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Brick Masonry Definition, Types, and Construction

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Contents:

  • Brick Masonry Definition
  • Types of Brick Masonry Work
    • 1. Brick Work in Mud
    • 2. Brick Work in Cement
  • Types of Bricks
  • Brick Masonry Construction
    • Materials and Equipment Used in Brick Masonry Construction 
    • Brick Masonry Construction Preparations
    • Brick Masonry Construction Procedure
    • Points Considered in Supervising Brick Masonry Constructions

Brick Masonry Definition

Brick masonry is a highly durable form of construction. It is built by placing bricks in mortar in a systematic manner to construct solid mass that withstand exerted loads. There are several types of bricks and number of mortars which  can be used to construct brick masonry.
The bond in brick masonry, which adheres bricks together, is produced by filling joints between bricks with suitable mortar. Special cautions shall be practiced while mortar is mixed and placed since it greatly affect the performance and durability of masonry structure.

Types of Brick Masonry Work

1. Brick Work in Mud

  • The mud is used to fill up various joints brick masonry work.
  • Thickness of the mortar joint is 12 mm.
  • it is the cheapest type of brick masonry
  • employed for construction of walls with maximum height of 4 m.

Fig. 1: Brick work in mud

2. Brick Work in Cement

This type of brick masonry is construction by laying bricks in cement mortar rather than mud which is used in brick work in mud. There are three major classes of brick work in cement which are summarized in Table 1.
Table 1 Different classes of brick work in cement and their descriptions

Classes Descriptions
First Class
  1. Cement of lime mortar is used,
  2. The surface and edges of bricks are sharp,
  3. And the thickness of mortar joints doesn’t exceed 10mm
Second Class
  1. Ground moulded bricks are used,
  2. Bricks are rough and shape is slightly irregular,
  3. The thickness of mortar joint is 12 mm.
Third Class
  1. Bricks are not hard ,rough surface with distorted shape,
  2. Used for temporary structures,
  3. Used in places where rainfall is not heavy.

Fig. 2: Brick work in cement

Types of Bricks

There are different types of brick used in the construction of brick masonry which include:

  1. Common Burnt Clay Bricks
  2. Concrete Bricks
  3. Sand Lime Bricks (Calcium Silicate Bricks)
  4. Fly ash Clay Bricks
  5. Engineering Bricks
  6. Other Brick Types include bullnose, channel, coping, cownose and hollow bricks.

Fig. 3: Types of masonry bricks

Brick Masonry Construction

Materials and Equipment Used in Brick Masonry Construction 

  1. Mortar Mix or Mason Mix Bricks
  2. Tape measure
  3.  hammer
  4. Hose, level, or theodolite
  5. Trowel Level
  6. Wheelbarrow
  7. Goggles
  8. Jointer
  9.  And other equipment according to project ans personal preferences

Brick Masonry Construction Preparations

  1. Check the level of the ground using level, theodolite or transparent hose level.
  2. Set the layout of the structure.

    Fig. 4: Setting out layout of masonry structure

  3. Trace of building axis and wall alignment using gypsum powder, chalk, or similar, marking the trenches for foundation.
  4. After that,install foundation wall, cure foundation for minimum two days before beginning of brick masonry construction.
  5. Distribute bricks in several stacks along project site to cut time and effort later.
  6. Wet bricks few hours prior to the work. Not only does this avoid absorbing too much water from mortar but also improve adherence of bricks and mortar.

Brick Masonry Construction Procedure

  1. Initially, mix the mortar with water and blend it until a smooth and plastic mortar is produced.

    Fig. 5: Mortar Preparation

  2. After that, place the mortar on foundation line evenly using trowel (25mm thickness and one brick wide is recommended for laid mortar).
  3. Then, lay the first course of stretcher bricks in the mortar. Start with second brick, apply mortar to the head joint end of each brick, After that shove the bricks into place firmly so that the mortar is squeezed out of all side of the joints.

    Fig. 6: laying bricks

  4. Utilize a level to examine the course for correct height. ensure that bricks are plumb and level.

    Fig. 7: Plumb line of brick masonry

    Fig. 8: Checking level of brick masonry

  5. Place another mortar line alongside the first course, then begin laying the second course.
  6. Use the two half bricks to begin the second to ensure that the first two courses are staggered for structural purposes.
  7. To finish the second course of the lead, lay three header bricks and make sure that they are plumb and level.
  8. The third and fifth courses consists of stretchers similar to the first course. The fourth course begins with single header, followed by stretchers. Use the level to make sure that the lead is true on each course. Lastly, this pattern of brick laying is used till the target height is reached.

Points Considered in Supervising Brick Masonry Constructions

The following points should be observed in the construction of brick masonry:

  • Use good quality bricks.
  • Ensure that brick courses are perfectly horizontal.
  • Verticality of the wall should be ensured by frequently checking with plumb-bob.
  • Whenever work is stopped brick masonry should be left with toothed end.
  • Use of brick bats should be avoided.
  • Raising walls by more than 1.5 m in one day shall be prevented.
  • Raise face joints to a depth of 12 to 20mm so as to be used as a key for plastering or pointing.
  • Brick masonry should be regularly cured for 2 weeks.
  • The thickness of mortar joints shall be 10 mm both horizontally and vertically.

Fig. 9: Brick bat

Read more:
Tolerances and Workmanship for Reinforced Masonry Construction as per ACIChecklist for Masonry Wall Construction

What is Masonry Wall? 5 Types of Masonry Wall

The work of Constructing Buildings is one kind of art. Thus, there is a linear relationship between construction and building materials. Today’s modern housing associations, architectures, and engineers are concerned about ‘masonry walls’.

Masonry together with wood is considered one of the most important building materials in the History of humankind. It has been used as the construction material for several thousand years and still it is used. In the last decades, other materials like steel and concrete have been used frequently and thus replacing masonry as a structural material. This situation is present and particularly remarkable all over the countries, where almost all new buildings are constructed using reinforced concrete.

Masonry has been mostly used as a non-structural material, as an infill of reinforced concrete and steel frames. Therefore, a question must arise in our mind – what is it? How does it work or what to do with is this? Let us dig into this explanation:

The Masonry Basics

Masonry is a term used to indicate the part of the construction that uses brick, concrete blocks, structural clay tile, and stone. These materials are held together with mortar. Mortar for masonry is not cement mix, the material used for sidewalks, patios, or driveways. The mortar mix contains lime, sand, and gypsum, each in the proper proportions. Cement mix, on the other hand, has stones in the sand and does not contain lime.

What are Masonry Walls?

Masonry walls are the most durable part of any building or structure. Masonry is the word utilized for development with mortar as a coupling material with singular units of blocks, stones, marbles, rocks, solid squares, tiles, and so forth. Mortar is a blend of restricting material with sand. Restricting materials can be concrete, lime, soil, or any other constructing materials.

Professionals do the Masonry projects and the unit works for various purposes. Some works for building constructions, some makes barriers for boundaries to separate property line and some make house wall for structural used.

Types of Masonry Wall

Masonry walls render strengths, lastingness to the structure, and help to maintain indoor and outdoor temperature as well as keeps protect the buildings from the outside world. Depending on the motor mix materials, there are various types of Masonry Walls used in building constructions.

Types or Categories:

  1. Load-bearing masonry wall
  2. Reinforced masonry wall
  3. Hollow/Cavity masonry wall
  4. Composite masonry wall
  5. Post-tensioned masonry wall

Brief descriptions of these masonry wall types are given below.

1. Load-bearing Masonry Wall

Based on load-bearing walls could be Load Bearing and Non-load Bearing walls.

A load-bearing wall is a wall that bears a load reposing upon it, which depends on weight construction and the work of foundation structure. Usually, this type of wall is used for large buildings. e.g. housing or tall buildings construction work. It is mainly made with brick, concrete blocks, or stone. The load-bearing wall helps to transfer weight from the root to the foundation. This type of wall depends on the types of buildings and their number of stories that are assessed to a suitable thickness to bear the weight above them. Without this wall, there is a chance for instability in walls’ foundation works. Another, this type of wall can also be exterior and interior. Load-bearing walls are flexible because it is easy to spend a little amount of money than other types of walls, as it is the traditional framed structure of constructing buildings. The load-bearing walls can be reinforced or unreinforced masonry walls.

Non-load bearing walls that are only intended to support themselves and the weight of the cladding or sheathings attached. This kind of walls provides no structural support and maybe interior or exterior walls

2. Reinforced Masonry Wall

A reinforced masonry wall is made with any type of brick, concrete, or other types of masonry materials that strengthened the use of other building’s materials to increase resistance to deterioration due to weight-bearing or other forms of stress. This type of wall could be non-load-bearing or load-bearing. One of the common examples of masonry involves exterior walls that are created using concrete blocks or clay bricks. Along with these materials, steel rods are works into the structure, often using some type of vertical framework that allows bearing the weight of connecting walls and floors within the building. The use of this type of wall helps it to resist pressure forces and heavy compression loads. During an earthquake or failure under heavy compression loads, the unreinforced walls could be crack horizontally. The purpose of this type of wall protects the walls from cracks and makes the strength to fight against unexpected earthquakes or other kinds of natural disasters. To defeat these problems, reinforced walls are used; and their quantity and spacing are based on walls and structure conditions. Reinforcement can be used both in horizontal and vertical order at a required layoff.

Depending on which materials are used, and how they are located, reinforced masonry (RM) walls can be divided into the following categories:

  • Confined Masonry
  • Reinforced Cavity Masonry
  • Reinforced solid Masonry
  • Reinforced hollow unit Masonry
  • Reinforced grouted Masonry
  • Reinforced pocket type Walls

3.

Hollow/Cavity Masonry Wall

Hollow masonry walls are made with cement blocks. This type of masonry wall is used to stop dampness from getting inside the building. It creates a hollow area between the outside and inside of masonry walls. Cavity walls will also assist with climate control. Modern masonry walls are constructed from hollow masonry units or combined hollow and solid masonry units.

Solid walls are systematically certified by metal ties, masonry investments, or collective reinforcement.

4. Composite Masonry Walls

Composite Masonry walls are made with the combination of two or more building materials; stones and bricks or hollow bricks and bricks. The purpose of this type of wall construction is –reduce the overall cost of construction and make the structure durable by providing materials of better quality and good workmanship in the faces. Composite masonry walls work to improve the appearance of a structure by covering up the inferior works by the use of superior quality material in the desired positions. This type of wall is better because it is cost-effective and optically appealing.

Types of Composite Masonry walls:

  • Brick Backed Ashlar
  • Brick facing with Rubble or Concrete Backing
  • Stone facing with Brick, Rubble, or concrete Backing

5. Post-tensioned Masonry Wall

Post-tensioning provides an additional axial load to masonry structures and thus increases resistance to lateral force. This type of wall has over their conventionally reinforced equivalents, such as increased in-plane strength and the absence of residual post-earthquake wall displacements. Post-tensioning now is used extensively in bridges, elevated slabs (parking structures and residential or commercial buildings), residential foundations, walls, and columns. Designers commonly take advantage of this method to produce buildings and structures with clear open spaces allowing more architectural freedom.

Brick Calculator with Mortar

Created by Mateusz Mucha and Kenneth Alambra

Reviewed by Bogna Szyk and Jack Bowater

Last updated: Jun 20, 2022

Table of contents:

  • How many bricks do I need for my brick wall?
  • How do I use the brick calculator?
  • Using the brick mortar calculator feature
  • Other considerations
  • FAQ

If you are going to start construction work and you want to optimize your costs, this brick calculator is your new best friend. This brick wall calculator will help you estimate how many bricks you need to cover a particular wall surface. Together with this tool is the brick mortar calculator, which will also enable you to order the other materials you will need, like cement and sand for your mortar.

Keep on reading to learn how the brick calculator works and how you can use it to accurately estimate how many bricks and how much mortar you will need for your project.

How many bricks do I need for my brick wall?

If you are wondering how many bricks you do need, it’s always better to calculate it than to guess it. Otherwise, in all probability, you’ll either run out of them, or you’ll have too many left.

The first step you can do to determine the number of bricks you will use is to consider the surface you want to cover with them. To do it by yourself, you have to calculate:

  • The area that a single brick covers;
  • The size of the mortar joint; and
  • The area of the wall.

You can work out how many bricks you need using this simple equation:

bricks needed = (L * H) / ((l + t) * (h + t)),

where:

  • L – Length of the wall;
  • H – Height of the wall;
  • l – Length of a brick;
  • t – Thickness of mortar joint; and
  • h – Height of a brick.

Our brick calculator will help you estimate how many bricks you need. There is also a function that counts the wastage, which means the percentage of the bricks that can be destroyed or written-off. As a result, the brick calculator provides you with two numbers. The first one tells how many bricks you will need to build a wall of particular dimensions, while the second one shows how many bricks you need when considering the inevitable wastage.

How do I use the brick calculator?

Using our brick calculator is very easy. All you have to do is key in the values needed, and our brick wall calculator will display the results right away. Here are the steps you can follow:

  1. Enter the dimensions of the brick you wish to use.
  2. Input your desired mortar joint thickness.
  3. Type in the brick wall’s length and height or its total area.
  4. Select the wall type you plan to build – either a brick wall with a single stack or a stack. Double-wall is what you want if you plan to build a brick wall sandwich with insulation in between the layers.
  5. With the above measurements, you will already know how many bricks you need. Enter a wastage percentage to know how many bricks to order.

Using the brick mortar calculator feature

The brick wall calculator is a useful tool for every builder, no matter their level of experience. This tool makes it easy to estimate how many bricks and mortar materials you need to finish a particular job. With the brick mortar calculator feature, you can avoid buying too much or too little of the materials you need, saving your time and money.

Imagine the effort you’ll save if you avoid paying for excess and having to deal with the delay and hassle that comes with needing to reorder. There are, of course, many different ways to estimate the number you need, but the more accurate the estimation is, the better it is for you.

Here are the steps on how to expand this tool to become a brick mortar calculator:

  1. Answer Yes to the question: Want to see the materials for your mortar?.
  2. If you have already worked out the number of bricks needed, you will instantly see the volume of the mortar needed. Enter your probable wastage percentage to find out how much dry volume of materials you need.
  3. Choose your desired mortar mix ratio. Select one that best suits your needs.
  4. You will then see thequantities of cement and sand you need.
  5. Input the size of an available cement bag on the market to find out how many bags you have to buy.

Other considerations

If you’re involved in interior decorating and need to know how many tiles you need to cover a wall or room, you’ll be better off using our dedicated tile calculator that works together with our grout calculator. You can also estimate the usage of other building materials; if you want to plan how much cement you will need to buy when redoing your garden, check out our concrete calculator.

FAQ

How many bricks per square foot of brick wall?

A brick wall needs approximately 5 bricks per square foot with the standard 7.5″ x 3.5″ bricks. We also need the same number of bricks per square foot with the standard size of 9.5″ x 2.75″ bricks. The larger the bricks are, the fewer bricks we need to cover a square foot.

How do I calculate the bricks I need?

  1. Decide on the mortar thickness you want to use and add it to the length of your brick.
  2. Add the mortar thickness to the height of your brick.
  3. Multiply these sums together to get the area of a brick with mortar on one side and its bottom.
  4. Divide your wall area by the product you got from step 3 to find your needed brick quantity.

How do I build a brick wall?

  1. After obtaining the needed materials, make sure you have a level surface to begin with.
  2. Apply a “Toblerone”-shaped mortar to the leveled surface for the entire length of the wall.
  3. Start laying bricks from one corner while applying mortar between two adjacent bricks.
  4. Once you finished the entire length of the wall, repeat step two, considering the top surface of the first layer as the new leveled surface.

How many bricks will I need to build a wall?

You will need approximately 38 bricks per foot length for an 8-foot wall if the bricks are the standard 7.5″ x 3.5″ bricks or 9.5″ x 2.75″ bricks with ²/₅” thick mortar joints. However, larger bricks take up a larger area, and means fewer bricks overall.

How much cement do I need for 1000 bricks?

You need approximately 120 kg (263 lbs) of cement for 1000 pieces of standard 9.5″ x 2.75″ bricks. Additionally, you will need around 0.4 cubic meters (0.54 cubic yards) of sand to mix with your cement to make a 1:5 mortar mix for your brick wall.

Mateusz Mucha and Kenneth Alambra

Wall details

Brick length (l)

Brick height (h)

Brick width (w)

Mortar joint thickness (t)

Wall length (L)

Wall height (H)

Wall area

Type of wall

You can also check our concrete column calculator if you also plan to build concrete columns as framing for your wall. 🙂

Bricks required

Bricks needed

1

Brick wastage

Total bricks needed

2

Want to see the materials for your mortar?

Cost of materials

Price per brick

$

Cost of bricks

$

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Masonry Construction: Advantages and Disadvantages

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Masonry consists of building structures from single units that are laid and bound together with mortar. Brick, stone and concrete blocks are the most common materials used in masonry construction.

Masonry is a popular construction technique around the world, due to its many advantages. However, like with any construction method, there are also limitations. This article summarizes the pros and cons of masonry construction.


Reduce material and labor costs with professional design and project management services.


Advantages of Masonry Construction

These general advantages apply for all types of masonry units (brick, stone or concrete blocks):

  • Masonry is non-combustible, so improves fire protection for the building and its occupants. Fireplaces are commonly made of masonry for the same reason.
  • Masonry offers a high resistance against rotting, pests, weather, and natural disasters such as hurricanes and tornadoes.
  • Masonry structures provide an attractive rustic or elegant look for a home or building, depending on the material used and the workers’ expertise.
  • Being durable and resistant, mansory can withstand large amounts of compressive weight loads.
  • Masonry units increase the thermal mass of a building.
  • Masonry buildings have longer lifespans than any other building type.
  • Using masonry in your construction improves its resale value.
  • Masonry doesn’t rot, and insects such as ants and termites can’t destroy its structure.
  • Using this method in construction costs less in terms of labor and materials as compared to using wood.

 

Masonry is arguably the best way to add grandeur and beauty to any construction. Additionally, there are various projects to do, which will provide an excellent upgrade to your home and then make you wonder: ‘are there masons near me?’ Whether you’re planning to use stone, brick, or concrete masonry, ensure that you choose a team carefully to achieve your plans.

Limitations of Masonry Construction

  • Masonry construction involves heavy materials such as bricks, stone and concrete blocks. These cannot be transported in conventional vehicles, and in some cases they must be ordered from special catalogs, especially stones.
  • The stability of masonry structures depends completely on their foundation. If any settling of the foundation occurs, cracks are likely and they must be repaired to prevent moisture infiltration and damage.
  • Masonry activities cannot be done during heavy rain or freezing conditions, since mortar will be severely affected.
  • Masonry construction requires a good amount of time and adequate project planning. Depending on the type or masonry, specialized manpower may be necessary.

Now that the general advantages and disadvantages of masonry have been established, let’s discuss the pros and cons of the most commonly used materials: brick, stone and concrete blocks.

Brick Masonry

Pros: Brick masonry does not require highly skilled labor, since the shape and size of the masonry units is uniform. Bricks are also lightweight (lower dead loads), easy to handle and transport, and cheaper that stones and concrete blocks. Brick walls are thinner, and units can be adhered with different types of mortar, depending on structural requirements. Openings for doors and windows are easily made with bricks, and costs are also reduced because the joints are thinner.

Cons: Bricks have a low resistance against tension and torsion loads, making them more susceptible to seismic damage. Compared with stone and concrete blocks, bricks are also less strong and durable, and limited in sizes and colors. Plasterwork is required as finishing, which raises construction costs.

Stone Masonry

Pros: Stone masonry is the most durable, strong and weather resistant, thanks to the natural durability of the material. Stone is recommended for buildings with high foot traffic, since it does not bend or dent. One of the main advantages of stone is its aesthetic look, with a variety of colors, sizes and textures – the design possibilities are endless. Finally, stone masonry requires little maintenance and repairs, thanks to its durability.

Cons: Stone walls are thick and heavy, reducing floor space. It also has a high self-weight, combined with low flexural strength, tensile strength and seismic resistance. Stone masonry is time-consuming and it requires skilled workers, since it cannot be altered, repaired or relocate easily. When using stone masonry, a careful installation will make the final structure safer for occupants.

Concrete Block Masonry

Pros: Concrete blocks are resistant against weather, pests, mold, and fire. Transporting concrete blocks can be quite expensive, but this material can be found locally in most cases. Concrete blocks are available in many sizes, finishes and colors. These units can also be manufactured to meet any set project requirements, and some concrete blocks are made using recycled materials. In addition, concrete blocks have good insulating properties against heat, sound and moisture.

Cons: Large concrete blocks are heavy and difficult to handle, requiring more manpower. Concrete blocks also increase the amount of steel required in reinforced cement concrete structures. The price of concrete blocks can vary depending on the region, cement costs and availability. Plumbing issues are harder to solve when they occur in a concrete masonry structure, since they can cause internal flooding. Concrete blocks must be cut open in this case, leading to material waste and expensive reparations. An effective drainage system is very important when dealing with concrete block masonry.

Final Thoughts-

The construction industry has introduced numerous methods of building construction. These techniques have undergone several improvements, which have paved the way for enhanced durability and minimized maintenance efforts. One of the most popular methods of construction used in building homes and high-rise and heavy buildings is masonry.

Masonry has its pros and cons as discussed above. In this method, you’ll need a professional team that’s committed to achieving your plans. Masonry work involves time, complete planning, and discussion. While it has its own share of disadvantages, it’s still considered the most reliable and durable method of construction.

Nearby EngineersNew York Engineers has a MEP design track record of 1,000+ projects. Contact us via email ([email protected]) or phone (646-877-0767212-575-5300), and make sure your building systems meet codes.

 

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Masonry Wall Systems | WBDG

Introduction

Within This Page
  • Introduction
  • Description
  • Fundamentals
  • Applications
  • Details
  • Emerging Issues
  • Relevant Codes and Standards
  • Additional Resources

Masonry has been used in building construction for thousands of years in construction. It can be used to form a durable cladding system and to achieve various aesthetic effects. The masonry units can be oriented in different positions to create different patterns on the exterior wall. In addition to forming the exterior cladding, masonry walls can serve as a portion of the structural framing for the building. Masonry walls also typically increase the fire resistance of the wall system or structural elements.

Masonry walls can be single or multi-wythe. A wythe of masonry refers to a thickness of wall equal to the thickness of the individual units.

Description

Masonry is typically site constructed (laid) using manufactured masonry units and site mixed mortar. The units are laid in mortar to various heights, with the strength of the assembly being achieved during curing of the mortar. Masonry can form structural elements (typically bearing walls, columns, or pilasters) and/or the finished cladding system.

Masonry Units

Several different types of masonry units are commonly used. Common masonry unit types include clay and concrete units, which may be solid or hollow, and glazed or unglazed. Other masonry unit types include cast stone and calcium silicate units.

Clay Units

Clay brick units are typically used in brick masonry construction. Depending on the clay used and the method of forming the units during manufacturing, clay units have various colors, sizes and textures. Other types of units include glazed brick (both clay and concrete) units, concrete brick, calcium silicate brick, and hollow clay tile (typically used in older masonry buildings).

Clay masonry units are typically formed of soft clay extruded into the required shape in the manufacturing plant. Several different finishes can be formed on the exterior surface of the brick such as wire cut or sand finished, depending on the method used to form the brick into the desired shape. Brick units are then heated in a kiln (fired) to a temperature of 1100 to 1200 Fahrenheit degrees in order create the structural properties of the units.

The units can be hollow (cores occupy greater than 25% of unit) or solid. Units categorized as solid typically contain cores for handling and to allow more uniform firing. For most exterior walls, units categorized as solid are used.

The standard for clay masonry units is ASTM C216 (Standard Specification for Facing Brick (Solid Masonry Units Made from Clay or Shale). In this standard, and in building specifications, clay units are categorized by grade (NW, MW or SW) and type (FBA, FBS and FBX). The masonry grade depends on the required durability of the units. Typically, Grade SW (severe weathering) is recommended in most areas of the US. These units are much more resistant to freeze-thaw cycling. MW (moderate weathering) units should only used in areas where freezing cycles are not anticipated. NW (negligible weathering) units should only be used in interior conditions where the interior air is conditioned and there is no exposure to moisture.

The type of unit depends on the required dimensional tolerances. Typically Type FBS is specified unless unusually tight tolerances are required. Where tight tolerances are required, Type FBX should be specified. Type FBA units are typically used to create a rustic appearance with a high dimensional tolerance.

Glazed clay masonry units should meet the requirements of ASTM C126 (Standard Specification for Ceramic Glazed Structural Clay Facing Tile, Facing Brick, and Solid Masonry Units).

Concrete Masonry Units (CMU)

Concrete masonry units (CMU) are made from a mixture of portland cement and aggregates under controlled conditions. The units can be made to various dimensions, but typically have face dimensions of 8 inches high by 16 inches wide (nominal). Concrete masonry units are typically made in forms to the desired shape and then pressure-cured in the manufacturing plant. The units are often used when masonry is to form a load-bearing wall or an interior partition between spaces within a building. Concrete masonry units can be manufactured in different sizes and with a variety of face textures.

Concrete masonry units should meet the requirements of ASTM C90. The units are categorized based on the weight (lightweight, normal weight and heavyweight). Structural masonry units are either normal weight or heavyweight. Lightweight units are used for non-load-bearing conditions or as veneers.

Since these units are typically larger than brick units, the construction time required for laying the units is typically less than that for brick. The units can be solid or hollow (two or three cores) and can have solid or flanged ends. The cores provide continuous vertical voids that are often reinforced. Steel bars are placed in the cores with grout installed surrounding the bars. In this fashion, the wall acts similar to a reinforced concrete element.

Mortar

Mortar is typically composed of cement, lime and sand, although lime mortars can also be composed in which no cement is used. Components and proportions of mortars vary depending on the desired mortar properties. Mortars consisting of portland cement and lime as well as sand are most common. Premixed mortars must be carefully reviewed to determine the actual components of the mix.

There are different mortar types depending on the required strength. Mortars for new construction are typically Types N, S, or M. For repairs to existing buildings, some other types such as Type O, or even softer mortars, may be required to replicate the original mortar properties. The most common masonry types and uses in new construction are as follows:

  • Type N—Used in general masonry walls above grade. This is the most common masonry mortar used in non-structural applications in new construction. This has good bond qualities and good resistance to water penetration.
  • Type S—Typically used in structural masonry applications. Has a higher proportion of cement and subsequently can have increased shrinkage of the mortar.
  • Type M—Typically used only in below grade applications.

Mortar proportions and mixing requirements are outlined in ASTM C270 and in the appropriate Technical Notes published by the Brick Institute of America (BIA). Generally, mortars are mixed on site with water to achieve a wet fluid mix, with sufficient water for workability. The mortar is retempered (additional water added to the mix) periodically to maintain workability. After two hours, the bond of fresh unused mortar to new units is significantly reduced. Therefore, mortar that is unused within two hours should be discarded.

Fundamentals

Installation

Masonry must be installed on a solid, rigid base. This is typically a concrete foundation or structural steel or concrete beam system. Most building codes do not allow the weight of the masonry to be supported be wood framing, due to the strength loss of the wood member when exposed to moisture. The support system must be designed for small deflections (typically 1/600th of the span) to avoid cracking of the masonry.

The masonry units are laid in a bed of mortar. The horizontal joints between units are called bed joints while the vertical joints are called head joints. Clay brick masonry should include solid (full) head and bed joints. In concrete masonry it is common to lay the units with mortar only on the face shells (face shell bedding). This is due to the size of the cores and the difficulty in installing mortar in the webs between cores without allowing significant amounts of mortar to fill the cores. Full bedding of concrete masonry units is typically only performed where a portion of the cells will be filled with grout. Where grouting is performed, mortar should be kept from falling into the cells since this will form a weak plane in the grout.

Coursing

Masonry units can also be different sizes and shapes to accommodate specific project needs. The units can also be oriented in various ways to form varying aesthetic effects. Common coursing patterns are as follows:

  • Stretchers—units are oriented horizontally with the full face exposed (most common)
  • Headers—units are oriented perpendicular to the face of the wall with the end exposed (can be true or false headers)
  • Soldiers—units are oriented vertically with the full face exposed
  • Rowlock—units are oriented perpendicular to the face of the wall with the end and face exposed (often used at sills and at tops of walls)

Expansion and Shrinkage of Units

Following manufacture, clay masonry units expand when exposed to moisture. This volumetric change in the unit results in an accumulated growth of the wall system that is irreversible. Concrete masonry units typically shrink following manufacturing. These movements, if not accommodated in the design of the masonry elements, can cause cracking, spalling, and displacements in the masonry. For this reason, expansion joints are required in clay masonry construction, particularly in areas exposed to the exterior in where the units will become wet. Expansion joints are typically required at corners, offsets, and other changes in wall plane; changes in wall construction; and at regular spacings (typically 20 to 30 feet on center maximum, depending on the units). Guidelines for expansion joint design/layout are provided in Brick Industry Association (BIA) Tech Note 18A.

Concrete masonry walls are typically reinforced with joint reinforcement for shrinkage control. Depending on the size and spacing of the reinforcement, the spacing of control joints will vary. However, control joints are required in all concrete masonry walls. Guidelines for control joint placement are provided in National Concrete Masonry Association (NCMA) Tek Note 10-A.

Both clay and concrete masonry also undergo cyclic thermal movements. These materials expand in warm temperatures and contract in cold temperatures. The movement joints must also accommodate these movements.

Wall Systems

Masonry walls can be of several different types:

  • Veneer (wall system provides cladding and only resists transfers wind loads to a structural backup)
  • Structural/Load Bearing Wall (can be cladding but also provides load bearing system)

Water penetration through exterior masonry elements exposed to rain should be anticipated. Water typically flows through separations between the mortar and the units. This can be due to bond separations, voids, and cracks. Water penetration can also occur, although typically to a lesser degree, due to absorption through the units and mortar. Systems must be provided in exterior masonry construction to address water penetration into the wall system.

Masonry Veneer

Masonry veneer consists of an exterior wythe of masonry that forms a cladding material only. Lateral support for the masonry veneer is required. This is typically provided by an interior wall. Common interior walls (backup walls) are cold-formed steel framed walls with water-resistant sheathing and concrete masonry.

Critical components in masonry veneers exposed to moisture include:

  • Drainage cavity behind veneer wythe
  • Flashing system at base of veneer
  • Seals for the cavity at fenestrations (window, door, louver frames, etc.)
  • Lateral tie system to anchor veneer to the structural back-up
  • Vertical support system to support weight of veneer
  • Provisions for expansion/contraction of the wall system

Veneer walls are designed as “drainage walls” in respect to their resistance to water penetration. An air space/drainage cavity should be installed behind the masonry veneer to allow water that penetrates the masonry to flow down to the base of the wall, where it can be directed to the exterior. This drainage cavity should remain open to allow water to freely drain. Where restrictions in the cavity exist, flashings are recommended to collect water and drain it to the exterior. This is required at openings in the masonry such as at windows, supports, etc. At the base of the drainage cavity, a flashing system should be installed that consists of a three-sided pan, typically formed by metal and/or membrane materials, to collect water that penetrates into the drainage cavity and direct it to the exterior via drains or weeps. These flashings must be designed to be watertight, particularly at corners, laps, and terminations of the masonry. End dams are required at terminations to prevent water from flowing laterally off the flashing and into the adjacent construction. Common flashing materials are stainless steel, copper, and lead-coated copper. These metal flashings are durable, can be sealed, and include soldered corners and end dams. Membrane materials such as rubberized asphalt and EPDM can also be used in conjunction with metal flashings to seal the top of the metal flashing to the backup construction.

It is critical that a moisture barrier be present on the interior face of the drainage cavity (on the surface of the backup) to prevent the passage of water into the backup construction. The recommended cavity width behind the masonry veneer is 2 inches minimum.

In summer months, the air space behind the brick veneer will typically contain air that is hot and humid relative to the interior. This air can achieve a relatively high vapor pressure relative to the interior. In winter months, this is air space can be filled with relatively cold air in relation to the interior. This is particularly true in northern climates. If this air contacts the interior portion of window frames or interior finishes, condensation can result. For this reason, cavity seals are typically recommended at windows, doors, and other openings to prevent the passage of cavity air (and moisture) to the door/window frames.

Vertical support for the masonry veneer is typically provided at each floor line. For a brick masonry veneer, provisions must be made at each of the vertical supports to accommodate vertical expansion of masonry. This is accomplished by omitting the mortar between the top course of masonry and the underside of the support. This joint should be designed to accommodate the vertical expansion of the masonry, as well as structural deflections of the support. In concrete structures, creep of the concrete frame should also be accommodated.

Metal ties are required to provide the lateral attachment of the veneer to the backup wall. These are typically spaced at 16 inches on center in each direction.

Structural Masonry Walls

Structural masonry walls are typically constructed using concrete masonry. The concrete masonry can be reinforced both vertically and horizontally to achieve the required flexural resistance. Vertical reinforcement that is installed within the cells of the concrete masonry is generally grouted solid. Horizontal reinforcement is typically installed using prefabricated welded wires that are embedded in the bed joints. Although this horizontal reinforcement improves the strength of the masonry, particularly for horizontal spans, but also serves to control shrinkage cracking.

If structural masonry walls are to serve as the exterior walls, a second wythe of masonry is typically recommended. In this construction, the masonry can be built as a composite wall (both wythes act as a unit to resist loads) or as a non-composite wall (individual wythes act independently to support loads). Since water penetration through the exterior wythe of masonry is to be expected, the reliance on a single wythe of masonry as the exterior wall system is typically not recommended. If single wythe exterior walls are to be installed, a barrier should be provided on the exterior surface, such as a fluid-applied, breathable masonry coating or over-cladding (EIFS, metal panels, stucco and similar) to prevent water penetration into the masonry. Admixtures can be used in the fabrication of concrete masonry units to reduce water penetration due to absorption into units themselves. However, the admixture must also be mixed into the mortar in order to achieve proper bond. These systems can be effective in reducing the amount of water penetration into the masonry; however, they should not be relied upon to eliminate water penetration.

Thermal Performance

Masonry is typically a large thermal mass that can be heated and cooled by it’s exposure to the sun and the exterior temperatures. Masonry exposed to sunlight can achieve temperatures well in excess of 100 degrees Fahrenheit. The masonry absorbs heat and will radiate the heat to the surrounding components of the wall system. During cold temperatures, masonry will be cool, particularly in shaded exposures. In design, the thermal performance characteristics of the masonry are typically based primarily on the insulation placed in the wall cavity or within the backup wall. The masonry is typically assumed to provide little insulating value.

Fire Safety

Masonry provides a significant improvement in fire safety for building walls. Concrete masonry is typically used for firewall construction. The fire resistive characteristics are based on the thickness of the masonry.

Acoustics

Because of the mass, masonry wall systems can provide better sound insulation than lighter wall systems such as metal panels. To improve acoustical performance, concrete masonry is typically filled with insulation to eliminate the voids in the cores.

Maintenance

When properly constructed, masonry wall systems require relatively little maintenance as compared to other wall systems. The service life of the masonry can be 100 years or more, depending on the detailing and maintenance. The most frequent maintenance is the regular replacement of sealant in expansion joints, perimeter of openings (windows, doors, etc.) and at through wall flashings. The time frame for sealant replacement depends on the sealant used but usually ranges from every 7 to 20 years.

Repointing of the mortar joints in exterior masonry is typically required between 20 to 30 years after installation, depending on the type and quality of the original masonry installation.

Applications

See Appendices for climate-specific guidance regarding building enclosure design.

Details

The following details can be downloaded in DWG format or viewed online in DWF™ (Design Web Format™) or Adobe Acrobat PDF by clicking on the appropriate format to the right of the drawing title.

The details associated with this section of the BEDG on the WBDG were developed by committee and are intended solely as a means to illustrate general design and construction concepts only. Appropriate use and application of the concepts illustrated in these details will vary based on performance considerations and environmental conditions unique to each project and, therefore, do not represent the final opinion or recommendation of the author of each section or the committee members responsible for the development of the WBDG.

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