ATT_02a_Division_04_Masonry.pdf

1 Division 04 - Masonry

DIVISION 04 - MASONRY

SECTION 04100- MORTAR AND MASONRY GROUT

PART 1 – GENERAL

A. Section Includes:

1. Mortar and grout for masonry.

B. Related Sections:

1. Division 4, Section “Cavity wall Masonry System”

2. Division 5, Section “Structural Steel”

3. Division 9, Section “Painting”

C. References:

1. ACI 530: Building Code Requirements for Masonry Structures.

2. ACI 530.1: Specification for Masonry Structures.

3. ASTM C91: Masonry Cement.

4. ASTM C94: Ready-Mix Concrete.

5. ASTM C144: Aggregate for Masonry Mortar.

6. ASTM C150: Portland cement.

7. ASTM C207: Hydrated Lime for Masonry Purposes.

8. ASTM C270: Mortar for Masonry Units.

9. ASTM C476: Grout for Masonry.

10. ASTM C780: Pre-Construction and Construction Evaluation of Mortars for Plain and Reinforced Unit Masonry.

11. ASTM C1019: Method of Sampling and Testing Grout.

12. IMIAC (International Masonry Industry All-Weather Council): Recommended

Practices and Guide Specifications for Cold Weather Masonry Construction.

13. INIAC (International Masonry Industry All-Weather Council): Recommended

Practices and Guides Specifications for Hot Weather Masonry Construction.

D. Submittals:

1. Submittals: Submit in accordance with Division 1 requirements

2. Samples: Submit 2 sets of mortar samples for color selection.

3. Product Data: Submit manufacturer’s specifications and other data for each type of masonry mortar and accessories used.

E. Quality Assurance:

1. Perform Work in accordance with ACI 530 and ACI 530.1.

F. Delivery, Storage, and Handling:

1. Maintain packaged materials clean, dry, and protected against dampness, freezing, and foreign matter.

G. Environmental Requirements:

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1. Cold Weather Requirements: IMIAC Recommended Practices and Guide

Specifications for Cold Weather Masonry Construction, and ACI 0530-1.

Section 04100- Mortar and Masonry Grout Cont.

2. Hot Weather Requirements: IMIAC Recommended Practices and Guide

Specifications for Cold Weather Masonry Construction.

PART 2 – PRODUCTS

1. Mortar:

1. ASTM C 270, 1 part cement (ASTM C150 and C91, Type II) ¼ part by volume lime (ASTM C207, not less than 2-1/4 nor more than 3 times the sum of volumes of cement and lime used, aggregate (sand) (ASTM C144; Type S

(Tuck pointing utilize Type N).

2. Maximum air content: 12%

3. Calcium Chloride additive will not be permitted.

2. Mortar Color:

1. Mortar Color will be selected from manufacturer’s standard palette to match concrete masonry units color.

3. Mortar Mixing:

1. Thoroughly mix mortar ingredients in accordance with ASTM C270 in quantities needed for immediate use.

2. Maintain sand uniformly damp immediately before the mixing process.

3. Do not use anti-freeze compounds to lower the freezing point of mortar.

4. If water is lost by evaporation, re-temper only within two hours of mixing.

5. Use mortar within two hours after mixing at temperatures of 90 degrees F. or two-and-one-half hours at temperatures under 50 degrees F.

4. Grout Mixes:

1. Bond beams, Engineered Masonry and Lintels: 3000 psi strength at 28 days; 8-

19 inches slump; mixed in accordance with ACI 318. Pre-mixed type in accordance with ASTM C94 with #8 aggregate size.

5. Grout Mixing:

1. Mix grout in accordance with ASTM C94.

6. Water:

1. Potable.

PART 3 – EXECUTION

A. Examination:

1. Request inspection of items to be grouted.

B. Preparation:

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1. Apply bonding agent to existing surfaces.

Section 04100- Mortar and Masonry Grout Cont.

2. Plug clean-out and visual inspection holes with masonry units. Brace masonry for wet grout pressure.

C. Installation:

1. Install mortar and grout in accordance with manufacturer’s instructions.

2. Install mortar and grout at ambient temperatures ranging between 40 degrees F.

and 120 degrees F.

3. Work grout into masonry cores and cavities to eliminate voids.

4. Keep mortar and grout from freezing by use of heating blankets or an enclosure until totally set.

3. Do not install grout in lifts greater than 16 inches (two CMU courses) without consolidating grout by rodding.

4. Do not displace reinforcement while placing grout.

5. Remove excess mortar from grout spaces.

6. Tuck point with mortar of the same color.

D. Field Quality Control:

1. Test and evaluate in accordance with ASTM C780.

2. Test and evaluate grout in accordance with ASTM C1019.

End of Section- 04100

4 Division 04 - Masonry

Section 04330- Cavity Wall Masonry System

PART 1 – GENERAL

A. Section Includes:

1. Concrete masonry face veneer.

2. Concrete masonry back-up wythe.

3. Reinforcement, anchorage, and accessories.

B. Products Installed but Furnished by Others:

1. Division 5, Section “Metal Fabrications”.

C. Related Sections:

1. Division 4, Section “Mortar & Masonry Grout”

2. Division 5, Section “Metal Fabrications”.

3. Division 7, Section “Building Insulation”

4. Division 7, Section “Sheet Metal Flashing and Trim”.

5. Division 7, Section “Joint Sealants”.

6. Division 8, Section “Steel Doors and Frames”

A. References:

1. ACI 530: Specifications for Masonry Structure.

2. ASTM A82: Cold Drawn Steel Wire for Concrete Reinforcement.

3. ASTM A641: Zinc Coated (Galvanized) Carbon Steel Wire.

4. ASTM A167: Stainless and Heat-Resisting Chromium-Nickel Steel Plate.

5. ASTM A525: Steel Sheet, Zinc Coated (Galvanized) by the Hot-Dip Process.

6. ASTM A580: Stainless and Heat-Resisting Steel Wire

7. ASTM A641: Zinc-Coated (Galvanized) Carbon Steel Wire.

8. ASTM B370: Copper Sheet and Strip for Building Construction

9. ASTM C55: Concrete Building Brick.

10. ASTM C90: Load Bearing Masonry Units

11. ASTM C190: Non-Load Bearing Masonry Units

12. IMIAC- International Masonry Industry All-Weather Council: Recommended

Practices and Guide Specification for Cold Weather Masonry Construction.

13. IMIAC- International Masonry Industry All-Weather Council: Recommended

Practices and Guide for Hot Weather Masonry Construction.

B. Submittals:

1. Submittals: Submit in accordance with Division 1 requirements.

2. Submit samples of brick and/or decorative CMU to illustrate color, texture, and extremes of color range and CMU used for back-up wall

3. Submit data sheets on mortar type, reinforcement and anchorages, flashings, damproofing, expansion joints and all masonry accessories.

4. Submit test reports on all fire rated hollow masonry units illustrating conformance to referenced ASTM standards.

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Section 04330- Cavity Wall Masonry System Cont.

5. Mock ups: Construct a 4’x6’ section of cavity wall for the ESD Project Manager and Inspector for approval.

C. Quality Assurance:

1. Perform Work in accordance with ACI 530 and ACI 530.1.

2. Obtain masonry units from a single manufacturer for each type required.

D. Qualifications:

1. Manufacturer: Company specializing in manufacturing the Products specified in the Section with a minimum of three years’ experience.

E. Regulatory Requirements:

1. Conform to applicable requirements for masonry walls and fire rated masonry construction where indicated on the drawings.

F. Delivery, Storage, and Handling:

1. Deliver, store, protect and handle products in accordance to manufacturer’s recommendations.

2. Acceptance of pre-faced units to be on site, after delivery. Inspect for damage.

3. Deliver all units on tight pallets. Broken pallets will be rejected.

4. Confirm color or material conforms to sample wall.

5. Do not install broken units.

G. Environmental Requirements:

1. IMIAC- International Masonry Industry All-Weather Council: Recommended

Practices and Guide Specification for Cold Weather Masonry Construction.

2. IMIAC- International Masonry Industry All-Weather Council: Recommended

Practices and Guide for Hot Weather Masonry Construction.

H. Coordination:

1. Coordinate the masonry Work with installation of embedded anchors, steel lintels, and other masonry accessories.

PART 2 – PRODUCTS

A. Mortar:

1. Type S, Compressive Strength- 3000 psi

B. Grout:

a. Manufacturers:

1. Quickrete or an Approved Equal meeting the specifications of ASTM C

476, “Standard Specification for Grout for Masonry”.

2. 3000 PSI at 28 days when tested in accordance with ASTM C 1019.

3. Raw materials used in the product formulation will meet the standard specification including:

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1. Type I Portland Cement meeting ASTM C 150, Standard Specification for

Portland Cement

2. Aggregates meeting ASTM C 404, Standard Specification for Aggregates for Masonry Grout

C. Concrete Masonry Units:

1. Conform to the following:

a. Backup & Interior Hollow Load Bearing Block Units- ASTM C90, Type I.

b. Backup & Interior Solid Load Bearing Units- ASTM C145, Type I

c. Size and Shape- Nominal 8”x8”x16”

d. Concrete Brick Units- ASTM C55.

D. Reinforcement & Anchorage:

1. Install of Horizontal Reinforcement: Install horizontal reinforcement at 16” o.c.

vertically. Lap joints 6” minimum, hot-dipped galvanized.

2. Extend horizontal reinforcement beyond outside face of back up block wall at adequate distance to accomplish the function veneer ties where veneer is indicated on the drawings (multiple wythe).

3. Manufacturers:

b. Dur-O-Wall, Inc.

c. Heckman Building Products, Inc.

d. Hohmann & Barnard Inc.

4. Multiple Wythe Joint Reinforcement: Ladder Type, ASTM A82, Class B-2, 9 ga.

5. Single Wythe Joint reinforcement: Truss Type, ASTM A641, Class B-2, 9 ga.

6. Reinforcing Steel: ASTM A615, 60 ksi yield grade, deformed billet bars, uncoated finish.

7. Veneer to concrete assembly equal to Dur-O-Wall 5213330.

8. For all assemblies which extend into exterior wythe, fabricated from steel with hot-dip galvanized coating, ASTM A123, Class B1, B2, or B3.

9. Veneer Steel Tie assembly will be Dur-O-Wall D/A 207, hot-dip galvanized, with Dur-O-Wall D/A 807 fasteners, or approved equal, and 5x5 triangular tie.

E. Face Brick:

a. Manufacturer: Boral Bricks

1. Size- Modular

2. Color- “Red Range, Semi Smooth”

b. Conform to ASTM C216, Grade SW, Type FBX

c. Anchorage and Ties:

1. Install brick ties at 16” o.c. vertically and 32” o.c. horizontally for wall cavity up to 4” in width, 16” x16” for cavity over 4” in width.

2. Hot-dipped galvanized, plate and pintle type.

1. Backplate thickness: 14 ga.

2. Pintle: ¼” dia.

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3. Conform to ACI 530, Section 6.2.

F. Mortar Net:

a. Manufacturer: Cav-Clear or an approved equal.

G. Flashings:

1. Copper Through-Wall Flashings for Masonry:

a. C-Kraft Duplex Flashing as manufactured by Hohmann & Barnard, Inc. or approved equal.

1. Weight: 5 oz.

2. Asphalt-bonded kraft paper to both sides of the copper.

3. Copper sheet conforming to ASTM B 370 (110 Alloy).

b. Pre- Molded Shapes: Install pre-molded inside, outside corners and end dams as manufactured by flashing manufacturer.

c. Sealant: Sealant at overlaps as manufactured by flashing manufacturer.

d. Asphalt Mastic: Asphalt mastic at conditions where indicated on the drawings. Mastic to be manufactured by flashing manufacturer.

e. Termination Bar: Provide termination bar where indicated on the drawings. Termination bars are to be manufactured by flashing manufacturer.

I. Accessories:

1. Joint Sealer: As specified in Section 07920, “Joint Sealants”.

2. Weeps: Open head joints with PVC sleeve inserts. 32 inches o.c. at base of wall, above all lintels, under all rowlocks, and above all solid surfaces or as noted on the drawings.

3. Cleaning Solution: Sure Clean or approved equal non-acid cleaner; not harmful to masonry work or adjacent material.

J. Damproofing:

1. Cavity damproofing for outside face of masonry back-up wall will be modified bitumen.

K. Control Joints:

1. Install control joints every 20 feet or at each column location. Start spacing at

20 inches from outside corner of building.

2. Do not continue horizontal joint reinforcement through control joints.

3. Install preformed control joint material in continuous lengths. Seal butt and corner joints in accordance with manufacturer’s instructions.

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PART 3 – EXECUTION

A. Examination:

1. Verify items provided by other Sections of work are properly sized and located.

2. Verify that built-in or formed items are in proper location, and ready for roughing into masonry work.

B. Preparation:

a. Direct and coordinate placement of metal anchors supplied in other Sections.

b. Provide temporary bracing during installation of masonry work. Maintain in place until building structure provides permanent bracing

C. Coursing:

1. Establish lines, levels, and coursing indicated. Protect from displacement.

2. Maintain masonry courses to uniform dimension. Form horizontal and vertical joints of uniform thickness.

3. Concrete Masonry Units:

1. Bond: Running unless otherwise indicated.

2. Coursing: One unit and one mortar joint to equal 8 inches.

3. Interior Mortar Joints: Flush.

4. Exterior Mortar Joints: Concave.

D. Placing and Bonding:

1. Lay masonry units in full bed of mortar, with full head joints, uniformly jointed with other work.

2. Lay masonry units with face shell bedding on head and bed joints.

3. Buttering corners of joints or excessive furrowing of mortar joint are not permitted.

4. Remove excess mortar as Work progresses.

5. Do not interlock intersections of walls.

6. Interlock external corners.

7. Do not shift or tap masonry units after mortar has achieved initial set. Where adjustment must be made, remove block, mortar and replace.

8. Perform job site cutting of masonry units with proper tools to provide straight, clean, unchipped edges. Prevent broken masonry unit corners or edges.

9. Cut mortar joints flush where resilient or ceramic base is schedule.

10. Isolate masonry walls from vertical structural framing members with control joint material.

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E. Weeps:

1. Install weeps in veneer at 32 inches o.c. (horizontally) at course above through-wall flashing, above shelf angles and lintels, window rowlocks, and at bottom of walls.

F. Cavity Wall:

1. Do not permit mortar to drop or accumulate into cavity air space or to plug weeps.

2. Build inner wythe ahead of outer wythe to receive cavity insulation air/vapor barrier adhesive.

3. Install inner cavity damproofing with minimum 1/16” WFT in compliance with manufacturer’s recommendations.

4. After full drying of damproofing, install cavity clear system and outer wythe.

5. Install mortar net at bottom of wall cavity to a height of 16” above thru-wall base flashing.

G. Damproofing:

1. All damproofing will be roller applied. Sprayed application is not acceptable.

H. Reinforcement and Anchorage:

1. Install horizontal joint reinforcement at 16 inches o.c. (vertically).

2. Place masonry joint reinforcement in first horizontal joint above and below openings. Extend minimum 16 inches each side of opening.

3. Place joint reinforcement continuous in first joint below top of walls.

4. Lap joint reinforcement ends minimum of 8 inches.

5. Reinforced joint corners with strap anchors at 16 inches o.c. (vertically).

I. Masonry Flashings:

1. Extend flashings horizontally at foundation walls, above ledge or shelf angles and lintels, window rowlocks, and at bottom of walls.

2. Turn flashing up minimum 8 inches and bed into mortar joint of masonry.

3. Lap flashing and end joints minimum 8 inches and seal watertight with sealant.

4. Turn flashing, fold, and seal at corners, bends, and interruptions.

5. Provide end dams at all horizontal flashings at lintels and rowlocks 8 inches beyond lintel by forming a vertical surface at ends and sealing connections within the wall cavity.

6. Extend all horizontal flashings 1 1/2 inches beyond exterior face of masonry wall for the purpose of inspection. The flashings are to be cut back flush with the exterior face of the masonry wall once the ESD PM and Inspector have approved the flashing installations.

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7. Install flashings at conditions where it cannot be installed in CMU bed joint or at concrete back-up walls in 6” (min) wide bed of mastic and termination bar as indicated on the drawings.

J. Lintels:

1. Install loose steel lintels over openings as indicated.

2. Install reinforced masonry lintels over openings where shown.

3. Do not splice reinforcing bars in lintels, except where not practical.

4. Support and secure reinforcing bars from displacement. Maintain position within 1/2 inch of dimensioned position.

5. Place and consolidate grout fill without displacing reinforcement.

6. Maintain minimum 8 inch bearing on each side of opening.

K. Grouted Components:

1. Reinforce bond beam with two (2) No. 5 bars minimum or as noted on the drawings with bars placed 1 inch from bottom web.

2. Lap splices minimum 24 bar diameters.

3. Support and secure reinforcement bars from displacement. Maintain position within 1/2 inch of dimensioned position.

4. Place and consolidate grout fill without displacing reinforcement.

5. Provide one No. 5 vertical bar, and fill masonry cores with grout from top of foundation block to a minimum 8 inches above and to each side of opening unless shown otherwise on the drawings.

6. Provide additional reinforcing as shown on the drawings.

L. Control Joints:

1. Do not continue horizontal reinforcement through control joints.

2. Install pre-formed control joint material in continuous lengths. Seal butt and corner joints in accordance with manufacturer’s instructions.

3. Size control joint in accordance with Section 07920, for sealant performance.

M. Built-In Work:

1. As Work progresses, install built-in metal door frames, fabricated metal frames, window frames, anchor bolts, plates, reglets, and other items deigned to be integral and built-in into Work and furnished by others.

2. Install built-in items plumb and level.

3. Bed anchors of metal door frames, and applicable window frames in adjacent mortar joints. Fill frame voids solid with grout as required for fire-rating.

4. Do not build in organic materials subject to deterioration.

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N. Tolerances:

1. Maximum Variation from Unit to Adjacent Unit: 1/32 inch.

2. Maximum Variation from Plane of Wall: ¼ inch in 10 ft. and ½ inch in 20 two stories or more.

3. Maximum Variation form Plumb: ¼ inch per story, non-cumulative.

4. Maximum Variation from Level Coursing: 1/8 inch in 3 ft. and 1/4 inch in 10 ft.; 1 /2 inch in 30 ft.

5. Maximum Variation of Horizontal Joint Thickness: 1/8 inch in 3 ft.

6. Maximum Variation from Cross Sectional Thickness of Walls: 1/4 inch.

O. Cutting and Fitting:

1. Cut and fit for pipes, conduits, and sleeves as required. Coordinate with other

Specification Sections to provide correct size, shape, and location.

2. Obtain approval prior to cutting or fitting masonry Work not indicated or where appearance or strength of masonry Work may be impaired.

P. Cleaning:

1. While installing brick, good workmanship and job housekeeping practice will be used so as to minimize the need for cleaning the brick and Work area.

2. Protect the base of the wall from mortar splashes and mortar droppings;

protect the wall by setting scaffolds in a manner that keep mortar from deflecting onto the wall. At the end of each work day, set scaffolding boards so they do not deflect rainfall onto newly laid masonry.

a. The bricklaying technique will be such that mortar does not run down the face of the wall, or smear the mortar onto the brick face.

b. After mortar joints are tooled, cut off mortar tailings with the trowel, and brush excess mortar burrs and dust from the face of brick. Do not “bag” or

“sack” the wall, but use a bricklayer’s brush made with medium soft hair.

3. Remove all large mortar particles with a hardwood scraper.

4. If, after using the above techniques, additional cleaning of the walls is found to be necessary, allow the walls to cure one month before prior to initiating further cleaning processes.

5. Saturate the brick wall with clean water. The wall will be thoroughly saturated prior to and at the time of cleaning solution is applied.

6. Clean the brick with a cleaning solution approved by brick manufacturer and applied as directed by written instructions starting at the top of the wall and working downward. The concentration and specific method of application of the cleaning agents will be as outlined on the container by the manufacturer.

7. High pressure water and/or sandblasting is not acceptable cleaning procedures.

8. Immediately after cleaning a small area of the brick, the wall should be rinsed thoroughly with large quantities of water.

9. Use non-metallic tools in cleaning operations.

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Q. Protection of Finished Work:

1. After the brick is cleaned, take necessary precautions to ensure the other contractors and subcontractors do not damage or soil the walls.

2. Provide mud protection around the base of wall. Protection will be left in place until the final grading work is completed and ground cover is installed.

3. Without damaging completed work, provide protective boards at exposed external corners, which may be damaged by construction activities.

End of Section- 04330