BORAL MASONRY

Build something great

Masonry Design Guide

MASONRY BLOCKS AND BRICKS NEW SOUTH WALES BOOK 2

[Link]/masonry

Updated September 2008

PAGE

PAGE

New South Wales Book 2 A

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2

Products at a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4

Fast Find Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3

About This Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6

A
B

Introduction

Planning and Design

Blockwork Design Considerations . . . . . . . . . . . . . . . . . . . . . B2

Reinforced Core-Fill Masonry Walls . . . . . . . . . . . . . . . . . . B10

Brickwork Design Considerations . . . . . . . . . . . . . . . . . . . . . B5

Construction Considerations . . . . . . . . . . . . . . . . . . . . . . . . B11

Control Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7

Cleaning Concrete Masonry . . . . . . . . . . . . . . . . . . . . . . . . B11

Mortar Mixes for Concrete Block and Brick . . . . . . . . . . . . . B8

Designer Block

Contemporary Colours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2

Split Face Series 100, 150 and 200 . . . . . . . . . . . . . . . . . C7

Pre-sealing Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3

Corner Details Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C8

Textures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4

Installation Details Series 100, 150 and 200 Blocks . . . . . . C9

Smooth, Honed, Shot-Blast and Polished Face . . . . . . . . . . C6

Formed Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C13

Engineered Blocks

Masonry One Series 100 . . . . . . . . . . . . . . . . . . . . . . . . D2

Masonry One Series 200 . . . . . . . . . . . . . . . . . . . . . . . . D6

Typical Component Usage Series 100 . . . . . . . . . . . . . . . D3

Typical Component Usage Series 200 . . . . . . . . . . . . . . D7

Masonry One Series 150 . . . . . . . . . . . . . . . . . . . . . . . . D4

Masonry One High Fire Rated . . . . . . . . . . . . . . . . . . . . D8

Typical Component Usage Series 150 . . . . . . . . . . . . . . . D5

Core-Fill Block

Construction Considerations . . . . . . . . . . . . . . . . . . . . . . . . . E2

Masonry One Series 200 . . . . . . . . . . . . . . . . . . . . . . . . E6

Quantity of blocks filled per cubic metre of grout . . . . . . . . E2

Typical Usage Series 200 . . . . . . . . . . . . . . . . . . . . . . . . . E7

Coloured and Specialty Designer Block . . . . . . . . . . . . . . . . E3

Masonry One Series 300 . . . . . . . . . . . . . . . . . . . . . . . . E8

Masonry One Series 150 . . . . . . . . . . . . . . . . . . . . . . . . E4

Typical Usage Series 300 . . . . . . . . . . . . . . . . . . . . . . . . . E9

Typical Usage Series 150 . . . . . . . . . . . . . . . . . . . . . . . . . E5

Engineered Bricks

Basalt-Concrete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2

FireLight (FL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4

Masonry One Brick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3

The information presented herein is supplied in good faith and to the best of our knowledge was accurate at the time of preparation. No responsibility can be accepted by
Boral or its staff for any errors or omissions. Users are advised to make their own determination as to the suitability of this information in relation to their particular purpose
and specific circumstances. Since the information contained in this document may be applied under conditions beyond our control, no responsibility can be accepted by us
for any loss or damage caused by any person acting or refraining from action as a result of this information.

A2

September 2008 | BORAL MASONRY DESIGN GUIDE

New South Wales Book 2 A

NLB = Non-loadbearing
LB = Loadbearing

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 Go straight to the
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For technical support and sales office details please refer to the outside back cover

BORAL MASONRY DESIGN GUIDE

September 2008

A3

New
Ne
N
eew
wS
South
oouuutth W
Wales
allees BBook
oookk 2 A

Architect: Harry Seidler and Associates

Architect: Department of Commerce - Government Architects Office

Boral Feature Face Masonry

for External and Internal Walls

Designer Block
4 Contemporary Colours.
5 Innovative Textures Smooth, Honed, Polished,
Shot-Blast or Split Face.

Masonry One Grey Block

Hollow Concrete Block suitable for loadbearing and
non-loadbearing applications.

Pre-Sealing Technology to reduce water absorption, and

hence reduce the possibility of efflorescence, mould
or mildew staining.
Suitable for loadbearing and non-loadbearing walls.

Architect: Arkhefield Architects

A4

Architect: Lawrence Nield and Partners

September 2008 | BORAL MASONRY DESIGN GUIDE

Neew
New
wS
So
South
out
uth
hW
Wa
Wal
Wales
ales
es BBoo
Bo
Book
okk 2 A

Architect: Nettleton Tribe Architects

Boral Engineered Bricks

for Structural, Fire and Acoustic Wall Systems

Masonry One Core-Fill Block

Grey Concrete Block or Designer Block in coloured
and textured finishes for reinforced retaining
walls and loadbearing walls requiring increased
robustness.

Basalt-Concrete Brick (B)

Standard Size, 119 high in Concrete-Basalt material for
good fire performance and loadbearing characteristics.

Masonry One Brick

Medium weight for non-loadbearing fire and/or acoustic
systems. Available in 76, 119 and 162mm heights for
faster, more cost effective construction.

FireLight Bricks (FL)

Lightweight for non-loadbearing fire and/or acoustic
systems where weight saving is important. Available in
119 and 162mm heights for faster, more cost effective
construction.

Architect: Suters Architects

BORAL MASONRY DESIGN GUIDE

Architect: Wolski Lycenko and Brecknock

September 2008

A5

New South Wales Book 2 A

Please note that this guide is based on products available at

the time of publication from Boral Masonry NSW sales region.
Different products and specifications may apply to Boral
products sourced from other regions.

Boral Masonry Construction Solutions

Boral Masonry offers a comprehensive range of proven products
and systems including Concrete Masonry Bricks and Blocks, Fire
and Acoustic Wall Systems, Segmental Block Retaining Walls and
Segmental Paving Products.

Additional Assistance and Information

Contact Details: Please refer to the outside back cover
of this publication for Boral Masonry contact details.

Whats in this Guide

The Boral Masonry Bricks and Blocks guide details a
comprehensive selection of decorative, structural, fire and
acoustic walling solutions not available with other materials.
Refer to Book 1 for Structural, Fire and Acoustic details.

Colour and Texture Variation: The supply of raw

materials can vary over time. In addition, variation can
occur between product types and production batches. Also
please recognise that the printed colours in this brochure
are only a guide. Always ask to see a sample of your
colour/texture choice before specifying or ordering.

This guide has been prepared as a comprehensive Boral

Product Reference Guide. It does not attempt to cover all
the requirements of the Codes and Standards which apply
to masonry construction. All structural detailing should
be checked and approved by a structural engineer before
construction. Boral reserves the right to change the contents
of this guide without notice.

Terms and Conditions of Sale: For a full set of Terms

and Conditions of Sale please contact your nearest Boral
Masonry sales office.

Guided Tour of a Typical Product Page

Designer Block

New South Wales Book 2 C

PAGE

BOOK

Book, Page
and Section
Identification

C10

Series
Series 200
200 Installation
Installation Details
Details
20.121

FFor window heights

1200mm
1200mm or
or 1800mm
1800mm

FFor window heights

900mm
900mm or
or 1500mm
1500mm

Product information
relating to features,
applications,
texture finishes and
accessories

Cut
110.39
Sill
Sill

110.39
Sill
Sill

Split
195mm
20.121/20.142
Mitre cut on site at 45
20.121/20.142
Cut one block
per course
Bolster
on site to
at 190mm
340mm length
to maintain
and
mitre
cut at 45
Even coursing
1/2 bond pattern

10.71
10.71

10.01
10.01
10.71
10.71

Product Name and

other identifying
feature, such as
texture finish

Flashing
Flashing

Flashing
Flashing

20.01
20.01

45mm

20.01
20.01

20.121

20.01
20.01

20.121

Fig C11
C11
Sill
Fig
SillDetail
Detail- -Single
SingleSkin
SkinWall
Wall
Series
Series 200
200 Feature
Feature Face
Face Designer
Designer Block
Block

20.121
B

80mm
80mm

40mm
40mm

Odd coursing
20.121/20.142

10.01
10.01
10.101
10.101cut
cutin
inhalf,
half,laid
laid
with cut end down.
80
80xx40mm
40mmbevel
bevelcut
cut
on
ontop.
top.
20.101
20.101

20.121

20.121
20.121/20.142
Bolster on site at 190mm
and mitre
A cut at 45

Product Icons
with dimensions
for products
available in your
region/state

20.121/20.142
Mitre cut on site at 45
Cut one block per course to
340mm length to maintain
Fig C13 Corner Bonding
Details
1/2 bond
pattern

Series 200 Split Face Designer Block

Fig C13 Corner Bonding Details
Series 200 Split Face Designer Block

Fig C12
C12
Sill
Fig
SillDetail
Detail- -Single
SingleSkin
SkinWall
Wall
Series
Series 200
200 Split
Split Face
Face Designer
Designer Block
Block

Availability
information for
products distributed
in your region/state

Full
Full block
block

3/4
3/4 block
block

3/4
3/4 block
block

Full
Full block
block

1/2
block
block
1/2
block
block
Cut
Cut block
block in
in half
half

Remove
Remove remainder
remainder
of
of centre
centre web
web
Lay
Lay end
end down
down

Fig C13
C14
Face
Fig
FaceLintel
LintelDetail
Detailwith
with1800mm
1800mmOpening
Openingfor
forSeries
Series150
150or
or200
200Blocks
Blocks

C10

A6

Product
Specifications

September 2008 | BORAL MASONRY DESIGN GUIDE

September 2008 | BORAL MASONRY DESIGN GUIDE

BORAL MASONRY

Build something great

Masonry Design Guide

MASONRY BLOCKS AND BRICKS NEW SOUTH WALES BOOK 2
B PLANNING AND DESIGN

New South Wales Book 2 B

Modular Planning

Blockwork
Design Considerations
Sizes
Blocks have a face dimension (nominal) of 400mm long x
200mm high. Because an allowance is made for 10mm wide
mortar joints, the actual face size of the block is 390mm x
190mm. There are 12.5 blocks per m2.
1 metre

1 metre

12.5 blocks/m2

The concrete block was one of the first building components to

be designed with modular construction in mind. Originally it was
based on a 4 inch module (as it remains in the USA) but when
the metric system was adopted in Australia during the 1970s, this
was changed to a 100mm module.

Module Selection
For greatest ease and efficiency when constructing with masonry
blockwork, it is recommended to plan a building using a 200mm
module, as a significant reduction in the number of special or cut
blocks can be achieved.
Providing the design of a building is based on this module, cutting of
blocks can generally be avoided. Coloured face blocks are generally
made in only full length units (390mm) with part sizes (halves,
etc) being cut on-site when required from the full length units, to
maintain colour consistency.
NOTE: All saw grindings must be washed off the cut blocks. They
are invisible while wet, but if allowed to dry, they appear as a pastel
colour and are difficult to remove (as they are cementitious).

Fig B1 Typical Block Dimensions

Most blocks are available in three thicknesses of 90mm (Series

100), 140mm (Series 150) and 190mm (Series 200).
Boral Masonry NSW offers many fractional sized blocks to
reduce the need for on-site cutting. However to maintain better
colour consistency with coloured blocks, part size blocks for
these applications are best prepared on-site by cutting or
splitting from full size blocks.
Other block types such as lintel blocks, capping pieces, corner
returns are made in various product ranges.
Core-Fill Blocks for reinforced wall construction are made in
thicknesses of 140mm (Series 150), 190mm (Series 200), and
290mm (Series 300). Refer to Section E of this guide.
Before specifying your choice, please contact your local Boral
Masonry sales office to confirm availability in your region.

Material and Dimensional Variation

Most building materials work to a 600mm module. Blocks

can also work to a 300mm module by using part sizes, which
include half height blocks, (e.g. A skirting course of half high
blocks and 5 courses of full blocks = 2100mm to suit typical
door head height).
Nominal widths of doors and windows are also based on this
module, e.g. 900mm wide single door; and 1200mm, 1800mm
or 2400mm windows and doors.
The preferred way of dimensioning drawings is to show the
Nominal Sizes on openings. However, because the blocks are
made 10mm shorter than the nominal (or modular) size, the actual
openings will be different. Openings include one more mortar
joint than units. For this reason, window and door frames are
manufactured to suit openings which are 10mm wider than the
module, e.g. 910mm 1210mm, 1810mm, 2410mm.
Note also that the length of piers and walls is 10mm less than the
modules, i.e. 890, 1790 etc., due to the omission of the last vertical
joint at the end of the pier/wall.

Concrete Blocks are formed in steel moulds using relatively stable

materials enabling the size of individual units to be controlled to
within small tolerances. The code for concrete masonry units,
AS/NZS4455 : 1997, permits a general tolerance of 3mm on the
overall dimension of each unit.

B2

September 2008 | BORAL MASONRY DESIGN GUIDE

New South Wales Book 2 B

Face Blockwork Design Considerations

The following items should be considered carefully during the
design stage to maximise the long-term beauty and to minimise
the need for maintenance of face masonry.

Setout of Face Blockwork

When designing with split face blocks, special consideration
should be given to the distances between openings and
between corners and openings to facilitate the bolstering of
block ends where required. Refer to additional information on
Corner Details in Section C of this guide.

Colour and Texture Selection

The colour and texture of the unit should take into account the
location of the masonry and the building. Dark coloured units
can mask unsightly staining from dirt and pollution. On the
other hand, darker units can accentuate the presence of any
efflorescence or calcium carbonate caused by poor construction
detailing, materials or cleaning.
It is important to note that concrete and clay products, due to
the raw materials used in their production, may effloresce, and
when preparing estimated costs, the cost of cleaning blockwork
of this naturally occuring process should be considered.

Mortar Selection
Less staining and more aesthetically pleasing walls are achieved
by ensuring the mortar colour is similar to the masonry unit. The
colour of mortar is determined by the colour of the cement and
sand used, and by the use or not of different coloured oxides. For
colours other than greys, off-white cement and clean sand will
assist colour matching. (Refer to page B8 for oxide details.)
Construction of sample walls is recommended to determine
the appropriate mortar colour.

Copings, Sills, Parapets

Sills should shed stormwater from the masonry by projecting at
least 30mm beyond the wall face. Copings or parapets should
also shed water by having a fall towards the unexposed (inner)
face. Copings and parapets should be covered with a metal
capping to prevent any water from penetrating the wall.

In-built Elements
Where there are in-built elements (e.g. signage support frames
etc.) they should slope away from the masonry. The soffit of
major elements, such as balconies, should be provided with a
drip mould.

Protecting Face Masonry

The presealing additive used in the manufacture of Designer Block
product and its mortar is designed to reduce the risk of staining,
but additional sealing is recommended for ease of maintenance.

BORAL MASONRY DESIGN GUIDE

September 2008

B3

New South Wales Book 2 B

Blockwork Mortar Joints

Hollow blocks are normally laid with face shell bedding, i.e.
there are two strips of mortar which are laid over the face
shells with no mortar being laid on the web (except at corner
construction). These two strips of mortar are continued up the
vertical joints. Refer to Fig B2.

Flush Joint
Where a plaster or textured coating is to be applied to the
blockwork, a flush joint may be used. Rub surface with a piece
of block when the mortar is firm to provide a flat surface for
the coating.

Fig B4 Flush Joint

Fig B2 Applying Mortar

Joint Finishing
Ironed Joint
The preferred finish for mortar joints in face blockwork is
an ironed finish which provides the following benefits:

Raked Joint
Although the raked joint is sometimes used in face brickwork
for aesthetic reasons, it should NOT be used with hollow blocks
which are not to be rendered. This is to avoid:

Reducing the face shell mortar width,

Adversely affecting the weatherproofing.

The ironing tool compresses the mortar at the face

of the masonry, making it denser and more durable;
The mortar is pushed against the top and bottom faces
of the blocks, improving the bond between the mortar
and block.

IMPORTANT: Because acid cannot be used to dissolve mortar

without affecting the masonry units appearance, mortar smears
should be cleaned off face blockwork before it sets hard onto
the face.

The finish is obtained by ironing the joints with an

ironing tool when the mortar is firm to touch (about 20
to 30 minutes after laying) and then lightly scraping off
the surplus mortar with a trowel, or by lightly brushing.
Refer to Fig B3.
The ironing tool should be made of 12mm diameter
round rod and be more than 400mm long to ensure that
a straight joint is produced.

Fig B3 Ironed Joint

B4

September 2008 | BORAL MASONRY DESIGN GUIDE

New South Wales Book 2 B

Brickwork
Design Considerations

Table B2 Brick Quantities per Square Metre

(No allowance for wastage)
Face Size

Bricks per m2

76 x 230

48.5

The dimensions of standard brick are: 76mm high x 230mm

long x 110mm thick.

119 x 230

32.3

119 x 390

19.4

Boral Masonry NSW manufactures a range of Concrete Bricks in

various modular sizes to complement standard blockwork and
brickwork construction.

162 x 230

24.3

162 x 290

19.4

Sizes

The Boral 11.162 Brick is 162mm high x 230mm long x 110mm

thick. This height matches two standard size brick courses, with
mortar. These are very popular for more cost effective laying.
Refer to Section F of this guide.

Additional information is provided on individual product pages

in section F of this guide.

Table B1 Brickwork Dimensions

(with 10mm mortar joints)
Number
of
Bricks
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
50
100

Brickwork Opening
Brick Length (mm)
230
230
250
470
490
710
730
950
970
1190
1210
1430
1450
1670
1690
1910
1930
2150
2170
2390
2410
2630
2650
2870
2890
3110
3130
3350
3370
3590
3610
3830
3850
4070
4090
4310
4330
4550
4570
4790
4810
5030
5050
5270
5290
5510
5530
5750
5770
5990
6010
11990
23990

Brickwork Opening
Brick Length (mm)
290
290
310
590
610
890
910
1190
1210
1490
1510
1790
1810
2090
2110
2390
2410
2690
2710
2990
3010
3290
3310
3590
3610
3890
3910
4190
4210
4490
4510
4790
4810
5090
5110
5390
5410
5690
5710
5990
6010
6290
6310
6590
6610
6890
6910
7190
7210
7490
7510
14990

29990

Brickwork Opening
Brick Length (mm)
390
390
410
790
810
1190
1210
1590
1610
1990
2010
2390
2410
2790
2810
3190
3210
3590
3610
3990
4010
4390
4410
4790
4810
5190
5210
5590
5610
5990
6010
6390
6410
6790
6810
7190
7210
7590
7610
7990
8010
8390
8410
8790
8810
9190
9210
9590
9610
9990
10010
19990

39990

Brickwork Height (mm)

76
86
172
257
343
429
514
600
686
772
857
943
1029
1114
1200
1286
1372
1457
1543
1629
1714
1800
1886
1972
2057
2143
4286
8572

Brick Height (mm)

90
119
100
129
200
257
300
386
400
514
500
643
600
772
700
900
800
1029
900
1158
1000
1286
1100
1414
1200
1543
1300
1671
1400
1800
1500
1929
1600
2057
1700
2176
1800
2316
1900
2435
2000
2572
2100
2691
2200
2810
2300
2929
2400
3086
2500
3205
5000
6410
10000
12820

162
172
343
514
686
857
1028
1200
1372
1543
1714
1886
2057
2228
2400
2572
2744
2915
3086
3257
3428
3600
3772
3943
4114
4286
8572
17144

NOTE: To calculate a length dimension including a half-brick, add x mm to Length or Opening figure. Where (x=120 for 230mm bricks), (x=150 for
290mm bricks), (x=200 for 390mm bricks). For example, an opening of 11.5 x 230mm long bricks = 2650 + 120 = 2770mm

BORAL MASONRY DESIGN GUIDE

September 2008

B5

New South Wales Book 2 B

Modular Planning

Mortar Joints

Standard size bricks, as with most building materials, work to

a 600mm module.

Mortar joints (both horizontal and vertical) are usually specified

as 10mm in thickness. Any raking, if specified, should not
exceed 10mm depth and should not penetrate closer than
5mm to any core or perforation in cored units. Tooling of joints
is particularly beneficial in improving durability and must
always be carried out as specified. Joint finishing options are
illustrated in Fig B8.

In standard height bricks, this module is 7 bricks high x 2.5

bricks long (for standard length brick).
600mm

600mm

Fig B5. 600mm Module for

Standard Height/Standard Length Brick

Shallow
Ironed

Deep
Ironed

In one-and-a-half height bricks, this module is 1 standard

height course plus 4 courses of brick-and-a-half high x 2.5
bricks long (for standard length brick).
600mm

600mm

Weather
Struck

Struck
Flush

Fig B8 Joint Finishing Options

Fig B6. 600mm Module for

One-and-a-Half Height/Standard Length Brick

In double height bricks, it is 1 standard course plus 3

courses of double height brick x 2.5 bricks long (for standard
length brick).
600mm

600mm

Fig B7. 600mm Module for

Double Height/Standard Length Brick

B6

September 2008 | BORAL MASONRY DESIGN GUIDE

New South Wales Book 2 B

Control Joints
(Expansion Gaps)

Articulation Joints

Blocks and bricks (both concrete and clay) expand when heated
and contract as they cool. They both expand when they absorb
moisture and contract as they dry.

Articulation joints are vertical gaps in brick walls or gaps

between brick masonry and windows or doors, that allow
for minor footing movements without causing distress or
significant wall cracking.

As they cure however, clay units expand and concrete units

contract. For this reason, they should not be banded in the
same wall.
Control joints are constructed and spaced to allow for these
movements and in some cases, movement due to foundation
settlement. Control joints should be used beside large
openings, at changes of level in footings and at other points
of potential cracking.
Table B3 details the recommended maximum control joint
spacings for non-reinforced concrete walls.
The design and construction of control gaps in the external
leaf of a full brick wall is identical to that in a brick veneer
wall. Except at re-entrant angles in long walls, control gaps
are not usually required in internal brick masonry. Where
an internal gap is required, it can usually be located at a fullheight opening such as a door or window.

Articulation joints provide the flexibility needed when building

on reactive clay soils. Articulation may not be required for
masonry on stable sites. The basic design and construction
of articulation joints in the outer leaf of a full brick house is
similar to that in a brick veneer. The principles are illustrated
in Fig B10.
Articulation joints
with compressible
backing and mastic
sealant

Dividing wall with

articulation joint
and MFA's at
intersection with
cavity wall

Articulation
joint

Brick ties in every

fourth course on
each side of
articulation joint

Table B3 Control Joint Spacing

Product

Spacing

Masonry One & Designer Block

8 metres

Lightweight Masonry (< 1500 kg/m3)

6 metres

Reinforced core-filled retaining walls

16 metres

NOTES:
Joint width is 10mm for panels up to 6000mm long.
For panels over 6000mm and up to 8000mm, joint width
is 14mm.
Joint sealants should be applied towards the end of
construction to minimise the effect of panel movement.

Colour matched
or paintable

Fig B10 Articulation Joint Plan View

Where it is not possible to provide ties to the other leaf on

either side of an articulation joint, it is necessary to provide
a structural connection across the joint. This is made with
masonry flexible anchors (MFAs) mortared into bed joints of
brick masonry. See Fig B11.
Compressible foam
backing strip built
into dry vertical
joint. Cut foam
around MFA

MFA set in bed

mortar

Joint width
(see note)

10mm
Sealant

Fig B11 Articulation Joint Construction

Open cell
polyurethane
foam backing
rod

Brush on primer
1 to 8 hours
before inserting
sealant

Fig B9 Control Joint

BORAL MASONRY DESIGN GUIDE

September 2008

Where MFAs are used in walls over 3m high or exposed to high

winds, they must be built into the masonry at half-height then
at every seventh course (600mm) above. Articulation joints
can usually be placed so that they function also as control
joints/gaps.
B7

New South Wales Book 2 B

Mortar Mixes for

Concrete Block and Brick
The three principal functions of mortar are:
To provide an even bedding for blocks and allow level coursing
by taking up small variations in unit height;
To transmit compressive loads; and
To hold the blocks together in the wall by bonding to them, so that
tensile and shear forces can be carried - often referred to as bond
strength. This is particularly important so that units on top of the
wall are not easily dislodged.
In order to provide a good bond between the units and the mortar,
the following guidelines should be followed:
An appropriate mortar mix should be selected (refer to Tables B4
and B5 together with the following section on Mortar for Laying
Designer Block product).
The mortar should be batched accurately using some consistent
form of volume measurement.
The sand used in the mortar should be clean pit sand or plasterers
sand. Clayey loam or sand containing organic impurities will affect
the mortar strength and should not be used. Sand should be well
washed to ensure it is free of salt.
Mortar should be discarded and not retempered, after the initial
set of the cement has taken place.

Sand
The sand used in making the mortar for standard grey concrete
blocks and bricks should not be the same as commonly used
for clay bricks. Brickies loam contains clay particles, which
make the mortar more workable, but also cause some additional
shrinkage in the mortar. As clay masonry units tend to expand,
this compensates for the mortar shrinkage. Concrete masonry
units, however, tend to shrink, thus, if used with a mortar with
high shrinkage, cracking of the joints may result.
For this reason, mortar for concrete blockwork and brickwork
should be prepared with clean sharp sand, such as pit sand, or
plasterers sand. Tests have shown that the sand can contain up
to 10% fines but it should not contain clay particles. Lime or Methyl
cellulose, such as Dynex, can be added to increase workability.
These additives or lime must not be used in mortar used for laying
Designer Block products. Refer to the following section.

B8

Mortar for Laying Boral Designer Block

Boral Designer Block products are manufactured using the
latest presealing technology to reduce water absorption,
and hence reduce the possibility of efflorescence, mould or
mildew staining.
Designer Blocks can be laid in conventional mortar, however
where single-leaf Designer Block masonry is required to be
weather-resistant; it should be laid in mortar containing
Tech-Dryad Mortar Additive. See Half-Bag Mixes below and
Tables B4 and B5.
Lime or plasticisers should not be added to mortar with
Tech-Dryad additive.
Clean, sharp sand may be difficult to use without lime
plasticiser and may require blending or substitution with
brickies sand. For colour-matching the mortar, the brickies
sand should be near-white.
Additives may be used with products other than Designer
Block products, however caution should always be exercised
when using lime replacing additives such as plasticisers or
workability agents. They should be cellulose based, and only
be used if specified by the architect or engineer and then
strictly in accordance with the manufacturers instructions.
Detergent and air entrainers should never be used.

Half-Bag mixes
M3 (general purpose) Half Bag Mix:
Half a Bag (20kg) of Off-White cement and oxide*
108kg clean sand (18 shovels @ 6kg)
0.5 litres Tech-Dryad mortar additive.
M4 (exposure grade) Half Bag Mix:
Half a Bag (20kg) of Off-White cement and oxide*
84kg clean sand (14 shovels @ 6kg)
0.5 litres Tech-Dryad mortar additive.

Oxide
* Oxide quantities below are approximate. Trial batches are
recommended and should be assessed when dry. Contrasting
mortar colour is not recommended due to difficulty of
cleaning smears. Boral accepts no responsibility in the final
colour of the mortar.
Alabaster: White oxide 0.8kg
Almond: Yellow oxide 0.1kg
Pearl Grey: Black oxide 0.01kg
Charcoal: Black oxide 0.5kg

September 2008 | BORAL MASONRY DESIGN GUIDE

New South Wales Book 2 B

Mortar mixing procedure:

Blocks must be dry when laid.
Put 12 litres of water into mixer.
Add 0.5 litres of Tech-Dryad mortar additive.
Add 20kg cement and sand as for M3 or M4 (exposure
grade) mortar.

Laying Designer Blocks:

3. Spread mortar on each side of perpends, leaving a cavity

between.
4. For non-grouted masonry, a horizontal weep-hole at the
floor joint of each core should be provided to drain water
that may be trapped inside the blocks. Partly fill the bottom
course with gravel or similar drainage material to prevent
mortar droppings from blocking the weep-holes.
5. Iron joints. Do not rake joints.

1. Lay dry blocks only.

2. Spread mortar on face shells. Do not spread mortar
on webs.

6. Mortar smears must be cleaned off before they set as

acid cleaning later can discolour masonry.
7. Freshly laid walls must be covered overnight and when
rain interupts work.

Table B4 Mortar Mixes

Mix Proportions by Volume
(See AS3700-2001: Table 10.1)
G.P. Portland Lime
Sand
Cement
1

5
1

4
1
1
6
1

5
1

0.5

4.5

Tech-Dryad
Additive

Methyl
Cellulose
Additive

Minimum
Mortar
Classification

Yes
Yes
No
No

No
No
No
Yes

M3
M4

Designer Block mortar for weather resistance.

M3

General purpose with moderate exposure.

No

No
M4

No

Yes

1
1

5
4

No
No

Yes
Yes

M3
M4

Where Used (exposure)

(See AS3700-2001: Table 5.1)

Structural blockwork and severe exposure (marine

and industrial environments). External walls adjacent
to seafront, below damp-proof course, fences.
Calcium Silicate-Basalt
Calsil

NOTES: Methyl Cellulose water thickener is used to prevent the rapid drying out of the mortar thus improving its workability as well as increasing bond
strength. It does not have the detrimental effect of the plasticiser or detergent admixtures which generally reduce bond strength. Methyl Cellulose
can cause long delays in drying in moist basement environments. Dynex is one brand of methyl cellulose additive available.

Table B5 Approximate Material Quantities for 1m3 of Mortar

Blocks
There are 12.5 full blocks per
square metre of wall surface
area.

Mortar
Classification

M3

For every 800 blocks or 64m2 of

wall, about 1m3 of mortar mix is
required, allowing for wastage.

Concrete Blocks and Bricks

Designer Block Options

Mix in 1 : 1 : 6 proportions

Mix in 1 : 5 proportions

Cement:

14 bags (20kg each)

Off-white Cement:

Lime:

5 bags (20kg each)

Tech-Dryad mortar additive:

Sand:

1.2m3 (~1.7t)

Sand:

Mix in 1 : 0.5 : 4.5 proportions

M4

NOTE: Designer Block should

be laid with Off-white cement
to match colour of face of block.

16 bags (20kg each)

8 litres

1.2m3 (~1.7t)
Mix in 1 : 4 proportions

Cement:

18 bags (20kg each)

Off-white Cement:

Lime:

3 bags (20kg each)

Tech-Dryad mortar additive:

Sand*:

1.2m3 (~1.7t)

Sand :
#

20 bags (20kg each)

8 litres

1.2m3 (~1.7t)

* Allowed 20% extra sand for bulking

Use clean sand
t = tonne
#

BORAL MASONRY DESIGN GUIDE

September 2008

B9

New South Wales Book 2 B

Grouting

Reinforced Core-Fill
Masonry Walls
Concrete blocks (140, 190, and 290mm) have large cores which
facilitate the placement of steel reinforcing rods and the pouring/
pumping of grout (grout is highly workable concrete).
If a wall is reinforced with bars spaced at 800mm centres or less
and fully grouted, the wall is referred to as reinforced masonry.
These walls can have similar strength and flexure characteristics
to reinforced insitu concrete walls.
Partially reinforced block walls are only grout filled where the
reinforcement is placed, usually in bond beams and vertically
in cores.
All reinforced walls must be designed by a structural engineer.

Grout Filling
Grout Specification
The correct grout specification (mix design) is critical to
achieving the structural design of a reinforced wall. The grout
used to fill the cores of blockwork walls should be specified
as follows:

Grout may be mixed on site and poured from buckets into

hoppers placed on top of the wall. Alternatively, for larger jobs,
the grout may be delivered by transit mixer and pumped into
the cores, using a small nozzle on the hose.
Before commencing placement of the grout, it is important that
the cores should be clean and free of mortar dags projecting
into the core. A steel rod is pushed down the core to knock off
these dags and to break up any mortar that has dropped onto the
footing. The cores are then hosed or swept out from the bottom
of each core through the clean-out block. The vertical steel rods
are tied to the starter bars, and then the clean-out blocks are
covered with formwork, ready for grouting.
In hot dry weather it may be necessary to hose the cores out
with water in order to cool the blocks and so prevent flashsetting of the grout. If so, this hosing should be completed at
least 30 minutes before the grout is placed.
Because of the high pressures developed at the bottom of the
cores when they are filled, grouting in lifts of more than 1.2
metres should not be attempted in one pour. Where the lift is
more than 1.2 metres, it is preferable to fill the cores in two
stages at least 30 minutes apart.

Characteristic Compressive Strength 20MPa;

When grouting Series 150 blocks, lifts should be reduced to
800mm (4 courses) to ensure no voids are left in the wall.

Cement content not less than 300kg/m3;

Round aggregate (if any) not bigger than 10mm;
Clean sand (salts can leach through to the face); and

A pouring consistency which ensures that the cores

are completely filled and the reinforcement completely
surrounded without segregation of the constituents.
The approximate number of blocks filled per cubic metre of
grout is shown in Table B6.

Grout for Designer Block Units

Due to the high hydrostatic pressure at the bottom of freshly
grouted cores, water will seep out of the wall. This MUST be
cleaned off. The admixture used with Designer Block units will
increase the time for the grout to firm and dry, therefore more care
must be used inspecting and cleaning any seepage on the surface
of these walls. Clean all grout spills before they set.

Table B6 Blocks filled per cubic metre of Grout

Block Type

Blocks Filled per m3

of Grout (approximate)

15.42 Notch

190

15.01 Full

190

15.142 Split Face

200

15.91 Double U

175

20.01 Full

120

20.42 Notch

120

20.142 Split Face

125

20.91 Double U

100

30.91 Double U

65

Connex 91

90

15.12 Bond Beam/lintel

200 (80 lineal metres)

20.12 Bond Beam/lintel

125 (50 lineal metres)

Grout Pumping and Core Filling

B10

September 2008 | BORAL MASONRY DESIGN GUIDE

New South Wales Book 2 B

Construction Considerations

Cleaning Concrete Masonry

Mortar Deposits

Good Building Practice

Mortar extruded from masonry joints during laying should

be cut off with an upward stroke of the trowel. In this way a
clean cut can be made without smearing the face of the unit.
On completion of laying and tooling, any mortar smears which
may be on the face of the work should be removed, firstly with
dry brushing and secondly, if necessary, by wet brushing. Do
not allow mortar smears and dags to set on the face of the
masonry. If these mortar deposits are allowed to set on face
masonry, high pressure water jets or in extreme cases a diluted
acid solution might be needed to remove mortar stains. See
Cleaning Face Concrete Masonry before testing either water
jets or acid solutions. Acid cleaning should be avoided as face
concrete blocks can be discoloured.

Block layers must exercise extra care when laying face concrete
masonry to minimise mortar staining.
Block layers must:
Keep face blocks as clean as possible while laying and tooling;
Keep unused pallets of blocks and tops of unfinished walls
covered during rain to prevent water penetration and excessive
efflorescence;
Clean any dags and mortar smears before they set hard.
Remaining stains could be removed following the procedures
set out below.

Scaffolding

Removal of Mortar Stains with Hand

Tools

Scaffolding planks should be placed with a clearance of at

least 150mm to the wall. This gap allows mortar droppings to
fall clear of the plank instead of splattering on the plank and
building, disfiguring the wall. At the end of each days work or
when rain interrupts work, the plank nearest the wall should
be propped on edge to prevent mortar from being splattered
onto the wall by overnight rain.

After using a bucket and brush, remove any remaining mortar

dags and smears by rubbing the surface with a piece of like
coloured block or a piece of wood if cleaning polished masonry
(to prevent scratching). Careful use of a paint scraper, wide
bladed chisel or wire brush can be helpful in removing mortar
buildup. However care must be taken not to scratch or damage
the masonry surface.

Concrete Droppings

Pressure Cleaning

Masonry, supporting reinforced concrete slabs and beams is

frequently disfigured by droppings from the concrete pour. If
such deposits are allowed to set it is sometimes impossible to
rectify the damage. Protection is best achieved by covering the
walls with plastic sheeting. Where this is not done, any concrete
on the wall must be thoroughly cleaned off before it sets.

This cleaning method is not a substitute for good building

practice and hand cleaning methods. It should only be used
after these procedures have been carried out if further cleaning
is required.

Rain Interruption
Overnight, and when rain interrupts blocklaying, the top of
newly laid walls should be protected with plastic sheeting or
similar. This is essential with face blockwork. When newly laid
masonry is saturated by rain, lime is put into solution either from
portland cement, or from saline (unwashed) sands or hydrated
lime in the mortar. This solution takes in carbon dioxide from
the atmosphere and precipitates calcium carbonate. This whitish
stain is very disfiguring and not easily removed. Frequently,
new masonry is marred by bands of calcium carbonate stain
confined to three or four courses of masonry - the result of rain
saturating freshly laid work.

Essential Preliminaries:
Thoroughly remove mortar smears and dags back to a flat
surface with hand tools as outlined above. Hand cleaning
must not leave any thickness of mortar, otherwise pressure
cleaning will damage the masonry face and mortar joints before
removing the thickness of mortar.
Allow the mortar to harden for a minimum of seven days prior
to pressure cleaning;
Carry out a pressure cleaning trial on a typical but inconspicuous
area and allow it to dry to determine:
The effectiveness of this cleaning method; and
That marking, damage or erosion of the surface has not been
caused before proceeding with the general cleaning.
NOTE: If there is no inconspicuous area, a small wall could be
constructed for this purpose.

BORAL MASONRY DESIGN GUIDE

September 2008

B11

New South Wales Book 2 B

Pressure cleaning may be carried out with pressure not

exceeding 7MPa (1000psi) and volume not exceeding 20
litres/minute and fan jet of a minimum 40 degree width,
held not closer than 500mm from the wall. Cleaning should
be continuous and even. The pressure jet should never be
stationary and should not needle or zero in on mortar stains
as surface erosion will almost certainly occur.
NOTE: If this method is not totally successful, further hand
cleaning and scraping should be carried out prior to further
pressure cleaning.

Caution:
High pressure water blasting can cause personal injury and
damage masonry. Mortar joints can be blown out and face
blockwork marked and eroded;

Procedures for Acid Cleaning

1. Remove mortar dags and smears as described under
Hand Tools;
2. Working from the top of the wall down in vertical runs,
thoroughly pre-wet (SOAK) an area of blockwork of
approximately 2m2 at a time;
3. Apply diluted acid to the water-soaked area by brush or
broom with a horizontally (sideways) action to prevent
runs and streaks;
4. Within 2 to 3 minutes, rinse this area from top to bottom
under tap pressure only;
5. Pressure clean this area thoroughly, gently and evenly,
as outlined previously;

Zero degree or needle jets, narrow fan jets and turbo jets should
not be used on blockwork because all concentrate the water
pressure on too small an area which can cause damage;

6. Repeat steps 1 to 5 as necessary to achieve the best

compromise between cleaning and damage caused by
excessive treatment.

Minimal pressure should be used to avoid mortar blowouts

and/or damage to the face of units.

Other Stains
Timber (Tannin)

Experienced operators should carry out pressure cleaning in

accordance with the above recommendations after appropriate
trials have taken place.

Acid Treatments
Only if hand cleaning and pressure washing methods have
failed to fully remove mortar stains, should acid treatments be
considered for cleaning of concrete blockwork.
NOTE: Acids react with and dissolve cement, lime and oxide
colourants in concrete blocks and mortar joints and are thus
capable of etching, fading and streaking the masonry finish.
When acid is applied to dry blockwork without pre-wetting, it
is drawn in below the surface it is intended to clean. Salts may
appear when the masonry dries out.
If it is considered necessary to use an acid for general cleaning,
it should only be used after trialling in an inconspicuous area
as outlined under Essential Preliminaries and strictly in
accordance with the following procedures.
Hydrochloric acid (otherwise known as Muriatic Acid or Spirits
of Salts) can be tested at a strength of 1 part acid to 20 parts
water. A less aggressive alternative is powdered Citric Acid
which can be used at strengths up to 1 Part acid to 10 parts
water (by volume).

These can usually be removed by the application of a chlorine

solution, preferably Sodium Hypochlorite (household bleach),
onto the dry surface. Re-apply as necessary to achieve the
desired result.

Clay or Loam Stains

If not too severe and intransigent, these stains may be removed
with a solution of 50ml household detergent and 500 grams of
oxalic acid dissolved in 4 litres of warm water. Lightly pre-wet
then apply the above solution with a nylon brush. Rinse off and
repeat as necessary. Pressure cleaning as outlined previously
may be of assistance.

Mosses, Moulds and Lichens

These commonly appear as a green to black area, often with
a hair like growth, around damp areas such as taps, gutter
overflow areas, south facing walls, etc.

1. Scrape off any thickness of moss/mould/lichen;

2. Pre-wet the mouldy area;
3. Apply a chlorine solution, preferably Sodium Hypochlorite
(household bleach), at sufficient strength to kill mould within
approximately 1 hour;
4. Scrubbing with a stiff brush or broom will normally assist;
5. Thoroughly flush the surface. If mould remains, repeat steps
1 to 3 as necessary to kill and remove the mould;
6. Pressure cleaning, as outlined previously, may assist.

B12

September 2008 | BORAL MASONRY DESIGN GUIDE

New South Wales Book 2 B

Efflorescence
The term efflorescence is given to a white powdery deposit
that forms on the surfaces of porous building materials such as
masonry units, mortar and concrete. The temporary appearance
of efflorescence is common on new masonry. For efflorescence
to occur, three conditions must be present:

1. There must be soluble or semi soluble salts present;

2. There must be water entering the masonry; and
3. The masonry must be able to dry out.
The absence of any of the above three conditions will prevent
efflorescence. Any situation which allows water to enter the
wall is likely to promote efflorescence. The most common
causes are:

Poor building practice such as partially built walls left

uncovered during rain. Delays in installation of window
sills and downpipes can exacerbate this problem, allowing
rainwater to enter block cavities and leach free lime to
the surface;
Poor storage of masonry units on site. Before units are
placed in the wall they can absorb ground salts and
excessive water in the stockpiled masonry and can
mobilise latent salts. It is desirable to store masonry
off the ground and loosely cover with a waterproof
membrane during rain;

becomes a very hard film of calcium carbonate. If this occurs, it

will almost certainly require professional advice and specialised
cleaning methods for its removal.
Wall sealers also help to prevent future efflorescence, mould
growth and general staining by reducing water absorption
from rain.
Concrete products due to their mix of raw materials used in
their manufacture, are prone to effloresce and allowances
must be made by the purchaser for this occuring. Boral does
not clean or accept to clean staining or efflorescence off
blockwork.

Safety Precautions and Warnings

When using chemicals, care must be taken to avoid damage
to adjacent materials and finished surfaces. Masking and
plastic sheeting may be necessary;
To avoid personal injury, wear protective clothing and
vapour cartridge breathing mask-particularly in confined
areas, as recommended by chemical manufacturers;
NEVER mix chemicals that you are unfamiliar with,
particularly chlorine and acid - it emits deadly chlorine gas.
Follow the chemical manufacturers recommendations;
Dilute acid by adding acid to water. Never add water
to acid;

Poor or missing copings and flashings;

Harsh acidic chemicals should never be used for the cleaning

of blockwork; and

Excessively raked joints which allow water to enter the

bed face of the masonry (ironed joints are recommended);
and

Chemical wastes must not be allowed to run down drains

and storm water outlets in accordance with Environmental
Protection Regulations.

The use of air entraining agents in the mortar which

makes the mortar act like a sponge.
Good laying practice and site procedures are necessary for
keeping efflorescence to a reasonable level. Care should also
be taken to ensure that excessive lime is not used in mortar
joints.
In conjunction with dry brushing, the cleaning methods
outlined previously will usually remove most normal levels
of efflorescence. Dry brush, then wet brush and wash down. It
is important to remove as much efflorescence as possible with
DRY brushing because powder efflorescence is water soluble.
Wet brushing can dissolve the powder and the dry block can
re-absorb it. If high levels of efflorescence are present on walls
exposed to continual wetting from rain or other sources of
dampness over an extended period, calcification or hardening
of the lime tends to take place. The powdery lime gradually

BORAL MASONRY DESIGN GUIDE

September 2008

B13

New
New
w So
S
South
ou
uth
th Wal
W
Wales
aleess Boo
Bo
Book
ookk 2 B

NOTES

B14

September 2008 | BORAL MASONRY DESIGN GUIDE

BORAL MASONRY

Build something great

Masonry Design Guide

MASONRY BLOCKS AND BRICKS NEW SOUTH WALES BOOK 2
C DESIGNER BLOCK

New South Wales Book 2 C

Architect: Micheal Fountain Architects Pty Ltd

Almond ShotBlast Face

Designer Block
Contemporary Colours
for External and Internal Walls

Architect: Turnbull Architects

Charcoal Polished Face

The colour palette has been developed in consultation

with designers and offers a broad and co-ordinated range.
The Designer Block colour palette provides the flexibility
of many colour combinations essential for the popular
composite building styles that require varying finishes
and materials.
Choose from a palette of 4 contemporary colours and 5
bold textures or customise to create an individual look
(please note longer lead times and surcharges may apply
for this service).

Architect: Micheal Dore (Architect) in association with Castles, Stephenson and Turner Architects

C2

Almond Split Face with Smooth Face banding

September 2008 | BORAL MASONRY DESIGN GUIDE

New South Wales Book 2 C

Architect: Woods Bagot

Architect: Micheal Fountain Architects Pty Ltd

Designer Block
Pre-sealing Technology

Designer Block products utilise the latest pre-sealing

technology to reduce water absorption, and hence
reduce the possibility of efflorescence, mould or mildew
staining.
Designer Block products are suitable for loadbearing and
non-loadbearing walls.

Architect: HPA Architects and Bates, Smart Architects

BORAL MASONRY DESIGN GUIDE

September 2008

Charcoal - Polished Face

C3

New South Wales Book 2 C

Architect: Micheal Fountain Architects Pty Ltd

Almond ShotBlast Face

Architect: Arkhefield Architects

Designer Block Textures

Smooth Face

Polished Face

A finely textured finish created through the standard

moulding process.

This involves producing a denser block which is honed

and then buffed. Polishing enriches the colour of the
aggregates. The finely finished polished surface is ideal
for feature walls, trim and banding.

Shot-Blast Face
This process subtly exposes the aggregates, producing
a finish like weathered ground stone.

Honed Face
The honing process grinds 2-3mm from the block
surface, producing a matt exposed-aggregate finish, like
sawn stone.

Split Face
The splitting process produces a bold textured, exposed
aggregate finish.

Block Ends
Honed, Shot-Blast or Polished finishes are available on
the end of blocks for corners, openings and free ends.

NSW Dept. of Commerce, Government Architects Office. Project Architect: Cathy Kubany

C4

September 2008 | BORAL MASONRY DESIGN GUIDE

New South Wales Book 2 C

Essential Colours
Shot-Blast Face

Honed Face

Polished Face

Split Face

Charcoal

Pearl Grey

Almond

Alabaster

Smooth Face

Availability and Quantities

Colour and Texture Variations

Lead times apply to all coloured blocks. Longer lead times apply to Honed, Polished and
Shot-Blast finishes as the product must be cured for four weeks, to harden sufficiently,
before processing. A lead time of approximately eight weeks applies.

The colours shown in this brochure are

provided as an indication of the colours and
textures available. Some variations in colour
will occur due to changes in raw materials.
In addition, variation can occur within and
between production batches due to the
curing process. Please ask to see a sample of
your chosen colour/texture before specifying
or ordering.

Minimum order quantities apply on Honed, Polished and Shotblast finishes.

Boral recommends part size blocks are cut/bolstered on-site to maintain colour consistency.

BORAL MASONRY DESIGN GUIDE

September 2008

C5

New South Wales Book 2 C

Designer Block
Smooth, Honed, Shot-Blast and Polished Face
INTRODUCTION
Designer Block is suitable for internal and
external walls in loadbearing and non-loadbearing
applications. They are popular for feature face
applications in double leaf construction.

FACE TEXTURES
Designer Block is available with the following
face texture finishes:

190

90

190

390
140

10.01
Full

390

190

390

190

15.01
Full (made-to-order)

20.01
Full

190

Smooth Face
Honed Face
140

Shot-Blast Face

390

Ends Honed, Shot-Blast or Polished finishes.

Refer to pg C4 for detailed description.

390

190

15.42
Recessed Web
(made-to-order)

Polished Face

190

20.42
Recessed Web

15
108
40

COLOURS
Designer Block units are available in 4
colours. Please refer to page C5 for additional
information.
Customised colours and textures are also
possible. Please note that extended lead times
and minimum order quantities may apply.
NOTE: Colour variations may occur between
recessed web and full blocks as these are
batched differently.

100
194

50

390
110

50.31
Capping

190

10.39 Victorian Sill

(made-to-order)
moulded back to back
for on-site split/cut.

Specifications
Code

Product Description

MPa

Wt kg

N/Pallet

10.01

Full

15

11.1

180

15.01

Full

15

12.5

120

15.42

Recessed Web

15

12.5

120

20.01

Full

15

14.2

90

20.42

Recessed Web

15

14.1

90

50.31

Capping

15

6.8

270

10.39

Victorian Sill

3.5

440*

* Supplied as 220 double units. Bolster on-site to achieve 440 units per pallet.

Availability
Lead times apply to all coloured blocks.
Part size blocks are best cut/bolstered on-site to maintain
colour consistency.
Contact Boral Masonry for further details.

C6

September 2008 | BORAL MASONRY DESIGN GUIDE

New South Wales Book 2 C

Designer Block Split Face - Series 100, 150 and 200

INTRODUCTION
Designer Block Split Face is suitable for internal
and external walls in loadbearing and nonloadbearing applications.

190
90

95

Designer Block Split Face is produced in three

block thicknesses, Series 100 (95mm thickness),
Series 150 (145mm thickness) and Series 200
(195mm thickness).

390

95

10.101 Full (1 in 3
blocks are half solid)

390

10.109 Half High

(made-to-order)

190

FACE TEXTURES
Split Face - The splitting process produces a
bold textured surface resulting in characteristics
much like split natural stone.

145

390

Designer Block units are available in 4

colours. Please refer to page C5 for additional
information.

145

20.121 Full

390

15.142
Recessed Web
(made-to-order)

DESIGN NOTES

When designing with split face blocks, special

consideration should be given to the distances
between openings and between corners and
openings to facilitate the bolstering of block
ends where required.

390

190

190

Customised colours are also possible. Please

note that extended lead times and minimum
order quantities may apply.

One in three 10.101 and one in four of 15.121

blocks delivered will be half solid to enable onsite bolstering to create split face textures at
sides of openings and corners where required.
Splitting details are on pages C8 to C11.

195

15.121 Full
(made-to-order)

COLOURS

190

195

390

20.142
Recessed Web

Specifications
Code

Product Description

MPa

Wt kg

N/Pallet

10.101

Full

15

13.9

144

10.109

Half Height

15

7.2

288

15.121

Full

15

15.8

120

15.142

Recessed Web

15

15.5

120

20.121

Full

15

17.7

90

20.142

Recessed Web

15

17.6

90

NOTE: Colour variations may occur between

recessed web and full blocks as these are
batched differently.

Availability
Lead times apply to all coloured blocks.
Part size blocks are best cut/bolstered on-site to maintain
colour consistency. Part size blocks can be made-to-order.
Contact Boral Masonry for further details.

BORAL MASONRY DESIGN GUIDE

September 2008

C7

New South Wales Book 2 C

Series 100 Corner Details

10.101

One third of 10.101

blocks are half solid

10.01

10.01 cut
on-site

10.101
10.01

10.01

10.101

10.101 bolstere
on-site

10.01 cut
on-site

290mm

295mm

95mm

10.01

10.101

10.01

10.101
10.01

10.101

290mm

295mm

90mm

10.101 bolstered on-site

95mm

95mm

Fig C1 Corner Bonding Details

Series 100 Split Face Designer Block

Fig C2 Corner Bonding Details

Series 100 Feature Face Designer Block

Series 150 Corner Details for Unreinforced Walls

One unit in four is
half-solid, for end splits

15.01 cut on-site to

maintain bond

15.01

15.01
15.01

340mm

45mm

15.01
15.01
15.121
340mm
145mm

345mm

Fig C3 Corner Bonding Details

15.121 Split Face Corner

C8

15.01 cut
on-site to
maintain
bond

Fig C4 Corner Bonding Details

Series 150 Feature Face Designer Block

September 2008 | BORAL MASONRY DESIGN GUIDE

New South Wales Book 2 C

Series 100 Installation Details

70mm
35mm

55mm

47mm

267mm

Cut 10.101
laid on cut
face

10.101 block
with 3 saw
cuts makes 2
sill blocks
(cut on site)

47mm

10.101

ALTERNATE COURSES

Fig C7 Sill Detail with Smooth Face Sill

Series 100 Split Face Designer Block

267mm
10mm
Capping piece 50.31
split to width if required,
set on mortar bed

67mm

Fig C5 45 Corner
Series 100 Split Face Designer Block

Split face block

10.101 (95mm)

Fig C8 Sill Detail with Capping Piece

Series 100 Split Face Designer Block
Paver
(cut to suit)

10.01

538mm
390mm

14mm

134mm

10.71
95mm
Flashing

10mm

Bolster
on-site

Cut on-site

10.01

10.01

338mm

ALTERNATE COURSES

Fig C9 Sill Detail with Raked Paver

Series 100 Feature Face Cavity Wall

10mm
338mm

10.39
Victorian Sill
(made to order)
10.01
Cut on-site

Bolster
on-site

10.71
Flashing

538mm
10.01

Fig C6 45 Acute Corner

Series 100 Split Face Designer Block

BORAL MASONRY DESIGN GUIDE

September 2008

10.01

Fig C10 Sill Detail with Victorian Sill profile

Series 100 Feature Face Cavity Wall

C9

New South Wales Book 2 C

Series 200 Installation Details

For window heights
900mm or 1500mm

For window heights

1200mm or 1800mm
10.39
Sill

10.39
Sill

20.121/20.142
Mitre cut on site at 45

10.71
10.01

Even coursing

20.121/20.142
Bolster on site at 190mm
and mitre cut at 45

10.71
Flashing

Flashing

20.01

20.01
20.01

Fig C11 Sill Detail - Single Skin Wall

Series 200 Feature Face Designer Block
80mm

40mm

Odd coursing
20.121/20.142

10.01
10.101 cut in half, laid
with cut end down.
80 x 40mm bevel cut
on top.

20.121/20.142
Bolster on site at 190mm
and mitre cut at 45

20.121/20.142
Mitre cut on site at 45

Fig C13 Corner Bonding Details

Series 200 Split Face Designer Block

20.101

Fig C12 Sill Detail - Single Skin Wall

Series 200 Split Face Designer Block

Full block

3/4 block

3/4 block

Full block

1/2
block
1/2
block

Cut block in half

Remove remainder
of centre web

Lay end down

Fig C13 Face Lintel Detail with 1800mm Opening for Series 150 or 200 Blocks

C10

September 2008 | BORAL MASONRY DESIGN GUIDE

New South Wales Book 2 C

Series 150 Installation Details for Reinforced Walls

15.142
Split
35mm

A
145mm

15.142 cut on-site

to maintain bond

B
145mm

Next course laid

with recesses down
to allow extra cover
to horizontal steel

Cut

Next course laid

with recesses down
to allow extra cover
to horizontal steel

15.42

15.42 cut on-site to

maintain bond

15.42

15.42

15.142
15.142
15.142
300mm
340mm
B

15.142

15.42

15.142
15.142

15.42
300mm

15.142 cut on-site to

maintain bond

Fig C14 Corner Bonding Details

Series 150 Split Face Designer Block

BORAL MASONRY DESIGN GUIDE

September 2008

Strike mortar
flush over recess
in end. Iron when
mortar is firm.

340mm

15.42 cut
on-site to
maintain
bond

Fig C15 Corner Bonding Details

Series 150 Feature Face Designer Block

C11

New South Wales Book 2 C

Series 200 Installation Details for Reinforced Walls

20.42
(inverted on
alternate courses)

20.142

20.42
20.42

Cut

20.01
45mm

B
Split

195mm

Cut one block per course to

340mm length to maintain
1/2 bond pattern

20.142

20.42

20.142

20.42

20.42
20.142

20.01
Cut two webs to
fit horizontal steel

Cut back face

if reinforced
around corner

Fig C16 Corner Bonding Details

Series 200 Smooth Face Designer Block

20.142
20.142
A

Cut one block per course to

340mm length to maintain
1/2 bond pattern

Fig C17 Corner Bonding Details

Series 200 Split Face Designer Block

NB: 20.01 and 20.42 may have colour variations.

C12

September 2008 | BORAL MASONRY DESIGN GUIDE

New South Wales Book 2 C

Formed Face
INTRODUCTION
Boral Formed Face Designer Block provides
a distinctive face pattern to create internal
and external walls with unique architectural
character.

190

140

FACE TEXTURES

390

15.01T
Tiled Face - Full (made to order)

Tiled Face a 140mm or 190mm thick block

with a formed finish manufactured with a
dummy centre joint to form a 190 x 190mm tile
face pattern.

190

Formed Face is available with the following face

textures:

190

smooth

20.01T
Tiled Face - Full (made to order)

390

honed
polished

Specifications

shotblast.

BORAL MASONRY DESIGN GUIDE

Code

Product Description

MPa

Wt kg

15.01T

Tiled Face - Full 140mm

10

12.5

120

20.01T

Tiled Face - Full 190mm

10

15.3

90

September 2008

N/Pallet

C13

New South Wales Book 2 C

NOTES

C14

September 2008 | BORAL MASONRY DESIGN GUIDE

BORAL MASONRY

Build something great

Masonry Design Guide

MASONRY BLOCKS AND BRICKS NEW SOUTH WALES BOOK 2
D ENGINEERED BLOCKS

New South Wales Book 2 D

190

190

390
90

90

10.01
Full

390

INTRODUCTION

90

290

10.02
Three Quarters

390

10.71
Half High

90

190

90

190

10.03
Half

Masonry One Grey Block is very

popular for internal walls and veneer
wall construction.

An extensive range of component

forms cater for most popular
construction requirements.

10.01 series blocks have a 120 min

insulation rating. For further details
refer to Book 1.

Masonry One Grey Block combines

strength, durability and ease of
construction and provides highly
cost effective solutions for every-day
construction applications.

ADDITIONAL INFORMATION

FIRE RATING

Please refer to the Boral Masonry

Design Guide (Book 1) for additional
structural, fire and acoustic
performance information.

390

10.83
Half High Solid

190

190

90

Masonry
Grey Block is a
90mm thickness block which is
manufactured from controlled light
weight concrete.
90

190

90

APPLICATIONS

One

10.31
Full Solid

90

Series 100
Masonry One Grey Block

90

390
90

10.34
Quarter

10.12
Lintel or Bond Beam

90
190

190

390

10.25
Corner Return

Colour and Availability

No minimum order quantities apply.
Lead time 0-2 weeks.
For coloured blocks, refer to the Designer Block
section of this guide.
NOTE:
* This product will have colour variations due to the
natural element of the raw materials. Boral Masonry
accepts no responsibility for variations in colour.

Natural Grey*

D2

Specifications
guc MPa

Wt kg

N/Pallet

Full

10

8.6

180

10.02

Three Quarters

10

6.1

240

10.03

Half

10

4.3

360

10.12

Lintel or Bond Beam

10

9.0

180

10.25

Corner Return

10

11.1

120

10.31

Full Solid

10

11.0

144

10.34

Quarter

10

2.7

432

10.71

Half High

10

4.2

360

10.83

Half High Solid

10

5.2

288

Code

Product Description

10.01

September 2008 | BORAL MASONRY DESIGN GUIDE

New South Wales Book 2 D

Typical Component Usage - Series 100 Masonry One Grey Block

10.01 or
10.31

10.12

Steel reinforcing
and grout to project
specifications
or
Steel lintel

10.02
10.03

10.03

2100mm

or
10.01 or
10.31

10.34
10.01

10.25
10.01 or
10.31

900m

10.71 or
10.83
Cut from
10.83

Cut from
10.83 or
10.34

Cut from
10.83

10.25
10.01

10.02

10.01

10.01
10.03

10.01

10.03

10.01

10.25

10.02

10.01

10.01
10.01

10.01

NOTE: 10.25 corner return only

available in Natural Grey.

10.01
NOTE: 10.02 three-quarter block
only available in Natural Grey.

10.01

10.01

Fig D1 Corner Bonding Detail

for Series 100 Construction Block

BORAL MASONRY DESIGN GUIDE

September 2008

Fig D2 Alternative Corner Bonding Detail

for Series 100 Construction Block

D3

New South Wales Book 2 D

190
90

390

140

140

15.01
Full

390

INTRODUCTION
One

Masonry
Grey Block is a
140mm thickness block which is
manufactured from controlled denseweight concrete.

15.71
Half High

190

90

290

140

140

390

15.83
Half High Solid

15.02
Three Quarters

190

190

140

15.03
Half

390

The Estate Wall Pier is used

extensively in the construction of
boundary fencing for properties and
subdivisions.

FIRE RATING

An extensive range of component

forms cater for most popular
construction requirements.

15.01 series blocks have a 120 min

insulation rating. For further details
refer to Book 1.

APPLICATIONS

ADDITIONAL INFORMATION

One

190

140

Series 150 Masonry One Grey Block

Masonry
Grey Block is very
popular for loadbearing and nonloadbearing wall construction and
the construction of small cantilevered
walls as it is the thinnest block
suitable for reinforced grout filling.
Also refer to the products in the Core
Fill Blocks section of this guide.

Please refer to the Boral Masonry

Design Guide (Book 1) for additional
structural, fire and acoustic
performance information.

15.12
Lintel or Bond Beam

140
140
190

190

390

15.25
Corner Return

Specifications
guc MPa

Wt kg

N/Pallet

Full

10

9.7

120

15.02

Three Quarters

10

7.7

160

15.03

Half

10

5.2

252

15.12

Lintel or Bond Beam

10

12.4

120

15.25

Corner Return

10

11.6

105

15.71

Half High

10

4.6

240

15.83

Half High Solid

10

8.6

192

Code

Product Description

No minimum order quantities apply.

Lead time 0-2 weeks.
For coloured blocks, refer to the Designer Block
section of this guide.

15.01

NOTE:
* This product will have colour variations due to the
natural element of the raw materials. Boral Masonry
accepts no responsibility for variations in colour.

Colour and Availability

Natural Grey*

D4

September 2008 | BORAL MASONRY DESIGN GUIDE

New South Wales Book 2 D

Typical Component Usage - Series 150 Masonry One Grey Block

15.01

15.12

Steel reinforcing
and grout to project
specifications
or
Steel lintel

15.02

15.03
15.02

15.03

2100mm

or

15.01

Cut from
15.03
15.01

15.01

15.25

900m

15.71 or
15.83
Cut from
15.83

15.71 or
15.83

Cut from
15.83

Cut 15.01 to
340mm
15.01

15.25

15.01

15.01
15.01

15.01

15.01
15.01

15.25
15.01

15.01
15.01

15.03

15.03

Cut 15.01 to
340mm
15.01

15.01
NOTE: 15.25 corner return only available in Natural Grey.

NOTE: Use where 15.25 corner return not available.

Fig D3 Corner Bonding and Free End Detail

for Series 150 Construction Block

Fig D4 Corner Bonding and Free End Detail

for Series 150 Construction Block

BORAL MASONRY DESIGN GUIDE

September 2008

D5

New South Wales Book 2 D

190
90
390

190

390

190

20.01
Full

20.71
Half High

190

190

190

290

20.02
Three Quarters

190

390

20.12
Lintel

190

190

20.03
Half

190

FIRE RATING

Masonry One Grey Block is a

190mm thickness block which is
manufactured from controlled light
weight concrete.

20.01 series blocks have a 120 min

insulation rating. For further details
refer to Book 1.

An extensive range of component

forms cater for most popular
construction requirements.

Please refer to the Boral Masonry

Design Guide (Book 1) for additional
structural, fire and acoustic
performance information.

ADDITIONAL INFORMATION

Masonry One Grey Block is very

popular for loadbearing and nonloadbearing wall construction and the
construction of cantilevered walls as it
is suitable for reinforced grout filling.
Also refer to the products in the Core
Fill Blocks section of this guide.

390

20.20
Knock-Out Bond Beam
(cut to order)

40

190
190

INTRODUCTION

APPLICATIONS

190
190

Series 200 Masonry One Grey Block

90

20.04
Quarter

194

390

50.31
Capping

Specifications
guc MPa

Wt kg

N/Pallet

Full

10

11.4

90

20.02

Three Quarters

10

8.7

120

20.03

Half

10

6.8

180

20.04

Quarter

10

4.3

360

NOTE:
* This product will have colour variations due to the
natural element of the raw materials. Boral Masonry
accepts no responsibility for variations in colour.

20.12

Lintel

15

16.4

90

20.20

Knock-Out Bond Beam

10

11.0

90

20.71

Half High

10

5.9

180

Natural Grey*

50.31

Capping

10

6.8

270

Code

Product Description

20.01
No minimum order quantities apply.
Lead time 0-2 weeks.
For coloured blocks, refer to the Designer Block
section of this guide.

Colour and Availability

D6

September 2008 | BORAL MASONRY DESIGN GUIDE

New South Wales Book 2 D

Typical Component Usage - Series 200 Masonry One Grey Block

20.01

20.12

Steel reinforcing
and grout to project
specifications
or
Steel lintel

20.03
20.03

20.02
2100mm

or

20.01

20.04
20.01

20.02

20.01

20.01

900m

20.71
Cut from
20.74
20.71
20.01
Cut from
20.71

20.01

20.01
20.01
20.01

20.01
20.01
20.01
20.01
20.03
20.01
NOTE: Also suitable for Series 200 Designer Block.

Fig D5 Corner Bonding and Free End Detail

for Series 200 Construction Block

BORAL MASONRY DESIGN GUIDE

September 2008

D7

New South Wales Book 2 D

Masonry One - High Fire Rated Grey Block

Series 150 and 200
INTRODUCTION
Masonry One blocks are manufactured from a
blend of material which reduces the weight and
increases the fire performance characteristics.
Masonry One blocks are ideal for nonloadbearing walls of commercial, industrial and
high-rise buildings with concrete and portal
framed structures.
Masonry One blocks are also suitable for
loadbearing walls, however the S rf values
from Designer Block units apply. Refer to the
Boral Masonry Design Guide (MDG Book 1) for
more information.

Masonry One is manufactured in 90, 110, 140

and 190mm thicknesses to suit most types of fire
and/or acoustic wall construction.

Specifications - Series 150

Product Product
Code
Description

Nominal
TxLxH
(mm)

Average
Unit
Weight kg

Unit
guc
MPa

No
per
Pallet

15.401

Full

140 x 390 x 190

14.2

120

15.422

Corner

140 x 340 x 190

11.1

135

15.403

Half

140 x 190 x 190

7.4

252

Nominal
TxLxH
(mm)

Average
Unit
Weight kg

Unit
guc
MPa

No
per
Pallet

Specifications - Series 200

Product Product
Code
Description
20.401

Full

190 x 390 x 190

13.2

90

20.403

Half

190 x 190 x 190

9.0

180

FIRE DESIGN CONSIDERATIONS

Masonry One blocks utilise a unique blend
of material, which has been shown through
fire testing to provide excellent fire insulation
characteristics.

ACOUSTIC DESIGN CONSIDERATIONS

Masonry One blocks provide excellent sound
resistance with a wide variety of board-lining
systems.

ADDITIONAL INFORMATION
Please refer to the Boral Masonry Design Guide
(MDG Book 1) for additional structural, fire and
acoustic performance information.

Availability
No minimum order quantities apply.
Lead time 0-2 weeks.

D8

September 2008 | BORAL MASONRY DESIGN GUIDE

New South Wales Book 2 D

Masonry One - High Fire Rated Grey Block

Series 150
190

140

390

140

15.401
Full

190

190

190

140

15.403
Half

340

15.422
Corner

Series 200

190
190

190

20.401
Full

390

190

190

20.403
Half

BORAL MASONRY DESIGN GUIDE

September 2008

D9

New South Wales Book 2 D

NOTES

D10

September 2008 | BORAL MASONRY DESIGN GUIDE

BORAL MASONRY

Build something great

Masonry Design Guide

MASONRY BLOCKS AND BRICKS NEW SOUTH WALES BOOK 2
E CORE-FILL BLOCK

New South Wales Book 2 E

Architect: Nettleton Tribe Architects

Architect: Nettleton Tribe Architects

Core-Fill Reinforced
CONSTRUCTION CONSIDERATIONS

Blocks Filled per

Cubic Metre
Block Type

Blocks Filled per m3

of Grout (approximate)

15.42 Notch

190

15.01 Full

190

15.142 Split Face

200

15.91 Full

175

20.01 Full

120

20.42 Notch

120

20.142 Split Face

125

20.91 Full

100

30.91 Full

65

Connex 91

90

E2

Before commencing placement of the grout, it is important that the

cores should be clean and free of mortar dags projecting into the
core. A steel rod is pushed down the core to knock off these dags and
to break up any mortar that has dropped onto the footing. The cores
are then hosed or swept out from the bottom of each core through the
clean-out space. The vertical steel rods are tied to the starter bars, and
then the clean-out blocks are covered with formwork, ready for grouting
(see Retaining Wall Details in Book 1). An alternative method, which
may be used in low height walls, is to leave a gap in the mortar bed at
the bottom of each core and to hose out the dropped mortar and dags
before the mortar has set.
When grouting Series 150 Blocks, lifts should be reduced to 800mm
(4 courses) to ensure no voids are left in the wall.

September 2008 | BORAL MASONRY DESIGN GUIDE

New South Wales Book 2 E

190

140

390

20.42 (Feature Face)

Recessed Web

190

145

190

390

15.142 (Split Face)

Recessed Web

INTRODUCTION

390

190

15.42 (Feature Face)

Recessed Web

Core-Fill Designer Block Coloured and Specialty Finishes

190

390

195

20.142 (Split Face)

Recessed Web

Boral Masonry Feature Face CoreFill Blocks are designed for the
construction of reinforced masonry
retaining walls and loadbearing
walls requiring increased robustness
characteristics and where a feature
face is required.

FACE TEXTURES
Core-Fill Block is available with the
following face texture finishes:
Smooth Face

INSTALLATION
CONSIDERATIONS
Hydrostatic pressure at the bottom
of a freshly grouted core is very
high, forcing water to seep out of the
wall. This MUST be cleaned off. The
admixture used with Designer Block
products will increase the time for
the grout to firm and dry, therefore
more care must be used inspecting
and cleaning any seepage on the
surface of these walls. Pours of 1.2m
max. lift are recommended.

Honed Face
Shot-Blast Face
Polished Face
Split Face
Ends Honed, Shot-Blast or
Polished finishes.
Please refer to page C4 for general
information.

COLOURS
Designer Block products are available
in 4 colours. Please refer to page C5
for additional information.
Customised colours and textures
are also possible. Please note that
extended lead times and minimum
order quantities will apply.

Specifications
Smooth, Honed, Shot-Blast or Polished Face
Face and one end available Polished, Honed or Shot-Blast on request

guc MPa

Wt kg

N/Pallet

Full - Recessed Web

15

12.5

120

Full - Recessed Web

15

14.1

90

guc MPa

Wt kg

N/Pallet

Code

Product Description

15.42
20.42

Split Face
Availability
Lead times apply to all coloured blocks.
Part size blocks are best cut/bolstered on-site to maintain
colour consistency.
Contact Boral Masonry for further details.

BORAL MASONRY DESIGN GUIDE

Code

Product Description

15.142

Full - Recessed Web

15

15.5

120

20.142

Full - Recessed Web

15

17.6

90

September 2008

E3

New South Wales Book 2 E

Core-Fill Block
190

Series 150 - Masonry One

INTRODUCTION

390

140

15.91
Double-U Stretcher

Boral Series 150 Core Fill Block is

designed for the construction of
140mm thickness reinforced masonry
retaining walls and loadbearing
basement walls.

190

Specifications
390

140

15.42
Recessed Web

guc MPa

Wt kg

N/Pallet

Recessed Web

15

9.7

120

15.91

Double-U Stretcher

15

9.4

120

15.49

Open End

15

9.7

120

15.03

Half

15

5.6

252

Code

Product Description

15.42

140

190

390

Cut to 340mm long

to maintain half-bond

15.49
Open End
15.91

15.49
15.91

15.91
190

140

190

15.49
15.91

15.03
Half

15.91

Cut to 340mm long

to maintain half-bond

15.91

Fig E1 Corner Bond Detail

for Series 150 Construction Block

Colour and Availability

No minimum order quantities apply.
Lead time 0-2 weeks.
NOTE:
* This product will have colour variations due to the
natural element of the raw materials. Boral Masonry
accepts no responsibility for variations in colour.

Natural Grey*

E4

September 2008 | BORAL MASONRY DESIGN GUIDE

New South Wales Book 2 E

Typical Usage - Series 150

15.91

15.91

15.91

15.91

Even Courses
Cut from
15.49
or 15.42

15.49 cut to
340mm length for
corner blocks
275

400

400

400

15.91

15.91

15.91

300

95

275

70

70

Steel spacings as specified by

engineer (200 or 400mm typical)

15.91 blocks with 2 cuts

150mm apart, 100mm up face,
knock out 150 x 100mm for
clean-out opening

15.49 cut to
340mm length
for corner
blocks

15.49 full length

at end of wall

Cut wings off

to allow for
clean-out

Steel reinforcing
starter bars

15.91 cut
to suit for
clean-out
course (cut
on site)

400 typical

15.91

15.91

100

150

Clean-out Course Detail

Fig E2 Typical Steel and Block Layout Detail for 15.91 Block Wall

BORAL MASONRY DESIGN GUIDE

September 2008

E5

New South Wales Book 2 E

Core-Fill Block
190

190

Series 200 - Masonry One

INTRODUCTION

390

190

390

190

20.42
Recessed Web

20.91
Double-U Stretcher

190

190

190

190

190

390

20.92
Corner and End

Boral Series 200 Core Fill Block

is designed for the construction of
190mm thickness reinforced masonry
retaining walls and loadbearing
basement walls.

20.93
Half End

190

Specifications
guc MPa

Wt kg

N/Pallet

Recessed Web

15

11.4

90

20.91

Double-U Stretcher

15

11.2

90

20.92

Corner and End

15

9.9

90

20.93

Half End

15

5.5

180

20.12

Lintel

15

22.3

90

20.96
10.34

Clean-Out
Quarter (10.34 optional)

15
10

11.9
2.8

90
432

Code

Product Description

20.42

390

190

20.12
Lintel

390

190
20.92

20.91

20.91

190

20.91
Optional

20.96 + 10.34
Clean-Out

20.91

20.91

20.92
20.91

Fig E3 Corner Bonding Detail

for 20.91 Core Fill Block System

Colour and Availability

No minimum order quantities apply.
Lead time 0-2 weeks.
NOTE:
* This product will have colour variations due to the
natural element of the raw materials. Boral Masonry
accepts no responsibility for variations in colour.

Natural Grey*

E6

September 2008 | BORAL MASONRY DESIGN GUIDE

New South Wales Book 2 E

100

Typical Usage - Series 200

80
20.92

20.91

20.91

20.92

Even Courses

20.91
Full
length

Steel spacings as specified by

engineer (200 or 400mm typical)

100

300

400

400

100

20.96

300
20.96

100
30.93

80

300

10.34

30.93
20.96

20.96 cut to
290mm length

Steel reinforcing
starter bars

400

Clean out all dropped and

rodded mortar before boarding
up and pouring grout

20.96

10.34
(optional
for extra
stability)

Clean-out Course Detail

Fig E4 Typical Steel and Block Layout for 20.91 Block Wall
using 20.96/10.34 Clean-out Course
80

BORAL MASONRY DESIGN GUIDE

September 2008

E7

New South Wales Book 2 E

Core-Fill Block
Series 300 - Masonry One
190

INTRODUCTION
Boral Series 300 Core Fill Block
is designed for the construction of
290mm thickness reinforced masonry
retaining walls and loadbearing
basement walls.

390

290

30.91
Double-U Stretcher

Specifications

190

390

290

30.92
End

190

290

guc MPa

Wt kg

N/Pallet

Double-U Stretcher

15

13.6

60

30.92

End

15

16.2

60

30.93

Half End

15

9.3

120

20.96

Clean-Out

15

11.7

90

10.03

Clean-Out

15

4.4

360

Code

Product Description

30.91

190
20.92

30.93
Half End

30.91
30.91

390

190
20.92

30.93
190
190
90

190
30.91

20.96 + 10.03
Clean-Out

30.91
10.34
30.92

Fig E5 Corner Bonding Detail

for 300 Series Core Fill Block

Colour and Availability

No minimum order quantities apply.
Lead time 0-2 weeks.
NOTE:
* This product will have colour variations due to the
natural element of the raw materials. Boral Masonry
accepts no responsibility for variations in colour.

Natural Grey*

E8

September 2008 | BORAL MASONRY DESIGN GUIDE

New South Wales Book 2 E

Typical Usage - Series 300

100

80mm min.
(refer to
engineer's
details)
30.91

20.92

30.91

10.34

30.91

30.93

Even Courses

30.91

100

Steel spacings as specified by

engineer (200 or 400mm typical)
400
400

300

20.96

20.96

80mm min.
(refer to
engineer's
details)

30.93

300

30.93

100

30.93

100

300

30.93 with leg

removed for
access or 20.96
cut to 290mm
long

10.03

10.03

10.34

Steel reinforcing
starter bars
Clean out all dropped and
rodded mortar before boarding
up and pouring concrete

20.96

400 typical

10.03

20.96

400 typical

10.03

10.03

Clean-out Course Detail

10.34
20.93 or 20.96 to suit
wall length

300

10.34

100

30.93 or 20.96
bolstered to 290mm
length as required
10.34

80mm min.
(refer to engineer's
details)

Fig E6 Steel and Block Layout

for 30.91 Core Fill Block System

BORAL MASONRY DESIGN GUIDE

September 2008

E9

New South Wales Book 2 E

NOTES

E10

September 2008 | BORAL MASONRY DESIGN GUIDE

BORAL MASONRY

Build something great

Masonry Design Guide

MASONRY BLOCKS AND BRICKS NEW SOUTH WALES BOOK 2
E ENGINEERED BRICKS

New South Wales Book 2 F

119

290

90

119

110

9.119B

230

11.119B

Basalt-Concrete Bricks (B)

INTRODUCTION
Boral Basalt-Concrete bricks have
an g uc of 12MPa, making them
excellent for loadbearing or nonloadbearing applications. They
provide good fire performance and
acoustic performance characteristics
where minimising weight is not a
primary consideration.
Boral Basalt-Concrete bricks are a
popular choice for walls in high-rise
units where they are commonly used
with a rendered finish. They are also
commonly used for loadbearing walls
in 3-storey unit construction with
plasterboard or render finish.
Basalt- Concrete bricks are
manufactured in 90 and 110mm
thicknesses and in a range of size
formats to suit most construction
formats.
Boral Basalt-Concrete blocks are
also available. Please refer to the
appropriate product pages in this
Boral Masonry Block Guide.

FIRE DESIGN
CONSIDERATIONS
Boral Basalt-Concrete bricks comprise
of a Basalt-Concrete blend which
provides good fire performance
characteristics in loadbearing
conditions.
All core areas are 25% of total
volume, therefore all of these bricks
can be considered as solid for fire
design purposes.

ACOUSTIC DESIGN
CONSIDERATIONS
The mass of Basalt-Concrete is similar
to Clay and Calsil therefore rendered
walls perform similarly.
Its texture is coarser and its porosity
is higher than Clay and Calsil, so it
performs better with plasterboard,
particularly when daub-fixed.
Please refer to acoustic test/estimate
data in Book 1 of the Boral Masonry
Design Guide for appropriate
systems.

Colour and Availability

No minimum order quantities apply.
Lead time 0-2 weeks.

Natural Grey

Specifications
Unit
g uc
MPa

g m
w/M3
Mortar
MPa

Perforation
%

N
per
m2

N
per
Palle t

Product
Code

Actual
TxLxH (mm)

Average
Unit
Wt
kg

9.119B

90x290x119

5.6

12

5.6

<20

25.8

336

11.119B

110x230x119

5.1

12

5.6

<25

32.3

350

F2

September 2008 | BORAL MASONRY DESIGN GUIDE

New South Wales Book 2 F

119

90

290

90

9.162 LW

119

110

INTRODUCTION
Boral Masonry One Brick is a nonloadbearing, medium density light
weight material which provides high
fire rated performance.

290

9.119 LW

162

Masonry One Brick is ideal for large

commercial, industrial and high-rise
buildings with concrete and portal
framed structures.

230
230

110

11.119 LW

11.162 LW

Masonry One Brick is manufactured

in 90 and 110mm thicknesses and in
a range of size formats to suit many
fire and/or acoustic wall construction
applications.
For larger masonry panel applications,
also refer to Block products in section
D (Engineered Blocks) in this guide.

76

110

Masonry One Brick

162

230

FIRE DESIGN
CONSIDERATIONS
Masonry One Brick utilises a
unique material blend which has
been shown through fire testing to
provide excellent fire insulation,
integrity and structural adequacy
characteristics.

ACOUSTIC DESIGN
CONSIDERATIONS
Boral Masonry One Brick provides
excellent sound resistance with a wide
variety of board-lining systems.
Please refer to acoustic test/estimate
data in Book 1 of the Boral Masonry
Design Guide for appropriate
systems.

11.76 VLS

Colour and Availability

No minimum order quantities apply.
Lead time 0-2 weeks.

Natural Grey

Specifications
Product
Code

Actual
TxLxH (mm)

Average
Unit
Wt
kg

9.119 LW

90x290x119

4.2

10

<20

25.8

336

9.162 LW

90x290x162

6.1

10

<20

19.4

288

11.119 LW

110x230x119

4.2

10

<25

32.3

350

11.162 LW

110x230x162

5.5

10

<25

24.2

300

11.76 VLS

110x230x76

3.2

10

Solid

48.5

560

BORAL MASONRY DESIGN GUIDE

September 2008

Unit
g uc
MPa

Perforation
%

N
per
m2

N
per
Pallet

F3

New South Wales Book 2 F

162

290

90

162

110

9.162FL

230

11.162FL

FireLight Bricks (FL)

INTRODUCTION
Boral FireLight bricks are
manufactured from a low-density
material which provides high fire
rated performance and minimum
weight for non-loadbearing
applications.
Boral FireLight is ideal for concrete
framed office buildings and high-rise
home units.
FireLight is manufactured in 90 and
110mm thicknesses and in a range of
size formats to suit all types of fire
and/or acoustic wall construction.
Boral FireLight blocks are also
available . Please refer to the
appropriate product pages in this
Boral Masonry Block Guide.

FIRE DESIGN
CONSIDERATIONS
FireLight is a fire tested lightweight
concrete which is unique to Boral,
and provides excellent fire rating
characteristics. Please refer to the
fire performance characteristics in
Book 1.

ACOUSTIC DESIGN
CONSIDERATIONS
Boral FireLight gives excellent sound
resistance with a wide variety of
tested board-lining systems.
Please refer to acoustic test/estimate
data in Book 1 of the Boral Masonry
Design Guide for appropriate
systems.

Colour and Availability

No minimum order quantities apply.
Lead time 0-2 weeks.

Natural Grey

Specifications
Product
Code

Actual
TxLxH (mm)

Average
Unit
Wt
kg

9.162FL

90x290x162

4.5

<20

19.4

288

11.162FL

110x230x162

4.5

<25

24.2

300

F4

Unit
g uc
MPa

Perforation
%

N
per
m2

N
per
Pallet

September 2008 | BORAL MASONRY DESIGN GUIDE

New South Wales Book 2 F

NOTES

BORAL MASONRY DESIGN GUIDE

September 2008

F5

eBC 03764 September 2008

Customer Support New South Wales

1.

Stock colours Colours other than stock colours are made to order. Not all colours displayed in this brochure are available in all states.
(Contact your nearest Boral Masonry office for your areas stock colours.)
A surcharge applies to orders less than the set minimum quantity.

2. Brochure colours The printed colours in this Masonry Design Guide are only a guide. Please ask to see a sample of your colour/texture
before specifying or ordering.
3. Colour and texture variation The supply of raw materials can vary over time. In addition, variation can occur between product types and
production batches.
4. We reserve the right to change the details in this publication without notice.
5. For a full set of Terms and Conditions of Sale please contact your nearest Boral Masonry sales office.

Technical Enquires

Specifier Line
Internet

1300 360 255

[Link]/masonry

Orders, Product Samples and Sales Enquires

NSW

Clunies Ross Street, Prospect, 2148

T: (02) 9840 2333

F: (02) 9840 2344

ACT

16 Whyalla Street, Fyshwick, 2609

T: (02) 6239 1029

F: (02) 6280 6262

Other Regional Sales Offices

Victoria

Level 1 Port IT, 63-85 Turner Street, Port Melbourne, 3207

T: (03) 9363 1944

F: (03) 9363 6008

South Australia

Main North Road, Pooraka, 5095

T: (08) 8262 3529

F: (08) 8260 3011

Queensland

62 Industrial Ave, Wacol, 4076

T: (07) 3271 9292

F: (07) 3271 1581

Cairns

8 Palmer Street, Portsmith, 4870

T: (07) 4035 1888

F: (07) 4035 1208

Townsville

360 Bayswater Road, Garbutt, 4814

T: (07) 4725 6285

F: (07) 4725 6043

Mackay

David Muir Street, Slade Point, 4740

T: (07) 4955 1155

F: (07) 4955 4130

North Queensland:

Masonry One, Designer Block and FireLight are registered trademarks of Boral Masonry.
Boral Masonry - all rights reserved 2008.