SECTION 04400 STONE PART 1 GENERAL 1.01 SUMMARY A. Section Includes: 1. Exterior stone paving. 2. Interior stone flooring. 3. Stone stair treads. 4. Interior stone base. 5. Interior and exterior stone veneer. 1.02 SYSTEM DESCRIPTION A. Design Responsibility: The contractor shall be fully responsible for the design, structural engineering, calculations, shop drawings, fabrication, installation, warranties, certification and submittal procedures. B. Performance Requirements: 1. The component parts shall be properly designed or selected for the application. 2. The installation methods shall be proper and adequate for the conditions of installation and use. 1.03 QUALITY ASSURANCE A. Subcontractor's Qualifications: The firm executing the work under this section shall have five (5) years experience in work of similar scope and nature to that specified. B. Stone shall be sound, durable and free of visible defects, which will impair the strength, durability or appearance; or concentrations of material that will cause objectionable staining or weakening under normal environments of use. C. All stone shall be obtained from a single quarry having adequate capacity and facilities to meet the specified requirements; and by a firm equipped to process the material promptly and in accordance with the Specifications. The Owner and/or Architect reserve the right to approve the material supplier for stone prior to award of Contract. D. Stone furnished under this Section shall comply with the applicable provisions and recommendation of the following: 1. American Society for Testing and Materials (ASTM): a. C97 - Absorption and Bulk Specific Gravity of Dimension Stone. b. C99 - Modulus of Rupture of Dimension Stone. c. C119 - Standard Terminology Relating to Dimension Stone. d. C120 - Flexural Testing of Slate e. C121 - Water Absorption of Slate f. C170 - Compressive Strength of Dimension Stone. g. C241 - Abrasion Resistance of Stone Subject to Foot Traffic. h. C503 - Marble Dimension Stone (Exterior). i. C880 - Flexural Strength of Dimension Stone. 2. Marble Institute of America, Inc. (MIA): a. Membership, Products and Services Directory. b. Design Manual - Dimension Stone - Volume IV. 98055A 04400-1 Rev. 1 December 11, 1998
c. Dimension Stone of the World - Volume I. 3. National Building Granite Quarries Association, Inc. (NBGQA): a. Specifications for Architectural Granite. 4. Indiana Limestone Institute of America, Inc. E. Mock-Ups: 1. Construct composite mock-up sample of area indicated on exterior elevations shown in the drawings. Coordinate with other trades. 2. Mock-ups shall show the shading, markings and characteristics of the variety of stone specified, including the full range of color, texture and finish intended for use on the project. 3. Mock-ups shall represent the final work for materials and finish; and will provide a standard of workmanship for acceptance of work when accepted by the Architect. a. Construct additional sample panels until the standard is approved. b. When accepted, mock-up shall be the standard of comparison for the remainder of the work. c. Upon completion of the Project, remove the mock-up from the site and dispose of in a legal manner. F. Regulatory Requirements: Materials and workmanship shall meet requirements of the building codes which are applicable to the jurisdiction in which Project is located. G. Perform tests for stone properties in accordance with ASTM Standards specified for each type of stone to be furnished. H. The Architect may waive any or all tests provided the stone manufacturer or supplier can furnish certified test reports by an acceptable testing laboratory showing that the stone to be furnished has been previously tested and meets or exceeds the specified performance requirements. 1.04 SUBMITTALS A. General: Comply with Section 01340 - Shop Drawings, Product Data and Samples. B. Shop Drawings: 1. Submit stone layout drawings for each piece of stone showing location, size, thickness, jointing, anchoring and identification marks. 2. Detail drawings sufficient to show profiles, dimension and shape of each stone unit; connections to adjoining work; and methods of installation. 3. Submit Manufacturers Data for proprietary products used. C. Test Reports: 1. Submit reports, data and test values of stone characteristics and strengths. 2. Certify that the test samples are representative of the production materials for the project. 3. Include all information for properties, modulus of rupture, flexural strength, tensile strength. 4. Reports and data to be verified by testing samples. 5. Submit reports indicating the coefficient of friction meets or exceeds current ADA requirements. 98055A 04400-2 Rev. 1 December 11, 1998
D. Certification: 1. Submit certification that the completed work complies with the Contract Documents, the component parts are properly designed or selected for the application made, the installation methods comply with the manufacturer's printed instructions and their field representatives verbal instruction, and the installation methods are proper and adequate for the conditions of installation and use. 2. The stone subcontractor shall submit certification stating that all stone quantities quarried are available from a single source; and that all stone material specified shall be furnished within the range of the approved sample sufficient to satisfy the total project requirements. E. Samples: Submit samples of each type of stone to the Architect for review prior to constructing job-site mock-ups, delivering materials to the site or commencing the work. 1. Stone Samples: Provide two (2) sets of labeled stone samples, 24 inches (200mm) square, to be used on the Project showing full range of texture and/or color variations of the exposed surfaces. Units provided to the Project shall match these samples. Submit mortar (grout) channels. 2. Samples shall designate the finished face and shall be clearly labeled on the back with the name of the stone, the group, classification for soundness and the use for which the stone is intended. F. Stone maintenance: Submit stone supplier's literature or instructions for preventive care and maintenance measures pertinent to the specific stone finishes for normal maintenance and special cleaning procedures. G. Warranty: Submit written copy of warranty as specified. 1.05 DELIVERY, STORAGE AND HANDLING A. Mark each unit with an identifying piece mark correlated with Shop Drawings. Carefully pack and load each stone for shipment. Do not use material for blocking or packing which will cause staining or discoloration. B. Transport and store stone on a stable bed and with sufficient battens, bracing and supports to prevent overstressing by vibration or impact loading. C. Deliver other materials (except bulk materials) in manufacturer's unopened containers fully identified with manufacturer's name, trade name, type, class, grade and color. D. Storage of materials and equipment: Store materials and equipment in unopened containers. Store off ground and under cover, protected from damage. 1.06 PROJECT/SITE CONDITIONS A. Field Dimensions and Conditions: 1. Verify dimensions and conditions shown on Drawings by field verifying all dimensions and conditions. 2. Proper fit and attachment of stone is required. 1.07 SCHEDULING AND SEQUENCING A. Coordination: Coordinate with other work relating to stone installation for placing required blocking, backing, furring, conduits and other items. 98055A 04400-3 Rev. 1 December 11, 1998
1.08 WARRANTY A. Warranty: Warrant all stone for one (1) year after date of Substantial Completion from defects in material and workmanship PART 2 PRODUCTS 2.01 MATERIALS A. Stone: 1. Granite: ASTM C615. a. Water Absorption: 0.40%. b. Density: 160 pounds per cubic foot. c. Compressive Strength: 19,000 psi (131 MPa). d. Modulus of Rupture: 1500 psi (10.34 MPa). e. Abrasive Hardness: 25. f. Flexural Strength: 1200 psi (8.27 MPa). 2. Slate: ASTM C629. a. Water Absorption: 0.40%. 1) Classification I (Exterior): 0.25% 2) Classification II (Interior): 0.45%. b. Modulus of Rupture: 1) Across grain: 9000 psi (62.1). 2) Along grain: 7200 psi (49.6). c. Abrasive Hardness: 8.0 d. Acid Resistance: 1) Classification I (Exterior): 0.015 inch (0.38 mm). 2) Classification II (Interior): 0.025 inch (0.64 mm). 3. Sandstone: ASTM C616. a. Water Absorption: 1) Classification I (Sandstone): 20%. 2) Classification II (Quartzitic Sandstone): 3%. 3) Classification III (Quartzite): 1%. b. Density: 1) Classification I (Sandstone): 135 pounds per cubic foot. 2) Classification II (Quartzitic Sandstone): 150 pounds per cubic foot. 3) Classification III (Quartzite): 160 pounds per cubic foot. c. Compressive Strength: 1) Classification I (Sandstone): 2000 psi (13.8 MPa). 2) Classification II (Quartzitic Sandstone): 10,000 psi (68.9 MPa). 3) Classification III (Quartzite):O 20,000 psi (137.9 MPa). d. Modulus of Rupture: 1) Classification I (Sandstone): 300 psi (2.1 MPa). 2) Classification II (Quartzitic Sandstone): 1,000 psi (6.9 MPa) 3) Classification II (Quartzite): 2,000 psi (13.9 MPa). e. Abrasive Hardness: 8. B. Setting Materials: 1. Mortar Bed for Mud Set Method (Floors): a. Portland cement: ASTM C150, Type 1. b. Sand: ASTM C144. c. Mortar: One part Portland cement to 6 parts damp sand by volume. 2. Mortar Bed for Stone Veneer (Walls): a. Portland cement: ASTM C150, Type 1. b. Sand: ASTM C144. 98055A 04400-4 Rev. 1 December 11, 1998
c. Mortar: Vertical - One part Portland cement to 6 parts damp sand by volume. Horizontal One part Portland cement to 6 parts damp sand by volume. D. Grout: 1. Latex grout: Conforming to ANSI 118.3 and the TCA Handbook, supplied by an approved Manufacturer. Grout shall be sealed. (for walls) 2. Epoxy grout: Chemical-resistant per ANSI 118.3, water-cleanable during installation, supplied by an approved Manufacturer. (for floors) 3. Colors shall per finish materials schedule in drawings. E. Hydrated Lime: ASTM C207, Type S. F. Sand: Pure silica sand or white marble dust. G. Water: Clear and free of deleterious material. 2.03 ACCESSORIES A. Anchors, Dowels, Ties, and Cramps: Steel, ASTM A36, galvanized after fabrication to ASTM A123, 1.25 oz./sq.ft. (35.44g/m 2 ); of sizes and configurations required for support of stone and applicable superimposed loads. B. Supports: Steel, ASTM A36, galvanized after fabrication to ASTM A123, 1.25 oz./sq.ft. (35.44g/m 2 ). C. Bolts, Washers and Nuts: Galvanized steel. D. Lifting Hooks: Removable type for panels in excess of 75 lbs. (34 kg). E. Setting Buttons: Lead. F. PTE Strips: Bronze, ¾ wide at curves, 1/8 wide at perimeter of stone flooring. 2.04 STONE FABRICATION A. Accurately cut, dress, drill, fit and finish stone to shapes and dimensions indicated. Make exposed plane surfaces true to line. B. Cut external corners with quirk-miter joints where indicated. Cut other joints and edges square and at right angles to face, and with backs parallel to face. Make arises straight, sharp, true, and continuous at joints. C. Cut and drill stone in shop as required for supports, anchors, ties, grab and Lewis bolts, and other inserts. D. Allow for expansion and contraction within the limits of the joint material when cutting for anchorage devices. 98055A 04400-5 Rev. 1 December 11, 1998
E. Provide greater stone thickness where thicknesses indicated are insufficient for the sizes or where extent of cutouts indicated decreases effective strength of the remaining material, or for proper and sufficient anchorage, suitable and adequate bearing areas or surfaces. The use of liners properly sized and secured to stone facing will be permitted only where indicated. F. Provide interior wall base stone in lengths as long as practical. G. Form external corners to quirk joint profile. H. Slope exposed top surfaces of stone and horizontal sill surfaces for natural wash. I. Coat back and cavity surfaces of stone with bituminous back coating to surfaces not in contact with mortar. Allow coating to cure. PART 3 EXECUTION 3.01 EXAMINATION A. Verification of Conditions: 1. Examine subsurfaces to receive Work and report detrimental conditions in writing to Architect. 2. Failure to observe this requirement constitutes a waiver to subsequent claims to the contrary and holds Contractor responsible for correction(s) Architect may require. 3. Commencement of Work will be construed as acceptance of subsurfaces. 4. Verify, before proceeding with this Work, that required inspections of existing conditions have been completed. 3.02 PREPARATION A. Protection: Protect sills, ledges, offsets and other projections from dropping of mortar and grout. B. Establish lines, levels, and coursing. Protect from disturbance. C. Clean stone prior to erection. Do not use wire brushes or implements which will mark or damage exposed surfaces. 3.03 ERECTION, INSTALLATION, APPLICATION A. Floors: 1. Interior Floors Thickset (Mudset): a. Install floors in thick-setting beds where indicated using Portland cement mortar bed in accordance with TCA Method F-112. b. Use damp mix. After final tamping, raise stone and coat back with pure neat cement. The joints shall be raked out before grouting. Remove cement stains with cool, clear water before cement sets. 2. Exterior Floors - Thickset (Mudset): a. Install floors over slabs on grade in thick-setting beds where indicated using Portland cement mortar bed in accordance with TCA Method F- 101. b. Install floors over exterior decks with waterproof membrane (slabs above grade) in thick-setting beds where indicated using Portland cement mortar bed in accordance with TCA Method F-103. 98055A 04400-6 Rev. 1 December 11, 1998
c. Use damp mix. After final tamping, raise stone and coat back with pure neat cement. The joints shall be raked out before grouting. Remove cement stains with cool, clear water before cement sets. 3. Edge strips: Install edge strips, adequately anchored to substrate where stone flooring meets other floor coverings, where exposed edges is raised above base flooring to meet "future floor coverings", and where indicated on the Drawings. 4. Joints: a. Provide perimeter and control joints in stone paver surfaces in accordance with Section 07900 - Sealants and Caulking. b. Expansion joint width shall be 1/2 inch minimum. Joints through stone and mortar directly over structural joints, including cold joints and sawcut control joints, in the backing must be at least the width of the structural joints. c. Make grout joint widths, unless otherwise indicated, as follows: 1) Exterior stone paving: 1/8-inch joints. 2) Interior stone paving: 1/8-inch joints. 5. Grouting: Apply grout release to stone pavers 24 hours before installing grout. Grout joints fully as each paver is set, using pre-mixed colored grout. Use plastic cushions and spacers where required to maintain uniform joints. After setting, tool joints slightly concave. Clean stone after grouting and remove all grout release. Cure stone flooring for a minimum of 7 days. B. Interior Stone Wall Veneer: 1. Thickset (Mudset): a. Stone panels shall be set firmly against mortar spots located at anchors and spaced not farther than 18 inches on center over the back of the pieces. b. Provide corrosion resistant metal anchors, dowels, pins, cramps, wires, etc. securely attached to structure and stone. c. Anchor units facing against or abutting concrete by the use of dovetailed flat bar anchors inserted in slots built into the concrete. 1) Space anchors not more than 16 inches (400mm) vertically and 24 inches (600mm) horizontally. 2) Maintain a space not less than ½ inch (12mm) width between masonry and concrete members, keeping space free of mortar or other rigid materials so as to permit differential movement. d. Fill dowel, Lewis, and lifting holes with mortar. 2. Lay units in uniform and true courses, level and plumb in accordance with specified tolerances. 3. Erect stone in accordance with stone supplier s instructions and erection drawings. 4. Arrange stone pattern to provide a consistent joint width of ¼ inch throughout. 5. Place setting buttons and set stone in full mortar setting bed to support stone over full bearing surface and to establish joint dimensions. 6. Shore up units until setting bed will maintain panel in position without movement and for a minimum of 7 days after setting. 7. Adjusting Units: a. Units shall be adjusted to be level, plumb and straightened into final position in the wall while the mortar is still soft and plastic enough to ensure a good bond. b. Avoid over-plumbing and pounding of the corners and jambs to fit units after they are set in position. c. If the position of the unit is shifted after the mortar has stiffened, or bond is broken or cracks are formed, re-lay unit in new mortar. 8. Do not lay chipped, cracked or otherwise defective units in the wall where exposed to view. Remove and replace units that chipped, cracked, broken, or otherwise defective whether before or after setting. 9. Openings: Provide openings in walls where required or indicated. Steel lintels shall be provided unless otherwise noted. 10. Cutting: When required, exposed units shall be cut with a power driven Carborundum or diamond disc blade saw. When using wet cutting methods, clean water shall be used on exposed units. 98055A 04400-7 Rev. 1 December 11, 1998
11. To accommodate pointing mortar, rake out joints a minimum of one-half of the total depth. Brush mortar joints clean. Fill joints with pointing mortar. Pack and work into voids. Neatly tool surface to concave joint. 3.04 TOLERANCES A. Variation from Level (Plumb): 1/8" in 20'-0". B. Paver Alignment between Adjacent Units: 1/32" offset C. Joint Thickness: 1. Floor: 1/4" sandstone and slate. 3.05 CUTTING AND FITTING A. Obtain approval prior to cutting or fitting any item not so indicated on Drawings. 3.06 CLEANING A. Daily Cleaning: Keep stone clean. Soiled masonry from mortar and grout spills which will be exposed to view at the completion of the Project shall be cleaned immediately, until the stone is free of dropped or spattered mortar. B. Remove scaffolding and equipment used in the Work. C. Clean up debris, refuse and surplus material and remove from premises in accordance with Section 01500. D. Interior Stone Floors: Unless otherwise recommended by Stone Manufacturer, comply with the following: 1. After the floor is thoroughly dry, clean it with "1-4-X Cleaner", mixing 4 oz. of the mild, non-filming detergent with 1 gal. of cool, clean water. Scrub floor thoroughly using a commercial soft pad buffing machine or soft bristle brush or broom if by hand. Use overlapping, swirling strokes to remove stains, dirt and other discolorations. Do not use acids, cleaning compounds or wire brushes. 2. Rinse floor thoroughly using lots of cool, clear water. Remove excess water with a commercial wet/dry vacuum cleaner. 3. Neutralize alkali by evenly swabbing the stone with "Tile Treat" mixed with 5 parts cool water using a string mop or towel which has not been wrung out. Do not rinse the "Tile Treat" and let the floor dry completely. E. Sealing - Interior Sandstone Flooring: 1. Apply "Tile Lab Surface Guard" penetrating sealer and Tile Lab Supersheen Matte Finish per manufacturer s recommendation. 3.07 ADJUSTING AND CLEANING A. Immediately prior to completion of the Work, clean stone by washing with water and bristle brushes to remove stains, dirt and other discolorations. Do not use acids, cleaning compounds or wire brushes. 3.08 PROTECTION A. Furnish temporary protection for exposed stone corners subject to injury. B. Rope off floor areas to permit curing of setting bed and grout. C. Protect stone from damage by subsequent construction operations. 98055A 04400-8 Rev. 1 December 11, 1998
PART 4 SCHEDULES 4.01 STONE A. Provide stone in accordance with Finish materials schedule in drawings. END OF SECTION 98055A 04400-9 Rev. 1 December 11, 1998