HomeMy WebLinkAbout04 72 00 Cast Stone MasonryTHE KENT
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SECTION 04 72 00 - CAST STONE MASONRY
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
A. Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division 01 Specification Sections, apply to this Section.
1.2 SUMMARY
A. Section Includes:
1. Cast-stone trim including the following:
a. Window sills.
b. Lintels.
c. Panels.
d. Wall caps.
e. Base courses.
B. Related Sections:
1. Section 04 20 00 "Unit Masonry" for installing cast-stone units in unit masonry.
2. Section 07 92 00 “Joint Sealants” for installing cast-stone units where designated.
1.3 ACTION SUBMITTALS
A. Product Data: For each type of product.
1. For cast-stone units, include construction details, material descriptions, dimensions of
individual components and profiles, and finishes.
B. Shop Drawings: Show fabrication and installation details for cast-stone units. Include
dimensions, details of reinforcement and anchorages if any, and indication of finished faces.
1. Include building elevations showing layout of units and locations of joints and anchors.
C. Samples for Initial Selection: For colored mortar.
D. Samples for Verification:
1. For each color and texture of cast stone required, 10 inches square in size.
2. For each trim shape required, 10 inches in length.
3. For colored mortar, make Samples using same sand and mortar ingredients to be used
on Project. Label Samples to indicate types and amounts of pigments used.
E. Full-Size Samples: For each color, texture and shape of cast-stone unit required.
1. Make available for Architect's review at Project site or at manufacturing plant, if
acceptable to Architect.
2. Make Samples from materials to be used for units used on Project.
3. Approved Samples may be installed in the Work.
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1.4 INFORMATIONAL SUBMITTALS
A. Qualification Data: For manufacturer and testing agency.
1. Include copies of material test reports for completed projects, indicating compliance of
cast stone with ASTM C 1364.
B. Material Test Reports: For each mix required to produce cast stone, based on testing according
to ASTM C 1364, including test for resistance to freezing and thawing.
1. Provide test reports based on testing within previous two years.
1.5 QUALITY ASSURANCE
A. Manufacturer Qualifications: A qualified manufacturer of cast-stone units similar to those
indicated for this Project, that has sufficient production capacity to manufacture required units,
and is a plant certified by the Cast Stone Institute and has ten years’ experience in producing
cast-stone of the type required for this project.
B. Testing Agency Qualifications: Qualified according to ASTM E 329 for testing indicated.
C. Mockups: Furnish cast stone for installation in mockups specified in Section 04 20 00 "Unit
Masonry."
1.6 DELIVERY, STORAGE, AND HANDLING
A. Coordinate delivery of cast stone with unit masonry work to avoid delaying the Work and to
minimize the need for on-site storage.
B. Pack, handle, and ship cast-stone units in suitable packs or pallets.
1. Lift with wide-belt slings; do not use wire rope or ropes that might cause staining. Move
cast-stone units if required, using dollies with wood supports.
2. Store cast-stone units on wood skids or pallets with non-staining, waterproof covers,
securely tied. Arrange to distribute weight evenly and to prevent damage to units.
Ventilate under covers to prevent condensation.
3. Number each piece individually to match shop drawings and schedule.
C. Store cast stone components in accordance with manufacturer’s instructions.
D. Store cementitious materials on elevated platforms, under cover, and in a dry location. Do not
use cementitious materials that have become damp.
E. Store mortar aggregates where grading and other required characteristics can be maintained
and contamination can be avoided.
1.7 PROJECT CONDITIONS
A. Cold-Weather Requirements: Do not use frozen materials or materials mixed or coated with ice
or frost. Do not build on frozen substrates. Comply with cold-weather construction requirements
in TMS 602/ACI 530.1/ASCE 6.
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1. Cold-Weather Cleaning: Use liquid cleaning methods only when air temperature is 40
deg F and above and will remain so until cast stone has dried, but no fewer than seven
days after completing cleaning.
B. Hot-Weather Requirements: Comply with hot-weather construction requirements in
TMS 602/ACI 530.1/ASCE 6.
PART 2 - PRODUCTS
2.1 MANUFACTURERS
A. Source Limitations for Cast Stone: Obtain cast-stone units from single source from single
manufacturer.
B. Source Limitations for Mortar Materials: Obtain mortar ingredients of a uniform quality, including
color, from one manufacturer for each cementitious component and from one source or
producer for each aggregate.
2.2 CAST-STONE MATERIALS
A. General: Comply with ASTM C 1364.
B. Portland Cement: ASTM C 150, Type I, containing not more than 0.60 percent total alkali when
tested according to ASTM C 114. Provide natural color or white cement as required to produce
cast-stone color indicated.
C. Coarse Aggregates: Granite, quartz, or limestone complying with ASTM C 33; gradation and
colors as needed to produce required cast-stone textures and colors.
D. Fine Aggregates: Natural sand or crushed stone complying with ASTM C 33, gradation and
colors as needed to produce required cast-stone textures and colors.
E. Color Pigment: ASTM C 979, synthetic mineral-oxide pigments or colored water-reducing
admixtures; color stable, nonfading, and resistant to lime and other alkalis.
F. Admixtures: Use only admixtures specified or approved in writing by Architect.
1. Do not use admixtures that contain more than 0.1 percent water-soluble chloride ions by
mass of cementitious materials. Do not use admixtures containing calcium chloride.
2. Use only admixtures that are certified by manufacturer to be compatible with cement and
other admixtures used.
3. Air-Entraining Admixture: ASTM C 260. Add to mixes for units exposed to the exterior at
manufacturer's prescribed rate to result in an air content of 4 to 6 percent, except do not
add to zero-slump concrete mixes.
4. Water-Reducing Admixture: ASTM C 494, Type A.
5. Water-Reducing, Retarding Admixture: ASTM C 494, Type D.
6. Water-Reducing, Accelerating Admixture: ASTM C 494, Type E.
G. Reinforcement: Deformed steel bars complying with ASTM A 615, Grade 60. Use galvanized or
epoxy-coated reinforcement when covered with less than 1-1/2 inches of cast-stone material.
1. Epoxy Coating: ASTM A 775.
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2. Galvanized Coating: ASTM A 767.
H. Embedded Anchors and Other Inserts: Fabricated from stainless steel complying with
ASTM A 240, ASTM A 276, or ASTM A 666, Type 304.
2.3 CAST-STONE UNITS
A. Manufacturers: Subject to compliance with requirements, available manufacturers offering
products that may be incorporated into the Work include, but are not limited to, the following:
1. Arriscraft International; P.O. Box 3190, Speedsville Road, Cambridge, Ontario, Canada,
N3H 4S8; tel.: 800.265.8123.
2. Continental Cast Stone Manufacturing, Inc.; 22001 West 83rd
St., Shawnee, KS 66227;
tel.: 913.422.7575.
3. Custom Cast Stone; 734 E. 169th
St., Westfield, IN. 46074; tel.: 317.896.1700.
B. Cast-Stone Units: Comply with ASTM C 1364.
1. Units shall be manufactured using the vibrant dry tamp or wet-cast method.
2. Units shall be resistant to freezing and thawing as determined by laboratory testing
according to ASTM C 666, Procedure A, as modified by ASTM C 1364.
C. Fabricate units with sharp arris and accurately reproduced details, with indicated texture on all
exposed surfaces unless otherwise indicated.
1. Slope exposed horizontal surfaces 1:12 to drain unless otherwise indicated.
2. Provide raised fillets at backs of sills and at ends indicated to be built into jambs.
3. Provide drips on projecting elements unless otherwise indicated.
4. Provide special pieces to eliminate mitered corners. Return profile shape at inside and
outside corners as required.
D. Fabrication Tolerances:
1. Variation in Cross Section: Do not vary from indicated dimensions by more than 1/8 inch.
2. Variation in Length: Do not vary from indicated dimensions by more than 1/360 of the
length of unit or 1/8 inch, whichever is greater, but in no case by more than 1/4 inch.
3. Warp, Bow, and Twist: Not to exceed 1/360 of the length of unit or 1/8 inch, whichever is
greater.
4. Location of Grooves, False Joints, Holes, Anchorages, and Similar Features: Do not vary
from indicated position by more than 1/8 inch on formed surfaces of units and 3/8 inch on
unformed surfaces.
E. Cure Units as Follows:
1. Cure units in enclosed, moist curing room at 95 to 100 percent relative humidity and
temperature of 100 deg F for 12 hours or 70 deg F for 16 hours.
2. Keep units damp and continue curing to comply with one of the following:
a. No fewer than five days at mean daily temperature of 70 deg F or above.
b. No fewer than six days at mean daily temperature of 60 deg F or above.
F. Acid etch units after curing to remove cement film from surfaces to be exposed to view.
G. Colors and Textures: As selected by Architect from manufacturer's full range.
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2.4 MORTAR AND GROUT MATERIALS
A. Portland Cement: ASTM C 150, Type I or II, except Type III may be used for cold-weather
construction. Provide natural color or white cement as required to produce mortar color
indicated.
1. Alkali content shall not be more than 0.1 percent when tested according to ASTM C 114.
B. Hydrated Lime: ASTM C 207.
1. Type N for brick veneer.
2. Type S for brick or block below grade and for structural block work.
C. Portland Cement-Lime Mix: Packaged blend of portland cement and hydrated lime containing
no other ingredients.
D. Portland Cement-Lime-Sand Mix: ASTM C 1714 Packaged blend of portland cement, hydrated
lime and sand containing no other ingredients.
1. Product: Subject to compliance with requirements, provide the following:
a. The Quickcrete Companies, Inc.; Spec Mix Portland lime and Sand Masonry
Mortar.
E. Portland Cement-Lime-Sand Mix (Colored Mortar): ASTM C 1714 Packaged blend of portland
cement, hydrated lime, sand and pigment containing no other ingredients.
1. Product: Subject to compliance with requirements, provide the following:
a. The Quickcrete Companies, Inc.; Spec Mix Colored Mortar.
F. Masonry Cement: ASTM C 91.
1. Products: Subject to compliance with requirements, provide one of the following:
a. Essroc, Italcementi Group; Brixment or Velvet.
b. Cemex S.A.B. de C.V.; Citadel Type S.
c. Lafarge North America; Lafarge Masonry Cement.
G. Masonry Cement-Sand Mix: ASTM C 1714 Packaged blend of masonry cement and sand
containing no other ingredients.
1. Product: Subject to compliance with requirements, provide the following:
a. The Quickcrete Companies, Inc.; Spec Mix Masonry Cement and Sand Masonry
Mortar.
H. Masonry Cement-Sand Mix (Colored Mortar): ASTM C 1714 Packaged blend of masonry
cement, sand and pigment containing no other ingredients.
1. Product: Subject to compliance with requirements, provide the following:
a. The Quickcrete Companies, Inc.; Spec Mix Masonry Cement and Sand Colored
Mortar.
I. Aggregate for Mortar: ASTM C 144.
1. For mortar that is exposed to view, use washed aggregate consisting of natural sand or
crushed stone.
2. For joints, less than 1/4-inch-thick, use aggregate graded with 100 percent passing the
No. 16 sieve.
J. Aggregate for Grout: ASTM C 404.
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K. Cold-Weather Admixture: Non-chloride, noncorrosive, accelerating admixture complying with
ASTM C 494, Type C, and recommended by manufacturer for use in masonry mortar of
composition indicated.
1. Manufacturers: Subject to compliance with requirements, available manufacturers
offering products that may be incorporated into the work include, but are not limited to the
following:
a. BASF Corporation; Construction Systems.
b. Euclid Chemical Company (The).
c. Grace Construction Products, a unit of W. R. Grace & Co. - Conn.; Morset.
L. Water: Potable.
2.5 ACCESSORIES
A. Anchors: Type and size indicated, fabricated from Type 304 stainless steel complying with
ASTM A 240, ASTM A 276, or ASTM A 666.
B. Dowels: 1/2-inch- diameter round bars, fabricated from Type 304 stainless steel complying with
ASTM A 240, ASTM A 276, or ASTM A 666.
C. Sealants: Refer to Specification section 07 92 00 Joint Sealants,” Subsection 2.3.D.
D. Proprietary Acidic Cleaner: Manufacturer's standard-strength cleaner designed for removing
mortar/grout stains, efflorescence, and other new construction stains from new masonry without
discoloring or damaging masonry surfaces. Use product expressly approved for intended use by
cast-stone manufacturer and expressly approved by cleaner manufacturer for use on cast stone
and adjacent masonry materials.
2.6 MORTAR MIXES
A. Comply with requirements in Section 04 20 00 "Unit Masonry" for mortar mixes.
B. Do not use admixtures including pigments, air-entraining agents, accelerators, retarders, water-
repellent agents, antifreeze compounds, or other admixtures unless otherwise indicated.
1. Do not use calcium chloride in mortar or grout.
2. Use portland cement-lime mortar unless otherwise indicated.
C. Comply with ASTM C 270, Proportion Specification.
1. For setting mortar, use Type N.
2. For pointing mortar, use Type N.
D. Pigmented Mortar: Use colored cement product or select and proportion pigments with other
ingredients to produce color required. Do not add pigments to colored cement products.
1. Pigments shall not exceed 10 percent of portland cement by weight.
2. Mix to match Architect's sample.
3. Application: Use pigmented mortar for exposed mortar joints.
E. Colored-Aggregate Mortar: Produce required mortar color by using colored aggregates and
natural color or white cement as necessary to produce required mortar color.
1. Mix to match Architect's sample.
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2. Application: Use colored-aggregate mortar for exposed mortar joints.
2.7 SOURCE QUALITY CONTROL
A. Engage a qualified independent testing agency to sample and test cast-stone units according to
ASTM C 1364.
1. Include one test for resistance to freezing and thawing.
PART 3 - EXECUTION
3.1 EXAMINATION
A. Examine substrates and conditions, with Installer present, for compliance with requirements for
installation tolerances and other conditions affecting performance of the Work.
B. Examine cast-stone components for fit and finish before installation. Do not install unacceptable
units.
C. Proceed with installation only after unsatisfactory conditions have been corrected.
3.2 SETTING CAST STONE IN MORTAR
A. Install cast-stone units to comply with requirements in Section 04 20 00 "Unit Masonry."
B. Set cast stone as indicated on Drawings. Set units accurately in locations indicated, with edges
and faces aligned according to established relationships and indicated tolerances.
1. Install anchors, supports, fasteners, and other attachments indicated or necessary to
secure units in place.
2. Coordinate installation of cast stone with installation of flashing specified in other
Sections.
C. Wet joint surfaces thoroughly before applying mortar or setting in mortar.
D. Set units in full bed of mortar with full head joints unless otherwise indicated.
1. Set units with joints 1/4 to 3/8 inch wide unless otherwise indicated.
2. Build anchors and ties into mortar joints as units are set.
3. Fill dowel holes and anchor slots with mortar.
4. Fill collar joints solid as units are set.
5. Build concealed flashing into mortar joints as units are set.
6. Keep head joints in copings and between other units with exposed horizontal surfaces
open to receive sealant.
7. Keep joints at shelf angles open to receive sealant.
E. Rake out joints for pointing with mortar to depths of not less than 3/4 inch. Rake joints to
uniform depths with square bottoms and clean sides. Scrub faces of units to remove excess
mortar as joints are raked.
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F. Point mortar joints by placing and compacting mortar in layers not greater than 3/8 inch.
Compact each layer thoroughly and allow it to become thumbprint hard before applying next
layer.
G. Tool exposed joints slightly concave when thumbprint hard. Use a smooth plastic jointer larger
than joint thickness.
H. Rake out joints for pointing with sealant to depths of not less than 3/4 inch. Scrub faces of units
to remove excess mortar as joints are raked.
I. Point joints with sealant to comply with applicable requirements in Section 07 92 00 "Joint
Sealants."
1. Prime cast-stone surfaces to receive sealant and install compressible backer rod in joints
before applying sealant unless otherwise indicated.
J. Provide sealant joints at head joints of copings and other horizontal surfaces; at expansion,
control, and pressure-relieving joints; and at locations indicated.
1. Keep joints free of mortar and other rigid materials.
2. Build in compressible foam-plastic joint fillers where indicated.
3. Form joint of width indicated, but not less than 3/8 inch.
4. Prime cast-stone surfaces to receive sealant and install compressible backer rod in joints
before applying sealant unless otherwise indicated.
5. Prepare and apply sealant of type and at locations indicated to comply with applicable
requirements in Section 07 92 00 "Joint Sealants."
3.3 SETTING ANCHORED CAST STONE WITH SEALANT-FILLED JOINTS
A. Set cast stone as indicated on Drawings. Set units accurately in locations indicated, with edges
and faces aligned according to established relationships and indicated tolerances.
1. Install anchors, supports, fasteners, and other attachments indicated or necessary to
secure units in place.
2. Shim and adjust anchors, supports, and accessories to set cast stone in locations
indicated with uniform joints.
B. Keep cavities open where unfilled space is indicated between back of cast-stone units and
backup wall; do not fill cavities with mortar or grout.
C. Fill anchor holes with sealant.
1. Where dowel holes occur at pressure-relieving joints, provide compressible material at
ends of dowels.
D. Set cast stone supported on clip or continuous angles on resilient setting shims. Use material of
thickness required to maintain uniform joint widths. Hold shims back from face of cast stone a
distance at least equal to width of joint.
E. Keep joints free of mortar and other rigid materials. Remove temporary shims and spacers from
joints after anchors and supports are secured in place and cast-stone units are anchored. Do
not begin sealant installation until temporary shims and spacers are removed.
1. Form open joint of width indicated, but not less than 3/8 inch.
F. Prime cast-stone surfaces to receive sealant and install compressible backer rod in joints before
applying sealant unless otherwise indicated.
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G. Prepare and apply sealant of type and at locations indicated to comply with applicable
requirements in Section 07 92 00 "Joint Sealants."
3.4 INSTALLATION TOLERANCES
A. Variation from Plumb: Do not exceed 1/8 inch in 10 feet, 1/4 inch in 20 feet, or 1/2-inch
maximum.
B. Variation from Level: Do not exceed 1/8 inch in 10 feet, 1/4 inch in 20 feet, or 1/2-inch
maximum.
C. Variation in Joint Width: Do not vary joint thickness more than 1/8 inch in 36 inches or one-
fourth of nominal joint width, whichever is less.
D. Variation in Plane between Adjacent Surfaces (Lipping): Do not vary from flush alignment with
adjacent units or adjacent surfaces indicated to be flush with units by more than 1/16 inch,
except where variation is due to warpage of units within tolerances specified.
3.5 ADJUSTING AND CLEANING
A. Remove and replace stained and otherwise damaged units and units not matching approved
Samples. Cast stone may be repaired if methods and results are approved by Architect.
B. Replace units in a manner that results in cast stone matching approved Samples, complying
with other requirements, and showing no evidence of replacement.
C. In-Progress Cleaning: Clean cast stone as work progresses.
1. Remove mortar fins and smears before tooling joints.
2. Remove excess sealant immediately, including spills, smears, and spatter.
D. Final Cleaning: After mortar is thoroughly set and cured, clean exposed cast stone as follows:
1. Remove large mortar particles by hand with wooden paddles and nonmetallic scrape
hoes or chisels.
2. Test cleaning methods on sample; leave one sample uncleaned for comparison
purposes. Obtain Architect's approval of sample cleaning before proceeding with cleaning
of cast stone.
3. Protect adjacent surfaces from contact with cleaner by covering them with liquid
strippable masking agent or polyethylene film and waterproof masking tape.
4. Wet surfaces with water before applying cleaners; remove cleaners promptly by rinsing
thoroughly with clear water.
5. Clean cast stone by bucket-and-brush hand-cleaning method described in BIA
Technical Notes 20.
6. Clean cast stone with proprietary acidic cleaner applied according to manufacturer's
written instructions.
END OF SECTION 04 72 00