04 20 00 Masonry.pdf

Annex Addition to B3010

SECTION 04 20 00 Page 1

SECTION 04 20 00

MASONRY

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

ACI INTERNATIONAL (ACI)

ACI 318 (2008; Errata 2008) Building Code

Requirements for Structural Concrete and Commentary

ACI 318M (2005) Metric Building Code Requirements for

Structural Concrete and Commentary

ACI 530 (2005) Building Code Requirements for Masonry

Structures Commentaries

ACI 530.1 (2005) Specification for Masonry Structures

ACI SP-66 (2004) ACI Detailing Manual

ASTM INTERNATIONAL (ASTM)

ASTM A 153/A 153M (2005) Standard Specification for Zinc

Coating (Hot-Dip) on Iron and Steel Hardware

ASTM A 167 (1999; R 2004) Standard Specification for

Stainless and Heat-Resisting Chromium-Nickel Steel Plate, Sheet, and Strip

ASTM A 615/A 615M (2008) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement

ASTM A 641/A 641M (2003) 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 (2003) Standard Specification for Copper

Sheet and Strip for Building Construction

ASTM C 1019 (2008) Standard Test Method for Sampling and

Testing Grout

SECTION 04 20 00 Page 2

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 1289 (2007) Standard Specification for Faced Rigid

Cellular Polyisocyanurate Thermal Insulation Board

ASTM C 129 (2006) Standard Specification for

Nonloadbearing Concrete Masonry Units

ASTM C 140 (2007a) 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 (2007) Standard Specification for Portland

Cement

ASTM C 207 (2006) Standard Specification for Hydrated

Lime for Masonry Purposes

ASTM C 216 (2007a) Facing Brick (Solid Masonry Units

Made from Clay or Shale)

ASTM C 27 (1998; R 2002) Fireclay and High-Alumina

Refractory Brick

ASTM C 270 (2007a) Standard Specification for Mortar for

Unit Masonry

ASTM C 315 (2007) Clay Flue Linings

ASTM C 476 (2007) Standard Specification for Grout for

Masonry

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

Admixtures for Concrete

ASTM C 55 (2006e1) Concrete Brick

ASTM C 578 (2007) Standard Specification for Rigid, Cellular Polystyrene Thermal Insulation

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

ASTM C 62 (2005) Building Brick (Solid Masonry Units

Made from Clay or Shale)

ASTM C 641 (2007) Staining Materials in Lightweight

Concrete Aggregates

SECTION 04 20 00 Page 3

ASTM C 652 (2007) Hollow Brick (Hollow Masonry Units Made from Clay or Shale)

ASTM C 67 (2007a) Standard Test Methods for Sampling and Testing Brick and Structural Clay Tile

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

Brick)

ASTM C 744 (2005) Prefaced Concrete and Calcium Silicate

Masonry Units

ASTM C 780 (2007a) Preconstruction and Construction

Evaluation of Mortars for Plain and Reinforced Unit Masonry

ASTM C 90 (2006b) Loadbearing Concrete Masonry Units

ASTM C 91 (2005) Masonry Cement

ASTM C 94/C 94M (2007) Standard Specification for Ready-Mixed

Concrete

ASTM C 989 (2006) 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 (2008) 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 (2006) Water Penetration and Leakage Through

Masonry

INTERNATIONAL CODE COUNCIL (ICC)

ICC IBC (2006; Errata 2006; Errata 2007; Supplement

2007; Errata 2007) International Building Code

U.S. DEPARTMENT OF DEFENSE (DOD)

SECTION 04 20 00 Page 4

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

U.S. GREEN BUILDING COUNCIL (USGBC)

LEED (2002; R 2005) Leadership in Energy and

Environmental Design(tm) Green Building Rating System for New Construction (LEED-NC)

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. 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

Structural Masonry; 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. Bar splice locations shall be shown. If the Contractor opts to furnish inch-pound CMU products, drawings showing elevation of walls exposed to view and indicating the location of all cut CMU products shall be submitted for approval. 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 to 50( 1/4 inch per foot).

Reinforcement bending details shall conform to the requirements of

ACI SP-66.

SD-03 Product Data

Local/Regional Materials; (LEED)

Documentation indicating distance between manufacturing facility and the project site. Indicate distance of raw material origin from the project site. Indicate relative dollar value of local/regional materials to total dollar value of products included in project.]

Environmental Data Concrete Brick; G Concrete Masonry Units (CMU); G (LEED) Cement; G (LEED) Insulation; G

SECTION 04 20 00 Page 5

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 Concrete Brick; G Clay or Shale Brick; 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.

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 400 by 600 mm( 16 by 24 inches) in size, containing the label indicating the rated permeance and R-values.

Portable Panel; G

One panel of clay or shale brick, 600 by 600 mm( 2 by 2 feet), containing approximately 24 brick facings to establish range of color and texture.

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.

SECTION 04 20 00 Page 6

SD-06 Test Reports

Efflorescence Test;

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.

Special Inspection; G

Copies of masonry inspector reports.

SD-07 Certificates

Clay or Shale Brick Concrete Brick Concrete Masonry Units (CMU) Control Joint Keys Anchors, Ties, and Bar Positioners Expansion-Joint Materials Joint Reinforcement Reinforcing Steel Bars and Rods Masonry Cement Mortar Coloring Insulation Admixtures for Masonry Mortar Admixtures for Grout

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

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.

1.3 SAMPLE MASONRY PANELS

SECTION 04 20 00 Page 7

After material samples are approved and prior to starting masonry work, a portable panel of clay or shale brick and sample masonry panels shall be constructed for each type and color of masonry required. At least 48 hours prior to constructing the sample panel or panels, the Contractor shall submit written notification to the Contracting Officer's Representative.

Sample panels shall not be built in, or as part of the structure, but shall be located where directed.

1.3.1 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 2.5 m( 8 feet) long by [1.2] [1.8] m( [4] [6] feet) high.

1.3.2 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, brick expansion joints, insulation, flashing, brick soldier, row lock courses and weep holes shall be shown in the sample panels. The panels shall contain [a masonry bonded corner] [a stacked bond 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 600 by 600 mm( 2 by 2 foot) opening placed at least 600 mm( 2 feet) above the panel base and 600 mm( 2 feet) away from all free edges, corners, and control joints. Required reinforcing shall be provided around this opening as well as at wall corners and control joints.

1.3.3 Construction Method

Where anchored veneer walls are required, the Contractor shall demonstrate and receive approval for the method of construction; i.e., either bring up the two wythes together or separately, with the insulation and appropriate ties placed within the specified tolerances across the cavity. Temporary provisions shall be demonstrated to preclude mortar or grout droppings in the cavity and to provide a clear open air space of the dimensions shown on the drawings. Where masonry is to be grouted, the Contractor shall demonstrate and receive approval on the method that will be used to bring up the masonry wythes; support the reinforcing bars; and grout cells, bond beams, lintels, and collar joints using the requirements specified herein.

If sealer is specified to be applied to the masonry units, sealer shall be applied to the sample panels. Panels shall be built on a properly designed concrete foundation.

1.3.4 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

SECTION 04 20 00 Page 8 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 DELIVERY, HANDLING, AND STORAGE

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

1.4.1 Masonry Units

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

1.4.2 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.

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

1.5 STRUCTURAL MASONRY

1.5.1 Special Inspection

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

SECTION 04 20 00 Page 9

1.5.2 Unit Strength Method

Compute compressive strength of masonry system "Unit Strength Method," ACI

530. Submit calculations and certifications of unit and mortar strength.

1.6 QUALITY ASSURANCE

1.6.1 Appearance

Bricks shall be manufactured 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.

1.6.3 Testing

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

1.6.4 Spare Vibrator

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

1.6.5 Bracing and Scaffolding

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

1.7 SUSTAINABLE DESIGN REQUIREMENTS

1.7.1 Local/Regional Materials

Use materials or products extracted, harvested, or recovered, as well as manufactured, within a 800km (500 mile) radius from the project site, if available from a minimum of three sources. See Section 01 33 29 LEED(tm) DOCUMENTATION for cumulative total local material requirements. Masonry materials may be locally available.

1.7.3 Plastic Identification

Verify that plastic products to be incorporated into the project are labeled in accordance with ASTM D 1972. Where products are not labeled, provide product data indicating polymeric information in the Operation and Maintenance Manual.

a. Type 1: Polyethylene Terephthalate (PET, PETE).

b. Type 2: High Density Polyethylene (HDPE).

c. Type 3: Vinyl (Polyvinyl Chloride or PVC).

d. Type 4: Low Density Polyethylene (LDPE).

e. Type 5: Polypropylene (PP).

f. Type 6: Polystyrene (PS).

g. Type 7: Other. Use of this code indicates that the package in question is made with a resin other than the six listed above, or is made of more than one resin listed above, and used in a multi-layer combination.

SECTION 04 20 00 Page 10

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. The Contractor has the option to use either hard metric or substitute inch-pound (soft-metric) CMU products. If the Contractor decides to substitute inch-pound CMU products, the following additional requirements shall be met:

a. The metric dimensions indicated on the drawings shall not be altered to accommodate inch-pound CMU products either horizontally or vertically. The 100 mm building module shall be maintained, except for the CMU products themselves.

b. Mortar joint widths shall be maintained as specified.

c. Rebars shall not be cut, bent or eliminated to fit into the inch-pound CMU products module.

d. Brick and inch-pound CMU products shall not be reduced in size by more than one-third (1/3) in height and one-half (1/2) in length. Cut CMU products shall not be located at ends of walls, corners, and other openings.

e. Cut, exposed brick and CMU products shall be held to a minimum and located where they would have the least impact on the architectural aesthetic goals of the facility.

f. Other building components, built into the CMU products, such as window frames, door frames, louvers, grilles, fire dampers, etc., that are required to be metric, shall remain metric.

g. Additional metric guidance shall conform to Section 00 31 10

METRIC MEASUREMENTS.

2.3 CONCRETE BRICK

Concrete brick shall conform to ASTM C 55, Grade [N] [S]. Concrete brick may be used where necessary for filling out in concrete masonry unit construction.

2.4 SALVAGED BRICK

Use [lead-free] salvaged bricks and other masonry units in place of new bricks or masonry units as indicated. Bricks salvaged from foundrys or industrial buildings shall be washed with appropriate metal-dust removing cleaner. When using salvaged brick, select exterior face bricks from salvaged exterior face bricks. Bricks shall meet standards of new bricks

SECTION 04 20 00 Page 11 otherwise used in application, and shall be cleaned of all mortar prior to use. Place exterior face towards the exterior.

2.5 CONCRETE MASONRY UNITS (CMU)

Cement shall have a low alkali content and be of one brand. Units shall contain a minimum of 5 percent post-consumer recycled content, or a minimum of 20 percent post-industrial recycled content.See Section 01 33 29 LEED(tm) DOCUMENTATION for cumulative total recycled content requirements. Units may contain post-consumer or post-industrial recycled content. Units shall be of modular dimensions and air, water, or steam cured. Surfaces of units which are to be plastered or stuccoed shall be sufficiently rough to provide bond;

elsewhere,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 [or medium weight] [or normal weight] 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 [or medium weight] [or normal weight] aggregate. Load-bearing units may be provided in lieu of non-load-bearing units.

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.

Use industrial waste by-products (air-cooled slag, cinders, or bottom ash), ground waste glass and concrete, granulated slag, and expanded slag in aggregates. Slag shall comply with ASTM C 989; Grade 100.

2.7 PRECAST CONCRETE ITEMS

Trim, lintels, copings, splashblocks and door sills shall be factory-made units from a plant regularly engaged in producing precast concrete units.

Unless otherwise indicated, concrete shall be [28] [20] MPa( [4,000] [3000] psi) minimum conforming to Section [03 31 00.00 10 CAST-IN-PLACE STRUCTURAL CONCRETE][03 30 00 CAST-IN-PLACE CONCRETE] using 13 mm( 1/2 inch) to No. 4 nominal-size coarse aggregate, and minimum reinforcement shall be the reinforcement required for handling of the units. Clearance of 19 mm( 3/4 inch) shall be maintained between reinforcement and faces of units. Unless precast-concrete items have been subjected during manufacture to saturated-steam pressure of at least 827 kPa( 120 psi) for at least 5 hours, the items, after casting, shall be either damp-cured for 24 hours or steam-cured and shall then be aged under cover for 28 days or longer. Cast-concrete members weighing over 35 kg( 80 pounds) shall have built-in loops of galvanized wire or other approved provisions for lifting and anchoring.

Units shall have beds and joints at right angles to the face, with sharp true arises and shall be cast with drip grooves on the underside where units overhang walls. Exposed-to-view surfaces shall be free of surface voids, SECTION 04 20 00 Page 12 spalls, cracks, and chipped or broken edges. Precast units exposed-to-view shall be of uniform appearance and color. Unless otherwise specified, units shall have a smooth dense finish. Prior to use, each item shall be wetted and inspected for crazing. Items showing evidence of dusting, spalling, crazing, or having surfaces treated with a protective coating will be rejected.

2.7.2 Sills and Copings

Sills and copings shall be cast with washes. Sills for windows having mullions shall be cast in sections with head joints at mullions and a 6 mm( 1/4 inch) allowance for mortar joints. The ends of sills, except a 19 mm( 3/4 inch) wide margin at exposed surfaces, shall be roughened for bond.

Treads of door sills shall have rounded nosings. [Reinforce sills with not less than two No. 15( No. 4) bars.]

2.7.3 Splash Blocks

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

2.10 MASONRY MORTAR

Type M mortar shall conform to ASTM C 270 and shall be used for foundation walls , basement walls, and piers. Mortar Type S N shall conform to the proportion specification of ASTM C 270 except Type S cement-lime mortar proportions shall be 1 part cement, 1/2 part lime and 4-1/2 parts aggregate;

Type N cement-lime mortar proportions shall be 1 part cement, 1 part lime and 6 parts aggregate. Type N or S mortar shall be used for non-load-bearing, non-shear-wall interior masonry; [approved commercial fire clay mortar or refractory cement (calcium-aluminate) mortar for fire brick and flue liners;] and Type S for remaining masonry work; except where higher compressive strength is indicated on structural drawings. When masonry cement ASTM C 91 is used the maximum air content shall be limited to 12 percent and performance equal to cement-lime mortar shall be verified.

Verification of masonry cement performance shall be based on ASTM C 780 and ASTM C 1072. Pointing mortar in showers 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.

2.10.3 Hydrated Lime and Alternates

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

SECTION 04 20 00 Page 13

2.10.4 Cement

Portland cement shall conform to ASTM C 150, Type I, IA, II, IIA, or III, IIIA. Masonry cement shall conform to ASTM C 91, Type N S M. Containers shall bear complete instructions for proportioning and mixing to obtain the required types of mortar. Incorporate to the maximum extent, without conflicting with other requirements of this section, up to 40 percent fly ash, up to 70 percent slag, up to 10 percent cenospheres, and up to 10 percent silica fume. Additives shall conform to requirements in Section 03

30 00 CAST-IN-PLACE CONCRETE 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 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, 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. Cement used in grout shall have a low alkali content. Grout slump shall be between ( 8 and 10 inches).

Minimum grout strength shall be 14 MPa( 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.

SECTION 04 20 00 Page 14

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 16 mm( 5/8 inch) mortar cover from either face.

2.13.1 Wire Mesh Ties

Wire mesh for tying 100 mm( 4 inch) thick concrete masonry unit partitions to other intersecting masonry partitions shall be 13 mm( 1/2 inch) mesh of minimum 16 gauge( 16 gauge) steel wire. Minimum lengths shall be not less than 300 mm( 12 inches).

2.13.2 Wall Ties

Wall ties shall be rectangular-shaped or Z-shaped fabricated of 5 mm( 3/16 inch) diameter zinc-coated steel wire. Rectangular wall ties shall be no less than 100 mm( 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 5 mm( 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 13 mm( 1/2 inch) eccentricity between each element of the tie.

Play between pintle and eye opening shall be not more than 2 mm( 1/16 inch).

The pintle and eye elements shall be formed so that both can be in the same plane.

2.13.3 Dovetail Anchors

Dovetail anchors shall be of the flexible wire type, 5 mm( 3/16 inch) diameter zinc-coated steel wire, triangular shaped, and attached to a 12 gauge( 12 gauge) or heavier steel dovetail section. These anchors shall be used for anchorage of veneer wythes or composite-wall facings extending over the face of concrete columns, beams, or walls. Cells within vertical planes of these anchors shall be filled solid with grout for full height of walls or partitions, or solid units may be used. Dovetail slots are specified in Section 03 31 00.00 10 CAST-IN-PLACE STRUCTURAL CONCRETE 03 30 00 CAST-IN-

PLACE CONCRETE.

2.13.4 Adjustable Anchors

Adjustable anchors shall be 5 mm( 3/16 inch) diameter steel wire, triangular-shaped. Anchors attached to steel shall be 8 mm( 5/16 inch) diameter steel bars placed to provide 2 mm( 1/16 inch) play between flexible anchors and structural steel members. Spacers shall be welded to rods and

SECTION 04 20 00 Page 15 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 16 mm( 5/8 inch) cover from either face. The distance between crosswires shall not exceed 400 mm( 16 inches). Joint reinforcement for straight runs shall be furnished in flat sections not less than 3 m( 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 16 mm( 5/8 inch) thick and 10 mm( 3/8 inch) thick flanges, with a tolerance of plus or minus 2 mm( 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 34 degrees C( 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

SECTION 04 20 00 Page 16 sealant manufacturer. Sealant shall conform to Section 07 92 00 JOINT SEALANTS, and shall be penetrating[ with a maximum volatile organic compound (VOC) content of 600 grams/liter].

2.19 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 except that the material shall be one which is not adversely affected by dampproofing material.

a. Coated-Copper Flashing: 0.2 kg( 7 ounce), electrolytic copper sheet, uniformly coated on both sides with acidproof, alkaliproof, elastic bituminous compound. Factory apply coating to a weight of not less than 1.8 kg/square meter( 6 ounces/square foot) (approximately 0.9 kg/square meter( 3 ounces/square foot) on each side).

b. Copper or Stainless Steel Flashing: Copper, ASTM B 370, minimum 450 kg( 16 ounce) weight; stainless steel, ASTM A 167, Type 301, 302, 304, or 316, 4 mm( 0.015 inch) thick, No. 2D finish. Provide with factory-fabricated deformations that mechanically bond flashing against horizontal movement in all directions. Deformations shall consist of dimples, diagonal corrugations, or a combination of dimples and transverse corrugations.

[c. 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 0 degrees C( 32 degrees F), shall show no cracking when, at that temperature, it is bent 180 degrees over a 2 mm( 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

Weephole 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 10 mm( 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 530.1, inspection. The Contracting Officer will serve as inspector or will select a masonry inspector.

3.1.1 Hot Weather Installation

The following precautions shall be taken if masonry is erected when the ambient air temperature is more than 37 degrees C( 99 degrees F) in the shade and the relative humidity is less than 50 percent or the ambient air

SECTION 04 20 00 Page 17 temperature exceeds 32 degrees C( 90 degrees F) and the wind velocity is more than 13 km/h( 8 mph). All masonry materials shall be shaded from direct sunlight; mortar beds shall be spread no more than 1.2 m( 4 feet) ahead of masonry; masonry units shall be set within one minute of spreading mortar; and after erection, masonry shall be protected from direct exposure to wind and sun for 48 hours.

3.1.2 Cold Weather Installation

Before erecting masonry when ambient temperature or mean daily air temperature falls below 4 degrees C( 40 degrees F) or temperature of masonry units is below 4 degrees C( 40 degrees F), a written statement of proposed cold weather construction procedures shall be submitted for approval. The following precautions shall be taken during all cold weather erection.

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

3.1.2.1 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 4 to 0 degrees C( 40 to 32 Degrees F). Sand or mixing water shall be heated to produce mortar temperatures between 4 and 49 degrees C( 40 and 120 degrees F)

b. Air Temperature 0 to minus 4 degrees C( 32 to 25 Degrees F). Sand and mixing water shall be heated to produce mortar temperatures between 4 and 49 degrees C( 40 and 120 degrees F). Temperature of mortar on boards shall be maintained above freezing.

c. Air Temperature minus 4 to minus 7 degrees C( 25 to 20 Degrees F).

Sand and mixing water shall be heated to provide mortar temperatures between 4 and 49 degrees C( 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 24 km/hour( 15 mph).

d. Air Temperature minus 7 degrees C( 20 Degrees F) and below. Sand and mixing water shall be heated to provide mortar temperatures between 4 and 49 degrees C( 40 and 120 degrees F). Enclosure and auxiliary heat shall be provided to maintain air temperature above 0 degrees C( 32 degrees F). Temperature of units when laid shall not be less than minus 7 degrees C( 20 degrees F).

3.1.2.2 Completed Masonry and Masonry Not Being Worked On

a. Mean daily air temperature 4 to 0 degrees C( 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 0 to minus 4 degrees C( 32 to 25 degrees F). Masonry shall be completely covered with weather-resistant membrane for 24 hours.

SECTION 04 20 00 Page 18

c. Mean Daily Air Temperature minus 4 to minus 7 degrees C( 25 to 20 degrees F). Masonry shall be completely covered with insulating blankets or equally protected for 24 hours.

d. Mean Daily Temperature minus 7 degrees C( 20 degrees F) and Below.

Masonry temperature shall be maintained above 0 degrees C( 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

Potect 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 3 mm( 1/8 inch). Sandblasting shall be used, if necessary, to remove laitance from pores and to expose the aggregate.

3.2 LAYING MASONRY UNITS

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, stacked, the indicated bond pattern. 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 13 mm( 1/2 inch). Each unit shall be adjusted to its final position while mortar is still soft and plastic. Units that have been disturbed after the mortar has stiffened shall be removed, cleaned, and relaid with fresh mortar. Air spaces, cavities, chases, expansion joints, and spaces to be grouted shall be kept free from mortar and other debris. Units used in exposed masonry surfaces shall be selected from those having the least amount of chipped edges or other imperfections detracting from the appearance of the finished work.

Vertical joints shall be kept plumb. Units being laid and surfaces to receive units shall be free of water film and frost. Solid units shall be laid in a nonfurrowed full bed of mortar. Mortar for veneer wythes shall be beveled and sloped toward the center of the wythe from the cavity 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 13 mm( 1/2 inch) into the space or cells to be grouted.

Means shall be provided to prevent mortar from dropping into the space below. In double wythe construction, the inner wythe may be brought up not more than 400 mm( 16 inches) ahead of the outer wythe. Collar joints shall be filled with mortar or grout during the laying of the facing wythe, and

SECTION 04 20 00 Page 19 filling shall not lag the laying of the facing wythe by more than 200 mm( 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 50 by 75 mm( 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 13 mm( 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):

SECTION 04 20 00 Page 20

TABLE II

TOLERANCES

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

In adjacent masonry units 3 mm In 3 m 6 mm In 6 m 10 mm In 12 m or more 13 mm

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

In 6 m 6 mm In 12 m or more 13 mm

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

In 6 m 6 mm In 12 m or more 13 mm

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

In 3 m 6 mm In 12 m or more 13 mm

Variations from horizontal lines

In 3 m 6 mm In 6 m 10 mm In 12 m or more 13 mm

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

Minus 6 mm Plus 13 mm

TABLE II

TOLERANCES

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

SECTION 04 20 00 Page 21

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 300 mm( 12 inches) wide for pipes, ducts, cable trays, and other wall penetrations, unless steel sleeves are used.

SECTION 04 20 00 Page 22

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.

3.2.8 Joint Widths

Joint widths shall be as follows:

3.2.8.1 Concrete Masonry Units

Concrete masonry units shall have 10 mm( 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.

SECTION 04 20 00 Page 23

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 100 mm( 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 100 mm( 4 inch) nominal thick units shall be tied to intersecting partitions of 100 mm( 4 inch) units, 125 mm( 5 inches) into partitions of 150 mm( 6 inch) units, and 175( 7 inches) into partitions of 200 mm( 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 100 mm( 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.

3.6 COMPOSITE…