.

3.8 CUTTING AND FITTING

A. Cut and fit for identification inserts

B. Obtain approval prior to cutting or fitting any area not indicated or where appearance or strength of masonry work may be impaired.

C. Cutting and fitting shall be demonstrated and accepted in the shop drawings as establishing the method and quality of acceptable workmanship and installation.

3.9 ADJUSTING AND CLEANING

A. Remove and replace stone masonry of the following description:

1. Broken, chipped, stained, or otherwise damaged stone.

2. Defective joints.

3. Stone masonry not matching approved samples.

4. Stone masonry not complying with other requirements indicated.

B. Replace in a manner that results in stone masonry matching approved sample, complying with other requirements, and showing no evidence of replacement.

C. In-Progress Cleaning: Clean stone masonry as work progresses.

Remove mortar fins and smears before tooling joints.

D. Final Cleaning: After mortar is thoroughly set and cured, clean stone masonry as follows:

1. Remove large mortar particles by hand with wooden paddles and nonmetallic scrape hoes or chisels.

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2. Protect adjacent stone and non-masonry surfaces from contact with cleaner by covering them with liquid strippable masking agent, polyethylene film, or waterproof masking tape.

3. Clean stone masonry by bucket and brush hand-cleaning method described in BIA Technical Note No. 20 Revised II, using job-mixed detergent solution.

3.10 EXCESS MATERIALS AND WASTE

A. Disposal as Fill Material: Dispose of clean masonry waste, including mortar and excess or soil-contaminated sand, by crushing and mixing with fill material as fill is placed.

1. Crush masonry waste to less than 4 inch in greatest dimension.

2. Mix masonry waste with at least two parts of specified fill material for each part of masonry waste. Fill material is specified in Section 31 20 00, EARTH MOVING.

3. Do not dispose of masonry waste as fill within 18 inches of finished grade.

4. Excess clean masonry materials may be allowed to be disposed of on site, only if the conditions and location are agreed to by the

COR.

B. Excess Masonry Waste: Remove excess clean masonry waste that cannot be used as fill, as described above, and other waste, and legally dispose of off Owner's property.

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