Technical Specification of Masonry Works

Benannain Weir and Appurtenance

SECTION 4
MASONRY WORKS

4.1 GENERAL

Masonry and stone works to be constructed, as part of the Works, shall be performed in
accordance with the provisions stipulated in this Technical Specification. This Section will
cover the following works.

Stone Masonry
Stone Pitching
Gabion Protection

The stone use for the works as specified in this Section shall be clean natural hard durable
stone as approved by the Engineer and shall be free from faults, crack, clay bands, iron
bands, spots, sand holes and other imperfection. All resources of material masonry and stone
works shall be subject to the approval of the Engineer.
A detailed method of statement for each work shall be submitted to the Engineer for his
approval at least thirty (30) days before starting such works.

4.2 MASONRY WORK

4.2.1 Material

(1) Stone
Stone masonry shall be constructed with river stones and quarried stones as approved by the
Engineer free from seams and other defect.
The stones shall have a specific gravity of not less than 2.5. The stones used in stone
masonry shall be random size, roughly hammer dressed, stones distributed so that they fit
closely together and there are no large voids between stones. Each stone shall be of weight
between 16kg and 25kg, but smaller stones may be used at the discretion of the Engineer.
The maximum size of the masonry stone shall be governed by the wall and abutment
dimensions such that no stone is larger than two-third of the thickness of the masonry or not
more than 30cm in diameter. Masonry stone stockpiled at the site shall be kept clean and
stones shall be watered before placed.

(2) Cement Mortar and joining

Cement mortar for joining stone masonry shall be made of Portland cement and sand, in
proportion of either 1:3 or 1:4 as prescribed on the Drawings for each type of work or as
directed by the Engineer. Unless otherwise so directed, cement mortar, which is used for
brickwork, shall be 1:1:1 (brick-dust: lime: sand) for normal work and 1: 3 (Portland cement:
sand) for waterproof work.
Sand shall be generally as specified for concrete sand in Clause 3.3 except that the grading
shall conform to the following limits:

Size of Sand Percent by Passing Screen

Sieve No. 8 (2.38mm) 100%
Sieve No. 100 (0.15mm) 15%maximum

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Within the above range the sand shall be well graded and as coarse as is practicable for the
production of mortar.
Cement shall be Ordinary Portland cement as specified in Clause 3.2.
Lime shall be quick lime conforming to the requirements of NI 7. Brick-dust shall conform to
the requirements of NI 20. It shall be thoroughly pounded into a fine state on site to the
approval of the Engineer.
Water used in the preparation of mortar shall be as specified in Clause 3.4. Only sufficient
water shall be used to produce the required workability of the mix.
The method and equipment used for mixing mortar shall be such as will accurately determine
and control the amount of each separate ingredient entering into the mortar and shall be
subject to the approval of the Engineer. If a mixer is used, it shall be approved design and the
mixing time after all the ingredients are set in the mixer, except for the full amount of water,
shall be not less than two minutes.
When the mixing of mortar by hand is permitted, the material shall be mixed on a close fitting
stage or in pans or though. The materials shall be turned twice in dry state and at least three
times after water has been added until the mortar has attained a uniform color and
consistency.
Mortar shall be mixed only in sufficient quantities for immediate use, and all mortar not used
within 30 minutes after mixing shall be wasted. Re-tampering of mortar will not be allowed.
Mixing through and pans shall be thoroughly cleaned and washed at the end of each days
work.

(3) Sand and Gravel

Sand and gravel to be used for mortar shall be clean, hard, durable river deposits or well-
graded broken stones, from 50mm to 1mm in size. Such materials shall be subject to
approval of the Engineer.

(4) Graded Gravel Filter

Graded filters shall consist of clean, hard durable siliceous material free from adherent
coatings such as clay. It shall not contain iron pyrites, sulfur, coal, mica, shale or similar
laminated, flaky or elongated materials, shells or other fragile or porous materials which, in
the opinion of the Engineer, will reduce the strength or life of the filter in the presence of water
or other materials.
The gravel shall consist of rounded particles and shall have a grading such that the conditions
below are satisfied:

(i) A 50% size is between 5 to 8 times of the 50% size of the material to be
protected.
(ii) Uniformity is equal to that of the material to be protected, where the uniformity is
the ratio of the 60% size to the 10% size.

The x percent size of a material is defined for the purpose of this Paragraph as the
dimensions of the sieve aperture through which passes x percent of a representative sample
of the material.
The Contractor shall make such grading tests of materials for the Engineers approval, in
compliance with the Technical Specifications.

(5) Sand Filter

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Sand for filters shall generally comply with the requirements of ASTM C 33 for fine aggregate,
and shall be free draining coarse and. Such filters materials shall be subject to the approval of
the Engineer.

(6) Storage of Materials

Cement and sand used for stone masonry shall be stored in accordance with the provisions in
Section 2 of this Technical Specifications. Lime and brick-dust shall be stored in bins on
concrete or sheet metal covered areas or on raised timber plat-forms to prevent the
absorption of moisture. It shall be adequately protected from the weathered by roofs and
waterproof coverings.

4.2.2 Plastering
Unless otherwise instructed, face joint in 1:3 (cement: sand) mortar shall be carefully pointed
flush and smooth. As the work proceed, care shall be taken to ensure that a uniform color is
attained. All joints that are not facing joints shall be filled flush with mortar.
Face joint mortar, 1:1:1 (Brick-dust : Limit : Sand) which is visible shall be plastered with a
mortar of 1 cement to 3 sand.
Where directed by the Engineer, the walls and floors or stone masonry shall be plastered with
a mortar of 1 cement to 3 sand.
Mortar for plastering shall comply with the provisions of Sub-clause 3.23.1 for materials and
mixing.
The plastering shall be applied in two layers to an overall thickness of 2.0cm. Unless
otherwise directed, stone masonry shall be plastered on the tops of walls, edges of canal
lining, and for 0.10m below the tops of walls and lining to form a cope.

4.2.3 Stone for Masonry

(1) Size of Stones

Random rubble masonry shall consist of stones of random size roughly hammer dressed, so
that they will closely fit together. Each stone shall weigh between 20kg and 50kg, but smaller
stones may be used at the discretion of the Engineer. Maximum size shall be governed by the
wall dimension and the weight limit above.

(2) Bedding and Jointing

Each stone for masonry shall be thoroughly wetted immediately before use and shall be laid
with its natural bed perpendicular to the direction of principal stress. Each stone shall bedded
in mortar, all joints being filled solid with mortar as the work proceeds. No joint shall be more
than 5.0cm wide and no stone shall touch each other.

(3) Facework
Masonry shall incorporate random ruble stones set with at least one bond stone to every
square meter. Facework shall rise with the masonry backing (or heating) so that bond stones
can be correctly laid. Stones shall be picked and laid carefully so that the exposed joints are
not less than, but as nearly as practicable 1.0cm thick.
All exposed facework shall be pointed. Mortar for all pointing unless otherwise ordered shall
be 1:2 (Portland cement : sand) mortar and the amount of water added shall be just sufficient
to produce the proper consistency for the intended use.
Before starting the point works, the joint of all face stone masonry shall be raked out before
the mortar is set (or chiseled out the old stone masonry). The surface shall be cleaned by wire
brush and moistened.

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Pointing works can be:

(a) recessed pointing : filling of joint to about 1.0cm average depth from the face
of stones,
(b) flush pointing : pointing is flush with the face of stone,
(c) raised pointing : pointing 1.0cm thick, and with not less than 2.0cm thick,
and with not less than 2.0cm width.

Unless otherwise ordered all pointing shall be flush pointing.

(4) Weepholes
Retaining walls, sloping lining, and abutments shall be provided with weepholes. Weepholes
shall be formed by PVC pipe 50mm and shall be provided one for each 2.0m 2 of facework.
Where graded filters adjoin the open ends of weepholes or pipes, selected stones suitability
graded shall be packed round the end of the hole or pipe to prevent loss of filters material,
and the stones shall be surrounded by a layer of ijuk or palm sugar fiber.

(5) False Joints

Where ordered or shown on the Drawings, false joint shall be provided in masonry sections
which are not designed as water retaining structures. Generally, false joints are required
wherever there is large change in section and where differential settlement will occur between
sections.
False joints shall be formed by omitting the bond stones and providing a graded stone/gravel
filter behind the masonry section to the full height of the joint. The graded filters shall consist
of selected stones and gravel suitably graded to prevent loss of filter material and shall be
surrounded by a layer of ijuk fiber of 3.0cm thick or an approved fiber made from geotextiles.

(6) Sample of Work

At the commencement of masonry work the Contractor shall construct sample sections of wall
until he shall have constructed one, the quality and appearance of which is to the approval of
the Engineer.
All subsequent masonry work shall be equal to or better than the approved sample.

(7) Protection and Curing

In constructing masonry work in unfavorable weathered and in protecting and curing the
finished work, Contractor shall observe the same conditions as are specified for concrete.
Stones shall not be placed during rains sufficiently heavy or prolonged to wash the mortar
from the masonry. Mortar already spread, which becomes diluted by rain, shall be removed
and replaced before continuing with the work. Workmen shall not be allowed to resume the
work the stone before it is fully set.

(8) Back Fill and Fill behind Masonry

Before backfilling or filling behind masonry which will not be visible, the masonry shall be
roughly plastered with 1:4 (Portland cement : sand), 2.0cm thick.
Filling shall not be placed before the approval of the Engineer. The fill material shall be free
drainage coarse sand. Gravel of uniform size shall be placed around the inside end of
weephole to prevent the loss of sand.

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4.2.4 Weepholes for Retaining Wall and Masonry Lining

Weephole consisting of PVC pipes and end filter shall be installed in masonry or concrete
retaining wall as shown on the Drawings or as directed by the Engineer.
All PVC pipes to be used for weepholes drains shall be furnished and installed as shown on
the Drawings or as approved by the Engineer.
Drains with a plastic pipe shall be constructed in the following manner:

Pipe description Construction sequence

PVC pipe 50mm for weepholes flip The ends of the pipe shall be wrapped with
PVC sheet until installation is complete.

Holes at least 5.0cm into the surrounding

rubble masonry may then be punctured by
mean of rounded tool through the pipe.

PVC pipe drains shall conform to ASTM D 2241 and PVC meeting shall be of quality
acceptable to the Engineer.
The filter shall be placed to the lines and dimensions as shown on the Drawings. The layer of
filter materials shall be placed carefully to the thickness and lines shown on the Drawings.
PVC pipes shall be wrapped with PVC netting at one end, which shall be placed into the filter
as shown on the Drawings. The pipes shall be installed to the prescribed positions and
grades as shown on the Drawings.

4.3 PROTECTION WORKS

(1) Preparation of Earth Formation for Pitching

The Contractor shall prepare the formation for pitching by the trimming the excavation
accurately to the specified dimensions. A graded gravel filter or gravel backing as specified
shall then be supplied and placed on the formation to the thickness shown on the Drawings to
give an even surface parallel to the finished surface of the pitching.

(2) Dry Stone Pitching

Where shown on the Drawings, the Contractor shall supply and lay dry stone pitching
consisting of stones roughly hammer dressed so that they will closely fit together. Watch
stone shall have a length and width of not less than 20cm and the depth not less than 20cm,
or as shown on the Drawings or as directed by the Engineer.
The stones shall be bedded on sand and laden their natural bed so that the surface is finished
to even true planes.

(3) Rubble Drains

Where shown on the Drawings, the Contractor shall construct rubble drains surrounded by
ijuk to the dimensions specified. They shall consist of trenches excavated and backfilled with
rubble. The rubble shall consist of stones as specified in Clause 3.3, which will be retained on
a 4.0cm sieve.

(4) Gabion

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Gabion shall be furnished and placed to the prescribed cut-line and thickness as shown on
the Drawings or as directed by the Engineer for protection of slopes, channel and other
structures.

Gabion shall consist of hard durable cobble stones having diameter more than 10cm but
limiting to 25cm and galvanized iron wire net of 10 x 8cm mesh having diameter 4mm. The
wire shall conform to SII: 0381-80 and PU BI-1982.
The Contractor shall submit samples of stones and wire-net at least thirty (30) days before
placing gabion at the required locations.
Gabion box (1.0 x 2.0 x 0.5 m) will be assembled at the site to the size designated. After
stuffing, the open end of gabion shall be closed with wire net and tied firmly along the edges
with binding wire of 2.7mm size. Type and shape of gabion shall be of box or mattress or
cylinder as designated on the Drawings.

4.4 MEASUREMENT AND PAYMENT

4.4.1 Masonry Work

(1) Masonry
Measurement, for payment, of the masonry works will be made based on the volume of
masonry actually in place to the lines, grades and thickness shown on the Drawings or as
established by the Engineer. Payment for the masonry works will be made at unit price per
cubic meter tendered thereof in Bill of Quantities, which unit price shall include the cost of all
materials, labor, equipment necessary for stone masonry works including preparation,
bedding, joining and finishing.

(2) Pointing
Measurement, for payment, of pointing will be made based on the area in place shown on the
Drawings or established by the Engineer.
Payment for pointing will be made at unit price per square meter tendered therefore in the Bill
of Quantities, which unit price shall include the cart of all material, labor, equipment, and
preparation required to place, produce and finish the pointing.

(3) Plaster Work

Measurement, for payment, of pointing will be made based on the area in place shown on the
Drawings or established by the Engineer.
Payment for pointing will be made at unit price per square meter tendered therefore in the Bill
of Quantities, which unit price shall include the cart of all material, labor, equipment, and
preparation required to place, produce and finish the plastering work.

4.4.2 Dry Stone Pitching

Measurement, for payment, of dry stone pitching will be made based on the cubic meter of
stones in place to the lines, grades and dimensions shown on the Drawings or as directed by
the Engineer.
Payment for dry stone pitching will be made at unit price per cubic meter tendered therefore in
the Bill of Quantities, which unit price shall include the cost of all material, labor, plant and
equipment necessary for the dry stone pitching work.

4.4.3 Rubble Drain

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Measurement, for payment, of rubble drain will be made based on the cubic meter of stone in
place to the lines, grades and dimensions shown on the Drawings or as directed by the
Engineer.
Payment for rubble drains will be made at unit price per cubic meter tendered therefore in the
Bill of Quantities, which unit price shall include the cost of material, labor, plant and equipment
necessary for rubble drain works including trench excavation.

4.4.4 Gabion
Measurement, for payment, of gabion will be made based on the volume of gabion in placed
at the locations shown on the Drawings or established by the Engineer.
Payment for gabion will be made at unit price per cubic meter tendered therefore in the Bill of
Quantities, which unit price shall include the cost of all operation required to furnish, produce
and place the gabion.

4.4.5 Weephole
Measurement, for payment, of weephole will be made based on number of pipes in placed at
the locations shown on the Drawings or established by the Engineer.
Payment for weepholes will be made at unit gabion price per cubic meter tendered therefore
in the Bill of Quantities, which unit price shall include the cost of all labor, materials, plant and
equipment necessary for weephole works including PVC pipe and ijuk (natural palm fiber).

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