MasonryMajor TopicsTopics con’tHistoryMasonry DefinedMortarMortar and Grout PropertiesMortar TypesMortar Properties/Function:Mortar Basics:Mortar Joints:Types of JointsGroutBrickSolid vs. With HolesClasses of BrickBrick KilnsBrick Types/SizesFace BrickGlazed Face MasonryFire Masonry (Brick)Paving MasonryNominal vs. Actual SizeMasonry Bond:Slide 25Slide 26Slide 27Examples of MasonryMasonry Walls (See Fig. 4.6-1, pg 184)Brick Walls con’tTiesSlide 32Structural Clay TileStructural Clay TilesConcrete Masonry Unit (CMU)CMU TypesCMU Screen UnitsSurface Bonding (BlockBond)Gypsum BlockGlass BlockGlass Block con’tSlide 42Slide 43Stone ClassificationStone- General InformationStones & UsesExamples of StoneStone MasonrySlide 49Masonry RestorationMasonry CleaningReferences1Masonry2Major TopicsHistoryMortarGroutBrickTypesBondJointsStructural Clay TileConcrete Block (CMU)3Topics con’tGypsum BlockGlass BlockStoneStone Masonry4HistoryOne of the oldest manufactured building materialsSun-baked brick was found in the remains of structures in the Tigres-Euphrates basin as early as 6000 B.C.Romans also used thin bricks in thick mortar made of volcanic materials and lime.1633 – 1st brick buildings erected in Manhattan Island (imported from Holland & England)5Masonry DefinedAn assembly or combination of small building units made of clay, shale, concrete, glass, gypsum, or stone that are set in mortar. Masonry consists entirely or partially of hollow or solid units laid contiguously in mortar.6MortarMust conform to ASTM C2704 basic types of mortar used: M, S, N, OComposed of: portland cement, hydrated lime, sand, and waterKey to forming a strong and durable bond with masonry units7Mortar and Grout PropertiesPlasticWorkability –uniform, cohesiveWater Retention - prevents bleedingHardeningBond Strength – very importantDurability –resist water penetrationCompressive Strength –depends on amount of portland cement in mixWatertightness –fine cracks mostly in vertical jointsColor8Mortar TypesTypeAvg Compressive StrengthUseM2500 psiMasonry below grade and in contact with earthS1800 psiWhere maximum flexural strength is required (winds >80 mph)N750 psiGeneral use in exposed masonry above grade; parapets, chimneys, and ext. walls subjected to severe weatheringO350 psiSolid unit load-bearing walls Where compressive strength < 100 psi9Mortar Properties/Function:Have a tendency to shrink very littleHave a high degree of resistance to moisture penetrationPossess adequate strength to resist the forces applied to itProvide aesthetic qualities to the structure through the use of color and type of joint10Mortar Basics:Brick masonry mortar made of portland cement, hydrated lime, and sand (stone masonry uses white portland cement [nonstaining].Retempering – adding water to the mortar mix to maintain consistencyMortar mix should be used within 2 – 2 ½ hours after initial mix is preparedEfflorescence – the soft white powder appearing on the face of brick; caused by salts in the brick or mortar brought to the surface11Mortar Joints:Joint sizes varyFacing brick – 3/8” to ½”Building brick – ½”Glazed brick – 1/4 “Although many types of joints exist (see Fig. 4-7-45, pg 216), the most weatherproof & recommended are: V-shaped, Weathered, & ConcaveJoints may be formed by using a trowel, tooled, or sealant filled.12Types of Joints13GroutThe water/cement ratio is less critical in grout than in mortar or concreteIt is intended to be very “fluid” in order to function in it’s “binding” capacity (slump of 8-11 inches)May be used to fill cavities between masonry walls (often around vertical reinforcement )14BrickMay be solid or hollow core (holes called “cells”)Cells should not exceed 25 % of the volume of the unitBricks vary in size, color, shape, and texture.15Solid vs. With HolesSolid brick used where holes may be unsightly (steps or window sills)Holes in Brick:Help units fire properlyPromote bonding with mortarReduce overall weightMake units easier to handle16Classes of BrickAdobe – sun-dried clays and a binderKiln-burned – natural sand and clay or shale (most widely used)Sand-lime – pearl-grey in color, dolomite lime is mixed with clean sand, pressed, and allowed to harden in closed vessels under steam pressureConcrete – portland cement and suitable aggregate, formed in molds17Brick KilnsBurning of brick is done in 4 stagesWater smoking: 400 °FDehydration: 300 -1800 °FOxidation: 1000 – 1800 °FVitrification: 1600 – 2400 °FFlashing (oxygen reduction)– produces different colors or color shadingCooling down – done in 2-3 days; rate of cooling will affect cracking, and color18Brick Types/SizesCommon (now called Building)Most widely usedDark orange to deep red colorMany finishes & sizes availableGrading criteria:SW – severe weathering for exposure to heavy rainfall & freezingMW – moderate weathering for avg. moisture and minor freezingNW – Negligible weathering for exposure to moisture & freezing19Face BrickMade from clay, shale, fire clay, or a mixture, under controlled conditionsMeets ASTM C216 standardAppearance types:FBS- general use in exposed & interior walls where wide color ranges & variation in sizes are permittedFBX- used in exterior & interior walls where a high degree of mechanical perfection, narrow color range & little variation of size is requiredFBA- nonconformity in size, color, & texture20Glazed Face MasonryUnits sprayed with a ceramic glaze and fired at high temperature to fuse glaze to the brickFinishes may appear dull, satin, or glossy21Fire Masonry (Brick)Made of clays with a large amount of alumina, silica, flint, and feldsparThese masonry units are used in fireplaces, chimney stacks, incinerators, and many industrial settings22Paving MasonryUnits are burned at much higher temperatures to make them resist water and wear from traffic23Nominal vs. Actual SizeUnit Nominal Dimension (in.) W x H x DActual Dimension (in.) ** W x H x DModular 4 x 2 2/3 x 8 3 5/8 x 2 ¼ x 7 5/8Utility 4 x 4 x 12 3 5/8 x 3 5/8 x 11 5/8** Note: actual dimensions may vary among manufacturers of brick – dimensions noted from Graphics Standards 2000 publication24Masonry Bond:Bond – the