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Designer Block
™
Architectural Feature Masonry – New South Wales
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Designer Block™ Commercial – New South Wales
Boral Masonry has been supplying coloured and textured
blocks for over 25 years to the Australian architectural
community. To meet the need of popular composite building
styles that require varying finishes and materials, Boral
Masonry in consultation with designers have developed
a palette of 4 contemporary colours and 5 bold textures.
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TM
The Designer Block range also utilises the latest pre-sealing
technology to reduce water absorption, and hence reduce the
possibility of efflorescence, mould or mildew staining.
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Designer Block™ Colours and Textures – New South Wales
Essential Colours
Smooth Face
Shot-Blast Face
Honed Face
Polished Face
Split Face
Alabaster
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Almond
Pearl Grey
Charcoal
Five Innovative Textures
Smooth Face A finely textured
finish created through the standard
moulding process.
Honed Face The honing process grinds
2-3mm from the block surface, producing
a matt exposed-aggregate finish.
the aggregates. The finely finished polished
surface is ideal for feature walls, trims
and banding.
Shot-Blast Face This process subtly
exposes the aggregates, producing
a weathered, sawn stone-like finish.
Polished Face This involves producing
a denser block which is honed and then
buffed. Polishing enriches the colour of
Split Face The splitting process produces
a bold textured, exposed aggregate finish.
Designer Block™ Material Qualities
Material Quantities for a 1 bag mix of Mortar
M3 Mortar Mix (general purpose)
One 20kg bag of Off-White cement and oxide#
100kg clean sand. (18 shovels @ 5.6kg)
0.1kg of Dynex or similar methyl cellulose
plasticiser.
This yields 0.08 cubic metres and will lay 60 to 70
Designer Blocks
M4 Mortar Mix (exposure grade)
One 20kg of Off-White cement and oxide#
80kg clean sand. (14 shovels @ 5.7kg)
0.1kg of Dynex or similar methyl cellulose
plasticiser.
This yields 0.06 cubic metres and will lay 45 to 55
Designer Blocks
Notes
• One cubic metre of mortar will lay approximately
800 blocks.
• Twenty percent extra sand included for bulking.
Masonry Units
Boral Designer Block™ is manufactured in
accordance with the provisions of Australian
Standard AS/NZS4455 : 1997.
Mortar
Mortar mix options in AS3700 include cement;
lime and sand in 1:1:6 proportions for M3
(general) and in 1:0.5:4.5 proportions for M4
(Exposure Grade). While these make better
mortar, the adjacent mixes, without lime, are
more common. Cement is now usually supplied
in 20kg bags. The adjacent mixes are based on
one 20kg bag per mix.
Block Laying
When core filling Designer Block™ walls, some
seepage may occur due to high hydrostatic
pressure. Ensure it is cleaned off before it dries,
otherwise staining will occur. It is essential that
the block work is kept clean from mortar smears.
This will eliminate the need for aggressive acid
based cleaning solutions which can damage the
face or change the colour of the concrete blocks.
#Oxide quantities below are approximate and
assume sand is near white. Trial batches should
be made and assessed for colour-match for blocks
when dry. Contrasting mortar colour is not
recommended due to difficulty of cleaning smears.
Alabaster
Almond
Pearl Grey
Charcoal
White oxide
Yellow oxide
Black oxide
Black oxide
0.8kg
0.1kg
0.01kg
0.5kg
Joints should be finished with an ironing rod to make
them smooth, dense and more water resistant.
Raked joints are NOT recommended.
Please refer to page 06 for Component range details and see back page for product lead times and additional information.
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Designer Block™ Residential – New South Wales
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Above Harry Seidler and
Associates, used Split
Face Designer Block™
to impart a warm texture
both inside and outside
this Birchgrove home.
Above and Top Right
Micheal Fountain Architects
– MFA used different
surface finishes to create
unique spaces in this
Pittwater home. The rugged
Split Face texture of the
entry (above) contrasts
with the finer Honed finish
of the formal living room
(top right).
Above T.J. Antiohos and
Associates combined
Polished Charcoal blocks
with white timber detailing
in this unique residence.
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Designer Block™ Commercial – New South Wales
This Page Ellington is a
contemporary apartment
development consisting of
three four-storey buildings.
Arkhefield Architects
combined full and half
height Split Face units for
the exterior to create a wall
that had a large, rough and
uniform texture.
Helping to emphasise the
exterior’s clean architectural
lines is the Designer Block™
Alabaster colour.
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Designer Block™ Commercial – New South Wales
Left Honed Designer
Block™ creates an
impressive blade wall in
the Ultimo Community
Centre, designed by
Lawrence Nield and
Partners Australia.
Below Architects Woods
Bagot used polished
Alabaster bands with Split
Face Designer Block™
panels in the design
of Discovery House in
Canberra. Designer Block™
provided the flexibility to
achieve different textural
finishes within the one
modular material.
Left and Above
The most striking features
of Prior + Cheney Architects
design, were two dramatically
curved walls that enclose and
protect the entry forecourt
from the elements. Designer
BlockTM Alabaster Smooth
was predominantly used for
this Beaconsfield Community
Centre in Melbourne, Victoria.
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Designer Block™ Component Range – New South Wales
Component Range
Corner Bonding Detail
Smooth, Shot-Blast, Honed and Polished Designer Block™
Split Face Designer Block™
10.101 (1 unit in 3 is
half solid, for on-site
bolstering for corners)
10.101
190
90
190
390
390
140
10.01 Full
190
140
15.01 Full*
10.101
10.101
390
15.42 Recessed Web*
Bolstered on-site
to 295mm
295mm
95mm
190
190
10.101
390
190
190
20.01 Full
10.101
390
10.101
20.42 Recessed Web*
295mm
Bolstered on-site
95mm
95mm
15
Series 100 Corner
108
100
40
50
190
110
190
10.39 Victorian Sill*
15.121 (1 unit in 4 is half solid,
for on-site bolstering for corners)
15.121
15.121
390
15.121
50.31 Capping
*Made to order only.
All these products are available in Honed, Shot-Blast or Polished finish.
For corner applications, these products are available with the face and
one end Honed, Shot-Blast or Polished, with the exception of capping.
15.121
Split Face Designer
Block™
15.121
15.121
15.121
Bolstered on-site
to 345mm
145mm
45mm
Series 150 Corner
190
90
95
390
95
10.101 Full
20.121
390
Cut
10.109 Half High*
45mm
A
B
Smooth face
200mm do not
need special
corner units
Split
195mm
Cut one block per course to 340mm
length to maintain 1/2 bond pattern
190
190
145
390
145
390
20.121
15.121 Full*
15.142 Recessed Web*
20.121
20.121
B
190
190
20.121
195
390
20.121 Full
*Made to order only.
195
390
20.142 Recessed Web
20.121
A
Cut one block per
course to 340mm
length to maintain
1/2 bond pattern
Series 200 Corner
Please refer to page 02 for detailed information on material quantities.
For further information on corner detailing, please call the Specifier Line
on 1300 360 255 or contact your local Boral Masonry sales office.
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Designer Block™
Designer Block™ Additional Information
Block Laying
Masonry walls are to be constructed in accordance with AS3700 : 2001.
Stock Colours and Textures
Lead times apply to all coloured blocks. Longer lead times apply to Honed,
Polished and Shot-Blast finishes as the product must be cured for four
weeks to harden sufficiently before processing. Boral recommends part
size blocks are cut/bolstered on site to maintain colour consistency.
Textures
Finishes including Honing, Polishing and Shot-Blasting are produced
on a ‘made to order’ basis. Lead times apply as the product must be
cured for four weeks to harden sufficiently before processing. Contact
your nearest Boral Masonry office for approximate lead times and
premiums on special textured finishes. Designer Block™ is available
standard with one face. Additional faces can be ‘made to order’
on honed, polished, and shotblast finishes. A surcharge may apply.
Not all finishes are available in all regions.
Colour and Texture Variations
The colours shown in this brochure are provided as an indication
of the colours and textures available. Some variations in colour may
occur due to changes in raw materials. In addition variation can occur
between production batches.
Brochure Colours
The printed colours in this brochure are only a guide. Please ask to see
a sample of your chosen colour/texture before specifying or ordering.
Construction Notes
1. Blocks must be kept dry on site before use and when laid. Freshly
laid walls must be covered overnight and when rain interrupts work
in order to prevent moisture entering the cores of the blocks.
2. Do not put mortar on the web of the blocks.
3. Ensure that perpends are buttered on each side with a void in the
middle. The mortar joints should be well ironed to provide a tight
sealed joint.
4. Ensure mortar smears are removed before mortar sets as acid
cleaning later can discolour the masonry.
5. It is important that retaining walls have good drainage behind the wall.
6. For non-grouted masonry, a horizontal weep hole at the floor joint
of each core should be provided to drain water that may be trapped
inside the blocks. Partially fill the bottom course blocks with 20mm
blue metal or similar drainage material to prevent mortar droppings
from blocking the weep holes.
Boral Masonry reserves the right to change the details in this publication without notice.
For a full set of Terms and Conditions of Sale please contact your nearest Boral Masonry sales office.
Front Cover
The Designer Block™, in Alabaster with a Polished Smooth Face finish,
has been used here by Wilson Davis Series Architects for the Harbord
Open Plan Living project in NSW.
™ Designer Block is a registered trademark of Boral Masonry Limited.
© Boral Masonry All Rights Reserved 2007.
Boral Masonry Limited ABN 13 000 223 718
Orders, product samples and sales enquiries
NSW
Clunies Ross Street,
Prospect NSW 2148
Tel (02) 9840 2333
Fax (02) 9840 2344
For technical assistance:
Call Specifier Line on 1300
Visit www.boral.com.au
360 255
V010607