4. HISTORY
BLD62003_MAK_STONES AND ROCKS
One of the oldest manufactured building
materials
Sun-baked brick was found in the remains of
structures in the Tigres-Euphrates basin as
early as 6000 B.C.
Romans also used thin bricks in thick mortar
made of volcanic materials and lime.
1633 – 1st brick buildings erected in Manhattan
Island (imported from Holland & England)
An assembly or combination of small building
units made of clay, shale, concrete, glass,
gypsum, or stone that are set in mortar.
Masonry consists entirely or partially of hollow
or solid units laid contiguously in mortar.
DEFINING MASONRY
4
6. • Mortar is the material that sticks two
masonry units together - it is the stuff
you can see between bricks
MORTAR
• Must conform to ASTM C270
• 4 basic types of mortar used: M, S, N, O
• Composed of: Portland cement,
hydrated lime, sand, and water
• Key to forming a strong and durable
bond with masonry units
BLD62003_MAK_STONES AND ROCKS
CORRECT & INCORRECT WAY IN ASSEMBLYING
6
7. MORTAR
BLD62003_MAK_STONES AND ROCKS
Type Avg
Compressive
Strength
Use
M 2500 psi Masonry below grade and in
contact with earth
S
1800 psi Where maximum flexural
strength is required (winds
>80 mph)
N
750 psi General use in exposed
masonry above grade;
parapets, chimneys, and ext.
walls subjected to severe
weathering
O
350 psi Solid unit load-bearing walls
Where compressive strength
< 100 psi
TYPES OF MORTAR
7
8. MORTAR
MORTAR BASICS
PROPERTIES
• Have a tendency to shrink
very little
• High degree of resistance
to moisture penetration
FUNCTIONS
BLD62003_MAK_STONES AND ROCKS
JOINTS
• Brick masonry mortar made of
Portland cement, hydrated lime,
and sand (stone masonry uses
white Portland cement [non
staining].
• Retempering – adding water to
the mortar mix to maintain
consistency
• Mortar mix should be used
within 2 – 2 ½ hours after initial
mix is prepared
• Efflorescence – the soft white
powder appearing on the face of
brick; caused by salts in the brick
or mortar brought to the surface
• Possess adequate strength to resist
forces applied to it
• Provide aesthetic qualities to the
structure through the use of color
and type of joint
• Joint sizes vary
• Facing brick – 3/8” to
½”
• Building brick – ½”
• Glazed brick – 1/4 “
• Although many types of
joints exist , the most
weatherproof &
recommended are: V-
shaped, Weathered, &
Concave
• Joints may be formed by
using a trowel, steel rod,
or specialized tools
TYPES OF JOINTS
8
10. MASONRY
HISTORY
MORTAR
GROUT
BLD62003_MAK_STONES AND ROCKS
BRICKS
STRUCTURAL CLAY TILES
CONCRETE BLOCK (CMU)
MASONRY PANELS
GYPSUM BLOCK
GLASS BLOCK
STONE
STONE MASONRY
“Grout is a
construction material
used to embed rebars
in masonry walls,
connect sections of
pre-cast concrete, fill
voids, and seal joints”
10
11. BLD62003_MAK_STONES AND ROCKS
GROUTS
• The water/cement ratio is less critical in
grout than in mortar or concrete
• It is intended to be very “fluid” in order to
function in it’s “binding” capacity (slump of
8-11 inches)
• May be used to fill cavities between
masonry walls (often around vertical
reinforcement )
• Grouts (fills cavities in the masonry unit).
DEFINITION
11
14. • The term “masonry” refers to
construction with stone
masonry describes the
stonework which is
incorporated into the building
• Masonry is held together with
mortar (between pieces of
masonry) and grout (fills cavities
in the masonry unit).
• Mortar is the material that sticks
two masonry units together - it
is the stuff you can see between
bricks
INTERACTION MASONRY , MORTAR & GROUT
BLD62003_MAK_STONES AND ROCKS
MASONRY
MORTAR
GROUTS
• (fills cavities in the masonry unit).
14
15. BRICKS
HISTORY
MORTAR
GROUT
BLD62003_MAK_STONES AND ROCKS
BRICKS
STRUCTURAL CLAY TILES
CONCRETE BLOCK (CMU)
MASONRY PANELS
GYPSUM BLOCK
GLASS BLOCK
STONE
STONE MASONRY
“A brick is a block or a single
unit of a kneaded clay-bearing
soil, sand and lime, or concrete
material, fire hardened or air
dried, used in masonry
construction.”
15
16. BRICKS
PROPERTIES TYPES
BLD62003_MAK_STONES AND ROCKS
CLASSES OF BRICKS
• 2 Types
TYPE I : SOLID
• May be solid or hollow
core (holes called “cells”)
• Cells should not exceed 25
% of the volume of the
unit
• Bricks vary in size, color,
shape, and texture.
TYPE II: WITH HOLES
• Solid brick used where holes may
be unsightly (steps or window sills
TYPE I : SOLID
TYPE II : WITH HOLES
• Holes in Brick:
• Help units fire properly
• Promote bonding with
mortar
• Reduce overall weight
• Make units easier to handle
• Adobe – sun-dried clays and
a binder
• Kiln-burned – natural sand
and clay or shale (most
widely used)
• Sand-lime – pearl-grey in
color, dolomite lime is mixed
with clean sand, pressed,
and allowed to harden in
closed vessels under steam
pressure
• Concrete – portland cement
and suitable aggregate,
formed in molds
16
17. BRICKS
BRICK KILNS BRICK TYPES/ SIZES
BLD62003_MAK_STONES AND ROCKS
(I) COMMON
DIFFERENT BRICK TYPES
• Burning of brick is
done in 4 stages
• Water smoking:
400 °F
• Dehydration:
300 -1800 °F
• Oxidation: 1000
– 1800 °F
• Vitrification:
1600 – 2400 °F
• Flashing (oxygen
reduction)– produces
different colors or
color shading
• Cooling down –
done in 2-3 days; rate
of cooling will affect
cracking, and color
• Common (now called Building)
• Most widely used
• Dark orange to deep red
color
• Many finishes & sizes
available
• Meets ASTM C62 grading
criteria:
• SW – severe weathering for
exposure to heavy rainfall
& freezing
• MW – moderate
weathering for avg.
moisture and minor
freezing
• NW – Negligible
weathering for exposure to
moisture & freezing
(II) FACE BRICKS
(III) GLAZED FACE BRICKS
(IV) FIRE BRICKS
(V) PAVING BRICKS
(I) COMMON BRICKS
17
18. BRICKS
BRICK TYPES/ SIZES
BLD62003_MAK_STONES AND ROCKS
(I) COMMON
DIFFERENT BRICK TYPES
(II) FACE BRICKS
(III) GLAZED FACE BRICKS
(IV) FIRE BRICKS
(V) PAVING BRICKS
(II) FACE BRICKS
• Made from clay, shale, fire
clay, or a mixture, under
controlled conditions
• Meets ASTM C216 standard
• Appearance types:
• FBS- general use in
exposed & interior
walls where wide color
ranges & variation in
sizes are permitted
• FBX- used in exterior &
interior walls where a
high degree of
mechanical perfection,
narrow color range &
little variation of size is
required
• FBA- nonconformity in
size, color, & texture
BRICK TYPES/ SIZES
(III) GLAZED FACE BRICKS
• Bricks sprayed with a
ceramic glaze and fired
at high temperature to
fuse glaze to the brick
• Finishes may appear
dull, satin, or glossy
(IV) FIRE BRICKS
• Made of clays with a
large amount of
alumina, silica, flint, and
feldspar
• These bricks are used in
fireplaces, chimney
stacks, incinerators, and
many industrial settings
(V) PAVING BRICKS
• Bricks are burned at
much higher
temperatures to make
them resist water and
wear from traffic
BRICK TYPES/ SIZES
18
21. BLD62003_MAK_STONES AND ROCKS
Unit Nominal Dimension
(in.)
W x H x D
Actual Dimension (in.)
**
W x H x D
Modular 4 x 2 2/3 x 8 3 5/8 x 2 ¼ x 7 5/8
Utility 4 x 4 x 12 3 5/8 x 3 5/8 x 11 5/8
** Note: actual dimensions may
vary among manufacturers of
brick – dimensions noted from
Graphics Standards 2000
publication
NOMINAL VS ACTUAL SIZE
21
22. BRICK BOND
BLD62003_MAK_STONES AND ROCKS
• Bond – the arrangement of bricks in rows (courses).
• Bonds are designed for:
• Appearance
• To tie together a structural or outer wall (wythe) to an inner wall
• Wythe – a vertical section of wall one brick thick
22
29. TYPES
BRICK
WALLS &
TIES
FACED WALLS
REINFORCED BRICK MASONRY
PROPERTIES OF BRICK WALLS
SOLID WALLS
BRICK WALLS & TIES
BLD62003_MAK_STONES AND ROCKS
• May be :-
• bearing (supports any
vertical load)
• or non-bearing
(I) LOAD BEARING WALLS
(I)NON LOAD BEARING WALLS
• Solid walls- 2 or more
wythes bonded together
by ties, headers
CAVITY WALLS
• Cavity walls – 2 walls spaced
2 in. apart by metal ties;
may fill cavity with
insulating material; Weep
holes must be in outer wall
in order for moisture to
escape ; not allowed in
earthquake zones
VENEERED WALLS
TYPES
• brick masonry units bonded to a
backup wall of another material
(common brick, hollow structural
clay tile, or CMU)
• facing material is securely tied to
a structural wall but NOT bonded
to it (common residential wood-
frame construction)
• steel reinforcement is placed
vertically & horizontally and
often grout surrounds it
(spacing governed by local code
requirements)
TIES
• May be standard unit ties/ adjustable
• Number and placement of ties
depends on application and building
code requirements
TYPES
DIFFERENT BRICK WALLS
(I) SOLID WALLS
(II) CAVITY WALLS
(III) FACED WALLS
(IV) VENEERED WALLS
(V) REINFORCED BRICK
MASONRY
29
30. TIES TYPES
BLD62003_MAK_STONES AND ROCKS
Z- TIES
DIFFERENT TYPES OF TIES
ADJUSTABLE BOX ANCHOR
CORRUGATED WALL TIES
(II) ADJUSTABLE BOX ANCHOR
TIES (PROPERTIES)
(III) Z- TIES
• May be standard unit ties or
adjustable
• Number and placement of
ties depends on application
and building code
requirements
• designed to tie multi-wythe
walls
• multi- wythe walls when
fully grouted
(I) “CORRUGATED “ WALL TIES
• veneer walls
TIES TYPES
TIES
TIESTYPES
TIES
30
32. STRETCHER
TYPES OF BLOCK
BLD62003_MAK_STONES AND ROCKS
Used in straight wall sections.
One flat end to create attractive walls at
corners.
Has special grooves, can be laid to receive
window.
Use to make door ways so the openings
are attractive and secure.
Used to prevent cutting of blocks when
only half a block is needed.
Used as top course of block on a poured
floor.
CORNER
SASH
JAMB
HALF
L-BLOCK
STRETCHER
32
33. STRETCHER
TYPES OF BLOCK
BLD62003_MAK_STONES AND ROCKS
Used in straight wall sections.
One flat end to create attractive walls at
corners.
Has special grooves, can be laid to receive
window.
Use to make door ways so the openings
are attractive and secure.
Used to prevent cutting of blocks when
only half a block is needed.
Used as top course of block on a poured
floor.
CORNER
SASH
JAMB
HALF
L-BLOCK
CORNER
33
34. STRETCHER
TYPES OF BLOCK
BLD62003_MAK_STONES AND ROCKS
Used in straight wall sections.
One flat end to create attractive walls at
corners.
Has special grooves, can be laid to receive
window.
Use to make door ways so the openings
are attractive and secure.
Used to prevent cutting of blocks when
only half a block is needed.
Used as top course of block on a poured
floor.
CORNER
SASH
JAMB
HALF
L-BLOCK
SASH
34
35. STRETCHER
TYPES OF BLOCK
BLD62003_MAK_STONES AND ROCKS
Used in straight wall sections.
One flat end to create attractive walls at
corners.
Has special grooves, can be laid to receive
window.
Use to make door ways so the openings
are attractive and secure.
Used to prevent cutting of blocks when
only half a block is needed.
Used as top course of block on a poured
floor.
CORNER
SASH
JAMB
HALF
L-BLOCK
JAMB
35
37. STRETCHER
TYPES OF BLOCK
Used in straight wall sections.
One flat end to create attractive walls at
corners.
Has special grooves, can be laid to receive
window.
Use to make door ways so the openings
are attractive and secure.
Used to prevent cutting of blocks when
only half a block is needed.
Used as top course of block on a poured
floor.
CORNER
SASH
JAMB
HALF
L-BLOCK
HALF
BLD62003_MAK_STONES AND ROCKS
37
38. STRETCHER
TYPES OF BLOCK
Used in straight wall sections.
One flat end to create attractive walls at
corners.
Has special grooves, can be laid to receive
window.
Use to make door ways so the openings
are attractive and secure.
Used to prevent cutting of blocks when
only half a block is needed.
Used as top course of block on a poured
floor.
CORNER
SASH
JAMB
HALF
L-BLOCK
HALF
BLD62003_MAK_STONES AND ROCKS
38
40. LAYING BLOCKS PROCEDURE
BLD62003_MAK_STONES AND ROCKS
• Lay several stretcher blocks in place by
working away from the end or corner block.
• Use the end of the trowel handle to tap the
block until each block is plumb, level, and the
course is straight.
• Apply a mortar bed on top of the first course
in preparation for the second course.
• If extra strength is needed in the wall, install
reinforcement in the mortar bed.
• Use a line to keep the courses straight. line
is positioned to be level along the top of
block.
• When a block must be cut, use a masons
hammer and make multiple strikes along
the line to cut; then make one sharp strike
on the web.
• Check the height to be sure each new
course is an additional 8 inches high.
• After the mortar dries and hardens slightly,
finish the joints by rubbing it with a broken
piece of block.
• If a joint other than a flush joint is desired,
use a jointer to compress the mortar and
create a watertight joint.
• Tools are available to create joints that are
concave, v-shape, flush or raked.
• Spread a layer of mortar called a mortar
bed as the footer.
• Position the block on the mortar bed so
that its outside corner rests where the
outside corner of the wall should be.
• Level the block by first placing the level
across the block and then lengthwise along
the block.
• Turn several stretcher blocks on end and
apply mortar to the ears with a wiping or
swiping stroke of the trowel.
• As the block laying progresses, cut off excess
mortar with the trowel.
40
42. BRICKS & BLOCKS
BLD62003_MAK_STONES AND ROCKS
NOTE#
A building laid by using whole and half blocks
• Door openings will have 2"
jambs on both sides and top.
• Door will be a standard
height (44" x 6'8").
• Door sill will accommodate a
concrete floor inside.
• Window openings will
accommodate standard size
windows.
• Space above the top of the
door will accommodate
appropriate trim under the
eaves of the roof.
• Reinforced concrete lintels
carry the weight over door and
window openings.
• There are no cut block in
the wall. Therefore, the
wall can be built with a
minimum of cost and labor.
42
43. BRICKS & BLOCKS
BLD62003_MAK_STONES AND ROCKS
PLACEMENT OF CORNER POLES FOR CONSTRUCTIONG A BLOCK WALL
PROCEDURE OF LAYING CONCRETE BLOCK WALLS
43
44. BRICKS & BLOCKS
BLD62003_MAK_STONES AND ROCKS
Method of laying concrete blocks. Good
workmanship is requires straight courses
with face of the wall plumb and true
(left hand side)
Usual practice of applying mortar
to concrete blocks
(right hand side)
44
45. BRICKS & BLOCKS
BLD62003_MAK_STONES AND ROCKS
8" x 8" x 16" Concrete Block Corner
in the Running Bond (right bottom)
Showing detail of joining an interior and
exterior wall in concrete block
construction.(left bottom)
45
46. BRICKS & BLOCKS
BLD62003_MAK_STONES AND ROCKS
typical 3/8" joint
8" x 8" 16" block
Concave joint V-Joint Flush Joint Raked
Joint
Types of joint finishes used on
block walls
Types of joint finishes used on block
walls
46
47. MORTAR
MORTAR BASICS
DEFINITION FUNCTIONS
BLD62003_MAK_STONES AND ROCKS
BASIC TERM
TYPES OF BRICKS
• Laying of bricks bonded
together with mortar is
known as brick masonry.
Types of Bricks
Modular
Bricks
Conventional
Bricks
• HEADER
• STRETCHER.
47
48. TYPES OF CLOSE: KING CLOSER
BLD62003_MAK_STONES AND ROCKS
48
49. TYPES OF CLOSE: QUEEN CLOSER
BLD62003_MAK_STONES AND ROCKS
1/2
1/2
49
50. TYPES OF CLOSE: MITRED CLOSER
BLD62003_MAK_STONES AND ROCKS
Angle 45° to 60°
50
51. TYPES OF CLOSE: BEVELLED BAT
BLD62003_MAK_STONES AND ROCKS
Types of
Bond
Stretcher Bond
Header Bond
English Bond
Flemish Bond
51
72. MASONRY
HISTORY
MORTAR
GROUT
BLD62003_MAK_STONES AND ROCKS
BRICKS
STRUCTURAL CLAY TILES
CONCRETE BLOCK (CMU)
MASONRY PANELS
GYPSUM BLOCK
GLASS BLOCK
STONE
STONE MASONRY
“Gypsum block is a massive
lightweight building material
composed of solid gypsum, for
building and erecting lightweight
fire-resistant non-load bearing
interior walls, partition walls,
cavity walls, skin walls and pillar
casing indoors.”
72
73. GYPSUM BLOCKS
USES
APPLICATION
RESISTANCE PROPERTIES
BLD62003_MAK_STONES AND ROCKS
SPECS/ SIZES
• In non load bearing application
• Fire resistance
• Interior location
CONCERN
• 80mm
• (656mm x 500mm x 80mm)
• 100mm
• (656mm x 500mm x 100mm)
• 120mm
• (656mm x500mm x120mm)
• 150mm
• (620mm x400mm x 150mm)
• (620mm x 500mm x 150mm)
• 200mm
• (620mm x320mm x200mm)
• (620mmx 400mm x 200mm)
• Concern: never use in areas in
which moisture exposure could
occur
73
74. BLD62003_MAK_STONES AND ROCKS
PROPERTIES
GYPSUM BLOCKS SPECIFICATION
GYPSUM
BLOCK
• Lightweight,
• used in non-load bearing
applications,
• fire-resistant,
• interior locations
• Concern: never use in
areas in which moisture
exposure could occur
74
75. MASONRY
HISTORY
MORTAR
GROUT
BLD62003_MAK_STONES AND ROCKS
BRICKS
STRUCTURAL CLAY TILES
CONCRETE BLOCK (CMU)
MASONRY PANELS
GYPSUM BLOCK
GLASS BLOCK
STONE
STONE MASONRY
“Glass Blocks are a
versatile building material
you can use for windows,
stairwells, shower screens,
paving, interior and
exterior walls” 75
76. GLASS BLOCKS
FORMS
APPLICATION
BLD62003_MAK_STONES AND ROCKS
UNIQUENESS
FACES/SURFACE TEXTURE
• Often used for their
decorative effect but also:
• Provide controlled light
transmission
• Good insulation
• Condensation
protection
• Good sound reduction
• The blocks are formed of 2
cast glass shells that are
fused together to form a
hollow unit containing a
partial vacuum. The
vacuum decreases heat
transmission and surface
condensation.
• Faces can be:
• Smooth – provides
vision through the
block
• Textured – provide
only light transmission
• Opaque – fired with a
ceramic finish
• Common sizes are 6”, 8”, 12”
sq. by 4 “ thick
• Mortar joints typically ¼ “
MORTAR JOINT
CONCERN
• Concern: glass block expands 1.5
to 2 times more than a brick wall
& therefore, must have expansion
joints
• Usually laid in a stack bond (can only
support their own weight)
76
79. STONES
GENERAL INFORMATIONS
BLD62003_MAK_STONES AND ROCKS
CLASSIFICATIONS
EXAMPLE
• Igneous – formed by the solidification
of molten rock such as volcanic activity
(Granite)
• Sedimentary – formed from silt,
marine life, and rocks that have been
deposited by running water
(Limestone, Sandstone, & Travertine)
• Metamorphic – igneous or
sedimentary rock that have been
changed by pressure, heat, or moisture
(Marble, Slate)
• The removal method (quarrying),
sizes, shapes (smooth round,
angular), thickness, textures,
finish, and application &
installation vary for each type.
• There are natural stones as well as
cultured (man-made) stones used
in building materials.
GENERAL INFORMATIONS
• Walls classified in 3 categories (based
on shape & surface finish)
• Rubble – stones as they are
collected (fieldstone) or as they
come from quarry
• Ashlar – constructed of squared
stones set in random or uniform
courses
• Cut stone (dimension)- fabricated
and finished at the mill ready to
set in place per the specifications 79
80. STONES
BLD62003_MAK_STONES AND ROCKS
STONE & USES
Stone Color Major Use Minor Use
Granite Wide Range Ext. & Int. wall facing Paving, Flooring
Limestone Buff, Gray Exterior wall facing Copings, Sills,
Interior wall facing
Marble Wide Range Ext. & Int. wall
facing, flooring
Countertops
Sandstone Yellow, Brown,
Reds, Tan
Exterior wall facing Paving
Slate Blue, Gray,
Green, Red, Black
Paving, Roof
Shingles
Wall facing
Travertine Tan, Buff, Gray Ext. & Int. wall facing Flooring, Paving
80
82. TYPES OF STONE
MASONRY WALLS
COMPOSITE WALL
(I) RUBBLE MASONRY
(II) ASHLAR MASONRY
LAYING OF STONE BLOCK IN A WALL
CAVITY WALLS
• made by laying stone
masonry over a
prepared bed of
mortar, and
proceeding in a
similar manner to
increase the height
(III) COARSED STONE MASONRY
BLD62003_MAK_STONES AND ROCKS
SOLID MASONRY WALLS
• made of an outer
wall of large stone
slabs, attached to a
backing of structural
frame or
brick/concrete
masonry wall
• made by two different
types of masonry wall
separated by a cavity,
which is either
insulated or empty
and connected
together by metal ties
• Composed of unsquared pieces
of stones; mason has to choose
carefully each stone so that it
can fit into the available space
• Made of squared pieces of
stones; mason has to carefully lift
the heavy stones by a hoist and
lower it into place
• has continuous horizontal joints
(IV) UNCOARSED STONE MASONRY
• Does not have defined bedding
planes for the wall
82
84. CHEMICAL
WET/ DRY CYCLE
ABRASIVE
FREEZE/ THAW
MURATIC ACID SOLUTION THERMAL EXPANSION/ CONTRACTION
BLD62003_MAK_STONES AND ROCKS
WATERMIST
SALT CRYSTALLIZATION
• will remove surface deposits;
problem is entrapment of
moisture
• Chemical – may
damage masonry if
not suitable for that
particular type
MASONRY
CLEANING/
RESTORATION
• may etch surface, change color of
masonry
• (sandblasting & pressure washing)
may damage surface; remove
mortar
• causes fractures
• capillary action produces force
that is stronger than the masonry
• entire structure
expands/contracts with change in
temperature
• if on surface of masonry will cause
efflorescence; if under surface
may lead to crumbling
MASONRY CLEANING (left hand side) MASONRY RESTORATION(right hand side)
84
85. BLD62003_MAK_STONES AND ROCKS
MASONRY UNITS
• Blocks made from concrete, cinders/
other aggregates.
LAYING BLOCKS
• The process of mixing mortar, applying
it to masonry block, and placing the
block to create wall
MORTAR BED
• A layer of mortar.
CORE
• The hollow space in a masonry block.
• E. Corner Pole:
• A straight piece of wood or metal held
plumb by diagonal supports.
• F. Course: A
• row of masonry units.
• Anything constructed of brick, stone,
tile, or concrete unit held in place with
portland concrete.
• Steel reinforced- concrete beams used
for support over windows and doors.
• Board used to hold mortar.
• Masonry block with two or three
holes per block.
Definitions of terms associated with concrete masonry units
CORNER POLE
COURSE
BRICK SET
• Wide chisel used for breaking masonry
units.
MASONRY
LINTEL
MORTAR BOARD
HOLLOW CORE BLOCK
CONCRETE SILLS
• Used under windows and doors.
• A continuous slab of concrete which
provides a solid, level foundation for block
or brick
FOOTINGS
85
