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CONSTRUCTION PROCEDUREFOR
CONCRETE MASONRY WALLS
AKADEMI BINAAN NEGARAWILAYAH TIMUR
08 APRIL 2008
integrated brickworks sdn bhd Incorporated in 1972 Pioneering producer of high quality concrete masonry Factories use dedicated state-of-the-art plants
Industry milestones: Wrapped and palletised product packaging Truck-mounted cranes Introduced Segmental Retaining Walls Introduced architectural concrete masonry SIRIM and BOMBA certification
Our Production Facility
Factory set up on 16-acre site near Port Dickson 2 high-capacity plants operational Dedicated high-tech automated dry-cast systems Customised product curing chambers Fully-equipped laboratory for QC and QA Ample product storage capacity
Our Products and ServicesConcrete Masonry Units
Load-bearing MasonryAcoustic MasonryInterlocking Masonry
Architectural MasonryFluted BlockSplitblox
Segmental Retaining Wall SystemsKeystoneCountry Manor
Services ProvidedDesign Assistance, Cost Estimations, Project & Site Advisory, Product & Installation Training
Product ApplicationsConcrete Masonry Units – Load Bearing
Product ApplicationsConcrete Masonry Units – Load Bearing
Product ApplicationsConcrete Masonry Units – Load Bearing
Product ApplicationsConcrete Masonry Units – Load Bearing
Product ApplicationsConcrete Masonry
Product ApplicationsConcrete Masonry
Product ApplicationsConcrete Masonry
Product ApplicationsConcrete Masonry
Product ApplicationsConcrete Masonry
Product ApplicationsConcrete Masonry
Product ApplicationsConcrete Masonry
Product ApplicationsConcrete Masonry – Acoustic Masonry
Product ApplicationsArchitectural Concrete Masonry
Product ApplicationsArchitectural Concrete Masonry
Product ApplicationsArchitectural Concrete Masonry
Product ApplicationsArchitectural Concrete Masonry
Product ApplicationsArchitectural Concrete Masonry
Product ApplicationsKeystone Retaining Wall Systems
Product ApplicationsKeystone Retaining Wall Systems
Product ApplicationsKeystone Retaining Wall Systems
Product ApplicationsKeystone Retaining Wall Systems
Product ApplicationsKeystone Country Manor
Product ApplicationsKeystone Country Manor
Product ApplicationsKeystone Country Manor
Product ApplicationsKeystone Country Manor
Product ApplicationsKeystone Country Manor
Product ApplicationsKeystone Country Manor
CONCRETE MASONRY
What is aConcrete Masonry
Unit?
Modular System ~ IBS componentInternational Usage and AcceptanceHollow cores provide improved insulation, reduced
weight and reinforcement channelsRange of basic and special units for plumbing,
corners, lintels, vertical/horizontal steel reinforcementLoad-bearing masonry structures built with
reinforcing steel for columns and tie-beamsCompleted walls can be fair-faceWalls can be plastered, painted, coatedModular Units include Architectural Masonry
CONCRETE MASONRY
CONCRETE MASONRYCONCRETE MASONRY UNITS
(CMU)
Modular Coordination
CMU WALL CONSTRUCTION
(Fair-face)
Mortar
CMU InstallationMaterials
Storage,Handling
Protection
SitePreparation
Services
Tools,Equipments, Material
Mixing Mortar
Tools
Cleaning & PatchingOf Mortar Joints
WallFoundation
WallIntersections
Door & Window Openings
Wall Corners
Electricity
Plumbing
ReinforcedWall
Wall Block Patterns
UnreinforcedWall
VerticalReinforcement
Columns andPilasters
Lintels & Sills
Door & Window Frames
Horizontal Reinforcement
CMU WALLS
Non-Load Bearing Structures
Load Bearing Structures
MODULAR CONCRETE MASONRY STRUCTURES
Modular DesignsUtilise modular coordinationLimits the variety of componentsReduces or eliminates customisingUse industrial mass-produced IBS components
Modular Designs, Methods and Systems:
Modular Methods and SystemsIncreases speed and efficiencyReduce wastagesLower costs
CONCRETE MASONRY UNIT MODULES
CMUs use a basic grid of 200mm x 200mm
CMU module sizing (inclusive 10mm mortar joints):
Full Block 200mm (H) x 400mm (W)
Half Block 200mm (H) x 200mm (W)
CMUs for reinforcement and services conform to above (for
bond beams, lintels, plumbing, corners, etc)
Special applications and designs may require ¼ and ¾ sized
units, half-height units or others, which can also be available
CONCRETE MASONRY WALL
1. Keep the CMUs dry2. Check for tools, materials and equipment3. Prepare the base or wall foundation4. Locate wall ends or corners5. Install alignment string lines6. Prepare mortar mix7. Lay the first course8. Install the last unit or Closure Block9. Continue laying second and upper courses10. Tool the mortar joints11. Clean the wall and patch the mortar joints as necessary.12. Cover the unfinished wall for continuation next day.
INSTALLATION GUIDELINES
Step 1: Keep the CMUs clean and dry
Masonry units at-site are to be kept clean and dry before use.Store the stocks on planks, pallets, etc to keep them above ground, and, where possible, covered to keep off rain.
INSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
CONCRETE MASONRY WALL
INSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
CONCRETE MASONRY WALL
Step 1: Keep the CMUs clean and dry
Masonry units at-site are to be kept clean and dry before use.Store the stocks on planks, pallets, etc to keep them above ground, and, where possible, covered to keep off rain.
CMUs are to be installed in dry condition for the most effective bonding strength of the mortar joints.
INSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
CONCRETE MASONRY WALL
INSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
CONCRETE MASONRY WALL
Step 2: To lay the FIRST COURSEEnsure the foundation face is clean and ready to receive mortar bedding for the base of the wall.Check and make good the bedding face level and alignment.Set out the wall ends, and install string lines for level and alignment.
CONCRETE MASONRY WALLINSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
INSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
CONCRETE MASONRY WALL
Step 2: To lay the FIRST COURSEEnsure the foundation face is clean and ready to receive mortar bedding for the base of the wall.Check and make good the bedding face level and alignment.Set out the wall ends, and install string lines for level and alignment.Install the wall end or corner blocks in mortar to correct level, alignment and plumb.
CONCRETE MASONRY WALLINSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
INSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
CONCRETE MASONRY WALL
Step 2: To lay the FIRST COURSEEnsure the foundation face is clean and ready to receive mortar bedding for the base of the wall.Check and make good the bedding face level and alignment.Set out the wall ends, and install string lines for level and alignment.Install the wall end or corner blocks in mortar to correct level, alignment and plumb.Do a test run by placing blocks without mortar in between the two end blocks to confirm.
CONCRETE MASONRY WALLINSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
INSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
CONCRETE MASONRY WALL
Step 2: Lay the FIRST COURSE (cont)Spread a full mortar bed on the foundation, and check for alignment and thickness.
CONCRETE MASONRY WALLINSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
INSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
CONCRETE MASONRY WALL
Step 2: Lay the FIRST COURSE (cont)Spread a full mortar bed on the foundation, and check for alignment and thickness.Install blocks by buttering mortar to the ends of the face shells for the vertical joints, and pressing them into the mortar bed and butting them against the block adjacent, ensuring 10mm thick mortar joints.
CONCRETE MASONRY WALLINSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
INSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
CONCRETE MASONRY WALL
INSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
CONCRETE MASONRY WALL
Step 2: Lay the FIRST COURSE (cont)Spread a full mortar bed on the foundation, and check for alignment and thickness.Install blocks by buttering mortar to the ends of the face shells for the vertical joints, and pressing them into the mortar bed and butting them against the block adjacent, ensuring 10mm thick mortar joints.Adjust the blocks to the string line for level, alignment and spacing by tapping with a small hammer.It is important to lay the first course carefully, as mistakes in alignment, level or plumb will lead to bigger problems the higher the wall is built.
CONCRETE MASONRY WALLINSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
INSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
CONCRETE MASONRY WALL
Step 3: Install the CLOSURE BLOCKCheck the opening for the last unit (Closure Block) in the course to ensure the last block fits.Butter mortar to the block for the vertical joint, and lower the block into the opening vertically from above. Adjust for joint thickness, alignment, plumb and level.
CONCRETE MASONRY WALLINSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
INSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
CONCRETE MASONRY WALL
Step 3: Install the CLOSURE BLOCKCheck the opening for the last unit (Closure Block) in the course to ensure the last block fits.Butter mortar to the block for the vertical joint, and lower the block into the opening vertically from above. Adjust for joint thickness, alignment, plumb and level.Mortar for the final vertical joint is to be packed in from above, ensuring a well-filled mortar joint.
CONCRETE MASONRY WALLINSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
INSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
CONCRETE MASONRY WALL
Step 4: Lay the SECOND COURSELay the corner or end blocks first to level, alignment and plumb, and install a string line.
INSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
CONCRETE MASONRY WALL
INSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
CONCRETE MASONRY WALL
Step 4: Lay the SECOND COURSELay the corner or end blocks first to level, alignment and plumb, and install a string line.Butter mortar to the horizontal face shells of the blocks in the first course.Next, butter mortar for vertical joints to the ends of the blocks to be laid, and lay them to the string line, with the necessary adjustment to level, plumb and alignment.
INSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
CONCRETE MASONRY WALL
INSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
CONCRETE MASONRY WALL
Step 4: Lay the SECOND COURSELay the corner or end blocks first to level, alignment and plumb, and install a string line.Butter mortar to the horizontal face shells of the blocks in the first course.Next, butter mortar for vertical joints to the ends of the blocks to be laid, and lay them to the string line, with the necessary adjustment to level, plumb and alignment.Remove excess mortar extruded from the joints.Do NOT use dead mortar.Do NOT adjust the block after the mortar has stiffened.
INSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
CONCRETE MASONRY WALL
INSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
CONCRETE MASONRY WALL
Step 5: Lay the THIRD and SUBSEQUENT COURSESTo continue installation of blocks in wall to completion, repeat the procedures as given above.
Closure Blocks should be staggered throughout the wall length.
Protect the uncompleted wall for continuing work the next day, by covering open cores from rain, and, if appropriate, protect the lower wall sections from mud splashes.
INSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS
CONCRETE MASONRY WALL
This fundamental 5 part installation guideline provides for the successful installation of a well constructed concrete masonry wall.
Adhering to this guideline will result in walls built to high workmanship, meeting the structural and aesthetic requirements of clients, architects and engineers.
CONCRETE MASONRY WALLINSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLSSUMMARY
THANK YOU
CONCRETE MASONRY UNITS (CMU)
Modular Coordination
CMU WALL CONSTRUCTION
(Fair-face)
Mortar
CMU InstallationMaterials
Storage,Handling
Protection
SitePreparation
Services
Tools,Equipments, Material
Mixing Mortar
Tools
Cleaning & PatchingOf Mortar Joints
WallFoundation
WallIntersections
Door & Window Openings
Wall Corners
Electricity
Plumbing
ReinforcedWall
Wall Block Patterns
UnreinforcedWall
VerticalReinforcement
Columns andPilasters
Lintels & Sills
Door & Window Frames
Horizontal Reinforcement
CMU WALLS
Non-Load Bearing Structures
Load Bearing Structures