1. Masonry Materials

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

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

4. 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

5. Masonry Units

6. 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.

7. 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.

8. 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.

9. 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.

10. 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.

11. 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.

12. 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.

13. 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.

14. 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.

15. 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.

16. Manufacturing Clay Brick

17. Manufacturing Clay Brick

18. Clay Unit Options - Sizes
Modular /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 /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

19. 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

20. Concrete Masonry Unit Surfaces
Spilt-face
Ground-face
Raked-face
Ribbed
Striated
Glazed
Etc...

21. Concrete Masonry Unit Manufacturing

22. Concrete Masonry Unit Manufacturing

23. Concrete Masonry Unit Manufacturing

24. 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

25. 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.

26. 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

27. 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 or 7-5/8 x 7-5/8 x 15-5/8
10 x 8 x 16
12 x 8 x 16

28. 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.

29. CMU Shapes Refer to page 311 in text Most common shapes are: Stretcher
Bullnose
Lintel
Half and Double Corners
Many others for specific uses

30. Masonry
Mortar

31. The Role of Mortar
Holds Units Together vs. Holds Units Apart

32. The Role of Mortar Accommodates Uneven Units
Mortar can fill non-uniform spaces to result in plumb and level masonry construction

33. The Role of Mortar Water Penetration Resistance Rain
Mortar Joints can be tooled different ways affecting appearance and resistance to water penetration.

34. Mortar Constituents
Cement
Lime
Sand
Water
Admixtures

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

36. Mortar Constituents Cement Lime Sand Water Admixtures
Hydrated Lime (C207)
workability
water retentivity
late strength
autogenous healing

37. Mortar Constituents Cement Lime Sand Water Admixtures
Masonry Sand (C144)
bulk
strength
shrinkage resistance

38. 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

39. 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

40. 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

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

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

43. Mortar is proportioned by volume

44. 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

45. ASTM C 270, specify by…. Proportion Specification --OR --
Property Specification
If neither is specified, which one governs?
Do not specify both

46. ASTM C 270 Proportion Spec.
Proportions by volume

47. 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.

48. ASTM C 270 Property Spec.
* for portland cement and lime mortars

49. ASTM C 270 Property Specs are NOT to be applied to….
...Field
Mortar

50. 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

51. 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

52. 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.

53. 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.

54. 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

55. 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.

56. Common QC Tests for Mortar
Compressive Strength
Air Content
Mortar Aggregate Ratio
Cone Penetration
Visual Inspection of Mortar Preparation

57. ASTM C 780, Mortar:Agg Ratio
Jar Jar Jar 3
Mortar + Alcohol Sand
(use 91% isopropyl alcohol)

58. 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.

59. 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)

60. 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.

61. Masonry Grout

62. 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)

63. 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.

64. ASTM C Grout Testing

65. ASTM C Grout Testing

66. What is f ‘ m ??
specified ^
The Compressive
Strength of Masonry

67. Methods of Demonstrating Compliance with f ‘ m
Unit Strength Method
Prism Test Method

68. 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

69. 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

70. 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
???? ????

71. 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
450
250
900
500

72. 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

73. Importance of Construction

74. Importance of
Curing

75. Masonry Materials
Questions ?????