Masonry

Masonry
 Great majority of masonry wall
is produced from performed
units, bonded by mortar.
 Bricks – easily handled with
one hand.
 Blocks – larger units, requiring
both hands
 Bricks
 The standard size of bricks is 215x102x65mm.
 Bricks will be categorized with different uses:
➢ Load bearing wall
➢ Non-load bearing wall
➢ Insulation wall
➢ Covering wall
 It can be made from clay and cement sand
Type of Bricks
 Concrete Brick
 Made with mix of cement, sand and water.
 High strength and durability.
 Normally, the design is not produced a good
appearance and come out with rough surface.
 Clay Brick
 Classified in 3 groups:
➢ Common bricks – ordinary brick which are not
designed to provide good finished appearance or
high strength. Cheapest bricks.
➢ Facing bricks – designed to give attractive
appearance and hence they are free from
imperfections such as cracks. It produces a variety
of colour and no need plaster when used as wall.
➢ Engineering bricks – designed primarily for
strength and durability. High density and well
fired.
Types of Face Brick
Types of Engineering
Brick
Manufacturing Process

RAW MATERIAL PREPARATION

MAKING PROCESS

SETTING & DRYING

FIRING

PACKAGING
Manufacturing Process
Raw Material Preparation
Raw Material Preparation
 After digging out, the clay is
prepared by crushing and
grinding and mixing until it is
of uniform consistency. Water
may be added to increase
plasticity and chemicals may
be added to prevent
efflorescence, crystallization
damage, etc.
 Making Process
 Clay will be grinded
with 15% of water;
 The clay will be
pushed through the
mould based on the
shape;
 After that, clay will cut
to get a standard size
of brick using wire.
 Setting and Drying
 Wet unit bricks will be drying in space or
room with control temperature to make sure
the bricks in complete dry.
 Must be carried out prior to firing when bricks
are made from clay of relatively high moisture
content.
 Drying enables brick to be stacked higher in
the kiln without lower bricks becoming
distorted by the weight of bricks above them.
 Also enable the firing temperature increased
more rapidly.
 Firing
 Dry bricks, was compile in kiln to firing process
with 600oC (temperature).
 The main stage of firing are:
– 100 oc evaporation of water
– 400 0c burning of carbon and sulfur
– 900 – 1000 0c strengthen the bricks
 Maintaining control of the temperature is most
important
– Too rapid fire – over burning the external
layer
– Too slow – seriously impairs the strength and
durability
 Stronger brick such as Engineering Brick, are
normally fired at higher temperature
 Firing

Brick inside kiln Firing brick

 Packaging
 After exiting the kiln, the brick is
allowed to cool prior to handling.
 Proper sorting and packaging of the
brick after burning is extremely
important.
 Broken, twisted and otherwise
mechanically defective brick are
discarded at this stage.
 Brick color and range is carefully
monitored to assure a quality product.
 Packaging

Brick awaiting packaging Manual Rechecking

Packaged cube of brick Inventory Packaging

 Advantages of Brick
 Brick will not burn, buckle or melt.
 Brick will not rot and allow Termites to invade.
 Brick will not rust and corrode.
 Brick will not dent.
 Brick will not fade from the Sun's UV Rays.
 Brick will not be damaged by high winds, rain or hail.
 Brick will not require constant maintenance.
 Brick will not devalue.
 Brick will not limit your personal expression.
 Brick will not limit your design options.
Advantages of Brick

Walk way

Decorative of brick work

 Properties
 Water absorption – an important property of clay bricks
since they have very low absorption resulting from high
durability.
 Efflorescence – build-up of white surface deposits on
brickwork when drying after earlier saturation. It results
from dissolved salts and spoils the appearance of new
brickwork.
 Soluble salt content – harmful in causing efflorescence
and leading to problems such as sulphate attack in the
mortar.
 Frost resistance – designated as frost resistance,
moderately frost resistance and not frost resistance.
 Properties
 Durability – more important than its strength and
most of the durability problems are associated with
moisture penetration.
 Frost damage – water contained in bricks moves into
cracks and damage occurring as ice crystals grow in
any enclosed positions when temperature is lowered.
 Crystallization damage – associated with the
crystallization of salts beneath the brick surface.
Avoiding methods: -
➢ Use clean materials and avoid contact between
brickwork and groundwater or soil.
➢ Design and detail brickwork to minimize exposure to
moisture.
 Properties
 Sulphate attack – occurs in cement
mortars in which the cement contains
tricalcium aluminate. Only occurs in
damp situation, result in expansion of
the brickwork. Use sulphate-resisting
cement or same methods on
crystallization damage to avoid
sulphate attack.
 Building Blocks
 Blockwork has developed into a major
form of construction for the following
reasons:
➢ Rate of production are greater than brick-
size units
➢ A great variety of sizes and types is
available to suit different purposes
➢ Modern factory production methods
ensure consistent and reliable
performance
➢ High quality surface finishes are
obtainable.
 Building Blocks
 Clay building blocks – hollow units and
used for walls and partitions.
 Concrete blocks – may be solid and
hollow.
➢ Solid blocks are largely voidless but may
have grooves or holes to reduce weight
and facilitate handling.
➢ Dense blocks can be used for load
bearing purposes, and decorative or
textured facings may be applied.
➢ Lightweight types are good in thermal
insulation.
 Masonry Mortars
 Defined as mixtures of sand, cement and
water.
 Prime function is to take up tolerances
between building units and act as
bonding between blocks.