04 20 00.pdf

SABER Solicitation FA2517-08-R-5002

04 20 00-1 05/08/09

SECTION 04 20 00

MASONRY

PART 1 GENERAL

1.1 REFERENCES

1.1.1 The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only. Unless otherwise noted, the latest published version and/or revision shall be used.

1.1.1.1 ACI INTERNATIONAL (ACI)

a. ACI 318 Building Code Requirements for Structural Concrete and

Commentary

b. ACI 530 Building Code Requirements for Masonry Structures

Commentaries

c. ACI 530.1 Specification for Masonry Structures

d. ACI SP-66 ACI Detailing Manual

1.1.1.2 ASTM INTERNATIONAL (ASTM)

a. ASTM A 153 Standard Specification for Zinc Coating (Hot-Dip) on Iron and

Steel Hardware

b. ASTM A 167 Standard Specification for Stainless and Heat-Resisting

Chromium-Nickel Steel Plate, Sheet, and Strip

c. ASTM A 615 Standard Specification for Deformed and Plain Carbon-Steel

Bars for Concrete Reinforcement

d. ASTM A 641 Standard Specification for Zinc-Coated (Galvanized) Carbon

Steel Wire

e. ASTM A 82 Standard Specification for Steel Wire, Plain, for Concrete

Reinforcement

f. ASTM B 370 Standard Specification for Copper Sheet and Strip for Building

Construction

g. ASTM C 1019 Standard Test Method for Sampling and Testing Grout

h. ASTM C 1072 Standard Test Method for Measurement of Masonry Flexural

Bond Strength

i. ASTM C 1142 Standard Specification for Extended Life Mortar for Unit

Masonry

j. ASTM C 1289 Standard Specification for Faced Rigid Cellular Polyisocyanurate

Thermal Insulation Board

k. ASTM C 129 Standard Specification for Nonloadbearing Concrete Masonry

Units

l. ASTM C 140 Standard Test Methods for Sampling and Testing Concrete

04 20 00-2 05/08/09

Masonry Units and Related Units

m. ASTM C 144 Standard Specification for Aggregate for Masonry Mortar

n. ASTM C 150 Standard Specification for Portland Cement

o. ASTM C 207 Standard Specification for Hydrated Lime for Masonry Purposes

p. ASTM C 216 Facing Brick (Solid Masonry Units Made from Clay or Shale)

q. ASTM C 27 Fireclay and High-Alumina Refractory Brick

r. ASTM C 270 Standard Specification for Mortar for Unit Masonry

s. ASTM C 315 Clay Flue Linings

t. ASTM C 476 Standard Specification for Grout for Masonry

u. ASTM C 494 Standard Specification for Chemical Admixtures for Concrete

v. ASTM C 55 Concrete Brick

w. ASTM C 578 Standard Specification for Rigid, Cellular Polystyrene Thermal

Insulation

x. ASTM C 593 Fly Ash and Other Pozzolans for Use with Lime

y. ASTM C 62 Building Brick (Solid Masonry Units Made from Clay or Shale)

z. ASTM C 641 Staining Materials in Lightweight Concrete Aggregates

aa. ASTM C 652 Hollow Brick (Hollow Masonry Units Made from Clay or Shale)

bb. ASTM C 67 Standard Test Methods for Sampling and Testing Brick and

Structural Clay Tile

cc. ASTM C 744 Prefaced Concrete and Calcium Silicate Masonry Units

dd. ASTM C 780 Preconstruction and Construction Evaluation of Mortars for Plain and Reinforced Unit Masonry

ee. ASTM C 90 Loadbearing Concrete Masonry Units

ff. ASTM C 91 Masonry Cement

gg. ASTM C 94 Standard Specification for Ready-Mixed Concrete

hh. ASTM C 989 Standard Specification for Ground Granulated Blast-Furnace

Slag for Use in Concrete and Mortars

ii. ASTM D 2000 Standard Classification System for Rubber Products in

Automotive Applications

jj. ASTM D 2240 Standard Test Method for Rubber Property - Durometer

Hardness

kk. ASTM D 2287 Nonrigid Vinyl Chloride Polymer and Copolymer Molding and

Extrusion Compounds

ll. ASTM E 119 Standard Test Methods for Fire Tests of Building Construction and Materials

mm. ASTM E 514 Water Penetration and Leakage Through Masonry

1.1.1.3 INTERNATIONAL CODE COUNCIL (ICC)

04 20 00-3 05/08/09

a. ICC IBC International Building Code

1.1.1.4 U.S. DEPARTMENT OF DEFENSE (DOD)

a. UFC 3-310-04 Seismic Design for Buildings

1.1.1.5 U.S. GREEN BUILDING COUNCIL (USGBC)

a. LEED Leadership in Energy and Environmental Design(tm) Green

Building Rating System for New Construction (LEED-NC)

1.2 SUBMITTALS

1.2.1 Government approval may be required on any of the following items. Items requiring submittals will be listed on the Submittal Register. Provide copies of all submittals per the requirements in Section 01 33 00, Submittal Procedures, or as listed on the Submittal Register.

1.2.1.1 SD-02 Shop Drawings

a. Structural Masonry

(1) Drawings including plans, elevations, and details of wall reinforcement; details of reinforcing bars at corners and wall intersections; offsets; tops, bottoms, and ends of walls; control and expansion joints; lintels; and wall openings. Bar splice locations shall be shown. Bent bars shall be identified on a bending diagram and shall be referenced and located on the drawings. Wall dimensions, bar clearances, and wall openings greater than one masonry unit in area shall be shown. No approval will be given to the shop drawings until the Contractor certifies that all openings, including those for mechanical and electrical service, are shown. If, during construction, additional masonry openings are required, the approved shop drawings shall be resubmitted with the additional openings shown along with the proposed changes. Location of these additional openings shall be clearly highlighted. The minimum scale for wall elevations shall be 1/4 inch per foot. Reinforcement bending details shall conform to the requirements of ACI SP-66.

1.2.1.2 SD-03 Product Data

a. Local/Regional Materials; (LEED)

(1) Documentation indicating distance between manufacturing facility and the project site.

Indicate distance of raw material origin from the project site. Indicate relative dollar value of local/regional materials to total dollar value of products included in project.

b. Environmental Data

c. Clay Brick (LEED)

d. Concrete Brick

e. Concrete Masonry Units (CMU) (LEED)

f. Cement (LEED)

g. Insulation

h. Flashing

i. Water-Repellant Admixture

04 20 00-4 05/08/09

(1) Manufacturer's descriptive data. Documentation indicating percentage of post-industrial and post-consumer recycled content per unit of product. Indicate relative dollar value of recycled content products to total dollar value of products included in project.

j. Cold Weather Installation

(1) Cold weather construction procedures.

k. Salvaged Brick (LEED)

(1) Documentation certifying products are from salvaged/recovered sources. Indicate relative dollar value of salvaged content products to total dollar value of products included in project.

1.2.1.3 SD-04 Samples

a. Concrete Masonry Units

b. Concrete Brick

c. Stone Items

d. Clay Brick

(1) Color samples of three stretcher units and one unit for each type of special shape. Units shall show the full range of color and texture. Submit sample of colored mortar with applicable masonry unit.

e. Anchors, Ties, and Bar Positioners

(1) Two of each type used.

f. Expansion-Joint Materials

(1) One piece of each type used.

g. Joint Reinforcement

(1) One piece of each type used, including corner and wall intersection pieces, showing at least two cross wires.

h. Insulation

(1) One piece of board type insulation, not less than 16 by 24 inches in size, containing the label indicating the rated permeance and R-values.

i. Portable Panel

(1) One panel of clay brick, 2 by 2 feet, containing approximately 24 brick facings to establish range of color and texture.

1.2.1.4 SD-05 Design Data

a. Pre-mixed Mortar

b. Unit Strength Method

(1) Pre-mixed mortar composition. Calculations and certifications of masonry unit and mortar strength.

1.2.1.5 SD-06 Test Reports

a. Efflorescence Test

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b. Field Testing of Mortar

c. Field Testing of Grout

d. Prism tests

e. Masonry Cement

f. Fire-rated CMU

(1) Test reports from an approved independent laboratory. Test reports on a previously tested material shall be certified as the same as that proposed for use in this project.

g. Special Inspection

(1) Copies of masonry inspector reports.

1.2.1.6 SD-07 Certificates

a. Clay Brick

b. Concrete Brick

c. Concrete Masonry Units (CMU)

d. Control Joint Keys

e. Anchors, Ties, and Bar Positioners

f. Expansion-Joint Materials

g. Joint Reinforcement

h. Reinforcing Steel Bars and Rods

i. Masonry Cement

j. Mortar Coloring

k. Insulation

l. Precast Concrete Items

m. Admixtures for Masonry Mortar

n. Admixtures for Grout

(1) Certificates of compliance stating that the materials meet the specified requirements.

o. Insulation

(1) Certificate attesting that the polyurethane or polyisocyanurate insulation furnished for the project contains recovered material, and showing an estimated percent of such recovered material.

1.2.1.7 SD-08 Manufacturer's Instructions

a. Masonry Cement

(1) When masonry cement is used, submit the manufacturer's printed instructions on proportions of water and aggregates and on mixing to obtain the type of mortar required.

1.2.1.8 SD-10 Operation and Maintenance Data

a. Take-Back Program

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(1) Documentation that includes contact information, summary of procedures, and the limitations and conditions applicable to the project. Indicate manufacturer's commitment to reclaim materials for recycling and/or reuse.

1.3 SAMPLE MASONRY PANELS

1.3.1 After material samples are approved and prior to starting masonry work, a portable panel of clay brick and sample masonry panels shall be constructed for each type and color of masonry required. At least 48 hours prior to constructing the sample panel or panels, the Contractor shall submit written notification to the Contracting Officer's Representative. Sample panels shall not be built in, or as part of the structure, but shall be located where directed.

1.3.1.1 Configuration

a. Panels shall be L-shaped or otherwise configured to represent all of the wall elements. Panels shall be of the size necessary to demonstrate the acceptable level of workmanship for each type of masonry represented on the project. The minimum size of a straight panel or a leg of an L-shaped panel shall be 8 feet long by 4 feet high.

1.3.1.2 Composition

a. Panels shall show full color range, texture, and bond pattern of the masonry work. The

Contractor's method for mortar joint tooling; grouting of reinforced vertical cores, collar joints, bond beams, and lintels; positioning, securing, and lapping of reinforcing steel; positioning and lapping of joint reinforcement (including prefabricated corners); and cleaning of masonry work shall be demonstrated during the construction of the panels. Installation or application procedures for anchors, wall ties, CMU control joints, brick expansion joints, insulation, flashing, brick soldier, row lock courses and weep holes shall be shown in the sample panels.

The panels shall contain a corner that includes a bond beam corner. Panels that represent reinforced masonry shall contain a 2 by 2 foot opening placed at least 2 feet above the panel base and 2 feet away from all free edges, corners, and control joints. Required reinforcing shall be provided around this opening as well as at wall corners and control joints.

1.3.1.3 Construction Method

a. Where anchored veneer walls are required, the Contractor shall demonstrate and receive approval for the method of construction; i.e., either bring up the two wythes together or separately, with the insulation and appropriate ties placed within the specified tolerances across the cavity. Temporary provisions shall be demonstrated to preclude mortar or grout droppings in the cavity and to provide a clear open air space of the dimensions shown on the drawings.

Where masonry is to be grouted, the Contractor shall demonstrate and receive approval on the method that will be used to bring up the masonry wythes; support the reinforcing bars; and grout cells, bond beams, lintels, and collar joints using the requirements specified herein. If sealer is specified to be applied to the masonry units, sealer shall be applied to the sample panels. Panels shall be built on a concrete foundation.

1.3.1.4 Usage

a. The completed panels shall be used as the standard of workmanship for the type of masonry represented. Masonry work shall not commence until the sample panel for that type of masonry construction has been completed and approved. Panels shall be protected from the weather and construction operations until the masonry work has been completed and approved. After completion of the work, the sample panels, including all foundation concrete, shall become the

04 20 00-7 05/08/09 property of the Contractor and shall be removed from the construction site.

1.4 DELIVERY, HANDLING, AND STORAGE

1.4.1 Materials shall be delivered, handled, stored, and protected to avoid chipping, breakage, and contact with soil or contaminating material. Store and prepare materials in already disturbed areas to minimize project site disturbance and size of project site.

1.4.1.1 Masonry Units

a. Cover and protect moisture-controlled concrete masonry units and cementitious materials from precipitation. Conform to all handling and storage requirements of ASTM C 90. Prefabricated lintels shall be marked on top sides to show either the lintel schedule number or the number and size of top and bottom bars.

1.4.1.2 Reinforcement, Anchors, and Ties

a. Steel reinforcing bars, coated anchors, ties, and joint reinforcement shall be stored above the ground. Steel reinforcing bars and uncoated ties shall be free of loose mill scale and rust.

1.4.1.3 Cementitious Materials, Sand and Aggregates

a. Cementitious and other packaged materials shall be delivered in unopened containers, plainly marked and labeled with manufacturers' names and brands. Cementitious material shall be stored in dry, weathertight enclosures or be completely covered. Cement shall be handled in a manner that will prevent the inclusion of foreign materials and damage by water or dampness.

Sand and aggregates shall be stored in a manner to prevent contamination or segregation.

1.5 STRUCTURAL MASONRY

1.5.1 Special Inspection

1.5.1.1 A qualified masonry inspector approved by the Contracting Officer shall perform inspection of the masonry work. Minimum qualifications for the masonry inspector shall be 5 years of reinforced masonry inspection experience or acceptance by a State, municipality, or other governmental body having a program of examining and certifying inspectors for reinforced masonry construction. The masonry inspector shall be present during preparation of masonry prisms, sampling and placing of masonry units, placement of reinforcement (including placement of dowels in footings and foundation walls), inspection of grout space, immediately prior to closing of cleanouts, and during grouting operations. The masonry inspector shall assure Contractor compliance with the drawings and specifications. The masonry inspector shall keep a complete record of all inspections and shall submit daily written reports to the

Quality Control Supervisory Representative reporting the quality of masonry construction.

1.5.2 Unit Strength Method

1.5.2.1 Compute compressive strength of masonry system "Unit Strength Method," ACI 530. Submit calculations and certifications of unit and mortar strength.

1.5.3 Seismic Requirement

1.5.3.1 In addition to design requirements of ICC IBC, the Contractor shall provide additional seismic

04 20 00-8 05/08/09 reinforcement in accordance with UFC 3-310-04.

1.6 QUALITY ASSURANCE

1.6.1 Appearance

1.6.1.1 Blend all brick to produce a uniform appearance when installed. An observable "banding" or

"layering" of colors or textures caused by improperly mixed brick is unacceptable.

1.6.2 Testing

1.6.2.1 Masonry strength shall be determined in accordance with ACI 530; submit test reports on three prisms as specified in ACI 530.1. The cost of testing shall be paid by the Contractor.

1.6.3 Spare Vibrator

1.6.3.1 Maintain at least one spare vibrator on site at all times.

1.6.4 Bracing and Scaffolding

1.6.4.1 Provide bracing and scaffolding necessary for masonry work. Design bracing to resist wind pressure as required by local code.

1.7 SUSTAINABLE DESIGN REQUIREMENTS

1.7.1 Local/Regional Materials

1.7.1.1 Use materials or products extracted, harvested, or recovered, as well as manufactured, within a

500 mile radius from the project site, if available from a minimum of three sources.

PART 2 PRODUCTS

2.1 GENERAL REQUIREMENTS

2.1.1 The source of materials which will affect the appearance of the finished work shall not be changed after the work has started except with Contracting Officer's approval.

2.2 CLAY BRICK

2.2.1 Color range and texture of clay brick shall be as indicated and shall conform to the approved sample. Brick shall conform to ASTM C 62; Grade SW shall be used for brick in contact with earth or grade and for all exterior work and for all nonvertical surfaces. Grade SW or MW shall be used in other brickwork. Average dimensions of brick shall be 3-5/8 inches thick, 2-

1/4 inches high, and 8 inches long (standard) or 4 inches thick, 2-2/3 inches high, and 8 inches long (nominal)), subject to the tolerances specified in ASTM C 62. Brick shall be tested for efflorescence. Clay brick units shall be delivered factory-blended to provide a uniform appearance and color range in the completed wall. Clay brick units may contain post-consumer or post-industrial recycled content.

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2.2.1.1 Solid Clay Brick

a. Solid clay brick shall conform to ASTM C 216, Type FBS or FBX as indicated. Brick size shall be modular and the nominal size of the brick used shall be 3-5/8 inches thick, 2-1/4 inches high, and 8 inches long (nominal) or 4 inches thick, 2-2/3 inches high and 8 inches long

(nominal).

2.2.1.2 Hollow Clay Brick

a. Hollow clay brick shall conform to ASTM C 652, Type HBS or HBX. Brick size shall be modular and the nominal size of the brick used shall be 2-1/4 inches thick, 2-1/4 inches high, and 8 inches long (nominal). Where vertical reinforcement is shown in hollow brick, the minimum cell dimension shall be 2-1/2 inches and the units shall be designed to provide precise vertical alignment of the cells.

2.2.1.3 Refractory Brick

a. ASTM C 27, low-duty type.

2.2.1.4 Closure or Utility Brick

a. ASTM C 216, Grade SW, Type FBS, 3-5/8 inches thick, 3-5/8 inches high, and 8 inches long

(closure) or 4 inches thick, 4 inches high, and 12 inches long (utility). Closure or Utility brick shall be used where required to match existing. Color, texture, and range of brick shall match the existing brick on the Building.

2.3 CONCRETE BRICK

2.3.1 Concrete brick shall conform to ASTM C 55. Concrete brick may be used where necessary for filling out in concrete masonry unit construction.

2.4 SALVAGED BRICK

2.4.1 Use salvaged bricks and other masonry units in place of new bricks or masonry units as indicated. When using salvaged brick, select exterior face bricks from salvaged exterior face bricks. Bricks shall meet standards of new bricks otherwise used in application, and shall be cleaned of all mortar prior to use. Place exterior face towards the exterior.

2.5 CONCRETE MASONRY UNITS (CMU)

2.5.1 Cement shall have a low alkali content and be of one brand. Units may contain post-consumer or post-industrial recycled content. Units shall be of modular dimensions and air, water, or steam cured. Exposed surfaces of units shall be smooth and of uniform texture. Exterior concrete masonry units shall have water-repellant admixture added during manufacture.

2.5.1.1 Hollow Load-Bearing Units

a. ASTM C 90, made with normal weight aggregate unless noted otherwise. Provide load-bearing units for exterior walls, foundation walls, load-bearing walls, and shear walls.

2.5.1.2 Hollow Non-Load-Bearing Units

a. ASTM C 129, made with lightweight or normal weight aggregate as indicated. Load-bearing

04 20 00-10 05/08/09 units may be provided in lieu of non-load-bearing units.

2.5.1.3 Solid Load-Bearing Units

a. ASTM C 90, normal weight units unless noted otherwise.

2.5.2 Aggregates

2.5.2.1 Lightweight aggregates and blends of lightweight and heavier aggregates in proportions used in producing the units, shall comply with the following requirements when tested for stain-producing iron compounds in accordance with ASTM C 641: by visual classification method, the iron stain deposited on the filter paper shall not exceed the "light stain" classification. Use industrial waste by-products (air-cooled slag, cinders, or bottom ash), ground waste glass and concrete, granulated slag, and expanded slag in aggregates. Slag shall comply with ASTM C

989.

2.5.3 Kinds and Shapes

2.5.3.1 Units shall be modular in size and shall include closer, jamb, header, lintel, and bond beam units and special shapes and sizes to complete the work as indicated. In exposed interior masonry surfaces, units having a bullnose shall be used for vertical external corners except at door, window, and louver jambs. Radius of the bullnose shall be 1 inch. Units used in exposed masonry surfaces in any one building shall have a uniform fine to medium texture and a uniform color.

a. Architectural Units

(1) Units shall have patterned face shell. Face shell pattern shall be fluted, vertical scored, split ribbed or other pattern as required by the TO SOW. Units shall be integrally colored during manufacture if indicated. Patterned face shell shall be properly aligned in the completed wall.

b. Patterned, Decorative Screen Units

(1) Patterned, decorative screen units shall conform to the applicable requirements of

ASTM C 90. Units shall have uniform through-the-wall pattern, color, and texture.

2.5.4 Fire-Rated CMU

2.5.4.1 Concrete masonry units used in fire-rated construction shown on the drawings shall be of minimum equivalent thickness for the fire rating indicated and the corresponding type of aggregates indicated in TABLE I. Units containing more than one of the aggregates listed in

TABLE I will be rated on the aggregate requiring the greater minimum equivalent thickness to produce the required fire rating. Construction shall conform to ASTM E 119.

a. TABLE I

FIRE-RATED CONCRETE MASONRY UNITS

See note (a) below

Minimum equivalent thickness inches for fire rating of:

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a. Minimum equivalent thickness shall equal net volume as determined in conformance with

ASTM C 140 divided by the product of the actual length and height of the face shell of the unit in inches. Where walls are to receive plaster or be faced with brick, or otherwise form an assembly;

the thickness of plaster or brick or other material in the assembly will be included in determining the equivalent thickness.

2.6 PRECAST CONCRETE ITEMS

2.6.1 Trim, lintels, copings, splashblocks and door sills shall be factory-made units from a plant regularly engaged in producing precast concrete units. Unless otherwise indicated, concrete shall be 4,000 psi minimum conforming to Section 03 30 00 Cast-In-Place Concrete using 1/2 inch to No. 4 nominal-size coarse aggregate, and minimum reinforcement shall be the reinforcement required for handling of the units. Clearance of 3/4 inch shall be maintained between reinforcement and faces of units. Unless precast-concrete items have been subjected during manufacture to saturated-steam pressure of at least 120 psi for at least 5 hours, the items, after casting, shall be either damp-cured for 24 hours or steam-cured and shall then be aged under cover for 28 days or longer. Cast-concrete members weighing over 80 pounds shall have built-in loops of galvanized wire or other approved provisions for lifting and anchoring. Units shall have beds and joints at right angles to the face, with sharp true arises and shall be cast with drip grooves on the underside where units overhang walls. Exposed-to-view surfaces shall be free of surface voids, spalls, cracks, and chipped or broken edges.

Precast units exposed-to-view shall be of uniform appearance and color. Unless otherwise specified, units shall have a smooth dense finish. Prior to use, each item shall be wetted and inspected for crazing. Items showing evidence of dusting, spalling, crazing, or having surfaces treated with a protective coating will be rejected.

2.6.1.1 Lintels

a. Precast lintels, unless otherwise shown, shall be of a thickness equal to the wall and reinforced with two No. 4 bars for the full length. Top of lintels shall be labeled "TOP" or otherwise identified and each lintel shall be clearly marked to show location in the structure. In reinforced masonry, lintels shall conform to ACI 318 for flexural and shear strength and shall have at least 8 inches bearing at each end. Concrete shall have a minimum 28 day compressive strength of 4,000 psi using 1/2 inch to No. 4 nominal-size coarse aggregate. Reinforcement shall conform to ASTM A 615 Grade 60,000 psi. Limit lintel deflection due to dead plus live

Aggregate Type 4 hours 3 hours 2 hours

Pumice 4.7 4.0 3.0

Expanded Slag 5.0 4.2 3.3

Expanded clay, shale, or slate

5.7 4.8 3.7

Limestone, scoria, cinders or unexpanded slag

5.9 5.0 4.0

Calcareous gravel 6.2 5.3 4.2

Siliceous gravel 6.7 5.7 4.5

04 20 00-12 05/08/09 load to L/600 or 0.3 inches. Provide top and bottom bars for lintels over 36 inches in length.

2.6.1.2 Sills and Copings

a. Sills and copings shall be cast with washes. Sills for windows having mullions shall be cast in sections with head joints at mullions and a 1/4 inch allowance for mortar joints. The ends of sills, except a 3/4 inch wide margin at exposed surfaces, shall be roughened for bond. Treads of door sills shall have rounded nosings. Reinforce sills with not less than two No. 4 bars.

2.6.1.3 Splash Blocks

a. Splash blocks shall be as detailed. Reinforcement shall be the manufacturer's standard.

2.6.1.4 Flue Linings and Thimbles

a. ASTM C 315, free from fractures. Sizes and shapes shall be as indicated.

2.7 STONE ITEMS

2.7.1 Stone for trim, sills, lintels, and copings shall be limestone, sandstone, or granite as indicated, and shall be cut to the design shown. Sandstone shall be standard grade, buff, gray, or buff brown, with a smooth finish free from clay pits and tool marks. Granite shall be a good commercial grade building granite of medium or moderately coarse grain, and a light or medium gray or light pink color, with a smooth machine finish on washes, 4-cut finish on treads, and 6-cut or equivalent machine finish on other exposed surfaces. Limestone shall be standard buff limestone with a smooth machine finish free from tool marks. Lintels, except when supported by a steel member, shall be 4 inches or more thick from face to back edge and of the depth required to support the masonry over the opening. Stone shall have beds and joints at right angles to the face, with sharp, true arises. Copings and sills shall be provided with washes, and where overhanging the walls, shall have drips cut on the underside.

2.8 MORTAR FOR STRUCTURAL MASONRY

2.8.1 ASTM C 270, Type S. Strength (f'm) as indicated. Test in accordance with ASTM C 780.

Use Type II portland cement. Do not use admixtures containing chlorides. When structural reinforcement is incorporated, maximum air-content shall be 12 percent in cement-lime mortar and 18 percent in masonry cement mortar. Use up to 40 percent Class F fly ash with type IP cement in cement-lime mortar. Fly ash shall comply with ASTM C 593.

2.9 MASONRY MORTAR

2.9.1 Mortar Type S or N shall conform to the proportion specification of ASTM C 270 except Type

S cement-lime mortar proportions shall be 1 part cement, 1/2 part lime and 4-1/2 parts aggregate; Type N cement-lime mortar proportions shall be 1 part cement, 1 part lime and 6 parts aggregate. Type N or S mortar shall be used for non-load-bearing, non-shear-wall interior masonry; approved commercial fire clay mortar or refractory cement (calcium-aluminate) mortar for fire brick and flue liners; and Type S for remaining masonry work;

except where higher compressive strength is indicated on structural drawings. When masonry cement ASTM C 91 is used the maximum air content shall be limited to 12 percent and performance equal to cement-lime mortar shall be verified. Verification of masonry cement performance shall be based on ASTM C 780 and ASTM C 1072. Pointing mortar in showers

04 20 00-13 05/08/09 and kitchens shall contain ammonium stearate, or aluminum tri-stearate, or calcium stearate in an amount equal to 3 percent by weight of cement used. Cement shall have a low alkali content and be of one brand. Aggregates shall be from one source.

2.9.1.1 Admixtures for Masonry Mortar

a. In cold weather, a non-chloride based accelerating admixture may be used subject to approval.

Accelerating admixture shall be non-corrosive, shall contain less than 0.2 percent chlorides, and shall conform to ASTM C 494, Type C.

2.9.1.2 Colored Mortar

a. Mortar coloring shall be added to the mortar used for exposed masonry surfaces as indicated to produce a uniform color matching sample identified by C.O. Mortar coloring shall be chemically inert, of finely ground limeproof pigment, and furnished in accurately pre-measured and packaged units that can be added to a measured amount of cement.

2.9.1.3 Hydrated Lime and Alternates

a. Hydrated lime shall conform to ASTM C 207. Lime alternates which have a current ICBO, ICBO UBC, Evaluation Report number whose findings state it may be used as an alternate to lime for Type S, N, and O mortars will be deemed acceptable provided the user follows the manufacturer's proportions and mixing instructions as set forth in ICBO report.

2.9.1.4 Cement

a. Portland cement shall conform to ASTM C 150, Type II. Masonry cement shall conform to

ASTM C 91, Type N or S. Containers shall bear complete instructions for proportioning and mixing to obtain the required types of mortar. Incorporate to the maximum extent, without conflicting with other requirements of this section, up to 40 percent fly ash, up to 70 percent slag, up to 10 percent cenospheres, and up to 10 percent silica fume. Additives shall conform to requirements in Section 03 30 00 Cast-In-Place Concrete.

2.9.1.5 Pre-Mixed Mortar

a. Pre-mixed mortar shall conform to ASTM C 1142, Type RN or RS.

2.9.1.6 Sand and Water

a. Sand shall conform to ASTM C 144. Water shall be clean, potable, and free from substances which could adversely affect the mortar.

2.10 WATER-REPELLANT ADMIXTURE

2.10.1 Polymeric type formulated to reduce porosity and water transmission. Construct panels of masonry units conforming to ASTM C 744 and mortar which contain the water-repellant admixture. When tested in accordance with ASTM C 1072, such panels shall have flexural strength not less than that specified or indicated. When tested in accordance with ASTM E

514, panels shall exhibit no water visible on back of test panel and no leaks through the panel after 24 hours, and not more than 25 percent of wall area shall be damp after 72 hours.

04 20 00-14 05/08/09

2.11 GROUT AND READY-MIXED GROUT

2.11.1 Grout shall conform to ASTM C 476. Cement used in grout shall have a low alkali content.

Grout slump shall be between 8 and 10 inches. Minimum grout strength shall be 2000 psi in

28 days, as tested by ASTM C 1019. Grout shall be used subject to the limitations of Table

III. Proportions shall not be changed and materials with different physical or chemical characteristics shall not be used in grout for the work unless additional evidence is furnished that the grout meets the specified requirements. Ready-Mixed grout shall conform to ASTM

C 94.

2.11.1.1 Admixtures for Grout

a. In cold weather, a non-chloride based accelerating admixture may be used subject to approval;

accelerating admixture shall be non-corrosive, shall contain less than 0.2 percent chlorides, and shall conform to ASTM C 494, Type C. In general, air-entrainment, anti-freeze or chloride admixtures shall not be used except as approved by the Contracting Officer.

2.11.1.2 Grout Barriers

a. Grout barriers for vertical cores shall consist of fine mesh wire, fiberglass, or expanded metal.

2.12 ANCHORS, TIES, AND BAR POSITIONERS

2.12.1 Anchors and ties shall be fabricated without drips or crimps and shall be zinc-coated in accordance with ASTM A 153, Class B-2. Steel wire used for anchors and ties shall be fabricated from steel wire conforming to ASTM A 82. Wire ties or anchors in exterior walls shall conform to ASTM A 641. Joint reinforcement in interior walls, and in exterior or interior walls exposed to moist environment shall conform to ASTM A 641; coordinate with paragraph Joint Reinforcement below. Anchors and ties shall be sized to provide a minimum of 5/8 inch mortar cover from either face.

2.12.1.1 Wire Mesh Ties

a. Wire mesh for tying 4 inch thick concrete masonry unit partitions to other intersecting masonry partitions shall be 1/2 inch mesh of minimum 16 gauge steel wire. Minimum lengths shall be not less than 12 inches.

2.12.1.2 Wall Ties

a. Wall ties shall be rectangular-shaped or Z-shaped fabricated of 3/16 inch diameter zinc-coated steel wire. Rectangular wall ties shall be no less than 4 inches wide. Wall ties may also be of a continuous type conforming to paragraph Joint Reinforcement. Adjustable type wall ties, if approved for use, shall consist of two essentially U-shaped elements fabricated of 3/16 inch diameter zinc-coated steel wire. Adjustable ties shall be of the double pintle to eye type and shall allow a maximum of 1/2 inch eccentricity between each element of the tie. Play between pintle and eye opening shall be not more than 1/16 inch. The pintle and eye elements shall be formed so that both can be in the same plane.

2.12.1.3 Dovetail Anchors

a. Dovetail anchors shall be of the flexible wire type, 3/16 inch diameter zinc-coated steel wire, triangular shaped, and attached to a 12 gauge or heavier steel dovetail section. These anchors shall be used for anchorage of veneer wythes or composite-wall facings extending over the face

04 20 00-15 05/08/09 of concrete columns, beams, or walls. Cells within vertical planes of these anchors shall be filled solid with grout for full height of walls or partitions, or solid units may be used.

2.12.1.4 Adjustable Anchors

a. Adjustable anchors shall be 3/16 inch diameter steel wire, triangular-shaped. Anchors attached to steel shall be 5/16 inch diameter steel bars placed to provide 1/16 inch play between flexible anchors and structural steel members. Spacers shall be welded to rods and columns.

Equivalent welded-on steel anchor rods or shapes standard with the flexible-anchor manufacturer may be furnished when approved. Welds shall be cleaned and given one coat of zinc-rich touch up paint.

2.12.1.5 Bar Positioners

a. Bar positioners, used to prevent displacement of reinforcing bars during the course of construction, shall be factory fabricated from 9 gauge steel wire or equivalent, and coated with a hot-dip galvanized finish. Not more than one wire shall cross the cell.

2.13 JOINT REINFORCEMENT

2.13.1 Joint reinforcement shall be factory fabricated from steel wire conforming to ASTM A 82, welded construction. Tack welding will not be acceptable in reinforcement used for wall ties.

Wire shall have zinc coating conforming to ASTM A 153, Class B-2. All wires shall be a minimum of 9 gauge. Reinforcement shall be ladder type design, having one longitudinal wire in the mortar bed of each face shell for hollow units and one wire for solid units. Joint reinforcement shall be placed a minimum of 5/8 inch cover from either face. The distance between crosswires shall not exceed 16 inches. Joint reinforcement for straight runs shall be furnished in flat sections not less than 10 feet long. Joint reinforcement shall be provided with factory formed corners and intersections. If approved for use, joint reinforcement may be furnished with adjustable wall tie features.

2.14 REINFORCING STEEL BARS AND RODS

2.14.1 Reinforcing steel bars and rods shall conform to ASTM A 615, Grade 60.

2.15 CONTROL JOINT KEYS

2.15.1 Control joint keys shall be a factory fabricated solid section of natural or synthetic rubber (or combination thereof) conforming to ASTM D 2000 or polyvinyl chloride conforming to

ASTM D 2287. The material shall be resistant to oils and solvents. The control joint key shall be provided with a solid shear section not less than 5/8 inch thick and 3/8 inch thick flanges, with a tolerance of plus or minus 1/16 inch. The control joint key shall fit neatly, but without forcing, in masonry unit jamb sash grooves. The control joint key shall be flexible at a temperature of minus 30 degrees F after five hours exposure, and shall have a durometer hardness of not less than 70 when tested in accordance with ASTM D 2240.

2.16 INSULATION

2.16.1 Rigid Board-Type Insulation

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2.16.1.1 Rigid board-type insulation shall be extruded polystyrene, polyurethane, or polyisocyanurate.

Polystyrene shall conform to ASTM C 578. Polyisocyanurate shall conform to ASTM C 1289, Type I, Class 1 or 2, faced with aluminum foil on both sides of the foam. The insulation shall be a standard product and shall be marked with not less than the manufacturer's trademark or name, the specification number, the permeance and R-values.

a. Aged R-Value

(1) The insulation shall provide a minimum aged R-value as indicated. The aged R-value shall be determined at 75 degrees F in accordance with the appropriate referenced specification. The stated R-value of the insulation shall be certified by an independent testing laboratory or certified by an independent Registered Professional Engineer if tests are conducted in the manufacturer's laboratory.

2.16.2 Insulation Adhesive

2.16.2.1 Insulation adhesive shall be specifically prepared to adhere the insulation to the masonry and, where applicable, to the thru-wall flashing. The adhesive shall not deleteriously affect the insulation, and shall have a record of satisfactory and proven performance for the conditions under which to be used.

2.17 EXPANSION-JOINT MATERIALS

2.17.1 Backer rod and sealant shall be adequate to accommodate joint compression equal to 50 percent of the width of the joint. The backer rod shall be compressible rod stock of polyethylene foam, polyurethane foam, butyl rubber foam, or other flexible, nonabsorptive material as recommended by the sealant manufacturer. Sealant shall conform to Section 07 92

00 Joint Sealants, and shall be penetrating.

2.18 FLASHING

2.18.1 Flashing shall be as specified in Section 07 60 00 Flashing And Sheet Metal. Provide one of the following types:

2.18.1.1 Coated-Copper Flashing: 7 ounce, electrolytic copper sheet, uniformly coated on both sides with acidproof, alkaliproof, elastic bituminous compound. Factory apply coating to a weight of not less than 6 ounces/square on each side.

2.18.1.2 Copper or Stainless Steel Flashing: Copper, ASTM B 370, minimum 16 ounce weight;

stainless steel, ASTM A 167, Type 301, 302, 304, or 316, 0.015 inch thick, No. 2D finish.

Provide with factory-fabricated deformations that mechanically bond flashing against horizontal movement in all directions. Deformations shall consist of dimples, diagonal corrugations, or a combination of dimples and transverse corrugations.

2.18.1.3 Reinforced Membrane Flashing: Polyester film core with a reinforcing fiberglass scrim bonded to one side. The membrane shall be impervious to moisture, flexible, and not affected by caustic alkalis. The material, after being exposed for not less than 1/2 hour to a temperature of

32 degrees F, shall show no cracking when, at that temperature, it is bent 180 degrees over a

1/16 inch diameter mandrel and then bent at the same point over the same size mandrel in the opposite direction 360 degrees. Use reinforced membrane flashing in unexposed areas only.

04 20 00-17 05/08/09

2.19 WEEP HOLE VENTILATORS

2.19.1 Weephole ventilators shall be prefabricated aluminum, plastic or sized to form the proper size opening in head joints. Provide aluminum and plastic inserts with grill or screen-type openings designed to allow the passage of moisture from cavities and to prevent the entrance or insects. Ventilators shall be sized to match modular construction with a standard 3/8 inch mortar joint.

PART 3 EXECUTION

3.1 PREPARATION

3.1.1 Prior to start of work, masonry inspector shall verify the applicable conditions as set forth in

ACI 530.1, inspection. The Contracting Officer will serve as inspector or will select a masonry inspector.

3.1.2 Hot Weather Installation

3.1.2.1 The following precautions shall be taken if masonry is erected when the ambient air temperature is more than 99 degrees F in the shade and the relative humidity is less than 50 percent or the ambient air temperature exceeds 90 degrees F and the wind velocity is more than

8 mph. All masonry materials shall be shaded from direct sunlight; mortar beds shall be spread no more than 4 feet ahead of masonry; masonry units shall be set within one minute of spreading mortar; and after erection, masonry shall be protected from direct exposure to wind and sun for 48 hours.

3.1.3 Cold Weather Installation

3.1.3.1 Before erecting masonry when ambient temperature or mean daily air temperature falls below

40 degrees F or temperature of masonry units is below 40 degrees F, a written statement of proposed cold weather construction procedures shall be submitted for approval. The following precautions shall be taken during all cold weather erection. Conform to ACI 530.1 for hot and cold weather masonry erection.

a. Protection

(1) Ice or snow formed on the masonry bed shall be thawed by the application of heat. Heat shall be applied carefully until the top surface of the masonry is dry to the touch.

Sections of masonry deemed frozen and damaged shall be removed before continuing construction of those sections.

(a) Air Temperature 40 to 32 Degrees F. Sand or mixing water shall be heated to produce mortar temperatures between 40 and 120 degrees F.

(b) Air Temperature 32 to 25 Degrees F. Sand and mixing water shall be heated to produce mortar temperatures between 40 and 120 degrees F. Temperature of mortar on boards shall be maintained above freezing.

(c) Air Temperature 25 to 20 Degrees F. Sand and mixing water shall be heated to provide mortar temperatures between 40 and 120 degrees F. Temperature of mortar on boards shall be maintained above freezing. Sources of heat shall be used on both sides of walls under construction. Windbreaks shall be employed when wind is in excess of 15

04 20 00-18 05/08/09 mph.

(d) Air Temperature 20 Degrees F and below. Sand and mixing water shall be heated to provide mortar temperatures between 40 and 120 degrees F. Enclosure and auxiliary heat shall be provided to maintain air temperature above 32 degrees F. Temperature of units when laid shall not be less than 20 degrees F.

b. Completed Masonry and Masonry Not Being Worked On

(1) Mean daily air temperature 40 to 32 degrees F. Masonry shall be protected from rain or snow for 24 hours by covering with weather-resistive membrane.

(2) Mean daily air temperature 32 to 25 degrees F. Masonry shall be completely covered with weather-resistant membrane for 24 hours.

(3) Mean Daily Air Temperature minus 25 to 20 degrees F. Masonry shall be completely covered with insulating blankets or equally protected for 24 hours.

(4) Mean Daily Temperature 20 degrees F and Below. Masonry temperature shall be maintained above 32 degrees F for 24 hours by enclosure and supplementary heat, by electric heating blankets, infrared heat lamps, or other approved methods.

3.1.4 Stains

3.1.4.1 Protect exposed surfaces from mortar and other stains. When mortar joints are tooled, remove mortar from exposed surfaces with fiber brushes and wooden paddles. Protect base of walls from splash stains by covering adjacent ground with sand, sawdust, or polyethylene.

3.1.5 Loads

3.1.5.1 Do not apply uniform loads for at least 12 hours or concentrated loads for at least 72 hours after masonry is constructed. Provide temporary bracing as required.

3.1.6 Surfaces

3.1.6.1 Surfaces on which masonry is to be placed shall be cleaned of laitance, dust, dirt, oil, organic matter, or other foreign materials and shall be slightly roughened to provide a surface texture with a depth of at least 1/8 inch. Sandblasting shall be used, if necessary, to remove laitance from pores and to expose the aggregate.

3.2 LAYING MASONRY UNITS

3.2.1 Coordinate masonry work with the work of other trades to accommodate built-in items and to avoid cutting and patching. Masonry units shall be laid in the indicated bond pattern. Facing courses shall be level with back-up courses. Each unit shall be adjusted to its final position while mortar is still soft and plastic. Units that have been disturbed after the mortar has stiffened shall be removed, cleaned, and relaid with fresh mortar. Air spaces, cavities, chases, expansion joints, and spaces to be grouted shall be kept free from mortar and other debris.

Units used in exposed masonry surfaces shall be selected from those having the least amount of chipped edges or other imperfections detracting from the appearance of the finished work.

Vertical joints shall be kept plumb. Units being laid and surfaces to receive units shall be free of water film and frost. Solid units shall be laid in a nonfurrowed full bed of mortar. Mortar for veneer wythes shall be beveled and sloped toward the center of the wythe from the cavity

04 20 00-19 05/08/09 side. Units shall be shoved into place so that the vertical joints are tight. Vertical joints of brick and the vertical face shells of concrete masonry units, except where indicated at control, expansion, and isolation joints, shall be completely filled with mortar. Mortar will be permitted to protrude up to 1/2 inch into the space or cells to be grouted. Means shall be provided to prevent mortar from dropping into the space below. In double wythe construction, the inner wythe may be brought up not more than 16 inches ahead of the outer wythe. Collar joints shall be filled with mortar or grout during the laying of the facing wythe, and filling shall not lag the laying of the facing wythe by more than 8 inches.

3.2.2 Forms and Shores

3.2.2.1 Provide bracing and scaffolding as required. Design bracing to resist wind pressure as required by local codes. Forms and shores shall be sufficiently rigid to prevent deflections which may result in cracking or other damage to supported masonry and sufficiently tight to prevent leakage of mortar and grout. Supporting forms and shores shall not be removed in less than 10 days.

3.2.3 Reinforced Concrete Masonry Units Walls

3.2.3.1 Where vertical reinforcement occurs, fill cores solid with grout. Lay units in such a manner as to preserve the unobstructed vertical continuity of cores to be filled. Embed the adjacent webs in mortar to prevent leakage of grout. Remove mortar fins protruding from joints before placing grout. Minimum clear dimensions of vertical cores shall be 2 by 3 inches. Position reinforcing accurately as indicated before placing grout. As masonry work progresses, secure vertical reinforcing in place at vertical intervals not to exceed 160 bar diameters. Use puddling rod or vibrator to consolidate the grout. Minimum clear distance between masonry and vertical reinforcement shall be not less than 1/2 inch. Unless indicated or specified otherwise, form splices by lapping bars not less than 40 bar diameters and wire tying them together.

3.2.4 Concrete Masonry Units

3.2.4.1 Units in piers, pilasters, columns, starting courses on footings, lintels, and beams, and where cells are to be filled with grout shall be full bedded in mortar under both face shells and webs.

Other units shall be full bedded under both face shells. Head joints shall be filled solidly with mortar for a distance in from the face of the unit not less than the thickness of the face shell.

Jamb units shall be of the shapes and sizes to conform with wall units. Solid units may be incorporated in the masonry work where necessary to fill out at corners, gable slopes, and elsewhere as approved. Double walls shall be stiffened at wall-mounted plumbing fixtures by use of strap anchors, two above each fixture and two below each fixture, located to avoid pipe runs, and extending from center to center of the double wall. Walls and partitions shall be adequately reinforced for support of wall-hung plumbing fixtures when chair carriers are not specified.

3.2.5 Clay Brick Units

3.2.5.1 Brick facing shall be laid with the better face exposed. Brick shall be laid in running bond with each course bonded at corners, unless otherwise indicated. Molded brick shall be laid with the frog side down. Brick that is cored, recessed, or has other deformations may be used in sills, treads, soldier courses, except where deformations will be exposed to view.

3.2.5.2 Wetting of Units

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a. Wetting of clay brick, or hollow brick units having an initial rate of absorption of more than 1 gram per minute per square inch of bed surface shall be in conformance with ASTM C 67. The method of wetting shall ensure that each unit is nearly saturated but surface dry when laid. Test clay or shale brick daily on the job, prior to laying, as follows: Using a wax pencil, draw a circle the size of a quarter on five randomly selected bricks. Apply 20 drops of water with a medicine dropper to the surface within the circle on each brick. If the average time that the water is completely absorbed in the five bricks is less than 1-1/2 minutes, wet bricks represented by the five bricks tested.

3.2.5.3 Solid Units

a. Bed, head, and collar joints shall be completely filled with mortar.

3.2.5.4 Hollow Units

a. Hollow units shall be laid as specified for concrete masonry units.

3.2.5.5 Brick-Faced Walls

a. For brick-faced walls, bond brick in the pattern as indicated on the drawings. Provide additional bonding ties spaced not more than 3 feet apart around the perimeter of and within 12 inches of all openings.

(1) Collar Joints: Fill collar joints solid with mortar as each course of brick is laid. Do not disturb units in place.

(2) Brick Sills: Lay brick on edge, slope, and project not less than 1/2 inch beyond the face of the wall to form a wash and drip. Fill all joints solidly with mortar and tool.

3.2.5.6 Cavity Walls

a. Provide a continuous cavity as indicated. Securely tie the two wythes together with horizontal joint reinforcement.