ABM Terengganu Training Presentation April 2008

CONSTRUCTION PROCEDURE
FOR
CONCRETE MASONRY WALLS
AKADEMI BINAAN NEGARA
WILAYAH TIMUR
08 APRIL 2008
integrated brickworks sdn bhd
Incorporated in 1972
Pioneering producer of high quality concrete masonry
Factories use dedicated state-of-the-art plants

Industry milestones:
Wrapped and palletised product packaging
Truck-mounted cranes
Introduced Segmental Retaining Walls
Introduced architectural concrete masonry
SIRIM and BOMBA certification

Our Production Facility
Factory set up on 16-acre site near Port Dickson
2 high-capacity plants operational
Dedicated high-tech automated dry-cast systems
Customised product curing chambers
Fully-equipped laboratory for QC and QA
Ample product storage capacity
Our Products and Services
Concrete Masonry Units
Load-bearing Masonry
Acoustic Masonry
Interlocking Masonry
Architectural Masonry
Fluted Block
Splitblox
Segmental Retaining Wall Systems
Keystone
Country Manor
Services Provided
Design Assistance, Cost Estimations, Project
& Site Advisory, Product & Installation Training
Product Applications
Concrete Masonry Units Load Bearing
Concrete Masonry
Concrete Masonry
Concrete Masonry
Concrete Masonry
Concrete Masonry
Concrete Masonry
Concrete Masonry
Concrete Masonry Acoustic Masonry
Architectural Concrete Masonry
Keystone Retaining Wall Systems
Keystone Country Manor
CONCRETE MASONRY
What is a
Concrete Masonry
Unit?
Modular System ~ IBS component
International Usage and Acceptance
Hollow cores provide improved insulation, reduced
weight and reinforcement channels
Range of basic and special units for plumbing,
corners, lintels, vertical/horizontal steel reinforcement
Load-bearing masonry structures built with reinforcing
steel for columns and tie-beams
Completed walls can be fair-face
Walls can be plastered, painted, coated
Modular Units include Architectural Masonry
CONCRETE MASONRY
CONCRETE MASONRY
CONCRETE MASONRY UNITS
(CMU)

Modular
Coordination

CMU WALL
CONSTRUCTION
(Fair-face)

Mortar

CMU
Installation
Materials
Storage,
Handling
Protection

Site
Preparation

Services
Tools,
Equipments, Material

Mixing Mortar

Tools
Cleaning & Patching
Of Mortar Joints
Wall
Foundation
Wall
Intersections

Door & Window
Openings
Wall Corners

Electricity

Plumbing
Reinforced
Wall

Wall Block
Patterns
Unreinforced
Wall
Vertical
Reinforcement
Columns and
Pilasters

Lintels & Sills

Door & Window
Frames

Horizontal
Reinforcement

CMU WALLS

Non-Load Bearing Structures

Load Bearing Structures
MODULAR CONCRETE
MASONRY STRUCTURES
Modular Designs
Utilise modular coordination
Limits the variety of components
Reduces or eliminates customising
Use industrial mass-produced IBS components
Modular Designs, Methods and Systems:
Modular Methods and Systems
Increases speed and efficiency
Reduce wastages
Lower costs
CONCRETE MASONRY
UNIT MODULES
CMUs use a basic grid of 200mm x 200mm
CMU module sizing (inclusive 10mm mortar joints):
Full Block 200mm (H) x 400mm (W)
Half Block 200mm (H) x 200mm (W)
CMUs for reinforcement and services conform to above (for
bond beams, lintels, plumbing, corners, etc)
Special applications and designs may require and sized
units, half-height units or others, which can also be available
CONCRETE MASONRY WALL
1. Keep the CMUs dry
2. Check for tools, materials and equipment
3. Prepare the base or wall foundation
4. Locate wall ends or corners
5. Install alignment string lines
6. Prepare mortar mix
7. Lay the first course
8. Install the last unit or Closure Block
9. Continue laying second and upper courses
10. Tool the mortar joints
11. Clean the wall and patch the mortar joints as necessary.
12. Cover the unfinished wall for continuation next day.
INSTALLATION GUIDELINES
Step 1: Keep the CMUs clean and dry

Masonry units at-site are to be kept clean and dry
before use.
Store the stocks on planks, pallets, etc to keep
them above ground, and, where possible,
covered to keep off rain.
INSTALLATION PROCEDURE TO CONSTRUCT
UNREINFORCED CONCRETE MASONRY WALLS
Step 1: Keep the CMUs clean and dry

Masonry units at-site are to be kept clean and dry
before use.
Store the stocks on planks, pallets, etc to keep
them above ground, and, where possible,
covered to keep off rain.

CMUs are to be installed in dry condition for the
most effective bonding strength of the mortar
joints.
Step 2: To lay the FIRST COURSE
Ensure the foundation face is clean and ready to receive
mortar bedding for the base of the wall.
Check and make good the bedding face level and alignment.
Set out the wall ends, and install string lines for level and
alignment.
alignment.
Install the wall end or corner blocks in mortar to correct
level, alignment and plumb.
alignment.
Install the wall end or corner blocks in mortar to correct level,
alignment and plumb.
Do a test run by placing blocks without mortar in
between the two end blocks to confirm.
Step 2: Lay the FIRST COURSE (cont)
Spread a full mortar bed on the foundation, and check for
alignment and thickness.

Install blocks by buttering mortar to the ends of the face
shells for the vertical joints, and pressing them into the
mortar bed and butting them against the block adjacent,
ensuring 10mm thick mortar joints.
Install blocks by buttering mortar to the ends of the face
shells for the vertical joints, and pressing them into the
mortar bed and butting them against the block adjacent,
ensuring 10mm thick mortar joints.
Adjust the blocks to the string line for level, alignment and
spacing by tapping with a small hammer.
It is important to lay the first course carefully, as mistakes
in alignment, level or plumb will lead to bigger problems
the higher the wall is built.
Step 3: Install the CLOSURE BLOCK
Check the opening for the last unit (Closure Block) in the
course to ensure the last block fits.
Butter mortar to the block for the vertical joint, and lower
the block into the opening vertically from above. Adjust
for joint thickness, alignment, plumb and level.
Step 3: Install the CLOSURE BLOCK
Check the opening for the last unit (Closure Block) in the
course to ensure the last block fits.
Butter mortar to the block for the vertical joint, and lower
the block into the opening vertically from above. Adjust
for joint thickness, alignment, plumb and level.
Mortar for the final vertical joint is to be packed in
from above, ensuring a well-filled mortar joint.

Step 4: Lay the SECOND COURSE
Lay the corner or end blocks first to level, alignment and
plumb, and install a string line.
Butter mortar to the horizontal face shells of the blocks in
the first course.
Next, butter mortar for vertical joints to the ends of the
blocks to be laid, and lay them to the string line, with the
necessary adjustment to level, plumb and alignment.
Butter mortar to the horizontal face shells of the blocks in the
first course.
Next, butter mortar for vertical joints to the ends of the blocks
to be laid, and lay them to the string line, with the necessary
adjustment to level, plumb and alignment.
Remove excess mortar extruded from the joints.
Do NOT use dead mortar.
Do NOT adjust the block after the mortar has stiffened.
Step 5: Lay the THIRD and SUBSEQUENT COURSES
To continue installation of blocks in wall to completion,
repeat the procedures as given above.

Closure Blocks should be staggered throughout the wall
length.

Protect the uncompleted wall for continuing work the next
day, by covering open cores from rain, and, if appropriate,
protect the lower wall sections from mud splashes.

This fundamental 5 part installation guideline
provides for the successful installation of a well
constructed concrete masonry wall.

Adhering to this guideline will result in walls built to high
workmanship, meeting the structural and aesthetic
requirements of clients, architects and engineers.
SUMMARY
THANK YOU
CONCRETE MASONRY UNITS
(CMU)

Modular
Coordination

CMU WALL
CONSTRUCTION
(Fair-face)

Mortar

CMU
Installation
Materials
Storage,
Handling
Protection

Site
Preparation

Services
Tools,
Equipments, Material

Mixing Mortar

Tools
Cleaning & Patching
Of Mortar Joints
Wall
Foundation
Wall
Intersections

Door & Window
Openings
Wall Corners

Electricity

Plumbing
Reinforced
Wall

Wall Block
Patterns
Unreinforced
Wall
Vertical
Reinforcement
Columns and
Pilasters

Lintels & Sills

Door & Window
Frames

Horizontal
Reinforcement

CMU WALLS

Non-Load Bearing Structures

Load Bearing Structures

ABM Terengganu Training Presentation April 2008

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CONSTRUCTION PROCEDURE

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