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

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Masonry Wall Mock-up Construction – Verification of Mortar Sand Compliance to ASTM C144Onsite Work with Masons – Wednesday, February 25, 2009. John P. Speweik, CSI

Replacement Brick -Water Soaked Prior to Use

SECTION 04211-4: 3.02 ERECTION, INSTALLATION, APPLICATION; B-4 , Soak replacement brick in clean water for 7 days before laying.

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Storage Area for Salvaged Brick

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.

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General Condition of Salvaged Brick After Disassembling Walls3/3/2009 4

Tracking Location of Salvaged Brick

SECTION 04211-4: 3.02 ERECTION, INSTALLATION, APPLICATION; B-1

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OBSERVATION: Evidence of fully filled collar joints/bed joints supporting SECTION 04211: 3.02; B-63/3/2009 6

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

OBSERVATION: Face Profile of Original Mortar and Brick Surface3/3/2009 8

OBSERVATION: Another View of an Original Collar Joint Filled with Mortar3/3/2009 9

OBSERVATION: Organic Growth on Mortar Joints - Indicating a Water Absorptive Formulation3/3/2009 10

Mortar Sample Preparation3/3/2009 11

Sample Comparison to Original Interior Mortar Surface3/3/2009 12

Portland Cement

SECTION 04100-1: 1.02 REFERENCES; B

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0225090816a

SECTION 04100-1: 1.02 REFERENCES; C

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Salvaged Brick Cleaning Area

SECTION 04211-4: 3.02 ERECTION, INSTALLATION, APPLICATION; B-2 , Clean all brick by hand using chisel and stiff brush.

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Salvaged Brick After Cleaning3/3/2009 16

OBSERVATION: Original Mortar Debris is Clean, Free of Brick Contamination and Small in Size3/3/2009 17

Original Brick Clean and Ready for Reuse3/3/2009 18

OBSERVATION: Original Mortar Footprint is Entirely Gone on Most Brick3/3/2009 19

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OBSERVATION: Immediate Heavy Foam in Reaction to Acid-Based Experiment3/3/2009 21

Establishing Mortar Mix Design Procedures and Documentation

SECTION 04100-3: 2.02 MIXING; B. Mortar Mix: Measure all ingredients by cubic volume using pre-established uniform measure.

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Known Measure Established with Volume Marks Inside the Bucket3/3/2009 23

Ingredients Dry Mixed

SECTION 04100-3: 2.02 Mortar Mix: D. Mixing Order

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OBSERVATION: The Sound Under My Feet – This Wall Section is Built with a Different Mortar3/3/2009 25

OBSERVATION: Mortar Debris Contaminated with Brick Fragments3/3/2009 26

OBSERVATION: Accommodation for Movement Minimal in this Wall Section3/3/2009 27

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OBSERVATION: Mortar Debris is Large – Appears to have “Pancaked” at the Brick Interface3/3/2009 29

Looking North3/3/2009 30

Looking Toward River3/3/2009 31

Soaking Salvaged Brick3/3/2009 32

Creating Channel Mortar Samples for Comparison3/3/2009 33

The Surface Texture Will be Affected by the Timing of the Finish3/3/2009 34

OBSERVATION: Water Misting to Expose Aggregate – Needs Verification in the Const. Phase3/3/2009 35

OBSERVATION: Wall Sections A, E, & H are different in color and profiles – clarification needed3/3/2009 36

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

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Mortar Color Influences

MATERIALS

• Sand: Standard deviations exist with natural sands. The precision of values in testing various samples is common.

• Formulation: Mortars will change in color due to mix designs: 1:1:6 will be darker than a 1:2:9 mix using the same ingredients

WORKMANSHIP

• Techniques in approach, tool selection, and timing in delivering the specified profile will be dependant on one another in combination with weather conditions

• Amount of water in the initial mixture

• Time of mortar placement in relation to SSD conditionrepointing and replacement

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Questions pertaining to this work can be directed to:John Speweik, CSI224-856-7449

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 ?

MIX DESIGN NOTE:Volumetric measurements of hydrated lime were adjusted per industry practice in accordance withThe 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.

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