CVEN342 Materials of Construction

Lecture 13 Masonry Components

Maryam S. Sakhaeifar, Ph.D. Assistant Professor Zachry Department of Civil Engineering Ph: (979) 845-9961 E-mail: msakhaeifar@civil.tamu.edu 1

Masonry
One of oldest construction materials
Pyramids, Greek & Roman Ruins, Great Wall of China

Components
Masonry units Mortar

Composite Behavior

Hagia Sophia

Hagia Sophia

Hagia Sophia

Basilica Cistern

Masonry Roof Structure

Water Storage

Masonry Units
Types Manufacturing Properties & Specifications
Use

Types of Masonry Units

Location
Interior Exterior Wall Facing Flooring

Type of construction
Hollow (cored 25-60%) Solid (cored < 25%)

Type of load
Structural Non-load bearing

Bed Stretcher Face

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Header Face

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Types of Masonry Units

Manufacturing Clay Brick

Raw Material Clays (Surface, Fire/Deep, Shale/Hardened)

Masonry Units Solid Hollow Concrete Masonry Unit

Silica, alumina, metallic oxides (appearance)

Stone

Glass Block Modular Cored < 25%

Clay Brick

Concrete Brick Nonmodular Common

Structural Clay Tile

Clay properties Impact strength, durability, expansion, appearance Plastic (shaped, molded) Sufficient strength (maintain shape) Fuse at elevated temperatures Blend clays to obtain desired properties

Focus on Clay Brick (Solid: Building, Facing, Paving; Hollow)

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Manufacturing Clay Brick

Winning & Storage Crushing, Sizing, & Blending Forming / Molding
Tempering by adding water Stiff-Mud (Extrusion) Process
Common <15% moisture Extrusion through die Wire-cut
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Manufacturing Clay Brick

Forming / Molding (continued)
Soft-Mud (Molded) Process
Older process, third-world Higher moisture content Pressed into molds lubricated with either sand (sandstruck) or water (water-struck)

Dry-Press Process
Low plasticity Pressed into molds using hydraulic or air pressure
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Manufacturing Clay Brick

Coating, Glazing, or Applying Texture (optional) Drying Firing in Kiln Cooling Drawing (Packing, Storing, & Shipping)

Properties of Clay Brick

Affected by
Composition of raw materials Manufacturing processes

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Durability (F/T) IRA Abrasion Index (paving) Aesthetics Color, Texture

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Durability
Ability to resist changes in environmental conditions
Freeze-thaw is primary concern

Controlled by degree of fusion Predictors of durability

Compressive strength Absorption Specified limits on these properties & saturation coefficient (F/T test may be used)
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Compressive Strength (ASTM C 67)

C = P / A C = Compressive strength P = Maximum load A = Average of upper & lower bearing surface areas

Water Absorption (ASTM C67)

Affects Durability (resistance to freezing) 24 hr submersion in cold water 5 hr submersion in boiling water % Absorption = 100 (Ws - Wd) / Wd Ws = saturated specimen weight after submersion Wd = dry specimen weight

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Saturation Coefficient (C/B ratio) (ASTM C67)

Ratio of easily fillable void space to total available void space C/B = (Wc24 - Wd) / (Wb5 - Wd) Wc24 = saturated specimen weight after 24 hr submersion in cold water Wb5 = saturated specimen weight after 5 hr submersion in boiling water Wd = dry specimen weight
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Initial Rate of Absorption (IRA) (ASTM C67)

IRA = ((Wa - Wd) / An) * 30 in2 Wa = Specimen weight after partial immersion (1/8) for 1 minute Wd = Dry specimen weight An = Net cross-sectional area of immersed surface

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Initial Rate of Absorption (IRA) (ASTM C67)

Affects bond strength Only small effect on durability Desired IRA/Suction < 30g/min per 30 in2 (Ideal IRA = 20 g/min per 30 in2) Pre-wet if > 30 g/min per 30 in2
SSD condition Excess water causes bleeding, floating
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Initial Rate of Absorption (IRA) (ASTM C67)

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Aesthetics
Color
Chemical composition, firing temperature, method of firing control Iron has greatest effect Flashing (reducing oxygen) used to change color of surface

Specifications for Clay Brick

Dimensions (Fig. 2.2) Type Specified Color Nominal = Specified + Texture Mortar Joint Thickness 1/2 or 3/8 = common Size (Fig. 2.1) mortar joints Shape (Fig. 2.3) Classification (ASTM)

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Surface Features
Texture Coatings Glazes (may trap moisture)

Grade Type Class Application

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Clay Brick Sizes

Clay Brick Shapes

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Specifications for Clay Brick

ASTM Standards (Types)
C 62 (Building Brick) C 216 (Facing Brick) C 902 (Paving Brick) C 652 (Hollow Brick)
Other Standards for Other Types of Masonry Units

ASTM C 62 Building Brick

Solid masonry units Appearance not a consideration Grades = f (environment)
SW - Severe weathering, may be frozen when permeated with water MW - Moderate weathering (TX) NW - No weathering, interior use

Other

C 126 (Ceramic Glazed Structural Clay Facing Tile, Facing Brick, & Solid Masonry Units) C 1088 (Thin Veneer Brick)
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ASTM C 62 Building Brick

Grade Requirements (Table 2.1)
Exposures Weathering Index Less 50 Than and 50 greater MW MW SW MW SW SW SW SW

In vertical surfaces: In contact with earth Not in contact with earth In other than vertical surfaces: In contact with earth Not in contact with earth

weathering index = (average annual number of freezing cycle days) * (average annual winter rainfall (inches)) 31

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ASTM C 62 Building Brick

Physical Requirements (Table 2.2)
Min. Compressive Strength psi (MPa) Grade Avg of 5 SW 3000 (20.7) MW 2500 (17.2) NW 1500 (10.3) Single 2500 (17.0) 2200 (15.2) 1250 (8.6) Max. Water Absorption by 5 hr boiling (%) Avg of 5 Single 17 20 22 25 Max. Saturation Coefficient Avg of 5 0.78 0.88 Single 0.80 0.90

ASTM C 216 Facing Brick

Solid Masonry Units Appearance is a consideration Limits chips, Cracks Tolerances on Dimensions, Distortions Grades (same requiremnts as C 62) SW - Severe Weathering, May be frozen when permeated with water MW - Moderate Weathering Types FBS - Standard, General exposed use FBX - Select, Tighter Control on size FBA - Architectural, Non-uniform, Used look
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No limit No limit No limit No limit

Saturation Coefficient = ratio of absorption by 24 hr submersion in cold water to absorption after 5 hr submersion in boiling water
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ASTM C 902 Paving Brick

Only for pedestrian & light vehicular traffic
Patios / plazas, walkways, floors, driveways

ASTM C 902 Paving Brick

Types
Type I - Extensive Abrasion
Driveways, Building Entrances

Classes
SX - severe exposure, may be frozen when saturated with water MX - moderate exposure, resistance to freezing not a factor NX - no exterior exposure, interior use with surface coating
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Type II - Intermediate Traffic

Store / Restaurant Floors, Exterior Walkways

Type III - Low Traffic

Floor / Patios in Homes

Applications
PS - Standard, with Mortar Joints PX - Select, without Mortar Joints, Tighter Control on Size PA - Architectural, Non-uniform, Used Look
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ASTM C 902 Paving Brick

Physical Requirements (Table 2.3)
Min. Compressive Strength psi (MPa) Class Avg of 5 SX 8000 (55.2) MX 3000 (20.7) NX 3000 (20.7) Single 7000 (48.3) 2500 (17.2) 2500 (17.2) Max. Water Absorption by 24 hr soaking (%) Avg of 5 Single 8 11 14 17 Max. Saturation Coefficient Avg of 5 0.78 Single 0.80

Concrete Paver Units

No limit No limit

No limit No limit No limit No limit

Saturation Coefficient = ratio of absorption by 24 hr submersion in cold water to absorption after 5 hr submersion in boiling water
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ASTM C 652 Hollow Brick

Hollow Masonry Units Grades (same requirements as C 62)
SW - severe weathering, may be frozen when permeated with water MW - moderate weathering

Mortar
Definitions Differences w/ other cementitious mixtures Classes Components Types Properties

Classes
H40V - 25-40% voids in cross section parallel to bearing surface H60V - 40-60% voids in cross section

Types
HBS - standard, general exposed use HBX - select, tighter control on size HBA - architectural, non-uniform, used look HBB - appearance not a consideration
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Mortar
Cementitious Materials
Lime Portland Cement

Mortar
Weak link in masonry construction Thin layer stronger (compression) than thick layer Lime added
Workability Adhesive properties Extensibility

Sand Water

Used with individual masonry units

Bonding Bedding / Seating Leveling Sealing Irregularities Providing Strength Providing Aesthetic Qualities

GROUT
Used to bond two masonry wythes together (walls one unit Fine and Coarse thick) Aggregate Filling cores and voids Cement Sand Water High Slump
Binding reinforcing steel and wythes Providing load carrying capability

Differences w/ Other Cementitious Mixtures

Component materials
Mortar
Cement, Lime, Water, Fine Aggregate

Grout
Cement, Water, Fine Aggregate, Small-sized Coarse Aggregate

ASTM C476 Fine and coarse grouts fC - less No Segregation in non-absorbent molds
Match with masonry fC

Portland cement concrete

Cement, Water, Fine Aggregate, Coarse Aggregate

Proportions

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Differences w/ Other Cementitious Mixtures

Structural Performance
PCC is structural material, resists mainly compressive stresses Mortar, grout are binders, develop strong & durable bond w/ masonry unit

Components
Portland Cement

Lime
Workability Water Retentivity Elasticity Bond Strength Extensibility

Durability High Early Strength High Compressive Strength Bond Strength

Workability & Placement Methods

PCC placed in non-absorbent forms, minimum water, w/c ratio very important to performance Mortar, grout placed in absorptive forms, much more water, w/c ratio less important
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Sand
Filler Strength

Water
Flow Required for Hydration

Admixtures

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Components
Portland Cement
Type I - General use when special properties not required Type II - When moderate sulfate resistance or moderate heat of hydration required Type III - When high early strength required Air entrained portland cements tend to reduce bond strengths

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