1.Extent of Each Type of Masonry Work Is Indicated on Drawings
SECTION 04200
MASONRY UNITS
PART 1 - GENERAL
1.1SUMMARY
A.Section Includes:
1.Extent of each type of masonry work is indicated on Drawings.
2.Types of masonry work required include:
a.Concrete unit masonry
b.Required Masonry Anchors
B.Related Documents:
1.Drawings and General Provisions of Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to work of this Section.
C.Related Sections:
1.Section 07620 - Sheet Metal Flashing and Trim
2.Section 07920 - Sealants
D.Products installed, but not furnished, under this Section include the following:
1.Steel Lintels for unit masonry, furnished under Section 05500, Metal Fabrications.
1.2SUBMITTALS
A.Product Data: Submit manufacturer's product data for each type of masonry unit, accessory, and other manufactured products, including certifications that each type complies with specified requirements.
1.3QUALITY ASSURANCE
A.Unit Masonry Standard: Comply with ACI 530.1/ASCE 6, "Specifications for Masonry Structures", except as otherwise indicated.
1.Revise ACI 530.1/ASCE 6 to exclude Sections 1.4 and 1.7; Parts 2.1.2, 3.1.2, and 4.1.2; and Articles 1.5.1.2, 1.5.1.3, 2.1.1.1, 2.1.1.2, and 2.3.3.9 and to modify Article 2.1.1.4 by deleting requirement for installing vent pipes and conduits built into masonry.
B.Fire Resistance Ratings: Where indicated, provide materials and construction which are identical to those of assemblies with fire-resistance ratings determined by testing in compliance with ASTM E 119 by a recognized testing and inspecting organization, by equivalent concrete masonry thickness, or by another means, as acceptable to authority having jurisdiction.
C.Single Source Responsibility for Masonry Units: Obtain exposed masonry units of uniform texture and color, or a uniform blend within the ranges accepted for these characteristics, through one source from a single manufacturer for each different product required for each continuous surface or visually related surfaces.
D.Single Source Responsibility for Mortar Materials: Obtain mortar ingredients of uniform quality, including color for exposed masonry, from one manufacturer for each cementitious component and from one source and producer for each aggregate.
E.Sample Panels: Before installing unit masonry, build sample panels, using materials indicated for the completed Work, to verify selection and to demonstrate aesthetic effects. Build sample panels for each type of exposed unit masonry assembly in sizes approximately 48 inches long by 48 inches high by full thickness.
1.Locate panels in the locations indicated or, if not indicated, as directed by Owner’s Representative.
2.Clean exposed faces of panels with masonry cleaner indicated.
3.Maintain sample panels during construction in an undisturbed condition as a standard for judging the completed Work.
4.Approval of sample panels is for color, texture, and blending of masonry units; relationship of mortar and sealant colors to masonry unit colors; tooling of joints; aesthetic qualities of workmanship; and other material and construction qualities specifically approved by the Owner’s Representative in writing.
a.Approval of sample panels does not constitute approval of deviations from the Contract Documents contained in sample panels, unless such deviations are specifically approved by the Owner’s Representative in writing.
5.Demolish and remove sample panels when directed.
1.4DELIVERY, STORAGE, AND HANDLING
A.Deliver masonry materials to project in undamaged condition.
B.Store masonry units on elevated platforms in a dry location. If units are not stored in an enclosed location, cover tops and sides of stacks with waterproof sheeting, securely tied. If units become wet, do not install until they are dry.
1.Limit moisture absorption of concrete masonry units during delivery and until time of installation to the maximum percentage specified for Type I units for the average annual relative humidity as reported by the U.S. Weather Bureau Station nearest project site.
C.Store cementitious materials on elevated platforms, under cover, and in a dry location. Do not use cementitious materials that have become damp.
D.Store aggregates where grading and other required characteristics can be maintained, and contamination avoided.
E.Store masonry accessories, including metal items, to prevent deterioration by corrosion and accumulation of dirt.
F.Deliver preblended, dry mortar mix in moisture-resistant containers designed for lifting and emptying into dispensing silo. Store preblended, dry mortar mix in delivery containers on elevated platforms, under cover, and in a dry location or in a metal dispensing silo with weatherproof cover.
1.5PROJECT/SITE CONDITIONS
A.Protection of Work: During construction, 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.
1.Extend cover a minimum of 24 inches down both sides and hold cover securely in place.
B.Do not apply uniform roof loading for at least 12 hours after building masonry walls or columns.
C.Do not apply concentrated loads for at least 3 days after building masonry walls or columns.
D.Staining: 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.
E.Protect base of walls from rain-splashed mud and from mortar splatter by means of coverings spread on ground and over wall surface.
1.6COLD AND HOT WEATHER PROTECTION
A.Cold-Weather Requirements: Do not use frozen materials or materials mixed or coated with ice or frost. Do not build on frozen subgrade or setting beds. Remove and replace unit masonry damaged by frost or by freezing conditions. Comply with cold weather construction requirements contained in ACI 530.1/ASCE 6/TMS 602.
B.Remove masonry damaged by freezing conditions.
C.Cold Weather Construction: When the ambient temperature is within the limits indicated, use the following procedures:
1.40 to 32 deg F: Heat mixing water or sand to produce mortar temperatures between 40 and 120 deg F.
2.32 to 25 deg F: Heat mixing water and sand to produce mortar temperatures between 40 and 120 deg F. Heat grout materials to produce grout temperatures between 40 and 120 deg F. Maintain mortar and grout above freezing until used in masonry.
3.25 to 20 deg F: Heat mixing water and sand to produce mortar temperatures between 40 and 120 deg F. Heat grout materials to produce grout temperatures between 40 and 120 deg F. Maintain mortar and grout above freezing until used in masonry. Heat masonry units to 40 deg F if grouting. Use heat on both sides of walls under construction.
4.20 deg F and Below: Heat mixing water and sand to produce mortar temperatures between 40 and 120 deg F. Heat grout materials to produce grout temperatures between 40 and 120 deg F. Maintain mortar and grout above freezing until used in masonry. Heat masonry units to 40 deg F. Provide enclosures and use heat on both sides of walls under construction to maintain temperatures above 32 deg F within the enclosures.
D.Cold-Weather Protection: When the mean daily temperature is within the limits indicated, provide the following protection:
1.40 to 25 deg F: Cover masonry with a weather-resistant membrane for 48 hours after construction.
2.25 to 20 deg F: Cover masonry with insulating blankets or provide enclosure and heat for 48 hours after construction to prevent freezing. Install wind breaks when wind velocity exceeds 15 mi./h.
3.20 deg F and Below: Provide enclosure and heat to maintain temperatures above 32 deg F within the enclosure for 48 hours after construction.
E.Cold-Weather Cleaning: Use liquid cleaning methods only when air temperature is 40 deg F and above and will remain so until masonry has dried out, but not less than 7 days after completion of cleaning.
F.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.
1.When ambient temperature exceeds 100 deg F, or 90 deg F with a wind velocity greater than 8 mph, do not spread mortar beds more than 48 inches ahead of masonry. Set masonry units within one minute of spreading mortar.
PART 2 - PRODUCTS
2.1CONCRETE MASONRY UNITS
A.General: Comply with referenced standards and other requirements indicated below applicable to each form of concrete masonry unit required.
1.Provide special shapes where required for lintels, corners, jambs, sash, control joints, headers, bonding and other special conditions.
2.Provide square-edged units for outside corners, unless indicated as bullnose.
B.Concrete Masonry Units: Provide units complying with characteristics indicated below for grade, type, face size, exposed face and, under each form of block included, for weight classification:
1.Grade N
2.Size
a.Unless noted otherwise, provide manufacturer's standard units with nominal face dimensions of 16" long x 8" high (15-5/8" x 7-5/8" actual) x thickness indicated.
3.Type I, Moisture-Controlled Units, as Indicated on Drawings
4.Exposed Faces
a.Manufacturer's Standard Gray Color and Texture
5.Hollow Loadbearing Block: ASTM C 90, and as follows:
a.Weight Classification: Medium weight, minimum compressive strength of 2000 psi (net area).
6.Solid Loadbearing Block: ASTM C 145, and as follows:
a.Weight Classification: Medium weight, minimum compressive strength of 2000 psi.
7.Integral Water Repellent: Provide units made with liquid polymeric, integral water-repellent admixture that does not reduce flexural bond strength. Units made with integral water repellent, when tested as a wall assembly made with mortar containing integral water-repellent manufacturer's mortar additive according to ASTM E 514, with test period extended to 24 hours, show no visible water or leaks on the back of the test specimen.
a.Manufacturers:
1)Block Plus W-10; Addiment Inc. (800-458-3090)
2)Dry-Block; WR Grace Masonry Products (800-558-7066)
3)Rheopel; Master Builders, Inc. (800-MBT-9990)
2.2SPECIAL SHAPES: Provide where shown and where required for lintels, corners, jambs, sash, control joints, headers, bonding, and other special conditions.
2.3FIRE RATINGS: Where fire ratings on masonry walls are shown on the Drawings, the Contractor shall make certain that the fire-resistant units to be used qualify for the ratings.
2.4MORTAR AND GROUT MATERIALS
A.Masonry Cement: ASTM C-91
1.Manufacturers:
a.Medusa Cement Co. (216-371-4000)
b.LeHigh Portland Cement Co. (800-523-5488)
c.LaFarge Corporation (703-264-3600)
d.The Riverton Corporation (800-336-2490)
B.Aggregate for Mortar: ASTM C 144; except for joints less than 1/4 inch thick, use aggregate graded with 100 percent passing the No. 16 sieve.
C.Aggregate for Grout: ASTM C 404.
D.Grout for Unit Masonry: Comply with ASTM C-476 for grout for use in construction of reinforced and nonreinforced unit masonry. Use grout of consistency indicated or, if not otherwise indicated, of consistency (fine or coarse) at time of placement which will completely fill all spaces intended to receive grout. Minimum compressive strength shall be 2,500 psi in 28 days.
1.Use fine grout in grout spaces less than 2" in horizontal direction, unless otherwise indicated.
2.Use coarse grout (maximum 3/8" aggregate) in grout spaces 2" or more in least horizontal dimension, unless otherwise indicated.
E.Water Repellent Admix:
1.Manufacturers:
a."Dry-Block System Mortar Additive"; WR Grace Masonry Products (800-558-7066)
b."Hydrocide Powder"; Sonneborn Building Products (800-496-6067)
2.Mortar additive shall be used in Type M or S Mortar Only.
F.Mortar Color: Gray.
G.Water: Potable
H.Mortar used to bond unit masonry shall be of Type M, S or N and shall comply with the property specifications set forth below:
MORTAR STRENGTH PROPERTY SPECIFICATIONS
TYPEMINIMUM AVERAGE STRENGTH (PSI)
M2500
S1800
N 750
The type of mortar based on consideration of the location of the unit masonry construction shall be as follows:
Use of LocationType of Mortar
Below Grade Foundation and WallsM
Retaining WallsM
Fire Resistive Walls Rated 2 Hours or
MoreM or S
Exterior Walls and Load Bearing WallsM or S
PartitionsM, S or N
Solid Masonry UnitsOne Classification
Less Than The
Above
Mortar or Grout Under Concentrated LoadsM
FencesM or S
2.5JOINT REINFORCEMENT, TIES AND ANCHORING DEVICES
A.Materials: Comply with requirements indicated below for basic materials and with requirements indicated under each form of joint reinforcement, tie and anchor for size and other characteristics:
1.Zinc-Coated (galvanized) Steel Wire: ASTM A 82 for uncoated wire and with ASTM C 641 for zinc coating of class indicated below:
a.Class 1 (0.40 oz. per sq. ft. of wire surface).
B.Joint Reinforcement: Provide welded-wire units prefabricated with deformed continuous side rods and plain cross rods into straight lengths of not less than 10', with prefabricated corner and tee units, and complying with requirements indicated below:
1.Width: Fabricate joint reinforcement in units with widths of approximately 2" less than nominal width of walls and partitions as required to provide mortar coverage of not less than 5/8" on joint faces exposed to exterior.
2.Wire Size for Side and Cross Rods: #9 Gauge
3.For single-wythe masonry, provide type as follows with single pair of side rods:
a.Truss design with continuous diagonal cross rods spaced not more than 16" o.c.
4.For multi-wythe masonry with cavity filled solid with mortar, provide type as follows:
a.Truss design with diagonal cross rods spaced not more than 16" o.c. and number of side rods as follows:
b.Number of Side Rods for Multiple-Wythe Concrete Masonry: One side rod for each face shell of concrete masonry back-up and of concrete masonry facing wythe.
5.For multi-wythe masonry with cavity containing insulation and air space, provide type as follows:
a.Ladder design with perpendicular cross roads spade not more than 16" o.c. vertically and one pintle tie for each 1.77 square feet of wall area.
b.Manufacturers:
1)"Ladur-eye"; Dur-O-Wall (847-577-6400)
2)"Lox-all Adjustable Eye Wire"; Hohmann and Barnard, Inc. (800-645-0616)
3)"AA525"; AA Wire Products Company (800-323-7170)
2.6REINFORCING STEEL
A.General: Provide reinforcing steel complying with requirements of referenced unit masonry standard and this article.
B.Steel Reinforcing Bars: Material and grade as follows:
1.Billet steel complying with ASTM A 615, Grade 60.
C.Deformed Reinforcing Wire: ASTM A 496.
D.Plain Welded Wire Fabric: ASTM A 185.
E.Deformed Welded Wire Fabric: ASTM A 497.
2.7ACCESSORIES
A.Reinforcing Bars: Deformed Steel, ASTM A 615, Grade 60 for Bars No. 3 to No. 18.
B.Bond Breaker Strips: Asphalt-Saturated Organic Roofing Felt Complying with ASTM D 226, Type I (No. 15 Asphalt Felt)
C.Anchor Bolts: Provide steel bolts wit hex nuts and flat washers complying with ASTM A-307, Grade A, hot-dip galvanized to comply with ASTM C-153, Class C, in sizes and configuration indicated.
2.8MASONRY CLEANERS
A.Job-Mixed Detergent Solution: Solution of tetrasodium polyphosphate (1/2 cup dry measure) and laundry detergent (1/2 cup dry measure) dissolved in one gallon of water.
B.Proprietary Acidic Cleaner: Manufacturer's standard strength general purpose cleaner designed for removing mortar/grout stains, efflorescence, and other new construction stains from new masonry surfaces of type indicated; composed of blended organic and inorganic acids combined with special wetting systems and inhibitors; expressly approved for intended use by manufacturer of masonry units being cleaned without damaging or discoloring masonry surfaces.
1.Manufacturers:
a."Sure Klean No. 600 Detergent”; ProSoCo, Inc. (800-255-4255)
b.“202 New Masonry Detergent”; Diedrich Technologies, Inc. (800-323-3565)
2.9MORTAR AND GROUT MIXES
A.General: Do not use admixtures, including coloring pigments, air-entraining agents, accelerators, retarders, water repellent agents, anti-freeze compounds or other admixtures, unless otherwise indicated.
1.Do not use calcium chloride in mortar or grout.
2.Add cold-weather admixture (if used) at the same rate for all mortar, regardless of weather conditions, to ensure that mortar color is consistent.
B.Mixing: Combine and thoroughly mix cementitious, water and aggregates in a mechanical batch mixer; comply with referenced ASTM standards for mixing time and water content.
C.Mortar for Unit Masonry: Comply with ASTM C 270, Proportion Specification, for types of mortar required, unless otherwise indicated.
PART 3 - EXECUTION
3.1INSTALLATION - GENERAL
A.Do not wet concrete masonry units.
B.Cleaning Reinforcing: Before placing, remove loose rust, ice and other coatings from reinforcing.
C.Thickness: Build single-wythe walls to the actual thickness of the masonry units, using units of nominal thickness indicated.
D.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.
E.Cut masonry units using motor-driven saws to provide clean, sharp, unchipped edges. Cut units as required to provide continuous pattern and to fit adjoining work. Use full-size units without cutting where possible.
1.Use dry cutting saws to cut concrete masonry units.
F.Select and arrange units for exposed unit masonry to provide a uniform blend of colors and textures.
3.2CONSTRUCTION TOLERANCES
A.Comply with tolerances in ACI 530-1/ASCE 6/TMS 602 and the following:
1.Variation from Plumb: For vertical lines and surfaces of columns, walls and arises do not exceed 1/4" in 10', or 3/8" in a story height not to exceed 20'. For external corners, expansion joints, control joints and other conspicuous lines, do not exceed 1/4" in any story or 20' maximum, nor 1/2" in 40' or more. For vertical alignment of head joints, do not exceed plus or minus 1/4" in 10'.
2.Variation from Level: For bed joints and lines of exposed lintels, sills, parapets, horizontal grooves and other conspicuous lines, do not exceed 1/4" in any bay or 20' maximum, nor 1/2" in 40' or more. For top surface of bearing walls, do not exceed 1/8" between adjacent floor elements in 10' or 1/16" within width of a single unit.
3.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.
4.Variation in Mortar Joint Thickness: Do not exceed bed joint thickness indicated by more than plus or minus 1/8", with a maximum thickness limited to 1/2". Do not exceed head joint thickness indicated by more than plus or minus 1/8".
3.3LAYING MASONRY WALLS
A.Lay out walls in advance for accurate spacing of surface bond patterns with uniform joint thicknesses and to accurately locate openings, movement-type joints, returns and offsets. Avoid the use of less-than-half-size units at corners, jambs and wherever possible at other locations.