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Masonry Restoration for Grafton Water & Wastewater Utility

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Masonry Restoration for Grafton Water & Wastewater Utility Masonry Restoration For Grafton Water & Wastewater Utility Location: 1900 Ninth Avenue – Grafton, WI Description: Tuckpointing brick masonry as necessary Supply and replace spalled/defective brick masonry 100% removal and replacement of all window and door perimeter sealant 100% removal and replacement of all sealant in vertical sealant control joints Caulk perimeter of all metal air vents/intakes Caulk all mortar joints in concrete window sills Rout and caulk all movement / stress cracks in brick masonry Saw cut deteriorated /cracked areas of concrete and patch as necessary TUCKPOINTING SPECIFICATIONS Scope of Work Furnish all materials, equipment, perform all labor and operations to mechanically prepare masonry joints and installation of new mortar to match the existing conditions, coloration and configuration of the surrounding mortar joints and wall surface. Approved Materials Portland Cement Type I Conforming to ASTM C-150 Masonry Aggregate Conforming to ASTM C-144 Color and texture to match existing Hydrated Lime Type S Conforming to ASTM C-207 Colored Mortar Pigments Commercial Iron Oxide, Manganese Dioxide, Chromium Oxide, or Carbon Black, compounded for use in mortar mixes Water Clean and free of deleterious amounts of acids, alkalis or organic materials. Admixtures Coloring admixtures and others are not allowed. Village of Grafton • Water and Wastewater Utility • 1900 Ninth Avenue • Grafton, WI 53024 p (262) 375-5331 • f (262) 375-6938 • [email protected] Mortar Joint Preparation Procedure Grind out the mortar from all head and bed joints between each course of bricks to a minimum depth of three- eighths (3/8”) inch to expose sound unweathered mortar. Remove old mortar utilizing a plugging chisel and mallet or angle grinder. The joint shall be ground out to expose the brick surface on both the top and bottom of the joint. Use care to prevent cracking or damage to the adjacent brick. Brush or vacuum the joints to remove all dirt and loose debris. Dampen the masonry surfaces. The masonry surface should be sufficiently dampened so that the newly installed mortar will not crack due to lack of moisture. Mortar Mixing Type N mortar shall be proportioned by one (1) part by volume of Portland cement, one (1) part by volume of hydrated lime, and sand (measured in a damp, loose condition) not less than two and one-quarter (2-1/4”) and not more than three (3) times the sum of the volume of cement and lime used, mixed with sufficient water. Mortar shall be mixed utilizing warm sand, aggregate and water when temperatures are below 45 degree F. during placement and troweling. Mix the mortar thoroughly adding only enough water to produce a damp mix which will retain its form when compressed into a ball. Maintain the mortar in this dampened condition for approximately one (1.0) hour for pre-hydration of the cementitious materials to reduce shrinkage. Add water to the mortar after this initial period to obtain a workable consistency. Do not use any admixtures of any kind. Samples of the mixed mortar shall be applied to the prepared wall joints to determine proper coloration to match remaining weathered mortar. The Contractor shall adjust his mix, aggregate, etc. to, as much as is possible, match the existing mortar joints throughout the wall area. All tuckpointing shall be used within two and one-half (2-1/2) hours of its original mixing and within one (1) hour of adding water to bring the mortar to working consistency. Re-tempering the mortar shall be permitted within these time parameters. All tuckpointing mortar not used within two and one-half (2-1/2) hours after initial mixing shall be discarded. Mortar Installation Procedure New mortar will be installed in all prepared mortar joints. The contractor shall be required to apply samples for color and texture match to be selected by the Building Owner. Apply the first layer of pointing mortar to areas where the existing mortar has been removed to a minimum depth of 5/8 inch. The mortar shall be applied in layers not greater than one-quarter (1/4) inch until a uniform depth is obtained. Compact each layer thoroughly and allow the mortar to become thumbprint hard before applying the next layer. After joints have been filled to a uniform depth with the first layer, the Contractor will continue to apply the second and third (final) layer to complete filling the joint. Fully compact each layer and allow to become thumbprint hard before applying the next layer. Where existing bricks have a slightly rounded face, recess the final layer of mortar from the face. Do not spread or feather edge the mortar over the masonry surface. When the final application of mortar is thumbprint hard, all mortar joints must be tool finished with the appropriate convex pointing trowel. Tool the mortar to create a slight concave recess from the surface of the brick. Joint finish and design shall approximate the surrounding joints on existing construction. Mortar joints shall be finished to match the original appearance of the joints. All head and bed joints shall be struck and finished to provide a uniform appearance. Remove excess mortar from the edge of the joint with a wire or nylon brush. Cure the mortar in a dampened condition for a period of not less than seventy-two (72) hours. All tuckpointing mortar must be allowed to cure for a minimum of thirty (30) days prior to chemical or pressure washing. CAULKING SPECIFICATION Product: Tremco Dymonic FC Description: A reactive oligomeric, low modulus, one-component, polyurethane joint sealant. Dymonic FC is specifically developed for sealing dynamically moving joints such as expansion and control joints, curtain wall joints and perimeter caulking (windows, doors, panels). Application: Joint surfaces receiving sealant must be clean, dry, and free from oil, loose mortar, laitance, waterproofing and other contaminants. After proper “surface preparation”, all surfaces (both metal and masonry) must be conditioned with Tremco 200 Cleaner immediately prior to application of Dymonic FC. Fill joints completely and tool immediately. Proper width-to-depth ratios must be maintained. CONCRETE RESTORATION SPECIFICATION ON TOP OF DIGESTER TANKS Product: SIKA TOP 122 Scope of Work Saw cut perimeter (key cut) of all cracked, unsound and delaminating areas of concrete a minimum of 1 ½” – 2” deep, using care not to damage embedded reinforcing steel. Concrete removal should be performed to a roughly uniform depth. This will necessitate removing both sound and unsound concrete from repair opening. Concrete removal should include chipping around all reinforcing steel exposed in the repair opening to create a ½ inch gap around the bar. Proper surface preparation of the exposed concrete and steel surfaces is essential for a durable repair. Extensive cleaning of steel will occur using an electric grinder with a wire wheel. Pins will be installed to help anchor the repair material. Pins will consist of ¼ inch diameter L-shaped stainless steel threaded rods anchored into the concrete substrate with epoxy, or stainless steel wedge or hammer-lock type anchors. Patch areas with latex modified patching compound SIKA TOP 122 Plus. Prime surfaces per manufacturer’s specifications. BRICK REPLACEMENT SPECIFICATIONS Scope of Work Mechanically grind out and carefully remove all cracked, broken and spalled brick units. Cut out full units from joint to joint in a manner to permit replacement with full size units and full size mortar joints. Support and protect remaining masonry that surrounds removal area. Fit replacement unit into bonding and coursing pattern of existing units. Lay replacement units with completely filled bed, head and collar joints. Butter ends with sufficient mortar to fill all sides. Maintain joint width to match existing Tool mortar joints in repaired areas to match adjacent profile..
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