Removing And Replacing Damaged Marble Veneer

THIS PROCEDURE SHOULD BE PERFORMED UNDER THE DIRECTION OF AN HISTORICAL ARCHITECT OR ENGINEER TO DETERMINE THE MOST EFFICIENT AND LEAST DESTRUCTIVE MANNER FOR EXECUTING THE WORK. APPROVAL FROM THE REGIONAL HISTORIC PRESERVATION OFFICER IS REQUIRED.

PART 1–GENERAL

1.01 SUMMARY

1. This procedure includes guidance on removing damaged pieces of marble veneer and replacing with new to match existing.
2. See 01100-07-S for general project guidelines to be reviewed along with this procedure. These 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)

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).

1.02 REFERENCES

1. Applicable Publications: The following publications of the issues listed below, but referred to thereafter by basic designation only, form a part of this specification to the extent indicated by the references thereto:
   1. American Society for Testing and Materials (ASTM), www.astm.org
      1. C119-71 - Definition of terms relating to natural building stone.
      2. C-241-51 - Test for abrasion resistance of stone subjected to foot traffic.
   2. American National Standard Institute (ANSI) www.ansi.org
      1. A-94.1 - Standard specification for interior marble.
   3. Marble Institute of America (MIA) www.marble-institute.com
      1. “Dimension Stone, Design Manual IV”

1.03 SUBMITTALS

1. Shop Drawings: Submit cutting and setting drawings showing sizes, dimensions, sections and profiles of marble units, arrangement and provisions of jointing, anchoring and fastening, supports and other necessary details for lifting devices and reception of other work. Indicate location of each unit of marble on setting drawings with number designation corresponding to number marked on each unit.
   1. Show location of inserts (for marble anchors and supports) which are to be built into concrete or masonry substrate.
2. Samples: Submit 3 sets of samples, not less than 12” x 12” x 1/4” of each different color, grade and finish of marble required. Include in each set the full range of exposed color and texture to be expected in completed work.

1.04 DELIVERY, STORAGE AND HANDLING

1. Acceptance at Site: Handle marble to prevent chipping, breakage, soiling or other damage. Do not use pinch or wrecking bars without protecting edges of marble with wood or other rigid materials. Lift with wide-belt type slings wherever possible; do not use wire rope or ropes containing tar or other substance which might cause staining. If required, use wood rollers and provide cushion at end of wood slide.
2. Storage and Protection:
   1. Protect marble, mortar materials and accessories during storage and construction against moisture, soiling, staining and physical damage.
   2. Store marble on wood skids or pallets, covered with non-staining, waterproof membrane. Place and stock skids and stones to distribute weight evenly and to prevent breakage or cracking of marble. Protect stored marble from weather with waterproof, nonstaining covers or enclosures, but allow air to circulate around marble.
   3. Handle marble to prevent chipping, breakage, soiling or other damage. Do not use pinch or wrecking bars without protecting edges of marble with wood or other rigid materials. Lift with wide-belt type slings wherever possible; do not use wire rope or ropes containing tar or other substances which might cause staining. If required, use wood rollers and provide cushion at end of wood slide.

PART 2–PRODUCTS

2.01 MATERIALS

1. Marble Materials: Of color, finish, size, and type to match existing.
2. Setting Materials:
   1. Portland Cement: ANSI/ASTM C 150, Type I, except complying with staining requirements of ASTM C 91 for not more than 0.03% water soluble alkali.
   2. Hydrated Lime: ANSI/ASTM C 207, Type I.
   3. Sand: ANSI/ASTM C 144, non-staining, except graded with 100% passing the No. 166 sieve for 1/4” and narrower joints.
      1. For white pointing mortar and grout, furnish natural white sand or ground white stone complying with specified requirements.
      2. For colored pointing mortar and grout, furnish ground marble, granite or other sound stone, meeting specified grading requirements for sand, of color required to match existing mortar and grout color.
   4. Water: Potable, clear and not of Clean and potable, free of oils, acids, alkalis, salts, organic matter or other deleterious materials which would impair the work.
   5. Dry-Set Mortar: Factory-sanded Portland cement and additives complying with ANSI A 118.1, of type approved by mortar manufacturer and marble supplier for application indicated.
   6. Molding Plaster: ANSI/ASTM C 59.
3. Marble Accessories:
   1. Anchors, Dowels or Cramps: Fabricate from corrosion resistant metals. Special cramps, dowels, and the like shall be used where shown on shop drawings but elsewhere #12 stubs gage half hard yellow brass wire anchors shall be used. It shall be the responsibility of the Contractor to anchor all marble pieces securely. In general, for standing marble, the following practices usually prevail:
      1. A minimum of 2 anchors shall be required on all pieces up to 2 square feet in area.
      2. A minimum of 4 anchors shall be required on all pieces 2 square feet to 20 square feet in area.
      3. A minimum of 2 additional anchors shall be required for each additional 10 square feet on pieces above 20 square feet.
   2.  Setting Buttons: Lead or plastic buttons of thickness required for joint size indicated and of size required to maintain uniform joint width.

PART 3–EXECUTION

3.01 PREPARATION

1. Protection: Protect surrounding surfaces of building from damage resulting from marble restoration work.
2. Protect marble surfaces during construction period with Kraft paper or other heavy covering of type that will not stain or discolor marble.

3.02 ERECTION, INSTALLATION, APPLICATION

1. Stone fabrication shall be in accordance with the applicable publications listed in Part 1. Fabrication shall include surface tolerances, dimensions and finishes.
2. Marble shall have setting number on the back or on an unexposed edge that corresponds with the number on the approved shop drawings.
3. Backs of pieces shall be sawn or roughly dressed so that maximum variation in thickness from that required shall not exceed 1/4”.
4. Cutting for work of other trades shall be done neatly and accurately to the required size.
5. Marble installation shall be in accordance with the publications listed in Part 1 applicable to the specified stone. For details and stone types not otherwise covered, erection shall be in accordance with the listed publications for marble. Erection shall include the mechanical anchorage system, jointing, setting, anchors and dowels, pointing protection and cleaning.
6. Remove all deteriorated or damaged wall pieces as directed by RHPO. Remove all non-original material including non-matching patches. Remove existing setting buttons and prepare substrate material as required to insure proper installation of new pieces.
7. Erect new facing stones and trim plumb and true with joints uniform in width and accurately aligned. Provide setting buttons as required to maintain joint width.
   1. Set marble units firmly against plaster spots located at or near the anchors and spaced not further than 18” apart over the back of the piece, unless otherwise indicated.
8. Point joints after setting with pointing mortar to match color of existing mortar or to match color of marble. Color of marble shall be established in mock-ups. Mix in proportions of 1 part Portland cement, 1 part lime, and 3 parts sand; unless otherwise indicated. Rub joints smooth with plastic tool.

3.03 ADJUSTING/CLEANING

1. Epoxy patch existing marble units which become chipped or cracked during execution of this procedure. For guidance on repair of marble using epoxies see 04455-03-R.
2. Before final inspection, remove protective covering and reclean any soiled surfaces. For guidance on specific cleaning procedures see 04455-02-R and 04455-06-R.