Attach 1.Spec 5.04 21 00.09R0007.pdf

Solicitation No. FA5270-09-R-0007

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DIVISION 4 - MASONRY

SECTION 04 21 00

REINFORCED MASONRY

PART 1 - GENERAL

1.1 REFERENCES

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. The most current editions shall be used.

AMERICAN CONCRETE INSTITUTE (ACI):

ACI SP-66-04 ACI Detailing Manual

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM):

ASTM A615/A 615M-08 Deformed and Plain Billet-Steel Bars For Concrete Reinforcement

ASTM C33-07 Concrete Aggregates

ASTM C39-05 Comprehensive Strength of Cylindrical Concrete Specimens

ASTM C91-05 Masonry Cement

ASTM C 94-04 Ready-Mixed Concrete

ASTM C140-07 Sampling and Testing Concrete Masonry Units

ASTM C144-04 Aggregate for Masonry Mortar

ASTM C150-07 Portland Cement

ASTM C207-06 Hydrated Lime for Masonry Purposes

ASTM C404-94 Aggregates for Masonry Grout

ASTM C426-99 Drying Shrinkage of Concrete Block

UNDERWRITERS LABORATORIES, INC. (UL):

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UL 618-79 Concrete Masonry Units, Eighth Edition

JAPANESE ARCHITECTURAL STANDARD SPECIFICATIONS (JASS):

JASS 5-97 Reinforced Concrete Construction

JAPANESE INDUSTRIAL STANDARDS (JIS):

JIS A 5308-98 Ready-Mixed Concrete

JIS A 5406-00 Hollow Concrete Blocks

JIS 5407-93 Decorative Concrete Blocks

JIS G 3112-87 Steel Bar for Concrete Reinforcement

JIS R 5210-97 Portland Cement

1.2 SUBMITTALS

Submit the following in accordance with Section 01 11 00, "General Requirements". See AF Form

66 on submittal schedule.

a. Shop Drawings:

1. Reinforcing Bars: Include plans, elevations, and details of reinforcing bars showing treatment of reinforcing at turns and offsets; intersections of similar and dissimilar materials; tops, bottoms, and ends of walls; control and expansion joints; and wall openings. Show details of positioning devices for vertical reinforcing bars.

b. Concrete Masonry Unit Test Reports:

1. Submit test reports on compressive strength, linear drying shrinkage, unit eight and absorption of each type of unit. Pop out and staining properties of lightweight aggregates used in the units.

c. Manufacturer’s Product Data:

1. Concrete masonry units (Hollow Concrete Block)

2. Decorative Blocks

3. Lime

4. Joint Reinforcement bars

d. Mortar and Grout Admixture: Submit test reports indicating the advantages that will result when mortar and grout admixtures are used.

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1.3 DELIVERIES, STORAGE, AND HANDLING

Handle, store, and protect masonry units to avoid chipping, breakage or contact with the soil.

Keep steel reinforcing bars free of rust and loose scale. Reject rusted steel reinforcement.

Deliver cement and lime in unbroken bags, barrels, or other sealed containers. Keep cement materials dry. Store and handle cement to prevent the inclusion of foreign materials. Store aggregates in a manner to avoid contamination or segregation. Plainly mark and label containers with the manufacturer's names and brands.

1.4 GROUTING EQUIPMENT

f. Grout Pumps: Do not pump through aluminum tubes. Operate pumps to produce a continuous stream of grout without air pockets. Upon completion of each day pumping, eject grout from pipeline without contamination of segregation of the grout. Remove waste materials and debris from the equipment.

g. Vibrators: Internal vibrators shall maintain speed of not less than 5,000 impulse per minute when submerged in the grout. Maintain at least one spare vibrator at the site at all times.

PART 2 - PRODUCTS

2.1 MASONRY UNITS

a. Concrete Masonry Units:

1. Aggregates: ASTM C33 or JIS A 5406, Table I except grading of aggregates as stipulated in ASTM C33.

b. Decorative Blocks:

1. JIS 5407, made with normal weight aggregate.

2.2 REINFORCING STEEL BARS

ASTM A615, Grade 40 or JIS G 3112, SD 30.

2.3 MATERIALS FOR MORTAR AND GROUT

a. Admixtures:

1. Other Admixtures: Another admixture may be used in mortar or grout provided that the admixture does not adversely affect bond or compressive strength of mortar or grout.

2. Prohibited Ingredients: Do not use anti-freeze or air entraining compounds, calcium chloride salts or other chemicals that will adversely affect metals or the coatings of metals embedded in the mortar or grout.

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a. Aggregate for Mortar: ASTM C144, except that not less than 3 percent nor more than

15.

1. percent shall pass the No. 100 sieve. Aggregate used in mortar for joints 1/4 inch or less shall have 100 percent passing the No. 8 sieve with 10 percent being retained on the No. 16 sieve.

a. Aggregate for Grout:

1. Fine Aggregate: ASTM C404, Size No. 2 or ASTM C144

a. Portland Cement: ASTM C150, Type I, II, low alkali or JIS R 5210, Type I.

b. Lime Putty: Slaked according to manufacturer's instructions.

1. Hydrated Lime: ASTM C207, Type S.

c. Water: Potable

2.4 MORTAR MIXES

a. Mortar shall be mixed in the proportion of two parts by volume of cement to five parts by volume of damp loose sand.

2.5 GROUT MIXTURES

a. Proportions: Mix in laboratory established proportions to attain a compressive strength at 28 days of not less than 1500 pounds per square inch when tested in accordance with ASTM C91 for fine aggregate and ASTM C39 for grout containing coarse aggregate.

Grout shall be classified as fine, types as specified below.

1. Fine Grout: Portland cement, fine aggregate, and sufficient water to obtain a pouring consistency without segregation of the constituents. Slump shall be approximately 5 inches.

b. Batching and Mixing: Conform to the applicable requirements of ASTM C94 or JIS A

5308.

2.6 SOURCE QUALITY CONTROL

Prior to delivery of masonry units to the site, select by random sampling nine individual whole units from the units proposed for use. Select units free from cracks or other structural defects.

Test in accordance with ASTM C140 and ASTM C426.

PART 3 - EXECUTION

3.1 PREPARATION

a. Protection:

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1. Forms and Shores: Where required, construct forms to the shapes, lines, and dimensions of the members indicated. Construct forms 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. Do not remove supporting forms or shores until the supported masonry has acquired sufficient strength to support its weight and construction loads to which it may be subjected.

In no case shall supporting forms or shores be removed in less than 10 days. Wait at least 16 hours after grouting masonry columns or walls before applying uniform loads and wait an additional 48 hours before applying concentrated loads.

2. Wall Bracing: Brace walls against wind and other forces during construction.

Allow sufficient time between lifts to prevent displacement of solid masonry units or cracking of face shells of hollow masonry units. If blowouts, misalignment, or cracking of face-shells should occur during construction, tear down and rebuild the wall.

b. Surface Preparation: Clean, dust, dirt, oil, organic matter or other foreign materials from concrete surface upon which reinforced masonry is to be placed. Use sand blasting, if necessary, to remove laitance from pores and to expose the aggregate.

3.2 LAYING MASONRY UNITS:

a. Wet Masonry Unit: Do not wet concrete masonry units. Do not lay units having a film of water on the surface.

b. Embedded Items: Build items required to be built-in as the masonry work progresses.

c. Unfinished Work: Step back unfinished work for joining with new work. Do not use toothing without the written approval of the Contracting Officer. Remove loose mortar and thoroughly clean the exposed joints before laying new work.

d. Placing Units: Lay hollow masonry units so as to preserve the vertical continuity of cells filled with grout. The minimum clear horizontal dimensions of vertical cores shall be 2 inches by 3 inches. Masonry bond units at corners. Anchor intersections by reinforcing bars or stirrups as indicated. Adjust each unit to its final position while mortar is still soft and plastic. If any unit is disturbed after mortar has stiffened, remove and re-lay in fresh mortar. Keep spaces to be grouted, free from mortar and other debris. Keep units in exposed masonry surfaces free from chipped edges or other imperfections detracting from the appearance of the finished work when viewed from a distance of ten feet.

e. Bond Pattern: Lay masonry units in pattern indicated.

f. Cutting and Fitting: Wherever possible, use full units of the proper size in lieu of cut units.

Use power masonry saws for cutting and fitting. Concrete masonry units shall be wet cut.

Make cut edges clean, true and sharp.

g. Mortar Joints: Spread bed joints with mortar for the full thickness of the face shells.

Where only cells containing reinforcement are to be grouted, spread cross webs around such cells with mortar to prevent leakage of grout. Butter head joints for the full thickness

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of the face shell and place the units. Avoid fins of mortar that protrude into cells to be grouted.

h. Jointing: Tool joints when the mortar is thumbprint hard. Tool horizontal vertical joints first.

i. Tooled Joints: Tool joints in exposed exterior and interior masonry surfaces slightly concave. Use a jointer slightly larger than the joint width so that complete contact is made along the edges of the unit. Perform tooling so that the mortar is compressed and the joint surface is sealed. Use a jointer of sufficient length to obtain a straight and true mortar joint.

j. Joint Widths: Make joint widths as follows:

1. Concrete Masonry Units: 3/8 inch wide for all other units.

3.3 PLACING REINFORCING STEEL:

Prior to placing grout, clean reinforcement of loose, flaky rust, scale, grease, mortar, grout, or other coating which might destroy or reduce its bond with the grout. Details of reinforcement shall be in conformance with ACI SP-66 or JASS 5. Do not bend or straighten reinforcing in a manner injurious to the steel. Do not use bars with kinks or bends not shown on the drawings.

Placement of reinforcement shall be inspected and approved prior to placing grout.

a. Positioning Bars: Position vertical bars accurately at the lateral position indicated.

Maintain a minimum clearance between the bars and masonry units of 1/2 inch and between parallel bars of one diameter of the reinforcement. Hold vertical reinforcing in place using metal supports, centering clips, spacers, ties or caging devices located near the ends of each bar and at intermediate intervals of not more than 192 diameters of the reinforcement. Laying ties in mortar joints will not be permitted.

b. Splices: Locate splices only as indicated. Stagger splices in adjacent bars at least 24 inches. Lap bars a minimum of 40 diameters of the reinforcement or two feet, whichever is greater. Welded or mechanical connections shall develop the full strength of the reinforcement.

3.4 PLACING GROUT:

a. Wall Bracing: Brace walls against wind and other forces during construction. Allow sufficient time between lifts to preclude displacement of solid masonry units or cracking of face shells of hallow masonry units. If blowouts, misalignment or cracking of face shells should occur during construction, tear down and rebuild the wall.

b. Grout Placement: Use a hand bucket. Place grout in final position within 1 1/2 hours after mixing. Where grouting is discontinued for more than one hour, stop the grout one inch below the top of a course to form a key at pour joints. Place grout so as to completely fill the grout spaces without segregation of the aggregates.

3.5 FIELD QUALITY CONTROL

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a. Mortar and Grout: Employ a qualified testing laboratory to proportion and test mortar and grout. Do not change laboratory established proportions or use materials with different physical or chemical characteristics in mortar and grout for the work unless additional evidence is furnished that the mortar and grout meets the specified requirements.

3.6 POINTING AND CLEANING

After mortar joints have attained their initial set but prior to hardening, completely remove mortar and grout daubs or splashings from exposed masonry surfaces. Before completion of the work, rake out defects in joints in exposed masonry surfaces, fill with mortar and tool to match existing joints. Immediately after grout work is completed remove scum and stains which have percolated through the masonry using a high pressure stream of water and a stiff bristled brush. Do not use metal tools or metal brushes for cleaning.

a. Concrete Masonry Units (CMU): Dry brush exposed concrete masonry unit surfaces at the end of work each day and after pointing. Use stiff-fiber bristled brushes only.

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