Brick Masonry

CHAPTER – IX
BRICK MASONRY

9.0. Brick Masonry:

Composition of Good Brick Earth
Alumina-20% to 30%
Silica – 50% to 60%
Lime <5%
Oxide of Iron <5% to 6%
Magnesia <1%
9.1. Type of Bricks:
9.1.1. Brick.
(a) Common Burnt clay building bricks – IS: 1077-1992
(b) Heavy duty burnt clay building bricks- IS: 2180-1988
(c) Pulverised fuel Ash-lime brick- IS: 12894-2002
9.1.1(a) Common Burnt Clay Bricks: (IS 1077-1992)
Physical Properties:
(i) Compressive Strength
Brick Classification
Class Average compressive strength (N/mm2)
35 35
30 30
25 25
20 20
17.5 17.5
15 15
12.5 12.5
10 10
7.5 7.5
5 5
3.5 3.5
(ii)Dimensions:
a. Modular :
Length (mm) Width (mm) Height (mm)
190 90 90
190 90 40
b. Non-Modular :
Length (mm) Width (mm) Height (mm)
230 110 70
230 110 30
(iii) Tolerances
 The dimensions of bricks when tested in accordance with clause 6.2.1 of IS: 1077 shall be
within the following limits per 20 bricks:
a) For modular size
Length 3720 to 3880 mm (3800±80 mm)
Width 1760 to 1840 mm (1800±40 mm)
Height 1760 to 1840 mm (1800±40 mm)
(For 90mm high bricks)
760 to 840 mm (800±40 mm)
(For 40mm high bricks)
b) For non-modular size
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Length 4520 to 4680 mm (4600±80 mm)

Width 2240 to 2160 mm (2200±40 mm)
Height 1440 to 1360 mm (1400±40 mm)
(For 70mm high bricks)
640 to 560 mm (600±40 mm)
(For 30mm high bricks)
9.1.1(b) Heavy duty Burnt Clay building bricks(IS: 2180-1988)
General Quality:
Heavy duty burnt clay bricks shall be manufactured either by pressing or extrusion. They
shall be made from a processed clay or clays blended in right proportions. The brick shall be
burnt to the correct maturing temperature of the clay or clay blend, properly soaked, annealed
and cooled under controlled conditions, When broken, the fractured surface of the brick shall
show a uniformly dense structure free from large voids, laminations and lime particles. Two
bricks when struck together shall emit a clear metallic ring.
The bricks shall have smooth rectangular faces with sharp corners and shall be
uniform in colour.
Physical Properties:

(i) Compressive Strength and Classification

Class Average Compressive Strength

Not less than Less than
2 2
N/mm (Kgf/cm ) N/mm2(Kgf/cm2)
approximate approximate
40 40.0 (400) 45.0 (450)
45 45.0 (450) -
(ii) Dimension:
The standard size of heavy duty clay building bricks shall be as follows:
Length Width Height
mm mm mm
190 90 90
190 90 40
(iii) Tolerance

The maximum permissible tolerances on the dimensions specified as follows:

Dimensions Tolerance on individual bricks

mm mm
190 ±4
90 ±2
40 ±2
(iv) Water absorption:

The bricks when tested according to the procedure laid down in IS: 3495 (Part 2) – 1976
after immersion in water for 24 hours, the average water absorption by mass shall not be
more than 10%.
(v) Efflorescence:
The bricks when tested in accordance with the procedure laid down in IS: 3495 (Part 3) –
1976, the rating of efflorescence shall be ‘Nil’.
(vi) Bulk Density:

The density of bricks shall not be less than 2.5 g/cm 3.

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9.1.1(C) Pulverised fuel Ash-lime brick- IS: 12894-2002

Physical Properties:

(i) Compressive Strength and Classification

Class Average Wet Compressive Strength
Designation Not less than
N/mm2 Kgf/cm2 (Approx)
(1) (2) (3)
30 30.0 300
25 25.0 250
20 20.0 200
17.5 17.5 175
15 15.0 150
12.5 12.5 125
10 10.0 100
7.5 7.5 75
5 5.0 50
3.5 3.5 35

(ii) Dimensions & Tolerances:

 Dimensions IS: 12894 - 2002
a. The standard modular sizes of pulverized fuel ash-lime bricks shall be as follows:
Length (mm) Width (mm) Height (mm)
190 90 90
190 90 40
b. The following Non-modular sizes of bricks may also be used:
Length (mm) Width (mm) Height (mm)
230 110 70
230 110 30
c. For obtaining proper bond arrangement and modular dimensions for the brick work, with the non
modular sizes, the following sizes of the bricks may also be used.
Length (mm) Width (mm) Height (mm)
70 110 70 1/3length brick
230 50 70 1/2 width brick
iii) Drying Shrinkage
The average drying shrinkage of the bricks when tested by the method described in IS: 4139,
being the average of three units, shall not exceed 0.15%.
iv) Efflorescence Test
The bricks when tested in accordance with the procedure laid down in IS: 3495 (Part 3) –
1976, shall have the rating of efflorescence not more than ‘moderate’ up to Class 12.5 and
‘slight’ for higher classes.
v) Water absorption:
The bricks when tested according to the procedure laid down in IS: 3495 (Part 2) – 1976 after
immersion in cold water for 24 hours, shall have average water absorption not more than 20%
by mass up to Class 12.5 and 15% by mass for higher classes.
vi) Material:
a. Pulverised Fuel Ash (Fly Ash)
It shall confirm to Grade 1 or 2 of IS 3812.
b. Bottom Ash
It is used as replacement of sand shall not have more than 12% loss or ignition when
tested according to IS 1727.
c. Sand
The sand should not content more than 5% clay and silt.
d. Lime
Lime shall conform to class C hydrated lime as per IS 712
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e. Additives
Any additive considered not detrimental to the durability of the bricks such as gypsum,
cement etc may be used.
9.1.1(D)
Fly Ash Lime- Gypsum / Cement Bricks(Ref:-Guidelines published by NTPC)1
In NTPC, Fly ash- lime / gypsum/ cement bricks are being manufactured in large quantity at its all
coal based stations using Vibro / Hydraulic press machines. These bricks are being manufactured for
in house construction works. The bricks are being manufactured using lime gypsum as well using
cement and cement & gypsum also. The guidelines have been prepared based on the many years
experience gained in manufacturing bricks. These guidelines can be followed by fly ash brick
manufacturing units and also by the prospective fly ash brick manufactures for producing fly ash
bricks of consistent quality conforming to IS: 12894 : 2002
The quality of the fly ash bricks produced depends on the following factors:
1. Quality of raw materials
2. Proportioning of raw materials
3. Handling and mixing of raw materials
4. Handling & pressing of the mix
5. Curing period

Quality of Raw Materials.

1 Fly Ash:
For production of good quality Fly Ash Bricks (FAB), fly ash should conform to its chemical and
physical requirements specified in 1IS:3812 Part 1- 2003. It has been experience that fly ash collected
from Ist & 2nd field of ESP's generally meet the quality requirement specified in above Indian
Standard. Pond ash /Mound ash, if it is mixture of bottom ash and fly ash, should not be used for
making Fly Ash Brick. This type of pond ash is comparatively less lime reactive than fly ash and also
it will not have uniform reactivity and therefore, affect the Fly Ash Brick quality. The pond /Mound
ash in which bottom ash is not mixed, can be used for making Fly Ash Brick after testing and making
trial. Fly ash should be stored either in bags or in silos or in covered bins to avoid fugitive dust
emission. Fly ash is transported from thermal power station to the Fly Ash Brick factory areas either
by closed tankers or trucks / trolleys covered with tarpaulin or in bagged condition.
2.Sand / stone dust:
The locally available sand/stone dust which is used for concreting works can be used for making Fly
Ash Brick. IS: 383 : 1970 specify the requirement for the sand to be used for cement concrete and
mortar work. Very fine quality of sand / stone dust should be avoided as it increases the cement/ lime
requirement for obtaining required strength. In sand/stone dust the deleterious materials such as clay
lumps, silt, coal particles shall not be more than 5%. This can be judged by doing field test with the
help of measuring cylinder with water for every truck load of sand/stone dust. Sand/ stone dust should
be stored in bins which can be covered with tarpaulin during rain to protect from increasing the
moisture content.
3.Hydrated Lime/ Sludge lime:
Hydrated lime is used for Fly Ash Brick making should conform to class C grade as specified in IS:
712 : 1984. The CaO purity in the lime should not be less than 85% which can be ascertained by
testing and as well as taking test certificate from the lime suppliers. The lime should be stored in bags
or silos or in covered bins as it has tendency to react with CO, present in the air in presence of
moisture and produces CaCO, which does not have biding properties and spoils the quality of lime to
be used for Fly Ash Bricks.
Sludge lime which is a by-product of acetylene gas plant can also be used with few precautions as
CaO content in this type of lime varies between 25 - 50% and is available in wet condition having
lumps. Therefore, each lot of sludge lime should be tested for CaO content and accordingly its
quantity in raw material mix should be adjusted. The testing for hydrated / sludge lime should be
carried out as per testing method specified in IS: 1514:1990 method of sampling and testing of quick
lime and hydrated lime.
4 Gypsum:
Chemical or mineral gypsum can be used for making Fly Ash Brick. The gypsum should be free of
lumps and having purity to the about 60%. If lumps are found, same should be removed by screening
and remainder over the screen can be crushed and re-screened before it is used for making bricks. The
purity of gypsum can be tested by the testing method specified in IS: 1288 : 1982. Mineral gypsum

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Brick Masonry

generally has less purity compared to chemical gypsum, therefore, in such case the percentage of
gypsum in the mix should be adjusted to obtain desired quality of finished bricks. Gypsum should
also be stored in bins with cover or in bags.
5 Cement:
Ordinary Portland cement of 43/53 grade can be used in place of lime and gypsum. Since it is a
factory finished product and thus generally does not require any testing.

Raw Material Proportion

Proportioning of raw materials in an important aspect for making of desired quality of Fly Ash Brick.
The proportioning will depend on the quality of the raw materials and the compressive strength &
water quality of brick required. The following mix proportion can be adopted for manufacture of Fly
Ash Brick.
Fly ash, sand, sludge lime and gypsum bricks.
Fly ash 55-60%
Sand/Stone dust 20-25%
Sludge lime 15-20%
Gypsum 5%
Fly ash, sand, hydrated lime and gypsum bricks
Fly ash 60-65%
Sand/Stone dust 18-27%
Hydrated lime 8-12%
Gypsum 5%
Fly ash, sand and cement bricks
Fly ash 50-60%
Sand/Stone dust 32-40%
Cement 8-10%
About 1% gypsum can also be mixed by reducing same percentage in sand / stone dust in this
proportion.

The strength of FAB produced with the above proportions is generally of the order of 7.5 to 10.0
N/mm2 at 28 days. Mix proportion as suggested above can be used as guidelines. The exact mix
proportion may be finalized by trial mixes to produce good quality Fly Ash Brick of required
compressive strength.

Batching
The raw materials are brought by wheel barrows/pull carts or by mechanized means to the mixers.
Weigh batching of all raw materials is ideally suited for the large capacity Fly Ash Brick plants. It can
be also by volume batching through calibrated wooden/ steel boxes. Name of material to be measured
by these boxes should be written in Hindi/English & local language so that it will be known to the
workers and mistakes will be avoided. Measurement of the raw materials should not be done by
Baskets/Tokaris.
Mixing
Pan mixer of adequate capacity should be used for thorough mixing of all ingredients. The pan mixer
also helps to break lumps in lime / gypsum during the mixing. When sludge lime and gypsum are
used as binding material, first sludge lime and gypsum (in measured quantity) is wet grinded in a pan
mixer with some water till the mix becomes a paste without lumps. Sand/ Stone dust and fly ash shall
then be added along with required quantity of water and mixing/grinding shall be continued at least
for about 3 to 5 minutes so as to get homogeneous mix of uniformity in colour.
In case hydrated lime and gypsum, the required quantity of sand/stone dust, fly ash, hydrated lime and
gypsum are initially dry mixed and then required quantity of water is added to get homogeneous mix.
The same procedure can be adopted when cement is used as binding material in place of hydrated
lime and Gypsum.

The total quantity of raw materials proposed to be loaded in the pan mixer for each mix should not
exceed the rated capacity of the mixer. Small lumps of lime, if left in the mix, starts hydrating later
after the curing period are over and causes cracks to the brick structure, thus weakening even those
bricks which have passed the compressive strength test conducted just after curing period is over.
Molding of bricks

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The semi dry homogeneous mix is fed into vibro / hydraulic press manually or through conveyer belt
to mould it into brick shape. The molded bricks are kept in wooden / steel pallets and taken to
stacking area for air drying. Following precautions should be taken during molding/ stacking:
i) Water content should be kept at optimum level especially while using vibro press.
ii) Green bricks should not be stacked one above the other in case vibro press is used and not more
than four layers in case hydraulic press is used.

iii) The pallets should be strong enough to carry the stack of green bricks without sagging.

Green bricks shall be air dried for 1-2 days. Thereafter, air dried bricks should be water cured for a
minimum period of 15-20 days. Curing is carried out by sprinkling water manually or by any other
means. It is recommended that the curing period may be extended during cold/wet weather.
Quality Requirements
Wet Compressive strength
Minimum average wet compressive strength of brick shall not be less than 75 N/mm’ when tested as
per 15-3495 (Part-I) : 1976. The compressive strength of any individual brick shall not fall below the
minimum average compressive strength by more than 20%. In case any test result of compressive
strength exceed 10.0 N/mm‘ the same be limited to 10.0 N/mm‘ for the purpose of averaging.
Water absorption
The bricks when tested in accordance with the procedure laid down in IS:3495 (Part-2) - 1976 after
immersion in cold water for 24 hours, shall have water absorption not more than 20%.
Drying Shrinkage
The average drying shrinkage of the bricks, when tested by the method described in IS- 4139 - 1989
being the average of three units, shall not exceed 0.15 percent.
Sampling and Criteria for Conformity
Sampling and criteria for conformity of the bricks shall be as given in I8:5454 - 1976.

Tests for wet compressive strength & water absorption shall be carried out on the brick samples of
everyday production. The other tests shall be carried out when the source of raw material is changed.
The wet compressive strength and water absorption for various classes of bricks have been specified
in 1S:12894- specification for Pulverized Fuel ash Lime Bricks 2002 and tabulated below:

Class Designation Size of Bricks Wet compressive Water Absorption

(l×w×h in mm) Strength not less than (Percent by mass)
(N/mm2)
5.0 For modular size 5.0 20
7.5 (190 x90x90) or 7.5 20
10.0 (190x90x40) or Non- 10.0 20
12.5 Modular size 12.5 20
(230x110x70) or
(230x110x30)

15.0 15.0 15

In order to carry out all the tests for raw materials and the quality of ash bricks produced, it is
suggested to have an independent laboratory having all the testing equipments, attached with the brick
making units to ensure regular production of quality bricks.

9.1.2. Materials required Mortar for Brick works:

i) Cement (Normally the following types of cement are used in Brick work)
(a) Ordinary Portland Cement Grade 33 (IS 269)
(b) Port land Slag Cement (IS 455)
(c) Portland Pozzolana Cement (IS 1489)
It is preferable to use only 33 grade OPC Cement for brick work.
ii) Water – Potable water (IS 3025).

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iii) Sand (Natural Source)

a. Grading of Sand (IS 1542-1992)

 The particle size grading of sand for plaster work for internal as well as external walls and
ceiling as analyzed by the method described in IS 2386 (Part I)-1973 shall be as specified
in Table-1. Where the grading falls outside the limits of the grading zone of sieves other
than 150, 300 and 600 micron IS sieve by a total amount not exceeding 5%, it will be
regarded as falling within the grading.
Table – 1
Grading of Sand for Internal wall, External Wall or ceiling Plaster.
IS sieve Designation (mm) Percentage passing by weight
10 100
4.75 95 - 100
2.36 95 - 100
1.18 90 - 100
600 micron 80 - 100
300 micron 20 - 65
150 micron 0 - 15
Note- For crushed stone sand and crushed gravel sands, the permissible limit on 150 micron IS sieve
is increased to 20%. This does not affect the 5% allowance permitted in the above para.


The fineness modulus of sand shall be not less than 1.4 in case of crushed stone sand and
crushed gravel sands and not less than 1.5 in case of naturally occurring sands.
 The various sizes of particles of which the sand is composed shall be uniformly
distributed throughout the mass.
 The required grading may often be obtained by screening and/or by blending together
either natural sans or crushed stone screenings, which are by themselves of unsuitable
grading.
b. Sand for Masonry Mortar (IS 2116-1980)
GRADING OF SAND:
The particle size grading of sand for use in mortars shall be within the limits as specified in Table 2.
Table 2
GRADING OF SAND FOR USE IN MASONRY MORTARS
IS SIVE DESIGNATION PERCENTAGE PASSING REF TO METHOD OF TEST
[See IS : 460 ( PART I )- 1978 ] BY MASS
4.75 mm 100 IS : 2386 ( Part I )-1963
2.36 mm 90 to 100
1.18 mm 70 to 100
600 micron 40 to 100
300 micron 5 to 70
150 micron 0 to 15
*Specification for test sieves : Part I Wire cloth test sieves ( second minion ).
+Methods of test for aggregates for concrete : Part I Particle size and shape.

b 1. A sand whose grading falls outside the specified limits due to excess or deficiency of coarse or
fine particles may be processed to comply with the standard by screening through a suitably
sized sieve and/or blending with required quantities of suitable sizes of sand particles. Based on
test results and in the light of practical experience with the use of local materials, deviation in
grading of sand given in b may be considered by the Engineer-in-Charge.
b 2. The various sizes of particles of which the sand is composed shall be uniformly distributed
throughout the mass.
c. Impurities (IS 2386 Part II)
The impurities should be limited to less than 5%.
d. Properties of Manufacture Sand and River sand are given below.
Table 3
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The Properties of M-sand and river sand

Properties Types of sand
M-sand River sand
1. Textural composition ( % by weight)
Coarse sand ( 4.75-2.00mm) 28.1 6.6
Medium sand (2.00-0.425mm) 44.8 73.6
Fine sand (0.425-0.075mm) 27.1 19.8
2. Specific gravity 2.63 2.67
3. Bulk density ( KN/ m3) 15.1 14.5
4. pH 10.11 8.66
5. Chemical composition of M-sand
M-sand contains elements like Si, Al, Ca, Mg, Na, K, Fe, etc
Test results and discussion for mortars.
1) The shape of the M-sand particles resembles with those of river sand particles. Flaky and
elongated coarse particles are absent in the M-sand.
2) M-sand is well graded and falls within the limits of grading zone-II sand, grading limits
specified in IS 383 code. Code allows 20% fines less than 150 microns for crushed stone
sands. M-sand is devoid of clay size fraction and fraction below 150 microns is about 18% (IS
383 code limit is 20%).
3) The specific gravity is 2.63 and 2.67 for M-sand and river sand respectively. Bulk densities of
M-sand and river sand are 15.1 and 14.5 kN/m 3 respectively. Bulk density of M-sand is
marginally higher than that of river sand. The pH of M-sand and river sand is 10.11 and 8.66
respectively.
4) M-sand contains typical rock forming minerals like quartz, feldspar, mica group of minerals,
etc as revealed by X-ray diffraction (XRD) studies. Rock forming minerals like Quartz,
feldspar, etc are basically insert in nature. Mica group consists of muscovite, biotite,
boromuscovite, etc. The mica group of minerals are not interfering in the cement hydration
and strength development in mortars and concrete.
b. Brick Mortar Test
One rich mortar (1:4) and one commonly used mortar (1:6) were selected. The following tests
has been conducted.
(i) Flow characteristics: BS 4551-1980
(ii) Water retentivity and compressive strength: IS 2250-1981(2000)
Water retentivity values for 1:6 cement mortar using river sand and M-sand are
27.3% and 28.5% respectively. For 1:4 cement mortar it is 25.6 % and 35 .6 % for
river sand and M-sand respectively. Thus, water retentivity of mortars improves with
the use of M-sand. Better water retentivity results in better strength and bond
development.
(iii) Masonry compressive strength: IS 1905-1987 (2002)
(iv) Brick Mortar Bond Strength
The flexure bond strength of masonry using 1:6 cement mortar (with 85% flow) was
0.06 MPa and 0.15 MPa for river sand and M-sand mortars respectively. The flexure
bond strength of masonry prism has improved by 150% when M-sand used instead of
river sand in the 1:6 cement mortar.

9.2.1 Quality Control Test

9.2.2 The Compressive strength mortars using River/ Manufacturer Sand.

Table – 4

Mortar Flow Water-cement ratio Compressive strength (MPa)

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Proportion (%)
(by volume)
Cement: sand River sand M-sand

River sand M-sand 7 days 28 days 7 days 28 days

1:6 85 1.72 1.30 2.10 4.03 5.15 8.53

100 1.75 1.34 1.96 3.82 4.88 8.19

1:4 85 1.13 0.84 2.84 7.35 12.89 15.96

100 1.18 0.88 2.77 6.04 11.89 15.50

9.2.1 Tests prior to construction of Brick Work.

TABLE 5
QUALITY CONTROL TESTS PRIOR TO CONSTRUCTION
Sl.No. Material Test / Check Frequency
1. Bricks a) Colour and Dimensional check 3 samples at random at source
b) Water absorption 3 samples at source or after
(IS:3495 Part 2) procurement
c) Efflorescence (IS:3495 Part 3) In case of doubt, at source3
20 bricks shall be tested out of 50,000
samples at random, at source &1,00,000 bricks in class 1000 and 75
d) Compressive strength
(IS:3495 Part 1)

2. Cement a) Setting time of cement 3 samples of same type and grade

(IS:4031 part 5) of cement.

3. Sand (Natural and crushed stone) a) Gradation (IS: 1552-1995) 3 samples for each source of
b) Deleterious material and supply If in doubt, one test
organic impurities
(IS: 2386 Part 2)
c)Specifications (IS:2386 Part-3-
1963)
d) Bulk density(IS:2386 Part-3-
1963)

4. Water Normally potable water is good Samples taken at each source

enough. If impurities are present tested at an approved test house
test as per IS:3025 (parts 17, 24, 32)

9.2.2 Tests during construction of Brick Work

TABLE 6

QUALITY CONTROL TESTS DURING CONSTRUCTION

Sl.No. Material / Work Test / Check Frequency
1. Bond and Plumbness English bond, verticality by For each course
Plumb bob
2. Laying in Mortar Laying in full bed of mortar with - do -
proper lapping
3. Individual Course Height of course and Joint thickness - do -
(IS:2212)
4. Top of coping (If provided) Sloping to drain off water Daily
5. Mortar for Joints* a) Mix proportions (Control on quantity Each batch
of cement/lime by weight)
b) Consistency and water retentivity As required at close interval
(IS:2250)
c) Compressive Strength (IS:2250) 3 samples of cubes where specified

9.2.3 Tolerance during Construction of Brick Work

TABLE 7
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WORKMANSHIP AND TOLERANCES

Item Permissible Value
Dimensions of Bricks + 5 per cent in size

Compressive Strength of Bricks + 2.5 MPa (No negative tolerance) on value specified or
7 MPa whichever is higher
Thickness of joints for general brick work Not more than 10 mm

9.3 Construction of Brick Masonry:

9.3.1 Storage of materials:
 Store cement bags on wooden platforms minimum 200 mm above the floor level and
minimum 600 mm above ground level whichever is higher in perfectly dry and water tight
sheds. Stack and store different types of cement separately, in a manner to facilitate their
removal and use in an ordinary manner.
 Store bricks in regular tiers as they are unloaded to minimize breakage and defacement. Stock
bricks for use in different situations or different types separately.
 Store sand, stone dust, marble dust etc. at proper place so as to prevent contamination of
foreign material due to wind etc. When stacked on ground, do not remove them from stock
pile within 300 mm of the ground.
9.3.2 Construction Procedure
 Soak all bricks for a minimum period of one hour before use and remove from tank
sufficiently in advance so that they are skin dry before actual laying.
 Before laying the bricks in foundation, hack the top surface of the foundation block, clean, wet
and spread a layer of mortar of 12 mm (minimum) thickness, to prepare the surface. In case of
masonry works resting on rock base, lay a leveling layer of 150 mm (average) thickness in
concrete of M10 grade.
 Lay all brickwork in English bond, even and true to line, plumb or specified batter and level.
Break all joints in successive courses and lay joints accurately.
The figures in English bond are shown as follows.

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 Lay all bricks with frogs up, if any on a full bed of mortar. Slightly press the bricks so that the
mortar gets into all hollow space of bricks to ensure proper adhesion. Flush all joints and pack
with mortar, to fill all hollow spaces.
 Build brickwork in uniform layers so that no part of brickwork shall rise more than one metre
above the general construction level, to avoid unequal settlement and improper jointing.
 Remove all loose bricks and mortar while joining partially set or entirely set brick masonry
with new one and roughen and wet with cement slurry to achieve proper bond. In case of
vertical and inclined joints, achieve proper bond by inter locking the bricks.
 Tool all joints on exposed faces to give a concave finish, the thickness of joint not exceeding
10 mm.
 Keep masonry work in cement mortar constantly moist on all faces for 14 days and maximum
for 28 days. Leave the top of masonry work flooded with water at the close of the day. During
hot weather wet or cover all finished or partly completed work to prevent rapid drying of
brickwork. Maintain watering and curing at the close of day’s work or for other period of
cessation of works. For inadequate curing, if the mortar in brick work become dry, powdery,
the same should be dismantled.
 Erect single scaffolding for plastering, pointing and any finishing in which one end of the put-
logs/pole shall rest in the hole provided in the header course of brick masonry. Provide double
scaffolding having two independent supports clear of the work when brick work is exposed
and not to be finished.
 The joints of the brick work are to be raked out and cleaned applying water and brooming. All
putlog holes shall be filled in advance. Wooden screeds 75 mm. wide and of the thickness of
the plaster shall be fixed vertically 2.5 to 4 mtr. Apart horizontally and vertically which will
act as guide. The mortars are placed by trowel and finished with wooden float and wooden
straight edge. The plaster shall be finished true to plumb and proper finish. The minimum
thickness shall not be less than the specified thickness by more than 3 mm. Any cracks on
surface any portion which sound hollow or otherwise defective shall be cut in rectangular
shape and removed and redone.

9.4 Quality Control Check at site

TABLE 8

QUALITY CONTROL CHECKS

Sl.No. Material / Work Test / Check

1. Brick masonry Verticality of Brick work

and horizontality of
courses/ general
workmanship and
compressive strength
(IS 3495 Part 1).
2. Weep holes Location, size and spacing
3. Mortar for Joints a) Consumption per m3
of brick masonry
b) Quality of Mortar*
4. Structural components Thickness, dimensions
and laying

9.5 Cement Mortar : (IS: 2250)

9.5.1 Grade of Masonry Mortar:

Table 9
Sl.No. Grade Cement Sand Compressive
Strength
1 MM 0.7 1 12 0.7 to 1.5
2 1 8

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3 1 10
4 MM 1.5 1 7 1.5 to 2
5 1 8.5
6 MM 2 1 9 2 to 3
7 MM 3 1 0 3 to 5
8 1 6
9 1 12
10 MM 5 1 5 5 to 7.5
11 1 6.5
12 MM 7.5 1 3 7.5 and above
13 1 4.5
14 1 4
15 1 2.1
16 1 3
17 1 3.75
18 1 8

9.5.2 CRITERIA FOR SELECTION OF MASONRY MORTARS:

9.5.2.1 The selection of masonry mortars from durability considerations will have to cover both the
loading and exposure conditions of the masonry. The requirements for masonry mortar shall
generally be as specified in 9.5.2.1 to 9.5.2.7 (see also Table 9).

9.5.2.2 In the case of masonry exposed frequently to rains and where there is further protection by
way of plastering or rendering or other finishes, the grade of mortar shall not be less than
MM 0.7 but shall preferably be of grade MM 2. Where no protection is provided, the grade of
mortar for external walls shall not be less than MM 2.

9.5.2.3 In the case of load bearing internal walls, the grade of mortar shall preferably be MM 0.7 or
more for high durability but in no case less than MM 0.5.
9.5.2.4 In the case of masonry in foundations laid below damp-proof course, the grades of mortar for
use in masonry shall be as specified below:
a. Where soil has little moisture, masonry mortar of grade not less than MM 0.7 shall be used;
b. Where soil is very damp, masonry mortar of grade preferably MM 2 or more shall be used.
But in no case shall the grade of mortar be less than MM 0.7.
c. Where soil is saturated with water, masonry mortar of grade MM 3 shall be used but in no
case shall the grade of mortar be less than MM 2.
9.5.2.5 For masonry in buildings’ subject to vibration of machinery, the grade of mortar shall not be
less than MM 3.
9.5.2.6 For parapets, where the height is greater than thrice the thickness, the grade of masonry
mortar used shall not be less than MM 3.
In the case of low parapets, the grade of mortar shall be the same as used in the wall masonry
below.
9.5.2.7 The grade of mortar for bedding joints in masonry with large concrete blocks shall not be less
than MM 3.
9.5.3 PREPARATION OF MASONRY MORTARS
Proportioning –
 Cement shall be proportioned only by full bags. Hydrated lime, pozzolana and, aggregates
shall be measured by volume using gauge boxes of suitable capacity.
 The quantities of some of the ingredients for measurement may also be taken on the basis
of the unit weight. The unit weight of some of the materials in loosely placed condition are
given in Table 2 for conversion from weight to volume.
9.5.4 Preparation of Cement Mortar - Mixing shall be done preferably in a mechanical mixer. If
done by hand, the operation shall be carried out on a clean watertight platform. Cement and
sand shall be mixed dry in the required proportions to obtain a uniform colour. The required

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Brick Masonry

quantity of water shall then be added and the mortar mixed to produce a workable
consistency. In the case of mechanical mixing, the mortar shall be mixed for at least three
minutes after addition of water; in the case of hand mixing, the mortar shall be hold back and
forth for 5 to 10 minutes with addition of water.
9.5.4.1 Generally, only as much quantity of cement mortar as would be sufficient for 30 minutes,
work shall be mixed at a time.
9.5.4.2 Retempering of Mortars
 In the case of mortar using cement, the mortar that has stiffened because of
evaporation of water from the mortar may be re-tempered by adding water as
frequently as needed to restore the requirements of consistency. But this re-tempering
shall be permitted only within 60 minutes from the time of addition of cement.
9.5.4.3 CONSISTENCY OF MASONRY MORTARS
 The working consistency of the mortar is usually judged by the worker during
application. The water should be enough to maintain the fluidity of the mortar during
application, but at the same time it shall not be excessive leading to segregation of
aggregates from the cementi- tious material. ‘The quantity of water needed for
maintaining consistency or fluidity will also depend upon the masonry to which the
mortar is used; for example, thinner joints will require greater fluidity; bed joints
subject to heavy pressure may require stiffer mortar. Also, the mortar should be able
to hold the water against suction by the masonry unit, particularly in the case of burnt
clay and concrete products.
 The consistency of mortars shall be measured in accordance with the procedure given
in Appendix B and the following values of depth of penetration are recommended.
For laying walls with solid bricks 90 to 130 mm
For laying perforated bricks 70 to 80 mm
For filling cavities 130 to 150 mm

9.5.4.4 Water Retentivity –

Measurement of water retentivity may be necessary only in the case where mortar is to be
used with masonry unit which has got high suction characteristics. Water retentivity shall be
determined as described in Appendix C and the flow after suction in the test shall not be less
than 70 percent of the flow before suction.
 The recommended values of consistency and water retentivity are given in Table 9.
TABLE 10

CONSISTENCY AND WATER RETENTIVITY

Property Work Value

Consistency - Laying of solid brick walls 90-130mm
- Filling cavities 130-150 mm
Water retentivity(Flow of suction) Masonry work with high suction More than 70% of flow before
characteristics suction

 It is important to prepare the quantity of mortar for brick work which can be used
immediately before initial setting time of cement used in the work i.e 30 minutes of mixing
with water.

9.6 Curing : (IS: 456-2000)

The curing period shall usually be upto 28 days and minimum 14days. The brick work shall
be frequently sprinkled with water or covered with jute mattress and top shall be kept flooded
with water after closer of the work. The brick work where the mortar joints become dry,
powdery and lack in bond due to improper curing shall be dismantled.
9.7 Test for Mortar :

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Brick Masonry

Besides testing of materials, the mortar cube 50 mm can be tested as per IS 2250-1981. The
frequency of testing shall be done as per contract or one sample for every 2 cubic meters of
mortar subject to a minimum 3 samples for a day’s work.

9.8 Miscellaneous Items

 For a surface which is subsequently plastered or pointed, make out the joints to a depth of 15
mm while mortar is green.
 Carry out pointing using mortar of proportion shown on drawings but not leaner than 1:3 by
volume of cement and sand. Fill and press mortar into the raked out joints before giving the
required finish.
 Execute plastering using mortar of proportion where shown on the drawings but not leaner
than 1:4 by volume of cement and sand to the specified thickness which will not be higher than
average thickness by 3 mm.
 Commence curing as soon as the mortar or pointing/plastering has hardened sufficiently. Keep
the surface wet for a period of atleast 7 days.
 Provide weep holes to masonry structures higher than 2 m to drain water from back filling. Use
100 mm dia AC pipes and extend to the full width of masonry with 1:20 slope to the draining
face. Stagger them suitably and their spacing shall not exceed 2 m in horizontal or 1 m in
vertical direction, with the lowest one at about 150 mm above the low water level or bed level
whichever is higher.
 Provide architectural concrete coping of 150 mm thickness over the masonry where specified.
While using precast or cast in site concrete coping, provide vertical construction joints at
spacing of not more than 1.5 m.
Do’s and Don’ts
Do’s Don’ts
1.Test the cement if it is more than 3 months old. 1.Do not Substitute 33 Grade Cement with 43 Grade or 53
Grade

2.Use lime undamaged by rain, moisture or air slaking. 2.Do not mix Blast Furnace Slag with OPC at site

3.Use bricks of rectangular faces with sharp corners 3.Do not use sand containing dust lumps soft or flaky
particles, mica or other harmful materials.

4.Mix Cement mortar in a mechanical mixer operated 4.Do not use cement mortar 30 minutes after addition of
manually or by power for large works. water or initial setting whichever is earlier

5.Break joints in successive courses and length of lap

5.Do not use brick bats or cut bricks except to obtain
between the joint of stretcher course with the header course
dimensions of different courses
not less than one fourth of the length of the brick.

6.For arch construction ensure proper centring and 6.Do not start masonry work earlier than 48 hours of casting
simultaneous commencement of work from both ends. foundation block

7.Do not build brick masonry arch bridges having spans

more than 6 m in seismic zones IV and V

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