Masonry

Materials

Components of Masonry

Masonry Units
Mortar
Grout
Reinforcement
Anchors / Ties
Accessories

Characteristics
Material Options
Testing / QA

Components of Masonry

Masonry Units
Mortar
Grout
Reinforcement
Anchors / Ties
Accessories

Masonry Prism

Concrete/Masonry Components
Concrete
Materials

CMU

Mortar

Grout

Cement, aggregates, water, admixtures

maybe lime

Aggregate Size

< 3/4 in. pea

Consistency

Preparation

< 3/8 in.

< #8
fine masonry
sand

Coarse: < #3/8

Fine: < #4
(concrete sand)

3-6 in.

8-10 in.

Pourable, stiff

No Slump

mixer

mixer,
vibrated into form

Fluffy
mixer

Pourable, runny
mixer

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

www.GlenGerybrick.com

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.

Clay Unit (brick) Options

www.GlenGerybrick.com

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.

Clay Unit (brick) Options

www.GlenGerybrick.com

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.

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

www.GlenGerybrick.com

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.

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
Engineer Modular
Economy Modular (Closure)
Norman
Engineer Norman
3" Bed Economy Norman (Utility)
Economy Norman (Utility)
Giant Norman
Kingsize
Full Bed Kingsize
Engineer Kingsize
Triple Brick
Danish Hand Mould
6" Thru Wall Unit
8" Thru Wall Unit

3 5/8 x 2 1/4 x 7 5/8

3 5/8 x 2 13/16 x 7 5/8
3 5/8 x 3 5/8 x 7 5/8
3 5/8 x 2 1/4 x 11 5/8
3 5/8 x 2 13/16 x 11 5/8
3 x 3 5/8 x 11 5/8
3 5/8 x 3 5/8 x 11 5/8
3 5/8 x 5 5/8 x 11 5/8
3 x 2 5/8 x 9 5/8
3 5/8 x 2 5/8 x 9 5/8
3 x 2 13/16 x 9 5/8
3 5/8 x 7 5/8 x 7 5/8
3 5/8 x 2 5/8 x 7 5/8
5 5/8 x 3 5/8 x 11 5/8
7 5/8 x 3 5/8 x 11 5/8

W
H
L
WxHxL

Standards for Clay Masonry Units

Specifications
ASTM C 62
ASTM C 126
ASTM C 216
ASTM C 1272
ASTM C 652
ASTM C 902

Building Brick
Ceramic Glazed Structural Clay Tile, Facing Brick, and Solid Masonry Units
Facing Brick (Solid)
Heavy Vehicular Paving Brick
Hollow Brick
Pedestrian and Light Traffic Paving Brick

Test Methods
ASTM C 67

Sampling and Testing Concrete Brick

Modulus of Rupture
Compressive Strength
Absorption
Size / Warpage / Square
Void Area
ASTM C 1006

Freezing and Thawing

Initial Rate of Absorption (IRA)
Efflorescence
Length Change

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

CMUs 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 CMUs 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
Absorption
Moisture Content
C426
C1262

Unit Weight
Compressive Strength

Drying Shrinkage of Concrete Block

Freeze-Thaw Durability of Concrete Masonry and Related Concrete Units

CMU Dimensions
Height Wi
dt
h

Dimensions for CMU expressed as:

Width x Height x Length

Length
Nominal
4 x 8 x 16
6 x 8 x 16
8 x 8 x 16
10 x 8 x 16
12 x 8 x 16

Actual / Standard / Specified

or

7-5/8 x 7-5/8 x 15-5/8

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

15-5/8
16 in.

8 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 nonuniform spaces to

result in plumb and
level masonry
construction

The Role of Mortar

Water Penetration Resistance
Rai
n

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
Old Mortar
Designations

A-2

A
S
O

O
R
K

New Mortar
Designations

A-1
Old Mortar
Designations

A-2

A
S
O

O
R
K

New Mortar
Designations

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
Do not specify
both

If neither is
specified,
which one
governs?

ASTM C 270 Proportion Spec.

Proportions by volume

Mortar
Type
M
S
N
O

Portland
Cement
1
1
1
1

Lime
Sand
0
2-3
- times the
- 1
sum of
1 - 2 cement
plus lime

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 C270s
property specifications.

ASTM C 270 Property Spec.

Mortar Compressive Water
Air
Type
Strength
Retention Content
M
2500 psi
75
12
S
1800 psi
75
12
N
750 psi
75
14
O
350 psi
75
14
* 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.

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.
1800
1600
1400
1200
1000
800
600
400
200
0
1

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

Jar 1

Jar 2

Mortar + Alcohol
(use 91% isopropyl alcohol)

Jar 3

Sand

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. Ovendry 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
1250
1900
2800
3750
4800

1300
2150
3050
4050
5250

To Satisfy Compliance
with this Specified
Compressive Strength
of Masonry
1000
1500
2000
2500
3000

Required Net Area

Compressive Strength
of CMU with
Type M/S
Type N
Mortar Mortar
1250
1900
2800
3750
4800

1300
2150
3050
4050
5250

To Satisfy Compliance
with this Specified
Compressive Strength
of Masonry
1000
1500
2000
2500
3000

Required Net Area

Compressive Strength
of CMU with
Type M/S
Type N
Mortar Mortar
1250
1900
????
2800
3750
4800

1300
2150
????
3050
4050
5250

To Satisfy Compliance
with this Specified
Compressive Strength
of Masonry
1000
1500
1750
2000
2500
3000

Required Net Area

Compressive Strength
of CMU with

To Satisfy Compliance
with this Specified
Compressive Strength
of Masonry

Type M/S
Type N
Mortar Mortar
1250
1900
2350
2800
3750
4800

1300
2150
2600
3050
4050
5250

450
900

1000
1500
1750
2000
2500
3000

250
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
Same as in structure
Same as in structure
Stack Bond

Importance of Construction

Importance of
Curing

Masonry
Materials
Questions ?????