Faculty of Technology Management and Business

Department of Construction Management

Universiti Tun Hussein Onn Malaysia

BPD30903 BUILDING MATERIALS AND TESTING
2. MASONRY, BRICKS AND BRICKWORK
Masonry is the building of structures from individual units laid in and bound together
by mortar; the term masonry can also refer to the units themselves. The common
materials of masonry construction are brick, building stone such
as marble,granite, travertine, and limestone, cast stone, concrete block, glass block,
and cob. Masonry is generally a highly durable form of construction. However, the
materials used, the quality of the mortar and workmanship, and the pattern in which the
units are assembled can significantly affect the durability of the overall masonry
construction. A person who constructs masonry is called a mason or bricklayer.

2.0 BRICKS
The term brick is used to denote solid clay masonry units. The term masonry refers to a
construction material formed by combining individual masonry units, such as stone and
brick, with a binding material: mortar.
Brick is one of the oldest building materials known. It is cheap, durable and easy to
handle and work with. A brick is rectangular in shape and may be made of burnt clay or
mixture of sand and lime or of Portland cement concrete. Clay bricks are most
commonly used as it is economical and easily available. It is used for building interior
and exterior walls, partitions, piers, footings as well as some other load bearing
structures.
Brick is one of the oldest building materials. Brick is a basic building unit which is in the
form of a rectangular block in which length to breadth ration is 2 but height can be
different
The length of brick = 2 x width + thickness of mortar
Height of brick = width of brick
The size of standard brick should be 19 x 9 x 9 cm and 19 x 9 x 4 cm. When placed in
masonry the 19 x 9 x 9 cm brick with mortar becomes 20 x 10 x 10 cm. Weight of such a
brick is 3.0 kg. An indent of 1-2cm deep x 10 x 4 cm called frog is provided for 9 cm
high bricks in order to hold the mortar.
Clay
Clay occurs in three principal forms of the same chemical composition but differing
physical properties.

PM Dr CPG 2016

1. Surface Clays
Found near the surface of the earth
2. Shales
Clays which have been subjected to high pressure until they have become relatively
hard.
3. Fireclays
Found at deeper levels and usually has more uniform physical and chemical properties,
able to withstand high temperatures.
Basically clays are compounds of silica and alumina with varying amounts of metallic
oxides and other ingredients. They can be divided into
(a) Calcareous containing 15% calcium carbonate and burn to a yellowish color, and (b)
noncalcareous clays composed of silicate of alumina, with feldspar and iron oxide, burns
to a bright red depending on the iron oxide content.

2.1 LIME AND CEMENT

Table 1.1 Comparison of Cement and Lime
Property

Lime

Cement

Colour
Slaking

White or grayish white

Slaking takes place on adding water

Setting

It sets slowly by taking CO2 form air

or by reacting with water
Slow
Less

Dark grey or greyish

Slaking doesnt take place
on adding water
It sets rapidily by reacting
with water
Rapid
High

Cheap
Suitable for ordinary construction
works

Costly
Suitable for all
construction works

Hardening
Compressive
Strength
Cost
Use

(From Dugall, S.K., 1998; p. 209)

Building mortars are mixtures used for joining of bricks, stones, blocks, etc. It is a paste
obtained by adding water to a mixture of fine aggregates and binding material such as
gypsum, lime or cement. When this paste is heated to redness it acquires hardness and
strength. Lime reacts to moisture present in the atmosphere and from the ground, hence
should be stored with extreme care.
The advantages of portland cement-lime mortar are its high tensile bond strength, and the
generally higher water-penetration resistance of masonry laid using it. Its disadvantages
are the additional complexity of mixing three ingredients, and some lack of workability
(stickiness) if not re-tempered. The first disadvantage can be overcome by single-bag or
silo mixes. The second can sometimes be overcome by re-tempering. The advantages of
masonry cement mortar are its relative simplicity of batching and its good workability. It
PM Dr CPG 2016

has a fluffy consistency (because of its entrained air), which leads to good productivity.
Its lower tensile bond strength is accounted for by lower allowable stresses in design
codes. In part because of these lower bond strengths, and in part because of other reasons,
masonry cement is prohibited in zones of high seismic risk in the US. Lower waterpenetration resistance of walls made with masonry cement mortar is not addressed. From
the viewpoint of cement producers, masonry cement is a profitable niche product. A
70-lb bag of masonry cement typically contains about 28 lb or less of portland cement,
about 40 lb of ground limestone, air-entraining additives, and possibly additives for
water-retention and plasticity. This bag commonly sells for the same price as 94 lb of
portland cement. Mortar cement was introduced in the 1990s to preserve the
construction advantages and potential profitability of masonry cement, while at the same
time increasing the tensile bond strength of the resulting mortar to values comparable to
those of portland cement-lime mortar. Mortar cement is regarded by building codes as the
equivalent of portland cement-lime mortar, and is permitted even in the most seismic
zones of the US.

To efficiently and effectively lay bricks, you must be familiar with the terms that identify
the position of masonry units and mortar joints in a wall. The following list, which is
referenced to figure 8-32, provides some of the basic terms you will encounter.

PM Dr CPG 2016

Figure 8-32.-Masonry units and mortar joints.

Course One of several continuous, horizontal layers (or rows) of masonry units
bonded together.
Wythe Each continuous, vertical section of a wall, one masonry unit thick. Sometimes
called a tier.
Stretcher A masonry unit laid flat on its bed along the length of a wall with its face
parallel to the face of the wall.
Header A masonry unit laid flat on its bed across the width of a wall with its face
perpendicular to the face of the wall. Generally used to bond two wythes.
Row lock A header laid on its face or edge across the width of a wall.

PM Dr CPG 2016

Bull header A rowlock brick laid with its bed perpendicular to the face of the wall.
Bull stretcher A rowlock brick laid with its bed parallel to the face of the wall.
Soldier A brick laid on its end with its face perpendicular to the face of the wall.
BONDS:
The term "bond" as used in masonry has three different meanings: structural bond, mortar
bond, or pattern bond.
Structural bond refers to how the individual masonry units interlock or tie together into a
single structural unit. You can achieve structural bonding of brick and tile walls in one of
three ways:

Overlapping (interlocking) the masonry units

Embedding metal ties in connecting joints
Using grout to adhere adjacent wythes of masonry

Mortar bond refers to the adhesion of the joint mortar to the masonry units or to the
reinforcing steel.
Pattern bond refers to the pattern formed by the masonry units and mortar joints on the
face of a wall. The pattern may result from the structural bond, or may be purely
decorative and unrelated to the structural bond. Figure 8-33 shows the six basic pattern
bonds in common use today: running, common or American, Flemish, English, stack, and
English cross or Dutch bond.

Figure 8-33.-Types of masonry bonds.

PM Dr CPG 2016

The running bond is the simplest of the six patterns, consisting of all stretchers. Because
the bond has no headers, metal ties usually form the structural bond. The running bond is
used largely in cavity wall construction, brick veneer walls, and facing tile walls made
with extra wide stretcher tile.
The common, or American, bond is a variation of the running bond, having a course of
full-length headers at regular intervals that provide the structural bond as well as the
pattern. Header courses usually appear at every fifth, sixth, or seventh course, depending
on the structural bonding requirements. You can vary the common bond with a Flemish
header course. In laying out any bond pattern, be sure to start the corners correctly. In a
common bond, use a three-quarter closure at the corner of each header course.
In the Flemish bond, each course consists of alternating headers and stretchers. The
headers in every other course center over and under the stretchers in the courses in
between. The joints between stretchers in all stretcher courses align vertically. When
headers are not required for structural bonding, you can use bricks called blind headers.
You can start the corners in two different ways. In the Dutch corner, a three-quarter
closure starts each course. In the English corner, a 2-inch or quarter closure starts the
course.
The English bond consists of alternating courses of headers and stretchers. The headers
center over and under the stretchers. However, the joints between stretchers in all
stretcher courses do not align vertically. You can use blind headers in courses that are not
structural bonding courses.
The stack bond is purely a pattern bond, with no overlapping units and all vertical joints
aligning. You must use dimensionally accurate or carefully rematched units to achieve
good vertical joint alignment. You can vary the pattern with combinations and
modifications of the basic patterns shown in figure 8-33. This pattern usually bonds to the
backing with rigid steel ties or 8-inch-thick stretcher units when available. In large wall
areas or load-bearing construction, insert steel pencil rods into the horizontal mortar
joints as reinforcement.
The English cross or Dutch bond is a variation of the English bond. It differs only in that
the joints between the stretchers in the stretcher courses align vertically. These joints
center on the headers in the courses above and below.
When a wall bond has no header courses, use metal ties to bond the exterior wall brick to
the backing courses. Figure 8-34 shows three typical metal ties.

PM Dr CPG 2016

Figure 8-34.-Metal ties.

Install flashing at any spot where moisture is likely to enter a brick masonry structure.
Flashing diverts the moisture back outside. Always install flashing under horizontal
masonry surfaces, such as sills and copings; at intersections between masonry walls and
horizontal surfaces, such as a roof and parapet or a roof and chimney; above openings
(doors and windows, for example); and frequently at floor lines, depending on the type of
construction. The flashing should extend through the exterior wall face and then turn
downward against the wall face to form a drop.
You should provide weep holes at intervals of 18 to 24 inches to drain water to the
outside that might accumulate on the flashing. Weep holes are even more important when
appearance requires the flashing to stop behind the wall face instead of extending through
the wall. This type of concealed flashing, when combined with tooled mortar joints, often
retains water in the wall for long periods and, by concentrating the moisture at one spot,
does more harm than good.
MORTAR JOINTS AND POINTING
There is no set rule governing the thickness of a brick masonry mortar joint. Irregularly
shaped bricks may require mortar joints up to 1/2 inch thick to compensate for the
irregularities. However, mortar joints 1/4 inch thick are the strongest. Use this thickness
when the bricks are regular enough in shape to permit it.
A slushed joint is made simply by depositing the mortar on top of the head joints and
allowing it to run down between the bricks to form a joint. You cannot make solid joints
this way. Even if you fill the space between the bricks completely, there is no way you
can compact the mortar against the brick faces; consequently a poor bond results. The
only effective way to build a good joint is to trowel it.

PM Dr CPG 2016

Although mortar forms only a small proportion of brickwork as a whole, its functional
performance has a significant effect, in particular, on the movement that affects the
structure within the wall itself and with the adjacent parts of the buildings. The function
of mortar, besides providing the necessary bonding between bricks, should give sufficient
flexural tensile strength. In turn, this will help to relieve the stress and reduce the risk of
cracking the brickwork. Therefore, strict quality control in batching and mixing of mortar
plays a vital in brickwork construction.
A good mortar renders the following properties and functions :1. good workability to ease laying work and improve quality of the joints
2. good water retentivity to prevent excessive suction of water by bricks that have
high initial rate of absorption and retain sufficient water required for hydration of
cement
3. development of suitable early and final strength
4. offers water-tightness and durability to a wall
5. good adhesion or bond for bricks

2.2 Brick Manufacture

The basic ingredient of brick is clay. However, the particular clay used is one which has
plasticity when mixed with water, so that it can be moulded or shaped. There are three
methods of manufacturing bricks.
1. In the stiff-mud process, clay containing a minimum amount of water (12-15% by
weight) to produce plasticity. The plastic clay goes through a deairing machine to
remove air pockets and bubbles. This also increases workability and strength.
The mass is forced through a die. The die moulds the mass into desired shapes
and sizes of bricks (as well as tiles etc.). The continuous band of clay that is
forced out is cut into bricks by a wire frame. These are then inspected for
imperfect units which are returned to be reprocessed.
2. The soft-mud process (only for bricks) is well suited for clays containing too
much water in their natural state. The ground clay is hydraulically pressed in
steel moulds. This is the oldest method, and all handmade bricks are made using
this process. When the inside of the moulds are sanded to prevent sticking of the
clay, the product is sand-struck brick, and water-struck brick when wetted.
3. The dry-press process uses the least water in tempering is suited for clays
possessing low plasticity. Moist clay (7-10% water) is dropped into dry press
forming machines. The bricks are moulded under low operating pressures. It

PM Dr CPG 2016

produces accurately formed bricks but is less widely used as it is more expensive
due to labour costs.
Bricks coming out of the forming machines contain about 7-30% moisture. The units are
sent to a dryer, where they are subjected to temperatures of 43-150o C for 28-48 hours.
After they are dried, the units are baked in burning kilns at a very high temperature (as
high as 1315o C) for 40 -150 hours. During this process, parts of the clay melt, fusing the
whole mass of the brick into a hard durable unit. Burning is followed by a cooling cycle
for about 48-72 hours. Variation in the composition of clays and the burning
temperatures results in a wide variety of bricks.
The brick sizes according to MS 7.6: 1972 is:
Length = 215mm 3.0mm , width = 102.5mm 1.8mm and thickness = 65 mm
2.5mm

2.3 GRADES AND TYPES

Bricks can be classified into different types, according to their uses, such as building
brick (common brick), facing brick, floor brick, paving brick and engineering brick.
Building brick is produced for construction, without much concern for appearance, and
used for partitioning of walls.
Facing brick is made specifically for facing purposes. It is manufactured from selected
clays and available in all sizes and colours, it is smooth, fine, medium or coarse textured.
Facing bricks are used for exposed surfaces where appearance is an important design
criterion. The selection of facing bricks is based on colour, dimensional tolearances,
surface texture, uniformity, and limits on the amount of cracks and defects.
Floor bricks are smooth, dense, highly resistant to abrasion and is used on finished floor
surfaces.
Paving brick is a low-abrasion brick, generally furnished with spacing lugs and produced
in smooth or wire-cut surface finishes, and used for roads, sidewalks, patios, driveways,
and interior floors.
Engineering brick is used as structural material where strength and durability are
important requirements. It is used for building the following structural components:
(i) Retaining walls
(ii) Load bearing walls
(iii)Bridge abutments
(iv) Brick defence walls (sea-facing)
(v) Other walls that are open to the action of erosion and attack by acids.
(these bricks should satisfy MS 7.6 requirements)

PM Dr CPG 2016

Calcium Silicate-Sand Bricks:

This is made from a mixture of lime (Calcium Silicate) and sand in the ratio of 1:8, mixed
with water. The moist mixture is placed in moulds (according to required shapes) under
high pressured steam for about 7 to 8 hours. The sand and lime then chemically bonds.
There are four different classes:
(i)
Special grade high strength for load-bearing or under water.
(ii)
Building bricks for outer fencing.
(iii)
Building bricks as in (ii) but not bonded with strong mortar.
(iv)
Bricks for interior building bonded with mortar based on BS 187.

2.4 Testing for Bricks:

The testing methods are as specified under MS 7.6: 1972. The tests to be conducted are:
(i)
(ii)
(iii)

Compressive Strength
Water Absorption
Soluble Salts

2.5 Properties of Bricks

The physical properties of clay bricks are:
Color
Textrure
Size
Density
The engineering or mechanical properties are:
Compressive strength
Modulus of rupture
Modulus of elasticity
Tensile strength
Absorption
Thermal conductivity
Fire resistance
A good brick should have plane faces, parallel sides, and sharp edges and angles. The
texture should be uniform, and bricks should give a clear ringing sound when struck a
sharp blow with a hard object. A good brick should absorb less than 20% of water by
weight. It should have high compressive and bending strengths.
The color of bricks depends on the composition of raw materials (presence of metallic
oxides) and the degree of burning. The standard color of bricks is terracotta, or
brownish-orange. Lime may be added to provide a white color to bricks. Metallic oxides
(iron, calcium, and magnesium) act as fluxes to promote fusion at lower temperatures,
and give burned clay the necessary strength and hardness. Higher burning temperatures
bring in darker color as well an increase in compressive strength.

PM Dr CPG 2016

Clay bricks are very durable (water absorption greatly affects durability), and require
very little maintenance. They have very good fire resistance and moderate insulating
properties (against transfer of heat). Non-combustability is an important property of
bricks, and is the main reason they are used in the construction of chimneys in masonry
as well as wood buildings. Being porous, brick is a poor conductor. Well-built brick
houses are cooler in summer and warmer in winter than are houses built of most other
materials.

Thermal properties of a wall:

The thermal properties of a wall are related to its ability to transmit or resist the
movement of heat and to its capacity to store thermal energy.
Thermal transmittance
Thermal transmittance, (U value) is measured in Watts (W) per square metre (m2) per
degree Celsius, W/m2 oC as the rate of heat flow through an element, e.g. a wall. The
lower the U value, the better the insulation properties of the wall: it has a greater
resistance to the flow of heat. The U value not only takes into account the resistance
offered by the wall, but also the outside and inside surface resistance. Since the U value
notionally provides a measure of the heat flow through a wall, it is the figure used to
compare the performance of different constructions and to make energy-use calculations.
Thermal capacity
Thermal capacity is measured in Joules (J) per square metre (m2) per degree Celsius,
J/m2 oC, and is a measure of the degree of heat that can be stored by a wall. Clay brick
walls, with their high thermal capacity, have the ability to store heat during the day and
release this heat at night. In climatic regions where there are high temperatures during the
day and low temperatures at night, this results in thermally comfortable dwellings with a
reduction in energy consumption to cool or heat the buildings.
Water Absorption:
Water absorption greatly affects the durability of brick. Very soft, underburned bricks
may absorb water to as much as one-third of their weight; whereas good, hard bricks may
absorb less than 10 percent water. The total water absorption of bricks is defined as the
increase in weight of brick due to water, expressed as percentage of the dry weight, and
can be calculated as:
Absorption = (water absorbed after 24h in cold water) x 100
(dry weight of brick)

Strength:
The compressive strength of brick units depend on:
Composition of the clay
Method of manufacture
Degree of burning
Suction is the initial rate of absorption of clay masonry units and has a great influence
upon bond strength. When a brick is laid in a bed of mortar, water is drawn up into the
PM Dr CPG 2016

bricks surface. If the brick is highly absorptive, this process will leave a dry bed of
mortar which will not develop adequate bond between the brick units. If the unit has
very low absorption, the water will allow the brick to float and when the mortar dries,
inadequate bond strengths will result.
Maximum bond strength will generally occur when the brick suction rate does not exceed
20g per minute. Bricks having suction rates in excess of this limit should be sprayed with
water prior to use; however, the surfaces should be allowed to dry before the brick is
used. A simple rule of thumb for checking is to sprinkle a few drops of water on the flat
side of a brick, if the drops are absorbed in less than a minute, pre-wetting is required.
2.6 Brick Bonds:
The term bond, used in connection with brick masonry, can be used in three different
ways. The method of laying bricks in a wall in order to form some distinctive pattern or
design is referred to as the pattern bond. The method by which the individual units in a
brick structure are tied together, either by overlapping or by meal ties is known as
structural bond.

Structural Bond
In solid walls, the structural bond is provided by header bricks. In cavity walls, the two
rows of brick are tied by metal ties.
Pattern Bond
Five basic pattern bonds are most commonly used in brickwork: running bond, common
bond, Flemish bond, English bond, and English cross bond. Variations of these basic
pattern bonds include double Flemish, garden wall, stack and many others.
Mortar Bond
The adhesion of mortar to bricks or to steel reinforcements used in conjunction with them
is called the mortar bond. The building of structures from brick is possible because a
mortar bond develops between the mortar and the brick. The strength of brick walls and
their ability to resist water penetration depends to a large extent on the strength and
completeness of the mortar bond. The mortar should be mixed with the minimum
amount of water that is possible to use and still maintain the proper plasticity. Mortar
thickness is about 10 mm.
The prime function of mortar in masonry is to take up tolerances between building units
such as bricks or blocks, and are also satisfy the following requirements.
1. They should impart sufficient strength to the complete unit.
2. They should permit movement (unless this is negligible or joints are provided).

When movement occurs within a well-constructed masonry unit, it should take

PM Dr CPG 2016

place in the form of microcracks within the mortar rather than cracking of the
bricks.
3. They should be durable, i.e. they should resist frost or other forms of
environmental attack.
4. They should resist the penetration of water through the unit.
5. They should contribute to the aesthetic appearance of the wall.
To permit effective use, mortars should be workable, yet cohesive in the fresh state.
Functions 1, 3 and 4 above are best provided by a strong mortar. Function 2 is best
satisfied with weak mortars which crack readily if movement occurs. The working rule is
that:
. The mortar must not be stronger than the units it is bonding.

Mortar is essentially a mixture of cement, sand and water, called cement mortar. When
made with lime, sand, and water it is called lime mortar. Before it begins to set, Portland
cement-sand mortar has a poor cohesion or bonding properties, and may fail to stick to
the edge of bricks. Addition of a small percent of lime makes the mortar more plastic but
does not affect the compressive strength or time for mortar to set.
With the addition of cement to lime mortar, it becomes cement-lime mortar. In general,
mortar is the term applied to any material used for bedding, jointing, and rendering
brickwork, stonework, and concrete blockwork. The weakest part of masonry is the
mortar, hence the less the mortar, the better the performance of the wall. The mortar
serves two purposes: to bond various units, and to form a cushion to distribute pressure
uniformly over the surface. The bricks should not be merely laid, but should be rubbed
and pressed down so as to force the mortar into the pores of the bricks to produce
maximum adhesion.
1. Cement Mortar
It is used in normal brick work with cement to sand ratio = 1:3. The sand and cement is
mixed thoroughly before water is added to obtain the plasticity, and it should be used
within 2 hours of mixing.
2. Lime Mortar
The three constituents are mixed together. Due to its low strength, lime mortar is not
generally recommended for permanent masonry construction. The ratio of lime to sand =
1:3, and should be used within 4 hrs of mixing.
3. Cement-Lime Mortar
The addition of Portland cement to lime mortar increases its strength. Often the lime and
sand is mixed with water and cement added before being applied. A higher percentage of
cement would be used where strength is required at an early age or when ultimate
strength must be fairly high. But for mortars that are used in places where freedom from

PM Dr CPG 2016

cracking, good bond, or resistance to rain penetration is paramount, the proportion of

cement to lime should be kept low.
Use of Plasticisers (see Taylor, G. D. Materials in Construction, p. 137)
Brick Arrangement:
The main principle in brick arrangement in constructing walls, is that the vertical tie for
each layer should not be less than a quarter of brick from the vertical tie of the next layer
above and below. This is to distribute point loads on walls equally to the lower bricks in
order to avoid failure. There are a number of arrangements to suit specific purposes.
They are: running bond, common bond, Flemish bond, English bond, and English cross
bond. Variations of these basic pattern bonds include double Flemish, garden wall, stack
and many others.
RUNNING BOND:
The arrangement along the length of wall consists of the bricks arranged on their sides.
The beginning and end of walls consists of sliced bricks as half-bricks alternating with
full bricks. The vertical arrangement consists of bricks overlapping over half of each
adjacent layer. This arrangement can only be used for walls of half-brick thickness and
not to be used for thicker walls.
ENGLISH BOND:
The arrangement along the length of wall consists of header brick layers alternating with
side brick layers. For the header layer, the closing end consists of a halved brick
sandwiched between two headers at the end and three-quarter brick used to start the side
brick layer.
FLEMISH BOND:
In this arrangement, all layers consists of header and side bricks alternating to form each
layer. The header bricks on each layer are placed in the middle of the side bricks in the
layers above and below to ensure adequate tie. To maintain adequate tie the end half
bricks are alternated along vertically.
2.6 Bond-finish
Bond-finish is the final process in terms of finishing of a brick wall in order to produce
an aesthetic appearance. There are two ways to carry out bond-finish. Bond-finish can
be done at the same time as brick laying is carried out, or after the process of brick laying
has been completed.
Bond-finish of the wall of brick is carried out as each layer of brick is layed: this is a
much more practical process and can be carried out more quickly and result in greater
strength. However, can be a problem during wet weather and the ability to obtain a
consistent colour.

PM Dr CPG 2016

Bond-finishing after the brick is layed: is carried out by indenting each joining mortar
bond to a depth of 15 mm using a sharp stick. The indented mortar between bricks is
allowed to harden as the wall construction is continued until finished. The brick wall
surface is brushed clean of free mortar and the wall cleaned with water. The wall is
allowed to dry and only then bond-finishing is carried out. This approach is carried out
whilst the brick bond is still damp and produces a better finish.
For wall surfaces that are exposed continuously to bad weather, the bond-finish is carried
out using mortar in the ratio of 1:2 (1 part cement and two parts sand), otherwise a ratio
of 1:3 is sufficient.

2.7 Plastering or Rendering Brick Walls

Plastering or rendering brick walls is carried out in order to provide a smooth and neat
finish. For the plaster to stick strongly to the wall, the bonding region and the bricks are
scraped before plastering. Three main types of plastering material are: Lime Plaster,
Cement Plaster and Gypsum plaster, whilst a combination of these are also often used.
The plastering consists of two layers.
(a) Foundation layer:
This layer consists of :
(i)
Lime plaster that is mixed with cement in the ratio of 1:2:8-9 (cement: lime:
sand)
(ii)
OR the above combination in the ratio of 1:1:5-6
(iii)
Lime plaster mixed with gypsum plaster in the ratio of 1:3:7-9
(iv)
Slow hardening Gypsum plaster semihydrate and sand in the ratio 1:1-3
(v)
Cement and plaster with a little or no lime in the ratio 1:3 (cement: sand).

(b) Finishing Layer:

This layer consists of:
(i)
Lime plaster mixed with gypsum plaster in the ratio of 2-4: 1 (lime: gypsum
plaster) depending on the required hardness of the surface.
(ii)
OR the above combination in the ratio of 1:1
(iii)
Slow hardening semihydrate gypsum with or without sand
(iv)
Anhydrous gypsum pieces.
The following points should be observed in the construction of brick masonry:
1. Use bricks of good quality with uniform colour, well burnt, with exact shape and size.
2. Before using the bricks in masonry, they should be soaked in water for 2 hours so that
bricks do not absorb water from the mortar.
3. Bricks should be laid with the frog pointing upward.
4. Construction of brick wall should start from the end or corner.
PM Dr CPG 2016

5. Brick courses should be perfectly horizontal.

6. Verticality of the wall should be ensured by frequently checking with plumb-bob.
7. Mortar used should be as per specification.
8. Whenever work is stopped brick masonry should be left with toothed end.
9. Use of brick bats should be avoided.
10. Walls should be raised uniformly. In no case difference between adjoining walls be
more
than 1 m. In a day no wall should be raised by more than 1.5 m.
11. To get proper key for plastering or pointing, the face joints should be raised to a depth
of 12 to 20 mm, when the mortar is green. If plastering or pointing is not to be provided,
face joints should be stuck flush and finished neatly.
12. Holdfasts for doors and windows should be embedded in brick masonry with cement
mortar or concrete, at the time of constructing the wall itself.
13. Brick masonry should be regularly cured for 2 weeks.
14. For carrying out brick work at higher levels, only single scaffolding should be used.

Advantages and Disadvantages of Brick Masonry Over Stone Masonry:

Advantages:
1. Since shape and size of bricks are uniform, it do not need skilled labour for the
construction.
2. Bricks are light in weight and hence handling them is easy.
3. Bricks are easily available around cities and their transportation cost is less because
their weight is less. Stones are to be brought from quarries which are located only at few
places.
4. It is possible to use all types of mortar in brick masonry. For unimportant buildings
even mud mortar can be used.
5. Thinner walls can be constructed with bricks but it is not so with stones.
6. It is easy to form openings for doors and windows.
7. Dead load of brick masonry is less.
8. In brick masonry mortar joints are thin and hence construction cost is reduced
considerably.
9. Brick masonry has better fire and weather resistance compared to stone masonry.
Disadvantages:
1. Strength of brick masonry is less than that of stone masonry.
2. Durability of brick masonry is less.
3. Brick masonry needs plastering and plastered surface needs colour washing. Stone
masonry dont need them and hence maintenance cost is more in brick masonry.
4. Brick masonry absorbs water and there are possibility of dampness. There is no such
problem in stone masonry.
5. More architectural effects can be given in stone masonry compared to that in brick
masonry.
6. Stone masonry gives massive appearance and hence monumental buildings are built in
stone masonry

PM Dr CPG 2016

COMPARISON OF CLAY BRICK AND CONCRETE BRICK (BLOCK):

When comparing clay brick to concrete brick, it should be noted that both materials
when properly installed can provide an attractive and structurally sound wall. However,
when comparing the two products the following points should be kept in mind.
1. Concrete Brick
(Reference ASTM Standard C55 Standard Specification for Concrete Brick)
Definition: A concrete masonry unit made from Portland cement, water, and suitable
aggregates, with or without the inclusion of other materials.
2. Clay Brick
(Reference ASTM Standard C 216 Standard Specification for Facing Brick (Solid
Masonry Units Made from Clay or Shale))
Definition: A solid masonry unit of clay or shale formed or extruded into a
rectangular prism while plastic and fired to high temperatures (up to 2000F) in a
kiln. Clay or shale brick is a ceramic product.
3. Compare Strength
Clay brick units are 2 to 3 times stronger than concrete units.
Clay Brick average compressive strengths typically range from 8,000 to 10,000 psi
Concrete Brick average compressive strengths typically range from 3,000 to 4,000
psi
4. Absorption
Compare Initial Rate of Absorption (IRA) products in natural state.
- The majority of Clay Brick absorbs approximately 15-35 grams of moisture per
minute per 30 sq. ins.
- Concrete Brick, between 40 and 80 grams per minute per 30 sq. in.
Or, in simple terms, Concrete Brick absorbs approximately 2-3 times more moisture
in the same amount of time as does Clay Brick.
If you examine the walls of clay brick and concrete brick buildings after heavy rains
you will note concrete brick walls can stay damp for days after a rain.)
Due to the high rate of absorption some manufactures will add an intregal water
repellent to the units to help minimize the potential of water related problems. If
intregal water repellent units are used you should also add a water repellent to the
mortar to be effective. This can add $3.00 to the cost of a bag of mortar.
5. Movement Joints
Most building materials exhibit some type of movement with changing weather
conditions (temperature and humidity). And all building designs should account for this
movement. Once put in service a clay unit will expand over time whereas a concrete unit
will shrink. Clay units Clay brick homes have been built for years without the use of
movement joints. Unless your home is unusually large this is still a good rule of thumb.
However, you should accommodate for expansion around all door and window openings.
(provide a 3/8 joint and fill with flexible caulk sealant).
Concrete units Because of the nature of shrinkage movement concrete brick homes
may be more susceptible to cracking. Because of this, joint reinforcing steel is required
with concrete units to help minimize cracking due to shrinkage. Consideration should
also be given to providing vertical control joints in the walls. The design of these joints
should consider the aesthetics, water permeance, and maintenance of the joint.
PM Dr CPG 2016

6. Material Cost
Depending on geographical location the following are typical price ranges (not including
labor, mortar, or mortar additives)
Clay Brick $230.00 - $300.00 / per thousand
Concrete Brick $190.00 $250.00 / per thousand
7. Labor Factors
Certain concrete brick units (i.e. frogged) are sometimes difficult to cut cleanly using a
trowel or brick hammer. This may require saw-cutting the units. Other factors such as the
ease of cleaning the units might also effect labor cost. You should consult with your
mason contractor to obtain a labor cost for either clay or concrete bricks.
8. Color and Texture
Both clay and concrete brick come in a wide variety of colors. Certain textures such as a
tudor effect is only available with clay bricks. You should view sample panels to make a
selection regarding color and texture. However you should be aware that concrete brick
are not color fast and they will fade over time.

PM Dr CPG 2016