Masonry Materials

Components of Masonry
Masonry Units Mortar Grout Reinforcement Anchors / Ties Accessories Characteristics Material Options Testing / QA

Components of Masonry
Masonry Units Mortar Grout Reinforcement Anchors / Ties Accessories

Masonry Prism

Concrete/Masonry Components
Concrete Materials CMU Mortar
maybe lime

Grout

Cement, aggregates, water, admixtures

Aggregate Size

< 3/4 in. pea

< 3/8 in.

< #8 fine masonry sand

Coarse: < #3/8 Fine: < #4 (concrete sand)

Consistency

3-6 in.

8-10 in.

Pourable, stiff

No Slump

Fluffy mixer

Pourable, runny

Preparation

mixer

mixer, vibrated into form

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

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.

www.GlenGerybrick.com

Clay Unit (brick) Options

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.

www.GlenGerybrick.com

Clay Unit (brick) Options

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.

www.GlenGerybrick.com

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

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.

www.GlenGerybrick.com

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 Test Methods ASTM C 67 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

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

CMUs 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 CMUs 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 8 in.

15-5/8

16 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
Cement Lime Sand Water Admixtures

Mortar Constituents
Cement Lime Sand Water Admixtures
Portland Cement (C150), Masonry Cement (C91) or Mortar Cement (C1329) Strength Early Setting Bond Durability Shrinkage

Mortar Constituents
Cement Lime Sand Water Admixtures
Hydrated Lime (C207)

workability water retentivity late strength autogenous healing

Mortar Constituents
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

A-1
Old Mortar

A S O N W O R K
New Mortar

A-2

Designations

B
C D

Designations

A-1
Old Mortar

A S O N W O R K
New Mortar

A-2

Designations

B
C D

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 2-3 - times the - 1 sum of 1 - 2 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 C270s 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

Compressive Strength Air Content Mortar Aggregate Ratio Cone Penetration Visual Inspection of Mortar Preparation

ASTM C 780, Mortar:Agg Ratio

Jar 1

Jar 2

Jar 3

Mortar + Alcohol

(use 91% isopropyl alcohol)

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

To Satisfy Compliance with this Specified Compressive Strength of Masonry

1250 1900 2800 3750 4800

1300 2150 3050 4050 5250

1000 1500 2000 2500 3000

Required Net Area Compressive Strength of CMU with Type M/S Type N Mortar Mortar

To Satisfy Compliance with this Specified Compressive Strength of Masonry

1250 1900 2800 3750 4800

1300 2150 3050 4050 5250

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 Type M/S Type N Mortar Mortar 1250 1900 2350 2800 3750 4800 1300 2150 2600 3050 4050 5250

To Satisfy Compliance with this Specified Compressive Strength of Masonry 1000 1500 1750 2000 2500 3000

450 900

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 ?????