Masonry Materials

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

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

Concrete/Masonry Components CMU Mortar Grout Materials Cement, aggregates, water, admixtures maybe lime 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 Pourable, runny Preparation mixer mixer, vibrated into form

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 W x H x L

Standards for Clay Masonry Units Specifications ASTM C 62 Building Brick ASTM C 126 Ceramic Glazed Structural Clay Tile, Facing Brick, and Solid Masonry Units ASTM C 216 Facing Brick (Solid) ASTM C 1272 Heavy Vehicular Paving Brick ASTM C 652 Hollow Brick ASTM C 902 Pedestrian and Light Traffic Paving Brick Test Methods ASTM C 67 Sampling and Testing Concrete Brick Modulus of Rupture Freezing and Thawing Compressive Strength Initial Rate of Absorption (IRA) Absorption Efflorescence Size / Warpage / Square Length Change Void Area ASTM C 1006 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 Unit Weight Absorption Compressive Strength Moisture Content C426 Drying Shrinkage of Concrete Block C1262 Freeze-Thaw Durability of Concrete Masonry and Related Concrete Units

CMU Dimensions Dimensions for CMU expressed as: Width Width x Height x Length Width Height Length Nominal Actual / Standard / Specified 4 x 8 x 16 6 x 8 x 16 8 x 8 x 16 or 7-5/8 x 7-5/8 x 15-5/8 10 x 8 x 16 12 x 8 x 16

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 A-2 B C D M A S O N W R K Old Mortar Designations New Mortar

A-1 A-2 B C D M A S O N W R K Old Mortar Designations New Mortar

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 If neither is specified, which one governs? Do not specify both

ASTM C 270 Proportion Spec. Proportions by volume

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. * 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 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.

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 Sand (use 91% isopropyl alcohol)

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 1300 1000 1900 2150 1500 2800 3050 2000 3750 4050 2500 4800 5250 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 1300 1000 1900 2150 1500 2800 3050 2000 3750 4050 2500 4800 5250 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 1300 1000 1900 2150 1500 ???? ???? 1750 2800 3050 2000 3750 4050 2500 4800 5250 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 1300 1000 1900 2150 1500 2350 2600 1750 2800 3050 2000 3750 4050 2500 4800 5250 3000 450 250 900 500

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 Stack Bond

Importance of Construction

Importance of Curing

Masonry Materials Questions ?????