Central Business District CBD EAST – Phase 1

Of the New Administrative Capital

SECTION 092400 - PORTLAND CEMENT PLASTERING

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division 01 Specification Sections, apply to this Section.

1.2 SUMMARY

A. Section Includes:

1. Interior Portland cement plaster on unit masonry and monolithic concrete surfaces.
2. Exterior Portland cement plaster on unit masonry and monolithic concrete surfaces.

B. Portland Cement Plaster Schedule: Types of Portland cement plaster works included in the
project are:

1. Interior Plaster on Walls:

a. Two-coat work over dash keying coat, 15.00 mm overall thickness, wood float
smooth finish on final surface.

1) Use for all internal walls except as noted here after.

b. Plaster Backgrounds: One-coat over dash keying coat, 15.00 mm overall

thickness, scored or scratch finish.

1) Use for walls to have ceramic wall tile or porcelain tile finish set with
thin adhesive bedding.

2. Plaster Interior Structural Concrete Slabs and Soffits:

a. One-coat work over dash keying coat, 15.00 mm overall thickness, wood float
smooth finish.

3. Exterior Portland Cement Plaster:

a. Two-coat work over dash keying coat, 20.00 mm, minimum overall thickness,
troweled smooth finish on final surface.

C. Related Sections include, but shall not be limited to, the following:

1. Division 7 Section "Joint Sealants" for sealants installed with exterior and interior
Portland cement plaster.

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1.3 SUBMITTALS

A. General: Submit in compliance with Division 01 Section “Submittal Procedures.”

B. Product Data: For each type of product indicated.

1. Comply with Division 01 Section "Product Requirements".

C. Shop Drawings: Show locations and installation details of control and expansion joints
including plans, elevations, sections, details of components, and attachments to other work.

D. Samples for Initial Selection: For each type of factory-prepared finish coat indicated.

E. Samples for Verification: For each type of factory-prepared and textured finish coat
indicated; 305 by 305 mm, and prepared on rigid backing.

F. Mix Designs: For each type of plaster. Include description of type and proportions of
ingredients.

1. Include test reports for plaster mixes required to comply with property specification.
Test according to ASTM C 109/C 109M for compressive strength, ASTM C 1506 for
water retention, and ASTM C 91 for air content.
2. Pull out Test at 28 days: > 0.5 N/mm2.

G. Qualification Data:

1. Qualification data for firms and persons specified in "Quality Assurance" article to
demonstrate their capabilities and experience. Include list of completed projects with
project name, addresses, names of Engineer and Employers, and other information
specified.
2. For Testing Agency Qualifications include proof of qualifications in the form of a
recent report on the inspection of the testing agency by a recognized authority.

H. Material test reports from a qualified accredited independent testing agency, approved by
Engineer, indicating and interpreting test results for compliance with requirements
indicated. Test report shall include manufacturer name and contacts in addition to tested
product name and detailed description.

1.4 LOCAL REGULATIONS AND CODES

A. Comply with applicable requirements of the laws, codes, and regulations of authorities
having jurisdiction.

1. Obtain necessary approvals from authorities having jurisdiction.

2. Comply with Egyptian Codes and Standards requirements and latest circulars.

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1.5 QUALITY ASSURANCE

A. General: Comply with Division 01 Section “Quality Requirements.”

B. Manufacturer Qualifications: A firm experienced in manufacturing products or systems

similar to those indicated for this Project and with a record of successful in-service
performance, as well as sufficient production capacity to produce required units. As
applicable, procure products from manufacturers able to meet qualification requirements,
warranty requirements, and technical or factory-authorized service representative
requirements. Experience: Minimum of 10 years.

C. Installer Qualifications: A firm or individual experienced in installing, erecting, applying, or

assembling work similar in material, design, and extent to that indicated for this Project,
whose work has resulted in construction with a record of successful in-service performance.
Experience: Minimum of 5 years.

D. Testing Agency Qualifications: An accredited, independent agency with the experience and
capability to conduct testing and inspection indicated, as documented according to
ASTM E329; and, where required by authorities having jurisdiction, that is acceptable to
authorities.

E. Mockups: Before plastering, install mockups of at least 10.0 sq. m in surface area to
demonstrate aesthetic effects and set quality standards for materials and execution.

1. Install mockups for each type of finish indicated.

2. Include all plastering accessories.
3. For interior plasterwork, simulate finished lighting conditions for review of mockups.
4. Approved mockups may become part of the completed Work if undisturbed at time of
Substantial Completion.

F. Preinstallation Conference: Conduct conference at Project site. Coordinate plaster works

with work of other trades.

1.6 WARRANTIES

A. Comply with Division 01 Section "Warranties".

B. Portland Cement Plaster Warranty: Provide warranty in which Manufacturer and Contractor
are jointly and severally responsible and agree to repair or replace, without limitations, all or
any part of the Portland Cement Plaster which fails or becomes defective in materials or
workmanship within specified warranty period. Failure includes, but is not limited to
cracking, failure of bonding to concrete structure.

1. Warranty Period: 5 years from date of Substantial Completion.

1.7 DELIVERY, STORAGE, AND HANDLING

A. 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.

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1.8 PROJECT CONDITIONS

A. Comply with ASTM C 926 requirements.

B. Interior Plasterwork: Maintain room temperatures at greater than 5 deg C for at least 48
hours before plaster application, and continuously during and after application.

1. Avoid conditions that result in plaster drying out during curing period. Distribute
heat evenly; prevent concentrated or uneven heat on plaster.
2. Ventilate building spaces as required to remove water in excess of that required for
hydrating plaster in a manner that prevents drafts of air from contacting surfaces
during plaster application and until plaster is dry.

C. Exterior Plasterwork:

1. Apply and cure plaster to prevent plaster drying out during curing period. Use
procedures required by climatic conditions, including moist curing, providing
coverings, and providing barriers to deflect sunlight and wind.
2. Apply plaster when ambient temperature is greater than 5 deg C.
3. Protect plaster coats from freezing for not less than 48 hours after set of plaster coat
has occurred.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. Available Manufacturers: Subject to compliance with requirements, manufacturers offering

products that may be incorporated into the Work include, but are not limited to, the
following:

1. Plaster Accessories:

a. Metal X.
b. Catnic Unitech.
c. Unitec.

2. Mortar Plasticizer:

a. BASF.
b. Sika.

2.2 PLASTER MATERIALS

A. Portland Cement: ASTM C 150, Type I, Gray.

B. Gypsum: Do not use gypsum.

C. Lime: Do not use lime. Chemical admixture that replaces effect of lime in cement mortar
may be used.

1. The Contractor has the option to use a chemical admixture that replaces effect of lime
in mortar. Admixture shall be used in the mix in accordance with manufacturer’s
printed instructions.

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D. Sand Aggregate: ASTM C 897.

1. Aggregate for Base Coat: Aggregate for use in base coat portland cement-based
plasters shall be graded as follows:

Table 1: Gradation of Aggregate for Plaster Base Coat

Percent Retained (by

U.S. Standard Weight)
Sieve Natural Sand
max min
No. 4 (4.75 mm) 0 0
No. 8 (2.36 mm) 10 0
No. 16 (1.18 mm) 40 10
No. 30 (600 μm) 65 30
No. 50 (300 μm) 90 70
No. 100 (150 μm) 100 95
No. 200 (75 μm) 100 97

a. Not more than 50 % shall be retained between any two consecutive sieves
shown in the above table, nor more than 25 % between No. 50 (300-μm) and
No. 100 (150-μm) sieves. The amount of material finer than a No. 200 (75-μm)
sieve shall not exceed 3 %.

2. Aggregate for Finish Coat Plaster: Shall all pass the No. 8 (2.36 mm) sieve and meet
the remaining gradation requirements of (Table 1) and subsequent paragraphs, except
where special texture finishes require gradation of aggregate outside of these limits.

a. When special texture finishes require gradation of the aggregate outside of the
limits of (Table 1), sample panels shall be required.

E. Water: Water used in mixing, application, and finishing of plaster shall be clean, fresh,
suitable for domestic water consumption, and free of such amounts of mineral or organic
substances as would affect the set, the plaster, or any metal in the system.

F. Admixtures: To ASTM C 494, certified by manufacturer to contain not more than 0.1 %
water-soluble chloride ions by mass of cementitious material and compatible with other
admixture and cementitious materials. Do not use admixtures containing calcium chloride.
Use only liquid type admixtures.

2.3 ACCESSORIES

A. General: Comply with ASTM C 1063 and coordinate depth of trim and accessories with
thicknesses and number of plaster coats required.

B. Metal Accessories:

1. Foundation Weep Screed: Fabricated from hot-dip galvanized-steel sheet,

ASTM A 653/A 653M, Z180 zinc coating.
2. Cornerite: Fabricated from metal lath with ASTM A 653/A 653M, Z180, hot-dip
galvanized zinc coating.
3. Cornerbeads: Fabricated from zinc-coated (galvanized) steel.

a. Small nose cornerbead with expanded flanges; use unless otherwise indicated.

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b. Bull nose cornerbead, radius 19.1 mm minimum, with expanded flanges; use at
locations indicated on Drawings.

4. Casing Beads: Fabricated from zinc-coated (galvanized) steel; square-edged style;

with expanded flanges.
5. Control Joints: Fabricated from zinc-coated (galvanized) steel; one-piece-type,
folded pair of unperforated screeds in M-shaped configuration; with perforated
flanges and removable protective tape on plaster face of control joint.
6. Expansion Joints: Fabricated from zinc-coated (galvanized) steel; folded pair of
unperforated screeds in M-shaped configuration; with expanded flanges.

2.4 PLASTER REINFORCEMENT

A. Galvanized Steel Lath Reinforcement: Prefabricated galvanized steel lath in coil form
specially produced for plaster reinforcement:

1. Form: Coil.
2. Provide special prefabricated pieces for internal corners.
3. Weight: 0.7 kg/m², minimum.

B. Polypropylene Plaster Reinforcement: Polypropylene bi-oriented net specially produced for

reinforcing of plaster coats up to 20 mm thickness.

1. Mesh Size: 15 x 12 mm.

2. Color: White.
3. Performance:

a. Easy to fix.
b. Chemical resistant.

2.5 METAL LATH

A. Expanded-Metal Lath: ASTM C 847 with ASTM A 653/A 653M, Z180, hot-dip galvanized
zinc coating.

1. Diamond-Mesh Lath: Flat, 1.8 kg/sq. m.

2.6 MISCELLANEOUS MATERIALS

A. Water for Mixing: Potable and free of substances capable of affecting plaster set or of
damaging plaster, lath, or accessories.

B. Fiber for Base Coat: Alkaline-resistant glass or polypropylene fibers, 13 mm long, free of
contaminants, manufactured for use in portland cement plaster.

C. Dash Coat: Apply to all surfaces to receive plaster.

D. Bonding Compound: ASTM C 932, after application of dash coat.

E. Fasteners, General: Complying with ASTM C 1063. Provide steel fasteners that are
protected from corrosion with hot–dip galvanizing.

F. Sealant: As specified in Division 7 Section "Joint Sealants."

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2.7 PLASTER MIXES

A. General: Comply with ASTM C 926 for applications indicated.

1. Measurement of Materials: The method of measuring materials for the plaster shall be
such that the specified proportions are controlled and accurately maintained.
2. Fiber Content: Add fiber to base-coat mixes after ingredients have mixed at least two
minutes. Comply with fiber manufacturer's written instructions for fiber quantities in
mixes, but do not exceed 0.60 kg of fiber/cu. m of cementitious materials.

B. Dash-Coat and Base Mixes:

1. Comply with Egyptian code for plastering:

a. Dash coat shall be 400 kg Portland cement per 1 m3 sand.

b. Base-Coat shall be 350 kg Portland cement per 1 m3 sand.

1) Fiber Reinforcement: Comply with manufacturer’s printed instructions.

C. Base-Coat Mixes for Use over Metal Lath: Scratch and brown coats for three-coat
plasterwork as follows:

1. Scratch Coat: 450 kg Portland cement per 1 m3 sand.

2. Base (Brown) Coat: 350 kg Portland cement per 1 m3 sand.

a. Fiber Reinforcement: Comply with manufacturer’s printed instructions.

D. Single-Coat Plaster for Concrete Slabs, Soffits and Backgrounds: 350 kg Portland cement
per 1 m3 sand. Fiber reinforcement and polymer additives shall be added to the mix in
conformance with manufacturer’s printed instructions.

E. Job-Mixed Finish-Coat Mixes: 350 kg Portland cement per 1 m3 sand.

F. Prepackaged Plaster Top Coat: Combinations of materials that have been formulated and
dry-blended by the manufacturer, requiring only the addition of and mixing with water to
produce plaster.

1. Material ingrediants shall be to the Standards specified in this Section.

2. Does not use products that include lime.
3. Provide proprietary prepackaged plaster top coat recommended for application in
thickness indicated consisting from Portland cement, sand and polymer additives. The
minimum properties shall be as follows:

a. Compressive Strength: 5 MPa, minimum.

b. Bond Strength to Cement-Based Substrates: 1.50 MPa.
c. Recommended for high temperature (ambient) working conditions.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine areas and substrates, with Installer present, and including welded hollow-metal
frames, cast-in anchors, and structural framing, for compliance with requirements and other
conditions affecting performance of the Work.

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B. Proceed with installation only after unsatisfactory conditions have been corrected.

3.2 PREPARATION

A. Protect adjacent work from soiling, spattering, moisture deterioration, and other harmful
effects caused by plastering.

B. Prepare solid-plaster bases that are smooth or that do not have the suction capability
required to bond with plaster according to ASTM C 926.

C. Plaster Reinforcement: At lines between different plaster backgrounds provide

reinforcement as specified. Reinforcement shall be not less than 300 mm wide, well
stretched and fixed with galvanized powder-actuated fasteners at not more than 600 mm
intervals:

1. Use for internal plaster, base coat to receive ceramic finish.

2. Use between concrete and masonry background and other separations as indicated.
3. Use at head of wall separation and between masonry and concrete columns, walls
posts and other elements.
4. Compliance Standard:

a. ASTM C 926.

3.3 INSTALLING ACCESSORIES

A. Install according to ASTM C 1063 and at locations indicated on Drawings.

B. Reinforcement for External Corners:

1. Install cornerbead at interior and exterior locations.

C. Control Joints: Install control joints in specific locations approved by Engineer for visual
effect as follows:

1. As required to delineate plasterwork into areas (panels) of the following maximum

sizes:

a. Vertical Surfaces: 13.4 sq. m.

b. Horizontal and other Non vertical Surfaces: 9.3 sq. m.

2. At distances between control joints of not greater than 5.5 m o.c.

3. As required to delineate plasterwork into areas (panels) with length-to-width ratios of
not greater than 2-1/2:1.
4. Where control joints occur in surface of construction directly behind plaster.
5. Where plasterwork areas change dimensions, to delineate rectangular-shaped areas
(panels) and to relieve the stress that occurs at the corner formed by the dimension
change.
6. where control joints are required, and no visible joints are to be shown as per design,
use invisible plaster control joints between panels, and to be submitted and approved
in shop drawings

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3.4 INSTALLING METAL LATH

A. Expanded-Metal Lath: Install according to ASTM C 1063.

1. Partition Framing and Vertical Furring: Install flat diamond-mesh lath.

2. Flat-Ceiling and Horizontal Framing: Install flat diamond-mesh lath.

3.5 PLASTER APPLICATION

A. General: Comply with ASTM C 926.

1. Do not deviate more than plus or minus 6.4 mm in 3 m from a true plane in finished
plaster surfaces, as measured by a 3-m straightedge placed on surface.
2. Plaster shall be flushed with metal frames and other built-in metal items or
accessories that act as a plaster ground unless otherwise indicated. Where casing
bead does not terminate plaster at metal frame, cut base coat free from metal frame
before plaster sets and groove finish coat at junctures with metal.
3. Provide plaster surfaces that are ready to receive field-applied finishes indicated.
4. Portland cement plaster shall be applied by hand to the nominal thickness specified.
Plaster mortar shall be applied with sufficient force to develop full adhesion between
plaster and substrate.
5. Plaster nominal thickness shall be measured from the back plane of the metal plaster
base, exclusive of ribs or dimples, or from the face of the solid backing with or
without metal plaster base, to the outer surface exclusive of texture variations.
6. Separation shall be provided where plaster abuts dissimilar construction materials or
openings.
7. Each plaster coat shall be applied to an entire wall or ceiling panel without
interruption to avoid cold joints and abrupt changes in the uniform appearance of
succeeding coats. Wet plaster shall abut set plaster at naturally occurring interruptions
in the plane of the plaster, such as corner angles, rustications, openings, and control
joints where this is possible. Joinings, where necessary, shall be cut square and
straight and not less than 150 mm away from a joining in the preceding coat.
8. Two-coat work shall be used only over solid bases. The combined total nominal
thickness shall be as specified. A dash-bond coat shall not replace one of the specified
numbers of coats.
9. Backplaster where required, shall be applied only after the coat on the opposite side
has set sufficiently to resist breaking or cracking the plaster keys.
10. Each coat shall be permitted to set before the next coat is applied.
11. Plaster coats that have become dry shall be evenly dampened with water prior to
applying subsequent coats to obtain uniform suction. There shall be no visible water
on the surface when plaster is applied.
12. Plaster Application on Solid Plaster Bases:

a. High-suction bases shall be evenly dampened with clean water prior to the
application of plaster. Do not dampen low-suction solid bases, such as dense
concrete or smooth brick.
b. Where masonry or concrete surfaces vary in plane, plaster thickness required to
produce level surfaces shall not be required to be uniform.

B. Dash Coat: Apply to all surfaces to receive plaster including, but not limited to, metal lath
surfaces.

C. Bonding Compound: Apply on unit masonry and concrete plaster bases, after application of
dash coat.

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D. Plaster Top Coats: Apply to provide float finish to match samples approved by Engineer.

1. Job-mixed or factory-prepared finish coats shall be applied, by hand.

2. The use of excessive water during the application and finishing of finish-coat plaster
shall be avoided.

E. Two-Coat Application on Solid Bases (Concrete and Masonry Walls and Vertical Surfaces):

1. Keying dash coat is to be applied cured and prepared as specified in this Section.
2. The first (scratch) coat shall be applied with sufficient material and pressure to ensure
tight contact and complete coverage of the solid base, to the nominal thickness
specified. As soon as the first (scratch) coat becomes firm, the entire surface shall be
scored in one direction only. The vertical surfaces shall be scored horizontally.
3. The second coat shall be applied using the same procedures specified for scratch coat,
bringing the surface to a true, even plane with a rod or straightedge, filling any
defects in plane with plaster and darbying. The surface shall be wood floated
uniformly to provide a surface receptive to the application of the finish coat.

a. Exposed surfaces to receive paint decoration finish shall be floated twice. The
second floating shall be with carpet float or cork float to obtain perfectly
smooth surface and reduce amount of filler used in surface preparation.

4. Two Coat Internal Plaster Applications:

a. Overall: 15.00 mm.

b. Base Coat: 10.00 mm.
c. Finish Coat: 5.00 mm.

5. External Plaster Applications:

a. Overall: 20.00 mm.

b. Base Coat: 15.00 mm.
c. Finish Coat: 5.00 mm.

F. One Work Application to Solid Bases:

1. Plaster to Ceiling: Comply with manufacturer’s printed instruction and the approved
method statement. Finish with wood float to a smooth uniform surface.
2. Plaster Backgrounds: Same as specified for base coat of the two-coat plaster work.

G. Plaster on Metal Lath: 3-coat work on dash coat. Comply with the following:

1. Scratch coat: Not less than 20 mm thick provided the holes of metal lath are totally
filled and mortar are protruding in the back face of lath.
2. Base (Brown) Coat: As specified in this Section.
3. Finish Coat: As specified in this Section.

3.6 PLASTER COATS FINISHES

A. Scored or Scratch Finish: Apply to the following:

1. Base coat of two-coat plaster work.

2. Base coat to receive ceramic tile finish set with thin adhesive.
3. Base coat of the three-coat plaster work on metal lath.

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B. Wood Float Finish: Apply to the following coats:

1. Second coat of two-coat plaster work.

2. Plaster coat of the one-coat work.
3. Finish coat of the three-coat plaster work on metal lath.

3.7 TOLERANCES

A. Plumbness: Not more than 1.00 mm per one meter of gradual change, maximum 3.00 mm.

B. Level: Not more than 1.00 mm per one meter of gradual change, maximum 3.00 mm.

3.8 CURING AND TIME BETWEEN COATS

A. Provide sufficient moisture in the plaster mix or by moist or fog curing to permit continuous
hydration of the cementitious materials. The most effective procedure for curing and time
between coats will depend on climatic and job conditions.

B. Sufficient time between coats shall be allowed to permit each coat to cure or develop
enough rigidity to resist cracking or other physical damage when the next coat is applied.

3.9 FIELD QUALITY CONTROL

A. Finished plaster works shall be tested for bond adherence to substrate (pullout test) for
compliance with requirements of referenced standards:

1. Test Frequency: One test each 500 sq. m.

2. Patch areas defected by testing.

B. Compressive Strength of Mortar: Test 3 cubes to ASTM C 109, 50 x 50 mm each 450 sq. m
of plaster.

3.10 CUTTING AND PATCHING

A. Repair or replace work to eliminate cracks, dents, blisters, buckles, crazing and check
cracking, dry outs, efflorescence, sweat outs, and similar defects and where bond to
substrate has failed.

B. Cut, patch, replace, and repair plaster as necessary to accommodate other work and to
restore cracks, dents, and imperfections. Repair or replace work to eliminate blisters,
buckles, crazing and check cracking, dry outs, efflorescence, sweat outs, and similar defects
and where bond to substrate has failed.

3.11 PROTECTION

A. Remove temporary protection and enclosure of other work. Promptly remove plaster from
door frames, windows, and other surfaces not indicated to be plastered. Repair floors, walls,
and other surfaces stained, marred, or otherwise damaged during plastering.

END OF SECTION 092400

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