Product Guide Specification

(Revised February 2006)

 

 

Specifier Notes:  This product guide specification is written according to the Construction Specifications Institute (CSI) 3-Part Format, including MasterFormat, SectionFormat, and PageFormat, as described in The Project Resource Manual—CSI Manual of Practice.

 

The section must be carefully reviewed and edited by the Architect to meet the requirements of the project and local building code.  Coordinate this section with other specification sections and the Drawings.  Delete all “Specifier Notes” when editing this section.

 

Section numbers and titles are from MasterFormat 1995 Edition, with numbers and titles from MasterFormat 2004 Edition in parentheses.  Delete version not required.

 

 

SECTION 04720 (04 72 00)

 

CAST STONE (CAST STONE MASONRY)

 

 

Specifier Notes:  This section covers cast stone masonry as manufactured by Continental Cast Stone companies.  Cast stone is a highly refined architectural precast concrete product manufactured to simulate natural cut stone.

 

Cast stone is manufactured by Continental Cast Stone using the Vibrant Dry Tamp (VDT) Casting Method. This casting method uses more carefully graded aggregate and less water than architectural precast concrete using the Wet Casting Method.  The most noticeable benefits are the fine grained texture and the total absence of bug holes.  This results in a product that more closely resembles natural cut stone.

 

Continental Cast Stone also manufactures Continental Select Stone using the Machine Casting Method.  This casting method uses a proprietary automated VDT method which produces modular cladding units in standard sizes with various finishes.

 

VDT cast stone components are custom fabricated for each project.  Select Stone units may be made to order or for immediate shipment from inventory.

 

Consult Continental Cast Stone for assistance in editing this section for the specific application.

 

 

PART 1        GENERAL

 

1.1       SECTION INCLUDES

 

A.      Cast stone masonry.

 

1.2       RELATED SECTIONS

 

Specifier Notes:  Edit the following list of related sections as required for the project.  List other sections with work directly related to the cast stone.

 

A.      Section 04060 (04 05 13) – Masonry Mortar (Masonry Mortaring).

 

B.      Section 04070 (04 05 16) – Masonry Grout (Masonry Grouting).

 

C.     Section 04080 (04 05 19) – Masonry Anchorage and Reinforcement (Masonry Anchorage and Reinforcing).

 

D.     Section 04200 (04 20 00) – Masonry Units (Unit Masonry).

 

E.      Section 07900  (07 90 00) – Joint Sealers (Joint Protection).

 

1.3       REFERENCES

 

Specifier Notes:  List standards referenced in this section, complete with designations and titles.  This article does not require compliance with standards, but is merely a listing of those used.

 

A.      ASTM C 150 – Standard Specification for Portland Cement.

 

B.      ASTM C 1116 – Standard Specification for Fiber-Reinforced Concrete and Shotcrete.

 

C.     ASTM C 1364 – Standard Specification for Architectural Cast Stone.

 

D.     Cast Stone Institute Standard Specification (www.caststone.org).

 

1.4       DEFINITIONS

 

A.      Cast Stone:  Highly refined architectural concrete stone product manufactured to simulate fine grain texture of natural stone.

 

B.      Vibrant Dry Tamp (VDT) Casting Method:  Vibratory ramming of damp, zero-slump concrete against rigid formwork until it is densely compacted and ready for immediate removal from form.

 

Specifier Notes:  Include the following definition when specifying Continental Select Stone.

 

C.     Machine Casting Method:  Proprietary automated VDT method which produces modular cladding units in standard sizes with various finishes.

 

1.5       SUBMITTALS

 

A.      Comply with Section 01330 (01 33 00) – Submittal Procedures.

 

B.      Product Data:  Submit manufacturer's product data.

 

Specifier Notes:  Continental Cast Stone can assist in the design process by providing various degrees of customization according to the complexity of the project.  Significant cost savings can be achieved by specifying standard or modular length units, instead of requiring the manufacturer to detail profiles and layout of piece lengths specific to the project.  Consult Continental Cast Stone for additional information.

 

Specify one of the following three paragraphs.

 

C.     Shop Drawings:  Submit manufacturer's shop drawings including profiles, cross sections, reinforcement, exposed faces, arrangement of joints, anchoring methods, anchors, annotation of components, and their locations in project as indicated on the Drawings.

 

C.     Shop Tickets:  Submit manufacturer's shop tickets including profiles, cross sections, modular unit lengths, reinforcement, exposed faces, and annotation of components proposed for use in project according to cross sections as indicated on the Drawings.

 

C.     Catalog Cuts:  Submit manufacturer's catalog cuts showing page and product numbers of units proposed for use in project.

 

D.     Verification Samples:  Submit pieces of actual cast stone components, 12 inches (305 mm) square, illustrating range of color and texture to be anticipated in components furnished for project.

 

E.      Test Results:  Submit manufacturer's test results of cast stone components made previously by manufacturer using materials from same sources proposed for use in project.

 

1.6       QUALITY ASSURANCE

 

A.      Manufacturer Qualifications:  A current producer member of Cast Stone Institute, with a minimum of 10 years of experience in producing cast stone of types required for project.

1.      Plant shall have adequate capacity to furnish quality, sizes, and quantity of cast stone required without delaying progress of the Work.

2.      Products previously produced by plant and exposed to weather shall exhibit satisfactory appearance.

 

B.      Standards:  Unless otherwise specified in this section, cast stone shall comply with the following:

1.      ASTM C 1364.

2.      Cast Stone Institute Standard Specification.

 

Specifier Notes:  Mock-ups are optional and will add expense to the project.  Scope of the mock-up construction must be clearly specified or indicated on the Drawings.

 

Mock-ups allow the Architect to verify:

1.         The color and texture of the cast stone.

2.         The fit of adjacent components.

3.         The quality of construction.

4.         The quality of repair methods, if needed.

 

Revise the following paragraph as required for the project.  Delete if mock-ups are not required.

 

C.     Mock-ups:  Provide full-size cast stone components for installation in mock-up of exterior wall.  Approved mock-ups will become standard for appearance and workmanship.

 

Specifier Notes:  Delete one of the following two sentences.

 

1.      Mock-ups shall remain as part of the completed Work.

1.      Mock-ups shall not remain as part of the completed Work.  At Architect's direction, demolish mock-ups and remove debris.

 

1.7       DELIVERY, STORAGE, AND HANDLING

 

A.      Delivery:

1.      Deliver cast stone components secured to shipping pallets and protected from damage and discoloration.

2.      Protect corners from damage.

3.      Number each piece individually to match shop drawings and schedules.

 

B.      Storage:

1.      Store cast stone components and installation materials in accordance with manufacturer's instructions.

2.      Store cast stone components on pallets with nonstaining, waterproof covers.

3.      Ventilate under covers to prevent condensation.

4.      Prevent contact with dirt.

 

C.     Handling:  Protect cast stone components during handling and installation to prevent chipping, cracking, or other damage.

 

Specifier Notes:  Revise the following article as required for the project.  Delete if not required.

 

1.8       SCHEDULING

 

A.      Schedule and coordinate production and delivery of cast stone components with unit masonry work to optimize on-site inventory and to avoid delaying the Work.

 

 

PART 2        PRODUCTS

 

2.1       MANUFACTURER

 

A.      Continental Cast Stone, Website www.continentalcaststone.com, E-Mail info@continentalcaststone.com.

 

2.2       CAST STONE MASONRY

 

A.      Cast Stone:

 

Specifier Notes:  The Vibrant Dry Tamp (VDT) Casting Method enables as many as 100 pieces of cast stone to be cast from a single mold in an eight-hour day.  This method is ideally suited to fast-track construction projects due to its high production capability and low formwork requirements.

 

The VDT process guarantees total absence of bug holes and a finish which is difficult to distinguish from natural stone.  The limitation of the process is that it generally requires one flat, unexposed side to the design.

 

Both VDT and machine casting methods may be used on the same project to achieve the same results.  Do not specify the wet cast method.

 

1.      Casting Method:  Vibrant dry tamp or machine cast.

2.      Compressive Strength:  ASTM C 1364.

3.      Absorption, Cold Water:  ASTM C 1364.

4.      Linear Shrinkage:  Cast Stone Institute Standard Specification.

 

B.      Surface Texture:  ASTM C 1364.

 

C.     Color and Finish:

 

Specifier Notes:  Continental Cast Stone can assist in the color selection process by either providing color samples from the wide assortment of existing colors or by custom color matching a color or material chosen by the Architect.  Specify one of the following three sentences.

 

1.      Match sample on file at Architect's office.

 

Specifier Notes:  Insert Continental Cast Stone color number.

 

1.      Continental Cast Stone Color No.:  _________________ .

 

Specifier Notes:  Insert name of brick, natural stone, or other material to be matched.

 

1.      Match Color:  _________________ .

 

D.     Permissible Variation in Color:

1.      Total Color Difference:  ASTM C 1364, 6 units.

2.      Hue Difference:  ASTM C 1364, 2 units.

 

2.3       CAST STONE MATERIALS

 

Specifier Notes:  Manufacturer will choose type and color of portland cement and aggregates based on the cast stone color specified by the Architect.

 

A.      Portland Cement:  ASTM C 150, Type I, white or gray as required to match specified color.

 

B.      Coarse Aggregate:  ASTM C 1364.  Granite, quartz, or limestone.

 

C.     Fine Aggregate:  ASTM C 1364.  Natural or manufactured sands.

 

D.     Coloring Pigments:  ASTM C 1364.  Inorganic iron oxides.

 

E.      Chemical Admixtures:  ASTM C 1364.

 

F.      Water:  Potable.

 

Specifier Notes:  Specify galvanized or epoxy coated reinforcing bars when reinforcing is required for safe handling, setting, and structural stress.

 

G.     Reinforcement:  Where required by ASTM C 1364.  [Galvanized]  [Epoxy coated].

 

Specifier Notes:  Fiber reinforcement in the form of fibrous nylon to control plastic shrinkage and thermal cracking may be used.  Include the following sentence if fiber reinforcement is required.

 

H.     Fiber Reinforcement:  ASTM C 1116, fibrous nylon.

 

2.4       MORTAR MATERIALS

 

Specifier Notes:  Specify the mortar.

 

A.      Mortar:  [Cast Stone Institute Standard Specification]  [As specified in Section 04060 (04 05 13)].

 

2.5       ACCESSORIES

 

Specifier Notes:  Specify Type 304 stainless steel anchors for highly corrosive environments, such as coastal areas, and for 100-year type construction.

 

Anchor pins and dowels should be stainless steel.  Shelf angles and other similar structural items should be galvanized.

 

Consult Continental Cast Stone for assistance in specifying anchors for the specific application.

 

A.      Anchors:  Non-corrosive type, sized for conditions.  [Brass]  [Hot-dip galvanized steel]  [Type 304 stainless steel].

 

B.      Sealants:  As specified in Section 07900 (07 90 00).

 

C.     Cleaner:

1.      Manufacturer's standard-strength, general-purpose cleaner designed for removing mortar and grout stains, efflorescence, and other construction stains from new masonry surfaces without discoloring or damaging masonry surfaces.

2.      Approved for intended use by cast stone manufacturer and approved by cleaner manufacturer for use on cast stone and adjacent masonry materials.

 

2.6       FABRICATION

 

A.      Shapes:  Unless otherwise indicated on the Drawings, provide:

1.      Suitable wash on exterior sills, copings, projecting courses, and components with exposed top surfaces.

2.      Drips on projecting components, wherever possible.

 

B.      Reinforcement:

1.      As required to withstand handling and structural stresses.

2.      Comply with ASTM C 1364.

3.      Minimum of 0.25 percent of cross-sectional area of panels which exceed 24 inches (600 mm) in width.

4.      Minimum Reinforcing Cover:  Twice diameter of reinforcing bars.

5.      Units less than 24 inches in either transverse or longitudinal direction may be unreinforced in that direction if structural conditions allow.

 

C.     Curing:

 

Specifier Notes:  Curing cast stone components with a direct-fired steam generator as used at Continental Cast Stone provides the following benefits:

1.         Increases the first-day strength of the cast stone.

2.         Increases the hardness of the corners of the cast stone.

3.         Minimizes efflorescence.  The carbonation in the steam interacts with the concrete matrix to prevent salts from traveling to the cast stone surface.

 

1.      Cure cast stone components with a direct-fired steam generator at a minimum temperature of 105 degrees F (41 degrees C) for a minimum of 6 hours, within 12 hours of fabrication.

2.      Cure cast stone components in presence of carbon monoxide and carbon dioxide to promote carbonation at surface, to minimize efflorescence.

 

D.     Finishing:  Remove blemishes from exposed surfaces before packaging for shipment.

 

E.      Manufacturing Tolerances:  Manufacture cast stone components within tolerances in accordance with Cast Stone Institute Standard Specification.

 

2.7       SOURCE QUALITY CONTROL

 

A.      Sampling and Testing:  ASTM C 1364.

 

 

PART 3        EXECUTION

 

3.1       EXAMINATION

 

A.      Examine construction to receive cast stone components.  Notify Architect if construction is not acceptable.  Do not begin installation until unacceptable conditions have been corrected.

 

B.      Visual Inspection:

1.      Visually inspect cast stone components for fit and finish in accordance with ASTM C 1364 before installation.

2.      Do not install unacceptable components.

 

3.2       INSTALLATION

 

A.      General:  Install cast stone components in conjunction with masonry, complying with Section 04200 (04 20 00).

 

B.      Setting:

1.      Drench cast stone components with clear, running water immediately before installation.

2.      Do not use pry bars or other equipment in a manner that could damage cast stone components.

3.      Fill dowel holes and anchor slots completely with mortar or non-shrink grout.

4.      Set cast stone components in a full bed of mortar, unless otherwise indicated on the Drawings.

5.      Fill vertical joints with mortar.

6.      Make joints 3/8 inch (9 mm), unless otherwise indicated on the Drawings.

7.      Leave head joints in copings and similar components open for sealant.

8.      Rake mortar joints 3/4 inch (19 mm) for pointing.

9.      Sponge face of each stone to remove excess mortar.

10.    Tuck point joints to a slight concave profile.

 

C.     Sealant Joints:

1.      Comply with Section 07900 (07 90 00).

2.      Prime ends of cast stone components, insert properly sized foam backing rod, and install required sealant using sealant gun.

3.      Provide sealant joints at following locations and as indicated on the Drawings.

a.      Cast stone components with exposed tops.

b.      Joints at relieving angles.

c.      Control and expansion joints.

 

3.3       SETTING TOLERANCES

 

A.      Tolerances:  Comply with Cast Stone Institute Standard Specification.

1.      Variation from Plumb:  Do not exceed 1/8 inch in 5 feet (3 mm in 1.5 m) or 1/4 inch in 20 feet (6 mm in 6 m) or more.

2.      Variation from Level:  Do not exceed 1/8 inch in 5 feet (3 mm in 1.5 m), 1/4 inch in 20 feet (6 mm in 6 m), or 3/8 inch (9 mm) maximum.

3.      Variation in Joint Width:  Do not vary joint width more than 1/8 inch (3 mm) or 1/4 of nominal joint width, whichever is greater.

4.      Variation in Plane Between Adjacent Surfaces:  Do not exceed 1/8-inch (3-mm) difference between planes of adjacent components or adjacent surfaces indicated to be flush with components.

 

3.4       REPAIR

 

A.      Surface Repair:

1.      Repair chipping and other surface damage noticeable when viewed in direct daylight at 20 feet (6 m).

2.      Repair with matching touchup material provided by manufacturer and in accordance with manufacturer's instructions.

3.      Repair methods and results to be approved by Architect.

 

3.5       FIELD QUALITY CONTROL

 

A.      Inspection and Acceptance:  Cast Stone Institute Standard Specification.

 

3.6       CLEANING

 

A.      In-Progress Cleaning:

1.      Clean cast stone components as work progresses.

2.      Remove mortar fins and smears before tooling joints.

 

B.      Final Cleaning:

1.      Clean exposed cast stone, after mortar is thoroughly set and cured.

2.      Cleaner:

a.      Wet surfaces with water before applying cleaner.

b.      Apply cleaner to cast stone in accordance with cleaner manufacturer's instructions.

c.      Remove cleaner promptly by rinsing thoroughly with clear water.

 

Specifier Notes:  The following article is optional.  Delete if not required.  Consult Continental Cast Stone for additional information regarding the use of a water repellant.

 

3.7       WATER REPELLANT

 

A.      Apply silane or siloxane water repellant for weatherproofing cast stone in accordance with manufacturer's instructions.

 

B.      Apply water repellant after pointing, repair, cleaning, inspection, and acceptance are completed.

 

3.8       PROTECTION

 

A.      Protect cast stone components from splashing and other damage.

 

 

END OF SECTION

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