OSUT_1_04_20_00B_Masonry.pdf

OSUT-AR RANGE PROJECTS FY19

SECTION 04 20 00B

MASONRY

02/09

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.

ACI INTERNATIONAL (ACI)

ACI 318 (2008; Errata 2008; Errata 2009; Errata 2009; Errata 2009; Errata 2009; Errata 2009) Building Code Requirements for Structural Concrete and Commentary

ACI 318M (2008; Errata 2008; Errata 2009) Metric Building Code Requirements for Structural Concrete and Commentary

ACI 530/530.1 (2008; Errata 2008; Errata 2009) Building Code Requirements and Specification for Masonry Structures; Containing Building Code Requirements for Masonry Structures, Specification for Masonry Structures and Companion Commentaries

ACI SP-66 (2004) ACI Detailing Manual

ASTM INTERNATIONAL (ASTM)

ASTM A 153/A 153M (2009) Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware

ASTM A 167 (1999; R 2009) Standard Specification for Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and Strip

ASTM A 615/A 615M (2009b) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement

ASTM A 641/A 641M (2009a) Standard Specification for Zinc-Coated (Galvanized) Carbon Steel Wire

ASTM A 82/A 82M (2007) Standard Specification for Steel Wire, Plain, for Concrete Reinforcement

ASTM B 370 (2009) Standard Specification for Copper

Sheet and Strip for Building Construction

ASTM C 1019 (2009) Standard Test Method for Sampling and Testing Grout

ASTM C 1072 (2006) Standard Test Method for Measurement of Masonry Flexural Bond Strength

ASTM C 1142 (1995; R 2007) Standard Specification for Extended Life Mortar for Unit Masonry

ASTM C 129 (2006) Standard Specification for Nonloadbearing Concrete Masonry Units

ASTM C 1364 Standard Specification for Architectural Cast Stone

ASTM C 140 (2009a) Standard Test Methods for Sampling and Testing Concrete Masonry Units and Related Units

ASTM C 144 (2004) Standard Specification for Aggregate for Masonry Mortar

ASTM C 150/C 150M (2009) Standard Specification for Portland Cement

ASTM C 207 (2006) Standard Specification for Hydrated Lime for Masonry Purposes

ASTM C 270 (2008a) Standard Specification for Mortar for Unit Masonry

ASTM C 33 (2008) Standard Specification for Concrete Aggregates

ASTM C 476 (2009) Standard Specification for Grout for Masonry

ASTM C 494/C 494M (2008a) Standard Specification for Chemical Admixtures for Concrete

ASTM C 55 (2009) Concrete Brick

ASTM C 593 (2006) Fly Ash and Other Pozzolans for Use with Lime

ASTM C 641 (2009) Staining Materials in Lightweight Concrete Aggregates

ASTM C 73 (2005) Calcium Silicate Brick (Sand-Lime Brick)

ASTM C 744 (2009) Prefaced Concrete and Calcium Silicate Masonry Units

ASTM C 780 (2009) Preconstruction and Construction Evaluation of Mortars for Plain and Reinforced Unit Masonry

ASTM C 90 (2009) Loadbearing Concrete Masonry Units

ASTM C 91 (2005) Masonry Cement

ASTM C 94/C 94M (2009a) Standard Specification for Ready-Mixed Concrete

ASTM C 979 (2005) Pigments for Integrally Colored Concrete

ASTM C 989 (2009a) Standard Specification for Ground Granulated Blast-Furnace Slag for Use in Concrete and Mortars

ASTM D 1972 (1997; R 2005) Standard Practice for Generic Marking of Plastic Products

ASTM D 2000 (2008) Standard Classification System for Rubber Products in Automotive Applications

ASTM D 2240 (2005) Standard Test Method for Rubber Property - Durometer Hardness

ASTM D 2287 (1996; R 2001) Nonrigid Vinyl Chloride Polymer and Copolymer Molding and Extrusion Compounds

ASTM E 119 (2009c) Standard Test Methods for Fire Tests of Building Construction and Materials

ASTM E 2129 (2005) Standard Practice for Data Collection for Sustainability Assessment of Building Products

ASTM E 514/E 514M (2009) Water Penetration and Leakage Through Masonry

INTERNATIONAL CODE COUNCIL (ICC)

ICC IBC (2009) International Building Code

U.S. DEPARTMENT OF DEFENSE (DOD)

UFC 3-310-04 (2007) Seismic Design for Buildings

1.2 SYSTEM DESCRIPTION

1.2.2 Environmental Data

Submit Table 1 of ASTM E 2129 for the following products: Masonry Units and

Mortar.

1.2.4 Design Requirements

1.2.4.1 Unit Strength Method

Compute compressive strength of masonry system "Unit Strength Method", ACI 530/530.1. Submit calculations and certifications of unit and mortar strength.

1.2.4.3 Special Inspection

Perform special inspections and testing for in accordance with Chapter 17 of the 2009 International Building Code ICC IBC.

1.2.4.4 Masonry Strength

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

1.2.5 Additional Requirements

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

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

1.3 SUBMITTALS

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

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Detail Drawings; G

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.

Drawings including dimensions and reinforcing of cast stone trim items.

SD-03 Product Data

Environmental Data

Concrete Masonry Units (CMU)including colors and special shapes; G Cast Stone; G Cement; G;

Insulation; G Flashing; G

Water-Repellant Admixture; G

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.

Cold Weather Installation; G

Cold weather construction procedures.

SD-04 Samples

Concrete Masonry Units (CMU); G

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.

Cast Stone; G

Two samples minimum 12" in length showing color and texture.

Anchors, Ties, and Bar Positioners; G

Two of each type used.

Expansion-Joint Materials; G

One piece of each type used.

Joint Reinforcement; G

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

Insulation; G

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.

SD-05 Design Data

Pre-mixed Mortar; G Unit Strength Method; G

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

SD-06 Test Reports

Field Testing of Mortar; G

Field Testing of Grout; G Prism tests; G Masonry Cement; G Fire-rated CMU; G

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.

Masonry Inspector Qualifications; G

Copies of masonry inspector reports.

SD-07 Certificates

Concrete Brick Concrete Masonry Units (CMU) Cast Stone Trim Control Joint Keys Anchors, Ties, and Bar Positioners Expansion-Joint Materials Joint Reinforcement Reinforcing Steel Bars and Rods Masonry Cement Mortar Coloring Insulation Precast Concrete Items Admixtures for Masonry Mortar Admixtures for Grout

Certificates of compliance stating that the materials meet the specified requirements.

Insulation

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

Contamination

SD-08 Manufacturer's Instructions

Masonry Cement

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.

SD-10 Operation and Maintenance Data

Plastic Identification

When not labeled, identify types in Operation and Maintenance Manual.

Take-Back Program

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.

SD-11 Closeout Submittals

Environmental Data Concrete Masonry Units (CMU) Cast Stone Trim Items Cement; G;

Flashing Water-Repellant Admixture

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.

1.4 QUALITY ASSURANCE

1.4.1 Appearance

Manufacture bricks at one time and from the same batch. 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.

Manufacture all cast stone trim items from the same mix using the same materials.

1.4.2 Contamination

When using bricks containing contaminated soil, supplier shall certify that the hazardous waste is neutralized by the manufacturing process and that no additional pollutants will be released, or that the product is free from hazardous contaminants.

1.4.3 Sample Masonry Panels

After material samples are approved and prior to starting masonry work, construct a panel of CMU and cast stone trim and sample masonry panels for each type and color of masonry and cast stone trim required. At least 48 hours prior to constructing the sample panel or panels, submit written notification to the Contracting Officer. Sample panels shall not be built in, or as part of the structure, but shall be located where directed.

1.4.3.1 Configuration

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 6 feet high.

1.4.3.2 Composition

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, insulation, flashing, shall be shown in the sample panels. The panels shall contain a masonry bonded corner that includes a bond beam corner. Panels shall show parging and installation of electrical boxes and conduit. 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.

1.4.3.3 Construction Method

Where anchored veneer walls are required, 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, 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 properly designed concrete foundation.

1.4.3.4 Usage

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 property of the Contractor and shall be removed from the construction site.

1.4.4 Masonry Inspector Qualifications

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 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.

1.4.5 Detail Drawings

Submit detail drawings showing bar splice locations. 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.

1.5 DELIVERY, STORAGE, AND HANDLING

Materials shall be delivered, stored, handled, 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.

1.5.1 Masonry Units

Cover and protect moisture-controlled concrete masonry units, cast stone, and cementitious materials from precipitation. Conform to all handling and storage requirements of ASTM C 90. Mark prefabricated lintels on top sides to show either the lintel schedule number or the number and size of top and bottom bars.

1.5.2 Reinforcement, Anchors, and Ties

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.

1.5.3 Cementitious Materials, Sand and Aggregates

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. Store sand and aggregates in a manner to prevent contamination or segregation.

1.6 PROJECT/SITE CONDITIONS

Conform to ACI 530/530.1 for hot and cold weather masonry erection.

1.6.1 Hot Weather Installation

Take the following precautions 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.

1.6.2 Cold Weather Installation

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, submit a written statement of proposed cold weather construction procedures for approval.

PART 2 PRODUCTS

2.1 GENERAL REQUIREMENTS

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.

2.5 CONCRETE MASONRY UNITS (CMU)

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.

a. Hollow Load-Bearing Units: ASTM C 90, made with lightweight aggregate. Provide load-bearing units for exterior walls, foundation walls, load-bearing walls, and shear walls.

b. Hollow Non-Load-Bearing Units: ASTM C 129, made with lightweight aggregate. Load-bearing units may be provided in lieu of non-load-bearing units.

c. Solid Load-Bearing Units: ASTM C 90, lightweight units. Provide solid units as indicated.

2.5.1 Aggregates

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.

2.5.2 Kinds and Shapes

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.

2.5.2.1 Architectural Units

Units shall have patterned face shell. Face shell pattern shall be split face. Units shall be integrally colored during manufacture. Color shall be selected by the Goverment to match the Ft. Benning Installation design guide. Patterned face and interior shell shall be properly aligned in the completed wall.

2.5.3 Fire-Rated CMU

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.

TABLE I

FIRE-RATED CONCRETE MASONRY UNITS

See note (a) below

Minimum equivalent thickness inches for fire rating of:

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, 5.7 4.8 3.7 or slate

Limestone, scoria, cinders 5.9 5.0 4.0 or unexpanded slag

Calcareous gravel 6.2 5.3 4.2

Siliceous gravel 6.7 5.7 4.5

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.

2.5 CAST STONE TRIM ITEMS

Window headers and sills shall be factory-made units from a plant regularly engaged in producing precast concrete units. The finish and color of the units are to closely match the trim units on the adjacent Ranger complex.

Comply with ASTM C 1364 and the following:

Portland Cement: ASTM C 150, Type I or Type III with not more than

0.60 percent total alkali when tested per ASTM C 114.;

Course Aggregate: ASTM C 33, with gradation and colors to produce required color and texture;

Fine Aggregates: ASTM C 33 with natural sand or crushed stone;

Color Pigment: ASTM C 979 nonfading and resistant to lime and other alkalis;

Admixtures: non-Chloride nor containing calcium chloride;

Reinforcement: ASTM C 494, deformed steel bars;

Embedded Anchors and Inserts: Stainless steel or hot dipped galvanized steel.

Manufacture cast stone complying with ASTM C 1364 and using either the vibrant dry tamp or wet-cast method. Units shall be resistant to freezing and thawing. Slope horizontal surfaces 1:12 to drain unless indicated otherwise. Provide raised fillets at backs of sills and ends indicated to be built into jambs. Maximum variation dimensions and cross section: 1/8 inch.

Cure units in an enclosed moist curing room. Acid etch units after curing to remove cement film from surfaces exposed to view.

Anchors and dowels shall be stainless steel or hot-dip galvanized steel.

2.9 MORTAR FOR STRUCTURAL MASONRY

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

2.10 MASONRY MORTAR

Mortar Type S and 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; 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 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.

2.10.1 Admixtures for Masonry Mortar

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/C 494M, Type C.

2.10.2 Colored Mortar

Mortar coloring shall be added to the mortar used for exposed masonry surfaces to produce a uniform color matching the integral color of the concrete masonry units. Quantity of pigment to cementitious content of the masonry cement shall not exceed 5 by weight; carbon black shall not exceed 1 percent by weight. Quantity of pigment to cementitious content of cement-lime mix shall not exceed 10 percent by weight, carbon black no more than 2 percent by weight. 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.

Colored mortar shall conform to ASTM C 207 Type S below grade and Type N for veneer above grade.

2.10.3 Hydrated Lime and Alternates

Hydrated lime shall conform to ASTM C 207, Type S.

2.10.4 Cement

Portland cement shall conform to ASTM C 150/C 150M. 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 31 00.00 10

CAST-IN-PLACE STRUCTURAL CONCRETE.

2.10.5 Pre-Mixed Mortar

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

2.10.6 Sand and Water

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

2.11 WATER-REPELLANT ADMIXTURE

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/E 514M, 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.

2.12 GROUT AND READY-MIXED GROUT

Grout shall conform to ASTM C 476, fine or coarse. Cement used in grout shall have a low alkali content. Grout slump shall be between 8 and 11 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/C 94M.

2.12.1 Admixtures for Grout

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/C 494M, Type C. In general, air-entrainment, anti-freeze or chloride admixtures shall not be used except as approved by the Contracting Officer.

2.12.2 Grout Barriers

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

2.13 ANCHORS, TIES, AND BAR POSITIONERS

Anchors and ties shall be fabricated without drips or crimps and shall be zinc-coated in accordance with ASTM A 153/A 153M, Class B-2. Steel wire used for anchors and ties shall be fabricated from steel wire conforming to ASTM A 82/A 82M. Wire ties or anchors in exterior walls shall conform to ASTM A 641/A 641M. Joint reinforcement in interior walls, and in exterior or interior walls exposed to moist environment shall conform to ASTM A 641/A 641M; 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.

2.13.1 Wire Mesh Ties

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.

2.13.2 Wall Ties

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.

2.13.4 Adjustable Anchors

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.

2.13.5 Bar Positioners

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.

2.14 JOINT REINFORCEMENT

Joint reinforcement shall be factory fabricated from steel wire conforming to ASTM A 82/A 82M, welded construction. Tack welding will not be acceptable in reinforcement used for wall ties. Wire shall have zinc coating conforming to ASTM A 153/A 153M, 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.

2.15 REINFORCING STEEL BARS AND RODS

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

2.16 CONTROL JOINT KEYS

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

2.18 EXPANSION-JOINT MATERIALS

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.

2.19 THROUGH WALL FLASHING

Flashing shall be as specified in Section 07 60 00 FLASHING AND SHEET METAL. Provide one of the following types 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.

a. 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.

2.20 WEEP HOLE VENTILATORS

Weep hole ventilators shall be prefabricated aluminum, plastic or wood blocking 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

Prior to start of work, masonry inspector shall verify the applicable conditions as set forth in ACI 530/530.1, inspection. The Contracting Officer will serve as inspector or will select a masonry inspector.

3.1.1 Protection

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 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.

3.1.2 Completed Masonry and Masonry Not Being Worked On

a. 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.

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

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

d. 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.

3.1.3 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.

3.1.4 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.

3.1.5 Surfaces

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

a. 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 running bond pattern, unless otherwise indicated.

Facing courses shall be level with back-up courses, unless the use of adjustable ties has been approved in which case the tolerances shall be plus or minus 1/2 inch. Each unit shall be adjusted to its final position while mortar is still soft and plastic.

b. 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.

c. 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 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.

d. 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.

3.2.1 Forms and Shores

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.

3.2.2 Reinforced Concrete Masonry Units Walls

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.

3.2.3 Concrete Masonry Units

Units in piers, pilasters, columns, starting courses on footings, solid foundation walls, 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. Foundation walls below grade shall be grouted solid. 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 Tolerances

Masonry shall be laid plumb, true to line, with courses level. Bond pattern shall be kept plumb throughout. Corners shall be square unless noted otherwise. Except for walls constructed of prefaced concrete masonry units, masonry shall be laid within the following tolerances (plus or minus unless otherwise noted):

TABLE II

TOLERANCES

Variation from the plumb in the lines and surfaces of columns, walls and arises

In adjacent masonry units 1/8 inch In 10 feet 1/4 inch In 20 feet 3/8 inch In 40 feet or more 1/2 inch

Variations from the plumb for external corners, expansion joints, and other conspicuous lines

In 20 feet 1/4 inch In 40 feet or more 1/2 inch

Variations from the level for exposed lintels, sills, parapets, horizontal grooves, and other conspicuous lines

In 20 feet 1/4 inch In 40 feet or more 1/2 inch

Variation from level for bed joints and top surfaces of bearing walls

In 10 feet 1/4 inch In 40 feet or more 1/2 inch

Variations from horizontal lines

In 10 feet 1/4 inch In 20 feet 3/8 inch In 40 feet or more 1/2 inch

Variations in cross sectional dimensions of columns and in thickness of walls

Minus 1/4 inch Plus 1/2 inch

3.2.6 Cutting and Fitting

Full units of the proper size shall be used wherever possible, in lieu of cut units. Cutting and fitting, including that required to accommodate the work of others, shall be done by masonry mechanics using power masonry saws. Concrete masonry units may be wet or dry cut. Wet cut units, before being placed in the work, shall be dried to the same surface-dry appearance as uncut units being laid in the wall. Cut edges shall be clean, true and sharp. Openings in the masonry shall be made carefully 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. Reinforced masonry lintels shall be provided above openings over 12 inches wide for pipes, ducts, cable trays, and other wall penetrations, unless steel sleeves are used.

3.2.7 Jointing

Joints shall be tooled when the mortar is thumbprint hard. Horizontal joints shall be tooled last. Joints shall be brushed to remove all loose and excess mortar. Mortar joints shall be finished as follows:

3.2.7.1 Flush Joints

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

3.2.7.2 Tooled Joints

Joints in exposed exterior and interior masonry surfaces shall be tooled slightly concave. Joints shall be tooled with a jointer slightly larger than the joint width so that complete contact is made along the edges of the unit. Tooling shall be performed so that the mortar is compressed and the joint surface is sealed. Jointer of sufficient length shall be used to obtain a straight and true mortar joint.

3.2.7.3 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.

3.2.8 Joint Widths

Joint widths shall be as follows:

3.2.8.1 Concrete Masonry Units

Concrete masonry units shall have 3/8 inch joints, except for prefaced concrete masonry units.

3.2.9 Embedded Items

Spaces around built-in items shall be filled with mortar. Openings around flush-mount electrical outlet boxes in wet locations shall be pointed with mortar. Anchors, ties, wall plugs, accessories, flashing, pipe sleeves and other items required to be built-in shall be embedded as the masonry work progresses. Anchors, ties and joint reinforcement shall be fully embedded in the mortar. Cells receiving anchor bolts and cells of the first course below bearing plates shall be filled with grout.

3.2.10 Unfinished Work

Unfinished work shall be stepped back for joining with new work. Toothing may be resorted to only when specifically approved. Loose mortar shall be removed and the exposed joints shall be thoroughly cleaned before laying new work.

3.2.11 Masonry Wall Intersections

Each course shall be masonry bonded at corners and elsewhere as shown.

Masonry walls shall be anchored or tied together at corners and intersections with bond beam reinforcement and prefabricated corner or tee pieces of joint reinforcement as shown.

3.2.12 Partitions

Partitions shall be continuous from floor to underside of floor or roof deck where shown. Openings in firewalls around joists or other structural members shall be filled as indicated or approved. Where suspended ceilings on both sides of partitions are indicated, the partitions other than those shown to be continuous may be stopped approximately 4 inches above the ceiling level. An isolation joint shall be placed in the intersection between partitions and structural or exterior walls as shown. Interior partitions having 4 inch nominal thick units shall be tied to intersecting partitions of 4 inch units, 5 inches into partitions of 6 inch units, and 7 inches into partitions of 8 inch or thicker units. Cells within vertical plane of ties shall be filled solid with grout for full height of partition or solid masonry units may be used. Interior partitions having masonry walls over 4 inches thick shall be tied together with joint reinforcement.

Partitions containing joint reinforcement shall be provided with prefabricated pieces at corners and intersections or partitions.

3.4 ANCHORED VENEER CONSTRUCTION

The inner and outer wythes shall be completely separated by a continuous airspace as shown on the drawings. Both the inner and the outer wythes shall be laid up together except when adjustable joint reinforcement assemblies are approved for use. When both wythes are not brought up together, through-wall flashings shall be protected from damage until they are fully enclosed in the wall. The airspace between the wythes shall be kept clear and free of mortar droppings by temporary wood strips laid on the wall ties and carefully lifted out before placing the next row of ties. A coarse gravel or drainage material shall be placed behind the weep holes in the cavity to a minimum depth of 4 inches of coarse aggregate or 10 inches of drainage material to keep mortar droppings from plugging the weep holes.

3.5 WEEP HOLES

Wherever through-wall flashing occurs, provide weep holes to drain flashing to exterior at acceptable locations as indicated on drawings. Weep holes shall be open head joints. Weep holes shall be provided as indicated on the drawings in mortar joints of the exterior wythe above wall flashing, over foundations, bond beams, and any other horizontal interruptions of the cavity. Weep holes shall be perfectly horizontal or slightly canted downward to encourage water drainage outward and not inward. Weep holes shall be constructed using weep hole ventilators. Other approved methods may be used for providing weep holes. Weep holes shall be kept free of mortar and other obstructions.

3.6 COMPOSITE WALLS

Masonry wythes shall be tied together with joint reinforcement or with unit wall ties. The facing wythe shall be anchored or tied to the backup at a maximum spacing of 16 inches on center vertically and 16 inches on center horizontally. Unit ties shall be spaced not over 16 inches on centers horizontally, in courses not over 16 inches apart vertically, staggered in alternate courses. Ties shall be laid not closer than 5/8 inch to either masonry face. Ties shall not extend through control joints. Collar joints between masonry facing and masonry backup shall be filled solidly with grout.

3.7 MORTAR MIX

Mortar shall be mixed in a mechanically operated mortar mixer for at least 3 minutes, but not more than 5 minutes. Measurement of ingredients for mortar shall be by volume. Ingredients not in containers, such as sand, shall be accurately measured by the use of measuring boxes. Water shall be mixed with the dry ingredients in sufficient amount to provide a workable mixture which will adhere to the vertical surfaces of masonry units.

Mortar that has stiffened because of loss of water through evaporation shall be retempered by adding water to restore the proper consistency and workability. Mortar that has reached its initial set or that has not been used within 2.5 hours after mixing shall be discarded.

3.8 REINFORCING STEEL

Reinforcement shall be cleaned of loose, flaky rust, scale, grease, mortar, grout, or other coating which might destroy or reduce its bond prior to placing grout. Bars with kinks or bends not shown on the drawings shall not be used. Reinforcement shall be placed prior to grouting. Unless otherwise indicated, vertical wall reinforcement shall extend to within 2 inches of tops of walls.

3.8.1 Positioning Bars

Vertical bars shall be accurately placed 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. Minimum clearance between parallel bars shall be one diameter of the reinforcement. Vertical reinforcing 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. Column and pilaster ties shall be wired in position around the vertical steel. Ties shall be in contact with the vertical reinforcement and shall not be placed in horizontal bed joints.

3.8.2 Splices

Bars shall be lapped a minimum of 48 diameters of the reinforcement.

Welded or mechanical connections shall develop at least 125 percent of the specified yield strength of the reinforcement.

3.9 JOINT REINFORCEMENT INSTALLATION

Joint reinforcement shall be installed at 16 inches on center or as indicated. Reinforcement shall be lapped not less than 6 inches.

Prefabricated sections shall be installed at corners and wall intersections.