8 BRICK MASONRY Stone and brick masonry: The strongest and most durable of pre-industrial building materials Mycenae, Lions Gate Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

8 BRICK MASONRY MORTAR Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Cushions masonry units, ensuring uniform bearing one against the other MORTAR Mortar Cushions masonry units, ensuring uniform bearing one against the other Seals joints between the masonry units, minimizing the flow of air and water Adheres units, providing resistance to lateral forces from wind, earthquakes Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

In combination with brick, contributes to the appearance of the wall MORTAR Mortar In combination with brick, contributes to the appearance of the wall Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Portland Cement-Lime Mortar Ingredients: Portland cement Primarily calcium silicates Sources of calcium: Limestone, marble, and other minerals Sources of silica: Clay, sand, shale, marl Portland cement is an hydraulic cement: It hardens by chemically combining with water (hydration). Lesser quantities of compounds of iron, aluminum, magnesium, and sulfate improve the hydration process. Very fine particle size: 0.0004 to 0.0006 inches diameter Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Portland Cement-Lime Mortar Ingredients: Aggregate Natural sand Manufactured sand made from crushed stone, gravel, or furnace slag Particle size: A well-graded mix with particles ranging in size from 0.003 – 0.187 inches in diameter Sands must be free of contaminants, physically sound, and not chemically reactive with the other mortar ingredients. Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Portland Cement-Lime Mortar Ingredients: Hydrated lime Quicklime: Limestone and other minerals are finely ground and heated to produce calcium and magnesium oxides: CaO/MgO. Hydrated lime: Sufficient water is added to quicklime to slake or chemically convert the oxides to hydroxides: Ca(OH)2/Mg(OH)2. Hydrated lime remains a dry powder. Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Portland Cement-Lime Mortar Ingredients: Water Clean, neutral pH, free of contaminants or organic material Potable water is generally considered suitable. Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Cement is the glue that binds the sand particles together. MORTAR The Mortar Mix There is almost one cubic foot of sand in a cubic foot or mortar. Sand provides the basic structural capacity of the hardened mortar. Cement is the glue that binds the sand particles together. Lime improves the workability of mortar in its plastic state. A minimum amount of water is necessary for the chemical hydration of the cement; additional water is added to produce a working consistency to the wet mortar. Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Lime & other workability agents MORTAR Blended hydraulic cement Portland cement mixed with other cementitious materials Replaces portland cement in cement-lime mortar mix Cement Lime & other workability agents Aggregate Portland cement-lime mortar portland cement lime sand Mortar with blended hydraulic cement blended hydraulic cement Mortar with masonry cement masonry cement Mortar with mortar cement mortar cement Lime mortar (non- hydraulic) (none) Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Lime & other workability agents MORTAR Masonry cement Proprietary mortar mix of cementitious materials, lime, plasticizers, and other ingredients No added lime Convenience and consistent quality of pre-mixed ingredients Good workability, and improvements in some properties of hardened mortar such as reduced drying shrinkage Lower bond strength than cement-lime mortars Cement Lime & other workability agents Aggregate Portland cement-lime mortar portland cement lime sand Mortar with blended hydraulic cement blended hydraulic cement Mortar with masonry cement masonry cement Mortar with mortar cement mortar cement Lime mortar (non- hydraulic) (none) Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Lime & other workability agents MORTAR Mortar cement A proprietary pre-mixed product, like masonry cement But produced to a standard that assures higher bond strength comparable to cement-lime mortar Cement Lime & other workability agents Aggregate Portland cement-lime mortar portland cement lime sand Mortar with blended hydraulic cement blended hydraulic cement Mortar with masonry cement masonry cement Mortar with mortar cement mortar cement Lime mortar (non- hydraulic) (none) Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Lime & other workability agents MORTAR Lime Mortar No hydraulic cement Cures by a chemical reaction called carbonation, where atmospheric CO2, combines with the hydroxides in the lime to create carbonates Has some ability to self-heal hairline cracks that may develop over time; as water and air enter the joint, carbonation can occur and repair the joint Used primarily for the restoration of historic masonry structures Cement Lime & other workability agents Aggregate Portland cement-lime mortar portland cement lime sand Mortar with blended hydraulic cement blended hydraulic cement Mortar with masonry cement masonry cement Mortar with mortar cement mortar cement Lime mortar (non- hydraulic) (none) Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Pigments, colored aggregate MORTAR Mortar Admixtures Pigments, colored aggregate Bond enhancers: Improve flexural strength, freeze-thaw resistance Set accelerators and retarders: Adjust setting time in cold or hot weather Water repellents: Improve water resistance (for concrete masonry units only) Workability enhancers: Ease placement of wet mortar Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Type S and Type N mortars are the most commonly specified. Mortar Types Higher-strength mortars have a higher proportion of cement to lime in the mortar mix, resulting in higher compressive strength in the hardened mortar. Higher strength mortars are more expensive and have poorer workability characteristics in comparison to lower-strength mortars. In general, the lowest strength mortar suitable for a particular job is the optimal choice. Type S and Type N mortars are the most commonly specified. ASTM C270 Designation Uses Type M Highest strength Very high-strength masonry Masonry subject to severe freeze-thaw Masonry in contact with the earth Type S Reinforced loadbearing masonry Exterior veneer subjected to high wind forces or seismic forces Type N Nonloadbearing masonry Exterior masonry not subject to severe lateral loads Type O Interior nonloadbearing masonry Historic masonry restoration Type K Lowest strength (not part of ASTM C270 standard) Designations for mortar types, in decreasing order of strength, come from every other letter in the phrase “MaSoN wOrK”. Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Mortar Type Specification: Proportion Specification Mortar types are defined by the proportion of ingredients. Proportion specification is the simpler and more common method of defining mortar requirements. Note the higher lime content of lower-strength mortar types. Note that no lime is added to mortar cement or masonry cement mixes. Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Mortar Type Specification: Property Specification Mortar types are defined by minimum strength and other properties demonstrated through laboratory testing for the proposed mix. This specification method is most suitable to large projects, where the added cost and complexity of laboratory testing can be offset by more flexibility in selecting ingredients and proportions in the mortar mix. Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

BRICK MASONRY 8 BRICK MASONRY Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Brick Raw Materials Preparation BRICK MASONRY Brick Raw Materials Preparation Natural clays are excavated from the earth. These raw materials are ground up and screened to control particle size. Water is added to achieve a plastic consistency ready for molding into bricks. Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Brick Forming: Extruded or Stiff mud process bricks BRICK MASONRY Brick Forming: Extruded or Stiff mud process bricks Moderately moist clay is extruded through dies and then sliced into individual units. Generally least expensive molding method Accounts for approximately 90% of US made bricks The extrusion process naturally produces brick units with a smooth face and high dimensional uniformity. Various post-extrusion distressing steps can be used to create bricks with greater variation in shape and surface texture (right). Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Brick Forming: Molded bricks BRICK MASONRY Brick Forming: Molded bricks Soft mud process: Relatively moist clay is pressed into individual molds Water-struck: Molds are pre-wetted Sand-struck: Molds are pre-dusted with sand May be hand- or machine-pressed Dry-press process: Low-plasticity clays are kept relatively dry and stiff, and machine-pressed into steel molds at high pressure. Molded bricks frequently are associated with more natural variation in texture and dimensional uniformity than extruded bricks. Molded brick costs vary with the molding process, but are frequently more expensive than extruded brick. Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

BRICK MASONRY Brick Firing After forming, bricks are dried and then packed into a firing kiln, where they pass through various stages of drying and chemical transformation. Tunnel kiln (right): Brick loads pass continuously from one end of the kiln to the other. Periodic kiln: Batches of bricks are loaded, fired, cooled, and removed. Firing takes 10 to 40 hours. Brick placement and firing conditions affect finished brick color, uniformity of shape, hardness, and other physical properties. Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Example Modular–Sized Brick Sizes BRICK MASONRY Brick Sizes Bricks are available in many sizes and standard sizes vary regionally. Some bricks are sized so that the dimension of one brick plus one mortar joint equals a convenient nominal dimension. Example: A modular brick combined with a mortar joint occupies 4 inches in width (3 5/8" + 3/8") and 8 inches in length (7 5/8" + 3/8"). Three courses occupy 8 inches in height( 3 x [2 1/4" + 3/8"] ). Example Modular–Sized Brick Sizes Nominal Dimensions, in. Joint Thickness, in. Actual Dimensions, in. Vertical Coursing W H L Modular 4 2 2/3 8 3/8 1/2 3 5/8 3 1/2 2 1/4 7 5/8 7 1/2 3 courses = 8 in. Engineer Modular 3 1/5 2 3/4 2 13/16 5 courses = Closure Modular 1 course = 4 in. Roman 2 12 1 5/8 1 1/2 11 5/8 11 1/2 2 course = Meridian 16 15 5/8 15 1/2 Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Example Non-Modular-Sized Brick Sizes BRICK MASONRY Brick Sizes Other bricks do not necessarily conform to convenient dimensions. Note the non-modular-sized lengths of the example bricks in the table below. Example Non-Modular-Sized Brick Sizes Nominal Dimensions, in. Joint Thickness, in. Actual Dimensions, in. Vertical Coursing W H L Standard 3/8 1/2 3 5/8 3 1/2 2 1/4 8 3 courses = 8 in. Engineer Standard 2 3/4 2 13/16 5 course = 8 in. Closure Standard 1 course = 4 in. King 2 3/4 - 3 2 5/8 - 2 3/4 9 5/8 - 9 3/4 5 courses = 16 in. Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Special Shapes and Sizes BRICK MASONRY Special Shapes and Sizes Special or custom-shaped bricks can be used to form arches, water tables, and many other surfaces and features. Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Brick Classifications BRICK MASONRY Brick Classifications Solid brick: Not less than 75% solid (in any section cut perpendicular to bearing). Solid bricks are frequently not 100% solid, to reduce weight and the costs of firing. Cored, solid bricks are lighter in weight than fully solid units. Frogged, solid bricks are less prone to shifting on a wet mortar bed. Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Brick Classifications Hollow brick: Up to 60% void BRICK MASONRY Brick Classifications Hollow brick: Up to 60% void With hollow brick, larger sized units can be kept lighter in weight Because of their lighter weight, hollow bricks require less energy to fire. The larger voids in hollow brick readily accommodate steel reinforcing in reinforced brick masonry. Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Brick Classifications BRICK MASONRY Brick Classifications Facing brick: Brick with appearance characteristics graded for exposed applications Building brick (right): Brick intended for concealed locations where appearance is not a concern Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Grade SW: Any weathering region, above or below grade BRICK MASONRY Brick Grade: Defines durability (e.g., compressive strength, absorption, freeze-thaw resistance) Grade NW: Interior brick, concealed building brick, and other brick not exposed to the weather Grade MW: Above grade brick only, in regions of negligible weathering (see map) Grade SW: Any weathering region, above or below grade Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Brick Type: Defines uniformity in size and shape BRICK MASONRY Brick Type: Defines uniformity in size and shape Applies only to facing brick Less uniform bricks, which may be considered more aesthetically desirable, may be more expensive than more uniform bricks. More uniform bricks are more suitable to applications where close dimensional tolerances must be maintained, such as in a brick masonry curtain wall. Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Brickwork Terminology Course: One horizontal row of bricks BRICK MASONRY Brickwork Terminology Course: One horizontal row of bricks Bed Joint: Horizontal joint between courses Head Joint: Vertical joint between bricks in same course Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Brickwork Terminology: Wythe: One vertical stack of bricks BRICK MASONRY Brickwork Terminology: Wythe: One vertical stack of bricks Collar Joint: Vertical joint between wythes Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Brickwork Terminology: BRICK MASONRY Brickwork Terminology: Rowlock: Brick laid on its face, with end visible Stretcher: Brick laid flat, with face visible Header: Brick laid flat, with end visible Soldier: Brick laid on its end, with its face visible Sailor: Like a soldier, but with its broader side visible Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

BRICK MASONRY Brick Bonds Headers or rowlocks in a multi-wythe wall serve an important functional purpose, tying together the two wythes. In a single-wythe wall, different brick bonds may be chosen purely for the visual patterns they create in the exposed face of the wall. Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Running Bond: All stretchers BRICK MASONRY Brick Bonds: Running Bond: All stretchers Common Bond: Stretcher courses, with a header row usually every 5 or 6 courses Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

English Bond: Alternating stretcher and header courses BRICK MASONRY Brick Bonds English Bond: Alternating stretcher and header courses Flemish Bond: Alternating stretchers and headers in each course Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Brick Masonry Dimensions To the greatest extent possible, brick masonry wall dimensions should be conform to the brick module, minimizing the need to cut bricks or work with very small pieces. Depending on the type measurement, the number of joint widths in the dimension may be one more, the same, or one less, than the number of bricks. Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Corner leads are constructed ahead of the rest of the wall. BRICK MASONRY Laying Bricks Corner leads are constructed ahead of the rest of the wall. Levels and string lines are used to keep the wall straight and true. Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Compacts joint surface to make it more durable and water-resistant BRICK MASONRY Joint Tooling Compacts joint surface to make it more durable and water-resistant Neatens joint appearance The concave joint and vee joint shed water most effectively and are the most resistant to freeze-thaw. Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Lintels (steel angle, stone, precast concrete, reinforced) Arches BRICK MASONRY Spanning Openings Lintels (steel angle, stone, precast concrete, reinforced) Arches Corbelling Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.

Reinforced Brick Masonry (RBM) Steel reinforcing and grouting are added to the masonry wall, to increase its strength, especially in bending and shear. Bottom image: a two-wythe RBM panel is load tested. Fundamentals of Building Construction, Materials & Methods, 5th Edition Copyright © 2009 J. Iano. All rights reserved.