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SECTION 09 2400
SECTION 09 2400
PORTLAND CEMENT PLASTERING
PART 1 - GENERAL
1.2 SUMMARY
A. Section Includes:
1. External thermal plastering & supplementary items for applying over cementations
substrates including CMU Masonry as indicated in the drawings.
2. External and internal Portland cement plastering & supplementary items for applying
over cementations substrates including CMU Masonry as indicated in the drawings.
1.3 SUBMITTALS
A. Product Data: Manufacturer’s technical literature for each product and system indicated.
1. Include manufacturer's specifications for materials, finishes, construction details,
installation instructions, and recommendations for maintenance.
B. Shop Drawings: Show details of fabrication and installation, including plans, elevations,
sections, details of components and attachments to other work.
C. Samples for Verification Purposes: Submit samples for each item listed below of size and
construction indicated. Where products involve normal color and texture variations, include
sample sets showing the full range of variations expected.
1. 18 in (450 mm) square layered sample consisting of each Thermal/Portland Cement
Plaster System layer; prepared on rigid backing.
2. 12 in (300 mm) long sample of each metal trim accessory.
3. 12 in (300 mm) long flashing with end dam.
D. Product Test Reports: Written reports based on evaluation of comprehensive tests performed
by qualified testing agency indicating that each product complies with requirements.
E. Field Quality Control Reports: Written report of testing and inspection required by “Field
Quality Control”.
F. List of Materials for Layered Mock-Up for Construction Quality Purposes:
1. Product, material, and equipment names, model numbers, lot numbers, batch numbers,
source of supply, and other information required to identify items used. Include mix
proportions for plaster and source of aggregates.
2. Receipt of list does not constitute approval of deviations from Contract Documents,
unless such deviations are specifically accepted by Engineer in writing.
G. Qualification Data: For manufacturer and installer: For firms and persons specified in
"Quality Assurance" to demonstrate their capabilities & experience. Include lists of
completed projects with project names & addresses, Engineer/ Clients names & addresses
and other information specified.
performance and completion of projects for a period of not less than 10 years and with
sufficient production capability, facilities, and personnel to produce required Work.
B. Installer Qualifications:
1. Experience: Installer with not less than 10 years’ experience in performing specified
Work similar to scope of this Project, with a record of successful in-service performance
and completion of projects for a period of not less than 10 years and with sufficient
production capability, facilities, and personnel to produce required Work.
2. Supervision: Installer shall maintain a competent supervisor who is at Project site during
times specified Work is in progress that is experienced in installing systems similar to
type and scope required for Project.
3. Manufacturer Acceptance: Installer shall be certified, approved, licensed, or acceptable
to manufacturer to install products.
C. Manufacturer’s Technical Representative Qualifications: Direct technical employee of
manufacturer with min of 5 years experience in providing recommendations, observations,
evaluations, and problem diagnostics. Sales representatives are not acceptable.
D. Pre-Construction Testing: Client may employ and pay an independent testing agency to
perform pre-construction testing to establish compliance of proposed Work with specified
requirements.
1. General Requirements: Test plaster mixes for composition to establish standard for field
testing specified under “Field Quality Control” Article.
2. Test Method: ASTM C 780, Annex A4.
3. Specimen Quantity: Provide not fewer than number of plaster samples required.
4. Reports: Interpret test results and prepare certified reports.
E. Mock-Ups: Prior to fabrication and installation, build mock-up for each form of construction
and finish required to verify selections made under sample Submittals and to demonstrate
aesthetic effects and qualities of materials and execution. Build mock-up to comply with the
following requirements, using materials indicated for the completed Work:
1. Build mock-up in the location and of the size indicated or, if not indicated, as directed by
Engineer. Contractor shall provide structural support framework.
a. Show typical components, attachments to building structure, and requirements of
installation.
2. Clean exposed faces of mock-up.
3. Notify Engineer seven days in advance of the dates and times when mock-up will be
installed.
4. Demonstrate the proposed range of aesthetic effects and workmanship.
5. Protect accepted mock-up from the elements with weather-resistant membrane.
6. Obtain Engineer acceptance of mock-ups before starting fabrication.
7. Maintain mock-ups during construction in an undisturbed condition as a standard for
review of the completed Work.
8. Acceptance of mock-ups does not constitute acceptance of deviations from the Contract
Documents contained in mock-ups unless such deviations are specifically noted by
Contractor, submitted to Engineer in writing, and accepted by Engineer in writing.
9. Demolish and remove mock-ups when directed by Engineer unless accepted to become
part of the completed Work.
F. Layered Mock-Up for Construction Quality Purposes: In addition to the Mock-ups described
above and prior to Pre-Installation Conference; build layered mock-ups for each type of
plastering assembly specified to demonstrate qualities of materials and to verify Work
construction execution quality with Contract Documents (not for aesthetic qualities), using
specified materials:
1. Notify Engineer 7 days in advance of the dates and times when mock-up will be installed.
2. Build mock-up in the location and of the size indicated or, if not indicated, as directed by
Engineer. Contractor shall provide structural support framework.
a. Show typical components, attachments to building structure, and requirements of
installation.
b. Clean exposed faces of mock-up prior to presentation to Engineer.
3. Obtain Engineer’s acceptance of mock-ups before starting installation of permanent
Work for the Project. Acceptance of mock-ups does not constitute acceptance of
deviations from the Contract Documents contained in mock-ups unless such deviations
are specifically noted by Contractor, submitted to Engineer in writing, and accepted by
Engineer in writing.
4. Protect accepted mock-ups from the elements with weather-resistant membrane.
5. Maintain accepted mock-ups during construction in an undisturbed condition as a
standard for review of the completed Work.
6. Arrange installation of products and materials in layered fashion to allow observation
into concealed areas of assembly; including the following:
a. Plastering in specified finish, including accents and design details.
b. Wall back-up, complete with cementitious substrate and waterproofing.
c. Metal lath and accessories.
d. Head, jamb, and sill of window or door opening:
1) Head shall include lintels, flashings, and accessories.
2) Jambs shall include edge flashings.
3) Sills shall include flashings.
7. Acceptance of layered mock-ups is for following Work execution qualities:
a. Application of modified cement waterproofing.
b. Installation and attachment of metal lath.
c. Application of Portland cement plaster.
d. Installation and attachment of accessories, including joinery.
e. Plastering uniformity and consistency.
f. Other material & construction qualities as determined by Engineer.
8. Demolish and remove mock-ups when directed by Engineer.
A. Pre-Installation Conference: Before Work begins, conduct conference at site to comply with
requirements of applicable Division 01 Sections.
A. Delivery: Deliver products in original unopened packages or containers, fully identified with
intact and legible labels.
B. Storage: Store materials inside under cover and keep them dry and protected against damage
from weather, direct sunlight, surface contamination, corrosion, construction traffic, and
other causes.
A. Stain Prevention: Prevent soil from staining exposed plaster. Immediately remove soil from
exposed plaster.
1. Protect base of walls from rain-splashed mud and plaster splatter.
1.8 COORDINATION
A. Coordinate installation of products and systems with interfacing and adjoining construction
to provide a successful installation without failure.
PART 2 - PRODUCTS
A. Single Source Responsibility: Furnish each type of product from single manufacturer.
Provide secondary materials only as recommended by manufacturer of primary materials.
A. Portland Cement:
1. Product Quality Standard: BS-12 and ASTM C 150, Type I;
a. Except Type III may be used for cold-weather construction (not applicable here).
B. Types of Cement Not Permitted: ASTM C 91 masonry cement and ASTM C 1329 mortar
cement are not acceptable and shall not be used.
C. Hydrated Lime: Product Quality Standard: BS 890 and ASTM C 206 BS EN 459-1:2001,
Type S.
D. Sand Aggregate: ASTM C 897 and BS 1198 & 1199 BS EN 13139:2002.
1. Sands shall be hard, clean chemically washed and structurally stable and sea originated,
its grading shall conform to the requirements of BS 1198 & 1199 BS EN 13139:2002:
Building sands from natural sources.
E. Reinforcing Fiber: Alkaline-resistant glass or polypropylene, 1/2 in (12 mm) long, free of
contaminants, manufactured for use in Portland cement plaster.
F. Water: Potable.
1. Water for plastering shall be clear, clean, drinkable fresh water free from all deleterious
matter or chemical impurities which may adversely affect the plaster and complying in all
respects with BS 3148 BS EN 1008:2002.
A. External / Internal plastering in ratio of 1:4, shall be applied in three coats to a minimum
total thickness of (20 mm for external plaster and 15mm for internal plaster ) on vertical
faces and 15 mm on ceiling (excluding the thickness of any initial dash coat).
B. On vertical faces the plaster shall be applied in widths not exceeding one meter between
screed laths prepared and set up true and plumb.
C. The finished faces of plaster shall be true to shape and angle even in all directions, free of
cracks and trowels marks to the complete satisfaction of the Engineer.
D. The plastering of each face between two corners shall be carried out in one operation and
work must be in no case be interrupted and continued the following day. All reveals for
jambs, lintels shall be plastered in one operation with the respective wall faces.
E. At least one day shall elapse between the executions of consecutive coats of plaster.
A. General: All internal plaster accessories shall be Galvanized steel and external plaster
accessories shall be stainless steel (grade 316).
B. Casing Beads:
1. Product Description: Square edge, expanded metal flange; perforated with minimum
1/4 in (6 mm) diameter holes at 12 in (300 mm) on centers when used at bottom of
plaster, non-perforated elsewhere; size required for plaster thickness.
2. Material Quality Standard: ASTM B 69, 99 percent pure zinc alloy.
C. Outside Corner Reinforcement:
1. Product Description: Small nose corner beads, expanded metal flanges, with continuous
stiffening ribs.
2. Material Quality Standard: ASTM B 69, 99 percent pure zinc alloy.
D. Expansion Joint:
1. Product Description: Two-piece, slip joint that allows multi-directional movement; size
required for plaster thickness.
2. Material Quality Standard: ASTM B 69, 99 percent pure zinc alloy.
E. Control Joint:
1. Product Description: Back-to-back J-shape that permits positive locking with plaster,
expanded metal lath flange; size required for plaster thickness.
2. Material Quality Standard: ASTM B 69, 99 percent pure zinc alloy.
F. Metal Lathing:
1. Internal Applications: Metal lathing for use in in-situ finishes shall be plain expanded
metal type complying with ASTM C847 or BS 1369, weighting not less than 1.8 kg/m2.
All metal lathing shall be zinc coated steel conforming to BS EN 10143: 1993 with a
coating of at least grade G275.
Metal lathing shall be secured by means of galvanized steel nails and washers at 300 mm
centers maximum. Metal lathing shall be provided over all junctions of concrete and
masonry block work or any other dissimilar materials which are to be rendered. The
minimum width of the metal lath shall be 100 mm on each side of the joint.
2. External and high humidity applications: Metal lathings for use in-situ finishes for
external applications and internal areas of high humidity shall be stainless steel grade
316.
G. Channels:
Shall be galvanized steel. Channels shall have flanges not less the 11 mms, wide. The
minimum weight of channels shall be for size 40 mms about 0.71 kg/m, size 20 about
0.45 kg/m.
H. Hunger Wire:
Shall be galvanized annealed wire with a tensile strength of 4900 kg/cm² Tie wire for
securing metal lath to supports and for lacing shall not be less than 1.6 mms in
diameter. Tie wire for attaching furring channels to runner channels in ceiling
construction shall be not less than 2.0 mms in diameter.
I. Corner Beads:
Provide metal beads at all corners to be plastered and at sills, sides & jambs of
windows and other openings without frames occurring in plastered walls. Unless
otherwise indicated on drawings, beads shall be fabricated from zinc-coated steel, not
lighter than 26 - gauge (0.45 mm) thick metal.
J. Expansion Beads:
Provide metal expansion beams in plaster ceilings and walls at the location and
spacing indicated on drawings or directed by the Engineer/Client, of the same previous
type.
K. Skirting Beads:
Provide skirting beads for all plaster work , types and size to be selected by Engineer
/Client.
L. Plaster Stop:
Plaster Stop shall be used where indicated and/or where it required by
Engineer/Client.
2.6 FASTENERS
A. Field Measurements: Where metal flashing is to fit, cope, or be tailored to other construction,
check actual dimensions of other construction by accurate field measurements before
fabrication.
B. Fabrication Procedures: Fabricate continuous flashings in sections 96 in (2400 mm) long
minimum, but not exceeding 12 ft (3.6 m). Provide splice plates at joints of formed, smooth
metal flashing.
1. Shop form flashing on a bending brake.
2. Shape, trim and hand seam on bench as far as practical with proper tools.
3. Form exposed metal Work without excessive oil canning, buckling, and tool marks and
that is true to line and levels indicated.
4. Make angle bends and folds for interlocking metal with full regard for expansion and
contraction to avoid buckling or fullness in metal after installation.
5. Form materials to shape indicated with straight lines, sharp angles and smooth curves.
6. Fold and hem exposed edges of flashings.
C. Flashing Joinery: Fabricate interior and exterior corners, intersections, and complex flashing
conditions in shop, rather than in field, with properly folded, constructed and continuous
soldered joints. Field fabricated units are not permitted and will not be allowed.
PART 3 - EXECUTION
3.1 EXAMINATION
3.3 PREPARATION
A. General: Comply with manufacturer’s instructions and recommendations for cleaning and
surface preparation. Surfaces shall have no defects, contaminants or errors which would
result in poor or potentially defective installation or would cause latent defects in Work.
B. Surface Conditioning: Immediately before plastering, dampen cementitious substrates that
are indicated for direct application of plaster, except where a bonding agent has been applied.
Determine and apply amount of moisture and degree of saturation that will result in
optimum suction for plastering.
C. Cleaning: Remove form oils, coatings, laitance, efflorescence, mortar, loose material and
substances that would adversely affect or reduce bonding.
D. Temporary Grounds and Screeds: Install as necessary to ensure accurate rodding of plaster to
true surfaces; coordinate with scratch-coat work.
E. Plaster shall not be applied to masonry or concrete surfaces that have been coated with a
bituminous compound or other waterproofing agents.
3.5 MIXING
A. Mechanical mixers, mixing boxes and tools shall be cleaned after mixing each batch and kept
free of material from previous mixes. All tools, implements, vessels and surfaces shall at all
times be kept scrupulously clean and strict precautions shall be taken to avoid materials
becoming contaminated by pieces of partially set material which would tend to retard or
accelerate the setting time.
B. Except where hand-mixing of small batches is approved by the Engineer, mechanical mixers
of an approved type shall be used for mixing.
C. Re-tempering will not be permitted and all render or screed which has begun to stiffen shall
be discarded.
A. General Requirements:
1. Install at locations indicated according to installation quality standard.
2. Attach securely with fasteners to hold accessories in place and alignment during
plastering; secure at ends and not more than 12 in (300 mm) on centers.
3. Install longest lengths possible, avoid butt joints.
4. Install so that finished plaster surfaces will be true to line, level, plumb, square, curved or
as otherwise required, without excessive thickness of plaster.
5. Set vertical accessories plumb, and horizontal accessories level, and form true and neat
corners.
6. Vertical accessories shall pass through horizontal accessories.
7. Miter or cope at corners; install with tight joints seated with sealant and in alignment.
8. Bed accessories in sealant as indicated on Drawings.
B. Casing Beads: Install continuous at edges and terminations of plaster. Use perforated beads
at bottom of plaster areas and non-perforated at sides and top.
C. Interior Corners: Install continuous inside corner reinforcement.
D. Exterior Corners: Install continuous outside corner reinforcement.
E. Corners of Openings: Install strip lath reinforcement diagonally.
F. Base of Wall: Install foundation weep screed at dimension above grade indicated.
G. Expansion and Control Joints:
1. Cementitious Substrates: As indicated on Drawings. If not indicated on drawings, then
as required to align with joints in substrates behind or below plaster system.
2. Metal Lath at Soffits: As indicated on Drawings. Otherwise as follows:
a. Divide plaster into areas (panels) of following maximum sizes with length-to-width
ratios of not greater than 2-1/2 to 1:
1) Horizontal Surfaces: 100 sq. ft. (9.3 sq. m).
b. Distances between control joints are not to be greater than 18 ft (5.4 m) on centers.
A. General:
1. Apply plaster by hand or by pneumatic wet gun application method.
2. Establish and follow an application pattern that produces an even drying surface.
3. Avoid using materials that are frozen, caked, lumpy, dirty, or contaminated by foreign
materials.
4. Avoid using excessive water in application of plaster materials.
5. Make internal corners and angles square; finish external corners flush with corner beads,
square and true with plaster faces.
B. Plaster Base Coats at Direct Bond Locations:
1. Modified Cement Waterproofing: Apply to uniformly cover substrates.
2. Brown Coat: After modified cement waterproofing coat has cured, apply brown coat to
uniform thickness with sufficient material and pressure to ensure tight, uniform bond.
3. Thickness of Plaster Base Coat:
a. Brown Coat: 5/8 in (15 mm) thick.
C. Plaster Base Coats at Metal Lath Locations:
1. Scratch Coat:
a. Apply to uniform thickness indicated to completely embed metal lath.
b. Uniformly score surface approximately 1/8 in (3 mm) deep.
c. Allow to cure before applying brown coat.
2. Brown Coat:
a. After scratch coat has cured to be sufficient rigid, apply brown coat to uniform
thickness indicated over damp scratch coat with sufficient material and pressure to
ensure tight, uniform bond.
b. Rod to true, even plane, filling surface defects with plaster.
D. Curing: Allow each coat to cure before applying subsequent coatings. Moist cure each coat
to comply with installation quality standard.
1. Compensate ambient climatic conditions by providing sufficient moisture in plaster mix
to permit continuous hydration of cementitious materials.
2. Allow sufficient time between coats to permit curing and development of sufficient
rigidity to resist cracking when subsequent coat is applied.
3. Utilize any of following for curing:
a. Fog spray of water.
b. Vapor barrier over plastered area.
c. Barriers to deflect sunlight and wind.
3.9 TOLERANCES
A. Finish Plane: Do not deviate more than + or - 1/8 in per 10 ft (3 mm per 3 m) from a true
plane in finished plaster surfaces, as measured by a 10 ft (3 m) straightedge placed on
surface.
A. Client’s Testing Agency Field Service: The Client may employ and pay a qualified
independent testing agency to perform field quality control. Materials and installation failing
to meet specified requirements shall be replaced at Contractor's expense. Retesting of
materials and installations failing to meet specified requirements shall be done at
Contractor’s expense.
1. Testing: Testing agency will test and evaluate Work during construction.
2. Plaster Tests: Verify plaster composition with specified requirements according to
ASTM C 780, Annex A4; made at following times during Work:
a. First day.
b. 5 percent.
c. 15 percent.
d. 30 percent.
e. 60 percent.
3. Evaluation of Quality Control Tests: Replace Work in areas where test results fail to
comply with requirements indicated.
3.11 ADJUSTING
A. Patching: Cut, patch, repair, and point-up Portland cement plaster as necessary to
accommodate other Work. Point-up finish plaster surfaces around items that are built into or
penetrate plaster surfaces.
B. Imperfections: Repair or replace Work to eliminate cracks, dents, blisters, buckles, crazing,
check cracking, dry outs, efflorescence, sweat outs, excessive pinholes, and similar
imperfections and where bond to substrate has failed.
END OF SECTION