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MASONRY

DESIGN GENERAL SPECIFICATION

MASONRY

0 16/05/01 A. KHALIK SHIREEN EL TAKI ABDUL AZIZ AL AMERI ISSUED FOR IMPLEMENTATION

A 24/11/99 A. KHALIK MOHAMED KULEIB MOHAMMED A. SAHOO ISSUED FOR COMMENTS

Rev Date WRITTEN BY CHECKED BY APPROVED BY STATUS

DD/MM/YY
DOCUMENT REVISIONS

Sections changed in last revision are identified by a vertical line in the right margin

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CONTENTS

1. GENERAL .............................................................................................................................................. 3
1.1 INTRODUCTION........................................................................................................................................ 3
1.2 P URPOSE.............................................................................................................................................. 3
1.3 DEFINITIONS ........................................................................................................................................... 3
2. CODES AND STANDARDS...................................................................................................................... 3
2.1 B RITISH STANDARDS (BS)........................................................................................................................ 4
2.2 NATIONAL CONCRETE M ASONRY ASSOCIATION (NCMA)................................ ................................ ................. 4
2.3 A MERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM) ................................ ................................ ............. 4
2.4 UNIFORM B UILDING CODE (UBC-94)............................................................................................................ 4
3. REFERENCE DOCUMENTS................................ ................................ ................................ ..................... 5

4. DOCUMENT PRECEDENCE................................ ................................ ................................ ..................... 5

5. SPECIFICATION DEVIATION/CONCESSION CONTROL ........................................................................... 5

6. QUALITY ASSURANCE/QUALITY CONTROL ........................................................................................... 5

7. DOCUMENTATION ................................ ................................ ................................ ................................ . 5

8. SUBCONTRACTORS/SUBVENDORS ....................................................................................................... 5

9. HANDLING................................ ................................ ................................ ................................ ............. 5

9.1 P ACKAGING A ND SHIPPING ....................................................................................................................... 5
9.2 P RESERVATION A ND STORAGE.................................................................................................................. 6
10. MATERIALS ........................................................................................................................................... 6

11. MORTAR AND MASONRY GROUT.......................................................................................................... 6

11.1 GENERAL .......................................................................................................................................... 6
11.2 MATERIALS ........................................................................................................................................ 6
11.3 EXECUTION ........................................................................................................................................ 6
12. MASONRY ACCESSORIES ................................ ................................ ................................ ..................... 8
12.1 GENERAL .......................................................................................................................................... 8
12.2 MATERIALS ........................................................................................................................................ 8
12.3 EXECUTION ........................................................................................................................................ 9
13. UNIT MASONRY................................ ................................ ................................ ................................ ..... 9
13.1 GENERAL .......................................................................................................................................... 9
13.2 MATERIALS ...................................................................................................................................... 10
13.3 EXECUTION ...................................................................................................................................... 10

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1. GENERAL

1.1 Introduction
This Design General Specification defines the technical requirements for the furnishing and
installation of all masonry and accessories.

1.2 Purpose
This Design General Specification is to provide criteria for the furnishing of all materials, equipment
and installation of all masonry and accessories as outlined on the DRAWINGS, in the contract and
this specification.

1.3 Definitions
Where used in this specification, the following terms shall have the meanings indicated below unless
otherwise clearly indicated by context of their use.

1.3.1 COMPANY - The Abu Dhabi Gas Company (ATHEER)

1.3.2 CONCESSION REQUEST - A deviation requested by the CONTRACTOR or VENDOR, usually after
receiving the contract documents or purchase order. Often, it refers to an authorization to use,
repair, recondition, reclaim, or release materials, components or equipment already in progress or
completely manufactured but which does not meet or comply with the COMPANY requirements. A
CONCESSION REQUEST is subject to COMPANY approval.

1.3.3 CONTRACTOR - The party which carries out all or part of the design engineering, procurement
,construction and commissioning or management of the project

1.3.4 SUBCONTRACTOR - An organization providing specific services to the CONTRACTOR.

1.3.5 PROJECT MANAGEMENT TEAM (PMT) - The COMPANY authorized party responsible for the
overall day -to-day execution of the Project. The PMT is to serve as the liaison between the
COMPANY and the CONTRACTOR(S) on the PROJECT.

1.3.6 MANUFACTURER/VENDOR/SUBVENDOR - The service organization which actually manufacturers

and/or supplies the material/product in question.

1.3.7 SHALL - Indicates a mandatory requirement.

1.3.8 DRAWINGS - Drawings provided by the CONTRACTOR.

2. CODES AND STANDARDS

The following codes and standards, to the extent specified herein, form a part of this specification.
When an edition date is not indicated for a Code or Standard, the latest edition and addendums in
force at time of contract award shall apply.
Alternate standards and codes meeting the requirements of the referenced standards and codes
may be used with the approval of the COMPANY.

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2.1 British Standards (BS)

BS 12 Portland Cement

BS 882 Aggregates from Natural Sources for Concrete

BS 890 Building Limes

BS 1200 Building Sands from Natural Resources

BS 1369 Metal lathing (steel) for plastering

BS 3148 Methods of test for water for making concrete

BS 4027 Sulfate resisting PORTLAND Cement

BS 4551 Methods of testing mortars, screeds and plasters

BS 4721 Specification for ready -mixed building mortars

BS 4887 Mortars Plasticizers

BS 6073 Part 1, Precast Concrete Masonry Units: Specification for Precast

Concrete Masonry Units

BS 6073 Part 2, Precast Concrete Masonry Units: Method for Specifying Precast
Concrete Masonry Units

BS PD 6472 Guide to Specifying the Quality of Building Mortars

BS 6477 Water repellent for masonry surfaces

2.2 National Concrete Masonry Association (NCMA)

NCMA TEK 53 Design of Concrete Masonry for Crack Control

2.3 American Society for Testing and Materials (ASTM)

ASTM C207 Specification for Hydrated Lime for Masonry Purposes
ASTM C476 Specification for Grout for Masonry
ASTM A615 Specification for Deformed and Plain Billet-Steel Bars for Concrete
Reinforcement

2.4 Uniform Building Code (UBC-94)

UBC-94 1994 Edition of the Uniform Building Code

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3. REFERENCE DOCUMENTS
The following reference documents, to the extent specified herein, form a part of this specification.
When an edition date is not indicated for a document, the latest edition in force at the time of
contract award shall apply.
DGS 2020-004 Specification for Thermal and Moisture Protection

4. DOCUMENT PRECEDENCE
It shall be the CONTRACTOR’S responsibility to be, or to become, knowledgeable of the
requirements of the referenced Codes and Standards.
The CONTRACTOR shall notify the PMT of any apparent conflict between this specification, the
related data sheets, the Codes and Standards and any other Design General Specifications noted
herein. Resolution and/or interpretation precedence shall be obtained from the PMT in writing before
proceeding with the design / manufacture.
In case of conflict, most stringent criteria shall apply.
Requirements as specified in MANUFACTURER’S instructions shall be followed where applicable.

5. SPECIFICATION DEVIATION/CONCESSION CONTROL

Any technical deviations to the Purchase Order and its attachments including, but not limited to the
Design General Specifications, shall be sought by the CONTRACTOR only through CONCESSION
REQUEST format. CONCESSION REQUESTS require the PMT'S review and approval, prior to the
proposed technical changes being implemented. Technical changes implemented prior to PMT
approval are subject to rejection.

6. QUALITY ASSURANCE/QUALITY CONTROL

Quality Management System shall comply with the applicable requirements of ISO 9001 (1994).

7. DOCUMENTATION
The construction drawings shall be issued by CONTRACTOR (or a SUBCONTRACTOR) and
“approved for CONSTRUCTION” before the work commence.
The procedures for tittle block, issuing of the documentation shall be strictly followed.

8. SUBCONTRACTORS/SUBVENDORS
(NOT APPLICABLE).

9. HANDLING

9.1 Packaging And Shipping

All materials shall be delivered at site under SUBCONTRACTOR’s (for construction) responsibility,
with application of relevant codes and/or procedures.

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9.2 Preservation And Storage
All materials shall be stored in accordance with relevant codes and/or procedures.

10. MATERIALS
The CONTRACTOR shall submit an “Affidavit of Compliance” before beginning construction. The
Affidavit shall confirm that all material meets the requirements of this specification.

11. MORTAR AND MASONRY GROUT

11.1 General

11.1.1 Scope of Work

Under this Section, the CONTRACTOR shall furnish all labor, equipment and materials required to
complete the mortar work and grouting required in connection with the unit masonry work.

11.1.2 Related Work Specified Elsewhere

♦ Masonry Accessories, See Section 12, herein
♦ Unit Masonry, See Section 13, herein

11.2 Materials

11.2.1 Materials shall be as follows:

Materials shall conform to the requirements of the BS recommendations indicated and/or such other
requirements as are stated in the following detailed listing:
Portland Cement: Type I meeting the requirements of BS 12 and type V meeting the
requirements of BS 4027 for mortar below ground
Hydrated Lime: Shall meet the requirements of BS 890, Part 2, Type O (i), (ii) or (iii)
Sand for Mortar: Clean, sharp, mason’s sand, meeting the requirements of BS 1200,
Table 1
Water: To be clean, potable and free from sulphides, chlorides and soluble
organic matter, tested to BS 3148
Aggregate for Grout: BS 882, coarse aggregate size No. 8 and fine aggregate size No. 1.
All cement shall be the products of a single manufacturer.

11.3 Execution

11.3.1 Required Mix

Mortar of all unit masonry shall be conform to ASTM C207, Mortar of unit masonry type S, and be
proportioned by volume as follows :
♦ 1 part of Portland cement
♦ ¼ to ½ part of hydrated lime
♦ 2 ½ to 4 ½ part of sand
A minimum compressive strength of 10.3 N/mm2 must be attained.

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Where joints reinforcements are necessary, lime shall be replaced by a mortar plasticiser meeting
the requirements of BS 4887.
All mortar shall contain the recommended amount of integral water-repellent admixture for mortar for
water repellency and to assure proper bond strength. The required amount of admixture per bag of
cement shall be per MANUFACTURER’s instructions. Mortar preparation and composition shall
comply with ASTM C207, Type S.
See Unit Masonry Section 13.0 herein for a list of acceptable admixture manufacturers.
All exterior block walls shall be laid with full mortar coverage on horizontal and vertical face shells,
and mortar shall contain the integral mortar admix as per label instructions. All joints shall be well
tooled. No raked joints shall be permitted. Attention shall be given to NCMA TEK 53 for joint and
crack control.
Grout for all unit masonry work shall attain a minimum compressive strength of 13.8 N/mm2 shall
conform to ASTM C476, and be proportioned by volume as follows:
♦ 1 part Portland cement
♦ 1/10 part hydrated lime
♦ 2-1/4 to 3 parts sand
♦ 1 to 2 parts coarse aggregate

11.3.2 Batching, Mixing, and Retempering

Methods of measuring shall be used, such that specified proportioning can be accurately controlled
and maintained.
All mortar shall be machine-mixed in a mechanically operated drum type batch mixer in which
quantity of water can be accurately controlled. Care shall be taken in adding final water to the mix
to avoid over-wetting. Mixing shall continue for not less than four minutes after all materials are in
the mixer. Mixer shall be completely empty and cleaned out before it is recharged.
When conditions are such as to cause drying of the mortar, batch size shall be such that all
materials will be used within two hours.
Mortar on the board shall be kept well tempered with water, so long as its cementing material has
not started to set, so that it will be soft and workable when placed in the wall. No retempering of
mortar will be permitted. All mixers, mortar boxes, etc., shall be cleaned out at noon and at night.

11.3.3 Grouting
Place reinforcement before grouting. Place before or after laying masonry units, as required by job
conditions.
Prior to grouting, inspect and clean grout spaces. Remove dust, dirt, mortar droppings, loose
pieces of masonry and other foreign materials from grout spaces. After final cleaning and
inspection, close cleanout holes and brace closures to resist grout pressures.
Do not place grout until entire height of masonry to be grouted has attained sufficient strength to
resist displacement of masonry units and breaking of mortar bond. Install shores and bracing, if
required, before starting grouting operations.
Limit grout pours to sections that can be completed in one working day with not more than one hour
interruption of pouring operation. Place grout in lifts that do not exceed 1500 mm. Allow not less
than 30 minutes, nor more than one hour between lifts of a given pour. Rod or vibrate each grout lift
during pouring operation. When more than one pour is required to complete a given section of

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masonry, extend reinforcement beyond masonry as required for splicing. Pour grout to within 40
mm of top course of first pour. After grouting masonry is cured, lay masonry units and place
reinforcement for second pour section before grouting. Repeat sequence if more pours are required.

12. MASONRY ACCESSORIES

12.1 General

12.1.1 Scope of Work

Under this Section, the CONTRACTOR shall furnish all labor, equipment and materials required to
complete the following items of work: provide and install all masonry reinforcing, anchors, flashings
and control joints required in connection with the laid-up masonry work.

12.1.2 Related Work Specified Elsewhere

♦ Mortar and Masonry Grout, See Section 11, herein.
♦ Unit Masonry, See Section 13, herein.
♦ Thermal and Moisture Protection, See Joint Sealants, Section 19, See Flashing and Sheet
Metal, Section 16.

12.1.3 Manufacturers
Local manufacturers (precast vendors) in UAE shall be approved by Contractor and Company for the
proposed application.

12.2 Materials

12.2.1 Materials shall be as follows:

Masonry control joints shall be equal to Rapid Control Joint, P.V.C. compound, regular type.
Masonry horizontal reinforcement shall consist of welded steel wire, truss type, with 5 mm diameter
deformed side rods connected with 4mm diameter diagonal cross rods. Prefabricated corner pieces
shall be used at all corners. Reinforcing shall be properly sized for the type of construction and
thickness of wall.
Masonry connections to adjacent concrete walls and columns shall be with cast-in-place dovetail
anchor slots, .91 mm (20 gage), in 3050 mm lengths, mill galvanized finish; triangular wire ties, 4.8
mm diameter wire, length as required, mill galvanized finish with dovetail anchor, 2.7 mm (12 gage),
mill galvanized. Dovetail anchor slots shall be furnished with continuous foam filler inserts to protect
channel from filling with concrete during installation.
Steel reinforcing bars and rods for use as vertical reinforcement and in bond beams and lintels shall
conform to ASTM A 615, Grade 60.
Catalog designations are listed for convenience in identification and to establish quality and type
required. Products by other manufacturers which are of equal quality and appearance shall be
considered for approval upon review of information submitted to the PMT.

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12.3 Execution

12.3.1 Control Joints

Install control joints in the locations shown on the DRAWINGS and/or in accordance with the
manufacturer’s standard details using concrete jamb block. Joints shall not be filled with mortar, but
shall be caulked as specified in Joint Sealants section.
Masonry Reinforcements
In all masonry walls, provide continuous horizontal reinforcing every second course in the mortar.
Reinforcing shall be discontinued at all control joints.
Reinforcing shall be lapped a minimum of 150 mm at all splices of truss type joint reinforcing and a
minimum of 900 mm at all splices of reinforcing bars.
Care shall be taken to keep reinforcing clean of all greases, oil or other foreign materials which might
affect its bonding properties with mortar. Storage and handling shall be done carefully and in a
manner to prevent the bending of wires.
Walls shall be vertically reinforced as required, vertical reinforcing bar shall be continuous from floor
to top of wall. Vertical reinforcement shall be secured to dowels at bottom of wall and at intervals as
necessary to hold the reinforcement in proper position. Cells with vertical reinforcement shall be filled
solid with grout.
Provide vertically reinforced and grouted cells also on each side of door openings.

13. UNIT MASONRY

13.1 General

13.1.1 Scope of Work

Under this Specification the CONTRACTOR shall furnish all labor, equipment and materials required
to complete the following items of work: provide and install all unit masonry required in connection
with laid-up masonry work; install all accessories furnished under other Specifications and built into
the masonry.

13.1.2 Related Work Specified Elsewhere

♦ Mortar and Masonry Grout. See Section 11, herein.
♦ Masonry Accessories. See Section 12, herein.
♦ Thermal and Moisture Protection. See Section 12.

13.1.3 Quality Assurance

CONTRACTOR shall construct a sample masonry panel onsite approximately 2000 mm long by
1200 mm high to establish a standard for quality. The sample may be constructed in place and
incorporated into the work if approved by the CONTRACTOR. Approval of sample shall be obtained
before proceeding with remainder of work.
CONTRACTOR shall meet the requirements of UBC-94, as well as all local code requirements, in
the installation of all masonry and accessories.

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13.2 Materials

13.2.1 Concrete Masonry Units

All concrete block units shall be 400 mm x 200 mm face size and conform to the BS 6073, parts 1
and 2 as applicable. Block widths shall be as shown on the DRAWINGS. Compressive strength of
concrete block units shall not be less than 13.1 Mpa.
The Aggregate for the manufacture of Blocks shall be as follows :
The maximum permitted total chloride ion content expressed as percentage by weght of dry
aggregate shall be as follows :
♦ Coarse aggregate : 0.08%
♦ Fine aggregate : 0.10%
Concrete block used to construct the exterior walls shall be smooth masonry units.
All concrete masonry units shall have a uniform texture and be smooth faced, as required.
Special shapes shall be supplied as required by the DRAWINGS.
All exterior concrete block, including precast lintels, shall contain the recommended amount of
integral water-repellent admixture.
Acceptable manufacturers for integral water-repellent admixtures shall be considered for approval
upon review of information submitted to the PMT.
No other admixtures or additives should be used unless written approval is given by the integral
water-repellent admixture MANUFACTURER.

13.2.2 Manufacturers
Acceptable manufacturers or suppliers shall be approved by CONTRACTOR and COMPANY.

13.3 Execution

13.3.1 Installation
All walls shall be built true to dimensions, plumb, and square. All work shall be laid to line, in level
courses and all individual face units shall be kept “in plane.”
All unit masonry shall be laid using running bond. Joints shall run straight and plumb. Block cores
shall be reinforced as indicated on the DRAWINGS.
All masonry units shall be laid in a full bed of mortar with full head joints. All such mortar shall
contain the recommended amount of integral water-repellent admixture mortar admix for water
repellency and to assure proper bond strength.
All required cutting of masonry units shall be done with power equipment which will produce true
edges free of chipping and undamaged surfaces.
Where fresh masonry joins masonry that is partially or totally set, the exposed surface of the set
masonry shall be cleaned and wet lightly so as to obtain the best possible bond with the new work.
All loose masonry and mortar shall be removed. If it is necessary to “stop off” a run of masonry, this
shall be done by raking back one-half unit length of each course. No toothing will be permitted.
Joints in all exposed masonry work shall be firmly and neatly tooled, when mortar is thumbprint
hard, to a slightly concave profile, unless indicated otherwise. All concealed joints shall be cut off
flush and surplus mortar shall be brushed off as work progresses.

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a . Brick work/block work shall be carried up in a uniform manner with no one portion being raised
more than 1.0 M above another at any time unless special circumstances render this
impracticable.

b. The maximum height which is to be built in one day is 1.5 M. In the case of walls built using
retarder mortars, the maximum height which is to be built in one day shall be 1.0 M.

c. Walls built using retarder mortar shall be adequately cured for a period of not less than 24 hours
before any further work on the wall can take place.

d. The mortar beds and vertical joints shall be 10 MM nominal thickness and shall not exceed
15 MM.
Other trades shall be consulted and provisions made to permit installation of their work in a manner
which will avoid cutting and patching as the work progresses.
Tapping of units shall not be permitted after mortar has taken its initial set. Irregular work shall be
replaced with fresh mortar.
Masonry wall intersections shall be bonded with joint reinforcing, except at control joints.
Masonry joints shown to be caulked shall be raked back 12 mm. Sides of caulking recess shall be
free of mortar.
All loose lintels (steel, precast concrete, etc.) shall be installed by the SUBCONTRACTOR.
All bond beams shall be built in as indicated on the DRAWINGS. They shall be reinforced and filled
as detailed.
All masonry reinforcement, control joints, and flashings shall be installed as specified in Masonry
Accessories section.

13.3.2 Protection
All masonry work shall be properly protected from staining, the elements, and from damage at all
times. Top of all walls shall be covered at end of each work day.

13.3.3 Cleaning and Pointing Masonry Work

All surplus mortar, splatter, drippings, etc. shall be removed as work progresses.
At end of each working day all masonry work that is to be exposed shall be cleaned and pointed.
Holes resulting from removal of line pins must be filled.
Final cleaning of all masonry work shall be with water and fiber brushes, without acid, at the
completion of the work as an entirety. Stains shall be removed.
Any defective mortar joints shall be cutout, filled solidly with mortar, and tooled to match adjacent
work.
No cleaning acid shall be used on masonry without special permission of the PMT.

13.3.4 Cleaning Up
Upon completion of the work all surplus materials, debris, tools, and equipment shall be removed
from the site.

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