Installing Grouted Exterior Brick Pavers

PART 1–GENERAL

1.01 SUMMARY

1. This procedure includes guidance on installing exterior brick paving and applying portland cement grout to replace deteriorated sections of existing paving and grout.

2. Read “General Project Guidelines” along with this specification. These guidelines should be reviewed prior to performing this procedure and should be followed, when applicable, along with recommendations from the Regional Historic Preservation Officer (RHPO). The guidelines cover the following sections:

   1. Safety Precautions

   2. Historic Structures Precautions

   3. Submittals

   4. Quality Assurance

   5. Delivery, Storage and Handling

   6. Project/Site Conditions

   7. Sequencing and Scheduling

   8. General Protection (Surface and Surrounding)

1.02 REFERENCES

1. American Society for Testing and Materials (ASTM International)

1.03 SUBMITTALS

1. Samples:

   1. Submit samples of brick pavers showing full extent of colors and texture; samples shall be compared to existing face brick on building.

   2. Submit grout color samples.

2. Product Data: Submit product data on latex additives for grout and setting bed.

1.04 DELIVERY, STORAGE AND HANDLING

Protect masonry materials during storage and construction against wetting by rain, snow or ground water and against soilage or intermixture with earth or other types of materials.

1.05 PROJECT/SITE CONDITIONS

Protect mortar bed and grout against uneven and excessive evaporation. Cure as required by climatic and job conditions so as to achieve proper hydration. Provide suitable coverings, moist curing barriers, etc. as required.

PART 2–PRODUCTS

2.01 MATERIALS

1. Brick Pavers: Pavers shall be solid, uncored, smooth units in color to match existing face brick color.

   1. Units shall conform to requirements of ASTM C902, Class SX, Type 1, Application PS.

   2. Not less than 10,500 psi average compressive strength.

   3. Not more than 8 percent cold water absorption after 24-hour submersion in cold water.

   4. Size shall be as indicated on the drawings.

2. Setting Materials:

   1. Portland Cement: ASTM C150, Type I or II, of natural color or white, as required to produce the required color of grout.

   2. Aggregate for Setting Bed: Clean, fine sand conforming to ASTM C144, uniformly graded from coarse to fine with 100% passing the No. 4 sieve and not more than 5% passing the No. 100 sieve.

   3. Aggregate for Grout: Clean, fine sand conforming to ASTM C144, uniformly graded from coarse to fine with not more than 5% passing the No. 100 sieve; 100% may pass the No. 30 sieve, but if the work requires a coarser sand, the coarse sieve size limit may be increased to the No. 16 size.

   4. Latex Additive for Thick Bed Mortar and Grout: An approved latex material which is recommended for use in thick bed mortars and grout for exterior applications, such as: 3701 Mortar Admix, made by Laticrete International, Inc.

   5. Color Pigments: For colored grout, use natural and synthetic iron oxides and chromium oxides, compounded for use in grout mixes. Use only pigments with record of satisfactory performance in masonry grouts, such as mortar colors, made by Solomon Colors, Inc. or True Tone colors, made by Huntsman.

   6. Water shall be clean, free of deleterious materials that can impair strength or bond.

   7. Latex Additive for Bond Coat, such as 4237 Latex Additive (made by Laticrete International, Inc.).

2.02 MIXES

1. Setting Bed: Proportions for setting bed shall be 1 part Portland cement, 3 parts sand, plus just enough of a 1:1 latex additive-to-water mixture to produce a moist surface when setting bed is ready for setting of paver units. Sand shall be measured in damp, loose condition.

2. Bond Coat: Proportions for setting bed shall be 1 part Portland cement, 3 parts sand, plus the amount of color pigment specified on product label, and just enough of a 1:1 latex additive-to-water mixture to produce a moist surface when setting bed is ready for setting of paver units. Sand shall be measured in damp, loose condition.

PART 3–EXECUTION

3.01 EXAMINATION

Installer must examine the areas and conditions under which brick paving is to be installed. Do not proceed with work until unsatisfactory conditions have been corrected in a manner acceptable to Installer. Commencement of work constitutes acceptance of surfaces.

3.02 ERECTION, INSTALLATION, APPLICATION

1. Paver Installation, General:

   1. Do not use units with chips, cracks, voids, discolorations or other defects which might be visible or cause staining in finished work.

   2. Cut units with motor-driven saw equipment designed to cut masonry with clean, sharp unchipped edges. Cut units as required to provide pattern shown and to fit adjoining work neatly. Use full units without cutting wherever possible.

   3. Set units in patterns shown with uniform joint width.

   4. Maintain surface plane for finished masonry paving not exceeding a tolerance of 1/8” in 10 feet when tested with a 10 foot straightedge.

2. Portland Cement Application:

   1. Spread and screed to uniform thickness, except for minor variations required to produce a true surface, level in plane or uniformly sloped for drainage as shown.

   2. Cut back, bevel edge, remove and discard setting bed material which has reached initial set prior to placing of paver units.

   3. Wet brick units several hours before laying, unless their gain in weight resulting from partial immersion flatware in 1/8” of water for 1 minute is less than 3/4 oz. per 30 sq. in. of immersed area. Do not lay bricks with free moisture on the surface.

   4. When mortar bed is plastic, apply bond coat with a notched trowel to a uniform thickness of 1/32” to 1/16”. Do not apply more mortar than can be covered within 20 to 30 minutes or before the surface has developed a skin.

   5. Each paver unit shall be back buttered with mortar before setting.

   6. Tamp and beat paver units for a complete contact between pavers and setting bed. Set and level each unit immediately.

   7. Grout joints as soon as possible after initial set of setting bed.

      1. Force grout into joints, taking care not to smear grout on adjoining paver units and other surfaces.

      2. After initial set of grout, finish joints by tooling to produce a very slightly concave polished joint, free from drying cracks.

   8. Cure grout by maintaining in a damp condition for 7 days.

3. Repair and Pointing:

   1. Remove and replace paver units which are loose, chipped, broken, stained or otherwise damaged, or if units do not match adjoining units.

   2. Provide new units to match adjoining units and install in fresh mortar or grout, pointed to eliminate evidence of replacement.

   3. Pointing: During the tooling of joints, enlarge voids of holes and completely fill with mortar or grout.