04720 - Cast Stone.pdf

SECTION 04720

CAST STONE

PART 1 GENERAL

1.01 SUMMARY

A. Section Includes

1. Architectural cast stone.

1.02 RELATED REQUIREMENTS

A. Section 04065 - Mortar and Masonry Grout: Mortar for setting cast stone.

B. Section 04810 - Unit Masonry Assemblies: Installation of cast stone in conjunction with masonry.

C. Section 07900 - Joint Sealers: Materials and execution methods for sealing soft joints in cast stone work.

1.03 REFERENCE STANDARDS

A. ACI 318 - Building Code Requirements for Structural Concrete and Commentary;

American Concrete Institute International; 2008.

B. ASTM A 185/A 185M - Standard Specification for Steel Welded Wire Reinforcement, Plain, for Concrete; 2007.

C. ASTM A 615/A 615M - Standard Specification for Deformed and Plain Billet-Steel

Bars for Concrete Reinforcement; 2007.

D. ASTM C 33 - Standard Specification for Concrete Aggregates; 2007.

E. ASTM C 150 - Standard Specification for Portland Cement; 2007.

F. ASTM C 270 - Standard Specification for Mortar for Unit Masonry; 2007a.

G. ASTM C 494/C 494M - Standard Specification for Chemical Admixtures for

Concrete; 2008.

H. ASTM C 642 - Standard Test Method for Density, Absorption, and Voids in Hardened

Concrete; 2006.

I. ASTM C 1364 - Standard Specification for Architectural Cast Stone; 2007.

1.04 QUALITY ASSURANCE

A. Manufacturer Qualifications: A current producer member of the Cast Stone Institute with a minimum of 5 years of experience in producing cast stone of the types required for project and:

1. Adequate plant capacity to furnish quality, sizes, and quantity of cast stone required without delaying progress of the work.

2. Products previously produced by plant and exposed to weather that exhibit satisfactory appearance.

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B. Mock-Up: Provide full size cast stone components for installation in mock-up of exterior wall.

1. Approved mock-up will become standard for appearance and workmanship.

2. Mock-up may remain as part of the completed work.

3. Remove mock-up not incorporated into the work and dispose of debris.

C. Source Quality Control: Test compressive strength and absorption of specimens selected at random from plant production.

1. Test in accordance with ASTM C 642.

1.05 DELIVERY, STORAGE, AND HANDLING

A. Deliver cast stone components secured to shipping pallets and protected from damage and discoloration. Protect corners from damage.

B. Number each piece individually to match shop drawings and schedule.

C. Store cast stone components and installation materials in accordance with manufacturer's instructions.

D. Store cast stone components on pallets with nonstaining, waterproof covers. Ventilate under covers to prevent condensation. Prevent contact with dirt.

E. Protect cast stone components during handling and installation to prevent chipping, cracking, or other damage.

F. Store mortar materials where contamination can be avoided.

G. Schedule and coordinate production and delivery of cast stone components with unit masonry work to optimize on-site inventory and to avoid delaying the work.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Cast Stone Systems; Product: Nebraska Pier Cap, PC5N24

B. Corinthian Cast Stone; Product PCN1H

C. Architectural Cast Stone, Inc

D. Any current producer member of the Cast Stone Institute.

2.02 ARCHITECTURAL CAST STONE

A. Cast Stone: Architectural concrete product manufactured to simulate appearance of natural sandstone, complying with ASTM C 1364.

1. Compressive Strength: As specified in ASTM C 1364; calculate strength of pieces to be field cut at 80 percent of uncut piece.

2. Freeze-Thaw Resistance: Demonstrated by field experience.

3. Surface Texture: Fine grained texture, with no bugholes, air voids, or other surface blemishes visible from distance of 6 meters (20 feet).

4. Color: Selected by Contracting Officer or Designated Representative from manufacturer's full range.

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5. Remove cement film from exposed surfaces before packaging for shipment.

B. Shapes: Provide shapes indicated on drawings.

1. Variation from Any Dimension, Including Bow, Camber, and Twist: Maximum of plus/minus 3 mm (1/8 inch) or length divided by 360, whichever is greater, but not more than 6 mm (1/4 inch).

2. Unless otherwise indicated on drawings, provide:

a. Wash or slope of 1:12 on exterior horizontal surfaces.

b. Drips on projecting components, wherever possible.

c. Raised fillets at back of sills and at ends to be built in.

C. Reinforcement: Provide reinforcement as required to withstand handling and structural stresses; comply with ACI 318.

2.03 MATERIALS

A. Portland Cement: ASTM C 150.

1. For Mortar: Type I or II, except Type III may be used in cold weather.

B. Coarse Aggregate: ASTM C 33, except for gradation; granite, quartz, or limestone.

C. Fine Aggregate: ASTM C 33, except for gradation; natural or manufactured sands.

D. Admixtures: ASTM C 494/C 494M.

E. Water: Potable.

F. Reinforcing Bars: ASTM A 615/A 615M deformed bars, galvanized or epoxy coated.

G. Steel Welded Wire Reinforcement: ASTM A 185/A 185M, galvanized or epoxy coated.

H. Embedded Anchors, Dowels, and Inserts: Type 304 stainless steel, of type and size as required for conditions.

I. Mortar: Portland cement-lime, ASTM C 270, Type N.

J. Sealant: As specified in Section 07900.

K. Cleaner: General-purpose cleaner designed for removing mortar and grout stains, efflorescence, and other construction stains from new masonry surfaces without discoloring or damaging masonry surfaces; approved for intended use by cast stone manufacturer and by cleaner manufacturer for use on cast stone and adjacent masonry materials.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install cast stone components in conjunction with masonry, complying with requirements of Section 04810.

B. Mechanically anchor each cast stone unit.

C. Setting:

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1. Drench cast stone components with clear, running water immediately before installation.

2. Set units in a full bed of mortar unless otherwise indicated.

3. Fill vertical joints with mortar.

4. Fill dowel holes and anchor slots completely with mortar or non-shrink grout.

D. Joints: Make all joints 9.5 mm (3/8 inch), except as otherwise detailed.

1. Rake mortar joints 19 mm (3/4 inch) for pointing.

2. Remove excess mortar from face of stone before pointing joints.

3. Point joints with mortar in layers 9.5 mm (3/8 inch) thick and tool to a slight concave profile.

E. Sealant Joints: Install sealants as specified in Section 07900.

F. Installation Tolerances:

1. Variation from Plumb: Not more than 3 mm in 3 m (1/8 inch in 10 feet) or 6 mm in 6 m (1/4 inch in 20 feet) or more.

2. Variation from Level: Not more than 3 mm in 3 m (1/8 inch in 10 feet) or 6 mm in

6 m (1/4 inch in 20 feet), or 9 mm (3/8 inch) maximum.

3. Variation in Joint Width: Not more than 3 mm in 900 mm (1/8 inch in 36 inches) or 1/4 of nominal joint width, whichever is less.

4. Variation in Plane Between Adjacent Surfaces (Lipping): Not more than 1.5 mm

(1/16 inch) difference between planes of adjacent units or adjacent surfaces indicated to be flush with units.

G. Repairs: Repair chips and other surface damage noticeable when viewed in direct daylight at 6 m (20 feet).

1. Repair with matching touchup material provided by the manufacturer and in accordance with manufacturer's instructions.

2. Repair methods and results subject to Contracting Officer or Designated

Representative's approval.

3.02 CLEANING

A. Keep cast stone components clean as work progresses.

3.03 PROTECTION

A. Protect completed work from damage.

B. Clean, repair, or restore damaged or mortar-splashed work to condition of new work.

END OF SECTION

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