SECTION 04200 UNIT MASONRY 00000000PART 1 - GENERAL 1.1 SECTION INCLUDES A. 1.

2 Concrete unit masonry and related accessories for walls and partitions as indicated on Drawings.

REFERENCES A. SASO - Saudi Arabian Standards Organization: SASO 87 Bricks and Blocks SASO 145 SASO 144/1979 SASO 186 SASO 184/1980 SASO 185/1980 SASO 227/1981 SASO 1580/1999 B. Methods of Test for Concrete Building Concrete Hollow Blocks for Building

Solid concrete (Cement) building bricks. Hollow Blocks Made From Burnt Clay Methods of test for bricks & blocks made from burnt clay. Bricks made from burnt clay Methods of testing test sieves. Lightweight Aggregates for concrete.

ASTM - American Society for Testing and Materials: ASTM A 82 Specification for Cold-Drawn Steel Wire for Concrete Reinforcement

ASTM A 153 Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware ASTM C 33 ASTM C 90 Specification for Concrete Aggregates Specification for Hollow Load-Bearing Concrete Masonry Units

ASTM C 144 Specification for Aggregate for Masonry Mortar ASTM C 150 Specification for Portland Cement ASTM C 207 Specification for Hydrated Lime for Masonry Purposes ASTM C 270 Specification for Mortar for Unit Masonry ASTM C 426 Drying Shrinkage of Concrete Block ASTM E 149 Bond Strength of Mortar to Masonry Units

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1.3

ICBO - International Conference of Building Officials: UBC Uniform Building Code

1.4

SUBMITTALS A. Product Data: Submit manufacturer's product data, including laboratory test reports for each type of concrete masonry unit, accessories and other manufactured products, as well as certifications of compliance with the specified requirements for each type. Shop Drawings: Submit cutting and setting drawings for trim units showing sizes, profiles and locations of each unit required. Samples: Submit concrete unit masonry samples showing color and texture as well as ties and anchors for the Engineer selection and approval.

B. C. 1.5

TRANSPORTATION, HANDLING AND STORAGE A. Deliver masonry materials to site in an undamaged condition marked with name of manufacturer and identification of contents. Store masonry materials under waterproof covers on planking clear of ground and protected from damage, dirt, stain, water and wind.

1.6

QUALITY ASSURANCE A. Engage a commercial testing laboratory approved by the Engineer to perform tests as specified below at no extra cost to Owner. Submit information regarding testing laboratory and qualifications of technical personnel to the Engineer for approval. Tests: Testing laboratory shall test mortar materials, mortar and masonry panels as specified. Certified test reports shall identify materials by type, brand name and manufacturer and/or by origin. Use no mortar materials until laboratory test reports are approved by the Engineer. After tests have been made and materials approved, no changes shall be made without additional test and approval of the Engineer. Testing: Materials proposed for use shall be tested for compliance with specifications in accordance with test methods contained in the referenced specifications and as follows: 1. Mortar Type N: Test for compressive strength and water retention. Mortar Type N shall have a compressive strengths at 7 days and 28 days as follows: 2. D. 3.10 MPa at 7 days 5.17 MPa at 28 days

B.

C.

Concrete Unit Masonry: Test for compressive strength, weight and water absorption.

Mock-Up: Before starting masonry work, construct sample panel 3 m long by 2 m high for the Engineer's approval.

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1.7

JOB CONDITIONS A. Protect partially completed masonry against weather, when work is not in progress, by covering top of walls with strong, waterproof, non-staining membrane. Extend membrane at least 600 mm down both sides of walls and anchor securely in place.

PART 2 - PRODUCTS 2.1. MATERIALS A. Concrete Unit Masonry: 1. Manufacturer: Obtain concrete masonry units from one manufacturer, of uniform texture and color for each kind required for each continuous area and visually related areas. Hollow Concrete Unit Masonry: Conform to SASO 87, SASO 145 or ASTM C 90, Type 1, normal weight and shall be of regular standard nominal sizes not less than 400 x 200 mm with standard widths as shown on the Drawings and permissible variations in dimensions of individual units not more than plus or minus 4 mm. Minimum thickness of face shell (FST)/web (WT) shall be 35 and 29 mm, respectively. Provide units with a compressive strength of not less than 11.7 MPa, oven-dried weight (concrete) over 2000 kg/m and water absorption of maximum 25 percent by weight for individual block. Provide half units for ends. Special Shapes: Provide where shown and where required for lintels, corners, jambs, sash, control joints, headers, bonding and other special conditions. Exposed Face: Provide manufacturer's standard color and texture unless otherwise indicated. Field Testing: Tests of concrete masonry units shall be completed in accordance with ASTM C 140 prior to installation of masonry.

2.

3.

4. 5. B.

Mortar and Grout Materials: 1. 2. 3. 4. 5. Portland Cement: ASTM C 150, Type I. Provide natural color cement as required to produce the required mortar color. Hydrated Lime: ASTM C 207, Type S. Sand (for Mortar): ASTM C 144, except for joints less than 6 mm use aggregate graded with 100 percent passing the No. 16 sieve. Fine Grout: Consist of fine aggregate conforming to ASTM C 404, size No. 1. Use fine grout in cells containing pipes and conduits. Coarse Grout: Consist of fine and coarse aggregates conforming to ASTM C 404, size No. 89.

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6. C.

Water: Clean, potable and free of deleterious materials.

Mortar and Grout Mixes: 1. Measurement: Use methods which will ensure that required proportions are controlled and accurately maintained. Measure aggregate materials in a damp, loose condition. Mortar: Comply with ASTM C 270, Type N for interior and Type S for exterior. Grout: Comply with ASTM C 476; grout to be used in cores where reinforcements are placed. Mixing: Combine and mix cement, lime, water, and aggregates for a minimum of 5 minutes in a mechanical batch mixer. Do not add air-entraining agents or other admixtures to mortar or grout materials unless otherwise indicated on Drawings or instructed by the Engineer. Do not use calcium chloride in mortar or grout.

2. 3. 4. 5.

6. D.

Reinforcing Bars: 1. Reinforcing bars shall conform to ASTM A 615, Grade 60, deformed; sizes as indicated on Drawings.

E.

Masonry Accessories: 1. Joint Reinforcement and Ties for Masonry: a Provide welded wire units from cold-drawn steel wire complying with ASTM A 82, with deformed continuous side rods and plain cross-rods, and a unit width of 38 mm to 50 mm less than thickness of wall or portion. Reinforcement shall be hot-dip galvanized after fabrication with 22 grams zinc-coating conforming to ASTM A 116, Class 3. Provide type of reinforcement as follows with 3.76 mm single pair of side rods: 1) 2) 2. Ladder design with perpendicular 3.76 mm cross rods spaced not more than 400 mm on center. Truss design with 3.76 mm continuous diagonal cross rods spaced not more than 400 mm on center.

Anchoring Devices for Masonry: Provide straps, bars, bolts and rods fabricated from not less than 3.76 mm sheet metal or 10 mm diameter rod stock, unless otherwise indicated. Concrete Inserts for Masonry: a Unit Type: Furnish cast iron or malleable iron inserts of the type and size shown, hot-dip galvanized after fabrication with 44 grams zinc

3.

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coating, ASTM A 153, Class B 2. b c Dovetail Slots: Where shown, furnish dovetail slots with filler strips, hot-dip galvanized as above. For installation of concrete inserts refer to the concrete Sections of these Specifications as well as the specific requirements of the concrete installer regarding placement of inserts which are to be used by the masonry installer for anchoring of masonry work.

4.

Pre-molded Control Joint Strips: Solid rubber strips with a durometer hardness of 60 to 80 as determined by ASTM D 2240, designed to fit standard sash block and maintain lateral stability in masonry wall, size and configuration as indicated.

PART 3 - EXECUTION 3.1 INSTALLATION A. B. Installation: Conform to the requirements of latest edition of UBC. Thickness: Build masonry construction to full thickness shown on Drawings. Build single-width walls to the actual thickness of the masonry units, using units of nominal thickness indicated. Build chases and recesses as shown or required to accommodate items specified in this and other Sections of the Specifications. Provide not less than 200 mm of masonry between chase or recess and jamb of openings and between adjacent chases and recesses. Cut masonry units with motor-driven saws to provide clean, sharp, un-chipped edges. Cut units as required to provide continuous pattern and to fit adjoining construction. Use full-size units without cutting where possible. Units erected when the ambient air has a temperature of more than 42 oC in the shade and a relative humidity of less than 5% shall be protected from direct exposure to wind or sun for 48 hours after construction. Absorption rates of masonry units shall be adjusted by previously wetting to ensure a good solid bond with the mortar. Bond Pattern for Exposed Masonry: Lay exposed masonry in the bond pattern shown, or if not shown, lay in running bond with vertical joint in each course centered on units in courses above and below. Bond and interlock each course of each width at corners, unless otherwise shown. Lay-up walls to comply with specified construction tolerances, with courses accurately spaced and coordinated with other construction. Stopping and Resuming Work: In each course, rack back 1/2-unit length for onehalf running bond or 1/3-unit length for one-third running bond; do not tooth. Clean exposed surfaces for set masonry, and remove loose masonry units and mortar prior to laying fresh masonry. Built-In Work: As construction progresses, build-in items specified under this and
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C.

D.

E.

F.

G. H.

I.

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other sections of the specifications. Fill in solidly with masonry around built-in items. 1. 2. Fill space between hollow metal frames and masonry solidly with mortar. Where built-in items are to be embedded in the cores of hollow masonry units, place a layer of metal lath in the joint below and rod mortar or grout into core.

J. K.

Non-Bearing Interior Partitions Walls: Build full height of story to underside of structure above, unless otherwise shown. Mortar Bedding and Jointing: 1. 2. Mortar Mixes: ASTM C 270, Proportion Specifications Type N. Mix mortar ingredients for minimum of 5 minutes in a mechanical batch mixer. Use water clear and free of deleterious materials which would impair the work. Do not use mortar which has begun to set, or if more than 1 hour has elapsed since initial mixing. Re-temper mortar during 1 hour period as required to restore workability. Lay solid masonry units with completely filled bed and head joint; butter ends with sufficient mortar to fill head joints and shove into place. Do not slush head joints. Lay hollow concrete masonry units with full mortar coverage on horizontal and vertical face shells; also bed webs on mortar in starting course on footings and foundation walls and in all courses of piers, columns and pilasters, and where adjacent to cells or cavities to be reinforced or to be filled with concrete or grout. Joints: Maintain joint width as shown, except for minor variations required to maintain bond alignment. If not shown, lay walls with 10 mm joints. Cut joints flush for masonry walls which are to be concealed or to be covered by other materials. Tool exposed joints slightly concave. Rake out mortar in preparation for application of caulking or sealant where shown. Remove masonry units disturbed after laying; clean and relay in fresh mortar. Do not pound corners at jambs to fit stretcher units which have been set in position. If adjustments are required, remove units, clean off mortar, and reset in fresh mortar.

3.

4.

5.

6.

L.

Horizontal Joint Reinforcement: 1. Provide continuous horizontal joint reinforcement as shown and as specified. Fully embed longitudinal side rods in mortar for their entire length with a minimum cover of 15 mm on exterior side of wall and 12 mm at other locations. Lap reinforcement a minimum of 150 mm at ends of units. Do not bridge control and expansion joints with reinforcing except at wall openings. Provide continuity at corners as well as wall intersections by using prefabricated L-sections and T-sections. Cut and bend unit as directed by manufacturer for continuity at returns, offsets, and other special conditions. For single-width walls, space continuous horizontal reinforcement at 400 mm on center, unless otherwise indicated on Drawings.

2.

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3.

Reinforce masonry openings greater than 300 mm wide, with horizontal joints approximately 200 mm apart, above the lintel and below the sill of the opening. Extend reinforcement a minimum of 600 mm beyond jambs of the opening, bridging control joints where provided.

M.

Control Joints: 1 2 Provide control joints in block partitions, finished or unfinished at not more than 6 m on centers unless indicate otherwise on Drawings. Control joints shall be vertical unbonded joints, maximum 9.5 mm wide, extending full height of the masonry work. Bond shall be broken with building paper placed against one face of joint with no mortar placed in continuous height of void. Control joint material shall be expandable closed cell neoprene conforming to ASTM D 1056, 38 mm deep and 25 percent thicker before compression than joint width. Top dress control joints with a sealant conforming to the requirements of Section 07900 - SEALANTS. Color of sealant shall be as selected and approved by the Engineer.

O.

Anchoring Masonry Work: 1. 2. Provide anchoring devices of types shown and as specified. If not shown or specified, provide standard type for facing and back-up involved. Anchor masonry to structural members where masonry abuts or faces such members to comply with the following: a Provide an open space not less than 12 mm in width between masonry and structural member, unless otherwise shown and keep space free of mortar or other rigid materials. Anchor masonry to structural members with metal ties embedded in masonry joints and attached to structure. Provide anchors with flexible tie sections, unless otherwise shown. Space anchors at no more than 600 mm on center vertically and 900 mm on center horizontally.

c P. Lintels: 1.

Provide masonry lintels where shown and wherever openings of more than 300 mm for brick size units and 600 mm for block size units are shown without structural steel or other supporting lintels. Provide precast or formed-in-place masonry lintels. Thoroughly cure precast lintels before handling and installation. Support formed-in-place lintels temporarily.

2. 3.

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4.

Unless otherwise shown, provide one reinforcing bar for each 100 mm of wall thickness and of a size number not less than three times the number of meter of opening width. For hollow masonry unit walls, use specially formed U-shaped lintel units with reinforcing bars placed as shown and filled with Type M mortar or coarse grout. Provide minimum bearing at each jamb of 200 mm or as indicated on the Drawings.

5.

6. 3.2

REPAIR, POINTING AND CLEANING A. Remove and replace masonry units which are loose, chipped, cracked, broken, stained or otherwise damaged, or if units do not match adjoining units as intended. Provide new units to match adjoining units and install in fresh mortar or grout, pointed to eliminate evidence of replacement. During tooling of joints, enlarge any voids or holes, except weep holes, and completely fill with mortar. Point-up joints at corners, openings and adjacent work to provide a neat, uniform appearance, properly prepared for application of caulking sealant compounds. Clean exposed concrete masonry units by dry brushing at the end of each day and after final pointing to remove mortar spots and drippings.

B.

C. 3.3

CURING A. When temperature exceeds 25 oC and where construction of a masonry wall is complete, cure mortar by covering the wall unit with wet burlap, jute sack or similar material for a minimum of two days. END OF SECTION

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