Hawthorne Hotel Specs for masonry work
PROJECT MANUAL
Phase 1 Masonry Repairs at the
Hawthorne
Hotel
Salem, MA
12 February 2016
Engineer:
Structures North Consulting Engineers, Inc.
60 Washington Street
Salem, MA 01970
978-745-6817
Please direct all project correspondence to:
John Wathne X10
jwathne@structures-north.com
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
TABLE OF CONTENTS
TABLE OF CONTENTS
Technical Specifications-
Section 01010 Summary of Work
Section 02050 Selective Dismantling and Demolition
Section 02210 Temporary Shoring and Bracing
Section 03300 Cast-in-Place Concrete
Section 04100 Masonry Repairs
Section 05200 Structural Metals
Section 05300 Structural Steel Repair and Protection
Section 07650 Flashing and Sheet Metal
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
01010-1
SECTION 01010
SUMMARY OF WORK
PART 1- GENERAL
1.1 GENERAL REQUIREMENTS
A. All work shall comply with the Massachusetts State Building Code and referenced standards.
B. All work shall be coordinated between related trades.
C. Contractor shall field verify all existing conditions and dimensions and shall be responsible for
dimensional coordination. Notify the Engineer of any and all discrepancies.
D. The contractor shall be responsible for all temporary shoring and guying of the existing and
new structure during the work, and for temporary protection of the surrounding environs.
E. The Contractor shall be solely responsible for all means and methods of construction
employed on this project, and for all temporary bracing, support, and protection of the existing
structure. Any sequences of work or methods indicated or implied in the contract documents
are present only as assumptions on which the design of the permanent installations were
based and are to be considered as suggested options for review by the contractor. Following
review of existing conditions and the scope of work, the contractor shall submit his own
statement of means and methods as well as schedule to the Engineer and shall keep the
Engineer abreast of all progress and the beginning and completion of each phase or item of
work.
F. The Contractor shall be solely responsible for m aintaining the safety and stability of the
structure and all adjacent structures during all phases of the work, and shall correct any
defects or damage which results from his actions.
G. The contractor may use a pre-designated portion of the parking lot in back of the Hotel as a
staging area, provided that all such use be coordinated with the Hotel. Full access and
egress to/ from the Hotel shall be maintained at all times.
H. The Contractor shall clean-up the Hotel property at the end of each day and for weddings
and funerals. Maintain site in a clean, unencumbered fashion from the end of work on
Friday to the start of work on Monday.
I. The Contractor shall protect the Hotel property, the street, sidewalk and abutters’
properties from any water spray, spatter or windblown soil or mortar materials.
J. There shall be no noise-producing operations during special events. The Hotel will notify
the contractor in at least 24-hours in advance of all funerals and 7-days in advance of all
weddings.
K. The Contractor shall submit a weekly schedule to the Hotel for its use, along with an
overall project schedule updated on a monthly basis.
L. Workers shall not swear, smoke or shout on the staging, and shall not look in any of the
Hotel Windows. The Hotel has the option of requiring the covering of windows with
opaque shrink wrapped plastic to protect the privacy of its guests.
M. Limit the loading on the existing roof surfaces to 30 pounds per square foot, and distribute
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
01010-2
all staging and storage loads over the roof surfaces with a horizontal spreader system that
will protect the roofing system and limit point loading on the structure below.
N. The Contractor shall be responsible for the repair of all roof surfaces beneath the staging
system and work area following the completion of work.
1.2 TECHNICAL SPECIFICATION SECTIONS
A. Section 02050- Selective Dismantling and Demolition
B. Section 02210- Temporary Shoring and Bracing
C. Section 03300- Cast-in-Place Concrete
D. Section 04100- Masonry Repairs
E. Section 05200- Structural Metals
F. Section 05300- Structural Steel Repair and Protection
G. Section 07650- Flashing and Sheet Metal
1.3 STRUCTURAL DRAWINGS
A. S-1 Elevations
B. S-2 Elevations
C. S-3 Elevations
D. S-4 Sections and Details
PART 2- PRODUCTS
2.1 PROVIDE: Products as indicated in the respective specification sections that are referenced in the
description of work.
PART 3- EXECUTION
3.1 DESCRIPTION OF WORK:
A. Perform all work in accordance with the drawings and specifications under the Base Bid
for this contract to include at least the following items of work along with all incidental
work required for the completion of these items:
1. Protection of all structural and architectural elements and adjacent structures to
remain, and erection of a protection system for passersby and to allow for safe
access and egress into and out of the Hotel at all times.
2. Protection of existing roofing systems under the work areas, and inspection and
repair of the systems following the work’s completion and staging removal.
3. Repair of damaged masonry, including crack repair, masonry re-setting and
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
01010-3
replacement of cracked units.
4. Cast stone repair.
5. Cutting and pointing.
6. Lintel replacement.
7. Incidental Flashing Work (that is part of the Base Bid Masonry Repairs).
8. Structural steel modifications and protection.
9. Re-sealing around all windows that are adjacent to or within masonry work areas,
and touch-up painting.
10. Exploration of at least five window lintel ends to confirm condition of installed
flashing, and closure of the exploratory holes.
11. Exposure, trimming painting and flashing of the relieving shelf at the South Tower
East Elevation.
12. Installation of Helical Reinforcing.
13. Application of a Water Repellant Coating.
B. Perform all work in accordance with the drawings and specifications under the
ALTERNATE #A1 for this contract to include at least the following items of work along
with all incidental work required for the completion of these items:
A1. Retrofitting installation of end dams at the ends of existing window flashings
including all brick removal and re-setting to match original appearance.
C. Perform all work in accordance with the drawings and specifications under the
ALTERNATE #A2 for this contract to include at least the following items of work along
with all incidental work required for the completion of these items:
A2. Exposure of existing lintels and addition of window flashing with end dams,
including all brick removal and re-setting to match original appearance.
D. The contractor shall return the premises to a clean, orderly and attractive condition
following completion of the all work.
PART 4- MEASUREMENT AND PAYMENT
4.1 All work shall be provided and paid for by the lump sum, except where specifically noted below as
unit cost items, including all incidental work that is required for the completion of the specified
work.
4.2 Unit Cost Items- The following work shall be paid by the unit cost for the measured completed
work:
Item #U1- Cutting and pointing of brickwork and cast stonework measured by gross square
foot. This shall include all right angle returns around windows and doors as
incidental to the unit cost.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
01010-4
Item #U2- Removal and re-setting or replacement of existing brickwork, cast stonework, and
clay tile back-up, including all setting, pinning and pointing, measured by the
square foot per 4 inch nominal thickness.
Item #U3- Rebonding repair of structural cracks in remaining masonry measured by the
lineal foot of crack.
Item #U4- Installation of helical reinforcement, including slot cutting, grouting, setting and
pointing, measured by the lineal foot in place. Overlapping bar lengths at lap
splices shall be incidental to the overall measured in-place lengths.
Item #U5- Cast stone spall repairs measured by the location.
Item #A1- Retrofitting installation of end dams at the ends of existing window flashings
including all brick removal and re-setting to match original appearance, measured
by the treated window location (2 end dams per window).
Item #A2- Exposure of existing lintels and addition of window flashing with end dams,
including all brick removal and re-setting to match original appearance, measured
by the window location.
.
All Unit Cost items shall include their apportioned share of Division 1, incidental, overhead and
profit costs in the Unit Cost prices submitted.
END OF SECTION
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Selective Dismantling and Demolition
02050-1
SECTION 02050
SELECTIVE DISMANTLING AND DEMOLITION
PART 1 - GENERAL
1.1 INCLUDED IN THIS SECTION
A. Dismantling and Demolition of designated exterior masonry.
B. Dismantling of additional masonry elements that have become loose.
C. Demolition of damaged back-up masonry to be disposed of.
D. Demolition of rusted metal elements.
1.2 RELATED SECTIONS
A. Section 02210 - Temporary Shoring and Bracing
B. Section 04100 - Masonry Restoration
1.3 REFERENCES
A. Comply with all applicable OSHA requirements.
1.4 SUBMITTALS
A. Submit certificates attesting to legal disposal of refuse materials if requested by the
Engineer.
1.5 PROTECTION
A. Provide for the uninterrupted safety of workers and adjacent structures to remain as well
as the general public during all phases of the work. Provide warning signs, and
barricades as required to maintain a separated, safe, secure site.
B. Protect all elements which are to remain and all historic elements to be retained and/or
re-set. Do not dismantle anything other than what is specifically indicated on the contract
documents unless specifically requested to do so in writing by the Engineer.
PART 2 - PRODUCTS AND MATERIALS
2.1 PROVIDE PRODUCTS AND MATERIALS: which are incidental to the dismantling and demolition
work, disposing of these or salvaging them for re-use as best suits the project conditions.
PART 3 - EXECUTION
3.1 SITE REVIEW: Perform full review of site to verify extent of dismantling and demolition and to
plan for coordination with other trades.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Selective Dismantling and Demolition
02050-2
3.2 DISMANTLING OPERATIONS
A. Carefully study each item to be dismantled and determine the safest, least disturbing and
potentially damaging method of disassembly.
B. Dismantle the specific items and store items designated for re-use or salvage in a safe
place.
C. Notify the Engineer immediately if any damage has occurred to any of the dismantled
items and propose appropriate methods of repair.
3.4 DEMOLITION OPERATIONS
A. Examine areas and conditions under which the Work will be performed. Correct
conditions which are detrimental to the timely and proper completion of the work. Proceed
only when unsatisfactory conditions have been corrected.
B. Protect items in or near the work that are to remain.
C. Minimize noise and dust. Provide wetting and protection as required.
D. Prevent accumulation of debris on the site. Remove refuse or salvaged items on a
continuous, on-going basis.
E. Do not demolish any elements on which other elem ents depend for their stability without
directly supporting them by another means. Proceed with all dismantling work in an
incremental fashion to avoid destabilizing the structure.
F. Return site to neat, tidy condition following dismantling operations.
END OF SECTION
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
02210-1
SECTION 02210
TEMPORARY SHORING AND BRACING
PART 1 - GENERAL
1.1 INCLUDED IN THIS SECTION
A. Detailing and installation of all required temporary shoring, bracing and support to enable
the specified masonry reconstruction and restoration to be completed in a safe and
expedient manner.
1.2 REFERENCES
A. Comply with the following standard material specifications that apply to the materials
used.
1.3 SUBMITTALS
A. Submit the following items to the Engineer for review:
1. Drawings showing shoring, bracing, and temporary supports.
2. A written sequence of all phases of restoration operations and related temporary
support.
1.4 QUALITY ASSURANCE
A. Comply with all referenced standards for the products employed.
B. Schedule all appropriate site visits and inspections.
PART 2 - PRODUCTS
2.1 MATERIALS AND PRODUCTS
A. Products and materials that are appropriate to the application and permitted by the
Massachusetts State Building Code.
PART 3 - EXECUTION
3.1 TEMPORARY SHORING, BRACING AND PROTECTION
A. The contractor shall be solely responsible for all means and methods of construction
employed on this project including all temporary bracing, support and protection of the
existing Structure. Contractor shall be prepared to retain the services of a
Massachusetts- registered professional structural engineer at his own expense if
necessary in order to maintain safe and stable conditions on the project. Any sequences
of work or methods indicated or implied in the contract documents are present only as
assumptions on which the design of the permanent installations are based and are to be
considered as a suggested option for review by the contractor.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
02210-2
B. Field Survey and Analysis:
1. Field verify indicated shoring locations and measure all existing geometry and
note existing conditions. Locate points of attachm ent and support that will best
suit progress of work.
2. Perform a structural analysis of the areas to be affected by the work and
determine loads on temporary shoring, bracing and support system.
C. Design Shoring, Bracing and Protection:
1. Shoring and bracing shall be designed to maintain existing lines and surfaces
without deflection during work. Design shall be in accordance with gravity dead,
live and wind load resistance requirements of the Massachusetts State Building
Code and referenced standards.
2. Shoring and bracing shall be sufficient for existing and new material loads and
anticipated construction loads.
3. Shoring and bracing shall allow for distribution of loads to supporting structure
and shall limit all movement to less than 1/16" at full loading. Stresses on
supporting structure shall not exceed safe, commonly allowable stresses for the
materials in consideration of their age and conditions. Bending members shall
allow deflections of not more than the span lengths divided by 720 at full loading.
4. Protection shall be detailed to protect the remaining structure, its contents, and
the immediate environs against damage from falling projectiles, debris and/or
soiling that is related to or a result of any of the operations that are part of this
project. This shall include barricades, shields, tarpaulins, scrims and restraining
devices, along with any other devices and structures as may be needed to
provide safe protection. All structures shall be detailed and constructed to
withstand all possible live, snow, wind and impact loads without failure.
D. Construct shoring, bracing and protection in accordance with approved submittals and
proper and standard construction practice. Work shall be installed so as not to
permanently mar or stain the exposed stone faces of the structure.
E. Maintenance: Maintain shoring, bracing and support in a safe condition during all phases
of work. Keep wood generally dry and at constant moisture content. Protect wood from
swelling or shrinking with weather and humidity fluctuations.
F. Removal: Remove all shoring and bracing after surrounding work is complete and
masonry has adequately cured to support itself. Remove all temporary inserts and clean
all contact surfaces and plug all holes.
END OF SECTION
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Cast-In-Place Concrete 03300 - 1
SECTION 03300
CAST-IN-PLACE CONCRETE
PART 1 - GENERAL
1.1 INCLUDED IN THIS SECTION
A. New concrete cap slabs for chimney reconstruction
1.2 RELATED SECTIONS
A. Section 04100 – Masonry Repairs
1.3 REFERENCES
A. ACI 211.2 – Standard Practice for Selecting Proportions for Structural Lightweight
Concrete
B. ACI 301 - Structural Concrete for Buildings.
C. ACI 302 - Guide for Concrete Floor and Slab Construction.
D. ACI 304 - Recommended Practice for Measuring, Mixing, Transporting and Placing
Concrete.
E. ACI 305R - Hot Weather Concreting.
F. ACI 306R - Cold Weather Concreting.
G. ACI 308 - Standard Practice for Curing Concrete.
H. ACI 318 - Building Code Requirement s for Reinforced Concrete.
I. ANSI/ASTM D1752 - Preformed Sponge Rubber and Cork Expansion Joint Fillers for
Concrete Paving and Structural Construction.
J. ASTM C33 - Concrete Aggregates.
K. ASTM C94 - Ready-Mixed Concrete.
L. ASTM C150 - Portland Cement.
M. ASTM C260 - Air Entraining Admixtures for Concrete.
N. ASTM C330 - Specification for Lightweight Aggregates for Structural Concrete
O. ASTM C494 - Chemicals Admixtures for Concrete.
P. ASTM C567 – Test Method for Density of Structural Lightweight Concrete
Q. ACI SP-66 - American Concrete Institute - Detailing Manual.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Cast-In-Place Concrete 03300 - 2
R. ANSI/ASTM A185 - Welded Steel Wire Fabric for Concrete Reinforcement.
S. CRSI - Concrete Reinforcing Steel Institute - Manual of Practice.
T. CRSI - Placing Reinforcing Bars.
1.4 SUBMITTALS
A. Product Data: Provide product data for all accessories, admixtures and inserts.
B. Shop Drawings: Fully show all bar sizes, spacing, locations, and quantities of reinforcing
steel and wire fabric. Provide bending and cutting schedules.
1.5 RECORD DOCUMENTS
A. Accurately record actual locations of embedded utilities and components which are
concealed from view.
1.6 QUALITY ASSURANCE
A. Perform Work in accordance with ACI 301.
B. Conform to ACI 305R when concreting during hot weather.
C. Conform to ACI 306R when concreting during cold weather.
D. Detailing and construction of formwork, shoring and bracing shall be sufficient to maintain
required alignments and surfaces. All work shall conform to ACI 318 and ACI 301, the
Massachusetts State Building Code, and accepted construction practice.
E. Reinforcing steel detailing and installation shall be in accordance with CRSI - Manual of
Standard Practice, ACI SP-66, and ACI 318.
F. The contractor shall take samples of concrete and pay for them to be compression tested
by a qualified, independent testing laboratory per Subsection 3.7 of this Section.
PART 2 - PRODUCTS
2.1 CONCRETE MATERIALS
A. Cement: ASTM C150.
B. Normal weight Fine and Coarse Aggregates: ASTM C33.
C. Water: Clean and not detrimental to concrete.
2.2 ADMIXTURES
A. Air Entraining admixture: ASTM C260.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Cast-In-Place Concrete 03300 - 3
B. Chemical: ASTM C494 Type A - Water Reducing
C. No admixtures shall contain calcium chloride.
2.3 REINFORCEMENT AND ACCESSORIES
A. Reinforcing Steel: ASTM A615, 60 ksi yield grade; deformed billet steel bars, epoxy
coated in accordance with ASTM A775.
B. Tie Wire: Minimum 16 gage annealed type.
C. Chairs, Bolsters, Bar Supports, Spacers: Sized and shaped for strength and support of
reinforcement during concrete placement conditions including load bearing pad on bottom
to prevent vapor barrier puncture.
D. Special Chairs, Bolsters, Bar Supports, Spacers Adjacent to Weather Exposed Concrete
Surfaces: Plastic coated steel type; size and shape as required.
E. Fabricate concrete reinforcing in accordance with CRSI Manual of Practice, ACI SP- 66,
ACI 318.
F. Locate reinforcing splices not indicated on drawings, at point of minimum stress.
G. Provide approved epoxy bonding agent between existing concrete to be placed against
and new.
2.4 CONCRETE MIX
A. Standards: Mix concrete in accordance with ACI 304. Deliver concrete in accordance with
ASTM C94. Select proportions for normal weight concrete in accordance with ACI 301
Method 1.
B. Mix Requirements:
1. Cast in Place Concrete shall have the following properties:
Compressive Strength (28 day) 4,000 psi
Water/Cement Ratio (maximum) 0.40 by weight
Aggregate Size to suit placement
Air Entrainment 4% to 6% percent
Water Reducing Agent As required
Slump to suit placement
Calcium Nitrate (corrosion inhibitor) 5 gal./cy.
2. Lightweight Concrete shall have the above properties and shall have a calculated
equilibrium density of no more than 115 lb/ft3 ± 3 lb/ft3 as determined by ASTM 567,
Section 9.2.
3. Use accelerating admixtures in cold weather when approved by Engineer but do not
relax other cold weather concrete placement requirements.
4. Do not use calcium chloride-containing admixtures.
5. Add air entraining agent to normal weight concrete mix for work exposed to exterior.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Cast-In-Place Concrete 03300 - 4
2.5 FORM MATERIALS AND ACCESSORIES
A. Plywood: Douglas Fir or Spruce species; plugged smooth-sided A/C grade; clean, smooth
sheets with true edges. P/T is to be used where in contact with existing framing.
B. Form Ties: Snap-off type, galvanized metal, fixed or adjustable length, with waterproofing
washer, free of defects that could create 1" of larger holes or defects in the concrete
surface.
C. Corners: Chamfer, rigid plastic or wood strip t ype, 3/4" x 3/4", maximum possible lengths.
PART 3 - EXECUTION
3.1 PREPARATION
A. Cleaning: Prepare surfaces to receive new concrete by cleaning and removing all materials
to which concrete will not bond.
3.2 ERECTION OF FORMWORK
A. Erect formwork, shoring and bracing in accordance with ACI 301 to achieve required
geometry and stability.
B. Arrange and assemble formwork to permit dismantling and stripping (to avoid damaging
concrete during stripping). Align joints and make watertight. Keep form joints to a
minimum. Provide chamfer strips on external corners of foundation walls. Maintain
tolerances required by ACI 301.
C. Where concrete is to be placed upon existing or as-built masonry, clean all masonry
contact surfaces for uninhibited bond.
D. Apply form release agent on formwork in accordance with manufacturer's
recommendations. Do not apply form release agent where concrete surfaces will receive
applied coverings which are effected by agent. Soak inside surfaces of untreated forms
with clean water. Keep surfaces coated prior to placement of concrete.
E. Clean forms as erection proceeds and clean formed cavities of debris prior to placing
concrete. Flush with water or use compressed air to remove remaining foreign matter.
Ensure that water and debris drain to exterior through clean-out ports. Do not allow ice or
snow to accumulate within forms, but remove manually if this accumulates. Do not use
de-icing salts and do not use water to clean out forms in cold weather conditions. Use
compressed air or other means to remove foreign matter.
3.3 PLACEMENT OF REINFORCING STEEL, EMBEDDED PARTS, AND ACCESSORIES
A. Place, support and secure reinforcement against displacement. Do not deviate from
required position. Accommodate placement of formed openings and inserts.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Cast-In-Place Concrete 03300 - 5
B. Provide formed openings where required for items to be embedded in passing through
concrete work. Locate and set in place items that will be cast directly into concrete.
Coordinate with work of other sections in forming and placing openings, slots, reglets,
recesses, sleeves, bolts, anchors, other inserts, and components of other work.
C. Install accessories in accordance with manufacturer's instructions, straight, level, and
plumb. Ensure items are not disturbed during concrete placement.
D. Provide temporary ports or openings in formwork where required to facilitate cleaning and
inspection. Locate openings at bottom of forms to allow flushing water to drain.
E. Install dowels to masonry work in accordance with Section 04100- Masonry.
F. Close temporary openings with tight fitting panels, flush with inside face of forms, and
neatly fitted so joints will not be apparent in exposed concrete surfaces.
G. Arrange for field inspection of reinforcing steel and accessories by the Engineer or a
representative of the Owner at least 4 days in advance of concrete placement, or send said
individual proper photographic documentation of the completed work, to be reviewed and
commented on before concrete placement.
3.4 CONCRETE PLACEMENT
A. Place concrete in accordance with ACI 304 or ACI 301. Notify Engineer a minimum of 24
hours prior to commencement of operations.
B. Ensure reinforcement, inserts and embedded parts are not disturbed during concrete
placement.
C. Maintain records of concrete placement: Record date, location, quantity, air temperature,
and test samples taken.
D. Place concrete continuously between predetermined expansion, control, and construction
joints. Do not interrupt successive placement; do not permit cold joints to occur.
3.5 CONCRETE FINISHING, CURING AND PROTECTION
A. Immediately after placement, protect concrete from premature drying, excessively hot or
cold temperatures, and mechanical injury. Maintain concrete with minimal moisture loss at
relatively constant temperature for period necessary for hydration of cement and hardening
of concrete.
B. As concrete has taken an initial set, “float” the top surface to obtain the proper grading and
then finish the surface. The exposed roof surface shall have a steel trowel finish.
3.6 FORM REMOVAL
A. Do not remove forms or bracing until concrete has gained sufficient strength to carry its
own weight and imposed loads. Loosen forms carefully. Do not wedge pry bars, hammers,
or tools against finish concrete surfaces scheduled for exposure to view.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Cast-In-Place Concrete 03300 - 6
B. Store removed forms in manner that surfaces to be in contact with fresh concrete will not
be damaged. Discard damaged forms.
3.7 FIELD INSPECTION AND TESTING
A. Arrange for pre-placement inspection per above requirements.
B. Mix Design Submission: Submit proposed mix design to inspection and testing firm for
review prior to commencement of work.
C. Cement and Aggregates: Tests of cement and aggregates may be performed to ensure
conformance with specified requirements.
D. Test Cylinders: Three concrete test cylinders will be taken for each day's batch.
E. One additional test cylinder will be taken during cold weather concreting, cured on job site
under same conditions as concrete it represents.
END OF SECTION
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Masonry Repairs 04100 - 1
SECTION 04100
MASONRY REPAIRS
PART 1 - GENERAL
1.1 INCLUDED IN THIS SECTION
A. Selective dismantling and reassembly of designated and/or shifted masonry.
B. Selective demolition and reconstruction of designated or failed masonry.
C. Repair of structural cracks.
D. Installation of masonry anchors and ties.
E. Cutting and pointing of brick and cast stone masonry.
F. Repair of damaged cast stone units.
G. Application of a Water Repellant coating.
1.2 SCOPE OF WORK
A. The Work shall include all masonry work, the nature and quantities of which are detailed
and described herein and on the contract drawings.
B. The masonry Contractor shall be responsible for coordinating and insuring that all
flashing and weep holes are installed.
1.3 RELATED SECTIONS
A. Section 02050 – Structural Dismantling and Demolition
B. Section 02210 – Temporary Shoring and Bracing
C. Section 05500 - Structural Metal Fabrications
1.4 REFERENCES
A. Comply with the following standard material specifications:
ASTM C141- Hydrated Hydraulic Lime
ASTM C144 - Sand for Mortar and Grout
ASTM C216 - Fired Clay Units
ASTM C270 - Mortar and Mortar Testing for Unit Masonry
ASTM C1713 – Mortars for the Repair of Historic Masonry
ASTM A276, Type 304 - Threaded Round Stainless Steel Bar Stock.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Masonry Repairs 04100 - 2
ACI 301 - Concrete Mix Design and Placement
ASTM C144 - Sand for Mortar and Grout
ACI 318 - Building Code Requirements for Reinforced Concrete for Buildings
ACI 530 - Building Code Requirements for Masonry Structures.
ACI 530.1 - Specifications for Masonry Structures.
ASTM A82 - Cold-Drawn Steel Wire for Concrete Reinforcement.
ASTM A123 - Zinc (Hot-Dipped Galvanized) Coatings on Iron and Steel Products.
ASTM A167 - Stainless and Heat-Resisting Chromium-Nickel Steel Plate.
ASTM A525 - Steel Sheet, Zinc Coated, (Galvanized) by the Hot-Dip Process.
ASTM A580 - Stainless and Heat-Resisting Steel Wire.
ASTM C216 - Facing Brick (Solid Masonry Units Made From Clay or Shale).
IMIAC - International Masonry Industry All-Weather Council: Recommended Practices
and Guide Specification for Cold Weather Masonry Construction.
UL - Fire Resistance Directory.
1.5 SUBMITTALS
A. Submit the following items to the Engineer for review:
1. Test reports required as per paragraph 1.6 - Quality Control.
2. Product Data: Submit manufacturers' technical data for each product indicated
including recommendations for their application and use. Include test reports and
certifications substantiating that products comply with requirements.
3. Product data sheets and samples.
4. Concrete mix design where needed.
B. Submit shop drawings and samples for all masonry fabrications.
1. Replacement stone sample where appropriate.
C. Perform field-constructed mock-ups for review by the Engineer:
1. Samples of new structural pointing and patching mortars and grouts cured in
same fashion as will be applied to structure.
2. 24”x24” raking (joint cutting) test/sample patches for (as preparation for
repointing work) to be provided by the Contractor at exterior and interior wall
surfaces and located as agreed with Engineer on site. No raking or joint cutting
shall be started until samples are approved.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Masonry Repairs 04100 - 3
3. 24”x24” pointing / repointing test/sample patches to be provided by the
Contractor at exterior and interior wall surfaces and located at agreed with the
Engineer on site. No repointing shall be started until samples are approved.
4. For each mason who will work on a particular task provide the following:
a. Mortar removal mock up for existing brick joints at brick harvest areas - 4’ x
4’
5. Work that does not match the approved sample panels shall be rejected and
redone. The Contractor shall be responsible for producing as many sample
panels as necessary to provide a match of existing adjacent work that meets the
satisfaction of the Engineer.
1.6 QUALITY CONTROL
A. Comply with all referenced standards for the products employed.
B. Comply with requirements of Massachusetts State Building Code.
C. Coordinate times of Special Inspections to comply with Massachusetts State Building
Code.
D. All masonry work shall be performed by individuals with more than ten year well-
referenced experience with historic brick and stone masonry restoration.
E. All masonry work shall be performed by individuals with more than ten years of well-
referenced experience with similar projects.
F. During periods of cold or questionable weather, keep a log of work including air
temperature and weather conditions, work started and completed per day, and tests
taken. No work shall be done when the ambient temperature of the structure or the air is
less than 45 degrees F.
G. Produce mortar and grout samples in the form of 2" x 2” x 2” flat slabs, placed against
wooden side forms and backing, for easy removal of cured sample. Provide 8 samples
per mortar and grout type taken on different days and cured under conditions that match
field conditions to testing laboratory for compression testing. Provide at least four 2" x 2"
x 2" field cut samples of existing mortar to the testing laboratory for comparative
compression testing. Contractor shall arrange for and pay for all testing and shall submit
results at 7 days and at 28 days to the Engineer. Adjustments in mix and re-tests shall
be made as required at no additional cost to the owner. Test existing mortar samples
and trial mixes at least three weeks before commencing masonry work.
H. Masonry Contractor shall be a qualified, well-referenced brick and stone mason with at
least 10 years of experience in masonry construction, repair, and restoration.
I. Mortar colors and textures shall match existing cleaned stone and mortar surfaces. The
contractor shall prepare an area of sufficient size to demonstrate the finish of tuck
pointing mortar between the stones and stone filler mortar on the stones.
1.7 DELIVERY, STORAGE AND HANDLING
A. Deliver materials to site in manufacturer's original and unopened containers and
packaging, bearing labels as to type and names of products and manufacturers.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Masonry Repairs 04100 - 4
B. Protect mortar and other cementitious materials from deterioration by moisture and
temperature. Store in a dry location or in waterproof containers. Keep containers tightly
closed and away from open flames. Protect liquid components from freezing. Comply
with manufacturer's recommendations for minimum and maximum temperature
requirements for storage.
C. Restore any damage to site caused by storage, mixing or construction work.
D. Packing and Loading of Materials: Carefully pack and load finished stone for shipment
using all reasonable and customary precautions against damage in transit. Do not use
any material that may cause staining or discoloration for blocking or packing.
E. Store brick in a way that is conducive to pre-wetting and moisture acclimation, removing
plastic wrapping. Spray with water at the beginning and end of each work day.
F. Store cementitious materials off the ground, under cover and in dry location.
G. Store aggregates where grading and other required characteristics can be maintained.
H. Protect mortar materials and stone accessories including metal items to prevent
deterioration by corrosion and accumulation of dirt.
1.8 SEQUENCING/SCHEDULING
A. Order replacement brick units (if needed) at the earliest possible date, to avoid delaying
completion of the Work.
B. Utilize sequence that best suits the work.
C. Schedule work to remove and/or at least brace all unstable masonry elements by the
earliest possible opportunity in order to make conditions safe.
1.9 PROJECT CONDITIONS
A. Prevent grout or mortar used in repointing and repair work from staining face of
surrounding masonry and other surfaces. Remove immediately grout and mortar in
contact with exposed masonry and other surfaces.
B. Protect sills, ledges and projections from mortar droppings.
C. Protection: Protect and maintain all work in a dry safe condition for the duration of the
work.
D. Protection of Work: Cover tops of walls with heavy waterproof sheeting at end of each
day's work. Cover partially completed structures when work is not in progress.
1. Extend cover a minimum of 24 inches down both sides and hold cover in place.
2. Staining: Prevent grout or mortar from staining the face of stone to be left
exposed. Remove immediately grout or mortar in contact with such stone.
3. Protect surrounding surfaces from rain-splashed soil and mortar splatter by
means of coverings spread on ground and over wall surface. Protect sills, ledges
and projections from droppings of mortar.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Masonry Repairs 04100 - 5
E. Remove all masonry determined to be frozen or damaged by freezing conditions.
F. Protect base of walls from rain-splashed mud and mortar splatter by means of coverings
spread on ground and over wall surface. Protect sills, ledges and projections from
droppings of mortar.
G. Protection During Cleaning: Protect persons, motor vehicles, construction site and
surrounding buildings from injury resulting from stone cleaning work.
1. Protect all non-stone surfaces. Review all protective measures with Engineer.
2. Protect all non-masonry surfaces. Review all protective measures with Engineer.
3. Prevent cleaning solutions from coming into contact with pedestrians, motor
vehicles, plant materials, buildings and other surfaces that could be injured by
such contact.
4. Do not clean stone during winds of sufficient force to spread cleaning solutions to
unprotected surfaces.
5. Dispose of run-off from cleaning operations by legal means and in a manner
which prevents soil erosion, undermining of paving and foundations, and damage
to adjacent landscaping.
1.10 COLD WEATHER PROTECTION
A. Do not perform any wet masonry work when temperature of surrounding area is below 40
degrees F., or below 45 degrees F. and falling, or forecast by public news media to fall to
or below 35 degrees F. within 24 hours without temporary heated enclosures or without
heating materials or other precautions necessary to prevent freezing. Minimum
temperature within heated enclosure shall be 40 degrees F. Do not use masonry
materials which are likely to contain frost. Do not use accelerating ingredients with any
mortar. Mortar shall harden without freezing and with no damage from frost. Protect all
work against freezing for not less than 48 hours after installation.
B. Do not lay masonry units that are cold and wet or frozen. Do not use frozen materials or
materials mixed or coated with ice or frost. Do not build on frozen setting beds.
C. Comply with requirements of International Masonry All-Weather Council's "Guide
Specification for Cold-Weather Masonry Construction". Heat materials and provide
temporary protection of completed portions of stone work.
1.11 HOT WEATHER PROTECTION
A. Protect masonry work in hot weather to prevent excessive evaporation of setting beds
and grout. Provide artificial shade, wind breaks and use cooled materials as required.
Use fresh mortar. Discard mortar that has stiffened due to hydration.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Masonry Repairs 04100 - 6
PART 2 - PRODUCTS
2.1 MASONRY UNITS
A. Brick: Re-use existing bricks wherever possible, and only units that are in “good-as-new”
condition. Otherwise, provide new ASTM C216, Grade SW, Low Absorption. Minimum
strength shall be 8,000 psi, maximum water absorption shall be 8%. New units shall
match size and shape of existing surrounding brick. Color shall be one shade darker
than the existing brick in its present condition.
B. Hollow Load Bearing Block Units (CMU): ASTM C90 Moisture Controlled; normal
weight.
C. Concrete Brick: New concrete brick units meeting ASTM C55, Grade N, Type 1 Moisture
Controlled, Normal Weight. Minimum Strength 3,500 psi (verify by test).
2.2 MORTAR AND GROUT
A. Mortar and Grout Materials:
1. Cement: Type 1 white and/or gray cement as follows: Portland Cement: ASTM
C150 complying with staining requirements of ASTM C91 for a low-alkali cement
having a maximum of 0.60% equivalent alkalis. Mortar shall show no
efflorescence when cast in a 2” x 7” x ½” slab consisting of 1 part of the cement
to be used, 2 parts Ottawa plastic mortar sand and distilled water, and subjected
to a 7 day “wick test” conforming to ASTM C67.
2. Hydrated Lime: ASTM C207, Type S.
3. Fine Aggregate / Sand for mortar and grout: ASTM C144, washed, clean and
free of salts. For use in mortar that will be used for pointing that is exposed to
public view sand shall match the sand in the original mortar in color, coarseness
and gradation, subject to review by the Engineer.
4. Water: Potable, clean, free of oils, acids, alkalis and organic matter.
B. Provide mortar conforming to ASTM C1713 “Proportion Specification” in the
formulation(s) as listed below.
1. Provide the following:
a. Structural mortar for Masonry Reconstruction and Re-setting shall be 1
part Portland Cement, 1 part Hydrated Lime and 6 parts Bulked Sand.
b. Mortar for exposed Masonry Pointing / Repointing shall be 1 part
Portland Cement, 1 part Hydrated Lime and 6 parts Bulked Sand.
Sand shall be properly selected and blended to match the color, texture
and appearance of the existing mortar sand, and when used, Portland
Cement shall be a combination of white and gray cement that bests suits
the color matching of the existing mortar binder. Where additionally
needed, up to 10% by mineral oxide pigment by weight of binder may be
added to best match the color of the original mortar. Pigments shall be
chemically pure mineral oxides, alkali proof and light fast, and shall be
equal or equivalent to “Solomon Grind” as manufactured by Chem
Services Inc, of Springfield, IL.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Masonry Repairs 04100 - 7
2. The Contractor shall review test data and products with the Engineer and any
required adjustments shall be made. Contractor shall then submit a record
mortar mix design along with product data sheets to the Engineer for verification
and review before beginning any mixing and/or setting.
C. Stone Repair Mortar for filling exposed holes, drill holes, surface joints and spalls in
exposed granite shall be equal or equivalent to Jahn M90 Concrete and Precast Repair
Mortar, as supplied by Cathedral Stone Products of Hanover, MD (410-782-9150).
D. Stone repair of cracked non-load bearing stones micro injection grout shall be equal or
equivalent to Jahn M30, Micro Injection Grout for Brick and Softstone.
E. Grout for grouted reinforced concrete unit masonry and formed grout construction:
1. For bond beams, formed grout arches and grouted bearing blocks- 3,000 psi strength
at 28 days; 3-6 inches slump; premixed type in accordance with ASTM C94 or mixed
in accordance with ASTM C476 Course grout.
2. For Grouted Cores of Reinforced Concrete Unit Masonry: 3,000 psi strength at 28
days; 8-10 inches slump; premixed type in accordance with ASTM C94 or mixed in
accordance with ASTM C476 Fine grout.
F. Adhesive Grout for boding of helical reinforcing shall be “Helibond” grout as supplied by
Conspec Inc. of East Haven, CT (203-467-4426).
G. “Restoration Grout” for filling voided collar joints behind projecting brick unit masonry and
cast stone, for filling head joints between cast stone units that are too deep to point, for
filling cavities within rubble stone and for filling any other masonry voids other than in
concrete unit masonry shall be the following:
“VoidSpan #600 Series PHLc70 Injection Grout” as supplied by VoidSpan Technologies
of Salem, MA (800-966-8643/ 800-966-VOID), with mixing water as specified by
manufacturer.
Water content shall be adjusted only as allowed by the manufacturer in order to reach
target values of shrinkage and compressive strength.
2.3 MORTAR AND GROUT MIXING
A. Thoroughly mix mortar ingredients in accordance with ASTM C270 in quantities needed
for immediate use.
B. Mix grout in accordance with ASTM C94 or thoroughly mix grout ingredients in quantities
needed for immediate use in accordance with ASTM C476 and/or manufacturer’s
instructions.
C. Mortar colors shall be chosen to match cleaned stone and mortar surfaces. Chemically
clean an 18" square area of wall at a location to be designated in the field by the
Engineer for use in color comparison.
D. Do not use anti-freeze compounds to lower the freezing point of grout.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Masonry Repairs 04100 - 8
2.4 REINFORCEMENT, ANCHORAGE AND ADHESIVE PRODUCTS
A. Horizontal Joint Reinforcement: Ladder type; steel wire, hot dip galvanized to ASTM
A641 Class 3 after fabrication, cold drawn steel wire conforming to ASTM A82, 3/16"
diameter side rods with 9 gage cross ties, hot dip galvanized.
B. Reinforcing Steel: ASTM A615, epoxy coated, grade 60 deformed bars.
C. Provide stainless steel ties and anchors for attachment of stone masonry to CMU back-
up construction meeting the requirements of ASTM A276, Type 316.
1. Ties and anchors shall be threaded over their entire lengths unless otherwise
noted.
2. Pins for sealant-setting to stonework shall be straight, unthreaded rod stock.
3. Provide steel fabrications as detailed on the Structural Drawings. Fabrications
shall be dimensioned and/or modified as needed to suit field conditions and shall
be fabricated or manufactured per approved shop drawings only.
D. Retrofit Joint Reinforcement: “Helibar” Helical Reinforcing, of Type 304 stainless steel, as
supplied by Conspec Inc. of East Haven, CT (t. 203-467-4426).
E. Sealant for Setting of Pins and Sealing Joints where indicated:
1. Provide 2-component polyurethane complying with ASTM C-920 and Federal
Specification TT-S-00227.
2. Sealant shall be equal or equivalent to the Sika or Tremco product lines.
F. Adhesive Anchoring System for Miscellaneous Embedded Items (pins, dowels and where
indicated on the Contract Drawings as “Adhesive Anchors”) and Repairs:
1. For anchorage to masonry: Hilti HY20 Adhesive Injection System with properly
sized Screen Tubes as manufactured by the HILTI Corporation of Tulsa, OK.
2. For anchorage to large, non-porous solid masonry units (w/out crossing voids or
cavities): Hilti RE 500 Adhesive Injection System as manufactured by the HILTI
Corporation of Tulsa, OK or Sikadur Injection Gel as manufactured by the Sika
Corporation of Lyndurst, NJ.
3. For pinning and bonding of stone dutchmen or fragments to parent units: Sikadur
Injection Gel as manufactured by the Sika Corporation of Lyndhurst, NJ.
2.5 MISCELLANEOUS PRODUCTS
A. Sealant and Backer Rods
1. Provide 2-component polyurethane complying with ASTM C-920 and Federal
Specification TT-S-00227E. Acceptable manufacturers: Sika, Tremco product
line.
2. Provide closed cell backer rod at all sealant joints. Backer rod shall be carefully
sized per sealant manufacturer instructions for each joint.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Masonry Repairs 04100 - 9
3. Backer Boards shall be Preservative Pressure Treated (P/T) Southern Yellow
Pine adhered to the interior faces of the step treads with an approved paste-type
epoxy adhesive.
B. Epoxy Adhesive for Injection of Cracks in Damaged Stone Units and for adhering loose
shards and repair Dutchmen: “Sikadur Injection Gel” as manufactured by the Sika
Corporation of Lyndhurst, NJ. or approved equal. Crack Sealant for Epoxy Injection:
“Sikadur 33” as manufactured by the Sika Corporation of Lyndhurst, NJ, or approved
equal, along with ports as required.
2.6 FINAL MORTAR WASHDOWN CLEANER
A. For non-pigmented mortars, use equal or equivalent to “Sure Klean 600 Detergent” as
manufactured by ProSoCo Corp.
B. For pigmented mortars use equal or equivalent to “Vana Trol” as manufactured by
ProSoCo Corp.
C. Use only water when cleaning marble.
2.7 WATER REPELLANT
A. A deep penetrating breathable siloxane repellant coating with the following minimum
properties:
1. ASTM C 67: Water Absorption Reduction – Brick 95%
2. ASTM D 6490: Water Vapor Transmission WVT (grains/h ft2) 1.40; Permeance
3.40
3. Color: clear
4. Luster: flat or satin
PART 3 - EXECUTION
3.1 GENERAL REQUIREMENTS OF THE WORK
A. An effort shall be made to minimize the need for on-site storage of masonry materials,
close coordination of the field personnel, material suppliers and the general contractor
shall be shall be maintained to provide for a steady flow of materials on a close to as-
needed basis.
B. Document all existing masonry during dismantling, including masonry thicknesses, sizing
and layout, openings and surrounds, bearing locations and critical coursing elevations.
All documentation shall be recorded on sketches with scalable dimensions, stored both
on site and offsite. All reconstructed work shall geometrically replicate the original
construction.
C. All dismantled work shall be fully documented and the original geometry of the structure
(before bulging and sagging) be established. Reconstruction shall be done to replicate
original geometry.
D. Inspect all masonry within work areas; identify all required repairs and removals.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Masonry Repairs 04100 - 10
E. Perform all other indicated masonry work in accordance with the requirements of this and
all related section and references.
3.2 REMOVAL OF DESIGNATED OR DAMAGED BRICK MASONRY
A. Provide and install all temporary shoring, bracing and support to surrounding construction
before beginning removal. Removal shall be done slowly and methodically to maintain
stability to all remaining elements at all times. Contractor shall be responsible for
maintaining integrity and safety of surrounding construction, in general, during work per
the requirements of Section 02210.
B. Carefully remove designated masonry, maintaining support to all surrounding and
supported elements that are otherwise dependent upon the masonry being removed for
support or stability. Following removal of the exterior grade veneer units, remove all
remaining back-up masonry, storing both in separate locations. Clean and store all
salvageable brick units for re-use, provide replacement bricks for units that cannot be re-
used.
C. At all re-usable exterior brickwork, remove all mortar material from joints using a
combination of hand tools and hand held grinders or specially designed mortar removal
pneumatic tools. The use of hand held grinders or pneumatic tools will be allowed where,
joint widths can accommodate a single pass of the blade without touching either edge of
the stone and, where mortar joints can be mechanically cut without damaging the stone.
Each mechanic must demonstrate proficiency in the use of hand held grinders or
pneumatic tools. Electric or pneumatic demolition hammers, chipping guns or the
equivalent will not be allowed for removing mortar from joints. Rake out mortar joints to a
minimum depth of 1 ½” inch.
D. Following removal of designated masonry, inspect and remove additional masonry that is
loose, damaged or can be separated with unassisted hands.
E. Clean the exposed surfaces of the remaining material, and remove shards of material
which have become loose during work or have shifted from their proper positions. Notify
Engineer immediately of the number of brick wythes that need to be removed before
preceding with work.
F. Notify the Engineer of any masonry beyond immediate work area which becomes
loosened during work. Stop work immediately, provide additional bracing and review with
Engineer before resuming.
G. Protect the existing interior structure from the external weather and from dust and debris
caused by these operations. Provide weather protection as needed until the external
envelope is restored.
3.3 BACK-UP MASONRY EVALUATION AND EXCAVATION
A. Following removal of the exterior veneer, inspect all exposed back-up masonry and
remove the following materials:
1. All loose, weakened and/or shifted clay tile units.
2. Cracked clay tile units that follow structural cracks that need to be replaced in
order to stitch crack together.
3. Mortar from all decomposed or cracked mortar joints.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Masonry Repairs 04100 - 11
B. Clean the exposed interior surfaces of the remaining material, and remove shards of
material, that have become loose during work or have shifted from their proper positions.
Notify Engineer immediately of the number of brick wythes that need to be removed
before preceding with work.
C. Provide and install all temporary shoring, bracing and support as may be necessary to
surrounding construction before beginning removal. Removal and replacement shall be
done sequentially to avoid weakening too much of the structure at one time. Contractor
shall be responsible for maintaining integrity and safety of surrounding work as well as
the tower, in general, during work per the requirem ents of Section 02210 – Temporary
Shoring and Bracing.
D. Notify the Engineer immediately of any adjacent masonry or supported elements beyond
the immediate work area that become loosened during work, of rotten wooden elements,
or of excessively rusted steel elements that become exposed during the work. Stop the
affected work and await Engineer’s instructions should these conditions be encountered.
3.4 REPAIR OF EXISTING BACK-UP MASONRY
A. Remove all loose masonry units, mortar and residue from surface of back-up construction
without disturbing or weakening or destabilizing the masonry. Employ a "pressure
washer" and regulate the nozzle pressure to clean but not damage the hollow clay tile
units.
B. Identify and remove loose and cracked brick and clay tile units. Re-set or replace brick
units with new mortar slushed into surrounding voids. Replace damaged portions of the
clay tile units with new CMU units.
1. Locate damaged and/or loose brick or stone units to be removed. Pull unit(s) out
of wall with a gentle rocking action, driving wedges into surrounding joints only as
required to snap this joint off. Bricks may be removed up to 4 at a time.
2. Set new replacement brick units into wall in orientation and locations of existing
damaged units. Pre-wet existing construction and fully butter all contact surfaces
of new units during setting.
C. Grout-inject cracks and small voids encountered, and fill hollow cavities encountered in
existing masonry to remain in accordance with this Section.
D. Inspect all joints and rake deteriorated or softened mortar joints to a minimum depth of 1”,
or as deeply as necessary to reach sound mortar, but not to exceed one half of the
thickness of the joint without supplementary means of support. Employ tools that are
sharp and will completely cut out joints at intersections without splitting or damaging
stones. Drive hardwood shims into joints that will be cut more deeply than 1 ½” to
prevent the wall construction from shifting. Cut joints shall match the approved sample
patch.
E. Moist-cure all work under a tarpaulin or plastic sheets. Following curing period, maintain
weather protection to interior of structure until exterior wall system is replaced.
3.5 REPAIR OF CRACKS IN BRICK MASONRY
A. Diagonal and Vertical Surface Crack Rebonding
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Masonry Repairs 04100 - 12
1. Before cutting and pointing operations, drill 1/2” diameter holes in the pointing
mortar along the cracks to a depth of 3 ½” from the outer wall face, spaced at 16”
and located at “T” joints where the cracks cross the bed joints.
2. Jet out all from within the crack using low to m oderate pressure water.
3. Gravity feed or inject Restoration Grout into the cracks through the drilled ports,
plugging them when they fill and working upward from port to port. Injection
pressures shall not exceed three feet of equivalent head.
4. After at least 14 days curing time, proceed to cut and point the mortar joints
within at least 16” of the cracks, or as part of the cutting and pointing program for
the rest of the wall.
B. Deep Diagonal and Vertical Crack Repair
1. Except at cracks that run in the extreme corners of the building, carefully remove
two wythes of brickwork along diagonal step and vertical cracks to expose
remaining depths of cracks in back-up construction.
2. Remove two brick wythes from each wall face, along with all loose mortar and
residue from remaining surfaces within crack excavations without disturbing or
weakening or destabilizing the masonry. Employ a "pressure washer" as needed
and regulate the nozzle pressure to clean but not damage the surfaces.
3. Working from the exposed back-up surfaces at all cracks, identify and remove
any loose remaining units and re-set them with new mortar slushed into
surrounding voids. Add new bricks in place of damaged bricks, toothing them
into the surrounding work to re-create solid conditions within the walls.
4. Point the cracks in the remaining back-up wythes and insert regularly spaced ½’
diameter plastic grouting tubes into the pointing mortar.
5. After the mortar has stiffened, gravity feed grout into the pointed cracks via a
funnel and the plastic tubes. Vary the injection pressure by varying the height of
the funnel with the plastic tubes. Randomly drill-test the grouted joints during the
first stages of grouting to verify the effectiveness of the injection procedures.
6. Following internal re-setting and/or grouting of the back-up construction, re-set
original bricks (or salvaged re-used replacement bricks) into the toothed
openings along the crack locations, fully bedding all of the units (top, bottom,
ends and back sides) in wet mortar. Strike and finish-point the work to match the
existing surrounding construction.
C. Horizontal Crack Repair
1. Mechanically widen and clean horizontal cracks in brickwork being careful not to
sever the self-support of the wall by cutting all of the way through it.
a. Remove mortar from sides of cracks to expose ends of bricks at each
side of widened horizontal joints.
b. Flood cracks with water at 10 psi maximum pressure and allow
deleterious materials and any sand or residue to flow out at bottom.
c. Temporarily shim widened cracks that may cause the supported
masonry above to shift downward after cleaning.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Masonry Repairs 04100 - 13
2. After cracks are cleaned and back-up wall surfaces are repaired (or inspected
showing no damage), pressure-pack grout into the crack in advance of pointing.
a. Pack a pasty mix of grout into the cleaned and widened horizontal
cracks, ramming the grout into place with metal or wooden packing tools.
b. Start at one end and progress to the other watching for the forward
advancement of grout from deep within the crack during the packing and
ramming process.
3. Following grouting, point the horizontal cracks, pushing mortar deeply into any
remaining recesses and voids. Tool to match the surrounding original
construction. Clean all newly re-set and repointed surfaces after completion of
masonry work.
4. Perform all work incrementally and brace wall as needed to maintain safe vertical
and lateral support.
D. Work under this subsection shall only be done when the ambient air, material, and
substrate temperatures are above 45 degrees F. by 9:00 AM and rising and less than 90
degrees F.
3.6 CAST STONE UNIT REPAIR
A. Identify all chips, spalls and cracks and soft or weathered areas, and notify the Engineer
of all such conditions.
B. Document conditions of units before and during removal. The Contractor shall be
responsible for replacement of any units that are irreparably damaged due to improper
removal or handling and shall replace such at no additional cost to the owner.
C. Remove all ferrous inserts and connectors from units and patch remaining holes.
D. Injection of Cracks in Intact Stones (both sides of crack in fixed position):
1. Drill holes in crack and insert grouting ports at between 4” and 6” on center.
Verify that crack width is equal to or less than ¼”.
2. Seal surface of crack between and around grouting ports with crack sealant.
Surface seal shall be pigmented to match surrounding stone.
3. Pressure-inject crack with injection gel, starting from bottom port and proceeding
upward as each successive port fills.
4. Allow to cure, remove ports and grind off crack sealant.
E. Re-attachment of Detached Cast Stone Fragments:
1. Remove loose stone fragments from parent material. Install straight 3/16”
diameter stainless steel threaded repair pins on a 4” by 4” pattern but at least 2”
from any stone edges where stone shards are more than 6” wide or 2” thick.
Hole shall be oversized for epoxy adhesive and shall be run through the loose
shard into the parent stone. Follow procedures detailed in Subsection 3.6 of this
Section for installation of adhesive-set pins.
2. Clean contact surfaces between stone fragments.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Masonry Repairs 04100 - 14
3. Pre-butter surfaces to be bonded with injection/ setting adhesive and adhere
together in position, and immediately inject the repair pin holes and insert the
rods to a depth of ½” from the surface of the stone shard. Refer to the Contract
Drawings and Subsection 3.4 of this Section for this repair-pinning work.
F. Spall, Hole and Chip Repair: Clean all spalls, holes and chips and inspect remaining
material, removing any loose flakes, spalls or cracked material.
1. Edge spalls and chips shall be repaired in accordance with the Contract
Drawings using matching stone Dutchmen. Carefully cut out the stone to the
proper geometry (as indicated), not removing any more material than absolutely
necessary. Adhesive-bond new dutchmen into the prepared recesses using gel
type adhesive, recess adhesive by 1/8” to ¼” on all exposed sides of the adhered
joint, which itself shall not exceed 1/16” in width. Push matching cast stone
repair mortar into the recessed joints and after curing the exposed joints shall be
grind smooth to create a barely visible repair.
2. Empty drill holes shall be repaired by coring or reaming to the smallest diameter
that will allow the hole to be cleaned and rounded, and new matching cores of
1/8” to ¼” smaller diameter shall be set into the holes with a neat mix of stone
repair mortar and the cured circular joint shall be ground smooth on all sides to
create a barely visible repair.
3. Surface spalls that do not cross any edges shall be prepared and repaired using
stone repair mortar in accordance with the repair mortar manufacture’s
instruction and requirements.
4. FOLLOW ALL INSTRUCTIONS AND REQUIREMENTS OF THE CAST STONE
REPAIR MORTAR SUPPLIER.
3.7 REPLACEMENT OF RUSTED ANGLE LINTELS
A. Remove rusted angle lintels and jacked supported and concealing masonry.
B. Following demolition and removal of brickwork for new opening, create 8” wide bearing
areas at each end of the top of the opening.
C. Install new galvanized steel angle lintels as indicated on the contract drawings, setting
these on a thin film of leveling mortar but not on a full bed so that the angles fit within a
coursing joint.
D. Replace brickwork around and over lintels, along with flashing and weeps if and as
indicated.
E. Provide proper and sufficient temporary support to the existing overburden above the
lintel during replacement.
3.8 INSTALLATION OF DOWELS, ANCHORS AND CONNECTORS
A. Drill holes for embedded anchors, dowels and rods as follows:
1. Locate holes within the existing masonry so that they are at least 2” from the
nearest joint intersection and within the faces of existing units rather than in the
joints.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Masonry Repairs 04100 - 15
2. Monitor Conditions of brick or stone units as the drill is advancing into them.
Check for vibration or movement of brick units halfway through each by tapping
with the bit. Notify the Engineer if the brickwork or stonework feels “soft”.
3. All holes greater than ½” diameter shall be drilled using a diamond tipped core
drill, dry application on interior surfaces, wet or dry application on exterior
surfaces. Do not use a rotary hammer or impact type hammer for holes greater
than ½” in diameter.
B. Install Adhesive-Set connectors, pins and dowels as shown on the Contract Drawings
and as described below using the applicable Injection System.
1. Carefully drill holes of the proper oversize diameter for the screen tube (in
masonry) and for injection resin or sealants 1/8" larger in diameter than the
anchor rod or pin, or as indicated on the Drawings or specified by the
manufacturer of the injection system if different.
2. Locate and size anchors and pins in as indicated in the Contract Documents and
as needed per Engineer’s field instructions following exposure of hidden
conditions.
3. Provide embedments as noted or instructed but not less than 8” embedment at
½” diameter and larger anchors or 4” embedment at anchors of less than ½’
diameter.
4. Incrementally core-drill all holes being careful not to damage or loosen substrate
and being careful to avoid embedded metal if any.
5. Simultaneously with injection of holes, pre-butter rods’ surfaces with injection
resin so that there is a uniform coating all around the rod of between 1/16” and
1/8” in thickness and insert rods immediately thereafter.
6. Monitor progress and quality of work, adjusting techniques as may be necessary
with approval of the Engineer. Check that annular space is filled around the end
of each rod following insertion. If properly installed, resin should be oozing out
beyond end of rod all around annular space, showing that the annular space and
the hole are completely filled. Supplementary injection may be necessary due to
the presence of voids.
3.9 HELICAL REINFORCING INSTALLATION
A. Sawcut horizontal slots in brickwork as indicated on the Drawings. Clean of all dust,
mortar and brick fragments. Apply manufacturer recommended primer to the surface if
found to be porous.
B. Inject back of slot with Helibond Grout and push Helibar into it. At lap joints apply
additional grout between the back bar and the front bar for bond. Lap a minimum of 12”.
C. Inject additional Helibond Grout to bond the bar to the top and bottom surfaces of the
slot, but not filling the entire slot with it.
D. Point the remaining joint depth in accordance with this specification.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Masonry Repairs 04100 - 16
3.10 MASONRY RECONSTRUCTION
A. Establish lines, levels, and coursing indicated. Protect from displacement. Maintain
masonry courses to uniform dimension. Form vertical and horizontal joints of uniform
thickness.
B. Document and match existing masonry bond as viewed from the exterior.
C. Set masonry units as follows:
1. Lay solid masonry units in full bed of mortar, with full head joints, uniformly
jointed with other work.
2. Buttering corners of joints or excessive furrowing of mortar joints are not
permitted.
3. Remove excess mortar as work progresses.
4. Do not shift or tap masonry units after mortar has achieved initial set. Where
adjustment must be made, remove mortar and replace.
5. Perform job site cutting of masonry units with proper tools to provide straight,
clean, un-chipped edges. Prevent broken masonry unit corners or edges.
6. Masonry units shall be laid in running bond full header courses set into the clay
tile back-up spaced vertically at 16” apart.
D. Inter-wythe Tying of Masonry
1. For tying between re-set brickwork and remaining backup construction in bonded
collar joint construction, provide custom adhesive set stainless steel wire ties as
detailed on the drawings.
2. For tying between between wythes of re-set brickwork, provide extended wire
ties (as described above) and joint reinforcing, in addition to perpendicular
header bricks as shown.
E. Install horizontal joint reinforcing per notes and details on structural drawings. Lap
reinforcing to develop full tension capacity of bar (50 bar diameters or greater). Support
and secure reinforcing bars from displacement.
F. Match all original recesses, header and soldier coursing, either with full or rotated half-
bricks and install all stone sills, stone lintels, metal lintels, flashing, accessories and other
embedded items as indicated or as needed to match the original construction.
G. Work around windows and doors, toothing and interlocking with existing brickwork to
remain.
H. Embed ends of sills in mortar; leave remainder of joint open until final pointing.
I. Recess all mortar joints by 2 ½-times their widths in preparation for final pointing.
J. Moist-cure all completed work for periods of not less than 72 hours.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Masonry Repairs 04100 - 17
K. Remove excess mortar from the surface before it sets using a bristle brush or by rubbing
the surface with burlap or clean sand. Dried mortar may be removed with chemical
excess mortar remove by written permission of the Engineer.
L. Perform no mortar work in wet weather or when rain is predicted within two days unless
work is protected within waterproof enclosures. Extend waterproof covers securely over
work area at the conclusion of each work day.
M. The Engineer reserves the right to reject any brickwork or stonework not meeting
requirements of this section or matching the approved test panel and shall have rejected
work removed and re-set at no additional cost to the owner.
3.11 SETTING/ RE-SETTING TOLERANCES
A. Maximum Variation from Plane of Wall: 1/4" in 10 feet or as required by elevator
clearances.
B. Maximum Variation from Plumb: 1/4" per story non-cumulative, 1/2" total, or as required
by elevator clearances.
C. Maximum Variation from Level Coursing: 1/8" in 4 feet, 1/4" in 10 feet.
D. Maximum Variation of Joint Thickness: 1/8".
3.12 PREPARATION OF JOINTS FOR REPOINTING
A. Rake mortar joints in existing construction in areas designated to be repointed to a
minimum depth of 2.5 times the mortar joint width, 1", or as deeply as necessary to reach
sound mortar (whichever is greatest), but not to exceed one half of the thickness of the
stone thickness without supplementary means of support. Employ tools that are sharp
and will completely cut out joints at intersections without splitting or damaging stones or
bricks. Raking work shall match the approved test sample.
B. Gently drive wedges or hardwood shims into wide, deep cracks in masonry where there
is a possibility that the vertical and in-plane lateral support of masonry work will be
compromised during deep raking of the joints. This should at least be done where more
than half of the length of a specific joint is removed to a depth of more than one third of
the thickness of the stone.
C. Cut flashing reglets in new or existing masonry as indicated on the Drawings.
D. Wire brush clean and then pre-wet the joints and allow for the existing mortar to dry or
saturate to a dull, non-glossy finish immediately before applying new mortar.
E. Where applicable, lead-abate all immediate lead-painted masonry surface areas that will
be affected by cutting and pointing work, prior to starting masonry operations.
3.13 MORTAR JOINT POINTING
A. Pre-wet prepared mortar joint surfaces until they are saturated but surface dry. At
flashing reglets, verify that flashing has been fully installed and is stable.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Masonry Repairs 04100 - 18
B. At new or re-set masonry and deeply cut mortar joints apply a 3/8" base lift of tuck
pointing mortar, and allow to cure. Base lift shall have a struck recess for tuck-pointing to
lock into.
C. Apply final "tuck" lift of pointing mortar, tooling joints to exactly match the existing joint
profiles that are adjacent to the work.
D. Where so specified, point joints and beds with specified sealant after first installing the
specified backup material and applying primer if required, all in strict accordance with the
printed instructions of the sealant manufacturer. Test all sealants for compatibility prior to
use. Tool all sealants to insure maximum adhesion to contact surfaces.
E. Moist cure all work, spraying with a water mist and cover with damp cloth or tarpaulin.
F. Clean mortar from all surfaces following completion and curing of work.
G. Work under this subsection shall only be done when the ambient air, material, and
substrate temperatures are above 40 degrees F. by 9:00 AM and rising.
H. The Contractor shall be responsible for matching the joints of the mock-up surrounding
work and shall re-cut and replace any joints that are poorly formed or do not match the
mock-up or the surrounding work, as determined by the Engineer, at the Contractor's
own expense.
I. Moist cure all work, spraying with a water mist and cover with damp cloth or tarpaulin.
J. Chemically clean all surfaces following completion and curing of work, being careful to
reveal the mortar aggregate but to not over-etch, weaken or discolor the mortar. Remove
excess mortar from the surface before it sets using a bristle brush or by rubbing the
surface with burlap or clean sand. If mortar is left on the surface, wash surface clean.
K. Completed work shall match approved sample patch or shall be re-done at the
Contractor’s expense.
3.14 CLEANING AND PROTECTION OF COMPLETED MASONRY W ORK
A. As work proceeds and upon completion, remove excess mortar, smears and droppings.
Clean adjacent and adjoining surface of marks arising out of execution of work in this
Section.
B. Sweep up and remove daily sand, cleaning compounds and mixtures, dirt, debris and
rubbish. Sweep or flush away nightly, all residual washed materials. Keep the premises
neat and clean at all times.
C. After installation and pointing are completed, carefully clean all surfaces of all dirt, excess
mortar, grout splatter, stains and/or other site incident defacements. Clean soiled
surfaces using a non-acidic solution that will not harm stone or adjacent materials.
Consult stone fabricator for acceptable cleaners. Do not use wire brushes, acid or other
solutions which may cause discoloration. Use nonmetallic tools in cleaning operation.
Apply in accordance with cleaner manufacturer recommendations.
D. Mechanically remove all loose mortar and concrete splatter with hand tools without
scratching, gouging or otherwise marring the existing substrate.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Masonry Repairs 04100 - 19
E. Chemically clean stone following completion of work, and where specifically specified on
the drawings.
3.15 APPLICATION OF WATER REPELLENT
A. Mortar cure: Allow pointing mortar to cure a minimum of 28 days before applying
water repellent.
B. Dry Surfaces: Do not apply water repellent directly after a rainfall or when masonry
is still wet. Moisture content of stone and mortar must be below 15% before water
repellent can be applied.
C. Window Protection: Cover windows prior to application.
D. Application
Apply in accordance with all requirements of Manufacturer’s Product Data Sheet for
Repellent including “Preparation” and “Safety Information” sections. Do not dilute or alter.
1. Vertical Surfaces:
a. Apply protective treatment in a single, saturating application. Thoroughly wet
the surface and create a slight rundown below the spray pattern. Apply
uniformly. Don’t over apply.
b. Brush heavy runs and drips thoroughly into the surface.
2. Horizontal Surfaces:
a. Apply protective treatment in a single application. Use enough material to
keep the surface wet for about a minute before penetrating.
b. Broom out all puddles thoroughly until they completely penetrate the surface.
c. Wipe down excess.
3. Weathered Porous Surfaces:
Provide two applications of protective treatment. Apply the second coat within a
few minutes after the first coat has penetrated and appears dry.
3.16 INSTALLATION OF FLEXIBLE SEALANTS
A. Provide backer rod and sealant where indicated on the Drawings.
B. Install backer rod and sealant in strict accordance to manufacturer's instructions. Use
primer where recommended by manufacturer.
C. Size backer rod for each joint size.
D. Install sealant to the depth recommended by the manufacturer for each width of joint.
Joint profile shall match adjoining mortar profile. Face of joint shall be sanded so that
color and texture shall match adjoining mortar joints.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Masonry Repairs 04100 - 20
E. Sealant at backer rod shall be installed at all locations indicated on Drawings and at all
locations subject to structural or thermal movement.
END OF SECTION 04100
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Structural Metals 05200 - 1
SECTION 05200-
STRUCTURAL METALS
PART 1 - GENERAL
1.1 INCLUDED IN THIS SECTION
A. Replacement steel lintels
1.2 RELATED SECTIONS
A. Section 04100 – Masonry Repairs
1.3 REFERENCES
A. Comply with the following standard material specifications:
1. AISC - Code of Standard Practice - Manual of Steel Construction - Allowable
Stress Design (ASD).
2. ASTM A276, Type 304 - Threaded Round Stainless Steel Bar Stock.
3. ASTM A240, Type 304 – Stainless Steel Plate Stock.
4. AWS A2.4 - Symbols for Welding, Brazing, and Nondestructive Examination.
5. AWS D1.1 - Structural Welding Code.
1.4 SUBMITTALS
A. Submit the following items to the Engineer for review:
1. Shop Drawings of all fabrications showing field verified dimensions, locations,
and connections to be made in the field.
2. Product literature for standard products and/or mass produced items to be used.
1.5 QUALITY CONTROL
A. Comply with all referenced standards for the products employed.
B. Coordinate times of Engineer’s Special Inspections.
PART 2 - PRODUCTS
2.1 STRUCTURAL STEEL MATERIALS (NON STAINLESS), PRODUCTS AND FABRICATIONS
A. Rolled shapes: ASTM A36
B. All new structural steel shall be hot-dipped galvanized after all modifications and shop-
welding have been completed in accordance with ASTM A 123 for fabricated products
and ASTM A 153 for hardware. Provide blow holes as necessary for galvanizing,
indicating sizes and locations on shop drawings.
Formatted
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Structural Metals 05200 - 2
C. Grout for Setting and Supporting Steel Bearing Surfaces: Non-shrink type, pre-mixed
compound consisting of non-metallic aggregate, cement, water reducing and plasticizing
additives, capable of developing a minimum compressive strength of 7,000 psi at 28
days.
PART 3 - EXECUTION
3.1 INSTALLATION OF STEEL LINTEL REPLACEMENTS
A. Install galvanized steel lintel replacements in accordance with Section 04100 –Masonry
Repairs.
END OF SECTION
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Structural Steel Repair and Protection 05300-1
SECTION 05300
STRUCTURAL STEEL REPAIR AND PROTECTION
PART 1 - GENERAL
1.1 INCLUDED IN THIS SECTION
A. Inspection, repair and restoration of existing structural steel.
1.3 REFERENCES
A. Comply with the following standard material specifications:
AISC - Code of Standard Practice - Manual of Steel Construction - Allowable Stress Design
(ASD).
ASTM A123 - Zinc (Hot Dipped Galvanized) Coatings on Iron and Steel Products.
ASTM A563 - Carbon and Alloy Steel Nuts.
ASTM A588 – High Strength Low Alloy Structural Steel (Corrosion Resistant)
ASTM A992- Structural Steel
AWS A2.4 - Symbols for Welding, Brazing, and Nondestructive Examination.
AWS D1.1 - Structural Welding Code.
1.4 QUALITY CONTROL
A. Comply with all referenced standards for the products employed.
B. All welding shall be performed with AWS certified welders in accordance with AWS standards
and requirements.
PART 2 - PRODUCTS
2.1 STRUCTURAL STEEL MATERIALS, PRODUCTS AND FABRICATIONS
A. Structural Steel Shapes and Plates: ASTM A992, Grade 50.
PART 3 - EXECUTION
3.1 CLEANING, INSPECTION AND REPAIR OF EXISTING STRUCTURAL STEEL
A. Coordinate exposure of existing structural steel members and schedule an inspection with the
Engineer.
B. Clean all flaking rust off of exposed members to make visible the remaining section.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Structural Steel Repair and Protection 05300-2
C. Engineer shall determine the nature and extent of repair work which may involve cover plating
or replacement and shall issue sketches showing the extent of the work.
1. All welding to existing members shall be done incrementally to avoid heating and yielding
loaded members.
2. Remove all rust from weld locations and adjust welding voltage as needed where sections
have thinned.
3. Follow the procedure described in AISC Engineering Journal “Field Welding to Existing
Steel Structures”, attached, including testing, and review in field with Engineer before
starting work.
4. Maintain proper support and bracing to all members during work.
D. Following work, clean and repaint members:
1. Remove all rust, dirt and scale from existing steel with scrapers and wire brushes until
bare metal is completely exposed.
2. Paint steel surface with and approved rust inhibitive primer, epoxy-based intermediate
coat and urethane-based top coat such as TNEMEC Series 90-97 Tneme-Zinc and
Series 66 or 69 Epoxoline and Series 73, 74 or 75 Endura Shield, respectively. Apply
first coat within 30 minutes of exposure of cleaned steel to atmosphere.
3. Surfaces shall be kept dry and of at least 50 degrees F. temperature during painting and
24 hour curing period.
3.2 FIELD QUALITY CONTROL
A. Satisfy all applicable requirements of the Massachusetts State Building Code, Article 17 and
the requirements of Subsection 1.5 of this Section.
END OF SECTION
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Flashing and Sheet Metal 07560-1
SECTION 07560
FLASHING AND SHEET METAL
PART 1 - GENERAL
1.1 RELATED DOCUMENTS
The general provisions of the Contract, including General and Supplementary Conditions, and
relevant sections of these Specifications, apply to the work specified in this Section.
1.2 DESCRIPTION OF WORK
A. Metal flashing repair and replacement shall include related built up roofing, ice and water
shield, felt and carpentry.
B. Reglets where identified on drawing.
C. Flashing and counter flashing. Re-cutting or cutting of reglets shall be done under this
section. Mortar pointing shall be done under Historic Masonry.
E. All hoisting, rigging and lifts required to complete the work of this Section.
1.3 RELATED WORK
A. Section 04100 - Masonry
B. Section 05100 - Structural Metalwork
C. Section 07700 – Metal Cornice Restoration
D. Section 09910 - Painting and Paint Removal
1.4 QUALITY ASSURANCE
A. Copper Contractor: The subcontractor shall have not less than five years successful
experience restoring and installing copper roofing. This experience shall include at least six
projects of comparable size and complexity on historically significant buildings during the
last three years.
1.5 SUBMITTALS
A. Submit shop drawings detailing special joint or termination conditions, and conditions of
interface with other materials.
B. Submit product data for sheet membrane, flashing membrane, joint and lap adhesives,
primers and sealants and insulation. Submit sample warranty prior to start of work.
C. Submit manufacturer's installation instructions.
1.6 JOB CONDITIONS
A. Installation: Do not install copper or membrane flashing on snow or ice-covered or wet
surfaces or when air temperature is below 40 degrees F.
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Flashing and Sheet Metal 07560-2
B. Field Conditions: The Installer must examine the roofing substrates and the conditions
under which the roofing work is to be performed, and notify the Contractor in writing of any
unsatisfactory conditions. Do not proceed with the work until unsatisfactory conditions have
been corrected in a manner acceptable to the Installer.
PART 2 - PRODUCTS
2.1 Miscellaneous Materials
A. Ice and watershield: "Ice and Watershield" manufactured by W. R. Grace.
B. Nailers, blocking and miscellaneous framing: #2 ACQ treated (.40 lb./c.f.) S.P.F.
C. Lead: 4 lb./s.f.
D. Rosin paper: Type 1, Grade A, 6 pounds per 100 square feet.
E. Roof cement: ASTM C2822, asphaltic red cement.
2.2 FLASHING AND ACCESSORIES
A. All flashing unless otherwise noted shall be 20 ounce cold rolled Zinc Coated Copper
(ZCC).
B. All fasteners shall be copper, brass, bronze or stainless steel as best suits the application.
C. All fasteners shall be concealed or protected from weather.
D. Sealant shall be polyurethane manufactured by Sika or Tremco.
E. Straps shall be cold rolled copper sized per drawing or if no specific information is given per
Revere "Copper and Common Sense" or SMACNA's recommendations.
F. Solder shall be 50 percent block tin and 50 percent pig lead per ASTM B32.
G. All exposed edges shall be hemmed.
PART 3 - EXECUTION
3.1 HOISTING, SCAFFOLDING, STAGING AND PLANKING: Provide, set-up and maintain all
required derricks, hoisting machinery, scaffolds, and staging and planking, and perform all
hoisting required to complete the work. Comply with OSHA and other relevant safety regulations.
3.2 EXAMINATION: Examine substrate and conditions under which copper work is to be performed;
notify Engineer in writing of unsatisfactory conditions. Do not proceed with work until
unsatisfactory conditions have been corrected.
3.3 REMOVAL OF EXISTING MATERIALS: All removal operations shall be in compliance with local,
state and federal regulations. All material to be removed shall carefully lowered to the ground and
legally disposed of off site. No free fall of roofing or flashing materials is permitted. Carefully
protect existing work.
3.4 SHEET METAL FABRICATION:
Structures North Hawthorne Hotel Phase 1 Repairs
February 2016 Salem, MA
Flashing and Sheet Metal 07560-3
A. Generally comply with SMACNA's "Architectural and Sheet Manual", and the requirements
of NRCA's "A Manual of Roofing Practice", or Revere Copper’s “Copper and Common
Sense”.
1. Teardrop hem all exposed, free edges.
2. Fully solder non-moving seams. Neutralize flux after soldering.
3. Fabricate to accommodate expansion and contraction. Provide sealant filled
expansion control joints within 8 feet of ends of long runs and not over 20 feet
on center in between.
4. Fabricate to be free from buckles, waves, oil canning, tool marks, and
appearance defects.
5. Fabricate with sharp, even, true, and accurately aligned lines, joints, and
seams.
6. Turn and fabricate lock joints to best shed water.
7. Fabricate work for maximum waterproofing and weathertight performance.
8. Form work to fit substrates and field conditions.
END OF SECTION