04220 Concrete Unit Masonry

Re-submit For Permit

SECTION 04 22 01

CONCRETE UNIT MASONRY

PART 1 - GENERAL

1.01 REFERENCE STANDARDS

A. American Concrete Institute (ACI): 1. 315 Details and Detailing of Concrete Reinforcing. 2. 530.1/ACSE 6/ Specification for Masonry Structures. TMS 602

B. American Society for Testing and Materials (ASTM): 1. A36/A36M Carbon Structural Steel. 2. A82 Steel Wire, Plain, for Concrete Reinforcement. 3. A153 Zinc Coating Hot-Dip on Iron and Steel Hardware. 4. A615/A615M Deformed and Plain Billet-Steel Bars for Concrete Reinforcement. 5. A641 Zinc-Coated (Galvanized) Carbon Steel Wire. 6. C90 Load-Bearing Concrete Masonry Units. 7. C129 Non-Load-Bearing Concrete Masonry Units. 8. C270 Mortar for Unit Masonry. 9. D1056 Flexible Cellular Materials - Sponge or Expanded Rubber. 10. D2000 Classification System for Rubber Products in Automotive Applications.

C. American Welding Society (AWS): 1. D1.1 Structural Welding Code - Steel.

D. Underwriters Laboratories Inc. (UL): 1. 618 Standards for Safety for Concrete Masonry Units.

1.02 SUBMITTALS

A. General: In compliance with Section 01 33 00 and as specified herein.

B. Letter of Conformance; (FIO): In compliance with requirements of, and in format included in, Section 01 33 00.

1.03 QUALITY ASSURANCE

A. Mock-Up: Decorative Concrete Masonry Unit Mock-Up: Lay 6U-0" long x 6U-0" high mock-up panel of decorative concrete masonry units with concrete masonry backup and mortar specified in other Sections of Project Manual. Mock-up location determined by Architect. 1. Mock-up must show: a. Bonding. b. Mortar color. c. Joint tooling. d. Each different masonry color and texture. e. Reinforcement. f. Cavity clearance. g. Workmanship. h. Erect mock-up minimum 14 days prior to beginning masonry Work. If initial mock-up is rejected, erect additional mock-ups until accepted by Architect. 2. Accepted mock-up establishes minimum design and quality standards for decorative concrete masonry work. 3. Do not destroy mock-up until directed by Architect.

4. Apply cleaning agent specified herein to test area of mock-up. Report all adverse affects to Architect immediately. 5. Protect mock-ups from elements with weather-resistant membrane.

B. Fire-Resistance Ratings: Where indicated, provide materials and construction identical to those of assemblies with fire-resistance ratings determined per ASTM E119 by testing and inspecting agency, or by equivalent concrete masonry thickness, or by UL classifications, or by another means, as acceptable to authorities having jurisdiction.

1.04 DELIVERY, STORAGE, AND HANDLING

A. Protect masonry materials during transportation, handling and storage. 1. Store above ground on level platforms which allow air circulation under stacked units. 2. Cover with heavy weatherproof coverings to prevent staining by weather, dirt, mud, oils and grease. 3. Carefully handle to prevent chipping, spalling, cracking and all other damage which impairs strength, durability and appearance. 4. Discard and remove damaged materials from Project site.

1.05 PROJECT CONDITIONS

A. Environmental Requirements: 1. Do not lay masonry when temperature is below 32E F. on rising temperature or below 40E F. on falling temperature, unless adequate precautions are taken to prevent Work from freezing. 2. During freezing or near freezing weather, provide adequate equipment or cover to protect completed portions of Work and to maintain minimum temperatures above 50E F.

PART 2 - PRODUCTS

2.01 CONCRETE MASONRY UNITS

A. Nonload-Bearing Concrete Block: ASTM C129, Type II, Grade N, nonmoisture-controlled hollow core and solid core lightweight units.

B. Load-Bearing Concrete Block: ASTM C90 hollow and solid core, Type II, Grade N, nonmoisture- controlled lightweight units.

C. Fire Rated Concrete Block: Manufacture in compliance with UL 618 to UL certifications for one hour rating.

E. Shapes and Sizes: Uniform texture, with square and bullnose corners, and free from chips, cracks and spalls. 1. Sizes: Standard units with nominal face dimensions of 8-inch x 16-inch, thicknesses indicated. Units smaller than one-half unit are not acceptable. 2. Shapes: Provide stretchers, lintel and bond beams, closed end partition blocks and other shapes indicated and required.

2.02 REINFORCEMENT, ANCHORAGES AND ACCESSORIES

A. Horizontal Reinforcing: 9 gauge wire conforming to ASTM A82. 1. Standard Ladder Type: a. Dur-O-Wal, Inc. "DA 3600 Ladur Eye". b. Hohmann & Barnard, Inc. “#270 Ladder-Eye Mesh”. c. Masonry Reinforcing Corporation of America, Wire Bond, “Core Clear Ladder Type Series 200". 2. At concrete masonry unit with brick veneer joints, provide integral box ties with double eye section welded every 1U-3" on center, and associated double leg box pintle ties for brick anchorage. 3. Finish: ASTM A153, Class B-2 with 1.5 ounces zinc coating per foot for exterior work and mill galvanized with 0.10 ounces zinc coating per foot for interior work. 4. Provide factory prefabricated "L" sections for corners, "T" wall intersections, and other special conditions; no toothing permitted.

5. Widths: As recommended by manufacturer for wall thicknesses indicated.

B. Reinforcing Bars: ASTM A615, Grade 60, as specified in Section 03 20 00. Provide ASTM A82 minimum W1.5 galvanized positioners.

C. Flexible Anchoring; Masonry to Steel Columns and Beams: Fabricated from ASTM A82 galvanized steel wire; 3/16-inch diameter wire fabricated with triangular ends with 1/4-inch diameter wire crimped anchors for welding to columns or machine nuts and sized to extend within one-inch of masonry unit face. 1. Dur-O-Wal, Inc. "DA 700". 2. Heckmann Building Products, Inc. “No. 317" with “No.316". 3. Hohmann & Barnard, Inc. “VBT”. 4. Masonry Reinforcing Corporation of America, Wire Bond, “1000, Type III” with “1100".

D. Dovetail Anchoring; Masonry to Concrete Walls and Columns: 1. Slots: Standard one-inch wide x one-inch deep with 5/8-inch throat, minimum 24 gauge galvanized steel. a. Dur-O-Wal, Inc. "DA 100". b. Heckmann Building Products, Inc. ”100". c. Hohmann & Barnard, Inc. “#305". d. Masonry Reinforcing Corporation of America, Wire Bond, “1304". 2. Anchors: 3-1/2 inch long x 3/16-inch diameter galvanized. a. Dur-O-Wal, Inc. "DA 720". b. Heckmann Building Products, Inc. “No. 103". c. Hohmann & Barnard, Inc. “#315-Flexible Dovetail Brick Tie”. d. Masonry Reinforcing Corporation of America, Wire Bond, “2102".

E. Wall Ties: As specified in Section 04 21 00 and of length to attach to wall and extend to midpoint of brick.

F. Control Joints: ASTM D2000, Designation 2AA-805, solid rubber, ASTM D2240 durometer hardness. 1. Dur-O-Wal, Inc. “DA 2005". 2. Heckmann Building Products, Inc. “No. 352". 3. Hohmann & Barnard, Inc. “RS Series". 4. Masonry Reinforcing Corporation of America, Wire Bond, “2902".

G. Compressible Filler: Neoprene, urethane or polyvinyl chloride premolded filler strips complying with ASTM D1056, Type 2, Class A, Grade 1; compressible up to 35%; of width and thickness indicated.

H. Thru-Wall Flashing: Stainless steel and self-adhering flexible flashing system specified in Section 07 60 00.

I. Sheet Metal Flashings: Specified in Section 07 60 00.

J. Weep Tubes: Standard 3/8-inch o.d. x 4-inch long clear plastic weep hole. 1. Dur-O-Wal, Inc. "DA 1005". 2. Heckmann Building Products, Inc. “No. 330". 3. Hohmann & Barnard, Inc. “#341". 4. Masonry Reinforcing Corporation of America, Wire Bond, “3600".

K. Weep Cell Vents: Flexible ultra-violet resistant polypropylene copolymer vent, 2-1/2 inch high x 3-3/8 inch long x 3/8-inch thick. Color selected by Architect. 1. Dur-O-Wal, Inc. “DA 1006". 2. Hohmann & Barnard, Inc. “”QV-Quadro-Vent”. 3. Masonry Reinforcing Corporation of America “3601".

L. Setting Bed: ASTM C270, Type "S" portland cement mortar, specified in Section 04 05 00.

M. Wire Mesh Hardware Cloth: 1/2-inch x 16 gauge galvanized steel mesh, 1U-4" long; 2-inches less than wall width.

N. Masonry Cleaning Compound: As recommended by, and tested by, masonry unit manufacturer.

PART 3 - EXECUTION

3.01 PREPARATION

A. Ensure items built-in by other trades for this work are properly located and sized.

B. Establish all lines, levels and coursing. Protect from disturbance.

C. Provide temporary bracing during erection of masonry work. Maintain in place until building structure provides permanent bracing.

3.02 ERECTION

A. Lay masonry units plumb, level and true to line with accurate coursing.

B. Fully bond external and internal corners and intersections. Stop off horizontal run by racking back in each course; toothing is not permitted.

C. Do not shift or tap masonry units after mortar has taken initial set. Where adjustment must be made, remove mortar and replace.

D. Perform cutting on Project site with proper power tools to provide straight and true, unchipped edges.

E. Ensure masonry courses are of uniform height. Make vertical and horizontal joints equal and of uniform thickness.

F. Lay concrete masonry units in full face bed shelling, except lay bottom course in full mortar bed. 1. Lay concrete block in stacked pattern at decorative concrete masonry units/ common /and running bond pattern for typical concrete masonry units. 2. Butter head joints before placing units. 3. Fill joints without slushing. 4. Remove excess mortar and projections. Take care to prevent breaking block corners.

G. Lay masonry units dry. During prolonged hot and dry periods, units may be lightly dampened if approved by Architect. 1. Do not lay freshly wet masonry, or masonry bearing a film of ice or frost. 2. Lay masonry units with 3/8-inch thick bed and head joints to work to modular dimensions. 3. Provide 1/2-inch joints where required by fire-rated assemblies.

H. Bed and Head Joints for Reinforced (Vertical Bar Reinforcing) and Fire-Rated Partitions: 1. Bed Joints: Lay all courses in full bed of mortar. 2. Head Joints: Apply mortar to vertical face shells on both masonry unit already laid and unit to be laid to ensure full head joint.

I. Build nonbearing partitions to within 3/8-inch of underside of floor, roof deck, or structural system, and fill gap with compressible filler.

J. Fire Rated Units: In locations indicated in Drawings.

K. Tool joints, where exposed to view, to hard concave surface with 5/8-inch radius x 18-inch long steel jointing tool.

L. Flush Cut Mortar Joints: 1. Where resilient floor base is scheduled. 2. Where dampproofing and waterproofing is scheduled. 3. Where concealed by finish materials other than paint. 4. Where walls are to receive direct-applied plaster finishes.

M. Cavity Wall: 1. Do not let mortar fall into cavity air space or plug weep holes; clean out promptly. 2. Install cavity vents and weep holes in veneer at 2U-0" on center horizontally at head joints and sill conditions of openings, in exterior walls at grade, and in other locations where flashing is indicated. Install cavity vents at top of cavity space at same spacing. 3. Install cavity cell vents in veneer at 2U-0" on center vertically at foundations, lintel angles, head joints and sill conditions. 4. Build inner wythe ahead of outer wythe to receive cavity insulation air/vapor barrier adhesive. 5. Where hollow units indicate grout filled, fill maximum every fourth course.

N. Tolerances: 1. Variation From Plumb: Do not exceed 1/4-inch in 10 feet, 3/8-inch in 20 feet or any story height, or 1/2-inch in 40 feet or more. 2. Variation From Level: Do not exceed 1/4-inch in 20 feet or any bay or 1/2-inch in 40 feet or more. 3. Variation From Linear Building Line: Do not exceed 1/4-inch in 20 feet or any bay or 1/2-inch in 40 feet or more. 4. Variation From Cross-Sectional Dimension: Do not exceed minus 1/4-inch or plus 1/2-inch from wall thickness indicated.

3.03 REINFORCEMENT AND ANCHORAGES

A. Horizontal: Reinforce interior and exterior masonry walls and partitions with ladder type reinforcing 1U-4" on center vertically and in alternate concrete masonry unit joints. 1. Provide additional reinforcement spaced 8-inches on center in first and second bed joints above lintels at wall openings. Extend 2U-0" minimum each side of opening. 2. Provide additional reinforcing in bed joint occurring 8-inches below top of walls. 3. Provide continuous prefabricated reinforcement at corners and intersections. 4. Provide ladder type reinforcing with minimum three longitudinal rods at double wythe masonry. 5. Provide ladder type reinforcing with adjustable pintle box ties at double wythe masonry and brick veneer.

B. Vertical: Continuous masonry joint reinforcing at 1U-4" on center, unless indicated otherwise in Drawings. 1. Reinforce interior masonry walls and partitions with #6 bars doweled and epoxied one foot into slab and extending 2U-0" high, spaced 1U-0" on center. 2. Reinforce exterior masonry walls with two #6 bars spaced 2U-8" on center, extended full height of wall. a. Fill cells with 2500 psi concrete. b. Lap all necessary splices 2U-0".

C. Anchors: 1. Anchor concrete masonry walls to abutting concrete walls and columns with dovetail anchors spaced not more than 1U-4" apart vertically. 2. Anchor masonry walls to structural steel columns with flexible column anchors. Weld anchors to columns 2U-8" o.c. on flange. Weld beam anchors 4U-0" o.c. 3. Anchor masonry walls to underside of concrete slab at 1U-4" on centers, unless indicated otherwise in Drawings. 4. Space anchors as indicated but not more than 16-inches o.c. vertically and 32-inches horizontally.

5. Install additional anchors within 12-inches of openings larger than 16-inches in either dimension. Place anchors at intervals around perimeter not exceeding 3U-0" o.c.

D. Reinforce joint corners and intersections with strap anchors 1U-4" on center.

E. Comply with ACI 315 bar schedules, stirrup spacing, bent bars, and arrangement of masonry reinforcing.

3.04 LINTELS

A. Provide reinforced masonry lintels over openings. Construct lintels using concrete and reinforcing specified and indicated in Drawings. 1. Use reinforcing bars of full lengths only. 2. Provide minimum 8-inches bearing at each end.

B. Place and consolidate concrete without disturbing reinforcing.

C. Allow lintels to reach maximum strength before removing temporary supports.

3.05 REINFORCED AND GROUTED COMPONENTS

A. Align vertical unit masonry cells to be filled to maintain clear, unobstructed vertical cell, continuous to foundation. Remove mortar droppings and debris from cells to be grouted.

B. Provide cleanouts at bottom of each vertically reinforced cell, at bottom cell of each pour of grout. Seal cleanouts after inspection of reinforcement, and before grouting begins, with concrete unit masonry or formwork.

C. Place reinforcement in compliance with Drawings, lapping as indicated. Secure at bottom and top and at intervals not exceeding 192 bar diameters.

D. Fill reinforced cells with cement grout in maximum 5U-0" lifts, consolidating by vibrating and rodding.

E. Form horizontal construction joints in grout lifts by stopping grout pour 1-1/2 inches below top of uppermost course in pour.

F. Grout fill cells of the block adjacent to all door jambs, at wall interruptions for structural elements, and at other locations indicated in Drawings.

G. Where units are indicated to be grouted, install wire mesh hardware cloth in cells to prevent migration of grout from masonry units.

3.06 CONTROL JOINTS AND EXPANSION JOINTS

A. Control Joints: Make joints 3/8-inch wide unless indicated otherwise. 1. Do not continue horizontal joint reinforcing across control joints. Stop horizontal joint reinforcement one-inch from control joints. 2. Provide Joints is compliance with Portland Cement Association Handbook (PCA) as follows: a. In running walls spaced maximum 20'-0" o.c. b. At corners, joint located one header or stretcher unit from corner. c. At intersecting walls, either of which is more than 10'-0" long. d. Above joints in foundations and floors and below joints in roofs and floors that bear on masonry walls. e. At abrupt changes in wall height. f. At changes in wall thickness, such as those at pipe or duct chases and those adjacent to columns or pilasters. g. At a distance of not over one-half of the allowable joint spacing from bonded intersections or corners. h. At door and window openings unless other crack control measures are used, such as joint reinforcement or bond beams. 1) At one side of openings less than 6'-0" wide. 2) At both sides of openings greater than 6'-0" wide.

3. Where control joints occur in running walls, provide sash block with rubber control joint filler. 4. Leave joint open and clean for caulking in compliance with Section 07 92 00. Caulk joints exterior and interior.

B. Building Expansion Joints: 1. Make joints one-inch wide, unless otherwise indicated. 2. Keep joint clear of mortar by temporarily filling with polystyrene as wall is laid. 3. Stop horizontal joint reinforcement one-inch from expansion joint. 4. Leave joint open and clean for caulking in compliance with Section 07 92 00.

3.07 BUILT-IN ITEMS

A. As work progresses, build-in hollow metal frames, access doors, steel angle lintels, anchors, sleeves, inserts, boxes, conduit, and other Work to be built into masonry. 1. Tightly enclose sleeves for pipes, ducts and other items which pass through masonry. 2. Verify anchorages embedded in concrete and attached to structural steel members are properly placed. Embed anchorages in every second joint. 3. Embed wall ties in masonry back-up for veneer at maximum 1U-4" on center vertically and 3U-0" on center horizontally. Place at maximum 3-inches on center, each way, around perimeter of openings, within 1U-0" of openings.

B. Hollow Metal Frames: 1. Fill in hollow metal frames solid with mortar grout as walls are constructed. 2. Rake back 1/2-inch joint between hollow metal frame and adjacent masonry to receive sealant. 3. Build-in anchors and enclose floor clips to secure tight, vibration-free frame.

3.08 MASONRY FLASHINGS

A. Extend flashings through veneer, turn up minimum 8-inches and secure to back-up with termination bar.

B. Lap end joints minimum 6-inches and seal watertight.

C. Use flashing manufacturerUs recommended adhesive.

3.09 CLEANING

A. Replacement: Remove and replace masonry units which are loose, chipped, broken, stained or otherwise damaged, or if units do not match adjoining units. Provide new units to match adjoining units and install in fresh mortar or grout, pointed to eliminate evidence of replacement.

B. Pointing: During tooling of joints, enlarge all voids or holes, except weep holes, and completely fill with mortar. Point-up all joints at corners, openings and adjacent work to provide neat, uniform appearance.

C. Cleaning: 1. Clean exposed masonry surfaces as Work progresses as soon as practical after erection. 2. Exercise care to avoid splashing mortar onto masonry and other finished surfaces. a. Remove loose mortar and fins with trowel and stiff fiber brushes. b. Remove mortar droppings and splashed mortar immediately. 3. Thoroughly wash down walls with clean water and leave in proper condition for applied finishes. 4. Thoroughly clean exposed masonry surfaces of efflorescence, stains, discolorations and other blemishes which will mar finished appearance of surfaces. 5. Protect clean surfaces from future soiling and reclean as necessary to leave completed Work in first-class condition.

3.10 PROTECTION

A. Protect partially completed masonry against weather, when work is not in progress, by covering top of walls with strong, waterproof, nonstaining membrane. 1. Extend membrane at least 2'-0" down both sides of walls and anchor securely in place.

B. Provide temporary bracing during erection of masonry work. Maintain in place until building structure provides permanent bracing.

END OF SECTION