Specification:Brick repair through patching

__NUMBEREDHEADINGS__

=GENERAL=

DESCRIPTION
 This specification provides guidance for brick repair through patching. This specification has been developed for use on historic resources (defined as any district, site, building, structure, landscape, or object 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 the Interior’s Standards for the Treatment of Historic Properties. The Contractor shall provide all labor, materials, equipment, and operations required to complete the 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. For the purposes of this document such person is referred to as the Architect. 

SECTION INCLUDES
 Brick repair through patching 

RELATED SECTIONS
<ol type="A"> Section 04211.01 – Historic Brick Properties and In-Kind Replacement</li> Section 04100.01 – Removal of Mortar Joints and Repointing</li> Section 04100.02 – Preparation of Lime and Cement-Amended Mortars</li> Section 04400.01 – Identifying Masonry Types and Failures</li> Section 07900.01 – Joint Sealer Properties and Application</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> 5-hour boil absorption</li> Saturation coefficient</li> Initial rate of absorption (suction)</li> </ol> </li> <li>The Contractor shall perform a scratch-hardness test to determine firing history and soundness of brick.</li> </ol> </li> <li>Samples: The Contractor shall submit samples of the replacement face brick units, masonry repair, and replacement materials for approval of color and texture match. No masonry restoration work shall proceed until all samples are approved. Brick product samples should show full range of color and texture available for both new manufactured bricks and for salvaged bricks.</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 (Note: Color matching when patching masonry is a critical part of the mock-up process.): Brick Restoration: All personnel proposed for work on the project shall prepare 3x3-foot 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>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. </ol>

DELIVERY, STORAGE, AND HANDLING (as applied to products and materials)
<ol type="A"> <li>The Contractor shall deliver products and materials to the site in original packaging, unopened, with manufacturer 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>Liquids shall be stored at temperatures between 40 and 85 degrees. Do not allow liquids to freeze.</li> <li>Bricks shall 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> </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 is responsible for protecting existing adjacent materials and surfaces during the execution of the work and shall provide all necessary protection and follow all work procedures to avoid damage to existing material assemblies not a part of the work in the 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. Completed work should be covered for a minimum of 48 hours to ensure proper curing.</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 with plywood or other sturdy barrier 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, flashing, 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 protect nearby vehicles and adjacent structures from damage during the course of the work.</li> <li>The 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=

MATERIALS
<ol type="A"> <li>Water: Clean and potable</li> </ol>

PATCHING HISTORIC BRICK
<ol type="A"> <li>Submit replacement brick product information and list of manufacturer(s) for Architect approval.</li> <li>Equipment: <ol> <li>Hand chisel, tooth chisel, mash hammers, pneumatic chisel</li> <li>Natural or nylon bristle brushes</li> <li>Trough, plastic bucket, trowel, mortar board, hawk, trowels</li> </ol> </li> </ol> =EXECUTION=

GENERAL
<ol type="A"> <li>The extent of the brick repair 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 to include: <ol> <li>Notation of existing general masonry and other structural failures that contribute to brick and mortar losses that should be scheduled for repair prior to this work.</li> <li>Analysis of brick composition and determination of density.</li> </ol> </li> <li>The Contractor shall complete masonry cleaning prior to beginning brick repair or replacement work.</li> </ol>

BRICK REPAIR - PATCHING
<ol type="A"> <li>Contractor shall follow manufacturer’s application instruction. Apply the patching material using the same methods used to prepare the approved mock-up.</li> <li>Substrate must be sound, dry, clean, and free of loose particles, oils, grease, or other coatings or substances.</li> <li>Mix patching material thoroughly until homogeneous, in accordance with manufacturer’s instructions.</li> <li>Apply patching material according to manufacturers specifications to match mock up. <ol> <li>With a clean brush or broom, remove excess material.</li> </ol> </li> <li>Let cure for 24 hours.</li> <li>Clean adjacent areas and tools immediately.</li> </ol>

BRICK – VERTICAL CRACK REPAIR
<ol type="A"> <li>Rake masonry joints to approximately 12 inches on either side of the crack to be repaired and a minimum depth of 1-1/2 inches. Rake entire crack down to sound mortar (where applicable). <ol> <li>Using a chisel, begin working from the center of the joint to remove the majority of the existing mortar from the center of the joints. Ease should be taken to clean remaining mortar from the edges of the joint without damaging the adjacent bricks.</li> <li>With the approval of the architect, a grinder may be used if the constraints can demonstrate that no brick edges will be nicked or cut in the process. If damage is occurring, grinding shall be stopped immediately and the remainder of the wood finished with hand chisels.</li> <li>Use a hand chisel to finish joints adjacent to door and window openings to avoid damage to frames and trim.</li> <li>If work is found unacceptable, all raking shall cease without additional cost to the Owner until deficiencies in tools, workmanship, or methodology have been corrected to the Architect’s satisfaction.</li> </ol> </li> <li>Where cracks extend through individual bricks, remove and replace cracked bricks with new toothed into the adjacent masonry.</li> <li>Repoint all joints full depth. Bed reinforcing rods in the horizontal joints every fourth course. Rods shall extend at least 12 inches on either side of the crack. Leave joints slightly recessed for subsequent stucco application if required.</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 affect has been achieved after the brick repairs have been executed and work has cured at least 30 days.</li> <li>Document the work and finished product 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>