SECTION 04236

SHOP FABRICATED MASONRY PANELS

PART 1 GENERAL

SECTION INCLUDES

Face brick.

Structural [steel stud] [metal] backing.

Reinforcement, anchorages, lifting devices, [window frame anchors] and accessories.

[Grouting under panels.]

PRODUCTS FURNISHED BUT NOT INSTALLED UNDER THIS SECTION

Section [_____-__________]: Site placement of [________] anchors.

PRODUCTS INSTALLED BUT NOT FURNISHED UNDER THIS SECTION

Section [_____-__________]: Supply of [anchors] [__________] for placement of [__________] by this Section.

Section [_____-__________]: Supply of fabricated steel items for placement by this Section.

Section [_____-__________]: Supply of window anchors for placement by this Section.

RELATED SECTIONS

Section 04100 - Mortar: Mortar and grout.

Section 04270 - Glass Unit Masonry.

Section 04300 - Unit Masonry System.

Section 04310 - Single Wythe Masonry System.

Section 04320 - Veneer Masonry System.

Section 04330 - Cavity Wall Masonry System.

Section 04340 - Reinforced Unit Masonry System.

Section [_____-__________]: Building structural frame.

Section 07175 - Water Repellant Coating.

Section 07190 - Vapor and Air Retarders: Vapor [and air] retarder membrane placed on interior face of erected panels.

Section [_____-__________]: Thermal insulation in stud spaces.

Section 07620 - Metal Flashing and Trim: Head and sill flashings.

Section 07900 - Joint Sealers: Rod and sealant at panel perimeter, [control] [and] [expansion] joints.

Section [_____-__________]: Window frames[.] [and anchors.]

REFERENCES

ANSI/ASTM A82 - Cold-Drawn Steel Wire for Concrete Reinforcement.

ANSI/ASTM C73 - Calcium Silicate Face Brick (Sand-Lime Brick).

ANSI/ASTM C126 - Ceramic Glazed Structural Clay Facing Tile, Facing Brick, and Solid Masonry Units.

ANSI/ASTM C216 - Facing Brick (Solid Masonry Units Made From Clay or Shale).

ANSI/ASTM C652 - Hollow Brick (Hollow Masonry Units Made From Clay or Shale).

ANSI/AWS D1.1 - Structural Welding Code.

ASTM A36 - Structural Steel.

ASTM A90 - Test Method for Weight of Coating on Zinc-Coated (Galvanized) Iron or Steel Articles.

ASTM A446 - Steel Sheet, Zinc-Coated (Galvanized) by Hot Dip Process, Physical (Structural) Quality.

ASTM A570 - Hot-Rolled Carbon Steel Sheet and Strip, Structural Quality.

ASTM A580 - Stainless and Heat-Resisting Steel Wire.

ASTM A611 - Steel, Cold-Rolled Sheet, Carbon, Structural.

ASTM A615 - Deformed and Plain Billet-Steel Bars for Concrete Reinforcement.

ASTM C94 - Ready-Mixed Concrete.

ASTM C476 - Grout for Masonry.

SYSTEM DESCRIPTION

Panel System: Brick and metal frame backup; fabricated as a composite panel with lifting devices for site erection.

****** [OR] ******

Panel System: Brick, internally reinforced, fabricated as an integral panel, with lifting devices set in mortar, for site erection.

DESIGN REQUIREMENTS

Size components to withstand design loads as follows:

Vertical Assembly: [___] psf ([___] kPa).

Horizontal Assembly: [___] psf ([___] kPa) live [and dead] loads.

Maximum Allow Deflection: [1/360] [1/600] [_____] span.

Design [panel] [________] system to provide for movement of components without damage, failure of joint seals, undue stress on fasteners or other detrimental effects, when subject to seasonal or cyclic day/night temperature ranges.

Design system to accommodate construction tolerances, deflection of building structural members, and clearances of intended openings.

Isolate masonry panels from vertical structural framing members with a control joint[.] [as indicated.]

Isolate top joint of masonry panels from horizontal structural framing members and slabs or decks with [compressible joint filler.] [____________________.]

SUBMITTALS

Submit shop drawings under provisions of Section [01300.] [01340.]

Submit shop drawings indicating component details, [bond pattern,] [framed openings,] [bearing,] [anchorage,] [loading,] [welds,] [frame anchor layout] [lifting hook locations] [type and location of fasteners] and accessories or items required of other related work.

Describe method for securing panels to building frame [connections] and loads imposed.

Provide calculations for loadings and stresses of fabricated panels sealed by Professional Structural Engineer registered in State of [_______________.]

Submit product data under provisions of Section [01300.] [01340.]

Submit product data for [face brick] [_______________] [stud framing members][,][.] [and] [_______________.] Describe materials and finish, product criteria, limitations and [_______________.]

Submit samples under provisions of Section [01300.] [01340.]

Submit [four] [_____] samples of face brick units to illustrate color, texture and extremes of color range.

QUALITY ASSURANCE

Perform welding Work in accordance with ANSI/AWS D1.1.

QUALIFICATIONS

Fabricator: Company specializing in fabricating the products specified in this Section with minimum [three] [_____] years [documented] experience.

Erector: Company specializing in applying the work of this Section [with minimum [_____] years [documented] experience.] [approved by manufacturer.]

Design fabricated panels under direct supervision of a Professional Structural Engineer experienced in design of this work and licensed [at the place where the Project is located.] [in the State of [_______________].]

MOCK-UP

Provide mock-up of fabricated masonry panel under provisions of Section [01400.] [01405.]

Construct panel prototype to [actual panel size] [3 x 6] [___x___] feet ([900 x 1 800] [___x___] mm) panel size, including lifting devices accessories specified.

[Provide testing of mock-up under provisions of Section [01400.] [01410.]]

When accepted, mock-up will demonstrate minimum standard for the Work. Mock-up may [not] remain as part of the Work.

PRE-INSTALLATION CONFERENCE

Convene a conference [one] [_____] week prior to commencing work of this Section, under provisions of Section [01200.] [01220.]

DELIVERY, STORAGE, AND HANDLING

Deliver products to site under provisions of Section [01600.] [01610.]

Store and protect products under provisions of Section [01600.] [01620.]

Receive panels on site and inspect for damage. [Store as directed.] [Erect immediately.]

FIELD MEASUREMENTS

Verify field measurements are as [shown on [Drawings] [shop drawings].] [instructed by the manufacturer.]

SEQUENCING AND SCHEDULING

Coordinate work under provisions of Section [01005] [01040.] [01041.]

Coordinate the prefabricated panel work with [building structural anchors.] [installation of windows.] [_______________.]

PART 2 PRODUCTS

MANUFACTURERS - BRICK UNITS

[______________________________] Product [__________.]

[______________________________] Product [__________.]

[______________________________] Product [__________.]

Substitutions: Under provisions of Section [01600.] [01630.]

BRICK UNITS

Face Brick: ANSI/ASTM C216, Type [FBS,] [FBX,] [FBA,] Grade [MW;] [SW;] [________] color[.] [as selected.]

Hollow Facing and Building Brick: ANSI/ASTM C652, Grade [SW,] [MW,] Type [HBS;] [HBX;] [HBA;] [HBB;] [________] color [.] [as selected.]

Sand-Lime Face Brick: ANSI/ASTM C73, Grade [SW.] [MW.]

Ceramic Glazed Face Brick: ANSI/ASTM C126, Grade

[S - Select,] [SS - Select Sized,] Type [I - Single]

[II - Two Faced] units.

Brick Masonry Units: Nominal modular size of [___x___x___] inches ([___x___x___] mm). Provide special units for [90] [___] degree corners, [half length units] [bullnosed corners][,][.] [and] [_______________.]

[Special Brick Shape: Shaped to [profile indicated;] [_______________;] surface texture on [___] sides [and ends.]]

BACKING MATERIALS

Structural Members: [ASTM A36.] [__________.]

Studs: ASTM [A446] [A570] [A611] [____] sheet steel, formed to [channel] [________] shape, [solid] [punched] [________] web, [knurled faces]; [18] [___] gage ([1.2] [___] mm) thick, [___x___] inch ([___x___] mm) nominal size.

Track: Formed [________] steel; channel shaped; same width as studs, tight fit; [___] gage ([___] mm) thick, solid web.

Plates, Gussets, Clips: [Formed] sheet steel, thickness determined for conditions encountered, [manufacturer's standard shapes,] same finish as framing members.

Self-drilling, Self-tapping Screws: ASTM A90, hot dip galvanized.

Anchorage Devices: [Drilled expansion bolts.] [Screws with sleeves.] [________.]

ACCESSORIES

Panel Filler: Closed cell [polyvinyl chloride;] [polyethylene;] [polyurethane;] [rubber;] [________;] oversized 50 percent to joint width; self-expanding [___] inch ([___] mm) wide x maximum lengths; [________] manufactured by [____________________.]

Weep Holes: [Galvanized steel tubes [wick filled];] [cotton wick;] [preformed plastic tubes;] [__________;] [__________] manufactured by [____________________.]

Brick Reinforcement: [Ladder] [Truss] type; [[hot dip galvanized after fabrication] [unprotected] cold-drawn steel conforming to ANSI/ASTM A82,] [stainless steel conforming to ASTM A580 Type 304,] [3/16] [___] inch ([4.8] [___] mm) side rods with [___] inch ([___] mm) cross ties; [________] manufactured by [_______________.]

****** [OR] ******

Brick Reinforcement: ASTM A615, [_____] ksi ([_____] MPa) yield grade billet-steel, [plain] [deformed] reinforcing steel bars, [uncoated] [galvanized] finish.

Masonry Ties: Galvanized steel, [bent rod;] [_________.] [__________] as manufactured by [_______________.]

MORTAR AND GROUT

Mortar: Refer to Section 04100.

Grout Mix: [3000] [____] psi ([21] [___] MPa) strength at 28 days; [7-8] [_____] inches ([175-200] [_____] mm) slump; [premixed type in accordance with ASTM C94.] [mixed in accordance with ASTM C476 [Fine] [Course] grout.]

FABRICATING PANEL BACKING

Fabricate panel frame in prepared jig[.] [prior to attachment to brick work.]

Align top and bottom tracks and panel edge frame. Secure with fasteners[.] [and weld.]

Attach and secure corner gussets to assure panel alignment and dimensional integrity.

Reinforce panel corners and integral openings with [strap] anchors.

Place [studs] [________] at [12] [16] [24] [___] inches ([300] [400] [600] [___] mm) oc.

Connect [studs] [________] to tracks using [crimping] [clip and tie] [fastener] method.

Double [stud] [________] at openings, [door] [window jambs] [panel edges][,][.] [and] [_______________.]

Place [studs] [__________] one piece full length.

Splicing of studs is not permitted.

Place [studs] [________], brace, and reinforce to develop full strength to meet design requirements.

Install framing between [studs] [________] for attachment of mechanical and electrical items and to prevent stud rotation.

FABRICATING FACE BRICK PANELS

Establish lines, levels, and coursing to panel.

Maintain masonry courses to uniform spacing.	Form joints to achieve uniform dimension.

Set brick units in [running] [stacked] [________] bond. Course three brick units and three joints to equal [8] [___] inches ([200] [___] mm).

Form brick joints to achieve [concave] [raked] [flush] [bevelled] [________] joints after panel removal from forms.

Install weep holes in face brick joints at [___] inches ([___] mm) on center horizontally at top and bottom course of panel[,][.] [and] [__________.]

Place face brick reinforcement in first [and second] [________] joints inside panel edges and ends and at [___] inch ([___] mm) spacing.

Place bar reinforcement in brick cores. Grout fill with mortar.

PANEL REINFORCEMENT AND ANCHORAGES

Install panel to brick reinforcement[.] [and lifting devices.]

Place, support, and secure face brick to panel.

PART 3 EXECUTION

EXAMINATION

Verify that openings are ready to receive work.

Verify items provided by other sections of work are

properly sized and located.

Verify that required utilities are available, in proper location, and ready for roughing into masonry work.

Beginning of installation means installer accepts existing conditions.

PREPARATION

Direct and coordinate placement of supplied metal anchors to other Sections.

Provide temporary bracing during erection of masonry work. Maintain in place until building structure provides permanent bracing.

Protect elements surrounding the work of this Section from damage or disfiguration.

ERECTING PANELS

Erect panels without damage to shape or finish. [Replace] [Repair] damaged panels.

Erect members level and plumb within allowable tolerances.

Align and maintain uniform horizontal and vertical panel joints as erection progresses.

When panels require adjustment beyond design or tolerance criteria, discontinue affected work; advise Architect/Engineer.

[Fasten] [and] [Weld] units in place. [Perform welding including tack welds, in accordance with ANSI/AWS D1.1.]

Touch-up [field welds and] scratched or damaged [primed painted] [galvanized] surfaces.

Set vertical units dry, without grout, attaining joint dimension with lead or plastic spacers.

****** [OR] ******

Set panels with grout, attaining full bearing contact with substrate.

BUILT IN WORK

Build in [glazed frames] [fabricated [__________] frames] [window frames] [anchor bolts] [plates] [__________] and other items furnished by other Sections.

Build in items plumb and level.

Do not build in organic materials subject to deterioration.

TOLERANCES

Maximum Variation From True Alignment of Building Line: [1/4] [___] inch ([6] [___] mm).

Maximum Variation From Panel to Adjacent Panel: [1/4] [___] inch ([6] [___] mm).

Maximum Variation From Intended Plane of Wall: 1/4 inch in 10 feet (6 mm/ 3 m) and 1/2 inch in 20 feet (13 mm/ 6 m) or more.

Maximum Variation From Plumb: 1/4 inch (6 mm) per story non-cumulative; 1/2 inch (13 mm) in two stories or more.

Maximum Variation of Panel Joint Thickness: 1/8 inch in 3 feet ( 3 mm /m).

Maximum Variation From Cross Sectional Thickness of Panel: [1/4] [___] inch ([6] [___] mm).

PANEL JOINTS

[Prepare panels for panel joint seal.]

Size panel joints in accordance with Section 07900 for sealant performance.

Form joint [as detailed.] [____________________.]

CUTTING AND FITTING

Cut and fit for [pipes] [conduit] [sleeves] [grounds][,][.] [and] [_______________.] Coordinate with other sections of work to provide correct size, shape, and location.

Obtain Architect/Engineer approval prior to cutting or fitting panels not indicated or where appearance or strength of panels may be impaired.

CLEANING

Clean work under provisions of [01700.] [01710.]

Remove excess mortar and concrete.

Clean soiled surfaces with non-acidic solution which will not harm masonry or adjacent materials. Consult masonry manufacturer for acceptable cleaners.

Use non-metallic tools in cleaning operations.

PROTECTION OF FINISHED WORK

Protect finished installation under provisions of Section [01500.] [01535.]

Maintain protective boards at exposed external corners of panels which may be damaged by construction activities.

Provide protection without damaging completed work.

END OF SECTION