MASONRY

Masonry units can be classified as

■ concrete masonry units
■ clay bricks
■ structural clay tiles
■ glass blocks
■ stone

CONCRETE MASONRY UNITS

Solid concrete units are commonly called concrete bricks, while hollow units are known as concrete
blocks, hollow blocks, or cinder blocks. Hollow units have a net cross-sectional area in every plane
parallel to the bearing surface less than 75% of the gross cross-sectional area in the same plane. If this
ratio is 75% or more, the unit is categorized as solid (Portland Cement Association, 1991).

Concrete masonry units are manufactured in three classes, based on their density: lightweight units,
medium-weight units, and normal-weight units. Well-graded sand, gravel, and crushed stone are used
to manufacture normal-weight units. Lightweight aggregates such as pumice, scoria, cinders, expanded
clay, and expanded shale are used to manufacture lightweight units. Lightweight units have higher thermal
and fire resistance properties and lower sound resistance than normal weight units.
Concrete masonry units are manufactured using a relatively dry (zero-slump) concrete mixture consisting
of portland cement, aggregates, water, and admixtures. Type I cement is usually used to manufacture
concrete masonry units; however, Type III is sometimes used to reduce the curing time. Air-entrained
concrete is sometimes used to increase the resistance of the masonry structure to freeze and thaw effects
and improve workability, compaction, and molding characteristics of the units during manufacturing. The
units are molded under pressure, then cured, usually using low-pressure steam curing. After manufacturing,
the units are stored under controlled conditions so that the concrete continues curing. Concrete masonry
units can be classified as load bearing (ASTM C90) and non load bearing (ASTM C129). Load-bearing
units must satisfy a higher minimum com pressive strength requirement than non–load-bearing units, as
shown in Table 8.2. The compressive strength of individual concrete masonry units is determined by cap
ping the unit and applying load in the direction of the height of the unit until failure (ASTM C140). A full-
size unit is recommended for testing, although a portion of a unit can be used if the capacity of the testing
machine is not large enough. The gross area compressive strength is calculated by dividing the load at
failure by the gross cross sectional area of the unit. The net area compressive strength is calculated by
dividing the load at failure by the net cross-sectional area. The net cross-sectional area is calcu lated by
dividing the net volume of the unit by its average height. The net volume is determined using the water
displacement method according to ASTM C140.

Concrete masonry units are available in different sizes, colors, shapes, and textures. Concrete masonry units
are specified by their nominal dimensions. The nominal dimension is greater than its specified (or modular)
dimension by the thickness of the mortar joint, usually 10 mm (3/8 in.). For example, a 200 mm * 200 mm
* 400 mm (8 in. * 8 in. * 16 in.) block has an actual width of 190 mm (7-5/8 in.), height of 190 mm (7-5/8
in.), and length of 390 mm (15-5/8 in.).
Load-bearing concrete masonry units are available in nominal widths of 100, 150, 200, 250, and 300 mm
(4, 6, 8, 10, and 12 in.), heights of 100 and 200 mm (4 and 8 in.), and lengths of 300, 400, and 600 mm (12,
16, and 24 in.). Also, depending on the position within the masonry wall, they are manufactured as stretcher,
single-corner, and double-corner units.

Solid concrete masonry units (concrete bricks) are manufactured in two types based on their exposure
properties: concrete building bricks (ASTM C55) and concrete-facing bricks (ASTM C1634). The concrete
building bricks are manufactured for general use in non-facing, utilitarian applications, while the concrete
facing bricks are typically used in applications where one or more faces of the unit is intended to be exposed.
The concrete-facing bricks have stricter requirements than the concrete building bricks. The maximum
allowable water absorption of the concrete-facing bricks is less than that of the concrete building bricks.
Also, the minimum net area compressive strength of the concrete-facing bricks is higher than that of the
concrete building bricks.
CLAY BRICKS
Clay bricks are small, rectangular blocks made of fired clay. The clays used for brickmaking vary widely
in composition from one place to another. Clays are composed mainly of silica (grains of sand), alumina,
lime, iron, manganese, sulfur, and phosphates, with different proportions. Bricks are manufactured by
grinding or crushing the clay in mills and mixing it with water to make it plastic. The plastic clay is then
molded, textured, dried, and finally fired. Bricks are manufactured in different colors, such as dark red,
purple, brown, gray, pink, or dull brown, depending on the firing temperature of the clay during
manufacturing. The firing temperature for brick manufacturing varies from 900°C to 1200°C (1650°F to
2200°F). Clay bricks have an average density of 2 Mg/m3.

Clay bricks are used for different purposes, including building, facing and aes thetics, floor making, and
paving. Building bricks (common bricks) are used as a structural material and are typically strong and
durable. Facing bricks are used for facing and aesthetic purposes and are available in different sizes, colors,
and tex tures. Floor bricks are used on finished floor surfaces and are generally smooth and dense, with
high resistance to abrasion. Finally, paving bricks are used as a paving material for roads, sidewalks, patios,
driveways, and interior floors. Paving bricks are available in different colors, such as red, gray, or brown,
are typically abrasion resistant and could usually be vitrified (glazed to render it impervious to water and
highly resistant to corrosion).
Clay bricks are very durable and fire-resistant and require very little maintenance. They have moderate
insulating properties, which make brick houses cooler in summer and warmer in winter, compared with
houses built with other construction materials. Clay bricks are also noncombustible and poor conductors.

MORTAR
Mortar is a mixture of cementitious material, aggregate, and water. Mortar can be classified as cement-lime
mortar, cement mortar, or masonry cement mortar. Mortar is used for the following functions:
■ bonding masonry units together, either non-reinforced or reinforced
■ serving as a seating material for the units
■ leveling and seating the units
■ providing aesthetic quality of the structure

Mortar starts to bind masonry units when it sets. During construction, bricks and blocks should be rubbed
and pressed down to force the mortar into the pores of the masonry units to produce maximum adhesion. It
should be noted, however, that mortar is the weakest part of the masonry wall. Therefore, thin mortar layers
generally produce stronger walls than thick layers. Unlike concrete, the compressive strength is not the
most important property of mortar. Since mortar is used as an adhesive and sealant, it must form a complete,
strong, and durable bond with the masonry units and with the rebars that might be used to reinforce masonry
walls. The ability to bond individual units is measured by the tensile bond strength of mortar (ASTM C952),
which is related to the force required to separate the units. The tensile bond strength affects the shear and
flexural strength of masonry. The tensile bond strength is usually between 0.14 and 0.55 MPa (20 to 80
psi) and is affected by the amount of lime in the mix.

GROUT
Grout is a high-slump concrete consisting of portland cement, sand, fine gravel, water, and sometimes lime.
Grout is used to fill the cores or voids in hollow masonry units for the purpose of
(1) bonding the masonry units,
(2) bonding the reinforcing steel to the masonry,
(3) increasing the bearing area,
(4) increasing fire resistance, and
(5) improving the overturning resistance by increasing the weight.

The minimum compressive strength of grout is 14 MPa (2000 psi) at 28 days, according to ASTM C476.

PLASTER

Plaster is a fluid mixture of portland cement, lime, sand, and water, which is used for finishing either
masonry walls or framed (wood) walls. Plaster is used for either exterior or interior walls. Stucco is plaster
used to cover exterior walls. The average compressive strength of plaster is about 13.8 MPa (2000 psi) at
28 days.

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