SECTION 04100 Page 1

ROCKVILLE MILL HOUSING MORTAR AND MASONRY GROUT 332 Canonchet Road Rockville, Rhode Island

URBAN DESIGN GROUP SECTION 04100 Page 1

SECTION 04100 - MORTAR AND MASONRY GROUT

PART 1 - GENERAL

1.01 WORK INCLUDED

A. See Section of Related Work.

B. Where masonry repairs occur to the exterior granite walls, the mortar shall match the consistency and color of the existing mortar, as will the joint configuration, as per the requirements of the Rehabilitation Standards for Historic Structures.

1.02 RELATED WORK

A. Other requirements of the Contract Documents including, but not necessarily limited to, pertinent portions of Sections in Division One of these Specifications, apply to the work of this Section as fully as though repeated herein.

B. Stone & Unit Pavers Pavers: Section 02520

C. Cast in Place Concrete: Section 03300

D. Masonry Repairs: Section 04230

E. Stone Masonry: Section 04231

1.03 QUALITY ASSURANCE

A. Standards: 1. ASTM C 144 Aggregate for masonry mortar. 2. ASTM C 150 Portland cement. 3. ASTM C 207 Hydrated lime for masonry purposes. 4. ASTM C 270 Mortar for unit masonry. 5. ASTM C 404 Aggregate for masonry grout. 6. ASTM C 476 Mortar and grout for reinforced masonry.

1.04 SUBMITTALS

A. Manufacturer's certification that materials meet specification requirements.

B. Samples to show colors and textures. ROCKVILLE MILL HOUSING MORTAR AND MASONRY GROUT 332 Canonchet Road Rockville, Rhode Island

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1.05 PRODUCT DELIVERY, STORAGE AND HANDLING

A. Deliver and store manufactured products in original unopened containers.

B. Store cementitious ingredients in weather-tight enclosures and protect against contamination and warehouse set.

C. Stockpile and handle aggregates to prevent contamination from foreign materials.

D. Store admixtures to prevent contamination or damage from excessive temperature changes.

E. Keep water free of harmful materials.

1.06 JOB CONDITIONS

A. Environmental requirements: 1. Heat mixing water when air temperature is below 40 degrees F. 2. Heat aggregates when air temperature is below 35 degrees F. 3. Assure mortar and grout temperatures between 40 degrees F and 120 degrees F until used. 4. Produce subsequent mortar and grout batches within + 10 degrees of first batch. 5. Do not heat water or sand above 120 degrees.

PART 2 - PRODUCTS

2.01 CONCRETE MASONRY MORTAR

A. Materials: 1. Portland cement: ASTM C 150 Type I. 2. Hydrated lime: ASTM C 207 Type S. 3. Aggregate: ASTM C 144. 4. Water: clean and free of deleterious amounts of acids, alkalis or organic materials. 5. Admixtures: use of accelerators or anti-freeze is prohibited without Architect's approval. 6. Use same brands of cement and lime, and same source of sand throughout the duration of masonry work.

B. Mix proportions: 1. Portland cement: one part by volume. 2. Hydrated lime: two parts by volume. 3. Aggregate: 6 to 7 parts by volume.

ROCKVILLE MILL HOUSING MORTAR AND MASONRY GROUT 332 Canonchet Road Rockville, Rhode Island

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2.02 MASONRY GROUT

A. ASTM C 476 Type PL: 1. Portland cement: ASTM C 150 Type I, light colored. 2. Hydrated lime: ASTM C 207 Type S. 3. Aggregates: ASTM C 404, light colored sand.

B. Mix proportions: 1. Portland cement: one part by volume. 2. Hydrated lime: 1/4 to 1/2 parts by volume. 3. Aggregate: 2-1/4 to 3 times the sum of the cementitious materials.

C. Vertical cell reinforcing grout: 1. Ultimate compressive strength of 2000 psi in 20 days. 2. Approximate 4" slump.

2.03 MIXING PROCEDURES

A. Measure materials by volume or equivalent weight.

B. Do not measure by shovel.

C. Use no more water than is needed to produce workable consistency, or required slump.

D. Use water clean and free of deleterious amounts of acids, alkalis, or organic materials.

PART 3 - EXECUTION

3.01 APPLICATION

A. Apply to pavers and masonry in accordance with Sections 02520, 04230 and 04231.

B. Apply grout as follows: 1. Wet surfaces of masonry to be in bond with grout. 2. Agitate grout thoroughly around reinforcing and other obstructions. 3. Cover top of grout surface to prevent loss of moisture and to assure proper curing.

END OF SECTION 04100 ROCKVILLE MILL HOUSING NON-SHRINK NON-METALLIC GROUT 332 Canonchet Road Rockville, Rhode Island

URBAN DESIGN GROUP SECTION 04102 Page 1

SECTION 04102 - NON-SHRINK NON-METALLIC GROUT

PART 1 - GENERAL

1.01 WORK INCLUDED

A. Column base and plate grouting, where structural support is require or where existing wood columns are removed.

1.02 RELATED WORK

A. Other requirements to the Contract Documents including, but not necessarily limited to, pertinent portions of Sections in Division One of these specifications, apply to the work of this Section as fully as though repeated herein.

B. Cast-in-Place Concrete: Section 03300

C. Metals: Section 05500

1.03 DELIVERY, STORAGE, AND HANDLING

A. Prevent damage to or contamination of non-shrink grouting materials during delivery, handling or storage.

B. Store non-shrink grouting materials in undamaged condition with seals and labels intact as packaged by manufacturer.

1.04 REFERENCE STANDARDS

A. ASTM C 33: Concrete Aggregates.

B. ASTM C150: Portland Cement.

PART 2 - PRODUCTS

2.01 MATERIALS

A. Non-shrink non-metallic grout conforming to the following requirements: 1. Manufactured under rigid quality control specifically for grout used in transferring heavy loads. ROCKVILLE MILL HOUSING NON-SHRINK NON-METALLIC GROUT 332 Canonchet Road Rockville, Rhode Island

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2. Contain non-metallic aggregates especially graded to minimize bleeding. 3. Contain non-metallic aggregate that is ductile and capable of withstanding impact without fracturing. 4. Have an initial setting time of approximately one hour at 70 degrees F. 5. Produce no settlement or drying shrinkage at 3 days or thereafter. 6. Have design strength of 8000 psi at 28 days.

B. Portland Cement: ASTM C-150, Type I.

C. Sand: ASTM C-33, Fine Aggregate.

D. Water: Potable.

E. Pea Gravel, ASTM: C-33. Coarse Aggregate, graded so that at least 90 percent passes 3/8" sieve and 90 percent is retained by a number 4 sieve.

2.02 MIXES

A. For less than 2" clearance, or where size or shape of space makes grouting difficult, grout mix shall consist of grout material and water.

B. For greater than 2" clearance where coarse aggregate will not obstruct free passage of the grout, extend grout by adding 50 pounds of pea gravel per 100 pounds grout materials.

C. Use the minimum amount of water necessary to produce a flowable grout without causing either segregation or bleeding.

D. Portland cement mortar for raked-out edges of non-shrink grout: 1 part portland cement, 2 parts sand and 0.05 parts water by weight.

2.03 MIXING

A. Mix non-shrink grouting materials and water in a mechanical mixer for no less than 3 minutes.

B. Mix grout as close to the work area as possible and transport the mixture quickly and in a manner that does not permit segregation of materials.

C. After the grout has been mixed, do not add more water for any reason.

ROCKVILLE MILL HOUSING NON-SHRINK NON-METALLIC GROUT 332 Canonchet Road Rockville, Rhode Island

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PART 3 - EXECUTION

3.01 PREPARATION PROCEDURES

A. Installation methods and procedures shall be approved by the Architect's representative before work is begun.

3.02 FORMWORK

A. Build leak proof forms that are strong and securely anchored and shored to withstand grout pressures.

B. Provide enough clearance between the formwork and the area to be grouted to permit proper placement of grout.

3.03 SURFACE PREPARATION

A. Remove all defective concrete, laitance, dirt, oil, grease and other foreign material from concrete surfaces by bush-hammering, chipping, or other similar means, until a sound, clean surface is achieved.

B. Lightly roughen the concrete, but not enough to interfere with the proper placement of grout.

C. Remove foreign materials from all steel from all steel surfaces in contact with grout.

D. Align, level and maintain final positioning of all components to be grouted.

E. Take special precautions during extreme weather conditions according to the manufacturer's written instructions.

F. Saturate all concrete surfaces with clean water; remove excess water and leave none standing.

3.04 PLACING

A. Place non-shrink grouting material quickly and continuously by the most practical means permissible; pouring, pumping or under gravity pressure.

B. Do not use either pneumatic-pressure or dry packing methods without written permission of the Architect.

C. Apply grout from one side only to avoid entrapping air. ROCKVILLE MILL HOUSING NON-SHRINK NON-METALLIC GROUT 332 Canonchet Road Rockville, Rhode Island

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D. Final installation shall be thoroughly compacted and free from air pockets.

E. Do not vibrate the placed grout mixture, or allow it to be placed if the area is being vibrated by nearby equipment.

F. Do not remove leveling shims for at least 48 hours after grout has been placed.

G. After shims have been removed, fill voids with plain cement-sand grout.

H. After the non-shrink grout has reached initial set, rake out all exposed edges approximately 1" into the grouted area and point with portland cement mortar.

3.05 CURING

A. Cure grout for 3 days after placing by keeping wet and covering with curing paper or by another approved method.

END OF SECTION 04102 ROCKVILLE MILL HOUSING MASONRY REPAIRS 332 Canonchet Road Rockville, Rhode Island

URBAN DESIGN GROUP SECTION 04230 Page 1

SECTION 04230 – MASONRY REPAIRS

PART 1 - GENERAL

1.01 WORK INCLUDED

A. The work in this Section centers on any necessary repairs to the existing grranite exterior walls of both the small and large mills.

B. Rebuilding and repair to the existing stone retaining wall along the south boundary line of the property. Excess stone found on the site shall be used in the rebuilding of this wall, where necessary.

C. For historical purposes, the 2 chimneys on the main mill and one on the small mill shall be demolished below the roof level, but shall remain as a feature above each roof. The exposed brick shall be repaired and repointed where necessary and installed on a structural harness installed just below the roof structure.

D. Repoint areas of defective mortar and loose stone.

1.02 RELATED WORK

B. Demolition: Section 02060

C. Cast in Place Concrete: Section 03300

D. Mortar and Masonry Grout: Section 04100

E. Flashing and Sheet Metal: Section 07620

1.02 QUALITY ASSURANCE

A. Qualifications of workmen: 1. Use skilled workmen who are thoroughly trained and experienced in the necessary crafts, and who are completely familiar with the specified requirements and the methods needed for proper performance of the work of this section.

ROCKVILLE MILL HOUSING MASONRY REPAIRS 332 Canonchet Road Rockville, Rhode Island

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2. Provide one skilled journeyman mason, to be present at all times during the execution of this portion of the Work and who will personally direct all work performed under this Section.

B. Codes and Standards: In addition to complying with the pertinent codes and regulations, comply with material standards of ASTM C90 and ASTM C145.

PART 2 - PRODUCTS

2.01 BRICK

A. Exposed brick to each chimney shall be repaired. Use salvaged units in good conditions can be reused for repair purposes.

2.02 OTHER MATERIALS

A. All other materials, not specifically described, but required for a complete and proper installation as indicated on the drawings, shall be new, suitable for intended use, and subject to the approval of the Architect.

PART 3 - EXECUTION

3.01 INSPECTION

A. Surface conditions: 1. Before work of this Section begins, carefully inspect the existing conditions and verify that this installation may properly commence. 2. Verify that Masonry may be completed in strict accordance with pertinent codes and regulations, the referenced standards, and the original design.

B. Discrepancies: 1. In the event of a discrepancy, immediately notify the Architect. 2. Do not proceed with installation in areas of discrepancy until such discrepancies have been fully resolved.

3.02 REPLACE OR REPAIR DAMAGED BRICKS

A. Replace bricks that are loose, missing or cracked.

ROCKVILLE MILL HOUSING MASONRY REPAIRS 332 Canonchet Road Rockville, Rhode Island

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3.03 REPOINTING

A. Loosen or broken joints shall be cleaned out to a minimum of 3/4 inch. These joints shall be pointed with a compatible mortar to within ¼ to 1/8 inch of the brick face.

3.04 WALL FLASHINGS

A. Place a two-piece counter flashing where chimneys meet the roof. Set in mortar a lead coated copper reglet with ¼” horizontal slot, 1 1/8” deep. Install reglet with tightly butted joints in horizontal mortar joints. Ensure this joint is not less than 4” above the roof. Mortar has to be above and below the reglet in mortar joint so as to tightly lock in position. After the roofing is completed, insert a lead coated copper spring-lock cap flashing into reglet, lapping each section at least 3 inches over preceding piece.

3.05 PROTECTION OF WORK

A. Protect all other work from any damage during construction.

3.06 CLEANING

A. Leave work and surrounding surfaces clean and free of spots and drippings.

END OF SECTION 04230

ROCKVILLE MILL HOUSING STONE MASONRY 332 Canonchet Road Rockville, Rhode Island

URBAN DESIGN GROUP SECTION 04231 Page 1

SECTION 04231 – STONE MASONRY

PART 1 - GENERAL

1.01 WORK INCLUDED

A. The work of this section comprises the repaira of the existing granite walls to both mills.

B. Exterior walls shall be repaired, where necessary and power washed.

C. Interior walls shall be repointed, wire-brushed and painted with a masonry paint.

D. Repair and reconstruct retaining wall and stairs at the south end of the Courtyard and the retaining wall with stairs at the end of the service driveway

E. Furnish and install granite steps to both sets of stairs (4’ – 0” x 18” x 6”)

1.02 RELATED WORK

B. Earthwork: Section 02200

C. Cast in Place Concrete: Section 03300

D. Mortar and Masonry Grout: Section 04100

1.02 QUALITY ASSURANCE

B. Field Example: 1. Prior to the start of the Work of this Section, erect a sample panel of not less than 12 sq. ft. Do not proceed further until said panel has been inspected and approved by the Architect. 2. Approved sample work will be used as the quality standard for the stone walls.

ROCKVILLE MILL HOUSING STONE MASONRY 332 Canonchet Road Rockville, Rhode Island

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PART 2 - PRODUCTS

2.01 STONE

A. There is a surplus of stone on the site which can be used for the repair and reconstruction of the exterior walls, where necessary.

2.02 OTHER MATERIALS

PART 3 - EXECUTION

3.01 INSPECTION

A. Surface conditions: 1. Before work of this Section begins, carefully inspect the existing conditions and verify that this installation may properly commence.

B. Discrepancies: 1. In the event of a discrepancy, immediately notify the Architect. 2. Do not proceed with installation in areas of discrepancy until such discrepancies have been fully resolved.

3.02 INSTALLATION

A. General: Masonry repairs shall follow the requirements set forth in the “Rehabilitation Standards for Historic Structures” by the National Park Service 1. Install masonry true to the line and dimensions indicated on the Drawings. 2. Adjust stones to final position to insure stability and permanence. 3. Provide temporary shoring or other supports as required to carry out the task. 4. The cap stones shall be laid up in mortar, make sure that there are no visual signs of its presence.

3.03 STONE CLEANING

A. On completion of the repairs, the exterior walls shall be thoroughly cleaned with low- pressure power-washing to clean and remove all extraneous debris etc.

ROCKVILLE MILL HOUSING STONE MASONRY 332 Canonchet Road Rockville, Rhode Island

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B. Cleaning shall not be performed in cold weather.

C. Caution should be exerted as to controlling the water pressure in order not to damage the stone surfaces.

D. Interior surfaces of both mills shall be thoroughly wire-brushed and finished with a coat of waterproof sealer and painted with masonry paint.

3.04 PROTECTION OF WORK

A. Protect all other work from any damage during construction.

3.05 CLEANING

A. Leave work and surrounding surfaces clean and free of spots and drippings.

END OF SECTION 04231