This document summarizes the onsite observations and technical assistance for the masonry wall repair project at Chalmette National Cemetery. It documents the inspection of the salvaged brick cleaning and storage, the mock-up of the mortar mix design, and comparisons to the original mortar. It raises questions about whether the original sand meets the ASTM C144 standard and notes that the mortar color will be influenced by the mix design and application techniques used.

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. 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. 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. General Condition of Salvaged Brick After Disassembling Walls
3/3/2009 4

5. SECTION 04211-4: 3.02 ERECTION, INSTALLATION,
APPLICATION; B-1
Tracking Location of Salvaged Brick
3/3/2009 5

6. OBSERVATION: Evidence of fully filled collar joints/bed joints supporting SECTION 04211: 3.02; B-6
3/3/2009 6

7. The mortar bond to brick is exceptional. Lime inclusions are visible.
3/3/2009 7

8. OBSERVATION: Face Profile of Original Mortar and Brick Surface
3/3/2009 8

9. OBSERVATION: Another View of an Original Collar Joint Filled with Mortar
3/3/2009 9

10. OBSERVATION: Organic Growth on Mortar Joints - Indicating a Water Absorptive Formulation
3/3/2009 10

11. Mortar Sample Preparation
3/3/2009 11

12. Sample Comparison to Original Interior Mortar Surface
3/3/2009 12

13. SECTION 04100-1: 1.02 REFERENCES; B
Portland Cement
3/3/2009 13

14. SECTION 04100-1: 1.02 REFERENCES; C
0225090816a
3/3/2009 14

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. Salvaged Brick After Cleaning
3/3/2009 16

17. OBSERVATION: Original Mortar Debris is Clean, Free of Brick Contamination and Small in Size
3/3/2009 17

18. Original Brick Clean and Ready for Reuse
3/3/2009 18

19. OBSERVATION: Original Mortar Footprint is Entirely Gone on Most Brick
3/3/2009 19

20. 3/3/2009 20

21. OBSERVATION: Immediate Heavy Foam in Reaction to Acid-Based Experiment
3/3/2009 21

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. Known Measure Established with Volume Marks Inside the Bucket
3/3/2009 23

24. SECTION 04100-3: 2.02 Mortar Mix:
D. Mixing Order
Ingredients Dry Mixed
3/3/2009 24

25. OBSERVATION: The Sound Under My Feet – This Wall Section is Built with a Different Mortar
3/3/2009 25

26. OBSERVATION: Mortar Debris Contaminated with Brick Fragments
3/3/2009 26

27. OBSERVATION: Accommodation for Movement Minimal in this Wall Section
3/3/2009 27

28. 3/3/2009 28

29. OBSERVATION: Mortar Debris is Large – Appears to have “Pancaked” at the Brick Interface
3/3/2009 29

30. Looking North
3/3/2009 30

31. Looking Toward River
3/3/2009 31

32. Soaking Salvaged Brick
3/3/2009 32

33. Creating Channel Mortar Samples for Comparison
3/3/2009 33

34. The Surface Texture Will be Affected by the Timing of the Finish
3/3/2009 34

35. OBSERVATION: Water Misting to Expose Aggregate – Needs Verification in the Const. Phase
3/3/2009 35

36. OBSERVATION: Wall Sections A, E, & H are different in color and profiles – clarification needed
3/3/2009 36

37. Profiles (under arrow) are Recessed and Brush-Pounded According to SECTION 04520: 3.04, B.2
3/3/2009 37

38. 3/3/2009 38

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. 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