AMEND 0005-ATTACH #1-Masonry and Paint Spec - Div 04 and 09.pdf

SECTION 04 20 00

UNIT MASONRY

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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 within the text by the basic designation only.

AMERICAN CONCRETE INSTITUTE (ACI)

ACI SP-66 (2004) ACI Detailing Manual

ASTM INTERNATIONAL (ASTM)

ASTM A1008/A1008M (2016) Standard Specification for Steel, Sheet, Cold-Rolled, Carbon, Structural, High-Strength Low-Alloy, High-Strength Low-Alloy with Improved Formability, Solution Hardened, and Bake Hardenable

ASTM A1064/A1064M (2017) Standard Specification for Carbon-Steel Wire and Welded Wire Reinforcement, Plain and Deformed, for Concrete

ASTM A153/A153M (2016) Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware

ASTM A167 (2011) Standard Specification for Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and Strip

ASTM A185/A185M (2007) Standard Specification for Steel Welded Wire Reinforcement, Plain, for Concrete

ASTM A615/A615M (2016) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement

ASTM A641/A641M (2009a; R 2014) Standard Specification for Zinc-Coated (Galvanized) Carbon Steel Wire

ASTM A653/A653M (2017) Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process

ASTM A951/A951M (2011) Standard Specification for Steel Wire for Masonry Joint Reinforcement

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ASTM A996/A996M (2016) Standard Specification for Rail-Steel and Axle-Steel Deformed Bars for Concrete Reinforcement

ASTM B370 (2012) Standard Specification for Copper Sheet and Strip for Building Construction

ASTM C1019 (2018) Standard Test Method for Sampling and Testing Grout

ASTM C129 (2017) Standard Specification for Nonloadbearing Concrete Masonry Units

ASTM C1384 (2012a) Standard Specification for Admixtures for Masonry Mortars

ASTM C1611/C1611M (2014) Standard Test Method for Slump Flow of Self-Consolidating Concrete

ASTM C207 (2018) Standard Specification for Hydrated Lime for Masonry Purposes

ASTM C270 (2014a) Standard Specification for Mortar for Unit Masonry

ASTM C476 (2018) Standard Specification for Grout for Masonry

ASTM C494/C494M (2017) Standard Specification for Chemical Admixtures for Concrete

ASTM C641 (2017) Standard Test Method for Iron Staining Materials in Lightweight Concrete Aggregates

ASTM C780 (2017) Standard Test Method for Preconstruction and Construction Evaluation of Mortars for Plain and Reinforced Unit Masonry

ASTM C90 (2016) Standard Specification for Loadbearing Concrete Masonry Units

ASTM C979/C979M (2016) Standard Specification for Pigments for Integrally Colored Concrete

ASTM D2000 (2012; R 2017) Standard Classification System for Rubber Products in Automotive Applications

ASTM D2287 (2012) Nonrigid Vinyl Chloride Polymer and Copolymer Molding and Extrusion Compounds

ASTM E514/E514M (2014a) Standard Test Method for Water Penetration and Leakage Through Masonry

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THE MASONRY SOCIETY (TMS)

TMS MSJC (2016) Masonry Standard Joint Committee's (MSJC) Book - Building Code Requirements and Specification for Masonry Structures, Containing TMS 402/ACI 530/ASCE 5, TMS 602/ACI 530.1/ASCE 6, and Companion Commentaries

1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for Contractor Quality Control approval. Submit the following in accordance with Section 01 33 00

SUBMITTAL PROCEDURES:

SD-03 Product Data

Hot Weather Procedures;

Cold Weather Procedures;

Cement;

Cementitious Materials;

SD-04 Samples

Concrete Masonry Units (CMU);

SD-05 Design Data

Masonry Compressive Strength;

SD-06 Test Reports

Field Testing of Mortar

SD-07 Certificates

Concrete Masonry Units (CMU)

Cementitious Materials

SD-08 Manufacturer's Instructions

Admixtures for Masonry Mortar

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Admixtures for Grout

SD-10 Operation and Maintenance Data

Take-Back Program

1.3 DELIVERY, STORAGE, AND HANDLING

Deliver, store, handle, and protect material 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.

1.3.1 Masonry Units

Cover and protect masonry units from precipitation. Conform to handling and storage requirements of TMS MSJC.

a. Pack glazed brick, glazed structural clay tile, and prefaced concrete masonry units in the manufacturer's standard paper cartons, trays, or shrink wrapped pallets with a divider between each unit. Do not stack pallets. Do not remove units from cartons until cartons are placed on scaffolds or in the location where units are to be laid.

b. Mark prefabricated lintels on top sides to show either the lintel schedule number or the number and size of top and bottom bars.

1.3.2 Reinforcement, Anchors, and Ties

Store steel reinforcing bars, coated anchors, ties, and joint reinforcement above the ground. Maintain steel reinforcing bars and uncoated ties free of loose mill scale and loose rust.

1.3.3 Cementitious Materials, Sand and Aggregates

Deliver cementitious and other packaged materials in unopened containers, plainly marked and labeled with manufacturers' names and brands. Store cementitious material in dry, weathertight enclosures or completely cover.

Handle cementitious materials in a manner that will prevent the inclusion of foreign materials and damage by water or dampness. Store sand and aggregates in a manner to prevent contamination and segregation.

1.4 PROJECT/SITE CONDITIONS

Conform to TMS MSJC for hot and cold weather masonry erection.

1.4.1 Hot Weather Procedures

When ambient air temperature exceeds 100 degrees F, or exceeds 90 degrees F and the wind velocity is greater than 8 mph, comply with TMS MSJC Article

1.8 D for: preparation prior to conducting masonry work; construction while masonry work is in progress; and protection for newly completed masonry.

1.4.2 Cold Weather Procedures

When ambient temperature is below 40 degrees F, comply with TMS MSJC

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Article 1.8 C for: preparation prior to conducting masonry work;

construction while masonry work is in progress; and protection for newly completed masonry.

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

2.1.1 Design - Specified Compressive Strength of Masonry

The specified compressive strength of masonry, f'm, is as indicated for each type of masonry .

2.1.2 Performance - Verify Masonry Compressive Strength

Verify specified compressive strength of masonry using the "Unit Strength Method" of TMS MSJC. Submit calculations and certifications of unit and mortar strength.

Verify specified compressive strength of masonry using the "Prism Test Method" of TMS MSJC when the "Unit Strength Method" cannot be used. Submit test results.

2.2 MANUFACTURED UNITS

2.2.1 General Requirements

Do not change the source of materials, which will affect the appearance of the finished work, after the work has started except with Contracting Officer's approval. Submit test reports from an approved independent laboratory. Certify test reports on a previously tested material as the same materials as that proposed for use in this project. Submit certificates of compliance stating that the materials meet the specified requirements.

2.2.2 Concrete Units

2.2.2.1 Aggregates

Test lightweight aggregates, and blends of lightweight and heavier aggregates in proportions used in producing the units, for stain-producing iron compounds in accordance with ASTM C641,visual classification method.

Do not incorporate aggregates for which the iron stain deposited on the filter paper exceeds 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.

2.2.2.2 Concrete Masonry Units (CMU)

2.2.2.2.1 Cement

Use only cement that has a low alkali content and is of one brand.

2.2.2.2.2 Recycled Content

Units may contain post-consumer or post-industrial recycled content.

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2.2.2.2.3 Size

Provide units with specified dimension of to match existing.

2.2.2.2.4 Surfaces

For units that are to be plastered or stuccoed, provide surfaces that are sufficiently rough to provide bond. Elsewhere, provide units with exposed surfaces that are smooth and of uniform texture.

2.2.2.2.5 Weather Exposure

Provide concrete masonry units with water-repellant admixture added during manufacture where units will be exposed to weather.

2.2.2.2.6 Unit Types

a. Hollow Load-Bearing Units: ASTM C90, lightweight or medium weight .

Provide load-bearing units for exterior walls, foundation walls, load-bearing walls, and shear walls.

b. Hollow Non-Load-Bearing Units: ASTM C129, lightweight or medium weight .

Load-bearing units may be provided in lieu of non-load-bearing units.

c. Solid Load-Bearing Units: ASTM C90, lightweight or medium weight units. Provide solid units as indicated.

2.2.2.2.7 Jamb Units

Provide jamb units 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.

Provide sash jamb units with a 3/4 by 3/4 inch groove near the center at end of each unit.

2.3 EQUIPMENT

2.3.1 Vibrators

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

2.3.2 Grout Pumps

Pumping through aluminum tubes is not permitted.

2.4 MATERIALS

2.4.1 Mortar Materials

2.4.1.1 Cementitious Materials

Provide cementitious materials that conform to those permitted by ASTM C270.

2.4.1.2 Hydrated Lime and Alternates

Provide lime that conforms to one of the materials permitted by ASTM C207 for use in combination with portland cement, hydraulic cement, and blended hydraulic cement. Do not use lime in combination with masonry cement or

SECTION 04 20 00 Page 6 mortar cement.

2.4.1.3 Colored Mortar

Use mortar pigment that conforms to ASTM C979/C979M. Add pigment to mortar to produce a uniform color matching existing. Furnish pigments in accurately pre-measured and packaged units that can be added to a measured amount of cementitious materials or supply pigments via preblended cementitious materials or dry mortar mix.

a. In masonry cement or mortar cement, do not exceed 5 percent of cement weight for mineral oxide pigment; do not exceed 1 percent of cement weight for carbon black pigment.

b. In cement-lime mortar mix, do not exceed 10 percent of cementitious materials' weight for mineral oxide pigment; do not exceed 2 percent of cementitious materials' weight for carbon black pigment.

2.4.1.4 Admixtures for Masonry Mortar

In cold weather, use a non-chloride based accelerating admixture that conforms to ASTM C1384, unless Type III portland cement is used in the mortar.

In showers and kitchens, use mortar that contains a water-repellent admixture that conforms to ASTM C1384. Provide a water-repellent admixture, conforming to ASTM C1384 and of the same brand and manufacturer as the block's integral water-repellent, in the mortar used to place concrete masonry units that have an integral water-repellent admixture.

2.4.1.5 Aggregate and Water

Provide aggregate (sand) and water that conform to materials permitted by

ASTM C270.

2.4.2 Grout and Ready-Mix Grout Materials

2.4.2.1 Cementitious Materials for Grout

Provide cementitious materials that conform to those permitted by ASTM C476.

2.4.2.2 Admixtures for Grout

Water-reducing admixtures that conform to ASTM C494/C494M Type F or G and viscosity-modifying admixtures that conform to ASTM C494/C494M Type S are permitted for use in grout. Other admixtures require approval by the Contracting Officer.

In cold weather, a non-chloride based accelerating admixture may be used subject to approval by the Contracting Officer; use accelerating admixture that is non-corrosive and conforms to ASTM C494/C494M, Type C.

2.4.2.3 Aggregate and Water

Provide fine and coarse aggregates and water that conform to materials permitted by ASTM C476.

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2.5 MORTAR AND GROUT MIXES

2.5.1 Mortar Mix

a. Provide mortar Type N unless specified otherwise herein.

b. Use ASTM C270 Type S cement-lime mortar or mortar cement mortar for seismic-force-resisting elements indicated.

c. Provide mortar that conforms to ASTM C270. Use Type M mortar for foundation walls .

d. For field-batched mortar, measure component materials by volume. Use measuring boxes for materials that do not come in packages, such as sand, for consistent batching. Mix cementitious materials and aggregates between 3 and 5 minutes in a mechanical batch mixer with a sufficient amount of water to produce a workable consistency. Do not hand mix mortar unless approved by the Contracting Officer. Maintain workability of mortar by remixing or retempering. Discard mortar that has begun to stiffen or is not used within 2-1/2 hours after initial mixing.

e. For preblended mortar, follow manufacturer's mixing instructions.

2.5.2 Grout and Ready Mix Grout Mix

Use grout that conforms to ASTM C476, coarse. Use conventional grout with a slump between 8 and 11 inches. Use self-consolidating grout with slump flow of 24 to 30 inches and a visual stability index (VSI) not greater than

1. Provide minimum grout strength of 2000 psi in 28 days, as tested in accordance with ASTM C1019. Do not change proportions and do not use materials with different physical or chemical characteristics in grout for the work unless additional evidence is furnished that grout meets the specified requirements. Use ready-mixed grout that conforms to ASTM C476.

2.6 ACCESSORIES

2.6.1 Grout Barriers

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

2.6.2 Anchors, Ties, and Bar Positioners

2.6.2.1 General

a. Fabricate anchors and ties without drips or crimps. Size anchors and ties to provide a minimum of 5/8 inch mortar cover from each face of masonry.

b. Fabricate steel wire anchors and ties shall from wire conforming to ASTM A1064/A1064M and hot-dip galvanize in accordance with

ASTM A153/A153M.

c. Fabricate joint reinforcement in conformance with ASTM A951/A951M. Hot dip galvanize joint reinforcement in exterior walls and in interior walls exposed to moist environment in conformance with ASTM A153/A153M.

Galvanize joint reinforcement in other interior walls in conformance with ASTM A641/A641M; coordinate with paragraph JOINT REINFORCEMENT

SECTION 04 20 00 Page 8 below.

d. Fabricate sheet metal anchors and ties in conformance with ASTM A1008/A1008M. Hot dip galvanize sheet metal anchors and ties in exterior walls and in interior walls exposed to moist environment in compliance with ASTM A153/A153M Class B. Galvanize sheet metal anchors and ties in other interior walls in compliance with ASTM A653/A653M, Coating Designation G60.

e. Submit two anchors, ties and bar positioners of each type used, as samples.

2.6.2.2 Wire Mesh Anchors

Provide wire mesh anchors of 1/4 inch mesh galvanized hardware cloth, conforming to ASTM A185/A185M, with length not less than 12 inches, at intersections of interior non-bearing masonry walls.

2.6.2.3 Wall Ties for Multi-Wythe Masonry Construction

Provide rectangular-shaped wall ties, fabricated of hot-dipped galvanized W1.7 diameter steel wire. Provide rectangular wall ties no less than 4 inches wide.

Provide adjustable type wall ties, if approved for use, that consist of two essentially U-shaped elements fabricated of minimum W2.8 diameter steel wire or pintle type ties that are inserted to eyes of horizontal joint reinforcement, hot-dip galvanized. Provide adjustable ties with double pintle legs and allows a maximum offset of 1-1/4 inch between each element of the tie and maximum distance between connecting parts no more than 1/16 inch. Form the pintle and eye elements shall be formed so that both can be in the same plane. Wall ties may also be of a continuous type conforming to paragraph JOINT REINFORCEMENT.

2.6.2.4 Dovetail Anchors

Provide dovetail anchors of 3/16 inch diameter steel wire, triangular shaped, and attached to a 12 gauge or heavier steel dovetail section. Use these anchors to connect the exterior masonry wythe as it passes over the face of concrete columns, beams, or walls. Fill cells immediately above and below these anchors unless solid units are used. Furnish dovetail slots, which are specified to be installed by others, in accordance with Section 03 30 00 CAST-IN-PLACE CONCRETE.

2.6.2.5 Adjustable Anchors

2.6.2.5.1 Anchorage to Structural Steel

Provide hot-dip galvanized adjustable anchors for connecting masonry walls to the structural steel frame . Provide zinc-rich paint for touching up paint after welding galvanized anchors to structural steel.

2.6.2.5.2 Anchorage of Veneer to Light Gauge Steel or Concrete Backing

Use one of the following types of adjustable anchors to connect veneer to light gauge steel or concrete backing:

a. sheet metal at least 7/8 inch wide, 0.06 inch thick, and with corrugations having a wavelength of 0.3 to 0.5 inch and an amplitude of

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0.06 to 0.10 inch or bent, notched or punched to provide equivalent performance;

b. wire anchors of minimum size W1.7 with ends bent to form a minimum 2 inches extension and without drips;

c. or wire pintle anchors used in conjunction with joint reinforcement.

Do not exceed 1/16 inch clearance between connecting parts of the tie.

Assemble adjustable anchors to prevent disengagement. Provide pintle anchors with one or more pintle legs of wire size W2.8 and an offset not exceeding 1-1/4 inch.

2.6.3 Joint Reinforcement

Factory fabricate joint reinforcement in conformance with ASTM A951/A951M, welded construction. Provide ladder type joint reinforcement, having one longitudinal wire in the mortar bed of each face shell for hollow units and one wire for solid units and with all wires a minimum of 9 gauge. Size joint reinforcement to provide a minimum of 5/8 inch cover from each face.

Space crosswires not more than 16 inches. Provide joint reinforcement for straight runs in flat sections not less than 10 feet long. Provide joint reinforcement with factory formed corners and intersections. If approved for use, joint reinforcement may be furnished with adjustable wall tie features. Submit one piece of each type used, including corner and wall intersection pieces, showing at least two cross wires.

2.6.4 Reinforcing Steel Bars

Reinforcing steel bars and rods shall conform to ASTM A615/A615M or ASTM A996/A996M, Grade 60.

2.6.5 Concrete Masonry Control Joint Keys

Provide control joint keys of a factory fabricated solid section of natural or synthetic rubber (or combination thereof) conforming to ASTM D2000 M2AA-805 with a minimum durometer hardness of 80 or polyvinyl chloride conforming to ASTM D2287 Type PVC 654-4 with a minimum durometer hardness of 85. Form the control joint key 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, to fit neatly, but without forcing, in masonry unit jamb sash grooves.

2.6.6 Through Wall Flashing and Weeps

2.6.6.1 General

Provide coated copper, copper or stainless steel sheet, self-adhesive rubberized sheet, or reinforced membrane sheet flashing except that flashing indicated to terminate in reglets shall be metal or coated-metal flashing and except that the material shall be one which is not adversely affected by dampproofing material.

2.6.6.2 Coated-Copper Flashing

Provide 7 ounce, electrolytic copper sheet, uniformly coated on both sides with acidproof, alkaliproof, asphalt impregnated kraft paper or

SECTION 04 20 00 Page 10 polyethylene sheets.

2.6.6.3 Copper or Stainless Steel Flashing

Provide copper sheet, complying with ASTM B370, minimum 16 ounce weight; or stainless steel, ASTM A167, Type 304 or 316, 0.015 inch thick, No. 2D finish.

2.6.6.4 Reinforced Membrane Flashing

Provide polyester film core with a reinforcing fiberglass scrim bonded to one side. Provide membrane that is impervious to moisture, flexible, is not affected by caustic alkalis, and after being exposed for not less than 1/2 hour to a temperature of 32 degrees F, shows 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.

2.6.6.5 Rubberized Flashing

Provide self-adhesive rubberized asphalt sheet flashing consisting of 32-mil thick pliable and highly adhesive rubberized asphalt compound bonded completely and integrally to 8-mil thick, high density, cross-laminated polyethylene film to produce an overall thickness of 40 mils. Provide rubberized, asphalt-based mastic and surface conditioner that are each approved by flashing manufacturer for use with flashing material.

2.6.6.6 Weep Ventilators

Provide weep ventilators that are prefabricated from stainless steel or plastic. Provide inserts with grill or louver-type openings designed to allow the passage of moisture from cavities and to prevent the entrance of insects, and with a rectangular closure strip to prevent mortar droppings from clogging the opening. Provide ventilators with compressible flanges to fit in a standard 3/8 inch wide mortar joint and with height equal to the nominal height of the unit.

2.6.6.7 Single-Wythe Exterior Wall CMU Flashing System

In single-wythe exterior CMU walls, provide a system of CMU cell flashing pans and interlocking CMU web covers made from UV-resistant, high-density polyethylene. For exterior CMU walls, provide a flashing/weep system in open cores that do not receive grout. Cell flashing pans are to have integral weep spouts built into mortar bed joints that extend into the cell to prevent clogging with mortar.

2.6.6.8 Metal Drip Edge

Provide stainless steel drip edge, 15-mil thick, hemmed edges, with down-turned drip at the outside edge and upturned dam at the inside edge for use with membrane flashings.

2.6.7 RIGID BOARD-TYPE INSULATION

Provide rigid board-type insulation as specified in Section 07 21 13 BOARD

AND BLOCK INSULATION.

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PART 3 EXECUTION

3.1 EXAMINATION

Prior to start of work, verify the applicable conditions as set forth in TMS MSJC, inspection.

3.2 PREPARATION

3.2.1 Stains

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.

3.2.2 Loads

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.

3.2.3 Concrete Surfaces

Where masonry is to be placed, clean concrete of laitance, dust, dirt, oil, organic matter, or other foreign materials and slightly roughen to provide a surface texture with a depth of at least 1/8 inch. Sandblast, if necessary, to remove laitance from pores and to expose the aggregate.

3.2.4 Shelf Angles

Adjust shelf angles as required to keep the masonry level and at the proper elevation.

3.2.5 Bracing

Provide bracing and scaffolding necessary for masonry work. Design bracing to resist wind pressure as required by OSHA and local codes and submit bracing calculations, sealed by a registered professional engineer. Do not remove bracing in less than 10 days.

3.3 ERECTION

3.3.1 General

a. Coordinate masonry work with the work of other trades to accommodate built-in items and to avoid cutting and patching. Lay masonry units in running bond pattern. Lay facing courses level with back-up courses, unless the use of adjustable ties has been approved in which case the tolerances is plus or minus 1/2 inch. Adjust each unit to its final position while mortar is still soft and has plastic consistency.

b. Remove and clean units that have been disturbed after the mortar has stiffened, and relay with fresh mortar. Keep air spaces, cavities, chases, expansion joints, and spaces to be grouted free from mortar and other debris. Select units to be used in exposed masonry surfaces from those having the least amount of chipped edges or other imperfections detracting from the appearance of the finished work.

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c. When necessary to temporarily discontinue the work, step (rack) back the masonry for joining when work resumes. Toothing may be used only when specifically approved by the Contracting Officer. Before resuming work, remove loose mortar and thoroughly clean the exposed joint.

Cover the top of walls subjected to rain or snow with nonstaining waterproof covering or membrane when work is not in process. Extend the covering a minimum of 610 mm 2 feet down on each side of the wall and hold securely in place.

d. Ensure that units being laid and surfaces to receive units are free of water film and frost. Lay solid units in a nonfurrowed full bed of mortar. Bevel mortar for veneer wythes and slope down toward the cavity side. Shove units into place so that the vertical joints are tight. Completely fill vertical joints between solid units with mortar, except where indicated at control, expansion, and isolation joints. Place hollow units so that mortar extends to the depth of the face shell at heads and beds, unless otherwise indicated. Mortar will be permitted to protrude up to 1/2 inch into the space or cells to be grouted. Provide means to prevent mortar from dropping into the space below or clean grout spaces prior to grouting.

e. In multi-wythe construction with collar joints no more than 3/4 inch wide, bring up the inner wythe not more than 16 inches ahead of the outer wythe. Fill collar joints with mortar during the laying of the facing wythe, and filling shall not lag the laying of the facing wythe by back-buttering each unit as it is laid.

3.3.1.1 Jointing

Tool mortar joints when the mortar is thumbprint hard. Tool horizontal joints after tooling vertical joints. Brush mortar joints to remove loose and excess mortar.

3.3.1.1.1 Tooled Joints

Tool mortar joints in exposed exterior and interior masonry surfaces concave , using a jointer that is 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.

No exterior joints are to be left un-tooled.

3.3.1.1.2 Flush Joints

Flush cut mortar joints in concealed masonry surfaces and joints at electrical outlet boxes in wet areas. Finish flush cut joints by cutting off the mortar flush with the face of the wall. Point joints in unparged masonry walls below grade tight. For architectural units, such as fluted units, completely fill both the head and bed joints and flush cut.

3.3.1.1.3 Door and Window Frame Joints

On the exposed interior side of exterior frames, joints between frames and abutting masonry walls shall be raked to a depth of 3/8 inch. On the exterior side of exterior frames, joints between frames and abutting masonry walls shall be raked to a depth of 3/8 inch.

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3.3.1.1.4 Joint Widths

a. Construct brick masonry with mortar joint widths equal to the difference between the specified and nominal dimensions of the unit, within tolerances permitted by TMS MSJC.

b. Provide 3/8 inch wide mortar joints in concrete masonry, except for prefaced concrete masonry units.

c. Provide 3/8 inch wide mortar joints on unfaced side of prefaced concrete masonry units and not less than 3/16 inch nor more than 1/4 inch wide on prefaced side.

d. Maintain mortar joint widths within tolerances permitted by TMS MSJC

3.3.1.2 Cutting and Fitting

Use full units of the proper size wherever possible, in lieu of cut units.

Locate cut units where they would have the least impact on the architectural aesthetic goals of the facility. Perform cutting and fitting, including that required to accommodate the work of others, by masonry mechanics using power masonry saws. Concrete masonry units may be wet or dry cut. Before being placed in the work, dry wet-cut units to the same surface-dry appearance as uncut units being laid in the wall. Provide cut edges that are clean, true and sharp.

a. Carefully make openings in the masonry so that wall plates, cover plates or escutcheons required by the installation will completely conceal the openings and will have bottoms parallel with the masonry bed joints. Provide reinforced masonry lintels above openings over 12 inches wide for pipes, ducts, cable trays, and other wall penetrations, unless steel sleeves are used.

b. Do not reduce masonry units in size by more than one-third in height and one-half in length. Do not locate cut products at ends of walls, corners, and other openings.

3.3.1.3 Unfinished Work

Rack back unfinished work for joining with new work. Toothing may be resorted to only when specifically approved by the Contracting Officer.

Remove loose mortar and thoroughly clean the exposed joints before laying new work.

3.3.2 Reinforced, Single Wythe Concrete Masonry Units Walls

3.3.2.1 Concrete Masonry Unit Placement

a. Fully bed units used to form piers, pilasters, columns, starting courses on footings, solid foundation walls, lintels, and beams, and where cells are to be filled with grout in mortar under both face shells and webs. Provide mortar beds under both face shells for other units. Mortar head joints for a distance in from the face of the unit not less than the thickness of the face shell.

b. Solidly grout foundation walls below grade.

c. Stiffen double walls at wall-mounted plumbing fixtures by use of strap anchors, two above each fixture and two below each fixture, located to

SECTION 04 20 00 Page 14 avoid pipe runs, and extending from center to center of each wall within the double wall. Adequately reinforce walls and partitions for support of wall-hung plumbing fixtures when chair carriers are not specified.

d. Submit drawings showing elevations of walls exposed to view and indicating the location of all cut CMU products.

3.3.2.2 Preparation for Reinforcement

Lay units in such a manner as to preserve the unobstructed vertical continuity of cores to be grouted. Remove mortar protrusions extending 1/2 inch or more into cells before placing grout. Position reinforcing bars accurately as indicated before placing grout. Where vertical reinforcement occurs, fill cores solid with grout in accordance with paragraph PLACING GROUT in this Section.

3.3.3 ANCHORAGE

3.3.3.1 Anchorage to Concrete

Anchorage of masonry to the face of concrete columns, beams, or walls shall be with dovetail anchors spaced not over 16 inches on centers vertically and 24 inches on center horizontally.

3.3.3.2 Anchorage to Structural Steel

Masonry shall be anchored to vertical structural steel framing with adjustable steel wire anchors spaced not over 16 inches on centers vertically, and if applicable, not over 24 inches on centers horizontally.

3.3.3.3 Anchorage at Intersecting Walls

Provide wire mesh anchors at maximum 16 inches spacing at intersections of interior non-bearing masonry walls.

Anchor structural masonry walls with strap anchors of minimum size 1/4 inch x 1-1/2 inch x 28 inches including 2 inch) 90 degree bends at each end to form U or Z shape at maximum spacing 48 inches, grouted into the wall, unless the drawings indicate a movement joint at the intersection.

3.3.4 Lintels

3.3.4.1 Masonry Lintels

Construct masonry lintels with lintel units filled solid with grout in all courses and reinforced with a minimum of two No. 4 bars in the bottom course unless otherwise indicated. Extend lintel reinforcement beyond each side of masonry opening 40 bar diameters or 24 inches, whichever is greater. Support reinforcing bars in place prior to grouting and locate 1/2 inch above the bottom inside surface of the lintel unit.

3.3.4.2 Precast Concrete and Steel Lintels

Provide precast concrete and steel lintels as shown on the Drawings. Set lintels in a full bed of mortar with faces plumb and true. Provide steel and precast lintels with a minimum bearing length of 8 inches unless otherwise indicated. In partially grouted masonry, provide fully grouted units under the full lintel bearing length, unless otherwise indicated.

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3.3.5 Sills and Copings

Set sills and copings in a full bed of mortar with faces plumb and true.

Slope sills and copings to drain water. Mechanically anchor copings and sills longer than 4 feet as indicated.

3.4 INSTALLATION

3.4.1 Bar Reinforcement Installation

3.4.1.1 Preparation

Submit detail drawings showing bar splice locations. Identify bent bars on a bending diagram and reference and locate such bars on the drawings.

Show wall dimensions, bar clearances, and wall openings. Utilize bending details that conform to the requirements of ACI SP-66. 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, resubmit the approved shop drawings with the additional openings shown along with the proposed changes. Clearly highlight location of these additional openings. Provide wall elevation drawings with minimum scale of 1/4 inch per foot. Submit 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.

Clean reinforcement of loose, flaky rust, scale, grease, mortar, grout, and other coatings that might destroy or reduce its bond prior to placing grout. Do not use bars with kinks or bends not shown on the approved shop drawings. Place reinforcement prior to grouting. Unless otherwise indicated, extend vertical wall reinforcement to within 2 inches of tops of walls.

3.4.1.2 Positioning Bars

a. Accurately place vertical bars within the cells at the positions indicated on the drawings. A minimum clearance of 1/2 inch shall be maintained between the bars and masonry units. Provide minimum clearance between parallel bars of 1/2 inch between the bars and masonry units for coarse grout and a minimum clearance of 1/4 inch between the bars and masonry units for fine grout. Provide minimum clearance between parallel bars of 1 inch or one diameter of the reinforcement, whichever is greater. Vertical reinforcement may be held in place using bar positioners located near the ends of each bar and at intermediate intervals of not more than 192 diameters of the reinforcement or by other means to prevent displacement beyond permitted tolerances. As masonry work progresses, secure vertical reinforcement to prevent displacement beyond allowable tolerances.

b. Wire column and pilaster lateral ties in position around the vertical reinforcing bars. Place lateral ties in contact with the vertical reinforcement and do not place in horizontal mortar bed joints.

c. Position horizontal reinforcing bars as indicated. Stagger splices in adjacent horizontal bars, unless otherwise indicated.

d. Form splices by lapping bars as indicated. Do not cut, bend or

SECTION 04 20 00 Page 16 eliminate reinforcing bars. Foundation dowel bars may be field-bent when permitted by TMS MSJC.

3.4.1.3 Splices of Bar Reinforcement

Lap splice reinforcing bars as indicated. When used, provide welded or mechanical connections that develop at least 125 percent of the specified yield strength of the reinforcement.

3.4.2 Placing Grout

3.4.2.1 General

Fill cells containing reinforcing bars with grout. Solidly grout hollow masonry units in walls or partitions supporting plumbing, heating, or other mechanical fixtures, voids at door and window jambs, and other indicated spaces. Solidly grout cells under lintel bearings on each side of openings for full height of openings. Solidly grout walls below grade, lintels, and bond beams. Units other than open end units may require grouting each course to preclude voids in the units.

Discard site-mixed grout that is not placed within 1-1/2 hours after water is first added to the batch or when the specified slump is not met without adding water after initial mixing. Discard ready-mixed grout that does not meet the specified slump without adding water other than water that was added at the time of initial discharge. Allow sufficient time between grout lifts to preclude displacement or cracking of face shells of masonry units. Provide a grout shear key between lifts when grouting is delayed and the lower lift loses plasticity. If blowouts, flowouts, misalignment, or cracking of face shells should occur during construction, tear down the wall and rebuild.

3.4.2.2 Vertical Grout Barriers for Multi-Wythe Composite Walls

In multi-wythe composite walls, provide grout barriers in the collar join not more than 30 feet apart, or as required, to limit the horizontal flow of grout for each pour.

3.4.2.3 Horizontal Grout Barriers

Embed horizontal grout barriers in mortar below cells of hollow units receiving grout.

3.4.2.4 Grout Holes and Cleanouts

3.4.2.4.1 Grout Holes

Provide grouting holes in slabs, spandrel beams, and other in-place overhead construction. Locate holes over vertical reinforcing bars or as required to facilitate grout fill in bond beams. Provide additional openings spaced not more than 16 inches on centers where grouting of hollow unit masonry is indicated. Fom such openings not less than 4 inches in diameter or 3 by 4 inches in horizontal dimensions. Upon completion of grouting operations, plug and finish grouting holes to match surrounding surfaces.

3.4.2.4.2 Cleanouts for Hollow Unit Masonry Construction

For hollow masonry units. provide cleanout holes at the bottom of every

SECTION 04 20 00 Page 17 grout pour in cores containing vertical reinforcement when the height of the grout pour exceeds 5 feet 4 inches. Where all cells are to be grouted, construct cleanout courses using bond beam units in an inverted position to permit cleaning of all cells. Provide cleanout holes at a maximum spacing of 32 inches where all cells are to be filled with grout.

Establish a new series of cleanouts if grouting operations are stopped for more than 4 hours. Provide cleanouts not less than 3 by 3 inch by cutting openings in one face shell. Manufacturer's standard cutout units may be used at the Contractor's option. Do not cleanout holes until masonry work, reinforcement, and final cleaning of the grout spaces have been completed and inspected. For walls which will be exposed to view, close cleanout holes in an approved manner to match surrounding masonry.

3.4.2.4.3 Cleanouts for Multi-Wythe Composite Masonry Construction

Provide cleanouts for construction of walls that incorporate a grout filled cavity between solid masonry wythes, provide cleanouts at the bottom of every pour by omitting every other masonry unit from one wythe. Establish a new series of cleanouts if grouting operations are stopped for more than 4 hours. Do not plug cleanout holes until masonry work, reinforcement, and final cleaning of the grout spaces have been completed and inspected. For walls which will be exposed to view, close cleanout holes in an approved manner to match surrounding masonry.

3.4.2.5 Grout Placement

A grout pour is the total height of masonry to be grouted prior to erection of additional masonry. A grout lift is an increment of grout placement within a grout pour. A grout pour is filled by one or more lifts of grout.

a. Lay masonry to the top of a pour permitted by TMS MSJC Table 7, based on the size of the grout space and the type of grout. Prior to grouting, remove masonry protrusions that extend 1/2 inch or more into cells or spaces to be grouted. Provide grout holes and cleanouts in accordance with paragraph GROUT HOLES AND CLEANOUTS above when the grout pour height exceeds 5 feet 4 inches. Hold reinforcement, bolts, and embedded connections rigidly in position before grouting is started. Do not prewet concrete masonry units.

b. Place grout using a hand bucket, concrete hopper, or grout pump to fill the grout space without segregation of aggregate. Operate grout pumps to produce a continuous stream of grout without air pockets, segregation, or contamination.

c. If the masonry has cured at least 4 hours, grout slump is maintained between 10 to 11 inches, and no intermediate reinforced bond beams are placed between the top and bottom of the pour height, place conventional grout in lifts not exceeding 12 feet 8 inches. For the same curing and slump conditions but with intermediate bond beams, limit conventional grout lift to the bottom of the lowest bond beam that is more than 5 feet 4 inches above the bottom of the lift, but do not exceed 12 feet 8 inches. If masonry has not cured at least 4 hours or grout slump is not maintained between 10 to 11 inches, place conventional grout in lifts not exceeding 5 feet 4 inches.

d. Consolidate conventional grout lift and reconsolidate after initial settlement before placing next lift. For grout pours that are 12 inches or less in height, consolidate and reconsolidate grout by mechanical

SECTION 04 20 00 Page 18 vibration or puddling. For grout pours that are greater than 12 inches in height, consolidate and reconsolidate grout by mechanical vibration. Apply vibrators at uniformly spaced points not further apart than the visible effectiveness of the machine. Limit duration of vibration to time necessary to produce satisfactory consolidation without causing segregation. If previous lift is not permitted to set, dip vibrator into previous lift. Do not insert vibrators into lower lifts that are in a semi-solidified state. If lower lift sets prior to placement of subsequent lift, form a grout key by terminating grout a minimum of 1-1/2 inch below a mortar joint. Vibrate each vertical cell containing reinforcement in partially grouted masonry. Do not form grout keys within beams.

e. If the masonry has cured 4 hours, place self-consolidating grout (SCG) in lifts not exceeding the pour height. If masonry has not cured for at least 4 hours, place SCG in lifts not exceeding 5 feet 4 inches. Do not mechanically consolidate self-consolidating grout. Place self-consolidating grout in accordance with manufacturer's recommendations.

f. Upon completion of each day's grouting, remove waste materials and debris from the equipment, and dispose of outside the masonry.

3.4.3 Joint Reinforcement Installation

Install joint reinforcement at 16 inches on center unless otherwise indicated. Lap joint reinforcement not less than inches. Install prefabricated sections at corners and wall intersections. Place the longitudinal wires of joint reinforcement in mortar beds to provide not less than 5/8 inch cover to either face of the unit.

3.4.4 Bond Beams

Reinforce and grout bond beams as indicated and as described in paragraphs above. Install grout barriers under bond beam units to retain the grout as required, unless wall is fully grouted or solid bottom units are used. For high lift grouting in partially grouted masonry, provide grout retaining material on the top of bond beams to prevent upward flow of grout. Ensure that reinforcement is continuous, including around corners, except through control joints or expansion joints, unless otherwise indicated.

3.4.5 Flashing and Weeps

a. Install through-wall flashing at obstructions in the cavity and where indicated on Drawings. Ensure continuity of the flashing at laps and inside and outside corners by splicing in a manner approved by the flashing manufacturer. Ensure that the top edge of the flashing is sealed by turning the flashing 1/2 inch into the mortar bed joint of backup masonry . Terminate the horizontal leg of the flashing by extending the sheet metal 1/2 inch beyond the outside face of masonry and turning downward with a hemmed drip . Provide sealant below the drip edge of through-wall flashing.

b. Wherever through-wall flashing occurs, provide weep holes to drain flashing to exterior at acceptable locations as indicated. Provide weeps of weep ventilators. Locate weeps not more than 24 inches on centers in mortar joints of the exterior wythe directly on the horizontal leg of through-wall flashing over foundations, bond beams, and any other horizontal interruptions of the cavity. Place weep holes

SECTION 04 20 00 Page 19 perfectly horizontal or slightly canted downward to encourage water drainage outward and not inward. Other methods may be used for providing weeps when spacing is reduced to 16 inches on center and approved by the Contracting Officer. Maintain weeps free of mortar and other obstructions.

3.5 APPLICATION

3.5.1 Insulation

Insulate cavity walls (multi-wythe noncomposite masonry walls), where shown, by installing board-type insulation on the cavity side of the inner wythe. Apply board type insulation directly to the masonry or thru-wall flashing with adhesive. Neatly fit insulation between obstructions without impaling insulation on ties or anchors. Apply insulation in parallel courses with vertical joints breaking midway over the course below and in moderate contact with adjoining units without forcing. Cut to fit neatly against adjoining surfaces.

3.5.2 Interface with Other Products

3.5.2.1 Built-In Items

Fill spaces around built-in items with mortar. Point openings around flush-mount electrical outlet boxes in wet locations with mortar. Embed anchors, ties, wall plugs, accessories, flashing, pipe sleeves and other items required to be built-in as the masonry work progresses. Fully embed anchors, ties and joint reinforcement in the mortar. Fill cells receiving anchor bolts and cells of the first course below bearing plates with grout, unless otherwise indicated.

3.5.2.2 Door and Window Frame Joints

On the exposed interior and exterior sides of exterior frames, rake joints between frames and abutting masonry walls to a depth of 3/8 inch.

3.5.2.3 Bearing Plates

Set bearing plates for beams, joists, joist girders and similar structural members to the proper line and elevation with damp-pack bedding mortar, except where non-shrink grout is indicated. Provide bedding mortar and non-shrink grout s specified in Section 03 30 00 CAST-IN-PLACE CONCRETE.

3.5.3 Tolerances

Lay masonry plumb, true to line, with courses level within the tolerances of TMS MSJC, Article 3.3 F.

3.6 FIELD QUALITY CONTROL

3.6.1 Tests

3.6.1.1 Field Testing of Mortar

Perform mortar testing at the following frequency: 2 times per day. For each required mortar test, provide a minimum of three mortar samples.

Perform initial mortar testing prior to construction for comparison purposes during construction.

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Prepare and test mortar samples for mortar aggregate ratio in accordance with ASTM C780 Appendix A4.

3.6.1.2 Field Testing of Grout

a. Perform grout testing at the following frequency: 2 times per day.

For each required grout property to be evaluated, provide a minimum of three specimens.

b. Sample and test conventional and self-conslidating grout for compressive strength and temperature in accordance with ASTM C1019.

c. Evaluate slump in conventional grout in accordance with ASTM C1019.

d. Evaluate slump flow and visual stability index of self-consolidating grout in accordance with ASTM C1611/C1611M.

3.6.1.3 Single-Wythe Masonry Wall Water Penetration Test

Prior to start of field construction of the single-wythe concrete masonry wall, perform masonry wall water penetration test on mock-up wall assemblies consisting of the identical design, materials, mix, and construction methods as the actual wall construction and in accordance with ASTM E514/E514M. Prepare a minimum of three specimens and cure for minimum 28 days prior to testing. Construct panels by the same methods, processes, and applications to be used on the project's construction site. Spray test for 6 hours on each specimen. If water is visible on back of test panels during the test and areas of dampness on the backside of the test panels do not exceed 25 percent of the wall area, the panels will be considered to have passed. Dampness is defined as any area of surface darkening or discoloration due to moisture penetration or accumulation below the observed surface.

Construct additional test panels for each failed test performed until three test panels pass the test. Factors that can affect test performance include materials, mixing, and quality of application and workmanship.

Materials, mixing, and methods adjustments may be necessary in order to provide construction that passes the water penetration test. Document and record the test specimen construction materials and application and provide written test report in accordance with ASTM E514/E514M, supplemented by a detailed discussion of the specifics of test panel construction, application methods and processes used, quality of construction, and any variances or deviations that may have occurred between test panels during test panel construction. For failed test panels, identify in the supplemental report the variances, deficiencies or flaws that contributed to test panel failure and itemize the precautions to be taken in field construction of the masonry wall to prevent similar deficiencies and assure the wall construction replicates test panel conditions that pass the water penetration test. Submit the complete, certified test report, including supplemental report, to the Contracting Officer prior to start of single-wythe concrete masonry wall construction. Significant changes to materials, proportions, or construction techniques from those used in the passing water penetration test are grounds for performing new tests, at the discretion of the Contracting Officer.

3.6.2 Special Inspection

Perform special inspections and testing in accordance with Section 01 45 35

SPECIAL INSPECTIONS.

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3.7 POINTING AND CLEANING

After mortar joints have attained their initial set, but prior to hardening, completely remove mortar and grout daubs and splashings from masonry-unit surfaces that will be exposed or painted.