Blockwork Manual

BORAL MASONRY
Build something great
Masonry Design Guide

MASONRY BLOCKS AND BRICKS VICTORIA BOOK 2
www.boral.com.au/masonry
Updated 2010
PAGE
PAGE
Victoria Book 2 A
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2
Products @ a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4
Fast Find Product and Application Guide . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8
Designer Block
Contemporary Colours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2
Split Face - Series 100, 150 and 200 . . . . . . . . . . . . . . . . . C11
Textures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4
Tiled Face Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C12
Smooth, Honed, Polished Face - Series 100/120 . . . . . . . . C6
Installation Details Series 100 Blocks . . . . . . . . . . . . . . . . C13
Smooth, Honed, Polished Face - Series 150 . . . . . . . . . . . . C8
Smooth, Honed, Polished Face - Series 200 . . . . . . . . . . . C10
Engineered Blocks
Scoria Blend (SB) High Fire Rated Block . . . . . . . . . . . . . D2
Typical Component Usage - Series 100 Block . . . . . . . . . . D10
Ash Grey Block (AG) - Series 100 and 120 . . . . . . . . . . . . . D4
Ash Grey Block (AG) - Series 150 . . . . . . . . . . . . . . . . . . . . D6
Ash Grey Block (AG) - Series 200 . . . . . . . . . . . . . . . . . . . . D7
AcousticellTM Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13
Back-Up Block - Ash Grey (AG) - Series 100 and 150 . . . . . D8
Core-Fill Block
Coloured Designer Block . . . . . . . . . . . . . . . . . . . . . . . . . . E3
Ash Grey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E4
Engineered Bricks
Concrete-Basalt Brick (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . F2
FireLight Quick Brick (FL) . . . . . . . . . . . . . . . . . . . . . . . . . . . F4
Scoria Quick Brick (SB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3
Omega Brick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5
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
2010 | BORAL MASONRY DESIGN GUIDE
Victoria Book 2 A
NLB = Non-loadbearing
LB = Loadbearing
W
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A
BORAL
MASONRY
BLOCK and
BRICK
PRODUCTS
ry
The quickest way to find a Boral Masonry Block or Brick Solution.

Simply follow the FAST FIND GUIDE on the right hand side of the table.
Fast Find
a Boral
Solution
NLB LB NLB LB NLB LB NLB LB NLB LB
Designer Block
Standard Ash Grey Block (AG)
C6
C6
D4 D4
D4 D4 D4 D4
E3
E3
1 Select your application

Back-Up Block - Ash Grey (AG)
D8 D8
D8 D8 D8 D8
Scoria Blend (SB) High Fire Rated Block
D2
D2
D2
Acousticell
D13
D13
Core-Fill Block
E3
E3
E3
E3
E3
E3
E3
E3
E3
E3
Concrete-Basalt Bricks (B)
F2
F2
F2
F2
F2
F2
Scoria Quick Brick (SB)
F3
F3
F3
FireLight Quick Brick (FL)
F4
Omega Brick
F5
F5
F5
criteria from the top of

the table
2 Go straight to the
section letter and page
number indicated at the
intersection of product
rows and application
columns (e.g. Section D,
Page D2 in this example)
Best performance is achieved

with plasterboard lining
For technical support and sales office details please refer to the outside back cover
BORAL MASONRY DESIGN GUIDE
2010
A3
Victoria
Vi
V
icctttor
oriiaa BBook
ooook 2 A
Architect: Harry Seidler and Associates
Architect: Paul Campbell Architects
Boral Feature Face Masonry

for External and Internal Walls
Designer Block
7 Contemporary Colours.
4 Innovative Textures Smooth, Honed, Polished
or Split Face
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.
Standard Ash Grey Block (AG)

Hollow Concrete Block suitable for loadbearing
and non-loadbearing applications. Basalt Content
>45%
Back-up Block
Ash Grey Concrete Block in 162mm height
(equivalent to 2 courses of standard brick). Designed
for cost effective construction of the back-up leaf
in face brick veneer walls.
Scoria Blend (SB)

Manufactured from fire tested Scoria Blend material
offering High Fire Performance, ideal for high rise
buildings of reinforced concrete or portal frames.
Architect: Lawrence Nield and Partners
A4
Victoria
V
Vic
icttor
oria
ia Book
BBoo
Bookk 2 A
Architect: Nettleton Tribe Architects
Boral Engineered Bricks

for Structural, Fire and Acoustic Wall Systems
Concrete-Basalt Brick (B)
Core-Fill Block
Ash Grey Concrete Block or Designer Block coloured
and textured finishes for reinforced retaining
walls and loadbearing walls requiring increased
robustness.
Acousticell
Engineered block for premium sound absorption

in entertainment centres, sound studios, around
transformers, generators and attenuation of
industrial and commercial noise.
2010
Standard Size and Quick Brick (162mm height) in

Concrete-Basalt material for good fire performance
and loadbearing characteristics.

Medium weight Quick Brick for non-loadbearing fire
and/or acoustic systems. Quick Brick format (162mm
height) for faster more cost effective construction.

Lightweight Quick Brick for non-loadbearing fire and/or
acoustic systems where weight saving is important.
Quick Brick format (162mm height) for faster more
cost effective construction.
A5
Victoria Book 2 A
Please note that this guide is based on products available at

the time of publication from Boral Masonry Victorian 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 Masonry Blocks, Masonry Bricks, 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 Blocks and Bricks guide, (this book),
details a comprehensive selection of decorative, structural,
fire and acoustic walling solutions not available with other
materials.
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. Please, 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
PAGE
Victoria Book 2 C
BOOK
Book, Page
and Section
Identification
C10
Designer Block
Series
Block
Series 200
200
Smooth, Honed
Honed and
and Polished
Polished Face
Face
Product information
relating to features,
applications,
texture finishes and
accessories
INTRODUCTION
INTRODUCTION
Series
Series 200
200 Designer
Designer Block
Block (190mm
(190mm thickness)
thickness)
is
is suitable
suitable for
for internal
internal and
and external
external walls
walls in
in
loadbearing
loadbearing and
and non-loadbearing
non-loadbearing applications.
applications.
9090
390
390
190
190
FACE
FACE TEXTURES
TEXTURES
Series
Series 200
200 Designer
Designer Block
Block units
units are
are available
available
with
with the
the following
following face
face texture
texture finishes:
finishes:
190
190
20.01
20.01
Full
Full
Smooth
Smooth Face
Face
Honed
Honed Face
Face
Polished
Polished Face
Face
390
390
20.71
20.71
Half
HalfHeight
Height
190
190
190
190
290
290
190
190
Ends
Ends Honed
Honed or
or Polished
Polished finishes.
finishes.
190
190
20.02
20.02
Three Quarters
Three Quarters
COLOURS
COLOURS
Designer Block units are available in 7 colours.
Designer Block units are available in 10
Please refer to page C5 for additional information.
colours. Please refer to page C5 for additional
information. colours and textures are also
Customised
390
390
190
190
190
190
20.03
20.03
Half
Half
40
40
190
190
190
190
190
190
90
90
20.04
20.04
Quarter
Quarter
390
390
50.31
50.31
Capping/Sill
Capping/Sill
NOTE: Designer Block units for reinforcement are detailed on page E3.
Specifications
Specifications
Availability
Availability
Lead times apply to all coloured blocks.
Leadsize
times
applyare
to best
all coloured
blocks.
Part
blocks
cut/bolstered
on-site to maintain
colour
Part size
blocks arePart
bestsize
cut/bolstered
to maintain
consistency.
blocks canon-site
be made-to-order.
Contact
Boral Masonry
forsize
further
details.
colour consistency.
Part
blocks
can be made-to-order.
Contact Boral Masonry for further details.
C10
A6
Product Icons
with dimensions
for products
available in your
region/state
20.12
20.12
Bond Beam or Lintel
Bond Beam or Lintel
190
190
possible. Please note that extended lead times

Customised colours and textures are also
and minimum order quantities may apply.
Availability
information for
products distributed
in your region/state
Product Name and

other identifying
feature, such as
texture finish
190
190
Code
Code
20.01
20.01
20.02
20.02
20.03
20.03
20.04
20.04
20.71
20.71
20.12
20.12
50.31
50.31
Product Description
Product Description
Full
Full
Three Quarters
Three Quarters
Half
Half
Quarter
Quarter
Half Height (cut/made-to-order)
Lintel or Bond Beam
Lintel or Bond Beam
Capping
Capping
MPa
MPa
10
10
10
10
10
10
10
10
10
10
10
10
Wt kg
Wt kg
15.9
15.9
12.0
12.0
7.5
7.5
5.6
5.6
8.0
8.0
18.0
18.0
6.0
6.0
N/Pallet
N/Pallet
90
90
96
96
144
144
252
252
162
162
72
72
216
216
Product
Specifications
BORAL MASONRY

B PLANNING AND DESIGN
Victoria Book 2 B
Material and Dimensional Variation
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.
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.
Modular Planning
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.
1 metre
1 metre
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.
12.5 blocks/m2
Fig B1 Typical Block Dimensions
Most blocks are available in three thicknesses of 90mm (Series

100), 140mm (Series 150) and 190mm (Series 200). For product
information, refer to Sections B and C of this guide.
Boral Masonry Victoria 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.
Boral Masonry Victoria also manufactures a range of Concrete
Back-Up Series Blocks. Back-Up Blocks are 162mm high to
match two standard size brick courses, with mortar. They are
generally used to construct one leaf of a wall, while the other is
constructed with standard size bricks. Boral Back-Up Blocks are
also made in fractional sizes, including 90, 190, 290 and 390mm
lengths to match standard block modules. Refer to technical
information later in this section, and to Section D of this guide
for Back-Up Block product details.
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.
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 (or factory cut to order) from the
full length units, to maintain colour consistency.
NOTE: All saw grindings must be washed off the cut blocks as they
are cementitious. They are invisible while wet, but if allowed to dry,
they appear as a pastel colour and are difficult to move.
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.
Before specifying your choice, please contact your local Boral

Masonry sales office to confirm availability in your region.
B2
Victoria 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.
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 iron oxides.
For colours other than greys, off-white cement and clean sand
will assist colour matching.
Construction of sample walls is recommended to determine
the appropriate mortar colour.
Staining on light coloured units can be reduced by the use of
off-white cements.
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, and additional sealing should not be required.
2010
B3
Victoria 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.
Raked Joint
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:
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
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.
Joint Reinforcement
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.
(Commonly known as Tram Track)

Masonry Mesh Joint Reinforcement is recommended for nonloadbearing and loadbearing wall applications.
The mesh should be laid between courses at height intervals of
600mm. This equates to every three courses using the 190mm
high standard unit.
At all openings, mesh should be included in the two courses
above and below the opening.
50mm wide mesh to be used for 90mm blockwork.

100mm wide mesh to be used for 140mm wide
blockwork.
Fig B3 Ironed Joint
150mm wide mesh to be used for 190mm wide

blockwork.
Masonry Mesh is available from Boral Masonry Victoria in the
above widths in 3 metre lengths in bundles of 10.
B4
Victoria Book 2 B
used to construct one leaf of a wall, while the other is constructed

with standard size bricks. Boral Back-Up Blocks are made in
various lengths (90, 190, 290 and 390mm) to match standard
block modules. Refer to Section D of this guide for Back-Up
Block product details.
Brickwork
Design Considerations
Sizes
The dimensions of standard brick are: 76mm high x 230mm
long x 110mm thick.
Boral Masonry Victoria manufactures a range of Concrete
Bricks and Back-Up Series Blocks in various modular sizes to
complement standard blockwork and brickwork construction.
The Boral Quick Brick is 162mm high x 230mm long x 110mm
wide. 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 for product details.
Boral Back-Up Series Blocks are also 162mm high to match two
standard size brick courses, with mortar. They are generally
Table B2 Brick Quantities per Square Metre

(No allowance for wastage)
Face Size
Bricks per m2
76 x 230
48.5
119 x 230
32.3
162 x 230
24.3
162 x 390
14.6
Additional information is provided on individual product pages

in the following sections 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
2010
B5
Victoria 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

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

Double Height/Standard Length Brick
B6
Victoria Book 2 B
Control Joints
Articulation Joints
(Expansion Gaps)
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.
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.
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.
Articulation joints provide the flexibility needed when building

on reactive clay soils. Articulation is not 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
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.
Table B3 Control Joint Spacing

Product
Spacing
Dense-Weight Masonry (Standard Concrete)
8 metres
Medium Density Masonry (Fire Rated Scoria Blend)
8 metres
Lightweight Masonry (< 1500 kg/m3)
6 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
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
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
2010
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
Victoria 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 force 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. (Sand supplies of a suitable standard are normally
readily available in Victoria).
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 Block products can be laid in convention
mortar, however for the presealing to be effective, it
MUST be laid in mortar containing Designer Block
Additive. Refer to Tables B4 and B5 for mortar mixture
details.
Lime or plasticisers must NOT be added to mortar with
Boral Designer Block additive.
Other Admixtures
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.
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 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 section
detailing mortar mixes in this guide.
B8
Victoria Book 2 B
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
1
0.5
Designer Block
Additive
Methyl
Cellulose
Additive
Minimum
Mortar
Classification
Yes
Yes
No
No
No
No
No
Yes
M3
M4
Designer Block products
M3
General purpose with moderate exposure.
No
No
M4
Structural blockwork and severe exposure (marine

and industrial environments). External walls adjacent
to seafront, below damp-proof course, fences.
4.5
No
Yes
Where Used (exposure)

(See AS3700-2001: Table 5.1)
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
Ash Grey Block
Designer Block products
Mix in 1 : 1 : 6 proportions
Mix in 1 : 5 proportions
Cement:
14 bags (20kg each)
Cement:
16 bags (20kg each)
Lime:
5 bags (20kg each)
Designer Block additive:
8 litres
Sand:
1.2m3
Sand:
1.2m3
Mix in 1 : 0.5 : 4.5 proportions
NOTE: Designer Block products

may also be used with white
cement to match coloured face
blockwork.
M4
Mix in 1 : 4 proportions
Cement:
18 bags (20kg each)
Cement:
20 bags (20kg each)
Lime:
3 bags (20kg each)
Designer Block additive:
8 litres
Sand*:
1.2m3
Sand :
1.2m3
* Allowed 20% extra sand for bulking

#
Use brickies sand
2010
B9
Victoria Book 2 B
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:
Characteristic Compressive Strength 20MPa;
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. (Based on 10mm rounded aggregate
and 300kg/m3 cement.)
Grouting
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 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). 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.
In hot weather it may be necessary to hose the cores out with
water in order to cool the blocks and so prevent flash-setting
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.
When grouting Series 150 blocks, lifts should be reduced to
800mm (4 courses) to ensure no voids are left in the wall.
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
15.48 H-block (Single Web)
175
20.01 Full
120
20.42 Notch
120
20.142 Split Face
125
100
65
Grout Pumping and Core Filling
B10
Victoria 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.
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.
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.
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.
2010
B11
Victoria Book 2 B
Pressure cleaning may be carried out with pressure not

exceeding 7MPa (1000 psi) 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 dilute 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
Victoria 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;
of the lime tends to take place. The powdery lime gradually

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.
2. There must be water entering the masonry; and
Safety Precautions and Warnings
3. The masonry must be able to dry out.
When using chemicals, care must be taken to avoid damage to

adjacent materials and finished surfaces. Masking and plastic
sheeting may be necessary;
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;
To avoid personal injury, wear protective clothing and vapour

cartridge breathing mask-particularly in confined areas, as
recommended by chemical manufacturers;
NEVER mix chemicals with which you are unfamiliar,
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;
Harsh acidic chemicals should never be used for the cleaning
of blockwork; and
Chemical wastes must not be allowed to run down drains
and storm water outlets in accordance with Environmental
Protection Regulations.
Poor or missing copings and flashings;

Excessively raked joints which allow water to enter the
bed face of the masonry (ironed joints are recommended);
and
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
2010
B13
Victoria
V
Vic
cto
tor
oriaa Bo
Book
Book
okk 2 B
NOTES
B14
BORAL MASONRY

C DESIGNER BLOCK
Victoria 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 7 contemporary colours and 4
bold textures or customise to create an individual look
(please note longer lead times and surcharges may apply
for this service).
Architect: Michael Dore (Architect) in association with Castles, Stephenson and Turner Architects
C2
Almond Split Face
Victoria Book 2 C
Architect: Woods Bagot
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.
To be effective, Designer Block units must be laid in
mortar containing Borals recommended additive.
Designer Block products are suitable for loadbearing and
non-loadbearing walls.
Architect: HPA Architects and Bates, Smart Architects
2010
Charcoal - Polished Face
C3
Victoria Book 2 C
Almond ShotBlast Face
Architect: Arkhefield Architects
Designer Block Textures

Smooth Face
Block Ends
A finely textured finish created through the standard

moulding process.
Honed or Polished finishes are available on the end of

blocks for corners, openings and free ends.
Honed Face
Availability and Quantities
The honing process grinds 2-3mm from the block

surface, producing a matt exposed-aggregate finish.
Lead times apply to all coloured blocks. Longer lead

times apply to Honed and Polished finishes as the
product must be cured for four weeks, to harden
sufficiently, before processing.
Polished Face
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.
Split Face
The splitting process produces a bold textured, exposed
aggregate finish.
No minimum order quantities apply to Essential

Colours.
Accent Colours are made to order. A surcharge may
apply. Ask your representative for details.
Boral recommends part size blocks are cut/bolstered
on-site to maintain colour consistency. Blocks can be
made to order.
NSW Dept. of Commerce, Government Architects Office. Project Architect: Cathy Kubany
C4
Victoria Book 2 C
Essential Colours
Smooth Face
Split Face
Honed Face
Polished Face
Alabaster
Almond
Charcoal
Accent Colours (minimum quantities or a surcharge may apply)

Smooth Face
Split Face
Four Innovative Textures
Sandune
Smooth Face A finely textured finish created

through the standard moulding process.
Honed Face The honing process grinds 23mm from the block surface, producing a
matt exposed-aggregate finish.
Sandstone Blend
Polished Face This involves producing

a denser block which is honed and then
buffed. Polishing enriches the colour of the
aggregates. The finely finished polished
Four Innovative Textures
surface is ideal for feature walls, trim and
Smooth Face A finely textured
banding. finish created through the standard
Paperbark
moulding process.
Split Face The splitting process produces a

Honed Face The honing process grinds
bold textured,
aggregate
2-3mmexposed
from the block
surface, finish.
producing
a matt exposed-aggregate finish.
Polished Face This involves producing
a denser block which is honed and then
Colour and Texture Variations
buffed. Polishing enriches the colour
The colours shown
in aggregates.
this brochure The
are provided
as an
of the
finely finished
indication of the
colours surface
and textures
available.
Some variations
polished
is ideal
for feature
walls,
in colour may trim
occurand
due banding.
to changes in raw materials.
Pearl Grey
In addition, variation can occur between production batches.

Split
Face The
splitting
produces
Please ask to see
a sample
of your
chosenprocess
colour/texture
before
specifying or ordering.
a bold textured, exposed aggregate finish.
2010
C5
Victoria Book 2 C
Designer Block Series 100 and Series 120

Smooth, Honed and Polished Face
INTRODUCTION
Series 100 Designer Block (90mm thickness) and
Series 120 Designer Block (110mm thickness)
are 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
Series 100 and 120 Designer Block are available
with the following face texture finishes:
Smooth Face
Specifications
Code
Product Description
MPa
Wt kg
N/Pallet
10.01
Full
10
11.6
149
10.02
Three Quarters
10
8.7
192
10.03
Half
10
5.5
252
10.04
Quarter
10
3.5
504
10.31
Full - Solid
10
14.3
139
10.32
Three Quarter - Solid
10
10.6
192
10.33
Half - Solid
10
7.0
252
10.34
Quarter - Solid
10
3.5
504
Honed Face
10.71
Half Height
10
5.5
300
Polished Face
10.83
Half Height - Solid
10
6.7
234
Ends Honed or Polished finishes.
10.26SM Corner Return
10
18.0
96
COLOURS
10.12
Lintel or Bond Beam
10
11.4
108

10.702
Squint
10
8.9
195
10.117
Quarter Height
10
3.0
432
10.39
Sill
6.8
440*
12.01
Full (110mm thickness)
10
14.0
120

* Supplied as 220 double units. Bolster on-site to achieve 440 units per pallet.
Availability
Part size blocks are best cut/bolstered on-site to maintain
colour consistency. Part size blocks can be made-to-order.
C6
Victoria Book 2 C
Designer Block Series 100 and Series 120

190
190
90
390
90
10.01
Full
290
90
10.02
Three Quarter
190
90
190
390
90
10.03
Half
190
290
90
10.32
Three Quarter
90
10.04
Quarter
190
90
10.31
Full
190
190
190
190
90
10.33
Half
90
10.34
Quarter
Series 120 Block

90
90
190
390
10.71
Half Height
390
110
12.01
Full
(1 in every 5 blocks is
universal solid)
90
90
390
10.83
Half Height
90
90
15
190
190
190
390
10.26SM
Corner Return
390
90
10.12
Bond Beam or Lintel
190
90
10.702
Squint
190
40
90
390
10.117
Quarter Height
108
50
190
50
50
110
110
100
10.39
Sill
220 double units per pallet.
Bolster on site
2010
C7
Victoria Book 2 C
Designer Block Series 150

INTRODUCTION
is suitable for internal and external walls in
Specifications
Code
Product Description
MPa
Wt kg
N/Pallet
15.01
Full
10
13.0
120
FACE TEXTURES
15.02
Three Quarters
10
9.4
128
Series 150 Designer Block units are available

15.03
Half
10
6.2
192
15.04
Quarter
10
3.3
384
Smooth Face
15.22
Corner (made-to-order)
10
11.3
108
Honed Face
15.71
Half Height
10
6.5
216
Polished Face
15.83
Half Height - Solid
10
10.4
192
15.12
Lintel or Bond Beam (made-to-order) 10
13.3
96
15.702
Squint (made-to-order)
10
12.0
84
50.31
Capping
6.0
216
COLOURS
Availability
C8
Victoria Book 2 C

190
190
190
190
390
140
290
140
15.01
Full
140
15.02
Three Quarter
190
190
140
15.03
Half
90
15.04
Quarter
140
340
15.22
Corner
90
140
390
15.71
Half Height
90
140
390
15.83
Half Height
190
190
40
140
390
130
350
190
390
15.12
Bond Beam or Lintel
15.702
Squint
50.31
Capping/Sill
*Made to order
(subject to quantity)
Made to order
*Made to order
Also refer to Core-Fill Blocks (Page E3 of this guide) for coloured retaining wall blocks.
*Made to order subject to quantity.
2010
C9
Victoria Book 2 C

INTRODUCTION
is suitable for internal and external walls in
190
90
390
190
20.01
Full
Series 200 Designer Block units are available

390
190
FACE TEXTURES
20.71
Half Height
Smooth Face
Honed Face
190
190
Polished Face
290
190
20.02
Three Quarters
COLOURS
390
190
20.12
Bond Beam or Lintel

190
190
190
20.03
Half
40
190
190
390
190
90
20.04
Quarter
50.31
Capping/Sill
Specifications
Availability
C10
Code
Product Description
MPa
Wt kg
N/Pallet
20.01
Full
10
15.9
90
20.02
Three Quarters
10
12.0
96
20.03
Half
10
7.5
144
20.04
Quarter
10
5.6
252
20.71
10
8.0
162
20.12
Lintel or Bond Beam
10
18.0
72
50.31
Capping
6.0
216
Victoria 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
390
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
390
145
10.109
10.101 Full
15.101 Full
190
40
FACE TEXTURES
Split Face - The splitting process produces a
bold textured surface resulting in characteristics
much like split natural stone.
190
90
290
95
390
95
10.102 Three Quarter
10.117 Quarter
Height
190
390
195
COLOURS
190

Customised colours are also possible. Please
note that extended lead times and minimum
order quantities may apply.
20.101 Full
190
95
10.103 Half
190
190
95
395
195
20.192 Split End
90
10.104 Quarter
15
95
95
190
108
50
190
50
50
110
40
110
100
195
395
10.39 Sill
10.26SP Corner Return

Bolster on site
190
390
50.31
Capping
Specifications
Availability
2010
Code
Product Description
MPa
Wt kg
N /Pallet
10.101
Full
t10
15.0
108
10.102
Three Quarter
t10
11.0
144
10.103
Half
t10
7.4
216
10.104
Quarter
t10
3.5
432
10.26SP Corner Return
t10
20
80
10.109
Half Height
t10
7.2
216
10.117
Quarter Height
t10
3.2
432
10.39
Sill
6.8
440*
50.31
Capping
6.0
216
15.101
Full (made-to-order)
15.5
96
20.101
Full
20.0
75
20.192
Split End (made-to-order)
20.5
48
t10
C11
Victoria Book 2 C
Tiled Face
INTRODUCTION
Boral Tiled Face Designer Block provides
a distinctive face pattern to create internal
and external walls with unique architectural
character.
FACE TEXTURES
Tiled Face is available in 90mm, 140mm or
190mm thickness blocks with a formed dummy
centre joint to form a 190 x 190mm tile face
pattern.
190
90
390
*10.01T
Tiled Face - Full
190
Tiled Face is available with the following face

textures:
Smooth
COLOURS
140
390
*15.01T
Tiled Face - Full

190
190
390
*20.01T
Tiled Face - Full
*Minimum quantities apply as made to order
Availability
Lead times apply to all Formed Face blocks.
All Formed Face blocks are made-to-order. Minimum
quantities may apply.
Also made-to-order in Honed and Polished Face.
C12
Specifications
Code
Product Description
MPa
Wt kg
N/Pallet
10.01T
Tiled Face - Full 90mm
10
10.9
180
15.01T
10
13.0
120
20.01T
10
15.9
90
Victoria Book 2 C
Series 100 Installation Details

10.101
10.101

10.101
10.26SP

BOLSTERED
ON SITE

10.101
MM
10.101
10.101
MM
10.26SP

MM
BOLSTEREDON SITE
MM
Fig C1 Corner Bonding Detail

Utilising 10.26SP Split Face Corner Block
MM

Using Bolstered-On-Site Split Face Block
10.01
10.01 cut
on-site
10.01
10.01
10.01
10.01
10.01
10.26SM
290mm
10.01 cut
on-site

Utilising 10.26 Smooth Face Corner Block
10.01
Architect: Bzowy Architecture
10.01
10.01
290mm
90mm

Utilising Cut-On-Site Corner Block
Alabaster Split Face with Quarter High Projected Courses
2010
C13
Victoria Book 2 C

70mm
35mm
55mm
Cut 10.101
laid on cut
face
10.101 block
with 3 saw
cuts makes 2
sill blocks
10.39 Sill
10.101
Split face block
10.109
Fig C7 Sill Detail with Smooth Face Sill

Series 100 Split Face Designer Block
Split face block

10.101
Fig C5 Sill Detail with Capping Piece

10.39 Sill
10.01
Capping piece 50.31

split to width if required,
set on mortar bed
Split face block

10.101
10.71
Flashing
10.01
10.01
Fig C8 Sill Detail with Victorian Sill profile

Series 100 Feature Face Cavity Wall
538mm
Fig C6 Sill Detail with Capping Piece

390mm
14mm
134mm
95mm
10mm
Bolster
on-site
Cut on-site
47mm
338mm
ALTERNATE COURSES
10mm
338mm
267mm
47mm
ALTERNATE COURSES
Cut on-site
Bolster
on-site
538mm
267mm
10mm
67mm
Fig C9 45 Obtuse Corner

C14
Fig C10 45 Acute Corner

Victoria Book 2 C

Split
A
95mm
15.01
10.101 split
on-site
145mm
15.22
15.01
15.101 cut on-site to

maintain bond
15.01
15.101
15.101
15.101
240mm
340mm
15.01
15.101
15.101
15.22
15.01
15.101
340mm
240mm
A
Fig C11 Corner Bonding Details

Utilising 15.22 Corner Block
Full block
15.101 cut on-site to

maintain bond

Utilising Cut-On-Site Split Face Blocks
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
2010
C15
Victoria Book 2 C
20.101
20.192
Split End
20.101
20.101
20.101
20.101
20.101
20.192
Split End
For window heights

900mm or 1500mm
For window heights

1200mm or 1800mm
80mm
10.39
Sill
10.39
Sill
40mm
10.71
10.01
10.01
10.101 cut in half, laid

with cut end down.
80 x 40mm bevel cut
on top.
10.71
20.01
Flashing
Flashing
20.101
20.01
20.01
Fig C15 Sill Detail - Single Skin Wall

Series 200 Feature Face Designer Block
C16
Fig C16 Sill Detail - Single Skin Wall

BORAL MASONRY

D ENGINEERED BLOCKS
Victoria Book 2 D
Scoria Blend (SB) - High Fire Rated Block

Series 100, 120, 150 and 200
INTRODUCTION
Scoria Blend (SB) is manufactured from a blend
of material which reduces the block weight and
increases the fire performance characteristics.
Scoria Blend (SB) is ideal for non-loadbearing
walls of commercial, industrial and highrise buildings with concrete and portal
framed structures.
Scoria Blend (SB) is 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.
Specifications - Series 100

Code
Product Description
MPa
Wt kg
N/Pallet
10.331
Full - Solid
13.1
139
10.332
9.5
192
10.333
Half - Solid
6.2
252
10.334
Quarter - Solid
2.9
504
10.383
Half Height - Solid
6.0
234
10.385
Half - Solid
2.9
504
MPa
Wt kg
N/Pallet
12.5
120
MPa
Wt kg
N/Pallet

Code
Product Description
12.401
Scoria Blend (SB) is manufactured in 90, 110,

140 and 190mm thicknesses to suit most types
of fire and/or acoustic wall construction.
Code
FIRE DESIGN CONSIDERATIONS
15.01SC Full
11.1
120
Scoria Blend (SB) utilises a unique blend

of material, which has been shown through
fire testing to provide excellent fire insulation
characteristics.
15.301
Full
12.6
120
15.302
Three Quarters
9.6
128
15.303
Half
6.3
192
15.304
Quarter
4.0
384
ACOUSTIC DESIGN CONSIDERATIONS
15.322
Corner
11.0
108
Scoria Blend (SB) provides excellent sound

resistance with a wide variety of board-lining
systems.
15.401
Full
14.3
120
15.402
Three Quarters
11.0
128
15.403
Half
7.6
252
ADDITIONAL INFORMATION
15.404
Quarter
5.0
336
Please refer to the Boral Masonry Design Guide

(MDG Book 1) for additional structural, fire and
acoustic performance information.
15.422
Corner
13.6
108
15.483
Half Height - Solid
9.3
192
15.485
Half - Solid
4.5
384
MPa
Wt kg
N/Pallet

Product Description

Code
Product Description
20.401
Full
15.3
90
20.402
Three Quarters
11.3
96
20.403
Half
7.4
144
20.404
Quarter
3.4
252
Availability
No minimum order quantities apply.
Lead time 0-2 weeks.
D2
Victoria Book 2 D
Scoria Blend (SB) - High Fire Rated Block

Series 100
Series 120
190
90
190
190
390
290
90
10.331
Full
190
90
10.332
Three Quarter
190
190
90
10.333
Half
110
90
10.334
Quarter
390
12.401
Full (1 in every 5 blocks
is universal solid)
Series 150
90
90
90
390
90
10.383
Half Height
190
190
10.385
Half
140
390
15.01SC
Series 150
190
140
390
290
140
15.301
Full
190
190
140
15.302
Three Quarter
190
190
190
190
140
15.303
Half
140
90
15.304
Quarter
190
340
15.322
Corner
190
190
190
390
140
290
140
15.401
Full
140
15.402
Three Quarter
190
140
15.403
Half
140
90
15.404
Quarter
340
15.422
Corner
90
90
140
390
140
15.483
Half Height
190
15.485
Half
Series 200
190
190
190
190
20.401
Full
390
190
290
20.402
Three Quarters
2010
190
20.403
Half
190
190
190
90
20.404
Quarter
D3
Victoria Book 2 D
Ash Grey Block (AG)

INTRODUCTION
Ash Grey Block (AG) units have a basalt
aggregate content greater than 45%.

Code
Product Description
uc MPa
Wt kg
N/Pallet
An extensive range of fractional sizes cater for

most construction requirements.
10.01
Full
10
11.6
149
10.02
Three Quarters
10
8.7
192
Ash Grey Block (AG) combines strength,

durability and ease of construction and provides
highly cost effective solutions for every-day
construction applications.
10.03
Half
10
5.6
252
10.04
Quarter
10
3.5
504
10.31
Full - Solid
10
14.3
139
10.32
10
10.6
192
APPLICATIONS
10.33
Half - Solid
10
7.0
252
Ash Grey (AG) Series 100 is a 90mm thickness

block which is manufactured from controlled
dense-weight concrete.
10.34
Quarter - Solid
10
3.5
504
10.71
Half Height
10
5.5
300
10.83
Half Height - Solid
10
6.7
234
Boral Series 100 Ash Grey Block (AG) is very

popular for internal walls and veneer wall
construction.
10.26
Corner Return
10
18.0
96
10.12
Lintel or Bond Beam
10
11.4
108
10.702
Squint
10
8.9
196
Ash Grey Block (AG) Series 150 is very popular

for loadbearing and non-loadbearing wall
construction, and the construction of small
cantilevered walls as it is the thinnest block
suitable for reinforced grout filling.
10.117
Quarter Height (cut to order)
10
3.0
432
10.39
Sill
6.8
440*
Ash Grey Block (AG) Series 200 is very popular

for loadbearing and non-loadbearing wall
construction, and the construction of small
cantilevered walls as it is suitable for reinforced
grout filling.

Code
Product Description
12.01
MPa
Wt kg
N/Pallet
10
14.0
120
COLOURS
Ash Grey Block (AG) is available in Natural Grey
only. For coloured blocks, refer to the Designer
Block section of this guide.
Also refer to Core-Fill Blocks (Section E of this
guide) for retaining wall blocks.
Availability
D4
Victoria Book 2 D
Ash Grey Block (AG)

Ash Grey Block (AG) - Series 100
90
190
190
190
390
290
90
90
10.01
Full
10.02
Three Quarter
190
90
190
190
90
10.03
Half
390
190
90
10.04
Quarter
10.26
Corner Return
(made to order)
190
90
390
90
10.31
Full
190
190
290
190
90
10.32
Three Quarter
10.33
Half
190
190
90
390
90
90
10.34
Quarter
10.12
Bond Beam or Lintel
90
90
190
390
190
90
10.71
Half Height
10.702
Squint
90
90
40
390
390
90
10.83
Half Height
10.117
Quarter Height
15
108
50
190
50
50
110
110
100
10.39
Sill
Bolster on site
2010
D5
Victoria Book 2 D

190
140
390
140
15.01
Full
190
190
290
140
15.02
Three Quarter
90
190
190
190
140
15.03
Half
15.04 (15.485)
Quarter
140
140
15.71
Half Height
290
140
15.72
Three Quarter
90
140
350
15.702
Squint
40
190
390
15.83 (15.483)
Half Height Solid
190
130
90
140
90
15.74
Quarter
Specifications
390
15.12
Bond Beam or Lintel
190
15.73
Half
190
140
15.22
Corner
90
90
390
340
140
90
Code
Product Description
MPa
Wt kg
N/Pallet
15.01
Full
10
13.0
120
15.02
Three Quarters
10
9.4
128
15.03
Half
10
6.2
192
15.04
Quarter (15.485)
10
3.3
384
15.22
Corner
10
11.3
108
15.71
Half Height
10
6.5
216
15.72
Three Quarter
10
4.4
288
15.73
Half
10
3.1
432
15.74
Quarter
10
2.4
768
15.83
Half Height Solid (15.483)
10
9.0
192
15.12
Lintel or Bond Beam
10
13.3
96
15.702
Squint (made-to-order)
10
12.0
84
50.31
Capping
10
6.0
216
390
50.31
Capping
NOTE: All units can be manufactured to 15MPa, enabling core filling

where required.
Availability
D6
Victoria Book 2 D

190
190
190
190
390
290
190
20.01
Full
20.02
Three Quarter
190
190
190
190
20.03
Half
20.04 (10.03)
Quarter
90
190
90
190
390
190
Note:
removable centre,
knock out on site.
390
190
390
20.12
Lintel Bond Beam
20.71
Half Height
40
50.31
Capping
18.0kg
72 per pallet
Availability
Specifications

2010
Code
Product Description
MPa
Wt kg
N/Pallet
20.01
Full
10
15.9
90
20.02
Three Quarters
10
13.4
96
20.03
Half
10
8.9
144
20.04
Quarter (10.03)
10
5.7
252
20.71
Half Height
15
7.0
162
20.12
Lintel or Bond Beam
10
18.0
72
50.31
Capping
10
6.0
216
D7
Victoria Book 2 D
Back-Up Block - Ash Grey (AG) - Series 100 and 150

INTRODUCTION
Boral Ash Grey (AG) Back-up Block is a 162mm
height block which equals two courses of standard
height brick (including mortar) making these
blocks ideal for use in conjunction with standard
height face brick veneer construction.
Ash Grey (AG) Back-up Block combines strength,
durability and ease of construction to provide
highly cost effective solutions for every-day
construction applications.

Code
Product Description
MPa
Wt kg
N/Pallet
10.201
Full
10
10.1
172
10.203
Half
10
4.8
294
10.231
Full - Solid
10
12.1
139
10.233
Half - Solid
10
6.0
294
An extensive range of fractional sizes cater for

most popular construction requirements.
Code
Product Description
15.201
APPLICATIONS
15.203
Ash Grey (AG) Back-up Block is generally

used to construct one leaf of a masonry wall
in conjunction with standard height face brick
veneer.
MPa
Wt kg
N/Pallet
Full
10
11.0
120
Half
10
5.4
197
Back-Up Block - Ash Grey (AG)

Series 100
COLOURS
Ash Grey (AG) Back-up Block is available in
Natural Grey, and can also be made-to-order in
any of the Designer Block colours. For colour
information, refer to the Designer Block section
of this guide.
90
10.201
Full
162
390
162
90
190
10.203
Half

162
162
390
90
90
10.231
Full
190
10.233
Half
Series 150
Back-up block
= 162mm
2 courses of
standard brick
+ mortar
= 162mm
162
162
140
390
15.201
Full
140
190
15.203
Half
Availability
Fig D1 Back-up Block Coursing
D8
No minimum order quantities apply to Natural Grey Blocks.

Longer lead times will apply for coloured blocks.
Minimum quantities may apply to coloured blocks.
Victoria Book 2 D
Typical Component Usage -
Series 100 Block

10.01 or
10.31
10.12
Steel reinforcing
and grout to project
specifications
or
Steel lintel
10.02
10.03
10.03
or 10.33
2100mm
OR
10.01 or
10.31
10.34
10.01
10.02
10.26
10.01 or
10.31
90 0m
10.71 or
10.83
10.74
10.72
or 10.84
10.73
or 10.85
10.26
10.01
10.02
10.01
10.01
10.03
10.01
10.03
10.01
10.26
10.02
10.01
10.01
10.01
10.01
10.01
10.01
10.01
Fig D2 Corner Bonding and Free End Detail

for Series 100 Block
2010
Fig D3 Alternative Corner Bonding and Free End

Detail for Series 100 Block
D9
Victoria Book 2 D
Series 150 Block

15.01
15.12
Steel reinforcing
specifications
or
Steel lintel
15.02
15.03
15.03
2100mm
OR
15.01
15.04
15.01
15.02
15.01
15.22
90 0m
15.71 or
15.83
15.74 or
15.86
15.71 or
15.83
15.98
15.73 or
15.85
15.22
15.01
15.01
15.01
15.01
15.03
15.22
15.01

D10
Victoria Book 2 D
Series 200 Block

20.01
20.12
Steel reinforcing
specifications
or
Steel lintel
20.03
20.03
20.02
2100mm
OR
20.01
20.04
20.01
20.02
20.01
20.01
90 0m
20.71
Cut from
20.04
20.71
20.01
Cut from 20.03
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.

2010
D11
Victoria Book 2 D
Acousticell
INTRODUCTION
Boral Acousticell is a purpose
designed block which combines
excellent acoustic absorption
and sound transmission loss
characteristics.
190
Boral Acousticell has been

successfully integrated into a wide
variety of industrial and commercial
acoustic applications, providing both
acoustic performance and unique and
attractive aesthetic qualities.
390
140
Acousticell
Full
The face slots and closed core base

of the Boral Acousticell block form
Helm-Holtz absorbers which control
low frequency noise where other
walling materials reflect noise,
adding to the original noise source.
Typical applications include auditoria,
theatres, radio, television and cinema
studios, churches, schools, canteens,
plant rooms, factories and workshops,
transformer sub-stations, swimming/
sports centres, multi-purpose centres
and wherever sound reverberation
can cause problems.
as
1.1
1.0
Sound Absorption
0.9
0.8
Boral Acousticell Blocks are made

from the same material and in the
same overall size as 15.01 Ash Grey
Block (AG). it is compatible with
Series 150 bond beams and part
size blocks.
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
16
31.5
63
125
250
500
1K
2K
4K
1/3 Octave Band Centre Frequency Hz (CPS)
8K
SOUND ABSORPTION
Boral Acousticell blocks combine the
high transmission loss characteristics
generally associated with a dense,
non-porous material (concrete block)
with efficient absorption of sound,
resulting in a very low radiated sound

level and effective control of both high
frequencies and troublesome low
frequency noise. Boral Acousticell
blocks provide maximum absorption
in the frequency range of 80Hz to
500Hz, peaking at 1.0 at 200Hz, and
provide absorption of 0.6 at 100Hz.
Where high frequency noise is to
be absorbed, fibreglass insulation
pads can be inserted into the HelmHoltz cells. In this case, absorption
of low frequency noise drops slightly,
but absorption of other frequencies
improves. (Note: Fibreglass is not
suitable for external use. Carbon fibre
pads are more suitable in external
situations).
Refer to accompanying absorption
graph for test results (on the left).
COLOURS
Boral Acousticell Block is Madeto-Order and can therefore be
manufactured in any of the Boral
Designer Block colours. Minimum
order quantities may apply to all
colours. Please refer to the Designer
Block section in this guide for
additional information.
Please refer to the Boral Masonry
Design Guide (MDG Book 1) for
additional performance information.
Availability
All Acousticell blocks are made-to-order

Minimum quantities may apply.
colour consistency. Part size blocks can be cut-to-order.
D12
Specifications
Code
Product Description
150mm
Acousticell Full
MPa
Wt kg
N/Pallet
10
14.0
120
BORAL MASONRY

E CORE-FILL BLOCK
Victoria Book 2 E
Core-Fill Reinforced
Retaining Walls
Designer Block Colours and Textures or Ash Grey
Core-Fill Block
For construction of reinforced masonry retaining walls
and loadbearing walls requiring increased robustness
characteristics.
Available in Ash Grey or Designer Block colours.
Available with Smooth, Honed, Polished and Split Face
textured finishes.
E2
Victoria Book 2 E
190
390
140
190
15.48 H Block
Smooth
20.48 H Block
Smooth
190
190
390
140
INTRODUCTION
390
190
15.42 Notch
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
390
190
Core-Fill Designer Block Coloured and Specialty Finishes
Core-Fill Block is available with the

following face texture finishes:
20.42 Notch
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.
Smooth Face
Honed Face
140
Polished Face
190
190
Split Face
190
190
15.03 Half
190
20.03 Half
Please refer to page C4 for general

information.
COLOURS
Designer Block products are available
in 7 colours. Please refer to page C5
for additional information.
190
140
340
Customised colours and textures

are also possible. Please note that
extended lead times and minimum
order quantities may apply.
15.22 Corner
190
145
190
390
15.142 Notch
Split Face
390
195
20.142 Notch
Split Face
Availability
INSTALLATION
CONSIDERATIONS
2010
Specifications
Code
Product Description
MPa
Wt kg
N/Pallet
15.48
H Block
15
13.9
120
15.42
Notch
15
13.2
120
15.03
Half
15
6.2
192
15.22
Corner
15
11.3
108
20.48
H Block
15
14.7
90
20.42
Notch
15
14.3
90
20.03
Half End
15
7.5
144
15.142
Notch (Split Face)
15
15.5
120
20.142
Notch (Split Face)
15
17.6
90
E3
Victoria Book 2 E
Core-Fill Block - Ash Grey - Series 150, 200 and 300

INTRODUCTION
Boral Core-Fill Block is designed for the
construction of reinforced masonry retaining
walls and loadbearing basement walls. requiring
increased robustness characteristics.
CONSTRUCTION CONSIDERATIONS
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.
Due to the high hydrostatic pressure at the
bottom of freshly grouted cores, water will seep
through 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. Clean all grout spills before they set.

Code
Product Description
MPa
Wt kg
N/Pallet
15.48
H Block
15
13.9
120
15.42
Notch
15
13.2
120
15.01
Full
15
13.0
120
15.03
Half
15
6.2
192
15.22
Corner
15
11.3
108

Code
Product Description
MPa
Wt kg
N/Pallet
20.48
H Block
15
14.7
90
20.42
Notch
15
14.3
90
20.03
Half
15
7.5
144
20.12
Lintel or Bond Beam
15
18.0
72
20.01E
Clean-Out
15
15.0
72

Code
Product Description
MPa
Wt kg
N/Pallet
30.48
H Block
15
18.3
6.0
20.02
Half and End
15
12.0
96
20.01E
Clean-Out
15
15.0
72
10.03
For clean-out course
10
5.6
252
10.32
End Closer
10
10.6
192

Blocks Filled per cubic metre of Grout

Block Type
Blocks Filled per

of Grout (approximate)
15.42 Notch
190
15.01 Full
190
15.142 Split Face
200
175
20.01 Full
120
20.42 Notch
120
20.142 split Face
125
100
65
E4

m3

Fig E1 Corner Bonding Detail

for Series 150 Core-Fill Block
Victoria Book 2 E
Series 150
190
190
190
190
190
390
140
390
140
15.48
H Block
140
15.42
Notch
390
140
15.01
Full
340
140
190
15.03
Half
15.22
Corner
Series 200
190
190
190
190
190
390
190
390
190
20.48
Single Web H
190
20.42
Notch
390
190
20.12
Lintel
190
390
190
20.03
Half End
20.01E
Clean-Out
Series 300
190
290
190
290
390
190
290
190
20.02
Half and End
30.48
H Block
90
10.32
End closer

190
390 90
190

190
190

20.01E + 10.03
Clean-Out

Fig E2 Corner Bonding Detail

for Series 200 Core-Fill Block

Fig E3 Corner Bonding and End Detail

for 300 Series Core-Fill Block
2010
E5
Victoria Book 2 E
NOTES
E6
BORAL MASONRY

E ENGINEERED BRICKS
Victoria Book 2 F
Concrete Basalt Bricks (B)
76
110
230
Brick (B1)
(1 in every 7 bricks supplied
is solid for pier applications)
162
110
230
162
110
Quick Brick Cored
230
Quick Brick Solid

(made to order
subject to quantity)
INTRODUCTION
Boral Masonry Victoria ConcreteBasalt Bricks have an uc of
12MPa, making them suitable for
most loadbearing or non-loadbearing
applications. They provide good
fire performance and acoustic
performance characteristics where
minimising weight is not a primary
consideration.
Concrete-Basalt Bricks are a
popular choice for walls in domestic
applications and 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.
BORAL CONCRETE-BASALT
QUICK BRICK
Boral Concrete-Basalt Quick Brick
(Victoria only) is 230mm long by
162mm high, equal to 2 courses of
standard brick with mortar, making
them a highly efficient and costeffective construction component.
FIRE DESIGN
CONSIDERATIONS
These products are manufactured
from a Concrete-Basalt blend which
provides good fire performance
characteristics in loadbearing
conditions.
ACOUSTIC DESIGN
CONSIDERATIONS
The mass of the Concrete-Basalt
material is 7% heavier than Clay
therefore walls from Concrete-Basalt
products perform slightly better.
Its texture is coarser and its porosity
is higher than Clay, so it performs
better with plasterboard, particularly
when daub-fixed.
Design Guide (MDG Book 1) for
additional information.
Colour
Specifications
Product
Code
Nominal
TxLxH (mm)
Average
Unit
Wt
kg
B1
Brick
110x230x76
3.8
12
4.8
nil
Nil to slight
48.5
450
Quick Brick
Cored
110x230x162
7.9
12
6.0
25
Nil to slight
24.3
250
Quick Brick
Solid
110x230x162
8.9
12
6.0
nil
Nil to slight
24.3
200
F2
Unit
uc
MPa
m
w/M3
Mortar
MPa
Perforation
%
Liability
to
Effloresce
N
per
m2
N
per
Pallet
Victoria Book 2 F
162
110
230
INTRODUCTION
Boral Masonry Victoria is constantly
developing new and innovative
products. The Boral Scoria Quick
Brick utilises a unique low-density
blended concrete material which
provides high fire rated performance
together with medium weight.
FIRE DESIGN
CONSIDERATIONS
Scoria Quick Brick is ideal for

non-loadbearing applications such
as walls in concrete framed office
buildings and high-rise home units.
Scoria Quick Brick is not recommended

for cement rendered acoustic walls,
but gives excellent sound resistance
with a wide variety of tested boardlining systems.
Scoria Quick Brick is 230mm

long by 162mm high, equal to
2 courses of standard brick with
mortar, making them a highly efficient
and cost-effective construction
component.
Scoria Quick Brick is a fire tested

lightweight concrete which is unique
to Boral, and provides excellent fire
rating characteristics.
ACOUSTIC DESIGN
CONSIDERATIONS
Design Guide (MDG Book 1)
for additional fire and acoustic
information.
Availability
Available 1st Quarter 2004
Specifications
Product
Code
Nominal
TxLxH (mm)
Average
Unit
Wt
kg
Scoria
Quick Brick
110x230x162
5.9
2010
Unit
uc
MPa
Perforation
%
Liability
to
Effloresce
N
per
m2
N
per
Pallet
<25
Not for external use
24.3
250
F3
Victoria Book 2 F

162
110
230
Availability
Available 1st Quarter 2004
INTRODUCTION
Boral Masonry Victoria is constantly
developing new and innovative
products. The Boral FireLight Quick
Brick utilises a unique low-density
blended concrete material which
provides high fire rated performance
together with minimum weight.
FIRE DESIGN
CONSIDERATIONS
FireLight Quick Brick is ideal for

non-loadbearing applications such
as walls in concrete framed office
buildings and high-rise home units.
FireLight Quick Brick is not

recommended for cement rendered
acoustic walls, but gives excellent
sound resistance with a wide variety
of tested board-lining systems (refer
MDG Book 1).
FireLight Quick Brick is 230mm

long by 162mm high, equal to
2 courses of standard brick with
mortar, making them a highly efficient
and cost-effective construction
component.
FireLight Quick Brick is a fire tested

lightweight concrete which is unique
to Boral, and provides excellent fire
rating characteristics.
ACOUSTIC DESIGN
CONSIDERATIONS
Design Guide (MDG Book 1)
for additional fire and acoustic
information.
Specifications
Average
Unit Unit
Liability N
N
Product Nominal
Wt
uc Perforation
to
per per
Code
TxLxH (mm) kg
MPa
%
Effloresce m2 Pallet
FireLight 110x230x162
Quick Brick
F4
4.5
<25
Not for 24.3

external use
250
Victoria Book 2 F
Omega Brick
INTRODUCTION
The unique shape of the Omega Brick has been designed to reduce the weight
for ease of construction.
This unique shape offers considerable benefits:
Lightweight for high productivity
Easy two-at-a-time handling
Anti-float design
Omega Brick
Standard Unit
Suitable for lintels and band beams

Accepts horizontal conduit
Good fire performance characteristics
Ideal surface for rendering.
Specifications
Omega Brick
Solid Unit
Product
Code
NB: 3 in every 16 bricks on a pallet is a solid unit.
Nominal
TxLxH (mm)
Average
Unit
Wt
kg
Unit
uc
MPa
N
per
m2
N
per
Pallet
Omega Brick:
Availability
Standard Unit
110x230x119
4.5
>10
33
300

Solid Unit
110x230x119
5.5
>10
33
300
2010
F5
eBC 04000 2010
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.
6. Important notice Please consult with your local council for design regulations prior to the construction of your wall. Councils in general
require those walls over 1m in height and/or where there is loading such as a car or house near the wall be designed and certified by a
suitably qualified engineer.
Technical Enquires
Specifier Line
Internet
1300 360 255

www.boral.com.au/masonry
Orders, Product Samples and Sales Enquires

Victoria
Level 1 Port IT, 63-85 Turner Street, Port Melbourne, 3207
T: (03) 9363 1944

F: (03) 9363 6008
Other Regional Sales Offices

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

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BORAL MASONRY

Build something great

Masonry Design Guide

Fast Find Product and Application Guide . . . . . . . . . . . . . . . A3

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

Planning and Design

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

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

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

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

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

Split Face - Series 100, 150 and 200 . . . . . . . . . . . . . . . . . C11

Tiled Face Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C12

Smooth, Honed, Polished Face - Series 100/120 . . . . . . . . C6

Installation Details Series 100 Blocks . . . . . . . . . . . . . . . . C13

Smooth, Honed, Polished Face - Series 150 . . . . . . . . . . . . C8

Installation Details Series 150 Blocks . . . . . . . . . . . . . . . . C15

Smooth, Honed, Polished Face - Series 200 . . . . . . . . . . . C10

Installation Details Series 200 Blocks . . . . . . . . . . . . . . . . C16

Scoria Blend (SB) High Fire Rated Block . . . . . . . . . . . . . D2

Typical Component Usage - Series 100 Block . . . . . . . . . . D10

Ash Grey Block (AG) - Series 100 and 120 . . . . . . . . . . . . . D4

Typical Component Usage - Series 150 Block . . . . . . . . . . D11

Ash Grey Block (AG) - Series 150 . . . . . . . . . . . . . . . . . . . . D6

Typical Component Usage - Series 200 Block . . . . . . . . . . D12

Ash Grey Block (AG) - Series 200 . . . . . . . . . . . . . . . . . . . . D7

AcousticellTM Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13

Back-Up Block - Ash Grey (AG) - Series 100 and 150 . . . . . D8

Coloured Designer Block . . . . . . . . . . . . . . . . . . . . . . . . . . E3

Concrete-Basalt Brick (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . F2

FireLight Quick Brick (FL) . . . . . . . . . . . . . . . . . . . . . . . . . . . F4

Scoria Quick Brick (SB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3

2010 | BORAL MASONRY DESIGN GUIDE

The quickest way to find a Boral Masonry Block or Brick Solution.

NLB LB NLB LB NLB LB NLB LB NLB LB

1 Select your application

Scoria Blend (SB) High Fire Rated Block

Concrete-Basalt Bricks (B)

Scoria Quick Brick (SB)

FireLight Quick Brick (FL)

criteria from the top of

Best performance is achieved

BORAL MASONRY DESIGN GUIDE

Architect: Harry Seidler and Associates

Architect: Paul Campbell Architects

Boral Feature Face Masonry

Standard Ash Grey Block (AG)

Scoria Blend (SB)

Architect: Lawrence Nield and Partners

2010 | BORAL MASONRY DESIGN GUIDE

Architect: Nettleton Tribe Architects

Boral Engineered Bricks

Concrete-Basalt Brick (B)

Engineered block for premium sound absorption

BORAL MASONRY DESIGN GUIDE

Standard Size and Quick Brick (162mm height) in

Scoria Quick Brick (SB)

FireLight Quick Brick (FL)

Please note that this guide is based on products available at

Boral Masonry Construction Solutions

Additional Assistance and Information

Whats in this Guide

Colour and Texture Variation: The supply of raw

This guide has been prepared as a comprehensive Boral