SECTION 04 21 00

CLAY UNIT MASONRY

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PART 1    GENERAL
1.1	SECTION INCLUDES
A.	Clay masonry units and accessories including:
1.	Facing brick.
2.	Hollow brick. 
3.	Thin veneer brick. 
4.	Ceramic glazed brick. 
5.	Special shapes. 
B.	Steel reinforcement 
C.	Anchors and ties.
D.	Flashing. 
E.	Expansion joints. 
F.	Weepholes. 
G.	Mortar.
1.2	PRODUCTS INSTALLED BUT NOT FURNISHED UNDER THIS SECTION
A.	Section 03 30 00 - Cast-in-Place Concrete.
B.	Section 04 20 00 - Unit Masonry.
C.	Section 05 50 00 - Metal Fabrications.
D.	Section 07 25 00 - WeatherBarriers.
E.	Section 07 60 00 - Flashing and Sheet Metal.
1.3	RELATED SECTIONS
A.	Section 03 30 00 - Cast-in-Place Concrete.
B.	Section 03 45 13 - Faced Architectural Precast Concrete.
C.	Section 04 20 00 - Unit Masonry.
D.	Section 05 12 13 - Architecturally-Exposed Structural Steel Framing.
E.	Section 05 40 00 - Cold-Formed Metal Framing.
F.	Section 05 50 00 - Metal Fabrications.
G.	Section 06 10 00 - Rough Carpentry.
H.	Section 07 10 00 - Dampproofing and Waterproofing.
I.	Section 07 25 00 - WeatherBarriers.
1.4	REFERENCES
A.	ASTM International (ASTM):
1.	ASTM A36 - Standard Specification for Carbon Structural Steel.
2.	ASTM A82 - Standard Specification for Steel Wire, Plain, for Concrete Reinforcement.
3.	ASTM A153 - Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware.
4.	ASTM A615 - Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement.
5.	ASTM A775 - Standard Specification for Epoxy-Coated Steel Reinforcing Bars.
6.	ASTM A996 - Standard Specification for Rail-Steel and Axle-Steel Deformed Bars for Concrete Reinforcement.
7.	ASTM B370 - Standard Specification for Copper Sheet and Strip for Building Construction.
8.	ASTM C67 - Standard Test Methods for Sampling and Testing Brick and Structural Clay Tile.
9.	ASTM C126 - Standard Specification for Ceramic Glazed Structural Clay Facing Tile, Facing Brick, and Solid Masonry Units. 
10.	ASTM C216 - Standard Specification for Facing Brick (Solid Masonry Units Made from Clay or Shale).
11.	ASTM C270 - Standard Specification for Mortar for Unit Masonry.
12.	ASTM C652 - Standard Specification for Hollow Brick (Hollow Masonry Units Made from Clay or Shale).
13.	ASTM C1088 - Standard Specification for Thin Veneer Brick Units Made from Clay or Shale.
14.	ASTM C1405 - Standard Specification for Glazed Brick (Single Fired, Brick Units). 
15.	ASTM D1056 - Standard Specification for Flexible Cellular Materials - Sponge or Expanded Rubber.
1.5	SUBMITTALS
A.	Submit under provisions of Section 01 30 00 - Administrative Requirements.
B.	Clay Brick: Manufacturer's letter of certification, including: 
1.	Test reports. 
2.	Cleaning recommendations. 
C.	Other Product Data: Manufacturer's data sheets on each product to be used, including:
1.	Preparation instructions and recommendations.
2.	Storage and handling requirements and recommendations.
3.	Installation methods.
D.	Samples: Furnish not less than five individual brick as samples, showing extreme variations in color and texture.
E.	Sample Panel: Mock-up or sample panels shall be used to review brick and mortar color and serve as the standard of workmanship for the Project.
1.	Approximately 4 feet (1.2 m) long by 3 feet (1 m) high, showing the proposed color range, texture, bond, mortar, and workmanship. Use all the brick shipped for the sample in assembling the sample panel.
2.	When required, provide a separate sample panel for each type of brick or mortar.
3.	Do not start work until the Architect/Engineer has accepted the sample panel.
4.	Use panel as a standard of comparison for all masonry work built of the same material.
5.	Do not destroy or move the panel until work is completed and accepted by Architect.
1.6	QUALITY ASSURANCE
A.	Manufacturer Qualifications: Minimum 5 years manufacturing similar products.
B.	Installer Qualifications: Minimum 2 years installing similar products.
C.	Brick Tests: Sample and test shall be in accordance with ASTM C67.
D.	Test Reports:
1.	An independent laboratory shall complete testing and reports.
2.	Test reports for each type of building and facing brick shall be submitted to the Architect/Engineer for review.
3.	Test reports shall indicate:
a.	Compressive strength.
b.	24-hour cold water absorption.
c.	5-hour boil absorption.
d.	Saturation coefficient.
e.	Initial rate of absorption.
f.	Efflorescence.
g.	For Glazed Brick: 
1)	Imperviousness. 
2)	Resistance to fading. 
3)	Resistance to crazing. 
4)	Scratch resistance and hardness. 
5)	Opacity. 
E.	Certificates: Before delivery, submit to Architect/Engineer certificates attesting compliance with the applicable specifications for grades, types, or classes included in these specifications.
F.	Costs of Tests: The cost of tests shall be borne by the purchaser unless tests indicate that units do not conform to the requirements of the specifications, in which the seller shall pay the case cost.
G.	Prism Tests: Prism Tests shall be required when using engineered masonry (f 'm) =________psi).
1.7	DELIVERY, STORAGE, AND HANDLING
A.	Store products in manufacturer's unopened packaging until ready for installation.
B.	Store brick off the ground to prevent contamination by mud, dust, or other materials likely to cause staining or other defects.
C.	Cover all materials with a non-staining waterproof membrane material when necessary to protect from elements.
D.	Store different types of materials separately.
1.8	ALLOWANCES
A.	Allowance includes the purchase of brick, taxes, delivery, and any special handling charges.
B.	Special shaped brick units shall have a separate allowance.
1.9	PROJECT CONDITIONS
A.	Protection of Work:
1.	Wall Covering:
a.	During construction, cover the top of the wall with a durable non-staining waterproof membrane at the end of each day or shutdown.
b.	Cover partially completed walls when work is not in progress.
c.	Extend cover minimum of 24 inches (610 mm) down both sides.
d.	Hold the cover securely in place.
2.	Load Applications:
a.	Do not apply uniform floor or roof loading for at least 12 hours after building masonry columns or walls.
b.	Do not apply concentrated loads for at least three days after building masonry columns or walls.
3.	Stain Prevention:
a.	Prevent grout or mortar from staining the face of the masonry.
b.	Remove grout or mortar immediately in contact with the face of such masonry.
c.	Protect all sills, ledges, and projections from droppings of mortar.
d.	Protect the base of the wall from rain-splashed mud and mortar splatter.
e.	Scaffold boards shall be turned on edge when work is not in progress.
B.	Cold Weather Protection:
1.	Preparation:
a.	When ice or snow has formed on the masonry bed, remove by carefully applying heat not to exceed 120 degrees F (49 degrees C) until the surface is dry to the touch.
b.	Remove all masonry deemed frozen or damaged.
2.	Products:
a.	When brick suction exceeds BIA reference standard, sprinkle with heated water:
1)	When units are above 32 degrees F (0 degrees C), heat water above 70 degrees F (21 degrees C).
2)	When units are below 32 degrees F (0 degrees C), heat water above 130 degrees F (54 degrees C).
b.	Use dry masonry units.
c.	Do not use wet or frozen units.
3.	Construction Requirements While Work is Progressing:
a.	Air temperature 40 degrees F (4 degrees C) to 32 degrees F (0 degrees C):
1)	Heat sand or mixing water to produce mortar temperatures between 40 degrees F (4 degrees C) to 32 degrees F (0 degrees C).
b.	Air temperature 32 degrees F (0 degrees C) to 25 degrees F (-4 degrees C):
1)	Heat sand and mixing water to produce temperatures between 40 degrees F (4 degrees C) and 120 degrees F (49 degrees C).
2)	Maintain the temperature of mortar on boards above freezing.
c.	Air temperatures 25 degrees F (-4 degrees C) to 20 degrees F (-7 degrees C).
1)	Heat sand and mixing water to produce mortar temperatures between 40 degrees F (4 degrees C) and 120 degrees F. (49 degrees C).
2)	Maintain the temperature of mortar on boards above freezing.
3)	Use salamanders or other heat sources on both sides of walls under construction.
4)	Use windbreaks when the wind is more than 15 mph (24 kms/h).
d.	Air temperature 20 degrees F (-7 degrees C) and below:
1)	Heat sand and mixing water to produce mortar temperatures between 40 degrees F (4 degrees C) and 120 degrees F (49 degrees C.).
2)	Provide enclosures and auxiliary heat to maintain air temperature above 32 degrees F (0 degrees C).
3)	Minimum temperature of units when laid: 20 degrees F (-7 degrees C).
4.	Protection Requirements for Completed Masonry and Masonry Not Being Worked On:
a.	Mean daily air temperature 40 degrees F (4 degrees C) to 32 degrees F (0 degrees C):
1)	Protect masonry from rain or snow for 24 hours by covering it with a weather-resistive membrane.
b.	Mean daily air temperature 32 degrees F (0 degrees C) to 25 degrees F (-4 degrees C):
1)	Completely cover masonry with weather-resistive membrane for 24 hrs.
c.	Mean daily temperature 25 degrees F (-4 degrees C) to 20 degrees F (-7 degrees C):
1)	Completely cover masonry with insulating blankets or equal protection for 24 hours.
d.	Mean daily air temperature 20 degrees F (-7 degrees C) and below:
1)	Maintain masonry temperature above 32 degrees F (0 degrees C) for 24 hours by:
a)	Method: Enclosure and supplementary heat.
b)	Method: Electric heating blankets.
c)	Method: Infrared lamps.
d)	Method: Other approved methods.
C.	Hot Weather Protection:
1.	Construction Requirements While Work is Progressing:
a.	When the temperature exceeds 100 degrees F or 90 degrees F with 8 mph wind (above 38 degrees C or 32 degrees C with 13 kms/h wind).
1)	Maintain the temperature of mortar and grout between 70 degrees F and 120 degrees F (21 degrees C and 49 degrees C).
a)	Limit spread of mortar bed to 4 feet (1.2 m). Place units within 1 minute of spreading mortar.
2)	Partially or recently completed walls may be fog sprayed and/or covered with opaque plastic or canvas or both to control moisture evaporation.
PART 2    PRODUCTS
2.1	MANUFACTURERS
A.	Acceptable Manufacturer for Clay Unit Masonry: Belden Brick Company (The), which is located at: 700 Tuscarawas Street W; Canton, OH 44702; Tel: 330-456-0031; Fax: 330-456-2694; Email: request info (info@beldenbrick.com); Web: http://www.beldenbrick.com.
B.	Substitutions: Not permitted.
C.	Requests for substitutions will be considered in accordance with provisions of Section 01 60 00 - Product Requirements.
D.	For all other products in this section, specify the desired manufacturer.
2.2	CLAY MASONRY UNITS
A.	All brick specified and shown on drawing shall be ______________________ as Manufactured by The Belden Brick Company.
1.	Facing Brick: ASTM C 216, Grade SW,
a.	Type FBS.
b.	Type FBX.
c.	Type FBA.
d.	Size (wxhxl): ___ x ___ x ___ inches (___ x ___ x ___ mm).
2.	Hollow Brick: ASTM C 652, Grade SW.
a.	Type HBS.
b.	Type HBX.
c.	Type HBA.
d.	Size (wxhxl): ___ x ___ x ___ inches (___ x ___ x ___ mm).
3.	Thin Veneer Brick: ASTM C 1088.
a.	Grade Exterior.
b.	Grade Interior.
c.	Type TBS.
d.	Type TBX.
e.	Type TBA.
f.	Size (wxhxl): ___ x ___ x ___ inches (___ x ___ x ___ mm).
4.	Ceramic Glazed Brick: ASTM C216, Grade SW, and C126 or ASTM C1405, Class Exterior. 
a.	Grade S. 
b.	Type FBS. 
c.	Type FBX. 
d.	Type FBA. 
e.	Size (wxhxl):  ___ x ___ x ___ inches (___ x ___ x ___ mm). 
5.	Special Shapes: Provide shapes as indicated on drawings. 
B.	Minimum Compressive Strength: ______.
C.	Maximum Initial Rate of Absorption (IRA): _______.
D.	Provide brick similar in texture, color, and physical properties to those available for inspection at the Architect/Engineer's office and/or as supplied on the approved sample panel.
E.	All brick supplied shall be pre-blended by the manufacturer.
2.3	STEEL REINFORCEMENT
A.	Reinforcing Bars:
1.	Billet Steel Deformed Bars: ASTM A 615.
2.	Rail Steel Deformed Bars: ASTM A 616 or A996.
3.	Axle Steel Deformed Bars: ASTM A 617 or A996.
4.	Epoxy Coated Billet Steel: ASTM A 615 and ASTM A 775.
2.4	ANCHORS AND TIES
A.	Corrugated Ties: ASTM A 1008, 20 Gage, Width: __________ inch, length: ___________ inches, Galvanized: ASTM A 153, Class B-2.
B.	Truss Joint Reinforcement: ASTM A 82 (ASTM A 666), Size________, Galvanized: ASTM A 153, Class B-2.
C.	Ladder Joint Reinforcement: ASTM A 82 (ASTM A 666), Size________, Galvanized: ASTM A 153, Class B-2.
D.	Wire Wall Ties: ASTM A 82, Wire Size: ________, Shape: ________, Length: ________ inches, Galvanized: ASTM A 153, Class B-2.
E.	Dovetail Anchors: ASTM A 1008, Gage: ______, Length: _______ inches, Galvanized: ASTM A 153, Class B-2.
F.	Anchors:
1.	Plate Bent Bar Anchors: ASTM A 36, Diameter: ________inch, Length: ________ inches, Galvanized: ASTM A 153, Class B-2.
2.	Plate Header Bar Anchors: ASTM A 36, Diameter: ________ inch, Length: ________ inches, Galvanized: ASTM A 153, Class B-2.
2.5	FLASHING
A.	Copper: ASTM B 370, 5 oz.
B.	Copper: ASTM B 370, 7 oz.
C.	Stainless Steel: ASTM A 666, Grade_______, Type 304.
D.	Plastic: PVC, 30 mil (0.75 mm) thick.
E.	Copper/Fabric: 5 oz.
F.	Plastic/Copper: 5 oz.
G.	Asphalt-Coated Copper: 5 oz.
2.6	EXPANSION JOINTS
A.	Premolded Foam: ASTM D 1056, Type 2, Class A, Grade 1.
B.	Neoprene: ASTM D 1056, Type 2, Class A, Grade 1.
C.	Backer Rod: Extruded, Closed Cell Polyethylene.
2.7	ACCESSORIES
A.	Weepholes:
1.	Rope Wicks: Cotton Sash Cord, 12 inches long with end laid in a cavity.
2.	Plastic Tubes: 1/4 inch (6 mm) minimum inside diameter by 4 inches (102 mm) long.
3.	Aluminum Weep/Vents.
4.	Plastic Weep/Vents.
2.8	MORTAR
A.	Mortar shall conform to ASTM C 270 under the guidelines provided in BIA Technical Notes No. 8 Series.
PART 3    EXECUTION
3.1	EXAMINATION
A.	Do not begin installation until substrates have been properly prepared.
B.	If substrate preparation is the responsibility of another installer, notify the Architect of inadequate preparation before proceeding.
3.2	PREPARATION
A.	Clean surfaces thoroughly prior to before installation.
B.	Cleaning Reinforcement: Remove mud, loose rust, ice, and other coatings from reinforcement that would interfere with the bond.
C.	Prepare surfaces using the methods recommended by the manufacturer to achieve the best result for the substrate under the project conditions.
3.3	INSTALLATION
A.	For thin brick, install following the manufacturer's thin brick system or adhesive manufacturer's instructions.
3.4	BONDING
A.	Lay masonry in bond pattern as indicated on drawings or general notes. Reference BIA Technical Note 30 for additional requirements.
3.5	LAYING MASONRY
A.	Lay masonry with full head and bed joints.
B.	Lay all brick plumb and true to lines.
C.	Where fresh mortar joins partially set mortar, remove loose brick and mortar, and lightly wet exposed surface of set masonry.
D.	Toothing shall be subject to approval by the Architect/Engineer.
E.	When adjustment is necessary to be made after mortar begins to harden, remove hardened mortar, and replace it with fresh mortar.
3.6	TOOLING AND POINTING
A.	Joint Profile: Tool mortar joints to a concave appearance.
B.	Joint Profile: Tool mortar joints to a concave V-shaped appearance.
C.	Joint Profile: Tool mortar joints to a concave grapevine appearance.
D.	Tool exposed joints when "thumb-print" hard.
E.	Flush cut all joints not tooled.
F.	When pointing, rake mortar joints to a depth of not less than 1/2 inch (12 mm). Fill solidly with pointing mortar. Tool joints.
3.7	FLASHING
A.	Clean from masonry surface any projections that might puncture flashing.
B.	Place through-wall flashing on a bed of mortar. Cover flashing with mortar.
C.	Lap flashing a minimum of 6 inches (152 mm).
D.	Leave flashing project from the face of the wall approximately 1/4 inch (6 mm) to form a drip. Flashing shall be cut back to the face of the wall after inspection if the drip is deemed objectionable by the Architect.
3.8	WEEPHOLES
A.	Provide weepholes in head joints of the first brick course immediately above flashing by placing weeps no more than 24 inches (610 mm) on the center horizontally.
B.	Keep the cavity free from mortar droppings.
3.9	EXPANSION JOINTS
A.	Keep clean from all mortar and debris. Locate as shown on drawings. Install neoprene pre-molded foam pad, backer rod, and sealant. Prime surfaces if necessary.
3.10	CLEANING
A.	Cut out all defective mortar joints and holes in exposed masonry and provide new mortar.
B.	Clean pre-selected sample wall area. Do not proceed with cleaning until approved by Architect.
C.	Clean brick as outlined in BIA Technical Note 20.
D.	All cleaning practices and products used shall follow the cleaning products manufacturer's printed instructions.
E.	For waxed thin brick, clean with 130 degrees F water using clean water and a low-pressure washer.

END OF SECTION