DIVISION 4 MASONRY DIVISION 4 - MASONRY

Transcription

1 DIVISION 4 MASONRY DIVISION 4 - MASONRY 85

2 SECTION MASONRY MASONRY PART 1 - GENERAL 1 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section. 2 SUMMARY A. This Section includes unit masonry assemblies consisting of the following: 1. Concrete Masonry Units 2. Decorative Concrete Masonry Units 3. Face Brick 4. Building (Common) Brick 5. Precast Stone Cap 6. Mortar and Grout 7. Ties and Anchots 8. Embedded Flashing 9. Miscellaneous Masonry Accessories B. Related Sections include the following: 1. See Division 05 Section "Metal Fabrications" for furnishing steel lintels and shelf angles for unit masonry. 3 SUBMITTALS A. Full-size units for each different exposed masonry unit required, showing the full range of exposed colors, textures, and dimensions to be expected in the completed construction. Material Certificates: For each type of product indicated. Include statements of material properties indicating compliance with requirements. B. Colored mortar Samples for each color required, showing the full range of colors expected in the finished construction. Make samples using the same sand and mortar ingredients to be used on Project. Label Samples to indicate types and amounts of pigments used. C. Comply with ACI 530.1/ASCE 6/TMS 602. D. Preconstruction Testing Service: Owner will engage a qualified independent testing agency to perform preconstruction testing required by authorities having jurisdiction. E. Cold-Weather Procedures: Detailed description of methods, materials, and equipment to be used to comply with cold-weather requirements. SECTION MASONRY 86

3 SECTION MASONRY 4 QUALITY ASSURANCE A. Source Limitations for Masonry Units: Obtain exposed masonry units of a uniform texture and color, or a uniform blend within the ranges accepted for these characteristics, through one source from a single manufacturer for each product required. B. Source Limitations for Mortar Materials: Obtain mortar ingredients of a uniform quality, including color for exposed masonry, from one manufacturer for each cementitious component and from one source or producer for each aggregate. C. Mockups: Before installing unit masonry, build mockups to verify selections made under sample Submittals and to demonstrate aesthetic effects and qualities of materials and execution. Build mockups to comply with the following requirements, using materials indicated for the completed Work: 1. Locate mockups in the locations indicated or, if not indicated, as directed by Architect. 2. Build mockups for the following types of masonry in sizes approximately 48 inches long by 48 inches high by full thickness, including face and backup wythes and accessories. Include a sealant-filled joint at least 16 inches long in each mockup. a. Each type of exposed unit masonry construction. b. Typical exterior wall with lower corner of window opening framed with stone trim at upper corner of mockup. Make opening approximately 12 inches wide by 16 inches high. c. Typical exterior wall with through-wall flashing installed for a 24-inch length in corner of mockup approximately 16 inches down from top of mockup, with a 12- inch length of flashing left exposed to view (omit masonry above half of flashing). d. Typical exterior masonry-veneer wall complete with wood studs, sheathing, veneer ties, flashing, and weep holes. 3. Clean exposed faces of mockups with masonry cleaner as indicated. 4. Where masonry is to match existing, erect mockups adjacent and parallel to existing surface. 5. Notify Architect seven days in advance of dates and times when mockups will be constructed. 6. Maintain mockups during construction in an undisturbed condition as a standard for judging the completed Work. 7. Approval of mockups is for color, texture, and blending of masonry units; relationship of mortar and sealant colors to masonry unit colors; tooling of joints; and aesthetic qualities of workmanship. a. Approval of mockups is also for other material and construction qualities specifically approved by Architect in writing. b. Approval of mockups does not constitute approval of deviations from the Contract Documents contained in mockups, unless such deviations are specifically approved by Architect in writing. 8. Approved mockups may become part of the completed Work if undisturbed at time of Substantial Completion. SECTION MASONRY 87

4 SECTION MASONRY PART 2 - PRODUCTS 1 CMU AND BRICK A. Concrete Masonry Units: ASTM C 90; Weight Classification, Normal Weight. 1. Integral Water Repellent (where exterior block finish is exposed to interiors): Addiment, Incorporated; Block Plus W-10 Grace Construction Products, a unit of W. R. Grace & Co. - Conn.; Dry-Block or Master Builders, Inc.; Rheopel. 2. Special shapes for lintels, corners, jambs, sash, control joints, and other special conditions. Square-edged units for outside corners, unless otherwise indicated. B. Decorative Concrete Masonry Units: ASTM C 90; Weight Classification, Normal Weight. 1. Finish: Exposed faces with ground finish. 2. Integral Water Repellent (where exterior block finish is exposed to interior): Addiment, Incorporated; Block Plus W-10 Grace Construction Products, a unit of W. R. Grace & Co. - Conn.; Dry-Block or Master Builders, Inc.; Rheopel. 3. Special shapes for lintels, corners, jambs, sash, control joints, and other special conditions. C. Face Brick: ASTM C 216, Grade SW. 1. Unit Compressive Strength: Provide units with minimum average net-area compressive strength of 3000 psi. 2. Initial Rate of Absorption: Less than 20 g/30 sq. in. per minute when tested per ASTM C Efflorescence: Provide brick that has been tested according to ASTM C 67 and is rated "not effloresced." 4. Size: Manufactured to the following actual dimensions: a. Modular: 3-1/2 to 3-5/8 inches wide by 2-1/4 inches high by 7-1/2 to 7-5/8 inches long. 5. Application: Use where brick is exposed, unless otherwise indicated. 6. Color and Texture: To be selected from manufactures full range of color. D. Building (Common) Brick: ASTM C 62, Grade SW. For use where brick is concealed. 2 MORTAR AND GROUT A. Mortar 1. Mortar: ASTM C 270, proportion specification. 2. Do not use calcium chloride in mortar. 3. For masonry below grade or in contact with earth, use Type M. 4. For reinforced masonry, use Type S. SECTION MASONRY 88

5 SECTION MASONRY 5. For exterior, above-grade, load-bearing and non-load-bearing walls and parapet walls; for interior load-bearing walls; for interior non-load-bearing partitions, and for other applications where another type is not indicated, use Type S. 6. Colored Mortar: For decorative concrete masonry units face brick, use colored cement or cement-lime mix of color selected. 7. Water-Repellent Additive: For mortar used with concrete masonry units made with integral water repellent, use product recommended by manufacturer of units. B. Grout 1. Grout: ASTM C 476 with a slump of 8 to 11 inches (200 to 280 mm). 3 REINFORCEMENT, TIES, AND ANCHORS A. Steel Reinforcing Bars: ASTM A 615/A 615M, Grade 60 (Grade 400). Joint Reinforcement: ASTM A 951. B. Coating: Mill galvanized at interior walls and hot-dip galvanized at exterior walls. C. Wire Diameter for Side Rods: W1.7 or inch (3.8 mm). D. Wire Diameter for Cross Rods: W1.7 or inch (3.8 mm). E. For single-wythe masonry, provide either ladder design or truss design. 4 EMBEDDED FLASHING MATERIALS A. Rubberized Asphalt Sheet Flashing: Pliable and highly adhesive rubberized asphalt compound, 26 mils (0.7 mm) thick, bonded to a polyethylene film, 4 mils (0.1 mm) thick, to produce an overall thickness of 30 mils (0.8 mm). B. Adhesives, Primers, and Seam Tapes for Flashings: Flashing manufacturer's standard products or products recommended by the flashing manufacturer for bonding flashing sheets to each other and to substrates. 5 MISCELLANEOUS MASONRY ACCESSORIES A. Compressible Filler: Premolded strips complying with ASTM D 1056, Grade 2A1. B. Preformed Control-Joint Gaskets: Designed to fit standard sash block and to maintain lateral stability in masonry wall; made from styrene-butadiene rubber or PVC. C. Weep Holes: Cellular-plastic extrusion, full height and width of head joint. D. Molded-Polystyrene Insulation Units: ASTM C 578, Type I; specially shaped units designed for installing in cores of masonry units. 1. Products: As available by Block Manufacturer. E. Proprietary Acidic Masonry Cleaner: Product expressly approved for intended use by cleaner manufacturer and manufacturer of masonry units. SECTION MASONRY 89

6 SECTION MASONRY 1. Products: SureClean by Pro-so-co. PART 3 - EXECUTION 1 INSTALLATION - GENERAL A. Cut masonry units with saw. Install with cut surfaces and, where possible, cut edges concealed. B. Mix units for exposed unit masonry from several pallets or cubes as they are placed to produce uniform blend of colors and textures. C. Fill cores in hollow concrete masonry units with grout 24 inches (600 mm) under bearing plates, beams, lintels, posts, and similar items, unless otherwise indicated. D. Build non-load-bearing interior partitions full height and install compressible filler in joint between top of partition and underside of structure above. E. Tool exposed joints slightly concave when thumbprint hard, unless otherwise indicated. Keep cavities clean of mortar droppings and other materials during construction. 2 LINTELS A. Install lintels where indicated. B. Minimum bearing of 8 inches (200 mm) at each jamb, unless otherwise indicated. 3 FLASHING AND WEEP HOLES A. Install embedded flashing and weep holes in masonry at shelf angles, lintels, ledges, other obstructions to the downward flow of water in the wall, and where indicated. B. Place through-wall flashing on sloping bed of mortar and cover with mortar. Seal penetrations in flashing before covering with mortar. C. Extend flashing 4 inches (100 mm) into masonry at each end and turn up 2 inches (50 mm) to form a pan. D. Trim wicking material used in weep holes flush with outside face of wall after mortar has set. 4 CLEANING A. Clean masonry as work progresses. Remove mortar fins and smears before tooling joints. B. Final Cleaning: After mortar is thoroughly cured, clean exposed masonry. C. Clean masonry with a proprietary cleaner applied according to manufacturer's written instructions. SECTION MASONRY 90

7 SECTION CAST STONE SILL CAST STONE SILL (ROW LOCK) PART 1 - GENERAL 1 RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section. 2 SUMMARY A. This Section includes unit masonry assemblies consisting of the following: 1. Cast Stone Sill B. Related Sections include the following: 1. Division 4 Section "Unit Masonry" for installing cast stone units in unit masonry. 3 DEFINITIONS A. Cast Stone: Architectural precast concrete building units intended to simulate natural cut stone. 4 SUBMITTALS A. Product Data: Include construction details, material descriptions, dimensions of individual components and profiles, and finishes for cast stone units. B. Shop Drawings: Show fabrication and installation details for cast stone units. Include dimensions; details of reinforcement and anchorages, if any; and indication of finished faces. 1. Include building elevations showing layout of units and locations of joints and anchors. C. Samples: For each color and texture of cast stone required, 10 inches square in size. D. Samples for Initial Selection: For colored mortar, showing the full range of colors available. E. Samples for Verification: For each mortar color required, showing the full range expected in the finished construction. Make samples using the same sand and mortar ingredients to be used on Project. Label samples to indicate type and amount of colorant used. F. Qualification Data: For firms and persons specified in "Quality Assurance" Article to demonstrate their capabilities and experience. Include lists of completed projects with project names and addresses, names and addresses of architects and owners, and other information specified. SECTION CAST STONE SILL 91

8 SECTION CAST STONE SILL 1. Include copies of material test reports for completed projects, indicating compliance of cast stone with ASTM C QUALITY ASSURANCE A. Manufacturer Qualifications: A firm experienced in manufacturing cast stone units similar to those indicated for this Project and with a record of successful in-service performance, as well as sufficient production capacity to manufacture required units. B. Source Limitations for Cast Stone: Obtain cast stone units through one source from a single manufacturer. C. Source Limitations for Mortar Materials: Obtain mortar ingredients of a uniform quality, including color, from one manufacturer for each cementitious component and from one source or producer for each aggregate. 6 DELIVERY, STORAGE, AND HANDLING A. Pack, handle, and ship cast stone units in suitable packs or pallets. 1. Lift with wide-belt slings; do not use wire rope or ropes that might cause staining. Move cast stone units, if required, using dollies with wood supports. 2. Store cast stone units on wood skids or pallets with nonstaining, waterproof covers. Arrange to distribute weight evenly and to prevent damage to units. Ventilate under covers to prevent condensation. B. Store installation materials on elevated platforms, under cover, and in a dry location. C. Store mortar aggregates where grading and other required characteristics can be maintained and contamination avoided. 7 COORDINATION A. Coordinate production and delivery of cast stone with unit masonry work to minimize the need for on-site storage and to avoid delaying the Work. PART 2 - PRODUCTS 1 CAST STONE MATERIALS A. General: Comply with ASTM C 1364 and the following: 1. Product Dimension: Length: 47-5/8 x Width 5-1/2 x Height 3-5/8 B. Portland Cement: ASTM C 150, Type I, containing not more than 0.60 percent total alkali when tested according to ASTM C 114. SECTION CAST STONE SILL 92

9 SECTION CAST STONE SILL C. Coarse Aggregates: Granite, quartz, or limestone complying with ASTM C 33; gradation as needed to produce required textures. D. Air-Entraining Admixture: ASTM C 260, certified by the manufacturer to be compatible with other admixtures used. 1. Add to mixes for units exposed to the exterior at manufacturer's prescribed rate to result in an air content of 5 to 7 percent. E. Reinforcement: Deformed steel bars complying with ASTM A 615/A 615M. 1. Galvanized Coating: ASTM A 767/A 767M. F. Embedded Anchors and Other Inserts: Fabricated from stainless steel complying with ASTM A 276 or ASTM A 666, Type CAST STONE UNITS A. Provide cast stone units complying with ASTM C Provide units that are resistant to freezing and thawing as determined by laboratory testing according to ASTM C 666, Procedure A, as modified by ASTM C B. Reinforce units as indicated and as required by ASTM C Use galvanized or epoxy-coated reinforcement when covered with less than 1-1/2 inches of material. C. Fabricate units with sharp arris and details accurately reproduced with indicated texture on all exposed surfaces, unless otherwise indicated. 1. Slope exposed horizontal surfaces at least 1:12, unless otherwise indicated. 2. Provide raised fillets at backs of sills and at ends indicated to be built into jambs. 3. Provide drips on projecting elements, unless otherwise indicated. D. Cure and finish units as follows: 1. Cure units in totally enclosed curing room under dense fog and water spray at 95 percent relative humidity for 24 hours. 2. Acid etch units to remove cement film from surfaces indicated to be finished. E. Colors and Textures: As selected by Architect from manufacturer's full range for these characteristics. 3 MORTAR MATERIALS A. Provide mortar materials that comply with Division 4 Section "Unit Masonry." SECTION CAST STONE SILL 93

10 SECTION CAST STONE SILL 4 ACCESSORIES A. Anchors: Type and size indicated, fabricated from steel complying with ASTM A 36/A 36M, and hot-dip galvanized to comply with ASTM A 123. B. Dowels: Round steel bars complying with ASTM A 36/A 36M or ASTM A 615/A 615M, 1/2- inch diameter, and hot-dip galvanized to comply with ASTM A 123. C. Job-Mixed Detergent Solution: Solution of 1/2 cup of dry-measure tetrasodium polyphosphate and 1/2 cup of dry-measure laundry detergent dissolved in 1 gal. of water. 5 MORTAR MIXES A. Setting Mortar: Comply with ASTM C 270, Proportion Specification, Type S. 1. Limit cementitious materials to portland cement and lime. 2. Packaged Portland Cement-Lime Mix Mortar: Use portland cement-lime mix of selected color. 3. Masonry Cement Mortar: Use masonry cement of selected color. PART 3 - EXECUTION 1 EXAMINATION A. Examine substrates and conditions, with Installer present, for compliance with requirements for installation tolerances and other conditions affecting performance of cast stone. B. Proceed with installation only after unsatisfactory conditions have been corrected. C. Set units in full bed of mortar with full head joints, unless otherwise indicated. Build anchors and ties into mortar joints as units are set. 1. Fill dowel holes and anchor slots with mortar. 2. Fill collar joint solid as units are set. 3. Build concealed flashing into mortar joints as units are set. 4. Leave head joints open in coping and other units with exposed horizontal surfaces. Keep joints clear of mortar, and rake out to receive sealant. D. Tool exposed joints slightly concave when thumbprint hard, using a jointer larger than joint thickness, unless otherwise indicated. E. Provide expansion, control, and pressure-relieving joints of widths and at locations indicated. 1. Sealing joints is specified in Division 7 Section "Joint Sealants." SECTION CAST STONE SILL 94

11 SECTION CAST STONE SILL 2. Keep joints free of mortar and other rigid materials. 2 INSTALLATION TOLERANCES A. Variation from Plumb: Do not exceed 1/8 inch in 10 feet or 1/4 inch in 20 feet or more. B. Variation from Level: Do not exceed 1/8 inch in 10 feet, 1/4 inch in 20 feet, or 3/8 inch maximum. C. Variation in Joint Width: Do not vary joint thickness more than 1/8 inch in 36 inches or onefourth of nominal joint width, whichever is less. D. Variation in Plane between Adjacent Surfaces (Lipping): Do not exceed 1/16-inch difference between planes of adjacent units or adjacent surfaces indicated to be flush with units. 3 ADJUSTING AND CLEANING A. Remove and replace stained and otherwise damaged units and units not matching approved Samples. Cast stone may be repaired if methods and results are approved by Architect. B. Replace units in a manner that results in cast stone matching approved Samples, complying with other requirements, and showing no evidence of replacement. C. In-Progress Cleaning: Clean cast stone as work progresses. Remove mortar fins and smears before tooling joints. D. Final Cleaning: After mortar is thoroughly set and cured, clean exposed cast stone as follows: 1. Remove large mortar particles by hand with wooden paddles and nonmetallic scrape hoes or chisels. 2. Protect adjacent surfaces from contact with cleaner by covering them with liquid strippable masking agent, polyethylene film, or waterproof masking tape. 3. Wet wall surfaces with water before applying cleaners; remove cleaners promptly by rinsing thoroughly with clear water. 4. Clean cast stone by bucket and brush hand-cleaning method described in BIA Technical Notes No. 20 Revised II, using job-mixed detergent solution. SECTION CAST STONE SILL 95