SECTION 04200 UNIT MASONRY WORK

PART 1 - GENERAL 1.1 A. DESCRIPTION OF WORK The extent of each type of unit masonry work shall be as shown on the drawings. QUALITY ASSURANCE Fire-Rated Masonry: Wherever a fire-resistance classification is shown or scheduled for unit masonry construct-ion (4 hours, 3 hours, and similar designations), comply with the requirements for materials and installation established by the American Insurance Association and other governing authorities for the construction shown. Construction Tolerances: Lay-up all walls and partitions plumb and true with courses level and accurately spaced and coordinated with other work. Variations from plumb, true or level of more than 3 mm in 2400 mm in any direction are unacceptable. Job Mock-up: Prior to installation of masonry work, erect sample wall panel mock-up using materials, bond and joint tooling shown or specified for final work. Provide special features as directed for caulking and contiguous work. Build mock-up at the site, where directed, of full thickness and approximately 1200 mm x 900 mm, unless otherwise shown, indicating the proposed range of color, texture, and workmanship to be expected in the completed work. Obtain MARAFIQ's acceptance of visual qualities of the mock-up before start of masonry work. Retain mock-up during construction as a standard for judging completed masonry work. Do not alter, move or destroy mock-up until work is completed. Provide mock-up panel for the following: 1. 2. D. 1.3 A. Siporex -fair faced. Typical interior partition of concrete masonry units.

1.2 A.

B.

C.

Sample and test concrete masonry units in accordance with ASTM C140. SUBMITTALS Product Data: Submit manufacturer's specifications and other data for each type of masonry unit and accessory required including certification that each type complies with the specified requirements. Include instructions for handling, storage, installation and protection of each. Indicate by transmittal that the installer has received a copy of each instruction.

P.O. Number : 7200018725

B. Samples: Submit samples of each type of exposed brick required. Include in each set the full range of exposed color and texture to be expected in the completed work. MARAFIQ's review will be for color and texture only. Compliance with all other requirements is the exclusive responsibility of the Contractor. 1.4 B. JOB CONDITIONS Protect partially completed masonry against weather, when work is not progress, by covering top of walls with strong, waterproof, nonstaining membrane. Extend membrane at least 600 mm down both sides of walls and anchor securely in place.

PART 2 - PRODUCTS 2.1. A. GENERAL Proprietary names used for materials are intended to imply that products of the named Saudi manufacturers are required. Equivalent products of other manufacturers may only be used where local supply is not available. MASONRY UNITS Manufacturer: Obtain masonry units from approved manufacturer, of uniform texture and color for each kind required, for each continuous area and visually related areas. Concrete Masonry Units. General: 1. Size: Manufacturer's standard units with nominal face dimensions of 400mm long x 200mm high x 200mm wide (390mm x 190mm x 190mm actual) and, 600mm long x 250mm high x 500mm wide actual size/ standard dimension. Special Shapes: Provide where shown and where required for lintels, corners, jambs, sash, control joints, headers, bonding and other special conditions. Hollow Load-bearing: Provide units complying with ASTM C90 of the following grade. 1. 2. 4. 5. Grade N. Grade S.

2.2 A.

B.

2.

3.

Hollow Non-Load-Bearing: Provide units complying with ASTM C129. Siporex lightweight blocks shall have a minimum compressive strength of 35 kg/cm2, a nominal density of 550 kg/m3 and a thermal conductivity factor of K=0.14 watt/mC.

P.O. Number : 7200018725

C.

Curing: 1. Cure units in a moisture-controlled atmosphere or in an autoclave at normal pressure and temperature to comply with ASTM C90 Type I.

D.

Exposed Face: 1. Provide manufacturer's standard color and texture, unless otherwise indicated.

2.3 A.

MORTAR MATERIALS Portland Cement: ASTM C150, Type I. Provide natural color or white cement as required to produce the required mortar color. Hydrated Lime: ASTM C 207, TYPE S. Sand: ASTM C144, except for joints less than 6 mm, use aggregate graded with 100% passing the No. 16 sieve. Mortar for Siporex lightweight blocks shall be 1:6 cement sand with gesol as recommended by Siporex. MASONRY ACCESSORIES Continuous Wire Reinforcing and Ties for Masonry: 1. Provide welded wire units prefabricated in straight lengths of not less than 3 m, with matching corner and tee units. Fabricate from cold-drawn steel wire complying with ASTM A82, with deformed continuous side rods and plain cross-rods, crimped for cavity wall construction (if any), and a unit width of 38 mm to 50 mm less than thickness of wall or portion. Provide units fabricated as follows: a. Truss type fabricated with single pair of 3.76 mm (9 gage) side rods and 3.76 mm (9 gage) continuous diagonal cross-rods spaced not more than 400 mm on center.

B. C.

D.

2.4 A.

2.

B.

Anchoring Devices for Masonry: 1. Provide straps, bars, bolts and rods fabricated from not less than 1.52 mm (16 gage) sheet metal or 9 mm diameter rod stock, unless otherwise indicated.

C.

Concrete Inserts for Masonry: 1. Dovetail Slots: Furnish dovetail slots with filler strips, where shown.

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a.

Fabricate from 0.61 mm (24 gage) galvanized steel unless otherwise indicated.

D. 1. E.

Flashings for Masonry: Provide concealed flashings, shown to be built into masonry. Miscellaneous Masonry Accessories: 1. Reinforcing Bars: Deformed steel, ASTM A615, Grade 60 of the sizes shown.

PART 3 - EXECUTION 3.1 A. INSPECTION Examine the areas and conditions under which masonry is to be installed. Do not proceed with the work until unsatisfactory conditions have been corrected. INSTALLATION, GENERAL Thickness: Build masonry construction to the full thickness shown, except, build single-wythe walls (if any) to the actual thickness of the masonry units, using units of normal thickness shown or specified. Build chases and recesses as shown and as required for the work of other trades. Provide not less than 200 mm of masonry between chase of recess and jamb of openings, and between adjacent chases and recesses. Cut masonry units with motor-driven saw designed to cut masonry with clean, sharp, unchipped edges. Cut units as required to provide pattern shown and to fit adjoining work neatly. Use full units without cutting wherever possible. Do not wet concrete masonry units. If the supplier recommend that the units be damp at erection this must be done in strict accordance with the manufacturers recommendation. Pattern Bond: 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. Lay concealed masonry with all units in a wythe bonded by lapping not less than 50 mm. Bond and interlock each course of each wythe at corners, unless otherwise shown. Layout walls in advance for accurate spacing of surface bond patterns, with uniform joint widths and to properly 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. Lay-up walls plumb and true and with courses level, accurately spaced and coordinated with other work.

3.2 A.

B.

C.

D.

E.

F.

G.

P.O. Number : 7200018725

H.

Stopping and Resuming Work: 1. As the work progresses, build-in items specified under this and other sections of these specifications. Fill in solidly with masonry around builtin items. a. Fill space between hollow metal frames and masonry solidly with mortar.

I.

Intersecting Load-bearing Walls: If carried up separately, block vertical joint with 200 mm maximum offsets and provide rigid steel anchors spaced not more than 1200 mm on center vertically, or omit blocking and provide rigid steel anchors at not more than 600 mm on center vertically. Form anchors of galvanized steel not less than 38 mm x 6 mm x 50 mm long-with ends turned up not less than 50 mm or with cross-pins. If used with hollow masonry units, embed ends in mortar filled cores. Non-bearing Interior Partition Walls: Build full height of story to underside of structure above, unless otherwise shown. Mortar Bedding and Jointing: 1. Mortar Mixes: ASTM C270, Proportion Specifications, and of the following type: a. b. 2. Type S for exterior work. Type N for interior work.

J.

K.

Mix mortar ingredients for a minimum of 5 minutes in a mechanical batch mixer. User 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 hours has elapsed since initial mixing. Retemper mortar during 1 hours period as required to restore workability. Where gesol additive is used it shall be mixed and the mortar laid in accordance with the manufacturers requirements. Lay hollow concrete masonry units with full mortar coverage on horizontal and vertical face shells; also bed webs in 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 widths shown, except for minor variations required to maintain bond alignment. If not shown, lay walls with 9 mm joints. Tool joints then cut 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 sealants where shown.

3.

4.

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5.

Remove masonry units disturbed after lying; 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. Collar Joints: Fill joints between wythes solidly with mortar by parging either the back of the facing, or the face of the backing, and shove units solidly into parging.

6.

L. Horizontal Joint Reinforcing: 1. Provide continuous horizontal joint reinforcing as shown and specified. Fully embed longitudinal side rods in mortar for their entire length with a minimum cover of 15 mm on exterior side of walls 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 and wall intersections by use of prefabricated "L" and "T" sections. Cut and bend unit as directed by manufacturer for continuity at returns, offsets, column fireproofing, pipe enclosures, and other special conditions. Reinforce masonry openings greater than 300 mm inches wide, with horizontal joints approximately 200 mm apart, both immediately above the lintel and immediately below the still. Extend reinforcing a minimum of 600 mm beyond jambs of the opening, bridging control joints where provided.

2.

M.

Anchoring Masonry Work: 1. Provide anchoring devices of the type 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. Keep open 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 as shown, but not more than 600 mm on center vertically and 900 mm on center horizontally.

2.

b.

c.

N.

Lintels: 1. Install loose lintels of steel and other materials where shown.

P.O. Number : 7200018725

2.

Provide masonry lintels where shown and where openings of more than 300 mm 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. Temporarily support formed-in-place lintels.

O.

Control and Expansion Joints: 1. Provide vertical expansion, control and isolation joints in masonry where shown. Build-in related masonry accessory items as the masonry work progresses. Rake out mortar in preparation for application of caulking and sealants. Refer to Section 07920 "Sealants and Caulking." a. Build flanges of metal expansion strips into masonry. Lap each joint 100 mm in direction of flow. Solder joints below grade and at junctures with horizontal expansion joints, if any. Build-in joint fillers where shown, specified in Section 07910.

b. 2.

If location of control joints is not shown, place vertical joints spaced not to exceed 15 m on center between joints for clay masonry or 10.5 m on center for concrete masonry wythes if reinforced, or 9 m on center if not reinforced. Locate control joints at points of natural weakness in the masonry work.

P.

Flashing of Masonry Work: 1. Provide concealed flashings in masonry work as shown. Prepare masonry surfaces smooth and free from projections which might puncture flashing. Place through-wall flashing on bed of mortar and cover with mortar. Seal flashing penetration with mastic before covering with mortar. Terminate flashing 12 mm from face of wall, unless otherwise shown. Extend flashings beyond edges of lintels and sills (if any) at least 100 mm and turn up edge on sides to form pan to direct moisture to exterior. Provide weep holes in the head joints of the first course of masonry immediately above concealed flashings, spaced 600 mm on center, unless otherwise shown. a. 2. Install flashings in accordance with manufacturer's instructions.

Install reglets and nailers for flashing and other related work where shown to be built into masonry work.

3.3 A.

REPAIR, POINTING, AND CLEANING Remove and replace masonry units which are loose, chipped, 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.

P.O. Number : 7200018725

B.

During the tooling of joints, enlarge any voids or holes, except weep holes, and completely fill with mortar. Point-up all joints at corners, openings and adjacent work to provide a neat, uniform appearance, properly prepared for application of caulking or sealant compounds.

++ END OF SECTION 04200 ++

P.O. Number : 7200018725