ACH 122 Lecture 05a (Brick Masonry)

MODULE #4
MASONRY
 Brick (part 1)
 Concrete (part 2)
 Stone (part 3)

MODULE #4
MASONRY
M A S O N RY
Definitions & History
Mortar
This lecture represents the intellectual property of Professor Brandi R.
Shepard. These materials are made available solely for the educational
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ACH 122-Construction Technology 2

WHAT IS MASONRY?
 The stacking of natural or manufactured fired
units to create a structural element.
 Mortar joins these units
 Acts in compression
 Durable, fireproof
 Suitable for all elements of the structural
 Labor intensive; requires exact skill
 Masonry is broken into units of brick, concrete,
stone

THE HISTORY of
MASONRY
 Earliest type of masonry was native field
stones piled upon one another without mortar
to join them
 Other types included sod or dried mud
 Clay & silt were mixed with water & formed by
hand into bricks
 The joints were packed with mud
 Kept out wind & rain
 Gave a level building surface

THE HISTORY of
MASONRY
 Clay bricks placed in or next to a fire became
harder & more weather resistant
 The invention of the “kiln” by the Romans
 Masons turned limestone into lime and added
this to mud for mortar

THE HISTORY of
MASONRY
 4000 B.C.
 Mesopotamians built stone and sun-dried brick
buildings
 3000 B.C.
 Egyptians built temples and pyramids of cut stone
 500 B.C.
 Greeks used limestone and marble
 100 A.D.
 Babylonians refined arches over small openings
 1100 A.D.
 Romans perfected the arch and vault, built forum
building, theaters, baths, aqueducts & homes

Examples of Historic
Masonry Structures Great Wall of China

Masonry StructuresRotunda at University of Virginia

Masonry Structures Markets of TrajanRoman Colosseum

CONTEMPORARY
MASONRY
 Materials
 Brick
 Concrete masonry units
 Cut stone
 Mortar
 Applications
 Structural
 Load-bearing concrete masonry construction
 Finish
 Brick veneer
 Thin cut stone slabs used for wall cladding
 Interior applications: floor, wall, stair treads

Examples of Contemporary Masonry
StructuresTycon Center, Fairfax, VAbuilding unknown

MORTAR FUNCTIONS
 Bind masonry units into an integral assembly (wall)
 Seals against water and air infiltration
 Provide a cushion and leveler between units
 Seals between masonry units
 Provide character & aesthetics to the masonry
assembly
 Joint size & type
 Color
 Consists of:
 Portland Cement (the “binder”)
 Sand (the “filler”)
 Water (the mixing agent)
 Lime (improves workability)

LIME
MORTAR
CHARACTERISTICS
 Workable when plastic
 Cohesive & easy to spread
 Water retention
 Retain water without bleeding
 Only enough water as needed
for absorption by units
 Water tightness
 Lime in mix provides
 Ability to flex in hardened state,
reducing cracking and related
leaks
 Strength
 Compressive
 Flexural tensile bond strength
Workability of mortar
Water rentivity of
mortar
Watertightness of
masonry wall
Strength of mortar and
the strength of
masonry wall,
particularly the wall’s
flexural tensile bond
strength
decreasesincreases

MORTAR
 Pre-packaged
 Color range
 Testing / Specifications
 Curing

MORTAR
 Mortar takes up 20%±
of wall area
 Affects the color and
texture of masonry
wall
 Mortar composition is
specified in testing
standard ASTM C-270

MORTAR TYPES
 MaSoNwOrK used to label types (M, S, N, O, K)
 Each type has
 Specific proportion of ingredients
 Specific uses based on performance characteristics

MORTAR TYPES
TYPES OF MORTAR: “MaSoNwOrK”
 Type "M" (High): Strength (2500 psi)
High lateral and compressive loads & below grade uses
 Type "S" (Medium-High): Strength (1800 psi)
High flexural and normal compressive loads (most common)
 Type "N" (Medium): Strength (750 psi)
General above grade uses
 Type "O" (Medium-Low): Strength (350 psi)
Non-Load bearing walls
 Type "K" (Low): Strength (75 psi)
Non-Load bearing where permitted (only used in preservation work)
Refer to Table 22.1 on page
547 in textbook

Joint Color that “Blends” w/ Brick Color

Joint Color contrasted w/ Brick Color

MODULE #4
MASONRY
1
Terminology
Manufacturing
Brick Bonding and Joints
Examples of Masonry Buildings
BRICK MASONRY

 Includes:
 Brick; Hollow clay tiles; Architectural terra-cotta
 Composed of:
 Pulverized clay & shale: oxides of silicon and
aluminum
 Water
 Minor components include metal oxides
 Clays are highly malleable
 Can be shaped and molded when mixed with water
 Once formed or placed into molds, then they are
fired or kiln-dried
BRICK MASONRY

 Interior or exterior applications
 Durable against freeze/thaw cycles
 Durable against erosion by rainwater and wind
 Strength 6,000 - 10,000 psi
 Fire resistant
 High thermal mass
 Historic associations: permanence & stability
 Generally used as a façade material
 Non-loadbearing applications
BRICK MASONRY

ACH 122-Construction Technology 2ACH 122-Construction Technology 2
GREEN MATERIALS:
BRICK
 Brick can be recycled
 Material is pulverized and recycled with newer
content
 Recycled glass and other waste materials are
combined
 Materials have reduced:
 Firing times
 Temperatures
 Toxic emissions
 Improve brick strength & durability
 Waste into landfills
SOURCE: http://www.sustainablebuild.co.uk/brick-
manufacture-use-construction.html

GREEN MATERIALS:
BRICK
 Compressed Earth Blocks (CEB’s)
 Manufactured from soil that is more sand than
clay
 High energy efficient using up to 15 times less
energy than a fired brick
 Durable, ecological, economical
SOURCE: http://www.sustainablebuild.co.uk/brick-
manufacture-use-construction.html

GREEN MATERIALS:
BRICK
 “Green Brick”
 Made of fly-ash (by-product of coal-fired power
plants)
 Takes 90% less energy to manufacture, which
produces 90% less carbon emissions per “brick”
 Curing process with chemical catalysts vs. kiln firing
 Can be any color or texture as a traditional clay
brick
 Brick Industry Association does not recognize it as a
“brick”, but thinks it should be called a “fly-ash modular
unit”
SOURCE: http://www.greenharbor.org/2009/10/new-brick-coming-to-a-construction-site-
near-you/SOURCE:
http://business.timesonline.co.uk/tol/business/industry_sectors/construction_and_property/
icle6870177.ece

Brick Positions:
 Stretcher
 Header
 Soldier
 Shiner
 Rowlock
 Sailor
BRICK MASONRY
Terminology

 Course:
 Continuous layer of
masonry units,
bonded with mortar.
 One course is equal
to the thickness of
masonry unit plus
thickness of one
mortar joint
BRICK MASONRY
Terminology

 Wythe:
 Continuous vertical
section of masonry
 Single-wythe wall : In
section, wall one brick
wide
 Double-wythe wall : In
section, wall two
bricks wide
BRICK MASONRY
Terminology

 Head Joint
 Vertical mortar joint
between ends of
masonry units
 Bed Joint
 Horizontal layer of
mortar into which a
masonry unit is laid
BRICK MASONRY
Terminology

 Collar Joint
 Interior longitudinal
vertical joint
between two wythes
of masonry
BRICK MASONRY
Terminology

Bed
Joint
Head
Joint
Course - horizontal layer of brick
BRICK MASONRY

Header - Bonds two wythes together
Wythe: vertical layer 1 unit thick
Soldier - Laid on its end, face parallel
Rowlock -
laid on face,
end visible
Stretcher - long dimension horizontal
& face parallel to the wall
BRICK MASONRY

 Corbel
 Shelf or ledge formed by
projecting successive courses of
masonry out from the face of a
wall
BRICK MASONRY
Terminology

 Quion
 Stone blocks
used to form
strong corners.
 Now mostly used
for decorative
purposes (these
can be bricks,
concrete or stone)
BRICK MASONRY
Terminology

BRICK MASONRY
Terminology
 Rowlock Course

BRICK MASONRY
Manufacturing Process
http://www.youtube.com/watch?v=Ar1Rh3yYyno
http://www.glengerybrick.com/about/manufacturing/index.html
Refer to Figures 22.13 – 22.18 on page 553 - 554 in textbook

Four Important Qualities:
 Molding process
 Color (firing process)
 Size
 Type/Grade (specified by ASTM C-216)
Considerations in Choosing
Brick

 “Molded” or “Handmade”
 solid units
 pressed into fiberglass or
steel molds
 used to be by hand, now
machines
 sand or water coated
molds to release bricks
 usually rougher surface
and edges
Brick
Four Important Qualities
Molding Process

 “Extruded” or “Wire Cut”
 hollow core
 formed into a column and cut
to size with wires
 usually smoother surface
and finer edges
Brick
Molding Process

Wood Mold
Extruded – Wire Cut Extruded – Smooth
Extruded – Raked

Textures available for extruded brick

 Soft Mud:
 Oldest process
 Moist clay pressed into molds (hand or machine)
 20-30% water content
 Dry Press:
 Drying clay machine pressed into steel molds
 10% water content
 Used for molded bricks in steel molds by machine
 Stiff Mud:
 12-15% water content
 Extruded through a rectangular die
 Most common process used today
Brick
Molding Process

 Types of Kilns:
 PERIODIC:
 Loaded w/ bricks, fired, cooled, &
unloaded
 TUNNEL KILN:
 Bricks loaded onto a palette on
rails, slowly moved thru oven
Brick
Firing Process

 Brick Color dependent on:
 Composition of the clay
 Temperature & Chemistry of the kiln fire
Brick
Firing Process

 1st Stage: “Water Smoking/Dehydration”
 Drives off remaining moisture in clay
 2nd Stage: “Oxidation/Vitrification”
 Clay is transformed into a ceramic material
 (kiln temps of 2,400°)
 3rd Stage: “Flashing” (optional)
 Burners used to create color variations in the brick
 4th Stage: “Cooling”
 Slowly cooled under controlled conditions to avoid
thermal cracking
Brick
Firing Process

 No standard size
 Normal coursing - 3 bricks = 8”
 Larger sizes
 Custom Shapes & Colors
Brick
Size

 MODULAR
 STANDARD
 THREE-INCH
 OVERSIZE
 ROMAN
 NORMAN
 SIX-INCH JUMBO
 JUMBO UTILITY
Brick
Size: vary due to scale, texture and design

 Specified dimension
 Ideal final dimension of brick as specified by architect
 There will always be some variation
 Actual dimension
 Actual size of each individual brick
 Dimensional tolerance
 Difference between specified dimension and actual dimension
 Established by industry for each product
 Nominal dimension
 Includes specified dimension plus one mortar joint
 Written with no inch labels
Brick
Size: dimensions of masonry units

 Nominal 4 x 2-2/3 x 8
 Specified 3-5/8 in x 2-1/4 in x 7-5/8 in
Brick
Example: nominal vs. specified
dimensions
Sequencing masonry unit
dimensions:
Width X Height X Length

Brick
Figures 22.22
on page 557;
commonly used
brick sizes.

 Facing brick (solid or cored)
 Graded for dimensional tolerances & warpage, and
durability
 Building brick (solid or cored)
 Graded for durability and strength only
 Used in brick walls later covered with a veneer
 Exposed with dimensional tolerances and warpage acceptable
 Paving brick (solid)
 Graded for freeze/thaw resistance and abrasion
Brick
Grade

Weatherability: evaluates how the bricks will hold up to
weather exposure (freeze/thaw, rain, etc.)
MOST COMMON
Brick
Grade

Facing Bricks: evaluates the uniformity of shape,
dimension, texture & color
Brick
Grade

 Cavity (Veneer) Walls
 Running bond
BRICK BONDS
Running bond and arching action
in masonry walls

 Cavity (Veneer) Walls
 Stacked bond
BRICK BONDS

Joint Considerations
Size
Joint Tooling
Joint Profile
Color (blended or contrast)

BRICK JOINTS
 WEATHERED
 CONCAVE
 (best joint, mortar
compacted, shed water,
most popular)
 VEE
 FLUSH
 RAKED
 STRIPPED
 STRUCK

Mortar joint thickness (approx 3/8 inch) & profile

Tooling Joints

Concave Joints

“Modified” Vee Joints

“Grapevine” Joints

Flush Joints

Raked Joints

Laying Masonry
 Layout & Leads
 Line

Brick Masonry ‘Mosaic’

San Francisco Museum of Modern Art

Robie House, Chicago

Oriole Park at Camden Yards, Baltimore

Johnson Wax Building, Racine, Wisconsin

Meyerhoff Symphony Hall, Baltimore

MODULE #4
MASONRY
2
Terminology: Concrete Masonry
Unit
Manufacturing
CMU Wall Construction &
Installation
CONCRETE
MASONRY

 Modular system
 Larger unit than brick
 Dimensions related to
modular brick
 Wide variety of size and
color
 Lower labor cost than brick
 Also called concrete block
& cinder block
CONCRETE MASONRY UNITS

 Additional admixtures
 Cinders
 Pumice
 Lightweight aggregates
 Several shapes & forms
available

 Units that are precast from steel
molds
 Portland cement
 Fine aggregate
 Crushed stone or gravel
 Water
 Types of CMU
 Hollow concrete block
 Solid concrete block
 Concrete brick
 Split-face block

 Nominal Size
 8 inches high x 16 inches long
(standardized)
 Only depth (thickness) changes
 4”, 6”, 8” (most common), 10”, 12”
 Actual size
 3/8” less than nominal size in each
direction
 HEIGHT - 7 5/8”; LENGTH 15 5/8
 Compensating for mortar joint
 HEIGHT - 8” = 3 COURSES OF BRICK

GRADES, TYPES & WEIGHTS

 Hollow Core CMU
 Allow for insertion of reinforcing steel &
grout
 Cores - conducive for reinforcement
 Increases load bearing, resist cracking
 Widely used in construction
 Easily laid for wall construction
 More economical
 Larger size - less to lay for same area
 Lay similar to brick
 Used as a backup wythe for brick or
stone masonry
 Accepts plaster, stucco, tile
TYPES

Hollow Core CMU

Typical Shape Bond Beam for Lintels
Bond Beam Corner – Round & Square

CONCRETE MASONRY
LINTELS

 Decorative Units
 Variety of surfaces, shapes, textures & patterns
SURFACE FINISHES
 Split-face block
 Scored-face block
 Ribbed-face block
 Slump block
 Striated blocks
 Burnished blocks

Decorative CMUs
Splitface CMU

Splitface (colored) and Brick

Painted CMU with Split Face

Splitface CMU with Brick and Ceramic Tile

Splitface CMU with Special Shapes

Split-face units

Accent CMU
GLAZED FACING AND BURNISHED (GROUND) CMU

Burnished (Ground) Face

Ribbed units

MANUFACTURING PROCESS
 Zero-slump (dry) concrete mix formed in molds
to desired shape
 Mold removed immediately
 Green units stacked and cured for 24 hours in
warm, supersaturated air
 Stored in yard until shipped

DETAILED PROCESS:
 Raw materials are delivered to plant
 Materials are weighted and mixed
 Batch is molded into units
 Concrete is settled by vibration & pressure
 1000 units produced per hour
 Molded (green) units are placed on steel curing
racks
 Done manually or with automated rack loader
 Units are stable, but can be broken by hand

 Units are cured
 Low-pressure Steam Curing
 Done in a kiln
 Rapid strength gain in units
 Very common practice
 High Pressure Steam Curing
 Done under pressure 125 and 150 psi
 Expensive, not widely used
 Units are “cubed”, banded & delivered
 Stacked 6 layers of 15 to 18 blocks

LAYING THE WALL

Construction of a reinforced CMU wall laying block a two-handed operation
LAYING THE WALL

 Laying a masonry wall is same for
either brick or CMU, with some
differences.
 Concrete masonry is often
reinforced
 Increases bearing capacity
 Resist to cracking under loading
 Horizontal & vertical reinforcing
 Cells are filled with grout
LAYING THE WALL

Laying the Block, using a Lead Line

LAYING THE WALL
Lay block to string

Installation of the Mortar Bed

Laying the CMU on Mortar Bed

Tooled Joints

MODULE #4
MASONRY
3
History
Quarrying Process
Types of Rock
Bond Patterns of Stone Masonry
Installation
STONE MASONRY
Professor Brandi R. Shepard©

HISTORY OF STONE
 The “original” building material
 Used as tools in early times (before Black &
Decker)
 One of the hardest minerals on the planet
 Earliest stone masonry were chiseled and
cut to form uniform units

Masonry StructuresParthenon, Greece (5th Century,
BC)
marble

Examples of Stone Masonry
BuildingsTaj Mahal, Angra, India marble

QUARRYING/MILLING OF
STONE
 Cut into Blocks
 CHAIN SAWS, BELT SAWS w/ DIAMOND BLADES
 HARDER STONES (GRANITE) DRILL & BLAST
 Sawn into Slabs (THICKNESS DEPENDS ON
STONE)
 GRANITE - 3/8 to 3/4
 MARBLE - 3/4 & UP
 LIMESTONE - 2” & UP
 Slabs fabricated to desired size and
finish

QUARRYING/MILLING OF
STONE
 Cost-Varies ($35 -100/sf)
 Lead Time
 SELECT QUARRY & STONE BLOCKS
 SHOP DRAWINGS
 CUT, POLISH, etc.
 SHIP & CUSTOMS
 2-4 MONTHS

Diamond belt saw
divides limestone
bedrock into long
cuts
QUARRYING PROCESS

QUARRYING PROCESS
Rubber air bags are
inflated to “turn the
cut”
Steel wedges are
driven to split
blocks

Front-end loader
removes blocks
and prepares them
for transport to the
mill
QUARRYING PROCESS

QUARRYING PROCESS

QUARRYING PROCESS
Stone Quarry in Revere, MA (outside of
Boston)

TYPES OF
ROCK
 Igneous (Magmatic)
 Rock deposited in a molted state & cooled
 Strongest and most dense stone, weathers
slowly
 Granular
 Fusion of feldspar, quartz and mica
 Color varies with composition of minerals
 Takes a good polish
IGNEOUS

SEDIMENTAR
Y

METAMORPHIC

 Sedimentary
 Rock deposited by glacial action of water and
wind
 Formed under water
 Reacts with acids causing stains
 Softer than marble or granite
 Relatively easy to quarry, saw and shape
 Reacts with acids causing stains
 Does not take a polished finish
TYPES OF
ROCKIGNEOUS

SEDIMENTAR
Y

METAMORPHIC

 Metamorphic
 Igneous or sedimentary rock that has been
transformed by heat & pressure
 Softer, more wear & breakage
 Stronger and denser than limestone, weaker than
granite
 Varied surface appearance: veiny, mottled or
without pattern
 Vulnerable to acid attack
TYPES OF
ROCKIGNEOUS

SEDIMENTAR
Y

METAMORPHIC

 Composed of mica,
feldspar & quartz
 Very hard (strongest
among common stones)
 Non-porous, strong,
durable
 Colors in black, gray,
purple, blue, green & red
 Quarried in VT, VA, NY &
PA
TYPES OF IGNEOUS ROCK
GRANITE

 Surface Textures
 POLISHED TO ROUGH
 Sources
 US - East and Upper
Midwest, Texas
 EUROPE (Italy & Spain),
Other
 COST (thickness, size, finish)
 Primary Uses
 EXTERIOR BUILDING
CLADDING
 DECORATIVE WALLS &
TYPES OF IGNEOUS ROCK
GRANITE

Polished Surface
Rough Texture

Texture Variations (Note the effect on appearances)

Shape: Flat to Round

Interior Uses: Floors and Walls

Interior Uses: Countertops (Venetian Gold Granite)

Interior Uses: Countertops (Tropical Green)

Exterior Application

World Financial Center, New YorkGranite & Glass
Cladding
Buildings

 Porous: contains
ground water “quartz
sap” that must be
dried out
 Can not accept a
polish
TYPES OF SEDIMENTARY
ROCK
LIMESTONE, SANDSTONE,
TRAVERTINE

 Sandstone
 mostly calcium &
magnesium
 Brownstone & Bluestone
 Quarried in NY, OH, PA
 Travertine
 looks like marble but is richly
pattern limestone
ROCK
TRAVERTINE

 Limestone
 Composed of calcium &
magnesium
(calcium carbonate)
 Porous, relatively weak
 absorbs water
 cut in thicker slabs
 Fine grain
 Sometimes possesses
fossil materials (little
shells)
ROCK
TRAVERTINE

 Color Range
 WHITE TO GRAY
 BUFF TO IRON OXIDE
WHITE TO GRAY
 BUFF TO IRON OXIDE
 Surface Textures
 ROUGH
ROCK
TRAVERTINE
 Sources
 MISSOURI
 INDIANA
 EUROPE
 Primary Uses
 EXTERIOR CLADDING
 DECORATIVE WALLS
(NOT FLOORS)

Limestone with Granite

Limestone Gardiner Museum,
Toronto

Limestone
http://www.archdaily.com/10044/gardiner-museum-renewal-kpmb-
Gardiner Museum,
Toronto

Simulated Limestone Cladding

Examples of Sandstone Veneers

BuildingsEast Wing of the National Gallery of Art, Washington, DC limestone

The Getty Center Museum, Los
Angeles
Split-face travertine
Buildings

 Re-crystallized form of
limestone
 Easily carved and polished
 Colors in white, black
 Quarried in AL, TN, VT,
GA, MO & Canada
TYPES OF METAMOPHIC
ROCK
MARBLE, SLATE

 Granular aggregate of crystals
 Calcite and dolomite
 The “veins” are a product of sediment differences
in color and size of the crystals
 Can be polished to a high gloss
 Comes in several different color combinations
 Quarried in the Mediterranean basin
 Italy, Greece, Turkey and Spain
TYPES OF METAMORPHIC
ROCK
MARBLE

ROCK
MARBLE

ROCK
MARBLE SLABS

Exterior Application: Marble

Interior Application: Marble Flooring

Exterior Application: Marble
Intricate exterior marble and mosaic stone archway outside of Hassan II Mosque in Casablanca, Morocco.
Marble columns supporting the pediment of the Memorial Amphitheater, Arlington National Cemetery

 Fine-grained and flakey stone
 But very tough and dense
 Weather tolerant
 Is not effected by changing freeze-thaw temps; will not warp or
delaminate
 Color is commonly muted grays and greens
 quarried in England and Wales
 Reds and purple slates are unusual colors
 Mined in Slate Valley in Vermont & New York
 Most common applications are floors and roofs
 Also used for countertops, stair treads, fireplace surround & wall
cladding
 Exterior applications include signs, plates, memorials, pavers
ROCK
SLATE

Exterior Application: Slate Roofing

Interior Application: Slate Flooring

Interior Application: Slate Shower Surround & Flooring

Exterior Application: Slate Pool Surround

 Fieldstone
 Rubble Stone
 Dimension Stone
Bond Patterns in Stone
Masonry

Masonry
 RUBBLE
 Random non-rectilinear shapes
 Rounded, river-washed stones
 Laid like brick, mason must carefully select stone
pieces
 Can be laid RANDOM

Masonry
 RUBBLE
 Random non-rectilinear shapes
 Laid like brick, mason must carefully select stone
pieces
or COURSED

Bond Pattern: RANDOM RUBBLE

Masonry
 ASHLAR
 Rectilinear shapes with continuous horizontal mortar joints
 Very similar to brickwork
 Mortar joints are raked to prevent uneven settlement

Masonry
 ASHLAR
 Rectilinear shapes with continuous horizontal mortar joints
 Very similar to brickwork
 Mortar joints are raked to prevent uneven settlement
 Can be laid RANDOMor COURSED

 Similarities:
 Both stacked
 Mortar Joints
 Differences:
 Shape:
 Brick is molded
 Stone is Cut and Carved
 Physical Properties:
 Brick is made/controlled
 Stone is provided by nature
INSTALLATION
STONE vs BRICK

 Laid in Mortar
(like bricks)
OR
 Mechanically
fastened in large
sheets to a support
system
INSTALLATION
STONE vs BRICK

Installation: Stone Mechanically Fastened

SUSTAINABILITY of
MASONRY MATERIALS
 Local production
 Reusability
 Recyclability
 No VOC emissions
 Thermal mass can be used to conserve
energy
 Mining raw materials causes soil erosion
and habitat loss
 Quarry pits can be reclaimed as lakes

Resources
Stone Sampler
By: Studio Marmo (Text by Marco Campagna)
Publisher: W.W. Norton & Company, 2003
Stone Style
By: Michael Reis and Jennifer Adams
Publisher: Gibbs Smith, 2002
In Chapter 25, review section on Glass Masonry Units
(GMU)

ACH 122 Lecture 05a (Brick Masonry)

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Editor's Notes