KNS1042

Civil Engineering Materials

Lectures by: Dr. Delsye Teo

TOPICS COVERED (Part 2)
 Masonry
I. Concrete blocks
II. Mortars
III. Applications and properties of brickwork and blockwork
I. CONCRETE BLOCKS

 The essential materials for making concrete blocks are a

hydraulic binder, water and aggregate, and in the case of
aerated concrete blocks only, a reactive foaming agent to
produce their characteristic cellular structure.
 Additives and/or admixtures are also used sometimes to extend
the product range.
 There are 2 main types of concrete blocks:

i. Aggregate concrete blocks

ii. Aerated concrete blocks
I. CONCRETE BLOCKS
 Aggregate concrete blocks
 The manufacturing process involves compaction of the newly
mixed constituent materials (basically binder, water and
aggregate) in a mould followed immediately by extrusion of the
pressed block so that the mould can be used repeatedly.
 Since the finished blocks are required to be self-supporting and
able to withstand any movement and vibration from the moment
they are extruded, very much drier, higher fine aggregate content
and leaner mixes are used than in normal concrete.
I. CONCRETE BLOCKS
 Aerated concrete block
 In this case, a slurry of binder, pre-heated water and siliceous
materials mixed together with aluminum powder is first cast as a
‘cake’ in large moulds (usually 1m × 2m × 1m high).
 The aluminum powder reacts with lime in the cement, producing a
mass of minute hydrogen bubbles within the mix, which thus
expands to fill the mould.
 As the mix sets, the hydrogen within the now cellular structure
diffuses and in replaced by air.
 After the initial set, while the aerated ‘cake’ is still in its plastic
stage, the mould shutters are stripped off and the ‘cake’ is cut into
the required block sizes by thin wires on a cutting machine.
 This cut cake is then placed in an auto-clave for high-pressure steam
curing for about 24 hours, when the blocks are ready for use as soon
as they have cooled to the ambient temperature.
I. CONCRETE BLOCKS
 There are 3 basic forms of concrete block (Figure 36.2):
i. Solid
ii. Cellular
iii. Hollow
 A solid block has no formed holes or cavities other than those
inherent in the material, although it may contain transverse
slots to facilitate cutting.
 Cellular and hollow blocks have one or more formed holes or
cavities which in hollow blocks pass right though them.
 All 3 forms of block can be produced using aggregate
concrete but with aerated concrete, only the solid form can be
manufactured.
I. CONCRETE BLOCKS
 British Standard BS6073: Part 1 defines a block as a masonry
unit of a larger size in all dimensions than specified for bricks,
but no dimension should exceed 650 mm nor should the height
exceed either its length or six times its thickness.
 The most commonly used block has a work face of 440mm ×
215 mm and is usually 100 mm thick.
 Typical work sizes of concrete blocks are shown in Table 36.1
II. MORTARS
 Typical mortars used in both brickwork and blockwork
are given in Table 37.1
 Cement-lime-sand mortars have improved working
qualities compared with ordinary cement-sand mortars as
a result of the effective replacement of part of the cement
with lime.
 III. APPLICATIONS AND PROPERTIES OF
BRICKWORK & BLOCKWORK
 Individual bricks and blocks when bonded together with mortar
are referred to collectively as brickwork and blockwork, or
alternatively brick and block masonry.
 Masonry construction today is used principally for non-load-
bearing and load-bearing walls, the distinction between these
being that the latter carry vertical roof and/or floor loads, as in
cross-wall construction, whilst the former only carry their self-
weight.
 Both may be subjected to wind loading.
III. APPLICATIONS AND PROPERTIES OF
BRICKWORK & BLOCKWORK
 Masonry may be prestressed, reinforced or unreinforced and
its many applications include retaining walls, parapet and
sewerage works.
 Desirable minimum qualities of units and mortars, based on
recommendations in the relevant British Standards, for
different applications are given in Table 37.2.