M asonry M aterials. Components of Masonry Masonry Units Mortar Grout Reinforcement Anchors / Ties...

Masonry

Materials

Components of Masonry

• Masonry Units

• Mortar

• Grout

• Reinforcement

• Anchors / Ties

• Accessories

CharacteristicsMaterial OptionsTesting / QA

Components of Masonry

• Masonry Units

• Mortar

• Grout

• Reinforcement

• Anchors / Ties

• Accessories

Masonry Prism

Concrete/Masonry Components

Concrete CMU Mortar GroutMaterials

Aggregate Size

Consistency

Preparation

maybe lime

< 3/4 in. pea < 3/8 in. < #8fine masonry

sand

Coarse: < #3/8Fine: < #4

(concrete sand)

Pourable, stiff No Slump Fluffy Pourable, runny

mixer mixermixer,vibrated into form

mixer

3-6 in.8-10 in.

Cement, aggregates, water, admixtures

Masonry

Units

Clay Unit (brick) Options

www.GlenGerybrick.com

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.

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.


Handmade:Each brick is individually formed and placed in a wooden mold to create a textured brick...no two being alike.



Molded:The soft irregular edges of molded brick are produced as a result of the manufacturing process in whichmaterial is dropped into a mold box, vibrated and released from the box. Molded brick normally havesand finish textures since sand is used as a releasing agent in the mold box.www.GlenGerybrick.com

Clay Unit (brick) OptionsRolled 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.


Clay Unit (brick) OptionsPapercut: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


Tumbled:The irregular edges of tumbled brick are a result of physically tumbling extruded fired brick and addingslurries to the mix. This result is a used-brick style.



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.




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.



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.



Engobe:After the material is extruded, a clay slurry is applied to the brick that becomes an integral part of the unitduring 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.

Manufacturing Clay Brick www.GlenGerybrick.com

Manufacturing Clay Brick www.GlenGerybrick.com

Clay Unit Options - SizesModular 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

HL

W x H x L

Standards for Clay Masonry UnitsSpecificationsASTM C 62 Building BrickASTM C 126 Ceramic Glazed Structural Clay Tile, Facing Brick, and Solid Masonry UnitsASTM C 216 Facing Brick (Solid)ASTM C 1272 Heavy Vehicular Paving BrickASTM C 652 Hollow BrickASTM C 902 Pedestrian and Light Traffic Paving Brick

Test MethodsASTM C 67 Sampling and Testing Concrete Brick

Modulus of Rupture Freezing and ThawingCompressive Strength Initial Rate of Absorption (IRA)Absorption EfflorescenceSize / Warpage / Square Length ChangeVoid 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• 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


• 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 UnitsSpecificationsC55 Concrete BrickC90 Loadbearing Concrete Masonry UnitsC129 Nonloadbearing Concrete Masonry UnitsC744 Prefaced Concrete and Calcium Silicate Masonry UnitsC936 Solid Concrete Interlocking Paving UnitsC1319 Concrete Grid Paving UnitsC1372 Segmental Retaining Wall Units

Test MethodsC140 Sampling and Testing Concrete Masonry Units

Dimensions Unit WeightAbsorption Compressive StrengthMoisture Content

C426 Drying Shrinkage of Concrete BlockC1262 Freeze-Thaw Durability of Concrete Masonry and Related Concrete Units

CMU DimensionsH

eigh

tW

idth

Length

Dimensions for CMU expressed as:

Width x Height x Length

4 x 8 x 166 x 8 x 168 x 8 x 16 or 7-5/8 x 7-5/8 x 15-5/810 x 8 x 1612 x 8 x 16

Nominal Actual / Standard / Specified

Nominal Dimensions

running bond

Nominal dimensions are equal to the standard dimensions plus the thickness of one mortar joint (typically 3/8 in.)

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

Old Mortar

Designations

New Mortar

Designations

M

A

S

O

N

W

O

R

K

A-1

A-2

B

C

D

Old Mortar

Designations

New Mortar

Designations

M

A

S

O

N

W

O

R

K

Mortar is proportioned by volume

ASTM Mortar StandardsASTM 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.

MortarType

PortlandCement Lime Sand

MSNO

1111

0 – ¼¼ - ½

½ - 1¼1¼ - 2½

2 ¼ - 3times thesum ofcement

plus lime

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.

MortarType

CompressiveStrength

WaterRetention

AirContent

MSNO

2500 psi1800 psi750 psi350 psi

75757575

12121414

* for portland cement and lime mortars

ASTM C 270 Property Specsare NOT to be applied to….

...FieldMortar

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?

All involved parties should be present

By preconstruction testing using:

• specified proportions

• same materials to be used in the field

• field batching and mixing procedures

• specified testing procedures

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.

0

200

400

600

800

1000

1200

1400

1600

1800

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

Mortar + Alcohol Sand(use 91% isopropyl alcohol)

Jar 1 Jar 2 Jar 3

Mortar:Agg Ratio, Jar #1Pour 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 ??

The Compressive

Strength of Masonry

specified

^

Methods of DemonstratingCompliance with f ‘ m

• Unit Strength Method

• Prism Test Method

Required Net Area

Compressive Strength

of CMU with…

Type M/S Type N

MortarMortar

To Satisfy Compliance

with this Specified


of Masonry

1250 1300 1000

1900 2150 1500

2800 3050 2000

3750 4050 2500

4800 5250 3000

Required Net Area


of CMU with…

Type M/S Type N

MortarMortar


with this Specified


of Masonry

1250 1300 1000

1900 2150 1500

2800 3050 2000

3750 4050 2500

4800 5250 3000

Required Net Area


of CMU with…

Type M/S Type N

MortarMortar


with this Specified


of Masonry

1250 1300 1000

1900 2150 1500

???? ???? 1750

2800 3050 2000

3750 4050 2500

4800 5250 3000

Required Net Area


of CMU with…

Type M/S Type N

MortarMortar


with this Specified


of Masonry

1250 1300 1000

1900 2150 1500

2350 2600 1750

2800 3050 2000

3750 4050 2500

4800 5250 3000

500

250

900

450

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 ofCuring

Masonry

Materials

Questions ?????

Date post:	24-Jan-2016
Category:	Documents
Upload:	brendan-owen
View:	224 times
Download:	0 times

M asonry M aterials. Components of Masonry Masonry Units Mortar Grout Reinforcement Anchors / Ties...

Documents