Masonry
Materials
Components of Masonry
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•
•
•
•
•
Masonry Units
Mortar
Grout
Reinforcement
Anchors / Ties
Accessories
Characteristics
Material Options
Testing / QA
Components of Masonry
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•
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Masonry Units
Mortar
Grout
Reinforcement
Anchors / Ties
Accessories
Masonry Prism
Concrete/Masonry Components
Concrete
Materials
CMU
Mortar
Grout
Cement, aggregates, water, admixtures
maybe lime
Aggregate Size
< 3/4 in. pea
Consistency
Preparation
< 3/8 in.
< #8
fine masonry
sand
Coarse: < #3/8
Fine: < #4
(concrete sand)
3-6 in.
8-10 in.
Pourable, stiff
No Slump
mixer
mixer,
vibrated into form
Fluffy
mixer
Pourable, runny
mixer
Masonry
Units
Clay Unit (brick) Options
The type of shale and clay, the plasticity of the mix, and the pressure under which the material is
forced into shape all contribute to the character of each individual brick.
The term brick is used to
denote solid clay masonry
units. Cored units are still
considered solid if cores do
not exceed 25% of total cross
sectional area.
The cores reduce weight,
increase bond to mortar, and
allowing faster drying during
fabrication.
www.GlenGerybrick.com
Clay Unit (brick) Options
Handmade:
Each brick is individually
formed and placed in a
wooden mold to create a
textured brick...no two being
alike.
www.GlenGerybrick.com
Clay Unit (brick) Options
www.GlenGerybrick.com
Molded:
The soft irregular edges of
molded brick are produced as
a result of the manufacturing
process in which
material is dropped into a
mold box, vibrated and
released from the box.
Molded brick normally have
sand finish textures since
sand is used as a releasing
agent in the mold box.
Clay Unit (brick) Options
www.GlenGerybrick.com
Rolled Edge:
Rolled Edge brick is produced
using the extruded method of
manufacturing. Once the column
of material is extruded, it is
forced through cutters and
wheels that roll an edge to each
brick. The degree and type of
edge is dependant on the
wheels. This method is used to
provide an economical soft look
extruded brick that looks similar
to a handmade or machine
molded one.
Clay Unit (brick) Options
www.GlenGerybrick.com
Papercut:
Papercut brick is
manufactured by placing a
sheet of kraft paper on top of
an extruded column of
material prior to cutting into
individual units. The
wirecutters are then sliced
down through the paper
slightly dragging into the
column and producing an
irregular edge.
Clay Unit (brick) Options
Tumbled:
The irregular edges of
tumbled brick are a result of
physically tumbling extruded
fired brick and adding
slurries to the mix. This
result is a used-brick style.
www.GlenGerybrick.com
Clay Unit (brick) Options
Thinbrick:
Thinbrick is manufactured
using the papercut extruded
method. A half-inch slab is
cut off the column during the
extruding process and
immediately laid back on the
column. The full brick is
fired and separated during
packaging.
www.GlenGerybrick.com
Clay Unit (brick) Options
www.GlenGerybrick.com
Extruded:
The crisp, angular edges of extruded
brick are produced as a result of the
manufacturing process in which material
is forced through a die under high
pressure, forming a stiff column of
material. After the column is formed, it
can be textured in a variety of ways. The
column is then sliced into individual
brick. Extruded brick can usually be
identified by its core holes.
Clay Unit (brick) Options
Glazed:
After the material is extruded, a glaze
is applied to the brick that becomes
an integral part of the unit during the
firing process. The glaze is available
in smooth, mottled or speckled finish
and a broad range of colors. Since the
color is produced by the applied
glaze, through-the-body color is not
available.
www.GlenGerybrick.com
Clay Unit (brick) Options
Engobe:
After the material is extruded, a clay
slurry is applied to the brick that
becomes an integral part of the unit
during the firing process. These
surface coatings allow water vapor to
pass through the face of the brick.
Engobe brick is available in a variety
of colors.
www.GlenGerybrick.com
Manufacturing Clay Brick
www.GlenGerybrick.com
Manufacturing Clay Brick
www.GlenGerybrick.com
Clay Unit Options - Sizes
Modular
3 5/8 x 2 1/4 x 7 5/8
Engineer Modular
3 5/8 x 2 13/16 x 7 5/8
Economy Modular (Closure)
3 5/8 x 3 5/8 x 7 5/8
Norman
3 5/8 x 2 1/4 x 11 5/8
Engineer Norman
3 5/8 x 2 13/16 x 11 5/8
3" Bed Economy Norman (Utility) 3 x 3 5/8 x 11 5/8
Economy Norman (Utility)
3 5/8 x 3 5/8 x 11 5/8
Giant Norman
3 5/8 x 5 5/8 x 11 5/8
Kingsize
3 x 2 5/8 x 9 5/8
Full Bed Kingsize
3 5/8 x 2 5/8 x 9 5/8
Engineer Kingsize
3 x 2 13/16 x 9 5/8
Triple Brick
3 5/8 x 7 5/8 x 7 5/8
Danish Hand Mould
3 5/8 x 2 5/8 x 7 5/8
6" Thru Wall Unit
5 5/8 x 3 5/8 x 11 5/8
8" Thru Wall Unit
7 5/8 x 3 5/8 x 11 5/8
W
H
L
WxHxL
Standards for Clay Masonry Units
Specifications
ASTM C 62
ASTM C 126
ASTM C 216
ASTM C 1272
ASTM C 652
ASTM C 902
Building Brick
Ceramic Glazed Structural Clay Tile, Facing Brick, and Solid Masonry Units
Facing Brick (Solid)
Heavy Vehicular Paving Brick
Hollow Brick
Pedestrian and Light Traffic Paving Brick
Test Methods
ASTM C 67
Sampling and Testing Concrete Brick
Modulus of Rupture
Compressive Strength
Absorption
Size / Warpage / Square
Void Area
ASTM C 1006
Freezing and Thawing
Initial Rate of Absorption (IRA)
Efflorescence
Length Change
Splitting Tensile Strength of Masonry Units
Concrete Masonry Unit Surfaces
•Spilt-face
•Ground-face
•Raked-face
•Ribbed
•Striated
•Glazed
•Etc...
Concrete Masonry Unit Manufacturing
Concrete Masonry Unit Manufacturing
Concrete Masonry Unit Manufacturing
Concrete Masonry Unit Manufacturing
• CMU’s require curing during the manufacturing process
• After removal from forms, units are moved to kilns for curing
• Low pressure steam is the most common method _ accelerates curing
• 28 day moist cured strengths can be reached in a few days
• Units set for 1 to 3 hours prior to steam curing (holding period)
• After holding period, steam fed into kiln until desired temperature is reached
• At desired temp, steam turned off and 12 to 18 hour soaking period begins
• High pressure steam can be used
• 28 day moist cured strength can be reached in 1 day
Concrete Masonry Unit Manufacturing
• Cement based product - Drying shrinkage will occur
• If units are placed in a structure too soon, cracking can occur
• Shrinkage is reduced if proper curing and drying techniques are used.
• If CMU’s are exposed to high amounts of carbon dioxide, Carbonation can occur
• The units absorb the CO2 and irreversible shrinkage occurs.
• This can be a concern in cold weather during construction where heating units are
used inside.
Standards for Concrete Masonry Units
Specifications
C55
Concrete Brick
C90
Loadbearing Concrete Masonry Units
C129
Nonloadbearing Concrete Masonry Units
C744
Prefaced Concrete and Calcium Silicate Masonry Units
C936
Solid Concrete Interlocking Paving Units
C1319 Concrete Grid Paving Units
C1372 Segmental Retaining Wall Units
Test Methods
C140
Sampling and Testing Concrete Masonry Units
Dimensions
Absorption
Moisture Content
C426
C1262
Unit Weight
Compressive Strength
Drying Shrinkage of Concrete Block
Freeze-Thaw Durability of Concrete Masonry and Related Concrete Units
CMU Dimensions
Dimensions for CMU expressed as:
Height
Width x Height x Length
Length
Nominal
4 x 8 x 16
6 x 8 x 16
8 x 8 x 16
10 x 8 x 16
12 x 8 x 16
Actual / Standard / Specified
or
7-5/8 x 7-5/8 x 15-5/8
Nominal Dimensions
Nominal dimensions are equal to the standard dimensions
plus the thickness of one mortar joint (typically 3/8 in.)
running bond
7-5/8
15-5/8
16 in.
8 in.
CMU Shapes
Refer to page 311 in text
Most common shapes are:
• Stretcher
• Bullnose
• Lintel
• Half and Double Corners
• Many others for specific uses
Masonry
Mortar
The Role of Mortar
• Holds Units Together vs. Holds Units Apart
The Role of Mortar
• Accommodates Uneven Units
Mortar can fill non-uniform
spaces to result in plumb
and level masonry
construction
The Role of Mortar
• Water Penetration Resistance
Rain
Mortar Joints can be tooled
different ways affecting
appearance and resistance
to water penetration.
Mortar Constituents
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Cement
Lime
Sand
Water
Admixtures
Mortar Constituents
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Cement
Lime
Sand
Water
Admixtures
Portland Cement (C150),
Masonry Cement (C91) or
Mortar Cement (C1329)
•Strength
•Early Setting
•Bond
•Durability
•Shrinkage
Mortar Constituents
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•
•
•
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Cement
Lime
Sand
Water
Admixtures
Hydrated Lime (C207)
•workability
•water retentivity
•late strength
•autogenous healing
Mortar Constituents
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•
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Cement
Lime
Sand
Water
Admixtures
Masonry Sand (C144)
•bulk
•strength
•shrinkage resistance
With mortar,
…. Stronger is not better
• Do not specify higher strength mortar than
needed
• Do not substitute higher strength mortar
than that specified without approval
Mortar selection:
...based on desired properties
• Plastic Mortar
– workability
– water retentivity
– stiffening
characteristics
• Hardened Mortar
– bond
– compressive
strength
– durability
Other factors: exposure, seismicity,
water penetration, shrinkage, color
Mortar selection:
...based on desired properties
• Plastic Mortar - Masons Criteria
– Easily Spread
– Supports Weight of Units
– Clings to Vertical Faces
– Is not squeezed out of joint
M
A-1
Old Mortar
Designations
A-2
A
S
O
B
N
C
W
D
O
R
K
New Mortar
Designations
M
A-1
Old Mortar
Designations
A-2
A
S
O
B
N
C
W
D
O
R
K
New Mortar
Designations
Mortar is proportioned by volume
ASTM Mortar Standards
ASTM C 270
vs.
ASTM C 780
What it Does:
• Defines mortar as a construction
material
• Specifies field proportions
• Provides lab evaluation criteria
What it does not do:
• Provide field strength testing
criteria for mortar
What it Does
• Provides job site quality control
methods based on
preconstruction and
construction testing
ASTM C 270, specify by….
Proportion Specification
--OR -Property Specification
Do not specify both
If neither is
specified, which
one governs?
ASTM C 270 Proportion Spec.
Proportions by volume
Mortar
Type
M
S
N
O
Portland
Cement
1
1
1
1
Lime
Sand
0–¼
2¼-3
¼ - ½ times the
½ - 1¼
sum of
1¼ - 2½ cement
plus lime
To use proportion specs, all
materials must meet their specs.
Oh no! My sand does not comply with
ASTM C144 gradation requirements,
What now!!!
This sand can still be used if laboratory
prepared mortar complies with ASTM
C270’s property specifications.
ASTM C 270 Property Spec.
Mortar Compressive Water
Air
Type
Strength
Retention Content
M
2500 psi
75
12
S
1800 psi
75
12
N
750 psi
75
14
O
350 psi
75
14
* for portland cement and lime mortars
ASTM C 270 Property Specs
are NOT to be applied to….
...Field
Mortar
ASTM Required Compressive Strength
Requirements for Field Mortar
Type M =
Type S =
Type N =
Type O =
???
???
???
???
ASTM has no requirements or even
suggested requirements for field mortar
How should requirements for field
mortar be determined?
By preconstruction testing using:
• specified proportions
• same materials to be used in the field
• field batching and mixing procedures
• specified testing procedures
All involved parties should be present
How should requirements for field
mortar be determined?
With regard to field testing, mortar is a self policing material
because the best mortar for the wall is the best mortar for
the mason
• For a mason to mess up the mortar, it hurts his own
productivity
• Workable - not too wet, not too dry
• Proportions - if any 1 item is too far off, mortar is not good
for masons productivity
• The best mortar for the mason is the best mortar for the
wall.
Sample of Compressive Strength Test Data from Field Samples.
Unlike concrete, if we do check field mortar, we look at the average.
Again, the field strength should be compared to the preconstruction
mix, not the ASTM 270 strengths.
1800
1600
1400
1200
1000
800
600
400
200
0
1
3
4
6
8
10
12
14
16
18
20
22
24
In the wall mortar strengths ...
Does the strength of a mortar cube represent the strength
of the mortar in the wall ?
NO !!
The mortar in the wall will be much stronger than the
tested strength of the cube because of …
• Smaller aspect ratio of mortar joint
• Lower water to cement ratio for mortar joint
In the wall mortar strengths ...
Tests have shown that an increase in mortar strength of
130% only increase wall strength 10%
Bond Strength, workability, and water retentivity are more
important than strength
Retempering in the field is OK. It is adding water to mortar
on the board to keep its workability. This will improve and
maintain bond strength.
2-1/2 hours is a usual board life.
Common QC Tests for Mortar
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•
•
•
Compressive Strength
Air Content
Mortar Aggregate Ratio
Cone Penetration
Visual Inspection of Mortar Preparation
ASTM C 780, Mortar:Agg Ratio
Jar 1
Jar 2
Mortar + Alcohol
(use 91% isopropyl alcohol)
Jar 3
Sand
Mortar:Agg Ratio, Jar #1
Pour mortar + alcohol into
pan and ignite to burn off the
alcohol. Place pan in oven.
Compare final mortar weight
to initial mortar weight to
determine water content of
the mortar.
Mortar: Agg Ratio, Jar 2
Pour jar 2 into 100
sieve. Rinse to pass
all fine material
through. Oven-dry
retained to
determine
percentage of fine
materials (sand and
cement)
Mortar:Agg Ratio, Jar 3
Oven-dry sand from
jar 3. Pour dry sand
into 100 sieve to pass
through fine particles.
Dry retained material
to determine percent
of fine aggregate.
Masonry
Grout
Masonry Grout - ASTM C 476
What is grout? Grout is a high slump concrete used to fill voids in
the masonry assemblage to bind together the masonry units,
mortar, and existing reinforcement into a single composite
assemblage.
C 476 covers two types of grout:
1) Fine Grout
2) Coarse Grout
Grout is specified either by:
1) Proportions contained in C 476, or
2) Strength requirements (must be greater than 2000 psi)
Masonry Grout
• Grout in place will typically have strengths of about 2500 psi
• It is poured wet, but is designed for water to absorb into the
units
• Grouts should be very fluid to fill in voids in the cells and flow
around reinforcement without honeycombing.
ASTM C 1019 - Grout Testing
ASTM C 1019 - Grout Testing
What is f ‘ m ??
specified
The Compressive
^
Strength of Masonry
Methods of Demonstrating
Compliance with f ‘ m
• Unit Strength Method
• Prism Test Method
Required Net Area
Compressive Strength
of CMU with…
Type M/S
Type N
Mortar Mortar
1250
1900
2800
3750
4800
1300
2150
3050
4050
5250
To Satisfy Compliance
with this Specified
Compressive Strength
of Masonry
1000
1500
2000
2500
3000
Required Net Area
Compressive Strength
of CMU with…
Type M/S
Type N
Mortar Mortar
1250
1900
2800
3750
4800
1300
2150
3050
4050
5250
To Satisfy Compliance
with this Specified
Compressive Strength
of Masonry
1000
1500
2000
2500
3000
Required Net Area
Compressive Strength
of CMU with…
Type M/S
Type N
Mortar Mortar
1250
1900
????
2800
3750
4800
1300
2150
????
3050
4050
5250
To Satisfy Compliance
with this Specified
Compressive Strength
of Masonry
1000
1500
1750
2000
2500
3000
Required Net Area
Compressive Strength
of CMU with…
To Satisfy Compliance
with this Specified
Compressive Strength
of Masonry
Type M/S
Type N
Mortar Mortar
1250
1900
2350
2800
3750
4800
1300
2150
2600
3050
4050
5250
450
900
1000
1500
1750
2000
2500
3000
250
500
ASTM C 1314: Compressive Strength
of Masonry Prisms
Mortar Bedding
Joint Thickness
Joint Tooling
Grouting
Unit Condition
Bonding Arrangement
Full
Same as in structure
Struck
Same as in structure
Same as in structure
Stack Bond
Importance of Construction
Importance of
Curing
Masonry
Materials
Questions ?????