M asonry M aterials. Components of Masonry Masonry Units Mortar Grout Reinforcement Anchors / Ties...
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Transcript of 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.
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
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.
www.GlenGerybrick.com
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
Clay Unit (brick) Options
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.
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
www.GlenGerybrick.com
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.
Clay Unit (brick) Options
www.GlenGerybrick.com
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
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
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.
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
Compressive Strength
of Masonry
1250 1300 1000
1900 2150 1500
2800 3050 2000
3750 4050 2500
4800 5250 3000
Required Net Area
Compressive Strength
of CMU with…
Type M/S Type N
MortarMortar
To Satisfy Compliance
with this Specified
Compressive Strength
of Masonry
1250 1300 1000
1900 2150 1500
2800 3050 2000
3750 4050 2500
4800 5250 3000
Required Net Area
Compressive Strength
of CMU with…
Type M/S Type N
MortarMortar
To Satisfy Compliance
with this Specified
Compressive Strength
of Masonry
1250 1300 1000
1900 2150 1500
???? ???? 1750
2800 3050 2000
3750 4050 2500
4800 5250 3000
Required Net Area
Compressive Strength
of CMU with…
Type M/S Type N
MortarMortar
To Satisfy Compliance
with this Specified
Compressive Strength
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
Same as in structure
Same as in structure
Stack Bond
Importance of Construction
Importance ofCuring
Masonry
Materials
Questions ?????