Chalmette National Cemetery Masonry Wall Repair 2 25 09

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Onsite observation and technical support for Contractors constructing brick walls in compliance with Secretary Standards for Rehabilitation

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Chalmette National Cemetery Masonry Wall Repair 2 25 09

  1. 1. Chalmette National Cemetery Masonry Wall Repair Contract # 1443C2011080371 JELA 119076A Onsite Observations and Technical Assistance for Project Specification Compliance; and Secretary Standards for Rehabilitation Department of Interior regulation 36 CFR 67 Masonry Wall Mock-up Construction – Verification of Mortar Sand Compliance to ASTM C144 Onsite Work with Masons – Wednesday, February 25, 2009. John P. Speweik, CSI 3/3/2009 1
  2. 2. SECTION 04211-4: 3.02 ERECTION, INSTALLATION, APPLICATION; B-4 , Soak replacement brick in clean water for 7 days before laying. Replacement Brick -Water Soaked Prior to Use 3/3/2009 2
  3. 3. SECTION 04211-4: 3.02 ERECTION, INSTALLATION, APPLICATION; B-1 , Salvage all non-foundation bricks for reuse. Salvaged brick must be returned to the same location upon reconstruction. Storage Area for Salvaged Brick 3/3/2009 3
  4. 4. General Condition of Salvaged Brick After Disassembling Walls 3/3/2009 4
  5. 5. SECTION 04211-4: 3.02 ERECTION, INSTALLATION, APPLICATION; B-1 Tracking Location of Salvaged Brick 3/3/2009 5
  6. 6. OBSERVATION: Evidence of fully filled collar joints/bed joints supporting SECTION 04211: 3.02; B-6 3/3/2009 6
  7. 7. The mortar bond to brick is exceptional. Lime inclusions are visible. 3/3/2009 7
  8. 8. OBSERVATION: Face Profile of Original Mortar and Brick Surface 3/3/2009 8
  9. 9. OBSERVATION: Another View of an Original Collar Joint Filled with Mortar 3/3/2009 9
  10. 10. OBSERVATION: Organic Growth on Mortar Joints - Indicating a Water Absorptive Formulation 3/3/2009 10
  11. 11. Mortar Sample Preparation 3/3/2009 11
  12. 12. Sample Comparison to Original Interior Mortar Surface 3/3/2009 12
  13. 13. SECTION 04100-1: 1.02 REFERENCES; B Portland Cement 3/3/2009 13
  14. 14. SECTION 04100-1: 1.02 REFERENCES; C 0225090816a 3/3/2009 14
  15. 15. SECTION 04211-4: 3.02 ERECTION, INSTALLATION, APPLICATION; B-2 , Clean all brick by hand using chisel and stiff brush. Salvaged Brick Cleaning Area 3/3/2009 15
  16. 16. Salvaged Brick After Cleaning 3/3/2009 16
  17. 17. OBSERVATION: Original Mortar Debris is Clean, Free of Brick Contamination and Small in Size 3/3/2009 17
  18. 18. Original Brick Clean and Ready for Reuse 3/3/2009 18
  19. 19. OBSERVATION: Original Mortar Footprint is Entirely Gone on Most Brick 3/3/2009 19
  20. 20. 3/3/2009 20
  21. 21. OBSERVATION: Immediate Heavy Foam in Reaction to Acid-Based Experiment 3/3/2009 21
  22. 22. SECTION 04100-3: 2.02 MIXING; B. Mortar Mix: Measure all ingredients by cubic volume using pre-established uniform measure. Establishing Mortar Mix Design Procedures and Documentation 3/3/2009 22
  23. 23. Known Measure Established with Volume Marks Inside the Bucket 3/3/2009 23
  24. 24. SECTION 04100-3: 2.02 Mortar Mix: D. Mixing Order Ingredients Dry Mixed 3/3/2009 24
  25. 25. OBSERVATION: The Sound Under My Feet – This Wall Section is Built with a Different Mortar 3/3/2009 25
  26. 26. OBSERVATION: Mortar Debris Contaminated with Brick Fragments 3/3/2009 26
  27. 27. OBSERVATION: Accommodation for Movement Minimal in this Wall Section 3/3/2009 27
  28. 28. 3/3/2009 28
  29. 29. OBSERVATION: Mortar Debris is Large – Appears to have “Pancaked” at the Brick Interface 3/3/2009 29
  30. 30. Looking North 3/3/2009 30
  31. 31. Looking Toward River 3/3/2009 31
  32. 32. Soaking Salvaged Brick 3/3/2009 32
  33. 33. Creating Channel Mortar Samples for Comparison 3/3/2009 33
  34. 34. The Surface Texture Will be Affected by the Timing of the Finish 3/3/2009 34
  35. 35. OBSERVATION: Water Misting to Expose Aggregate – Needs Verification in the Const. Phase 3/3/2009 35
  36. 36. OBSERVATION: Wall Sections A, E, & H are different in color and profiles – clarification needed 3/3/2009 36
  37. 37. Profiles (under arrow) are Recessed and Brush-Pounded According to SECTION 04520: 3.04, B.2 3/3/2009 37
  38. 38. 3/3/2009 38
  39. 39. Mortar Color Influences MATERIALS WORKMANSHIP • Techniques in approach, • Sand: Standard deviations tool selection, and timing in exist with natural sands. The delivering the specified precision of values in testing profile will be dependant on various samples is common. one another in combination • Formulation: Mortars will with weather conditions change in color due to mix • Amount of water in the designs: 1:1:6 will be darker initial mixture than a 1:2:9 mix using the • Time of mortar placement same ingredients in relation to SSD condition repointing and replacement 3/3/2009 39
  40. 40. MIX DESIGN NOTE: Volumetric measurements of hydrated lime were adjusted per industry practice in accordance with The National Lime Association, supported by the late Morgan Phillips in his published paper titled: “A source of confusion about mortar formulas”, APT bulletin , XXV , no. 3-4 (1994) pp. 50-53. ITEM TO BE VERIFIED: SECTION 04100-2: 2.01 MATERIALS; C. Sand: Requires to conform to ASTM C144, natural sand; C.1 states that the new mortar use sand that matches the original in color, size, texture, material properties, and grading. Do we know if the original sand meets ASTM C144 Standard ? Questions pertaining to this work can be directed to: John Speweik, CSI 224-856-7449 3/3/2009 40

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