SECTION 04400 EXTERIOR STONE CLADDING
PART 1 GENERAL 1.1
GENERAL REQUIREMENTS A.
1.2
Work of this Section, as shown or specified, shall be in accordance with the requirements of the Contract Documents. SECTION INCLUDES
A.
The Work of this Section includes all labor, materials, equipment and services necessary to complete the exterior stone cladding as shown on the drawings and specified herein, including, but not limited to, the following: 1.
Stone panels anchored to masonry and concrete at the base of the new structures.
2.
Attachment of stone to steel stud back up with masonry anchoring system.
3.
Drilling, fitting and cutting of stone work as required for the proper completion of the work.
4.
Accessories and hardware required for complete installation, including flashing.
5.
Filling of stone to stone and stone joints with mortar.
6.
Shop drawings, engineering calculations, samples.
7.
Protection of stone during transit, storage, erection and after installation. Cleaning of stone prior to acceptance.
8.
Field measurements of adjacent and/or supporting construction and verification of existing conditions.
9.
Coordination and provision for and interfacing with adjoining construction.
10. Construction of visual sample layout. 1.3
RELATED SECTIONS A.
Submittals – Section 01300
B.
Cold formed metal framing – Section 05400.
C.
Flashing – Section 07600.
D.
Firestops and smokeseals - Section 07840.
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1.4
DESIGN REQUIREMENTS A.
General: Design, fabricate and install stonework to withstand normal loads from wind, gravity, movement of building structure, and thermally induced movement, as well as to resist deterioration under conditions of normal use including exposure to weather, without failure.
B.
Retain the services of a cladding engineer, as described below, to design the cladding support and retention system. Cladding engineer will prepare engineering calculations for the justification of all principal stonework, units, fasteners, and anchorage components for compliance with the performance criteria established herein.
C.
Engineering Calculations: base calculations on design loads, material properties, and applicable safety factors. Include the following information as part of the calculations:
D.
Stone loads and allowable loads,
E.
Stone thicknesses,
F.
Support and anchorage loads, stresses, safety factors, design loads, and allowable loads,
G.
Support and anchorage sizes.
H.
Design connections and attachments for limestone to carry the design loads with safety factors and allowable stresses in accordance with the American Institute of Steel Construction (AISC), except that steel supports carrying gravity loads shall be stressed not more than 50 percent of the yield stress in bending.
I.
Design, detail and fabricate connections to provide allowance for fabrication tolerances, erection tolerances and structural deflections. Refer to ASTM C1242.
J.
Control of Corrosion: Prevent galvanic and other forms of corrosion by insulating metals and other materials from direct contact with non-compatible materials, or by suitable coating.
K.
Loads: Per State of New Jersey Building Code and Structural Drawings, whichever is more restrictive.
1.5
QUALITY ASSURANCE A.
Cladding Engineer: Professional engineer experienced in cladding design, registered to practice engineering in State of New Jersey.
B.
Fabricator: Company having sufficient capacity to quarry, cut, and deliver the stonework on schedule.
C.
Installer: Company or person specializing in commercial stone work with 10 years experience. Employ skilled stone fitters at the site to do necessary field cutting as stones are set.
D.
Obtain stone from a single quarry source with resources to provide materials of specified consistent quality.
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E.
Obtain mortar ingredients of uniform quality and from a single manufacturer for each cementitious and admixture component and from one source or producer for each aggregate.
F.
Obtain each type of stone accessory, sealants and other materials from a single manufacturer for each product.
G.
The Architect reserves the right to visit the fabricating facilities for which the Sub-Contractor is responsible at any time when the work is in progress. All shop and field materials and workmanship shall be subject to inspection by the Architect and his representatives at all times. Such inspections do not relieve the Sub-Contractor from obligations to provide materials conforming to all requirements of the Contract Documents.
H.
The Sub-Contractor by commencing the work of this Section, assumes overall responsibility, as part of his warranty of the work, to assure that all assemblies, components and parts shown or required within the work of this Section, comply with the Contract Documents. The Sub-Contractor shall further warrant: 1.
That all components, specified or required to satisfactorily complete the installation, are compatible with each other and with the conditions of installation and expected use.
2.
The overall effective integration and correctness of individual parts and the whole of the system.
3.
There shall be no premature material failure due to improper design and fabrication of the stone. All materials are to fully perform to their normal life expectancy.
4.
Each and every piece of stone shall be subject to the Architect's approval, and any piece or pieces which may be rejected after having been set shall be carefully cut out and replaced with new suitable stone without delay, and without cost to the Owner. Any piece or pieces damaged in the removal and resetting of defective pieces shall also be removed, and suitable, approved pieces provided and set.
I.
Architect's inspection of the stone does not relieve the Sub-Contractor of his responsibility to provide all stonework in accordance with the approved samples and shop drawings.
J.
Examination Criteria: All examinations, selections and approvals shall be for the purpose of achieving a final appearance of stone with the greatest possible uniformity, and will be based upon the following criteria: 1.
Color within approved, pre-selected color ranges and finish.
2.
Only one source of each type of stone shall be used throughout the work. Stone shall match the type, pattern, color, texture and finish of samples available for inspection in the office of the Architect.
3.
Conformance to approved shop drawings and details within specified dimensions and tolerances.
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4. 1.6
Other criteria as specified in Part 2 - Products, herein.
FABRICATION AND ERECTION TOLERANCES A.
Tolerances are as follows: 1.
Except as noted, all joints shall be 1/4".
2.
Unit Length: plus or minus 1/8".
3.
Unit Height: plus or minus 1/8".
4.
Deviation From Square: plus or minus 1/8", with measurement taken using the longest edge as the base.
5.
Bed Depth: plus or minus 1/8".
6.
Offset at Joints: Do not exceed +/- 1/32" including joints on the wall and on the floor which are in alignment.
B.
Variations From Plumb: For lines and surfaces of columns, walls and arrises, do not exceed 1/4" in 10', 3/8" in a story height or 20' maximum, nor 1/2" in 40' or more. For external corners, expansion joints and other conspicuous lines, do not exceed 1/4" in any story or 20' maximum, nor 1/2" in 40' or more.
C.
Variation From Level: For grades indicated for exposed lintels, sills, parapets, horizontal grooves and other conspicuous lines, do not exceed 1/2" in any bay or 20' maximum, nor 3/4" in 40' or more.
D.
Variation of Linear Building Line: For position shown in plan and related portion of columns, walls and partitions, do not exceed 1/2" in any bay or 20' maximum, nor 3/4" in 40' or more.
E.
Variation in Cross-Sectional Dimensions: For columns and thickness of walls from dimensions indicated, do not exceed minus 1/4", nor plus 1/2".
F.
Offset at joints: Do not exceed plus or minus 1/32".
1.7
MOCK-UPS A.
Provide a visual mock up at site showing the full range and variation of stone, i.e., color matching, surface texture and finish at corners. Use a minimum of 8 stones, 4' x 4' or more in size, assembled vertically in an arrangement similar to the actual arrangement of the exterior cladding. The mock-up should represent the unique conditions of the exterior cladding, including stones exposed on more than one side and the finish at the corners where these exposed sides meet. Show proposed method of identification for each stone piece. Stone used must also show full finishes as specified herein.
B.
Provide job site mock-up over masonry back-up showing stone anchorage system, relationship to adjacent construction, joint treatment, weeps, related flashing and all other accessories required to show how stone cladding will go together on the structure.
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Refer to drawings for size of mock-up; remove mock-up when directed by the Architect. 1.8
STANDARDS A. ASTM A580/A580M-98: Standard Specification for Stainless Steel Wire. B.
ASTM C73-97a: Standard Specification for Calcium Silicate Face Brick.
C.
ASTM C144-99: Standard Specification for Aggregate for Masonry Mortar.
D. ASTM C150-98: Standard Specification for Portland Cement. E.
ASTM C207-91(1997): Standard Specification for Hydrated Lime for Masonry Purposes.
F.
ASTM C270-99: Standard Specification for Mortar for Unit Masonry.
G. ASTM C1242-96b: Standard Guide for Design, Selection, and Installation of Exterior Dimension Stone Anchors and Anchoring Systems. H. International Masonry Institute All-Weather Council: Recommended Practices and Guide Specifications for Cold Weather Masonry Construction. I. 1.9
Masonry Advisory Council: Hot and Cold Weather Construction. SUBMITTALS
A.
B.
Shop Drawings: Submit shop drawings for the fabrication and installation of all work and associated components. Include: 1.
Wall elevations at 3/8" scale minimum, typical unit elevation at 1" scale minimum.
2.
Show details of all conditions for every member, joint, anchorage and provision for expansion and contraction and sealant application.
3.
Include coordination details for related and adjoining work, insert drawings and erection diagrams. Show relative layout for all adjacent walls, beams, columns and slabs, all correctly dimensioned.
Provide structural calculations, prepared in compliance with referenced documents and these specifications. Where specifications and code differ, the more stringent requirement shall govern. Subcontractor to follow Code requirements. Calculations shall be legible and shall incorporate sufficient cross references to shop drawings to make the calculations readily understandable and reviewable. Test reports are not an acceptable substitute for calculations. Calculations shall include the following information: 1.
Analysis for all applicable loads on framing members.
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2.
Analysis for all applicable loads on anchors, including anchors embedded in concrete.
3.
Section property computations for steel framing members.
4.
Analysis of stress in stone.
5.
Seal and signature of professional engineer registered in the State of New Jersey. The Architect and/or his Consultants will not provide said seal and signature.
C.
Review of calculations and shop drawings by the Architect will not relieve the SubContractor of any responsibilities for providing a system within the required performance requirements. If the structural calculations indicate any deficiencies, the Sub-Contractor shall, at his expense, provide all items necessary to comply with the performance requirements.
D.
Architect shall consider alternative stone anchor systems in lieu of system shown on the drawings. Sub-Contractor shall submit complete engineering calculations as specified herein for alternative system, as well as any cost savings achieved.
E.
Submit complete Cutting and Setting Drawings to Architect for approval. Shop sizes, shapes, thicknesses, jointing, anchoring, connection with other work, typical and special anchoring details, supports, dimensions, setting numbers, and color range for each piece of stone. Clearly indicate dimensions for locating slots in stone and for locating inserts to be built into concrete and masonry. Do not fabricate any stone (except for samples) until shop drawings have been approved by the Architect.
F.
Manufacturer's Data: Submit copies of manufacturer's specifications and installation instructions for each stonework accessory required. Include data substantiating that materials comply with specified requirements.
G.
Test Reports: Submit written, certified test reports for required tests, recording dates, locations, method of testing, test results and interpretation of results.
H.
Samples Size
Description
12" x 24"
Each stone type with finish each kind and color (NOTE: Submit four (4) sets of color range/stone variation samples for each finish)
Actual
Stone anchoring devices, shims, each type and kind
1.10
DELIVERY, STORAGE AND HANDLING
A.
Protect stone during storage and construction against moisture, soiling, staining and physical damage.
B.
Handle stone to prevent chipping, breakage, soiling or other damage. Do not use pinch or wrecking bars without protecting edges of stone with wood or other rigid materials.
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Lift with wide-belt type slings wherever possible; do not use wire rope or ropes containing tar or other substances which might cause staining. If required, use wood rollers and provide cushion at end of wood slides. C.
Store stone on wood skids or pallets, covered with non-staining, waterproof membrane. Place and stack skids and stones to distribute weight evenly and to prevent breakage or cracking of stones. Protect stored stone from weather with waterproof, non-staining covers or enclosures, but allow air to circulate around stone.
D.
Protect mortar materials and stonework accessories from weather, moisture and contamination with earth and other foreign materials.
1.11 A. 1.12
JOB CONDITIONS Sub-Contractor must review installation procedures and coordination with other work, with Contractor and other trades whose work will be affected by stonework. PROTECTION
A.
Protect adjacent surfaces from damage. Protect exposed surfaces of stone units from damage or defacement. Prevent materials used for installing work of this Section from staining or damaging the exposed surfaces of stone units or the exposed surfaces of the adjoining construction.
B.
Protect all stone work from other materials that will cause staining or defacement. Stone subject to damage after setting shall be properly covered or protected.
C.
No lumber or other material liable to stain or deface the stone shall be used.
1.13
GUARANTEE
A.
Unless stated otherwise in these specifications, guarantee shall state that all work is in accord with drawings and specifications, as amended by any changes thereto authorized by the Architect, free from defects in materials and workmanship and weathertight for a period of two (2) years from the date of acceptance of the work by the Owner. SubContractor shall agree to repair or replace defective materials and workmanship during the guarantee period at no additional cost to the Owner.
B.
Defective materials and workmanship are hereby defined to include evidence of abnormal deterioration, aging or weathering of the work, structural failure of components resulting from exposure to normal load and forces, deterioration or discoloration of finishes in excess of normal weathering and aging, and failure to fulfill other specified performance requirements.
C.
Sub-contractor shall be responsible for damage to the building and furnishings occasioned by defective materials or workmanship or damage as part of repairs to the stone cladding.
D.
The guarantee, the enforcement or lack of enforcement thereof, shall not deprive the Owner of other actions, rights or remedies available to him. Guarantee shall be inform approved by the Architect.
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PART 2 PRODUCTS 2.1
STONE A.
Stone shall be “calcium silicate masonry units from “Renaissance” Series, as manufactured by Arriscraft color Cafe. Stone finish as indicated shall be as selected by Architect.
B.
Calcium Silicate Masonry Units: to ASTM C 73, Grade SW; solid units having been pressure formed and autoclaved; having the following average properties when tested to the identified standard:
C. 2.2
1.
Compressive Strength: 6,600 psi, to ASTM C170.
2.
Absorption: 8.8 percent, to ASTM C97.
3.
Density: 129 lbs/ft3, to ASTM C97.
4.
Modulus of Rupture: 770 psi, to ASTM C99.
All stone shall meet with Architect's approval. STONE ACCESSORIES
A.
Stainless Steel for All Accessories in Contact with Stone 1.
Sheet, bar and plate - AISI Type 302/304
2.
Fasteners, anchor bolts, nuts and washers - AISI Type 302/304, non-magnetic, ASTM A67.
3.
Shims - AISI Type 302/304.
B.
Setting Pads: Setting pads shall be lead or plastic.
C.
Tubes for venting and weeping shall be H & B #QV Quadro-Vent.
D.
Flashing: Stainless steel, see Section 07600.
E.
Non-Shrink Grout: "Set Grout" by Master Builders or approved equal.
F.
Mortar for Calcium Silicate Masonry Units: ASTM C270, Proportion specification, 1 part Portland cement, 1 part hydrated lime, 6 parts mortar aggregate by volume for both cementitious materials and aggregate; integral color as selected by Architect.
G.
Flashing Protection (Mortar Net): Mortar/VGT or approved equal.
2.3
MORTAR MIXING A.
Thoroughly mix mortar ingredients in proper quantities needed for immediate use to requirements of ASTM C270.
B.
Add mortar color and admixtures to requirements of manufacturer's instructions.
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C.
Provide uniformity of mix and coloration.
D.
Take representative samples for testing consistency of strength and color according to ASTM C780.
E.
Use mortar within 2 hours after mixing at temperatures of 84 degrees F, or 2-1/2 hours at temperatures under 52 degrees F.
2.4
FABRICATION TOLERANCES A.
2.5
Fabricate calcium silicate masonry units to the following tolerances: 1.
Unit Length: Plus or minus 1/16”.
2.
Unit Height: Plus or minus 1/16”.
3.
Deviation from Square: Plus or minus 1/16”, with measurement taken using the longest edge as the base.
4.
Bed Depth: Plus or minus 1/8”.
5.
Custom Dimensions: Plus or minus 1/8”.
6.
Unit Face Deviations: Plus or minus 3/8”.
CUTTING, DRILLING AND FITTING A.
Provide holes and sinkages required for anchors, dowels, other devices required to support and/or suspend stone, and to accommodate other items which connect to or penetrate the stone.
B.
Include all cutting, drilling and fitting of stone work required to accommodate the work of other trades. In cutting and fitting, carefully cut and grind edges to a neat tight fit. Do cutting in such manner so as not to impair strength or appearance of stone. Use physical templates for all cutting and drilling; obtain required templates from proper trades.
PART 3 EXECUTION 3.1
EXAMINATION OF STRUCTURE A.
Examine all parts of the supporting structure and the conditions under which the stonework is to be installed, and correct any conditions detrimental to the proper and timely completion of the work. Do not proceed with the installation of stonework until unsatisfactory conditions are corrected to permit proper installation of the work.
B.
Review installation procedures and coordinate with other work, and with other subcontractors whose work will be affected by the stonework.
C.
Advise Contractor of requirements relating to his placement of any inserts which are to be used by the Stone Subcontractor for anchoring and supporting of stonework.
D.
Tolerances
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3.2
1.
Variation In Alignment From Unit To Adjacent Unit: 1/16” maximum.
2.
Variation Of Mortar Joint Thickness: 1/8” every 36”.
SETTING STONE - GENERAL A.
Set stones plumb, true, and level, to requirements indicated on drawings and approved shop drawings.
B.
Align stone edges and faces according to established relationships and indicated tolerances.
C.
Provide movement joints of widths and at locations indicated on drawings. Do not fill movement joints with mortar.
3.3
SETTING STONE WITH MORTAR A.
Set stones in full bed of mortar with vertical joints buttered and placed full, except where otherwise specified. Completely fill anchor, dowel and lifting holes.
B.
Lay stone veneer in pattern as indicated on drawings. Connect stone veneer to structural back-up with approved wall ties, spaced not more than 16” horizontally and 24” vertically, unless greater required per calculations.
C.
Place bed joint reinforcement and seismic clips in mortar beds, spaced not greater than 16” OC vertically.
D.
Lay stone panel cladding to patterns indicated on drawings. Install anchors, dowels and cramps. Shim and adjust supports to set stones accurately in locations indicated with uniform joints of widths indicated.
E.
Make joints 3/8” thick.
F.
Embed only ends of lugged sills and steps in mortar. Leave balance of joint open for final pointing.
G.
Place setting buttons under stones to maintain joint thickness. Set heavy stones and projecting courses after mortar in courses below has hardened sufficiently to support weight.
H.
Brace and anchor projecting stones until wall above is set.
I.
Use setting buttons to support stone in proper alignment until mortar has set.
J.
Install through-wall flashing at continuous shelf angles, steel lintels, ledges and similar obstructions to the downward flow of water.
K.
Install weep vents in veneer at 24” on center horizontally above through-wall flashing, above shelf angles, and at bottom of walls.
L.
Install cavity vents at top of cavity space at same spacing as weeps.
M.
Rake out joints to 1” depth and make ready for pointing with pointing mortar. Sponge stone face along joints and remove droppings and splashed mortar immediately.
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3.4
REPAIRING AND CLEANING (AFTER ERECTION) A.
Remove and replace stone units which are broken, chipped, stained or otherwise damaged. Where directed, remove and replace units which do not match adjoining stonework. Patching or hiding defects in stone will not be permitted. Provide new matching units, install as specified and reseal joints to eliminate evidence of replacement. Reseal defective and unsatisfactory joints to provide a neat, uniform appearance.
B.
Clean stone as work progresses. Allow mortar droppings on stone to partially dry then remove by means of brushing with a stiff fibre brush.
C.
Post-Construction: Clean mock-up panel as directed below and leave for one week. If no harmful effects appear and after mortar has set and cured, clean masonry as follows:
D. 3.5
1.
Protect windows, sills, doors, trim and other work from damage.
2.
Remove large particles with stiff fiber brushes without damaging surface. Saturate masonry with clean water and flush off loose mortar and dirt.
3.
Scrub with solution of 1 tsp. trisodium phosphate and 1 tsp. household detergent dissolved in 4 cups of clean water using stiff fibre brushes, then clean off immediately with clean water using hose.
4.
Repeat cleaning process as often as necessary to remove mortar and other stains.
Use alternative cleaning solutions and methods for difficult to clean stone only after consultation with masonry unit manufacturer. PROTECTION
A.
After installation and cleaning, protect stone work from damage during subsequent construction activities.
B.
Protect all stone work from other material that will cause stain. Stone subject to damage after setting shall be properly covered or protected.
C.
Provide protection for finished work such as jambs, exposed edges, corners, sills and all other stone liable to physical injury or staining. Protection shall include but is not limited to non-staining approved coverings, and clean non-staining wood boxing. All fastenings or hold-back devices shall be stainless steel. Fastening to stone joints is prohibited.
D.
At completion of construction work, remove all temporary protection from the work of this Section.
E.
Examine all work and repair all damage. Clean soiled or stained surfaces. In the event damage is irreparable, or soiled or stained surface cannot be cleaned, then remove and replace such items at no additional cost to Owner.
END OF SECTION
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SECTION 04720 CAST STONE PART 1 GENERAL 1.1
GENERAL REQUIREMENTS A.
1.2
Work of this Section, as shown or specified, shall be in accordance with the requirements of the Contract Documents. SECTION INCLUDES
A.
1.3
The Work of this Section includes all labor, materials, equipment and services necessary to complete the cast stone as shown on the drawings and/or specified herein, including, but not necessarily limited to, the following: 1.
Cast stone bands and niches on building facade.
2.
Mortar.
3.
Anchors and accessories.
4.
Joint filler.
RELATED SECTIONS A.
Exterior stone cladding - Section 04400.
B.
Masonry work - Section 04800.
C.
Sealant - Section 07900.
1.4
QUALITY ASSURANCE A.
Qualifications of Workmen 1.
For the actual cutting and placing of cast stone units, use only skilled journeyman masons who are thoroughly experienced with the materials and methods specified and thoroughly familiar with the design requirements.
2.
In acceptance or rejection of installed cast stone units, no allowance will be made for lack of skill on the part of workmen.
B.
Manufacturer shall have a minimum of ten (10) years experience in the manufacture of cast stone. Manufacturer's products must have previously been used on the exterior with satisfactory results. Manufacturer must have capability to produce cast stone on schedule and must be a member of the Cast Stone Institute.
C.
Casting Tolerances: Maintain casting, bowing, warping and dimension tolerance within the following maximums:
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1.
Overall dimension for height and width of units a.
2.
Twist, Bowing or Warping a.
3.
D.
Do not exceed length/360 or 1/8”, whichever is less.
Insert Locations a.
4.
Plus zero of unit dimension to minus 3/32" for 10'-0" and over.
Place within plus or minus 1/8" in each direction.
Length of units shall not deviate by more than +/- 1/8" from approved dimensions.
Reference Standards: Comply with applicable provisions and recommendations of the following, except as otherwise shown or specified. 1.
ASTM C 1364 Standard Specification for Architectural Cast Stone, except where more stringent standards are specified herein.
2.
ASTM C 150
Specification for Portland Cement.
3.
ASTM C 33
Specification for Concrete Aggregates
4.
ASTM C 979
Specification for Pigmented Concrete.
5.
ASTM C 494
Specification for Concrete Admixtures
6.
ASTM A 615
Specification for Deformed and Plain Billet Steel Bars for Concrete Reinforcement.
7.
ASTM C 1194
Test Method for Compressive Strength of Architectural Cast Stone.
8.
ASTM C 1195
Test Method for Absorption of Architectural Cast Stone.
9.
ASTM C 642
Test Method for Specific Gravity, Absorption, and Voids in Hardened Concrete. for
Coloring
Pigments
Compressive
Strength
for
of
Integrally
10. ASTM C 39
Test Method Cylinders.
Concrete
11. ASTM D 2244
Test Method for Calculation of Color Differences from Instrumentally Measured Color Coordinates.
E.
Testing: Test three specimens per 500 cubic feet at random from plant production in accordance with referenced standards.
F.
Cold weather setting practices shall conform to the requirements specified in Section 04800.
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1.5
SUBMITTALS A.
Submit samples of cast stone with documented independent testing laboratory reports to the Architect for approval.
B.
Samples: Before any cast stone materials are delivered to the job site, submit twelve (12) inch long samples of each profile type cast stone unit required. 1.
C.
D. 1.6
Submit 6" x 6" cast stone samples showing full range of colors and texture available.
Shop Drawings: Submit complete shop drawings of all cast stonework showing anchorage, type, location and spacing, joint fillers, mortar, and cast stone profiles, sizes, connections, location, type and size of reinforcing and adjacent construction. 1.
The shop drawings shall show the setting mark of each stone and its location on the structure. The stone when delivered shall bear the same corresponding setting mark on an unexposed surface.
2.
Shop drawings must show exact profiles for each piece.
Certification: Submit certification from an independent testing laboratory certifying to test results required under Article 1.4, Para. E. herein. MOCK-UP
A. 1.7
Provide full size unit(s) for use in construction of wall mock-up specified in Section 04800. The mock-up becomes the standard of workmanship for the project. PRODUCT HANDLING
A.
Protection: Use all means necessary to protect cast stone and related materials before, during and after installation and to protect the installed work and materials of all other trades. 1.
B.
Stone shall be stored on skids off the ground and covered with plastic sheeting; all material in contact with stone shall be non-staining.
Replacements: In the event of damage, immediately make all repairs and replacements necessary to the approval of the Architect and at no additional cost to the Owner.
PART 2 PRODUCTS 2.1
CAST STONE COLOR AND FINISH A.
The Cast Stone used in this work shall match color and texture of samples approved by the Architect.
B.
Exposed surfaces, unless otherwise specified, shall exhibit a typically fine grained texture similar to natural stone. No bug holes will be permitted and all facing material shall be mixed in a muller mixer.
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C. 2.2
The samples shall be approved by the Architect before the manufacturer shall be required to proceed with the work. MANUFACTURER
A.
All Cast Stone used in this work shall be manufactured by Dura Art Stone Co., Continental Cast Stone Mfg. Inc. or approved equal and conform to the following properties: 1.
Compressive Strength, ASTM C 1194: 6500 psi min. for products at 28 days.
2.
Absorption, ASTM C 1195 or ASTM C 642: 6% max. for products at 28 days.
3.
Cumulative Percent Weight Loss (CPWL) shall be less than 5% after 300 freeze/thaw cycles when tested in accordance with ASTM C 1364.
4.
Air Content: ASTM C 173 or C 231, for wet cast product only shall be 4-8%. Air entrainment is not required for dry cast products.
5.
Linear Shrinkage - ASTM C 426: Shrinkage shall not exceed 0.065%.
6.
Color Variation a. b.
2.3
Must match color and finish of approved sample when viewed in direct daylight at a 5 foot distance. ASTM color variation allowed - 2% hue; 6% lightness, chrome and hue combined.
MATERIALS A.
Cement shall be Portland Type I white, meeting ASTM C 150.
B.
Fine aggregate shall be carefully graded and washed natural sands, or manufactured granite, marble, quartz or limestone sands meeting ASTM C 33, except that gradation may vary to achieve desired finish and texture.
C.
Coarse aggregate shall be carefully graded and washed natural gravel, or crushed graded stone such as granite, marble quartz, limestone or other durable stone meeting ASTM C 33, except that gradation may vary to achieve desired finish and texture.
D.
Coloring: All colors added shall be inorganic (natural or synthetic) iron oxide pigments meeting ASTM C 979 excluding the use of a cement grade of carbon black pigment, and shall be guaranteed by the manufacturer to be light fast and lime proof. The amount of pigment shall not exceed ten (10) percent by weight of the cement used. Colorant shall be manufactured by Davis Colors or approved equal.
E.
Cast stone shall be reinforced with new billet steel reinforcing bars meeting ASTM A 615, grade 60, when necessary for safe handling, setting and structural stress, and the size of the reinforcing shall be as shown on approved shop drawings. If the surfaces are to be exposed to the weather, the reinforcement shall be galvanized or epoxy coated when covered with less than two (2) inches of material for bars larger than 5/8 inch and 1-1/2 inches for bars 5/8 inch or smaller. The material covering in all cases shall be at
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Cast Stone
least twice the diameter of the bars. Stone shall be fully reinforced to take all stresses including handling, temperature changes and structural stress. F.
All anchors, dowels and other anchoring devices shall be furnished by the stone setter as shown on approved shop drawings using building stone anchors fabricated of Stainless Steel Type 304. 1.
2.4
Anchors shall allow for wracking of the structure (seismic) without stressing the cast stone units.
FABRICATION A.
Cast stone, after being made, shall be cured as noted below in Article 2.5.
B.
Cast stone shall be "dry cast" or "wet cast" (depending upon selected finish) to produce sharp arrises to match profiles on approved shop drawings. Provide stone with sinkages to receive anchors.
C.
Cast stone for copings shall be fabricated to largest practical length, as shown on approved shop drawings.
D.
Acid etch exposed surfaces as required to remove cement film prior to packaging and shipment. Sandblasting or chemical retardation finishing is not permitted.
2.5
CURING A.
2.6
Cure units in a warm curing chamber approximately 100 deg. F. at 95% relative humidity for approximately 12 hours, or cure in a 95% moist environment at a minimum 70 deg. F. for 16 hours after casting. Additional yard curing at 95% relative humidity shall be 350 degree days (i.e. 7 days at 50 deg. F. or 5 days at 70 deg. F. prior to shipping. Form cured units shall be protected from moisture evaporation with curing blankets or curing compounds after casting. ACCESSORIES
A.
Mortar for setting of cast stone sections shall conform to ASTM C 270, Type N, with not more than 1/2 part lime per part of white non-staining Portland cement.
B.
Joint Filler: Fill all joints with exposed tops with "Emseal" Greyflex Expanding Foam Sealant as manufactured by Emseal, Inc. or approved equal. Material shall be designed for compression in joint twenty-five (25) percent of its original width, depth of filler as per manufacturer's standard. Joint filler shall be recessed 3/4" from finished surface.
PART 3 EXECUTION 3.1
INSPECTION A.
Examine the areas and conditions where cast stone is to be installed and correct any conditions detrimental to the proper and timely completion of the work. Do not proceed with the work until unsatisfactory conditions are corrected to permit proper installation of the work.
Monmouth County Prosecutors – PH II
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Cast Stone
3.2
INSTALLATION A.
3.3
Carefully coordinate with all other trades to ensure proper and adequate interface of the work of other trades with the work of this Section. JOINTING
A.
Joint Size: 3/8", unless otherwise noted.
B.
Joint Material
C. 3.4
1.
Use a full bed of mortar at all bed joints.
2.
Flush vertical joints full with mortar.
3.
Leave all joints with exposed tops open for sealant.
Location of Joints: As shown on approved shop drawings. SETTING
A.
All cast stone shall be set by experienced stone masons, accurately and in accordance with the shop and setting drawings. All anchors and dowels shall be firmly placed and all anchor holes and dowel holes and similar holes filled completely with mortar.
B.
Setting Tolerances: Plus/minus 1/32" allowable out of plane with adjacent units.
C.
When setting with mortar, all stones not thoroughly wet shall be drenched with clear water just prior to setting.
D.
All stone shall be protected from splashing mortar or damage by other trades. Any foreign matter splashed on the stone shall be removed immediately.
E.
All joints with exposed tops shall be filled with joint filler specified herein recessed 3/4" from stone surface; balance of joint shall be filled with back-up rod and sealant by Section 07900.
3.5
PATCHING A.
The repair of chipped or damaged cast stone shall be done only by mechanics skilled in this class of work, with materials furnished by the manufacturer and according to his direction.
B.
Patching will not be permitted on copings and any other piece which can be removed and replaced without undue difficulty. Replace such pieces which are chipped or damaged with identical new pieces. Reseal and/or repoint to remove any evidence of replacement.
C.
Cast stone shall show no obvious repairs or imperfections other than minimal color variations when viewed with the unaided eye under good typical lighting at a ten (10) foot distance.
Monmouth County Prosecutors – PH II
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Cast Stone
3.6
CLEANING A.
3.7
Before pointing, the face of all cast stone shall be scrubbed with a fiber brush, using soap powder and water and shall then be rinsed thoroughly with clean running water. Any mortar on the face of the cast stone shall be removed. No acids or prepared cleaners shall be used without the approval of the cast stone manufacturer. POINTING
A.
3.8
When ready for tuck pointing, the mortar joints shall be dampened and raked back 3/4" for pointing. Pointing shall form a slight concave profile. No pointing shall be done in freezing weather nor in locations exposed to hot sun unless properly protected. Pointing mortar shall be composed of one (1) part non-staining cement (ASTM C 91), one (1) part hydrate lime (ASTM C 207, Type S) and four (4) parts of clean, washed sand (ASTM C 144). Coloring pigments shall be added as specified in Section 04800 for face brick construction. The Architect shall approve color of pointing mortar before proceeding with pointing. PROTECTION
A. 3.9
All projecting cast stone pieces shall be fully protected when installed against damage of any kind. Any piece damaged shall be replaced at no additional cost. INSPECTION AND ADJUSTMENT
A.
Upon completion of the work, make a thorough inspection of all installed cast stone and verify that all units and joints have been installed in accordance with the provisions of this Section; make all necessary adjustments.
END OF SECTION
Monmouth County Prosecutors – PH II
04720-7
Cast Stone
SECTION 04800 UNIT MASONRY PART 1 GENERAL 1.1
GENERAL REQUIREMENTS A.
1.2
Work of this Section, as shown or specified, shall be in accordance with the requirements of the Contract Documents. SECTION INCLUDES
A.
1.3
The Work of this Section includes all labor, materials, equipment, and services necessary to complete the unit masonry work as shown on the drawings and/or specified herein, including, but not necessarily limited to, the following: 1.
Concrete block walls and partitions.
2.
Metal joint reinforcing, anchors, ties, weeps, closures and related accessories for masonry.
3.
Control and expansion joints in masonry, filled with joint fillers.
4.
Chases, recesses, pockets and openings in masonry as required for installation of work by others.
5.
Building in of items furnished by others into masonry, including access doors, door frames, anchors, sleeves and inserts, and other similar items to be embedded in masonry.
6.
Grouting in of metal items built into masonry work.
7.
Protection, pointing and cleaning of masonry.
RELATED SECTIONS A.
Concrete - Section 03300.
B.
Exterior stone cladding – Section 04400.
C.
Cold formed metal framing - Section 05400.
D.
Building insulation - Section 07210.
E.
Metal flashing - Section 07600.
F.
Firestops and smokeseals - Section 07840.
G.
Sealant - Section 07900.
H.
Aluminum assemblies - Section 08910.
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Unit Masonry
1.4
SUBMITTALS A.
B.
C.
D.
Submit shop drawings for the following: 1.
Anchoring details.
2.
Control and expansion joint locations and details.
Submit samples of the following: 1.
Joint reinforcing, each type, width and proposed location (labeled).
2.
Anchors, wedges and ties, each type, width and proposed location (labeled).
3.
Joint filler, each type.
Submit technical and installation information for: the following 1.
Mortar materials, each material and mortar type.
2.
Certification of mortar mix, including test reports. Test in accordance with ASTM C109, C1506 and C91.
3.
Flashing material, descriptive literature.
4.
Concrete block, joint reinforcing, anchors, ties and joint filler; submit manufacturer's technical and descriptive literature.
5.
Block manufacturer shall submit certifications of compliance with ASTM C 90, C 331 and UL 618 prior to any job site delivery. Field sampling of concrete block may be tested by an Independent Testing Laboratory retained by the Owner according to the requirements of ASTM C 140.
Construction Procedures (Submit the following) 1.
1.5
Procedures and materials for cleaning masonry work; including certification that cleaner will not adversely affect stone, gaskets, sealants, etc.
QUALITY ASSURANCE A.
Conform to the following non-cumulative tolerances (any masonry work not meeting these standards shall be re-built as directed by the Architect). 1.
Variation from the plumb: a.
b.
In lines and surfaces of columns, walls and arrises: 1). In 10 feet 1/8" 2). In any story of 25 feet maximum 1/4" 3). In 40 feet or more 1/4" For external corners, expansion joints and other conspicuous lines: 1). In any story of 25 feet maximum 1/4" 2). In 40 feet or more 3/8"
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Unit Masonry
2.
Variation from the level or the grades indicated on the drawings; for exposed lintels, sills, parapets, horizontal grooves and other conspicuous lines: a. b.
3.
C.
1/4" 1/2"
Minus Plus
1/8" 1/8"
Variation in dimensions of masonry openings: a. b.
B.
In any bay or 20 feet maximum In 40 feet or more
Variation in cross-sectional dimensions of columns and in thickness of walls: a. b.
5.
1/4" 1/4"
Variation of the linear building lines from established position in plan related portion of columns and partitions: a. b.
4.
In any bay or 20 feet maximum In 40 feet or more
Horizontal dimension Vertical dimension
-0" + 1/16" +0" - 1/16"
Job Mock-Up 1.
Prior to installation of masonry work, erect sample wall panel mock-up using materials, bonding patterns and joint tooling required for final work and including cavity wall, masonry sill, typical pier with returns and stone base, window unit and sill, projecting courses, anchors and reinforcement as detailed. Provide special features as directed by the Architect for caulking and contiguous work. Build mock-up at the site, 4' x 4' size as directed by the Architect, indicating the proposed range of colors, textures and workmanship to be expected in the completed work. Reconstruct mock-up if directed by the Architect until it meets with Architect's approval. Obtain Architect's acceptance of visual qualities of the mock-up before start of masonry work. Retain mock-up during construction as a standard for judging completed masonry work. Do not alter, move or destroy mock-up until work is completed and accepted by the Architect. Use sample panels to test proposed cleaning procedures after sample panel meets with Architect's approval.
2.
Approved sample panel shall remain on view at the site until completion of face brick work.
3.
Architect shall direct distribution of brick color and texture variation within mockup.
Work of this Section shall conform to the requirements of the following: 1.
2005 ACI 530/ASCE 5/TMS 402 Building Code Requirements for Masonry Structures.
2.
2005 ACI 530-1/ASCE 6/TMS 602 Specifications for Masonry Structures.
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Unit Masonry
D.
1.6
Pre-Construction Conference: Prior to installation of masonry and associated work, Contractor shall arrange a meeting with Masonry Subcontractor, installers of related work, and other entities concerned with masonry wall performance, including the Architect and Owner. Contractor shall record discussions and agreements and furnish copy to each participant. Provide at least seventy-two (72) hours’ advance notice to participants prior to convening conference. Review methods and procedures related to masonry work, including, but not limited to, the following: 1.
Review masonry requirements (drawings, specifications and other Contract Documents).
2.
Review required submittals, both completed and yet to be completed.
3.
Review and finalize construction schedule related to masonry work and verify availability of materials, installer’s personnel, equipment and facilities needed to make progress and avoid delays.
4.
Review required inspection, testing, certifying and material usage accounting procedures.
5.
Review weather and forecasted weather conditions, and procedures for coping with unfavorable conditions.
PRODUCT HANDLING A.
General: Deliver, store, handle and protect all materials from damage, moisture, dirt and intrusion of foreign matter. Store all masonry units and mortar materials on raised platforms and under ventilated and waterproof cover. Store packaged materials in manufacturer's unopened containers, marked with manufacturer's name and product brand name. Immediately reseal containers after partial use. Remove and replace damaged materials.
B.
Masonry Units: Pack, deliver and store to prevent breakage, cracking, chipping, spalling or other damage. Store, protect and ventilate units at project site.
C.
Aggregate: Store with provisions for good drainage.
D.
Reinforcement and Anchors: Store and protect so that when placed, joint reinforcement and anchors will be free of soil, dirt, ice, loose rust, scale, or other coatings which would destroy or reduce bond with mortar, and will not be disfigured or bent out of shape.
1.7
CODE REQUIREMENTS A.
1.8
Work of this Section shall conform to all applicable requirements of the New Jersey Building Code. JOB CONDITIONS
A.
In cold weather, when the outside temperature is below forty (40) degrees F., conform to the requirements of "Cold Weather Masonry Construction and Protection Recommendations" publication by Brick Industry Association (BIA). No anti-freeze admixtures are permitted.
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Unit Masonry
B.
Hot-Weather Requirements: Protect unit masonry work when temperature and humidity conditions produce excessive evaporation of water from mortar and grout. Provide artificial shade and wind breaks and use cooled materials as required. Do not apply mortar to substrates with temperatures of 100 deg. F. and above.
C.
Protection of Masonry: During erection, cover tops of walls, projections, and sills with waterproof sheeting at end of each day's work. Cover partially completed masonry when construction is not in progress.
D.
1.
Extend cover a minimum of 24" down both sides and hold cover securely in place.
2.
Where one wythe of multi-wythe masonry walls is completed in advance of other wythes, secure cover a minimum of 24" down face next to unconstructed wythe and hold cover in place.
Stain Prevention: Prevent grout, mortar, and soil from staining the face of masonry to be left exposed or painted. Immediately remove grout, mortar, and soil that come in contact with such masonry. 1.
Protect base of walls from rain-splashed mud and mortar splatter by coverings spread on ground and over wall surface.
2.
Protect sills, ledges, and projections from mortar droppings.
3.
Protect surfaces of window and door frames, as well as similar products with painted and integral finishes, from mortar droppings.
4.
Turn scaffold boards near the wall on edge at the end of each day to prevent rain from splashing mortar and dirt on completed masonry.
PART 2 PRODUCTS 2.1
MATERIALS A.
Standard Concrete Block 1.
Portland cement, ASTM C 150, Type 1, one source.
2.
Aggregates, ASTM C 331, lightweight expanded shale, clay or slate aggregates, manufactured by the rotary kiln process equal to "Solite," "Norlite," or "Haydite." a.
3.
All block shall be from one aggregate type and from one manufacturer.
Concrete Masonry Units: Load bearing lightweight aggregate concrete masonry units conforming to the requirements of ASTM C 90, with a minimum compressive strength of 1500 psi. a. b. c.
Block behind stone and block for rated walls shall be 75% solid units. All other block may be hollow units. All CMU shall be lightweight units.
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Unit Masonry
4.
The producer of the concrete masonry units shall furnish certification from an independent testing laboratory confirming that all 8" or larger masonry units meet all of the UL 618 requirements for two (2) hours or better (as required), referencing full scale fire test reports (ASTM E 119). All 4" and 6" units shall conform to "National Bureau of Standards" and "National Research Council" full scale fire tests.
5.
Sizes and Shapes: Nominal face size 8" x 16" by thickness as indicated on drawings, with stretcher units, jamb units, header units, square corner units (at ends and corners of exposed or painted work), sash units (at control joints within masonry wall), lintel units and other special shapes and sizes required to complete the work.
6.
Finish: For exposed or painted block surfaces. In addition to ASTM requirements, block shall have uniformly dense, flat, fine grain texture, with no cracks, chips, spalls, or other defects which would impair appearance. For concealed CMU, surfaces shall be free from deleterious materials that would stain plaster or corrode metal.
7.
Curing: All concrete block shall be steam cured, and air dried for not less than thirty (30) days before delivery.
8.
Density of concrete block shall not exceed one hundred and five (105) lbs. per cubic foot.
9.
Shrinkage: Shrinkage of concrete blocks shall not exceed 0.065% when tested in accordance with ASTM C 426-99.
10. Water Content a. b. B.
At the time of delivery to the job site, concrete masonry units shall have a value, in weight of contained water, of not more than thirty (30) percent of the fully saturated content for the unit tested. Ship all units from the factory, and store at the job site, with all necessary protection to prevent increase of water content from rain and other sources.
Joint Reinforcing for Masonry Walls 1.
For block walls forming part of exterior wall construction behind exterior stone veneer, provide super heavy duty reinforcing fabricated of 3/16" dia. side and cross rods, truss or ladder design, ties, spaced every block course. Provide prefabricated pieces at corners and intersections of walls or partitions. a.
2.
Reinforcing assembly shall be hot dip galvanized steel finish conforming to ASTM A 153 with zinc coating of 1.5 oz. of zinc per sq. ft., after fabrication.
For interior block walls and partitions, provide standard reinforcing fabricated of 9 ga. side and cross rods, truss or ladder design, no ties, spaced every other block course. Provide prefabricated pieces at corners and intersections of walls or partitions. Reinforcing shall be mill galvanized conforming to ASTM A 641, Class B-1, applied after fabrication.
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Unit Masonry
3.
Wire used in assemblies noted above shall be cold drawn steel wire conforming to ASTM A 82.
4.
Approved Joint Reinforcing Manufacturers a. b. c. d.
C.
Hohmann & Barnard Dur-O-Wal Heckmann Building Products National Wire Products Industries, Inc.
Anchors and Ties 1.
Dovetail Anchor Slots: Hot-dip galvanized steel equal to No. 100 Dovetail Anchor Slot made by Heckmann Building Products, No. 305 anchor slot made by Hohmann & Barnard, or approved equal by other manufacturers noted above.
2.
Flexible Metal Ties for Dovetail Slots: Hot-dip galvanized steel, 16 gauge by 1" wide by Heckmann Building Products Inc., or approved equal. a. b.
No. 106 Dovetail Corrugated Anchor. No. 129 Dovetail Triangle Tie.
3.
Wire Mesh: Hot-dip galvanized sixteen (16) gage steel wire, square mesh, width 3" by length to suit condition; No. 268 by Heckmann Building Products, or approved equal by H&B.
4.
For anchoring face brick to concrete back-up where there are no dovetail slots provided, provide "CMU/Concrete Screw Wing-Nut Pos-I-Tie®" with five (5) gauge hot-dip galvanized (ASTM A 153, Class B-2) wire pintle tie made by Heckmann Building Products, or approved equal.
5.
For anchoring CMU wall, at the exterior masonry cavity wall, to the underside of the concrete beam, provide dovetail slot as noted above and the following: a. b.
6.
No. 121 galvanized steel dowel anchor and No. 421 tube as manufactured by Heckmann Building Products. Galvanized to conform to ASTM A 153, Class B-2 or No. PTA-310 galvanized steel dowel anchor and No. NS-TA joint filler as manufactured by Hohmann & Barnard or approved equal. Galvanizing to conform to ASTM A 153, Class B-2.
For anchoring masonry to structural steel, provide hot-dip galvanized steel, as listed, or approved equal: a.
b.
Made by Heckmann Building Products. Galvanizing shall conform to ASTM A 153, with zinc coating of 1.5 oz. of zinc per sq. ft. 1). No. 195 Column Anchors 2). No. 197 Column Anchors 3). No. 315 Weld-On Anchor Rods with No. 316 Triangle Ties 4). No. 315-B Weld-On Anchor Straps with No. 316 Triangle Ties Made by Hohmann & Barnard or approved equal. Galvanizing shall conform to ASTM A 153, with zinc coating of 1.5 oz. of zinc per sq. ft.
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Unit Masonry
1). 2). 3). 4).
No. 355 Column Anchors No. 356 Column Anchors No. 357 Beam Anchors No. 359 F anchor straps with VWT tie.
7.
For anchoring CMU interior partitions to underside of steel beams, provide hot dip galvanized steel tube anchors equal to No. 419 and No. 421 made by Heckmann Building Products, No. PTA-420 made by Hohmann & Barnard, or approved equal.
8.
For anchoring CMU interior partitions to underside of structural deck, provide 4" x 4" x 1/4" galvanized steel angles (ASTM A 36), 3'-0" long spaced 3'-0" o.c. alternately on each side of partition. Anchor partition securely to structural deck.
D.
Reinforcing Bars and Rods: ASTM A 615, Grade 60. See Drawings for size.
E.
Control and Expansion Joint Fillers 1.
Vertical Installation Within Concrete Masonry Wall: Extruded high grade neoprene rubber, cross shape, for use with concrete masonry sash units, which shall provide a force fit in the grooves of the sash block, and shall have 1/2" diameter tubular ends (compressed 25% when installed in 3/8" wide joint). a.
b. 2.
Isolation Joint Filler at Abutting Construction and at Intersecting CMU Walls: Compressible and resilient closed cell neoprene gasket with pressure sensitive adhesive backing, thickness 30% greater than thickness of joint. Acceptable joint filler shall be "Everlastic, Type NN-1" by Williams Products, Inc., or approved equal. Recess joint filler and install backer rod and sealant as per drawings and Section 07900 of these specifications.
3.
Within Face Brick: Provide "Emseal" installed to twenty-five (25) percent compression, as manufactured by Emseal or approved equal, behind filler rod and sealant installed by Section 07900. Filler depth shall be 2 x joint width. a.
2.2
Provide the following sizes: 1). 2-5/8" wide control joint fillers for 4" block walls. 2). 4-5/8" wide for 6" block walls. 3). 6-5/8" wide for 8", 10" and 12" block walls. Provide backer rod and sealant joint over joint filler as per drawings and Section 07900 of these specifications.
Compressible filler between top of brick and bottom of shelf angle shall be "Soft Joint Sealant" made by Polytite.
MORTAR MATERIALS A.
Portland Cement: ASTM C 150, Type 1, standard color, one source.
B.
Hydrated Lime: ASTM C 207, Type S, as manufactured by Corsons, or approved equal.
C.
Sand: Clean, washed, buff colored sand, graded per ASTM C 144.
Monmouth County Prosecutors – PH II
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Unit Masonry
D. 2.3
Water: Clean, fresh and suitable for drinking. MORTAR MIX
A.
Exterior Block Back-Up Construction: Provide Portland cement/lime mortar as noted above conforming to ASTM C 270, Type N.
B.
Interior Masonry Construction: Provide Portland cement/lime mortar conforming to ASTM C 270, Type N, for load bearing conditions, mortar shall conform to ASTM C 270, Type M.
C.
Mortar for Cement Cants: One (1) part Portland cement and four (4) parts sand, by volume.
D.
Grout for Unit Masonry: Comply with ASTM C 476 for grout for use in construction of unit masonry. Use grout of consistency (fine or coarse) at time of placement which will completely fill all spaces intended to receive grout.
E.
Mixing
F.
1.
General: Add cement just before mixing and mix dry. Use sufficient amount of water as necessary to produce workable mix. Mix in small batches to make plastic mass.
2.
Mixing: Machine mix all mortars in approved type mixer with device to accurately and uniformly control water. Add hydrated lime dry. Mix dry materials not less than two (2) minutes. Add water, then mix not less than three (3) minutes. Mix only amount of mortar that can be used before initial set. Do not use mortar which has reached its initial set or two (2) hours after initial mixing, whichever comes earlier. Mortar may not be re-tempered. Clean mixer for each batch, whenever mortar type is changed, and at end of each day's work.
3.
Acceleration or other admixtures not permitted.
4.
Mortar shall have a flow after suction of not less than seventy-five (75) percent of that immediately after mixing as determined by ASTM C 91.
Admixtures 1.
No air-entraining admixtures or cementitious air-entraining admixtures shall be used in the mortar.
materials
containing
2.
No antifreeze compounds or other substances shall be used in the mortar to lower the freezing point.
3.
Calcium chloride or admixtures containing calcium chloride shall not be used in mortar.
PART 3 EXECUTION 3.1
SURFACE CONDITIONS A.
Inspection
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B.
3.2
1.
Prior to all work of this Section, carefully inspect the installed work of all other trades and verify that all such work is complete to the point where this installation may properly commence.
2.
Verify that masonry may be completed in accordance with all pertinent codes and regulations, the referenced standards, and the original design.
3.
Do not start any work until mock-ups are approved by the Architect.
Discrepancies 1.
In the event of discrepancy, immediately notify the Architect in writing.
2.
Do not proceed with installation in areas of discrepancy until all such discrepancies have been fully resolved.
COORDINATION A.
3.3
Carefully coordinate with all other trades to ensure proper and adequate interface of the work of other trades with the work of this Section. PREPARATION
A. 3.4
Concrete Block: Do not wet concrete block units. INSTALLATION
A.
General 1.
Build walls to the full thickness shown. Build single wythe walls to the actual thickness of the masonry units, using units of nominal thickness shown.
2.
Build chases and recesses as shown or required for the work of other trades.
3.
Leave openings for equipment to be installed before completion of masonry work. After installation of equipment, complete masonry work to match work immediately adjacent to the opening.
4.
Lay out walls in advance for accurate spacing of surface bond patterns with uniform joint widths and to properly locate openings, movement type joints, returns and off-sets. Avoid the use of less than half size units at corners, jambs and wherever possible.
5.
Lay up walls plumb and true with courses level, accurately spaced and coordinated with other work.
6.
Provide templates made of steel studs for plumbing of two story masonry openings.
7.
Pattern Bond: Lay exposed masonry patterns as noted on drawings. If not shown, provide running bond. Lay concealed concrete block with all units in a wythe bonded by lapping not less than two (2) inches. Bond and interlock each course of each wythe at corners. Do not use units of less than four (4) inches horizontal face dimensions at corners or jambs.
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B.
8.
Where possible, masonry walls and partitions shall be built after all overhead ducts, pipes and conduits are in place and tested. Masonry shall be neatly built around the items above. Walls and partitions shall be plumb, true to line and free from defects such as open cells, voids, dry joints and other similar defects. In rooms and spaces scheduled to have concrete block finish, all such surfaces including upper wall surfaces up to termination of structural ceiling in spaces without suspended ceilings, shall be made suitable for paint application. Cutting of openings in walls and partitions in place shall be done only with the approval of the Architect.
9.
Refer to structural drawings for limit on unsupported height of masonry shaft walls.
Mortar Bedding and Jointing 1.
Lay concrete masonry units with full mortar coverage on horizontal and vertical face shells. Bed webs in mortar in starting course on exterior walls and in all courses of piers, columns and pilasters, where solid CMU is used and where adjacent to cells or cavities to be reinforced or filled with concrete or grout.
2.
Lay masonry walls with 3/8" joints unless otherwise shown on drawings.
3.
Tool exposed joints slightly concave. Concealed joints shall be struck flush.
4.
Remove masonry units disturbed after laying; clean and reset in fresh mortar. Do not pound corners at jambs to fit stretcher units which have been set in position. If adjustments are required, remove units, clean off mortar and reset in fresh mortar.
C.
Stopping and Resuming Work: Rake back 1/2 block length in each course; do not tooth. Clean exposed surfaces of set masonry, wet units lightly (if required) and remove loose masonry units and mortar prior to laying fresh masonry.
D.
Built-In Work 1.
As the work progresses, build in items specified under this and other Sections of these specifications. Fill in solidly with masonry around built-in items.
2.
Mortar in door frames, access doors, louvers and other metal items embedded or built into masonry work solidly with mortar as the masonry units are laid up.
3.
Grout under lintels, bearing plates, and steel bearing on masonry with solid bed grout.
4.
Sleeves, pipes, ducts and all other items which pass through masonry walls shall be caulked with interior grade sealant meeting requirements of Section 07900, so as to be air tight and prevent air leakage. Refer to Section 07840 for packing of voids in rated masonry walls.
5.
Fill vertical cells of masonry units solid with grout which have anchoring, reinforcing rods, supporting or hanging devices embedded in the cell including stone anchors and window or curtain wall anchors.
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E.
F.
G.
6.
Fill vertical cells of masonry units solid with mortar on each side of door frames to sixteen (16) inches beyond.
7.
Unless otherwise noted, fill vertical cells of masonry units solid with grout which are below steel bearing plates, steel beams, and ends of lintels, to eight (8) inches beyond bearing and from floor to bearing.
8.
Place wire mesh in horizontal joint below masonry unit cells to be filled with mortar, to prevent mortar from dropping into unfilled cells below.
9.
Masonry indicated as being reinforced shall have all voids filled solid with grout. Grout shall be consolidated in place by vibration or other methods which insure complete filling of cells. When the least clear dimension of the grouted cell is less than two (2) inches, the maximum height of grout pour shall not exceed twelve (12) inches. When the least clear dimension is two (2) inches or more, maximum height of grout pour shall not exceed forty-eight (48) inches. When grouting is stopped for one (1) hour or longer, the grout pour shall be stopped 1-1/2" below the top of a masonry unit. Vertical bar reinforcing shall be accurately placed and held in position while being grouted, and shall be in place before grouting starts. All such reinforcing shall have a minimum clear cover of 5/8". Lap all bars a minimum of forty (40) bar diameters and provide steel spacer ties (not to exceed 192 bar diameter) to secure and position all vertical steel and prevent displacement during grouting. Provide continuous horizontal reinforcement embedded in mortar joints every second course.
Cutting and Patching 1.
All exposed masonry which requires cutting or fitting shall be cut accurately to size with motorized carborundum or diamond saw, producing cut edges.
2.
Do not saw cut any masonry openings in face brick construction without Architect's approval and after a procedure has been reviewed and approved.
3.
Holes made in exposed masonry units for attachment of handrail brackets and similar items shall be neatly drilled to proper size.
4.
All masonry which requires patching in exposed work, if approved by Architect, shall be patched neatly with mortar to match appearance of masonry as closely as possible and to the Architect's satisfaction. Rake back joints and use pointing mortar to match as required.
Solid Wall Construction 1.
Fill the vertical longitudinal joint between wythes solidly with mortar by parging the in-place wythe and shoving units into the parging.
2.
Tie wythes with continuous horizontal reinforcement embedded in mortar joints sixteen (16) inches o.c. vertically.
Cavity Walls 1.
All exterior masonry walls, unless otherwise indicated, shall be cavity walls of thickness indicated.
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H.
2.
Where stone veneer is used (Section 04400) in cavity wall configuration, back-up block shall be reinforced every block course.
3.
Refer to Section 07210 – Building Insulation for material and installation of cavity wall insulation.
Interior Block Partitions 1.
Build to full height unless otherwise shown on drawings. At non-rated partitions fill void between CMU and structural deck with continuous neoprene filler conforming to the requirements of Section 07910. At fire rated partitions, fill void with fire stop material meeting the requirements of Section 07840. Fasten to structure at top of partition using steel angles as specified herein.
2.
Provide continuous horizontal joint reinforcing every other block course, except as otherwise noted. Fully embed longitudinal side rods in mortar for their entire length with a minimum cover of 5/8". Lap reinforcement a minimum of six (6) inches at ends of units.
3.
Provide continuity at corners and wall intersections by use of prefabricated "L" and "T" sections. Cut and bend units as directed by manufacturer for continuity at returns, offsets, column fireproofing, pipe enclosures and other special conditions.
4.
Corners a. b.
5.
Intersecting and Abutting Walls a. b.
I.
Unless vertical control joints are shown as part of structural frame, provide interlocking masonry bond. Provide starters and special shapes as shown on the drawings to bond these walls. In addition to masonry bonding, provide horizontal reinforcement using prefabricated "T" units at interior partitions.
Ties and Anchors for Masonry Construction 1.
Provide ties and anchors as shown or specified, but not less than one metal tie, spaced not to exceed sixteen (16) inches o.c. horizontally and/or vertically. Provide additional ties within 1'-0" of all openings and spaced not more than 24" apart around perimeter of openings.
2.
Anchor masonry to structure complying with the following: a.
J.
Provide interlocking masonry unit bond in each course at corners. Provide continuity at corners with prefabricated "L" reinforcement units, in addition to masonry bonding.
Provide an open space not less than 1/2" in width between masonry and structural member, unless otherwise shown. Keep open space free of mortar or other rigid materials.
Control and Expansion Joints
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1.
Provide vertical expansion, control and isolation joints in masonry as shown. Build in related items as the masonry work progresses.
2.
CMU Control Joint Spacing: If location of control joints is not shown, place vertical joints spaced not to exceed 20'-0" o.c. In addition, locate joints at points of natural weakness in the masonry work, including the following: a. b. c. d. e. f.
K.
3.5
At structural column or joint between bay. Above control joints in the supporting structure. Above major openings at end of lintels upward and below at ends of sills downward. Place at one side of jamb for openings not less than 7'-0" wide and at both sides for openings over 6'-0" wide. At reduction of wall thickness. Where masonry abuts supporting structure. If additional joints are required, indicate same on approved shop drawings.
Lintels 1.
Install loose steel lintels furnished by Section 05500, allowing eight (8) inch bearing at ends.
2.
For concrete block walls, use specially formed U-shaped concrete block lintel units with reinforcing bars See Structural Drawings, filled with grout.
CANTS A.
3.6
Provide specified mortar for cement cants at beams and other projections in elevator shafts, where adjoining wall is of masonry construction. Cants shall slope seventy (70) degrees from the horizontal. CLEANING, PROTECTION, ADJUSTMENT
A.
B.
Protection 1.
The Contractor shall take adequate precautions for the protection of all surfaces against mortar spatter, and shall immediately remove any such spatter should it inadvertently occur, leaving no stain or discoloration.
2.
Excess mortar shall be wiped off the masonry surfaces as the work progresses.
3.
Wood coverings shall be placed over all such masonry surfaces as are likely to be damaged during the progress of the entire project.
4.
Protective measures shall be performed in a manner satisfactory to the Architect.
5.
Damaged masonry units shall be replaced to satisfaction of the Architect.
6.
Exterior masonry walls shall be draped with waterproof covering until copings are in place, to prevent water penetration in cavity.
Clean-Up: Upon completion, all exposed masonry shall be thoroughly cleaned following recommendations of the IMI Technical Note No. 20. Before applying any cleaning agent to the entire wall, it shall be applied to a sample wall area of
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approximately 4' x 4' in a location approved by the Architect. No further cleaning work may proceed until the sample area has been approved by the Architect, after which time the same cleaning materials and method shall be used on the remaining wall area. If stiff brushes and water do not suffice, the surface shall be thoroughly saturated with clear water and then scrubbed with a solution of an approved detergent masonry cleaner, equal to "Vana Trol" made by ProSoCo Inc. or equal made by Diedrich or approved equal, mixed as per manufacturer's directions, followed immediately by a thorough rinsing with clear water. All lintels and other corrodible parts shall be thoroughly protected during cleaning. C.
Pointing: Point any defective joint with mortar identical with that specified for that joint.
END OF SECTION
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