Base Build-Out, ANA Regional Brigade, Herat, Afghanistan AFHERATA

SECTION 04200

MASONRY

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the

extent referenced. The publications are referred to within the text by
basic designation only.

ACI INTERNATIONAL (ACI)

ACI 530 (1999) Building Code Requirements for

Masonry Structures

ACI 530.1 (1999) Specifications for Masonry

Structures and Related Commentaries

AMERICAN SOCIETY OF CIVIL ENGINEERS (ASCE)

ASCE 5 (1999) Building Code Requirements for

Masonry Structures

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM A 167 (1999) Stainless and Heat-Resisting

Chromium-Nickel Steel Plate, Sheet, and
Strip

ASTM A 615/A 615M (2001b) Deformed and Plain Billet-Steel

Bars for Concrete Reinforcement

ASTM B 370 (1998) Copper Sheet and Strip for Building

Construction

ASTM C 90 (2002) Loadbearing Concrete Masonry Units

ASTM C 94/C 94M (2000e2) Ready-Mixed Concrete

ASTM C 270 (2001a) Mortar for Unit Masonry

ASTM C 476 (2001) Grout for Masonry

ASTM C 494/C 494M (1999ae1) Chemical Admixtures for Concrete

ASTM C 780 (2000) Preconstruction and Construction

Evaluation of Mortars for Plain and
Reinforced Unit Masonry

ASTM C 1019 (2000b) Sampling and Testing Grout

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1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. The
following shall be submitted in accordance with Section 01335 SUBMITTAL
PROCEDURES FOR DESIGN/BUILD PROJECT:

SD-03 Product Data

Concrete Masonry Units (CMU); G

Flashing; G

Manufacturer's descriptive data.

Cold Weather Installation; G

Cold weather construction procedures.

SD-04 Samples

Expansion-Joint Materials; G

One piece of each type used.

Joint Reinforcement; G

One piece of each type used, including corner and wall

intersection pieces, showing at least two cross wires.

SD-05 Design Data

Unit Strength Method; G

Pre-mixed mortar composition. Calculations and certifications

of masonry unit and mortar strength.

SD-08 Manufacturer's Instructions

Masonry Cement; G

When masonry cement is used, submit the manufacturer's printed

instructions on proportions of water and aggregates and on mixing
to obtain the type of mortar required.

1.3 DELIVERY, HANDLING, AND STORAGE

Materials shall be delivered, handled, stored, and protected to avoid

chipping, breakage, and contact with soil or contaminating material.

1.3.1 Masonry Units

Masonry units shall be covered or protected from inclement weather. Store

Type II, masonry units at the site for a minimum of 28 days for air cured
units, 10 days for atmospheric steam or water cured units, and 3 days for
units cured with steam at a pressure of 800 to 1000 kPa and at a
temperature of 180 to 185 degrees C for at least 5 hours. Protect
moisture controlled units from rain and ground water.

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1.3.2 Cementitious Materials, Sand and Aggregates

Cementitious and other packaged materials shall be delivered in unopened

containers, plainly marked and labeled with manufacturers' names and
brands. Cementitious material shall be stored in dry, weathertight
enclosures or be completely covered. Cement shall be handled in a manner
that will prevent the inclusion of foreign materials and damage by water or
dampness. Sand and aggregates shall be stored in a manner to prevent
contamination or segregation.

1.4 STRUCTURAL MASONRY

1.4.1 Unit Strength Method

Compute compressive strength of masonry system "Unit Strength Method," ACI

530.1 or per equivalent DIN, BS, or EN standards. Submit calculations and
certifications of unit and mortar strength.

Unit masonry shall have a compressive strength of not less than 360
kg/sq. cm.

PART 2 PRODUCTS

2.1 CONCRETE MASONRY UNITS (CMU)

Cement shall have a low alkali content and be of one brand. Units shall be
of modular dimensions and air, water, or steam cured. Surfaces of units
which are to be plastered shall be sufficiently rough to provide bond;
exposed surfaces of units shall be smooth and of uniform texture.

a. Hollow Load-Bearing Units: Meeting ACI 530, ASCE 5, or ASTM C 90,

or equivalent DIN, BS, or EN standards made with normal weight
aggregate. Provide load-bearing units for exterior walls,
foundation walls, load-bearing walls, and shear walls.

2.2 PRECAST CONCRETE ITEMS

2.2.1 Splash Blocks

Splash blocks shall be as detailed. Reinforcement shall be the

manufacturer's standard.

2.3 MORTAR FOR STRUCTURAL MASONRY

ASTM C 270, Type S. Strength (f'm) as indicated. Use Type I portland

cement. Do not use admixtures containing chlorides. When structural
reinforcement is incorporated, maximum air-content shall be 12 percent in
cement-lime mortar and 18 percent in masonry cement mortar.

2.4 GROUT AND READY-MIXED GROUT

Grout shall conform to ASTM C 476 coarse, or equivalent DIN, BS, or EN

standards. Cement used in grout shall have a low alkali content. Grout
slump shall be between 200 and 250 mm. Minimum grout strength shall be 14
MPa in 28 days, as tested by ASTM C 1019 or equivalent DIN, BS, or EN
standards . Grout shall be used subject to the limitations of Table III.
Proportions shall not be changed and materials with different physical or
chemical characteristics shall not be used in grout for the work unless
additional evidence is furnished that the grout meets the specified

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requirements. Ready-Mixed grout shall conform to ASTM C 94/C 94M or

equivalent DIN, BS, or EN standards.

2.4.1 Admixtures for Grout

In cold weather, a non-chloride based accelerating admixture may be used

subject to approval; accelerating admixture shall be non-corrosive, shall
contain less than 0.2 percent chlorides, and shall conform to ASTM C 494/C
494M, Type C or equivalent DIN, BS, or EN standards. In general,
air-entrainment, anti-freeze or chloride admixtures shall not be used
except as approved by the Government.

2.4.2 Grout Barriers

Grout barriers for vertical cores shall consist of fine mesh wire,
fiberglass, or expanded metal.

2.5 EXPANSION AND CONTROL JOINTS

General: Install control and expansion-joint materials in unit masonry as

masonry progresses. Do not allow materials to span control and expansion
joints without provision to allow for in-plane wall or partition movement.

2.5.1 Control Joints in Concrete Masonry

Form control joints in concrete masonry using one of the following methods:

1. Fit bond-breaker strips into hollow contour in ends of concrete

masonry units on one side of control joint. Fill resultant core with
grout and rake out joints in exposed faces for application of sealant.

2. Install preformed control-joint gaskets designed to fit standard

sash block.

3. Install interlocking units designed for control joints. Install

bond-breaker strips at joint. Keep head joints free and clear of
mortar or rake out joint for application of sealant.

2.6 REINFORCING STEEL BARS AND RODS

Reinforcing steel bars and rods shall conform to ASTM A 615/A 615M, Grade 60.

2.7 FLASHING

Flashing shall be as specified in Section 07600 SHEET METALWORK, GENERAL.

Provide one of the following types except that the material shall be one
which is not adversely affected by dampproofing material.

a. Copper or Stainless Steel Flashing: Copper, ASTM B 370 minimum

450 g weight; stainless steel, ASTM A 167 Type 301, 302, 304, or
316, 4 mm thick, No. 2D finish. Provide with factory-fabricated
deformations that mechanically bond flashing against horizontal
movement in all directions. Deformations shall consist of
dimples, diagonal corrugations, or a combination of dimples and
transverse corrugations.

b. Reinforced Membrane Flashing: Polyester film core with a

reinforcing fiberglass scrim bonded to one side. The membrane
shall be impervious to moisture, flexible, and not affected by

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caustic alkalis. The material, after being exposed for not less
than 1/2 hour to a temperature of 0 degrees C , shall show no
cracking when, at that temperature, it is bent 180 degrees over a
2 mm diameter mandrel and then bent at the same point over the
same size mandrel in the opposite direction 360 degrees.

PART 3 EXECUTION

3.1 PREPARATION

Prior to start of work, masonry inspector shall verify the applicable

conditions as set forth in ACI 530.1 inspection. The Government will serve
as inspector or will select a masonry inspector.

3.1.1 Hot Weather Installation

The following precautions shall be taken if masonry is erected when the

ambient air temperature is more than 37 degrees C in the shade and the
relative humidity is less than 50 percent or the ambient air temperature
exceeds 32 degrees C and the wind velocity is more than 13 km/h . All
masonry materials shall be shaded from direct sunlight; mortar beds shall
be spread no more than 1.2 m ahead of masonry; masonry units shall be set
within one minute of spreading mortar; and after erection, masonry shall be
protected from direct exposure to wind and sun for 48 hours.

3.1.2 Cold Weather Installation

Before erecting masonry when ambient temperature or mean daily air

temperature falls below 4 degrees C or temperature of masonry units is
below 4 degrees C , a written statement of proposed cold weather
construction procedures shall be submitted for approval. The following
precautions shall be taken during all cold weather erection.

3.1.2.1 Protection

Ice or snow formed on the masonry bed shall be thawed by the application of
heat. Heat shall be applied carefully until the top surface of the masonry
is dry to the touch. Sections of masonry deemed frozen and damaged shall
be removed before continuing construction of those sections.

a. Air Temperature 4 to 0 degrees C. Sand or mixing water shall be

heated to produce mortar temperatures between 4 and 49 degrees C.

b. Air Temperature 0 to minus 4 degrees C . Sand and mixing water

shall be heated to produce mortar temperatures between 4 and 49
degrees C. Temperature of mortar on boards shall be maintained
above freezing.

c. Air Temperature minus 4 to minus 7 degrees C. Sand and mixing

water shall be heated to provide mortar temperatures between 4 and
49 degrees C. Temperature of mortar on boards shall be maintained
above freezing. Sources of heat shall be used on both sides of
walls under construction. Windbreaks shall be employed when wind
is in excess of 24 km/hour .

d. Air Temperature minus 7 degrees C and below. Sand and mixing

water shall be heated to provide mortar temperatures between 4 and
49 degrees C. Enclosure and auxiliary heat shall be provided to
maintain air temperature above 0 degrees C. Temperature of units

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when laid shall not be less than minus 7 degrees C.

3.1.2.2 Completed Masonry and Masonry Not Being Worked On

a. Mean daily air temperature 4 to 0 degrees C . Masonry shall be

protected from rain or snow for 24 hours by covering with
weather-resistive membrane.

b. Mean daily air temperature 0 to minus 4 degrees C . Masonry shall

be completely covered with weather-resistant membrane for 24 hours.

c. Mean Daily Air Temperature minus 4 to minus 7 degrees C . Masonry

shall be completely covered with insulating blankets or equally
protected for 24 hours.

3.1.3 Stains

Protect exposed surfaces from mortar and other stains. When mortar joints
are tooled, remove mortar from exposed surfaces with fiber brushes and
wooden paddles. Protect base of walls from splash stains by covering
adjacent ground with sand, sawdust, or polyethylene.

3.1.4 Loads

Do not apply uniform loads for at least 12 hours or concentrated loads for
at least 72 hours after masonry is constructed. Provide temporary bracing
as required.

3.1.5 Surfaces

Surfaces on which masonry is to be placed shall be cleaned of laitance,

dust, dirt, oil, organic matter, or other foreign materials and shall be
slightly roughened to provide a surface texture with a depth of at least 3
mm . Sandblasting shall be used, if necessary, to remove laitance from
pores and to expose the aggregate.

3.2 LAYING MASONRY UNITS

Coordinate masonry work with the work of other trades to accommodate

built-in items and to avoid cutting and patching. Masonry units shall be
laid in running bond pattern. Facing courses shall be level with back-up
courses, unless the use of adjustable ties has been approved in which case
the tolerances shall be plus or minus 13 mm . Each unit shall be adjusted
to its final position while mortar is still soft and plastic. Units that
have been disturbed after the mortar has stiffened shall be removed,
cleaned, and relaid with fresh mortar. Air spaces, cavities, chases,
expansion joints, and spaces to be grouted shall be kept free from mortar
and other debris. Units used in exposed masonry surfaces shall be selected
from those having the least amount of chipped edges or other imperfections
detracting from the appearance of the finished work. Vertical joints shall
be kept plumb. Units being laid and surfaces to receive units shall be
free of water film and frost. Solid units shall be laid in a nonfurrowed
full bed of mortar. Units shall be shoved into place so that the vertical
joints are tight. Vertical joints of block and the vertical face shells of
concrete masonry units, except where indicated at control, expansion, and
isolation joints, shall be completely filled with mortar. Mortar will be
permitted to protrude up to 13 mm into the space or cells to be grouted.
Means shall be provided to prevent mortar from dropping into the space
below.

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3.2.1 Reinforced Concrete Masonry Units Walls

Where vertical reinforcement occurs, fill cores solid with grout. Lay
units in such a manner as to preserve the unobstructed vertical continuity
of cores to be filled. Embed the adjacent webs in mortar to prevent
leakage of grout. Remove mortar fins protruding from joints before placing
grout. Minimum clear dimensions of vertical cores shall be 50 by 75 mm.
Position reinforcing accurately as indicated before placing grout. As
masonry work progresses, secure vertical reinforcing in place at vertical
intervals not to exceed 160 bar diameters. Use puddling rod or vibrator to
consolidate the grout. Minimum clear distance between masonry and vertical
reinforcement shall be not less than 12 mm. Unless indicated or specified
otherwise, form splices by lapping bars not less than 40 bar diameters and
wire tying them together.

3.2.2 Concrete Masonry Units

Units in piers, pilasters, columns, starting courses on footings, solid

foundation walls, lintels, and beams, and where cells are to be filled with
grout shall be full bedded in mortar under both face shells and webs.
Other units shall be full bedded under both face shells. Head joints shall
be filled solidly with mortar for a distance in from the face of the unit
not less than the thickness of the face shell. Jamb units shall be of the
shapes and sizes to conform with wall units. Solid units may be
incorporated in the masonry work where necessary to fill out at corners,
gable slopes, and elsewhere as approved.

3.2.3 Tolerances

Masonry shall be laid plumb, true to line, with courses level. Bond
pattern shall be kept plumb throughout. Corners shall be square unless
noted otherwise. Except for walls constructed of prefaced concrete masonry
units, masonry shall be laid within the following tolerances (plus or minus
unless otherwise noted):

TABLE II

TOLERANCES

Variation from the plumb in the lines

and surfaces of columns, walls and arises
____________________________________________________________

In adjacent masonry units 3 mm

In 3 m 6 mm
In 6 m 10 mm
In 12 m or more 13 mm

Variations from the plumb for external corners,

expansion joints, and other conspicuous lines
____________________________________________________________

In 6 m 6 mm
In 12 m or more 13 mm

Variations from the level for exposed lintels,

sills, parapets, horizontal grooves, and other
conspicuous lines

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TOLERANCES
____________________________________________________________

In 6 m 6 mm
In 12 m or more 13 mm

Variation from level for bed joints and top

surfaces of bearing walls
____________________________________________________________

In 3 m 6 mm
In 12 m or more 13 mm

Variations from horizontal lines

____________________________________________________________

In 3 m 6 mm
In 6 m 10 mm
In 12 m or more 13 mm

Variations in cross sectional dimensions of

columns and in thickness of walls
____________________________________________________________

Minus 6 mm
Plus 13 mm

3.2.4 Cutting and Fitting

Full units of the proper size shall be used wherever possible, in lieu of
cut units. Cutting and fitting, including that required to accommodate the
work of others, shall be done by masonry mechanics using power masonry
saws. Concrete masonry units may be wet or dry cut. Wet cut units, before
being placed in the work, shall be dried to the same surface-dry appearance
as uncut units being laid in the wall. Cut edges shall be clean, true and
sharp. Openings in the masonry shall be made carefully so that wall
plates, cover plates or escutcheons required by the installation will
completely conceal the openings and will have bottoms parallel with the
masonry bed joints.

3.2.5 Jointing

Joints shall be tooled when the mortar is thumbprint hard. Horizontal

joints shall be tooled last. Joints shall be brushed to remove all loose
and excess mortar. Mortar joints shall be finished as follows:

3.2.5.1 Tooled Joints

Joints in exposed exterior and interior masonry surfaces shall be tooled

slightly concave. Joints shall be tooled with a jointer slightly larger
than the joint width so that complete contact is made along the edges of
the unit. Tooling shall be performed so that the mortar is compressed and
the joint surface is sealed. Jointer of sufficient length shall be used to
obtain a straight and true mortar joint.

3.2.5.2 Door and Window Frame Joints

On the exposed interior side of exterior frames, joints between frames and

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abutting masonry walls shall be raked to a depth of 10 mm . On the

exterior side of exterior frames, joints between frames and abutting
masonry walls shall be raked to a depth of 10 mm .

3.2.6 Joint Widths

Joint widths shall be as follows:

3.2.6.1 Concrete Masonry Units

Concrete masonry units shall have 10 mm joints.

3.2.7 Embedded Items

Spaces around built-in items shall be filled with mortar. Openings around
flush-mount electrical outlet boxes in wet locations shall be pointed with
mortar. Anchors, ties, wall plugs, accessories, flashing, pipe sleeves and
other items required to be built-in shall be embedded as the masonry work
progresses. Anchors, ties and joint reinforcement shall be fully embedded
in the mortar. Cells receiving anchor bolts and cells of the first course
below bearing plates shall be filled with grout.

3.2.8 Unfinished Work

Unfinished work shall be stepped back for joining with new work. Toothing
may be resorted to only when specifically approved. Loose mortar shall be
removed and the exposed joints shall be thoroughly cleaned before laying
new work.

3.2.9 Masonry Wall Intersections

Each course shall be masonry bonded at corners and elsewhere as shown.

Masonry walls shall be anchored or tied together at corners and
intersections with bond beam reinforcement and prefabricated corner or tee
pieces of joint reinforcement as shown.

3.2.10 Partitions

Partitions shall be continuous from floor to underside of floor or roof

deck where shown. Openings in firewalls around joists or other structural
members shall be filled as indicated or approved. Where suspended ceilings
on both sides of partitions are indicated, the partitions other than those
shown to be continuous may be stopped approximately 100 mm above the
ceiling level. An isolation joint shall be placed in the intersection
between partitions and structural or exterior walls as shown. Interior
partitions having 100 mm nominal thick units shall be tied to intersecting
partitions of 100 mm units, 125 mm into partitions of 150 mm units, and
175 into partitions of 200 mm or thicker units. Cells within vertical
plane of ties shall be filled solid with grout for full height of partition
or solid masonry units may be used. Interior partitions having masonry
walls over 100 mm thick shall be tied together with joint reinforcement.
Partitions containing joint reinforcement shall be provided with
prefabricated pieces at corners and intersections or partitions.

3.3 MORTAR

Mortar shall be mixed in a mechanically operated mortar mixer for at least

3 minutes, but not more than 5 minutes. Measurement of ingredients for
mortar shall be by volume. Ingredients not in containers, such as sand,

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shall be accurately measured by the use of measuring boxes. Water shall be

mixed with the dry ingredients in sufficient amount to provide a workable
mixture which will adhere to the vertical surfaces of masonry units.
Mortar that has stiffened because of loss of water through evaporation
shall be retempered by adding water to restore the proper consistency and
workability. Mortar that has reached its initial set or that has not been
used within 2-1/2 hours after mixing shall be discarded.

3.4 REINFORCING STEEL

Reinforcement shall be cleaned of loose, flaky rust, scale, grease, mortar,

grout, or other coating which might destroy or reduce its bond prior to
placing grout. Bars with kinks or bends not shown on the drawings shall
not be used. Reinforcement shall be placed prior to grouting. Unless
otherwise indicated, vertical wall reinforcement shall extend to within 50
mm of tops of walls.

3.4.1 Positioning Bars

Vertical bars shall be accurately placed within the cells at the positions
indicated on the drawings. A minimum clearance of 13 mm shall be
maintained between the bars and masonry units. Minimum clearance between
parallel bars shall be one diameter of the reinforcement. Vertical
reinforcing may be held in place using bar positioners located near the
ends of each bar and at intermediate intervals of not more than 192
diameters of the reinforcement. Column and pilaster ties shall be wired in
position around the vertical steel. Ties shall be in contact with the
vertical reinforcement and shall not be placed in horizontal bed joints.

3.4.2 Splices

Bars shall be lapped a minimum of 48 diameters of the reinforcement.

Welded or mechanical connections shall develop at least 125 percent of the
specified yield strength of the reinforcement.

3.5 PLACING GROUT

Cells containing reinforcing bars shall be filled with grout. Hollow

masonry units in walls or partitions supporting plumbing, heating, or other
mechanical fixtures, voids at door and window jambs, and other indicated
spaces shall be filled solid with grout. Cells under lintel bearings on
each side of openings shall be filled solid with grout for full height of
openings. Walls below grade, lintels, and bond beams shall be filled solid
with grout. Units other than open end units may require grouting each
course to preclude voids in the units. Grout not in place within 1-1/2
hours after water is first added to the batch shall be discarded.
Sufficient time shall be allowed between grout lifts to preclude
displacement or cracking of face shells of masonry units. If blowouts,
flowouts, misalignment, or cracking of face shells should occur during
construction, the wall shall be torn down and rebuilt.

3.5.1 Grout Holes and Cleanouts

3.5.1.1 Grout Holes

Grouting holes shall be provided in spandrel beams, and other in-place

overhead construction. Holes shall be located over vertical reinforcing
bars or as required to facilitate grout fill in bond beams. Additional
openings spaced not more than 400 mm on centers shall be provided where

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grouting of all hollow unit masonry is indicated. Openings shall not be

less than 100 mm in diameter or 75 by 100 mm in horizontal dimensions.
Upon completion of grouting operations, grouting holes shall be plugged and
finished to match surrounding surfaces.

3.5.1.2 Cleanouts for Hollow Unit Masonry Construction

Cleanout holes shall be provided at the bottom of every pour in cores

containing vertical reinforcement when the height of the grout pour exceeds
1.5 m . Where all cells are to be grouted, cleanout courses shall be
constructed using bond beam units in an inverted position to permit
cleaning of all cells. Cleanout holes shall be provided at a maximum
spacing of 800 mm where all cells are to be filled with grout. A new
series of cleanouts shall be established if grouting operations are stopped
for more than 4 hours. Cleanouts shall not be less than 75 by 100 mm
openings cut from one face shell. Manufacturer's standard cutout units may
be used at the Contractor's option. Cleanout holes shall not be closed
until masonry work, reinforcement, and final cleaning of the grout spaces
have been completed and inspected. For walls which will be exposed to
view, cleanout holes shall be closed in an approved manner to match
surrounding masonry.

3.5.2 Grouting Equipment

3.5.2.1 Grout Pumps

Pumping through aluminum tubes will not be permitted. Pumps shall be

operated to produce a continuous stream of grout without air pockets,
segregation, or contamination. Upon completion of each day's pumping,
waste materials and debris shall be removed from the equipment, and
disposed of outside the masonry.

3.5.3 Grout Placement

Masonry shall be laid to the top of a pour before placing grout. Grout
shall not be placed in hollow unit masonry until mortar joints have set for
at least 24 hours. Grout shall be placed using a hand bucket, concrete
hopper, or grout pump to completely fill the grout spaces without
segregation of the aggregates. The height of grout pours and type of
grout used shall be limited by the dimensions of grout spaces as indicated
in Table III. Low-lift grout methods may be used on pours up to and
including 1.5 m in height. High-lift grout methods shall be used on pours
exceeding 1.5 m in height.

3.5.3.1 Low-Lift Method

Grout shall be placed at a rate that will not cause displacement of the
masonry due to hydrostatic pressure of the grout. Mortar protruding more
than 13 mm into the grout space shall be removed before beginning the
grouting operation. Grout pours 300 mm or less in height shall be
consolidated by mechanical vibration or by puddling. Grout pours over 300
mm in height shall be consolidated by mechanical vibration and
reconsolidated by mechanical vibration after initial water loss and
settlement has occurred. Low-lift grout shall be used subject to the
limitations of Table III.

3.5.3.2 High-Lift Method

Mortar droppings shall be cleaned from the bottom of the grout space and

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from reinforcing steel. Mortar protruding more than 6 mm into the grout
space shall be removed by dislodging the projections with a rod or stick as
the work progresses. Reinforcing, bolts, and embedded connections shall be
rigidly held in position before grouting is started. CMU units shall not
be pre-wetted. Grout, from the mixer to the point of deposit in the grout
space shall be placed as rapidly as practical by pumping and placing
methods which will prevent segregation of the mix and cause a minimum of
grout splatter on reinforcing and masonry surfaces not being immediately
encased in the grout lift. The individual lifts of grout shall be limited
to 1.2 m in height. The first lift of grout shall be placed to a uniform
height within the pour section and vibrated thoroughly to fill all voids.
This first vibration shall follow immediately behind the pouring of the
grout using an approved mechanical vibrator. After a waiting period
sufficient to permit the grout to become plastic, but before it has taken
any set, the succeeding lift shall be poured and vibrated 300 to 450 mm
into the preceding lift. If the placing of the succeeding lift is going to
be delayed beyond the period of workability of the preceding, each lift
shall be reconsolidated by reworking with a second vibrator as soon as the
grout has taken its settlement shrinkage. The waiting, pouring, and
reconsolidation steps shall be repeated until the top of the pour is
reached. The top lift shall be reconsolidated after the required waiting
period. The high-lift grouting of any section of wall between vertical
grout barriers shall be completed to the top of a pour in one working day
unless a new series of cleanout holes is established and the resulting
horizontal construction joint cleaned.

TABLE III

POUR HEIGHT AND TYPE OF GROUT FOR VARIOUS GROUT SPACE DIMENSIONS

Minimum Dimensions of the

Total Clear Areas Within Grout
Maximum Spaces and Cells (mm) (1,2)
Grout Pour
Height Grout Grouting Multiwythe Hollow-unit
(m) (4) Type Procedure Masonry (3) Masonry
____________ _______ ____________ ___________ _____________

0.3 Fine Low Lift 20 40 x 50

1.5 Fine Low Lift 50 50 x 75
2.4 Fine High Lift 50 50 x 75
3.6 Fine High Lift 65 65 x 75
7.3 Fine High Lift 75 75 x 75
0.3 Coarse Low Lift 40 40 x 75
1.5 Coarse Low Lift 50 65 x 75
2.4 Coarse High Lift 50 75 x 75
3.6 Coarse High Lift 65 75 x 75
7.3 Coarse High Lift 75 75 x 100

Notes:
(1) The actual grout space or cell dimension must be larger than the
sum of the following items:
a) The required minimum dimensions of total clear areas given in
the table above;
b) The width of any mortar projections within the space;
c) The horizontal projections of the diameters of the horizontal
reinforcing bars within a cross section of the grout space or cell.

(2) The minimum dimensions of the total clear areas shall be made up

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of one or more open areas, with at least one area being 20 mm or

greater in width.

(3) For grouting spaces between masonry wythes.

(4) Where only cells of hollow masonry units containing reinforcement

are grouted, the maximum height of the pour shall not exceed the
distance between horizontal bond beams.

3.6 POINTING AND CLEANING

After mortar joints have attained their initial set, but prior to
hardening, mortar and grout daubs or splashings shall be completely removed
from masonry-unit surfaces that will be exposed or painted. Before
completion of the work, defects in joints of masonry to be exposed or
painted shall be raked out as necessary, filled with mortar, and tooled to
match existing joints. Immediately after grout work is completed, scum and
stains which have percolated through the masonry work shall be removed
using a high pressure stream of water and a stiff bristled brush. Masonry
surfaces shall not be cleaned, other than removing excess surface mortar,
until mortar in joints has hardened. Masonry surfaces shall be left clean,
free of mortar daubs, dirt, stain, and discoloration, including scum from
cleaning operations, and with tight mortar joints throughout. Metal tools
and metal brushes shall not be used for cleaning.

3.6.1 Concrete Masonry Unit

Exposed concrete masonry unit shall be dry-brushed at the end of each

day's work and after any required pointing, using stiff-fiber bristled
brushes.

3.7 BEARING PLATES

Bearing plates for beams, joists, and similar structural members shall be
set to the proper line and elevation with damp-pack bedding mortar, except
where non-shrink grout is indicated. Bedding mortar and non-shrink grout
shall be as specified in Section 03300 CAST-IN-PLACE STRUCTURAL CONCRETE.

3.8 PROTECTION

Facing materials shall be protected against staining. Top of walls shall

be covered with nonstaining waterproof covering or membrane when work is
not in progress. Covering of the top of the unfinished walls shall
continue until the wall is waterproofed with a complete roof or parapet
system. Covering shall extend a minimum of 600 mm down on each side of
the wall and shall be held securely in place. Before starting or resuming,
top surface of masonry in place shall be cleaned of loose mortar and
foreign material.

3.9 MORTAR AND GROUT TESTS

3.9.1 Field Testing of Mortar

At least three specimens of mortar shall be taken each day. A layer of

mortar 13 to 16 mm thick shall be spread on the masonry units and allowed
to stand for one minute. The specimens shall then be prepared and tested
for compressive strength in accordance with ASTM C 780 or equivalent DIN,
BS, or EN standards.

SECTION 04200 Page 13

Base Build-Out, ANA Regional Brigade, Herat, Afghanistan AFHERATA

3.9.2 Field Testing of Grout

Field sampling and testing of grout shall be in accordance with the

applicable provisions of ASTM C 1019 or equivalent DIN, BS, or EN
standards. A minimum of three specimens of grout per day shall be sampled
and tested or equivalent DIN, BS, or EN standards. Each specimen shall
have a minimum ultimate compressive strength of 13.8 MPa at 28 days.

-- End of Section --

SECTION 04200 Page 14