TEK 03-08A - Concrete Masonry Construction

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NCMA TEK

National Concrete Masonry Association


an information series from the national authority on concrete masonry technology

CONCRETE MASONRY CONSTRUCTION TEK 3-8A


Construction (2001)

Keywords: ASTM specifications, bond patterns, cleaning, perform as a unit.


construction techniques, construction tolerances, grout, mortar. Grout is used to fill masonry cores or wall cavities to
improve the structural performance and/or fire resistance of
masonry. Grout is most commonly used in reinforced con-
INTRODUCTION struction, to structurally bond the steel reinforcing bars to the
Concrete masonry is a popular building material because masonry, allowing the two elements to act as one unit in
of its strength, durability, economy, and its resistance to fire, resisting loads.
noise, and insects. To function as designed however, concrete Reinforcement incorporated into concrete masonry struc-
masonry buildings must be constructed properly. tures increases strength and ductility, providing increased re-
This TEK provides a brief overview of the variety of sistance to applied loads and, in the case of horizontal rein-
materials and construction methods currently applicable to forcement, to shrinkage cracking.
concrete masonry. In addition, a typical construction sequence Specifications governing material requirements are listed
is described in detail. in Table 1.

MATERIALS CONSTRUCTION METHODS

The constituent masonry materials: concrete block, mor- Mortared Construction


tar, grout, and steel, each contribute to the performance of a Most concrete masonry construction is mortared con-
masonry structure. Concrete masonry units provide strength, struction, i.e., units are bonded together with mortar. Varying
durability, fire resistance, energy efficiency, and sound attenu- the bond or joint pattern of a concrete masonry wall can create
ation to a wall system. In addition, concrete masonry units are a wide variety of interesting and attractive appearances. In
manufactured in a wide vari-
ety of sizes, shapes, colors,
and architectural finishes to
achieve any number of ap-
pearances and functions. The
Concrete Masonry Shapes
and Sizes Manual (ref. 4)
illustrates a broad sampling
of available units.
While mortar consti-
tutes approximately 7% of a
typical masonry wall area, its
influence on the performance
of a wall is significant. Mor-
tar bonds the individual ma-
sonry units together, allow-
ing them to act as a compos-
ite structural assembly. In
addition, mortar seals joints
against moisture and air leak-
age and bonds to joint rein-
forcement, anchors, and ties
to help ensure all elements Placement of Concrete Masonry Units

TEK 3-8A © 2001 National Concrete Masonry Association (replaces TEK 3-8)
Table 1—Masonry Material Specifications contains further information on this method of construction.

Units CONSTRUCTION SEQUENCE


Loadbearing Concrete Masonry Units, ASTM C 90
Concrete Building Brick, ASTM C 55 Mixing Mortar
Calcium Silicate Face Brick (Sand-Lime Brick), ASTM C 73 To achieve consistent mortar from batch to batch, the same
Nonloadbearing Concrete Masonry Units, ASTM C 129 quantities of materials should be added to the mixer, and they
Prefaced Concrete and Calcium Silicate Masonry should be added in the same order. Mortar mixing times,
Units, ASTM C 744 placement methods, and tooling must also be consistent to
achieve uniform mortar for the entire job.
Mortar In concrete masonry construction, site-mixing of mortar
Mortar for Unit Masonry, ASTM C 270 should ideally be performed in a mechanical mixer to ensure
proper uniformity throughout the batch. Mortar materials
Grout should be placed in the mixer in a similar manner from batch
Grout for Masonry, ASTM C 476 to batch to maintain consistent mortar properties. Typically,
about half the mixing water is added first into a mixer. Ap-
Reinforcement proximately half the sand is then added, followed by any lime.
Axle-Steel Deformed and Plain Bars for Concrete The cement and the remainder of the sand are then added. As
Reinforcement, ASTM A 617 the mortar is mixed and begins to stiffen, the rest of the water
Deformed and Plain Billet-Steel Bars for Concrete is added. Specification for Masonry Structures (ref. 7) re-
Reinforcement, ASTM A 615 quires that these materials be mixed for 3 to 5 minutes. If the
Epoxy-Coated Reinforcing Steel Bars, ASTM A 775 mortar is not mixed long enough, the mortar mixture may not
Low-Alloy Steel Deformed Bars for Concrete attain the uniformity necessary for the desired performance. A
Reinforcement, ASTM A 706 longer mixing time can increase workability, water retention,
Rail-Steel Deformed and Plain Bars for Concrete and board life.
Reinforcement, ASTM A 616 The mortar should stick to the trowel when it is picked up,
Zinc-Coated (Galvanized) Steel Bars for Concrete and slide off the trowel easily as it is spread. Mortar should
Reinforcement, ASTM A 767 also hold enough water so that the mortar on the board will not
Masonry Joint Reinforcement, ASTM A 951 lose workability too quickly, and to allow the mason to spread
mortar bed joints ahead of the masonry construction. The mor-
Ties & Anchors tar must also be stiff enough to initially support the weight of
Steel Wire, Plain, for Concrete Reinforcement, ASTM A 82 the concrete masonry units.
Stainless and Heat-Resisting Steel Wire, ASTM A 580 To help keep mortar moist, the mortarboard should be
moistened when a fresh batch is loaded. When mortar on the
board does start to dry out due to evaporation, it should be
addition, the strength of the masonry can be influenced by the retempered. To retemper, the mortar is mixed with a small
bond pattern. The most traditional bond pattern for concrete amount of additional water to improve the workability. After a
masonry is running bond, where vertical head joints are offset significant amount of the cement has hydrated, retempering
by half the unit length. will no longer be effective. For this reason, mortar can be
Excluding running bond construction, the most popular retempered for only 11/2 to 21/2 hours after initial mixing,
bond pattern with concrete masonry units is stack bond. Al- depending on the site conditions. For example, dry, hot, and
though stack bond typically refers to masonry constructed so windy conditions will shorten the board life, and damp, cool,
that the head joints are vertically aligned, it is defined as calm conditions will increase the board life of the mortar. Mor-
masonry laid such that the head joints in successive courses are tar should be discarded if it shows signs of hardening or if 21/2
horizontally offset less than one quarter the unit length (ref. 2). hours have passed since the original mixing.
Concrete Masonry Bond Patterns (ref. 3) shows a variety of
bond patterns and describes their characteristics. Placing Mortar
Head and bed joints are typically 3/8 in. (10 mm) thick, except at
Dry-Stacked Construction foundations. Mortar should extend fully across bedding sur-
The alternative to mortared construction is dry-stacked faces of hollow units for the thickness of the face shell, so that
(also called surface bonded) construction, where units are joints will be completely filled. Solid units are required to be
placed without any mortar, then both surfaces of the wall are fully bedded in mortar.
coated with surface bonding material. Shims or ground units are Although it is important to provide sufficient mortar to
used to maintain elevations. This construction method results in properly bed concrete masonry units, excessive mortar should
faster construction, and is less dependent on the skill of the not extend into drainage cavities or into cores to be grouted.
laborer than mortared construction. In addition, the surface For grouted masonry, mortar protrusions extending more than
bonding coating provides excellent rain penetration resistance. 1/2 in. (13 mm) into cells or cavities to be grouted should be

Surface Bonded Concrete Masonry Construction (ref. 9) removed (ref. 7).


and angle of the corners. It is essential that the corner be built
The Importance of Laying to the Line as shown on the foundation or floor plan, to maintain modular
Experienced masons state that they can lay about five times dimensions.
as many masonry units when working to a mason line than when
using just their straightedge. The mason line gives the mason a Laying the Corner Units
guide to lay the block straight, plumb, at the right height, and Building the corners is the most precise job facing the
level. The line is attached so that it gives a guide in aligning the mason as corners will guide the construction of the rest of the
top of the course. wall. A corner pole can make this job easier. A corner pole is
If a long course is to be laid, a trig may be placed at one or any type of post which can be braced into a true vertical posi-
more points along the line to keep the line from sagging. Be- tion and which will hold a taut mason’s line without bending.
fore work begins, the mason should check to see that the line Corner poles for concrete block walls should be marked every
is level, tight, and will not pull out. 4 or 8 in. (102 to 203 mm), depending on the course height,
Each mason working to the same line needs to be careful and the marks on both poles must be aligned such that the
not to lay a unit so it touches the line. This will throw the line mason’s line is level between them.
off slightly and cause the rest of the course to be laid out of Once the corner poles are properly aligned, the first course
alignment. The line should be checked from time to time to be of masonry is laid in mortar. Typically, a mortar joint between
certain it has remained in position. 1/4 and 3/4 in. (6.4 to 19 mm) is needed to make up for irregu-

larities of the footing surface. The initial bed joint should be a


PLACING UNITS full bed joint on the foundation, footing, or slab. In some ar-
eas, it is common practice to wet set the initial course of ma-
The Foundation sonry directly in the still damp concrete foundation.
Before building the block wall, the foundation must be Where reinforcing bars are projecting from the founda-
level, and clean so that mortar will properly adhere. It must tion footing or slab, the first course is not laid in a full mortar
also be reasonably level. The foundation should be free of ice, bed. In this case, the mason leaves a space around the rein-
dirt, oil, mud, and other substances that would reduce bond. forcing bars so that the block will be seated in mortar but the
mortar will not cover the area adjacent to the dowels. This per-
Laying Out the Wall mits the grout to bond directly to the foundation in these loca-
Taking measurements from the foundation or floor plan tions.
and transferring those measurements to the foundation, foot- After spreading the mortar on the marked foundation, the
ing, or floor slab is the first step in laying out the wall. first block of the corner is carefully positioned. It is essential
Once two points of a measurement are established, cor- that this first course be plumb and level.
ner to corner, a chalk line is marked on the surface of the foun- Once the corner block is in place, the lead blocks are set—
dation to establish the line to which the face of the block will three or four blocks leading out from each side of the corner.
be laid. Since a chalk line can be washed away by rain, a grease The head joints are buttered in advance and each block is lightly
crayon, line paint, nail or screwdriver can mark the surface for shoved against the block in place. This shove will help make a
key points along the chalk line, and a chalk line re-snapped along tighter fit of the head joint, but should not be so strong as to
these key points. After the entire surface is marked for loca- move the block already in place. Care should be taken to spread
tions of walls, openings, and control joints, a final check of all mortar for the full height of the head joint so voids and gaps do
measurements should be made. not occur.
If the mason is not working with a corner pole, the first
The Dry Run—Stringing Out The First Course course leads are checked for level, plumb, and alignment with
Starting with the corners, the mason lays the first course a level.
without any mortar so a visual check can be made between the Corners and leads are usually built to scaffold height, with
dimensions on the floor or foundation plan and how the first each course being stepped back one half block from the course
course actually fits the plan. During this dry layout, concrete below. The second course will be laid in either a full mortar
blocks will be strung along the entire width and length of the bed or with face shell bedding, as specified.
foundation, floor slab, and even across openings. This will show
the mason how bond will be maintained above the opening. It Laying the Wall
is helpful to have 3/8 in. (10 mm) wide pieces of wood to place Each course between the corners can now be laid easily
between block as they are laid dry, to simulate the mortar joints. by stretching a line between. It should be noted that a block has
At this dry run the mason can check how the block will thicker webs and face shells on top than it has on the bottom.
space for openings which are above the first course—windows, The thicker part of the webs should be laid facing up. This pro-
etc., by taking away block from the first course and checking vides a hand hold for the mason and more surface area for mor-
the spacing for the block at the higher level. These checks will tar to be spread. The first course of block is thereafter laid
show whether or not units will need to be cut. Window and from corner to corner, allowing for openings, with a closure
door openings should be double checked with the window shop block to complete the course. It is important that the mortar
drawings prior to construction. for the closure block be spread so all edges of the opening
When this is done, the mason marks the exact location between blocks and all edges of the closure block are buttered
before the closure block is carefully set in place. Also, the brushed off with a stiff brush.
location of the closure block should be varied from course to Masons will sometimes purposefully not spend extra
course so as not to build a weak spot into the wall. time to keep the surface of the masonry clean during con-
The units are leveled and plumbed while the mortar is still struction because more aggressive cleaning methods may
soft and pliable, to prevent a loss of mortar bond if the units have been specified once the wall is completed. This is of-
need to be adjusted. ten the case for grouted masonry construction where grout
As each block is put in place, the mortar which is squeezed smears can be common and overall cleaning may be neces-
out should be cut off with the edge of the trowel and care should sary.
be taken that the mortar doesn’t fall off the trowel onto the The method of cleaning should be chosen carefully as
wall or smear the block as it is being taken off. Should some aggressive cleaning methods may alter the appearance of
mortar get on the wall, it is best to let it dry before taking it off. the masonry. The method of cleaning can be tested on the
All squeezed out mortar which is cut from the mortar joints sample panel or in an inconspicuous location to verify that
can either be thrown back onto the mortar board or used to it is acceptable.
butter the head joints of block in place. Mortar which has fallen Specification for Masonry Structures (ref. 7) states
onto the ground or scaffold should never be reused. that all uncompleted masonry work should be covered at
At this point, the mason should: the top for protection from the weather.
• Use a straightedge to assure the wall is level, plumb and
aligned. DIMENSIONAL TOLERANCES
• Be sure all mortar joints are cut flush with the wall, await-
ing tooling, if necessary. While maintaining tight construction tolerances is de-
• Check the bond pattern to ensure it is correct and that sirable to the appearance, and potentially to the structural
the spacing of the head joints is right. For running bond, integrity of a building, it must be recognized that factors
this is done by placing the straightedge diagonally across such as the condition of previous construction and non-
the wall. If the spacing of head joints is correct, all the modularity of the project may require the mason to vary the
edges of the block will be touched by the straightedge. masonry construction slightly from the intended plans or
• Check to see that there are no pinholes or gaps in the specifications. An example of this is when a mason must
mortar joints. If there are, and if the mortar has not yet vary head or bed joint thicknesses to fit within a frame or
taken its first set, these mortar joint defects should be other preexisting construction. The ease and flexibility with
repaired with fresh mortar. If the mortar has set, the only which masonry construction accommodates such change is
way they can be repaired is to dig out the mortar joint one advantage to using masonry. However, masonry should
where it needs repairing, and tuckpoint fresh mortar in still be constructed within certain tolerances to ensure the
its place. strength and appearance of the masonry is not compromised.
Specification for Masonry Structures (ref. 7) contains
Tooling Joints site tolerances for masonry construction which allow for
When the mortar is thumbprint hard, the head joints are deviations in the construction that do not significantly alter
tooled, then the horizontal joints are finished with a sled run- the structural integrity of the structure. Tighter tolerances
ner and any burrs which develop are flicked off with the blade may be required by the project documents to ensure the fi-
of the trowel. When finishing joints, it is important to press nal overall appearance of the masonry is acceptable. If site
firmly, without digging into the joints. This compresses the tolerances are not being met or cannot be met due to previ-
surface of the joint, increasing water resistance, and also pro- ous construction, the Architect/Engineer should be notified.
motes bond between the mortar and the block. Unless other-
wise required, joints should be tooled with a rounded jointer, Mortar Joint Tolerances
producing a concave joint. Once the joints are tooled, the wall Mortar joint tolerances are illustrated in Figure 1. Al-
is ready for cleaning. though bed joints should be constructed level, they are per-
mitted to vary by ± 1/2 in. (13 mm) maximum from level
Cleanup provided the joint does not slope more than ± 1/4 in. (6.4
Masonry surfaces should be cleaned of imperfections that mm) in 10 ft (3.1 m).
may detract from the final appearance of the masonry structure Collar joints, grout spaces, and cavity widths are per-
including stains, efflorescence, mortar droppings, grout drop- mitted to vary by -1/4 in. to + 3/8 in. (6.4 to 9.5 mm). Provi-
pings, and general debris. sions for cavity width are for the space between wythes of
Cleaning is most effective when performed during the wall non-composite masonry. The provisions do not apply to situ-
construction. Procedures such as skillfully cutting off excess ations where the masonry extends past floor slabs or span-
mortar and brushing the wall clean before scaffolding is raised, drel beams.
help reduce the amount of cleaning required.
When mortar does fall on the block surface, it can often Dimensions of Masonry Elements
be removed more effectively by letting it dry and then knock- Figure 2 shows tolerances that apply to walls, columns,
ing it off the surface. If there is some staining on the face of and other masonry building elements. It is important to note
the block, it can be rubbed off with a piece of broken block, or that the specified dimensions of concrete masonry units are
3
/8 in. (9.5 mm) less than the nominal dimensions. Thus a Location of Elements
wall specified to be constructed of 8 in. (203 mm) concrete Requirements for location of elements are shown in Fig-
masonry units should not be rejected because it is 7 5/8 in. (194 ures 4 and 5.
mm) thick, less than the apparent minimum of 7 3/4 in. (197
mm) (8 in. (203 mm) minus the 1/4 in. (6.4 mm) tolerance).
Instead the tolerance should be applied to the 7 5/8 in. (194
mm) specified dimension.

Plumb, Alignment, and Levelness of Masonry Elements


Tolerances for plumbness of masonry walls, columns,
and other building elements are shown in Figure 3. Masonry
building elements should also maintain true to a line within
the same tolerances as variations from plumb.
Columns and walls continuing from one story to an-
other may vary in alignment by ± 3/ 4 in. (19 mm) for
nonloadbearing walls or columns and by ± 1/2 in. (13 mm)
for bearing walls or columns.
The top surface of bearing walls should remain level
within a slope of ± 1/4 in. (6.4 mm) in 10 ft (3.1 m), but no
more than ± 1/2 in. (13 mm).

Figure 3—Permissible Variations From Plumb

Figure 1—Mortar Joint Tolerances

Figure 4—Location Tolerances in Plan

Figure 2—Element Cross Section and Elevation


Tolerances Figure 5—Location Tolerances in Story Height
REFERENCES
1. Building Block Walls, VO 6. National Concrete Masonry Association, 1988.
2. Building Code Requirements for Masonry Structures, ACI 530-99/ASCE 5-99/TMS 402-99. Reported by the Masonry
Standards Joint Committee, 1999.
3. Concrete Masonry Bond Patterns, TEK 14-6. National Concrete Masonry Association, 1999.
4. Concrete Masonry Shapes and Sizes Manual, CM 260A. National Concrete Masonry Association, 1997.
5. Inspection of Concrete Masonry Construction, TR 156. National Concrete Masonry Association, 1996.
6. Nolan, K. J. Masonry & Concrete Construction. Craftsman Book Company, 1982.
7. Specification for Masonry Structures, ACI 530.1-99/ASCE 6-99/TMS 602-99. Reported by the Masonry Standards Joint
Committee, 1999.
8. Standard Specification for Loadbearing Concrete Masonry Units, ASTM C 90-00. American Society for Testing and
Materials, 2000.
9. Surface Bonded Concrete Masonry Construction, TEK 3-5A. National Concrete Masonry Association, 1998.

NATIONAL CONCRETE MASONRY ASSOCIATION To order a complete TEK Manual or TEK Index,
2302 Horse Pen Road, Herndon, Virginia 20171-3499 contact NCMA Publications (703) 713-1900
www.ncma.org

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