Specification:Historic brick properties and in-kind replacement

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=GENERAL=

DESCRIPTION
 This specification provides guidance for identifying historic brick properties and appropriate repair and replacement methods for historic brick. This specification has been developed for use on historic properties (defined as any district, site, building, structure, or object that is listed in or eligible for listing in the National Register of Historic Places) and provides an overview of accepted practices. The Architect will provide site-specific specifications, when appropriate. All work described herein and related work must conform to the Secretary of Interior’s Standards for the Treatment of Historic Properties. The Contractor shall provide all labor, materials, equipment, and operations required to complete the rehabilitation work indicated herein. All work described herein and related work must have the approval of a Cultural Resources Manager, Conservator, Historic Architect, or other professional who meets the standards outlined in the Secretary of the Interior’s Standards – Professional Qualifications Standards pursuant to 36 CFR 61. Such person is referred to in this document as the Architect. 

SECTION INCLUDES
 Historic Brick Properties Criteria for Replacement</li> Procedure for In-kind Replacement</li> </ol>

RELATED SECTIONS
<ol type="A"> 04211.02 – Repair through Patching</li> 04100.01 – Removal of Mortar Joints and Repointing</li> 04100.02 – Preparation of Lime and Cement-Amended Mortars</li> 04400.01 – Identifying Masonry Types and Failures</li> </ol>

SUBMITTALS
<ol type="A"> Schedule of Selection and Installation: The Contractor shall submit a detailed schedule to the Architect for approval of the areas for repair, including an assessment of the problem areas, a historic mortar analysis, and detailed procedures for brick repair.</li> Product Data: The Contractor shall submit product data for all manufactured masonry materials used in the project work. Manufacturer’s product data shall include certification of compliance with specified standards and instructions for handling, storage, and installation of the material, and Material Safety Data Sheets for each material.</li> Test Reports:  Test reports for each type of facing brick are to be submitted to the Architect.</li> Testing and reports are to be competed by an independent laboratory and will provide the following: Compressive strength</li> 24-hour cold water absorption</li> Five-hour boil absorption</li> Saturation coefficient</li> Initial rate of absorption (suction)</li> </ol> </li> <li>The Contractor shall undertake a scratch-hardness test to determine firing history and soundness of brick.</li> </ol> </li> <li>Samples: No masonry restoration work shall proceed until all samples are approved. The Contractor shall submit samples of the following masonry repair and replacement materials for approval of color and texture match: <ol> <li>Replacement face brick units. Product samples should show full range of color and texture available for both new manufactured bricks and for salvaged bricks.</li> <li>Mortar shall conform with Historic Mortar Specifications 04100 and be approved by the Architect.</li> </ol> </li> </ol>

QUALITY ASSURANCE
<ol type="A"> <li>Work Experience: The Contractor to perform the work in this section shall have a minimum of seven years experience with historic masonry and brick repairs. He/she shall demonstrate a working knowledge of the Secretary of the Interior’s Standards for the Treatment of Historic Properties with Guidelines for Preserving, Rehabilitating, Restoring, and Reconstructing Historic Buildings.</li> <li>The Contractor shall not change sources or manufacturers of mortar or brick materials during the course of the work unless approved by the Architect.</li> <li>Warranty: The Contractor shall provide a warranty in writing against defects in material and installation for a period of five years.</li> </ol>

MOCK-UPS
<ol type="A"> <li>After completion of the masonry cleaning mock-ups specified in Section 04510, the Contractor, at locations designated by the Architect, shall prepare test panels of the following work: <ol> <li>Brick Restoration: All personnel proposed for work on the project shall prepare 3x3 ft. samples demonstrating brick restoration techniques, including mortar removal, repointing, and brick replacement. Mock-ups will be reviewed after the mortar removal and again after completion of repointing. Mock-ups shall display the full range of materials and workmanship required for completion of the project for approval by the Architect.</li> <li>Color Matching: The project requires matching of the existing mortar color(s) for brick masonry. The Contractor shall place the initial sample panel using the mix from the approved sample. The sample panel must be cured in the same manner as is expected for the work based on expected temperatures.</li> <li>Brick Matching: The Contractor will be responsible for identifying potential matches to the existing brick for use as replacement units, subject to the approval of the Architect.</li> </ol> </li> <li>The Contractor shall prepare up to three additional mock-ups of each mortar, joint type, and mortar color without further compensation. Approved test panel(s) shall become part of the work and shall serve as the quality standard for all subsequent work.</li> </ol>

DELIVERY, STORAGE, AND HANDLING
<ol type="A"> <li>Materials shall be delivered to the site in original packaging, unopened, with manufacturer’s name and product identification thereon. Cementitious materials shall be protected from contamination by foreign matter and deterioration by moisture or temperature. Contaminated or deteriorated material shall not be used. Products stored longer than six months shall not be used.</li> <li>Bricks will be protected from the ground and weather, and kept free from exposure to contaminants such as mud, dust, or materials that could cause staining.</li> <li>Masonry materials shall be stored in such a manner as not to interfere with the operation and daily maintenance of the facility. Proposed storage locations shall be approved by the Owner prior to the delivery of materials. Masonry materials shall not be stored inside the building.</li> </ol>

PROJECT/SITE CONDITIONS
<ol type="A"> <li>Normal conditions for the work of this Section shall be defined as when the air and surface temperatures are 40 degrees F and rising or less than 90 degrees F and falling. When temperatures are predicted to rise above or fall below this temperature range, the Contractor may proceed using approved hot and cold weather procedures as defined by the Masonry Institute of America. Work shall not commence when rain, snow, or below-freezing temperatures are expected within 24 hours. All surfaces shall be free of standing water, frost, and ice.</li> <li>The Contractor shall cover the top of the wall with strong waterproof membrane at the end of each day or prior to any work shutdown. Cover partially completed walls when work is not in progress. Covering will extend a minimum of 24 inches on each side and be fastened securely.</li> <li>The Contractor is responsible for protecting existing adjacent materials and surfaces during the execution of the work, and shall provide all necessary protection and follow all necessary work procedures to avoid damage to existing material assemblies not a part of the work in this Section: <ol> <li>Minimize levels of dust during mortar removal and masonry repointing operations.</li> <li>Protect open copings, reglets, and other vulnerable areas from water penetration to prevent leakage during the course of the work. Open areas shall not be left exposed overnight or when inclement weather is predicted.</li> <li>Temporarily remove and store metal downspouts during masonry restoration work. Install temporary drainage leaders if required. Reinstall immediately upon completion of work in the immediate area. Protect open boots at grade from accumulation of masonry debris.</li> <li>Protect existing gutters and gutter outlets from damage and accumulation of mortar debris during restoration of brick chimneys.</li> <li>Protect window sashes and frames a sturdy barrier like plywood during repointing and repair of masonry around window openings.</li> <li>Protect the existing roof surfaces from damage during the course of the masonry restoration work. Repair all damage to wood and metal roofing, gutters, flashings, etc., to the satisfaction of and at no additional cost to the Owner.</li> <li>Remove and store light fixtures, signage, security devices, and miscellaneous appurtenances from masonry surfaces to be repointed. Provide temporary protection for exposed fixture boxes.</li> </ol> </li> <li>The Contractor shall provide visible barriers and/or warning tape around the perimeter of the work area for visitor protection, and shall protect nearby vehicles and adjacent structures from damage during the course of the work.</li> <li>Contractor shall coordinate brick repairs with the other trades involved in exterior and interior restoration work, including but not limited to masonry cleaning, sealing, and painting.</li> </ol> =PRODUCTS=

EQUIPMENT FOR BRICK REMOVAL, SALVAGE, AND BRICKLAYING
<ol type="A"> <li>Equipment for Brick Removal: <ol> <li>Traditional Method: Hand chisels and mash hammers</li> <li>Modern Method: Small pneumatically-powered chisels. Hand removal of mortar is still highly recommended.</li> </ol> </li> <li>Equipment for Salvage, Mortar Removal, and Cleaning: Hand chisels (including cape chisels, plugging chisels, and quirks), mason’s hammers, and natural bristle or nylon brushes.</li> <li>Equipment for Bricklaying: <ol> <li>Mortar pan mill or equipment for mortar mixing</li> <li>Plastic buckets, mortar board, hawk, trowels, pointing rod, and mason’s hammers</li> <li>Natural bristle or nylon brushes (metal bristle brushes are NOT to be used)</li> </ol> </li> </ol>

BRICK REMOVAL AND SALVAGE
<ol type="A"> <li>Representative samples of the removed brick shall be tested for salt content and quality.</li> <li>Decorative and specially molded or cut brick may be retained for consolidation and should be reviewed by the Architect.</li> </ol>

BRICK FOR IN-KIND REPLACEMENT
<ol type="A"> <li>Salvaged: Where disassembly and reconstruction of portions of the wall are required, the Contractor shall salvage any bricks that are sound and free of cracks. Bricks disfigured by mortar patching shall be salvaged for re-use with clean sides exposed. Should brick units be damaged during disassembly, the Contractor shall be responsible for supplying approved replacements to match. All salvaged bricks shall be cleaned of loose debris and mortar on all faces.</li> <li>New Brick: ASTM C-216-07a, Grade SW, Type FBS. Replacement brick is to match historic brick in size, color, and composition. Manufacturer and product sample are to be approved by the Architect.</li> <li>The Contractor shall have the option of providing clean, sound, salvaged antique bricks from other sites, subject to the approval of the Architect for color, size, and texture match.</li> </ol>

ACCESSORY MATERIALS
<ol type="A"> <li>Pins for crack stitching in brick masonry shall be 18-8 stainless steel, all-thread rods. Dimensions to be as indicated on the Drawings.</li> <li>Through-wall flashing for window heads and sills to be rebuilt shall be composite Copper Fabric and must be approved by the Architect.</li> <li>Masonry Ties: The Contractor shall provide galvanized steel masonry wall ties as indicated on the Drawings. Ties shall be 18 gauge crimped metal strip in lengths as required for the application. Selection of ties and manufacturer must be approved by the Architect.</li> </ol> =EXECUTION=

GENERAL
<ol type="A"> <li>The extent of the brick replacement shall be reviewed by the Architect on site prior to beginning operations. The Contractor shall submit a schedule, including methods and materials to be used.</li> <li>The Contractor shall complete a survey of the condition of the mortar and masonry prior to repairs. Contractor survey shall include: <ol> <li>Notation of existing general masonry failures that contribute brick and mortar losses and should be scheduled for repair prior to this work.</li> <li>Determination of the brick composition and density. See Test Reports under Submittals above.</li> <li>Determination of the method of bricklaying and type of bond of the historic masonry.</li> </ol> </li> <li>Masonry cleaning shall be completed prior to beginning brick repair or replacement work (see Section 04500).</li> </ol>

BRICK MASONRY REPAIRS
<ol type="A"> <li>Individual Brick Replacement: <ol> <li>Remove selected cracked, spalled, or otherwise damaged bricks where indicated without causing damage to the adjacent brickwork to remain. Replacements shall be either new matching brick or matching salvaged brick placed so as to replicate the existing bond pattern. Bond patterns are important structural components of brick construction. If large areas need to be replaced, the traditional bonding should be replicated to prevent future delamination of the wythes in the wall.</li> <li>Remove all existing mortar from adjoining bricks in order to lay new brick entirely in new mortar. Clean joints of all loose mortar and flush with clean water.</li> <li>Ensure head and bed joints are packed full with mortar. Rake construction mortar to allow space for pointing mortar. Where bedding mortar and pointing mortar are the same, tool joints to match existing.</li> </ol> </li> </ol>

FINAL REPORT
The Contractor shall: <ol type="A"> <li>Revisit the site with the Architect to compare the finish and color of the repair to see if the desired effect has been achieved after the brick repairs have been executed and new mortar has cured at least 30 days.</li> <li>Document the work before, during, and after with photographs.</li> <li>Provide a written summary of the project and results upon final inspection and approval. The summary shall outline steps taken or new findings not specified in the initial documentation.</li> </ol>