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M asonry M aterials

M asonry M aterials. Characteristics Material Options Testing / QA. Components of Masonry. Masonry Units Mortar Grout Reinforcement Anchors / Ties Accessories. Masonry Prism. Components of Masonry. Masonry Units Mortar Grout Reinforcement Anchors / Ties Accessories. 3-6 in.

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M asonry M aterials

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  1. MasonryMaterials

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

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

  4. 3-6 in. Cement, aggregates, water, admixtures 8-10 in. < 3/4 in. pea < 3/8 in. < #8 fine masonry sand Coarse: < #3/8 Fine: < #4 (concrete sand) Pourable, stiff Pourable, runny No Slump Fluffy mixer, vibrated into form mixer mixer mixer Concrete/Masonry Components Concrete CMU Mortar Grout Materials maybe lime Aggregate Size Consistency Preparation

  5. MasonryUnits

  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. www.GlenGerybrick.com

  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. www.GlenGerybrick.com

  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. www.GlenGerybrick.com

  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. www.GlenGerybrick.com

  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. www.GlenGerybrick.com

  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. www.GlenGerybrick.com

  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. www.GlenGerybrick.com

  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. www.GlenGerybrick.com

  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. www.GlenGerybrick.com

  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. www.GlenGerybrick.com

  16. Manufacturing Clay Brick www.GlenGerybrick.com

  17. Manufacturing Clay Brick www.GlenGerybrick.com

  18. 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

  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 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

  28. running bond Nominal Dimensions 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.

  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. Rain The Role of Mortar • Water Penetration Resistance 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. Plastic Mortar workability water retentivity stiffening characteristics Hardened Mortar bond compressive strength durability Mortar selection: ...based on desired properties Other factors: exposure, seismicity, water penetration, shrinkage, color

  40. Plastic Mortar - Masons Criteria Easily Spread Supports Weight of Units Clings to Vertical Faces Is not squeezed out of joint Mortar selection: ...based on desired properties

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

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

  43. Mortar is proportioned by volume

  44. 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 Mortar StandardsASTM C 270 vs. ASTM C 780

  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 Specsare 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

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