Attachment__9_-_Photo_Exterior_Standards.pdf

PHOTO OF EXTERIOR STANDARDS:

Building No. 61

415 McPherson Ave.

Building No. 320

410 McPherson Ave.

Building No. 45

410 Kearney Ave.

Building No. 61

415 McPherson Ave.

Building No. 224

740 W. Warehouse Road

Building No. 318

350 Biddle Blvd.

Building No. 80

810 McClellan Ave.

Building No. 198

600 Thomas Ave.

Quality Workmanship

Standards on Fort Leavenworth, Kansas

Historic Buildings

Table of Contents

Purpose of the Standards

Introduction. How the Standards Work

Section I. Quality Woodworking Standards

Acceptable Practices

Unacceptable Practices

Section II. Quality Masonry Standards

Acceptable Practices

Unacceptable Practices

Conclusion

Purpose of the

Standards

1. To provide a clear, visual standard to contractors, DPW and COE inspectors on all woodworking and masonry projects on Historic Buildings at Fort Leavenworth, Kansas.

2. By providing a standard, each worker and inspector can understand what level of quality is expected before the project begins.

3. During the construction phase, the inspector(s) will use the standard as a visual guide for identifying acceptable and unacceptable workmanship. Therefore, it also becomes a continuous training tool for contractor(s) and inspector(s).

4. Increasing the level of quality produces:

A longer-lasting product

A work of craftsmanship

A savings of repair and replacement dollars

Introduction How the Standards Work

To Contractors and Inspectors:

These standards shall be the guide for all work and inspections on historic buildings at Fort Leavenworth, Kansas.

Historic buildings require strict construction practices and a high degree of quality work.

By not following these standards and/or identified by the Government Representative or representative, will require the contractor to remove the unacceptable work and replace it, at contractor's cost, with the acceptable, quality craftsmanship described in these standards.

These standards will help the contractor and the inspector to clearly identify acceptable craftsmanship, as well as, poor workmanship on historic projects. Following these acceptable practices preserves the existing historical material, prolongs the life of a new repair and restoration work, delivers a higher quality product that will last, and save future funding dollars.

Section I Quality Woodworking Standards

Section I. Quality Woodworking Standards

Acceptable Practices

Areas of Concern: Wood Repair and Restoration

Miter Joints

Railings/Flooring

Edge Joints

Special Cuts

Coping Trim

Unacceptable Practices

Working with Original Historic Materials

Poor Wood Cutting Techniques

Poor Joinery Techniques

Substandard Wood Quality

Poor Wood Member Attachments

Painting/Clean-Up

Conclusion

This is the first ever comprehensive standard to visually, as well as descriptively, describe acceptable practices in renovation and building repair on historic military structures.

These standards will initially be applied as guidelines to allow design, construction, and inspection to utilize and adapt to them - and to provide valuable feedback for further development.

Areas of Concern: Wood Repair and Restoration Quality Assurance

Under Architectural Woodworking Institute (AWI) Requirements, all finished work shall be Custom Grade.

Original Historic Materials:

Match existing historic design of materials or use historic drawings.

Follow the way the individual wood members are cut and designed.

Wood Cutting Techniques:

Paint all end cuts with oil based primer - DO NOT THIN OUT!

Cuts shall be clean, with no rough edges, sanded smooth, mounted flush, with no gaps to the attaching surface.

Caulking shall be used as an exception, rather than the rule and shall not be used to cover poor woodcuts and poor joint fits.

Molding Matches.

Eliminate multiple molding cuts, use one piece.

Joinery Techniques:

Miter Cuts: A maximum tolerance of 1/32" space between members, such as miter cuts, and member to member attachment.

Joint Fitting Criteria

Wood Quality

Dryness 12 - 15%

Decision to Use or Not to Use

Defects Use/Fix Criteria

Block Sanding Methods:

Sanding shall follow the wood grain, unless you just want to remove a lot of material in the "roughing" stage.

If you are doing something long, like a leading edge, be sure to start at one end with part of the block off the workpiece and move the entire length of the workpiece. A very common mistake on a leading edge is to do shorter strokes spending more time on the center portion and then ending up with a curved leading edge. To avoid this, do long end-to-end strokes and stop frequently to make sure it's still straight.

Visual - Use only clean, smooth face materials that are exposed to the visual so that it does not detract from the beauty of the construction.

Sanding requirements: Before panting over an existing painted or primed surface, sand with a light 150 grit sandpaper, blow or wipe off dust residue, then paint.

Structural Requirements/

Acceptable Woodworking Practices - Exterior

Solutions to Defects - Glue, with clamps, Bracing, Plates, Epoxy.

Wood Member Attachments

Nails - Use galvanized nails for exterior work only.

Set nails below the surface of the wood to receive filler putty, let dry, then sand the wood surface smooth for a clean finish, then prime and paint. Screws and Bolts - Use lag bolts and washers where there may be structural concerns.

Use Detailing from DPW

The DPW will supply details for porch elements where there are several kinds of unmatching wood trim, columns, bases, spindles, and railings.

Paint Clean-up

Preventive - The contractor shall take measures to ensure protection of areas not to be painted. Examples are adjacent brick, stone, other painted areas, sidewalks, and metal elements.

Clean up mistakes - If the contractor allows new paint to drop on adjacent brick, stone, other painted areas, sidewalks, or metal elements, it shall be cleaned completely with no paint residue showing.

Caulking Cracks - Criteria

If there is more than 1/32" space between members, such as miter cuts, member to member attachment, it will be the responsibility of the contractor to remove the member(s), re-cut a new member, and tighten the joint spacing.

Use elastomeric, expanding type caulking.

Inspection Process

Daily, Weekly, Unannounced.

Use different times. Do not use the same schedule of Inspection. Don't be predictable.

Be consistent with accepting quality work; encourage the contractor when work is done with quality.

Be consistent with rejecting.

Woodwork & Trim

Ensure exact profiles and original materials when replacing and rebuilding molding profiles, siding profiles, balusters and ornamental trim.

Documentation of original or similar style/date building should be provided for any design change or missing ornamentation; Victoria's Heritage Advisory Committee must approve design changes.

There are few heritage buildings on which plywood is historically accurate; most old porches were fir floored with bull-nosed edges and stair treads; such materials are still commonly available.

All woodwork must be primed on all sides at time of installation; be sure your quote includes both priming and finishing paint, and installation.

Windows

All windows will be operational after painting even if the window was not operational before painting.

Windows with bars if the bars can not be removed the contractor will paint through the bars and because of extra labor to do this given the cost to remove and replace the security bars.

Miter Joints

Standard

The first requirement of a good miter joint is that the two mating surfaces must fit together perfectly. This means there are no discernible gaps. For edge joining, the mating surfaces must be flat and square to both faces of the board. Nails should be recessed for caulking.

Drawing Notes

Horizontal and vertical cuts. Members fit tight, no gaps or uneven cuts.

Good miter cuts have no need for caulking. Joints are clean, no gaps, no inaccurate cutting.

Edges should be sharp and level

Nails should recess deep enough to receive exterior caulking.

Nails are recessed and puttied, dried, then sanded.

Miter Cut is clean, tight, and requires no caulking.

The first requirement of a good edge joint is that the two mating surfaces must fit together perfectly. This means there are no discernible gaps. For edge joining, the mating surfaces must be flat and square to both faces of the board.

Drawing Notes

Horizontal and vertical cuts. Members fit tight, no gaps or uneven cuts.

Miter cuts have no need for caulking.

Joints are clean, no gaps, no inaccurate cutting. Both pieces fit within 1/32" tolerance

Edges should be sharp and level, no filler required.

Photo Notes

Horizontal and vertical cuts. Members fit tight, no gaps or uneven cuts.

Miter cuts have no need for caulking.

Joints are clean, no gaps, no inaccurate cutting. Both pieces fit within 1/32" tolerance

Edges should be sharp and level, no filler required.

Should have a full coverage of the required paint coatings.

Photo Notes

Structural boards are flush and cut evenly.

Miter cuts are clean with no inaccurate cutting.

Edges should be sharp and level

Railings

Spindles

Building No. 44 - Size 3 ½” square by 19” tall

Building No. 58 – Size 2 ½” square by 22” tall

Railings/Flooring

Edge Joints Standard

The first requirement of a good edge joint is that the two mating surfaces must fit together perfectly. This means there are no discernible gaps. For edge joining, the mating surfaces must be flat and square to both faces of the board.

Drawing Notes

Horizontal and vertical cuts. Members fit tight, no gaps or uneven cuts.

Edges should be sharp and level.

Special Cuts Standard

The two mating surfaces must fit together perfectly. This means there are no discernible gaps. For edge joining, the mating surfaces must be flat and square to both faces of the board. Nails should be recessed for caulking.

Note: All end cuts shall be primed before joined together.

Drawing Notes

Members fit tight, no gaps or uneven cuts.

Joints are clean, no gaps, no inaccurate cutting

Edges should be sharp and level.

Coping Trim Standard

The first piece is butted to the wall. The second piece is mitered as for an inside corner, but the mitered end is cut off where it meets the molding face, leaving a negative profile that fits over the butted piece tightly.

Drawing Notes

Members fit tight, no gaps or uneven cuts.

Good coping cuts have no need for caulking. Joints are clean, no gaps, no inaccurate cutting.

Edges should be sharp and level.

The coped edge should conform to the shape of the other piece with no gaps.

Top Rail Standard

The first piece is butted to the wall. The second piece is mitered as for an inside corner, but the mitered end is cut off where it meets the molding face, leaving a negative profile that fits over the butted piece tightly.

Drawing Notes

Horizontal and vertical cuts are at the proper angle to each other. Members fit tight to spindles, no gaps or uneven cuts.

Good top rails have joints that are clean, no gaps, no inaccurate cutting.

Edges should be sharp, parallel, and level.

Nails should recess deep enough to receive exterior caulking.

Surfaces are flat and smooth with no saw cut or hammer marks.

Porch Decking Standard

The first requirement of good decking is the tongue and groove mating surfaces that fit together perfectly. This means there are no discernible gaps. For edge joining, the mating surfaces must be flat and square to both faces of the board. Nails should be deep within the groove to allow a tight fit.

Drawing Notes

Members fit tight, no gaps or uneven cuts.

Joints are clean, no gaps, no inaccurate cutting.

Nails should recess deep enough to receive tongue.

Install bead of caulk length of tongue

Round edge of flooring, seal end using epoxy consolidate. Suggested supplier Abatron

Structural

Standard

Areas under columns required additional support.

Boxed-in areas shall be designed as to distribute the loading of each column on all porches and structural support areas.

Unacceptable Practices

Note to Contractor:

If the Contacting Officer or Representative observes any Unacceptable Woodworking Practice described within this Standard, the Contractor, at his/her own expense, shall replace the member or structural unit or woodworking system to the satisfaction of the Contacting Officer or representative.

All work on Fort Leavenworth shall comply with these Quality Standards.

It takes only a few extra minutes to do a job correctly ...it may take hours to correct a hurried job.

Pieces of wood split off because of a poor section of wood, nail, screw, or bolt protrusion

Pieces of wood that are not placed to form a clean, 90 degree even-edge, but leaves gaps. Meeting wood members should have a tight fit and flush to one another.

When pieces of wood split or pop off, either reattach with a bonding agent or replace entire member, depending on the loss of material. Replace if the structural integrity is compromised.

Unacceptable Woodworking Practices - Exterior

Structural members shall not have broken parts or splitting through members.

Structural members, with this kind of poor wood quality, shall be replaced by contractor.

Unsanded, visual surfaces with wood particles under the paint job.

Unsquare, unleveled, or out of line workmanship on any wood system.

REPLACE entire system to create a square, even look to the work.

Unsquare, unleveled, or out of line workmanship on any wood system shall be REPLACED. New work shall be square, parallel, level, and even.

Uneven Miter Cuts: Miter cuts should not require caulking to complete the work.

Caulking in wide joints will pop out and open the end cuts to moisture penetration.

REPLACE both boards.

Uneven Miter Cuts: Using poor miter cuts that produce wide joints requiring caulking.

REPLACE poorly cut piece(s).

Uneven Miter Cuts: Using poorly sawn miter cuts that require resawing to meet the corner.

REPLACE both boards.

Section II.

Acceptable Masonry Practices

Section I. Quality Masonry Standards

Acceptable Practices

Quality Assurance

Original Historic Brick and Stone Materials

Tuckpointing Techniques

Matching Brick and Stone

Mortar Application Techniques

Mock-Ups Requirements

Use of Hand Tools/Power Equipment

Mortar Mix Quality

Clean-Up and Finish Work

Unacceptable Practices

Working with Original Historic Materials

Poor Mortar Application Techniques

Poor Mortar Mixing Techniques

Clean-Up and Finish Work

What is Quality Masonry Restoration?

Quality is key to masonry restoration and is defined as a "degree or grade of excellence" according to The American Heritage Dictionary. However, quality is still not clearly defined but we all know it when we see it.

However, with these visual standards, quality can be identified, at least, in regards to masonry restoration. This will help improve the life span of these historic properties.

Tuckpointing

Tuckpointing is the re-pointing of the deteriorated mortar joints in an existing masonry wall.

Once mortar joints are ground out to desired depth, we recommend a minimum of 1/2" deep, dust out joints with brush to remove dust particles. Then, rinse joint with water hose to make it dust-free and ensure proper bonding.

Proceed with tuckpointing and look for the following quality standards:

No air bubbles in mortar in joint

No openings in mortar in joint

Mortar is flush with brick (or as specified)

No mortar is on the face of the brick, that is, smeared

No dust is on edge of brick reducing proper bonding

Allow time for joints to dry. If the mortar turns white and smears the brick, it is too dry. If mortar begins to turn white, misting is needed and color of joint.

When to re-tuckpoint

When a lot of mortar falls out and the joint is already a 1/4".

Appearance is poor and you ant to dress it up.

Tuckpoint 100% solid when more than 50% of the joints are deteriorated. Recommend using type N mortar.

Patching Masonry

Patching masonry is repairing deteriorated/spalled masonry such as concrete, brick, stone and terra cotta to ensure it being weather-tight and/or to repair the masonry so it looks better and is not a safety hazard.

One product in particular that is superior is Jahn Restoration Mortars manufactured by Cathedral Stone Products, Inc. installed by trained craftspeople that are certified to install Jahn products.

When patching masonry with any material, the applicator will generally follow these steps:

Remove all loose materials in patched area

Square off edges to be patched

Create a minimum of a 1/2" deep for patched area

Dust out area to remove dust and dirt

Apply primer with brush to area

Apply paint/rust inhibitor to exposed rebar

Apply patching material with margin trowel

Apply straight edge to material and smooth out to ensure material is flush with adjacent masonry surfaces

Mist patched area three times a day for three consecutive days

Acceptable Masonry Practices

Look for these performance standards:

Material is flush/even

No dents or holes in patch

No smear on outside of patch

Area is damp

Texture matches existing

Knowing when to patch masonry

Where loose masonry is severely cracking, spalling, rupturing, or popping off.

When you have water damage or leaks inside.

When the appearance is very noticeable.

When the deterioration could cause damage to property and/or persons.

Cleaning Masonry

There are several methods of cleaning masonry. Knowing which method is vital to restoring/preserving existing masonry. Most masonry can be cleaned using only water at varying pressures (psi). However, some form of chemical cleaning and/or sandblasting may be necessary when your masonry has any of the following problems;

deep rust stains, chemical residue, efflorescence, graffiti, paint, and years of neglect. Determine what chemical and psi will cut existing dirt/stains. Always do a sample when chemical cleaning masonry and get data sheets.

Historical Preservation

Do not ever sandblast a historical site unless you do not mind losing its historical heritage and/or recognition.

Always use a low psi between 300-1000 when cleaning masonry on a historical site.

Always use a properly mixed historical mortar consisting of the following:

1. 6 parts sand or matching aggregates

2. 1/5 part Portland cement

3. 2 parts hydrated lime

4. 5 gallons of water or until mortar can be rolled into a ball and provides a thumbprint

Screws and Bolts - Use lag bolts and washers where there may be structural concerns.

Use Detailing from DPW - the DPW will supply details for porch elements where there are several kinds of mismatched wood trim, columns, bases, spindles, and railings.

Stone brick face is free from unwanted mortar and has a clean look and feel.

Mortar joints are clean, smooth, uniform, within the spaces between the stones, and consistent with color. Matching color of existing historic mortar.

Brick is free from unwanted mortar and has a clean look and feel.

Masonry mock-ups are required before starting work. Construct 3' x 5' units. Mortar must be completely dry before inspection and final acceptance before work begins.

Structural members shall not have broken parts or splitting through members.

Unacceptable Practices

Mortar is smeared or left across stone or brick face.

Applying the wrong color of mortar, which should match the existing mortar.

Poor color selection of brick.

Unacceptable Masonry Practices - Brick

Historic Preservation Standards

From the Secretary of the Interior’s Standards for Rehabilitation of Historic Buildings

IDENTIFY, PRESERVE, PROTECT, MAINTAIN, REPAIR, and

REPLACEMENT OF HISTORIC MATERIALS

Required

Identifying, retaining, and preserving wood features that are important in defining the overall historic character of the building such as siding, cornices brackets, window architraves, and doorway pediments;

and their paints, finishes, and colored walls, brackets, railings, cornices, windows architraves, door pediments, steps, and columns and details such as tooling and bonding patterns, coatings, and color.

Protecting and maintaining wood features by providing proper drainage so that water is not allowed to stand on flat, horizontal surfaces or accumulate in decorative features.

Replacing an entire wood feature such as a cornice or wall when repair of the wood and limited replacement of deteriorated or missing parts are appropriate.

Not Allowed

Removing or radically changing wood features which are important in defining the overall historic character of the building so that, as a result, the character is diminished.

Removing a major portion of the historic wood from a facade instead of repairing or replacing only the deteriorated wood, then reconstructing the facade with new material in order to achieve a uniform or

"improved" appearance.

Not Allowed

Using substitute materials for the replacement part that does not convey the visual appearance of the surviving parts of the wood feature or that is physically or chemically incompatible.

Failing to undertake measures to assure the protection of wood features.

Recommended

Repairing wood features by patching, piecing-in, consolidating, or otherwise reinforcing the wood using recognized preservation methods. Repair may also include the limited replacement in kind, or with compatible substitute material, of those extensively deteriorated or missing parts of features where there are surviving prototypes such as brackets, molding, or sections of siding.

Brick was destroyed by pneumatic tools and wider the space.

Unacceptable Masonry Practices - Brick

Structural

Areas under columns required additional support.

Boxed-in areas shall be designed as to distribute the loading of each column on all porches and structural support areas.

DIRECTORATE OF PUBLIC WORKS

820 McCLELLAN AVE

FORT LEAVENWORTH, KANSAS 66027

PROJECT TASK ORDER RECONCILIATION FORM

Project Name: _____________________________________________

Project Number: __________________

Task Order number: _______

Signature of Contracting Officer’s Representative Date

Signature of Contractor Date

Continuation Form

Line item No.

Description Quantity Cost per

Unit

Cost