Professional Documents
Culture Documents
117 Bt1 Notes Text
117 Bt1 Notes Text
Week 1 - 2
Topic: HISTORY OF CONSTRUCTION AND MATERIALS
People have constructed buildings and other structures since prehistory.
• Bridges • Pylons
• Amphitheaters • Roads
• Dams • Canals
Lime plaster
USES OF THE TOOLS
-to cut such as with the hand axe, chopper, adze, and celt
-to scrape, chop such as with a flake tool, pound, pierce, roll, pull, leaver, and carry
VERNACULAR ARCHITECTURE
- locally available materials and traditional designs and methods
Skara Brae- Europe's most complete Neolithic village, quite elaborate stone structures with
ingenuity using dry stone walling techniques
The first mud bricks, formed with the hands rather than wooden moulds, belong to the late
Neolithic period and were found in Jericho.
Neolithic architecture
• Megalith
rock-cut architecture
post and lintel
woodhenge
* There is also evidence of prefabrication of the stonework; the symmetrical geometric arrays
of stone clearly indicate that the builders of Stonehenge had mastered sophisticated surveying
methods.
-The ancient Greeks never developed the strong mortars which became an important feature
of Roman construction.
Roman Empire
In striking contrast to previous cultures, an enormous amount is known about Roman building
construction. A very large amount survives, including complete intact buildings like the
Pantheon, Rome and very well preserved ruins at Pompeii and Herculaneum. We also have the
first surviving treatise on architecture by Vitruvius which includes extensive passages on
construction techniques.
• Materials
• hydraulic lime mortar-"Roman Cement", building material that was a great Roman
development
• Pozzolana -also known as pozzolanic ash (pulvis puteolanus in Latin), is a siliceous or
siliceous and aluminousmaterial which reacts with calcium hydroxide in the presence of
water at room temperature
• They used brick or stone to build the outer skins of the wall and then filled the cavity
with massive amounts of concrete
• Arches
• Barrel vaults
• domes
• Later they used wooden shuttering which was removed for the concrete to cure.
• The Romans substituted bronze for wood in the roof truss(s) of the Pantheon's portico
which was commissioned between 27 BC and 14 AD.
• Lead was used for roof covering material and water supply and waste pipes.
• Romans also made use of glass in construction with colored glass in mosaics and clear
glass for windows.
China
Materials
• rammed earth
• Bricks
• Stones
• Wood
• tiles with lime mortar
• Traditional Chinese timber frames do not use trusses but rely only on post and lintel
construction.
• Yingzao Fashi is the oldest complete technical manual on Chinese architecture
• Nanchan Temple iwutatil-oldest wooden building
• An important architectural element is the dougong bracket sets.
Middle Ages
The Middle Ages of Europe span from the 5th to 15th centuries AD from the fall of the
Western Roman Empire to the Renaissance and is divided into Pre-Romanesque and
Romanesque periods.
Greatest Construction Projects:
• Fortifications
• Castles
• cathedrals
A revival of stone buildings in the 9th century and the Romanesque style of architecture began
in the late 11th century.
Materials
Most buildings in Northern Europe were constructed of timber until c. 1000 AD.
Brick continued to be manufactured in Italy throughout the period 600-1000 AD
Medieval stone walls were constructed using cut blocks on the outside of the walls and rubble
infill, with weak lime mortars.
Techniques
Romanesque buildings of the period 600-1100 AD were entirely roofed in timber or had stone
barrel vaults covered by timber roofs.
The Gothic style of architecture with its vaults, flying buttresses and pointed gothic arches
developed in the twelfth century.
Thin stone vaults and towering buildings were constructed using rules derived by trial and
error.
The pile driver was invented around 1500.
Renaissance
The invention of moveable type and the Reformation changed the character of building.
The master mason and master carpenters learnt their trades by word of mouth and relied on
experience, models and rules of thumb to determine the sizes of building elements.
Filippo Brunelleschi was one of the first of the new style of architects.
He started life as a goldsmith and educated himself in Roman architecture by studying ruins.
He went on to engineer the dome of Santa Maria del Fiore in Florence.
Materials
Water mills in most of western Europe were used to saw timber and convert trees into planks.
Bricks were used in ever increasing quantities.
An increasing amount of ironwork was used in roof carpentry for straps and tension members.
Roofing was typically of terracotta roof tiles
Stone, where available, remained the material of choice for prestige buildings.
Materials
• Glass-The major breakthrough in this period, the first cast plate glass being developed in
France.
• Iron was increasingly employed in structures.
• Christopher Wren- used iron hungers to suspend floor beams at Hampton Court Palace,
and Iron rods to repair Salisbury Cathedral and strengthen the dome of Paul's Cathedral.
• Most buildings had stone ashlar surfaces covering rubble cores, held together with lime
mortar.
Tools
Many tools have been made obsolete by modern technology, but the line gauge, plumb-line,
the carpenters. square, the spirit level, and the drafting compass e still in regular use.
A. FILL MATERIALS
- SOIL, CRUSHED STONE, AND SAND USED
TO RAISE AN EXISTING GRADE, OR AS A MAN-
MADE-DEPOSIT; GENERALLY USED UNDER
FOOTINGS, PAVERS, OR CONCRETE SLABS ON
GRADE; CLASSIFIED UNDER THE UNIFIED SOIL
C. BORROW FILL
- SELECTED LABORATORY-APPROVED PIT-RUN
GRAVEL, DISINTEGRATED GRANITE, SAND, SHALE,
CINDERS OR OTHER SIMILAR MATERIALS WITH NOT
MORE THAN 35% FRACTION PASSING THE NO. 200
SIEVE.
- WIRE-ENCLOSED RIPRAP
- CONSISTS OF MATS OR BASKETS FABRICATED FROM WIRE MESH, FILLED
WITH SMALL RIPRAP, AND ANCHORED TO A SLOPE.
- WRAPPING THE RIPRAP ENABLES USE OF SMALLER ROCKS FOR THE SAME
RESISTANCE TO DISPLACEMENT BY WATER ENERGY AS LARGER
DUNWRAPPED RIPRAP.
- IS PARTICULARLY ADVANTAGEOUS IN AREAS INACCESSIBLE TO TRUCKS OR
LARGE CONSTRUCTION EQUIPMENT.
- WIRE BASKETS ALSO ALLOW STEEPER (I.E., VERTICAL) CHANNEL LININGS
TO BE CONSTRUCTED.
- GABION BASKETS OR MATTRESSES CAN BE MADE FROM COMMERCIALLY
AVAILABLE WIRE UNITS OR FROM AVAILABLE WIRE FENCING MATERIAL OR
MAY BE FABRICATED FROM NO. 9 OR NO- 12 GALVANIZED WIRE.
1.05 GEOSYNTHETICS
A. GEOTEXTILES
ARE THE MOST COMMON GEOSYNTHETICS AND CONSIST OF
WOVEN OR NONWOVEN FABRIC MADE FROM POLYMERIC MATERIALS
SUCH AS POLYESTER OR POLYPROPYLENE GENERALLY USED FOR
REINFORCEMENT, SEPARATION, FILTRATION, AND IN- PLANE
DRAINAGE.
IN-PLANE DRAINAGE
PARTICULAR THICK-NEEDLED NONWOVEN GEOTEXTILES HAVING
SUFFICIENT IN-PLANE FLOW CAPACITY FOR USE AS FLOW CONDUITS IN
DRAINAGE APPLICATIONS.
B. GEOMEMBRANES
- ARE CONTINUOUS POLYMERIC SHEETS THAT ARE IMPERMEABLE. THE
MOST FREQUENTLY USED FOR GROUND APPLICATIONS ARE:
D. GEONETS
E. GEOCELLS
3 TYPES
A. PHYSICAL BARRIERS
B. CHEMICAL BARRIERS
C. COLONY ELIMINATION (BAIT) SYSTEM
A. PHYSICAL BARRIERS:
TINY TERMITES FROM PASSING THROUGH IT. TERMITE MESH IS USED IN SLAB
CONSTRUCTION (CONCRETE SLABS ARE
POURED OVER OR WITH THE MESH). IT IS ALSO USED TOP WRAP PIPES AND
OTHER
ACCESS AREAS.
A. BORROW MATERIAL
C. CHOCKER AGGREGATE
B. BITUMINOUS SURFACING
CEMENTING MATERIALS
1.01 LIME One of the oldest manufactured building materials used as a mortar and plaster by all the
early civilizations: Egyptians used lime plaster before 2600 B.C. Greeks used it extensively for mortars
and plasters Romans developed a mixture of lime putty and volcanic ash for the first real cement.
1.01 LIME The carbonates decompose into carbon dioxide, which is expelled, and calcium oxide (CaO)
called quicklime. QUICKLIME KEEP DRY Before quicklime can be used, it must first be mixed
with water in the process called staking or hydration. The lime has now become calcium hydroxide
(Ca(OH)2), known as slaked lime or hydrated lime.
Hydrated lime mixed with water to make lime putty, is used as an ingredient of hard finish coat
for two-and three coat Portland cement plasters. It is also used for mixing with cement mortar or
concrete to: • increase its workability • decrease its permeability to water LIME • reduce cracking due
to shrinkage A type of lime which will set under water is hydraulic lime, used only where slow underwater
setting is required.
Hydraulic Lime Hydraulic lime - is produced in a similar way but from limestones with naturally
occurring impurities and it's these minerals that allow the mortar to set and harden through chemical
reactions with water (hydration). Available in powder form, hydraulic lime sets faster than non-hydraulic
lime and has a higher strength but a lower permeability. Natural hydraulic lime (NHL) is sold in various
strengths (NHL 2, 3.5 and 5) to suit different building's needs.
Natural Hydraulic Lime (NHL) NHL5 is the most hydraulic, then NHL3.5, and NHL2 the least
hydraulic lime. They do not perform in the same way as modern cements, nor contain the same
damaging components. It should be noted however that limes marked with NHL-Z or just HL on the
bag can contain some additions that could be potentially damaging and at worst be not much better
than cement. Only use limes marked NHL - these meet the highest British and European standards.
1.02 GYPSUM
Gypsum, like lime, was used as a plaster by the Egyptians, Greeks and Romans. "Plaster" from the
Greek (gypsos) word for both the raw material and calcined product. In architectural terminology the
words "Plaster" and "gypsum" are often used interchangeably. Gypsum rock is ground fine and heated
(calcined) to between 325 °F. to 340 °F. when it loses about three-fourths of its combined water. The
remaining product is Plaster of Paris, if pure gypsum is used, or hard wall plaster, if 39.5 % impurities
are present or added to retard the set and improve the setting qualities. Hard wall plaster is harder than
lime plaster, sets more quickly and thoroughly.
Gypsum plaster is rendered more plastic by the addition of hydrated lime. Fiber or hair is also
sometimes added for greater cohesiveness. The fiber may be hemp, sisal or jute; the hair is generally
cleaned goat or cattle hair.
1.03 CEMENT
• First developed by the Romans by mixing slaked lime with pozzolana (volcanic ash) which hardened
under water.
• With the fall of the Roman Empire the art of cement making was lost and for several centuries. • In
1756, Smeaton, an Englishman, rediscovered hydraulic cement but it was not until 1824 that Aspdin,
an English bricklayer and mason, invented and patented Portland cement. Today, the word "cement"
generally refers to Portland cement which is the principal type of cement in use.
Cement should be protected at the building site from injury through contact with dampness. They
should be stored in shed with a wood floor raised about 300mm (12") from the ground. • Cement is soft
and silky to the touch. If it has lumps that do not readily break, the cement has already absorbed a
damaging amount of moisture. Cement should be used as soon as possible after delivery. • Piles should
be limited to twelve sacks in height. Warehouse set - when the cement is stored in high piles for long
periods, there is a tendency for the lower layers to harden caused by the pressure above.
3.01 DEFINITION
Concrete is:
• a proportioned mixture of cement, aggregate and water. a plastic mass which can be cast, molded or
formed into predetermined size or shape
• upon hydration, becomes stone-like in strength, hardness and durability The hardening of concrete is
called setting. • when mixed with water and a fine aggregate of less than 6mm (%) is known as mortar,
stucco or cement plaster.
• when mixed with water, fine aggregate and a large aggregate of more than 6mm (4) in size produces
concrète.
• when strengthened by embedded steel, is called reinforced concrete when without reinforcement, is
called plain or mass concrete.
3.02 QUALITIES OF GOOD Concrete should be: Strong, Durable, of uniform quality, and thoroughly
sound.
These are obtained through:
• careful selection of materials
• correct proportioning
• thorough mixing
• careful transporting and placing
• proper curing or protection of the concrete after it is placed
B. AGGREGATES
Are inert mineral fillers used with cement and water in making concrete, should be particles that
are durable strong, clean, hard and uncoated, and which are free from injurious number of dusts,
lumps, soft and flaky particles, shale, alkali, organic matter loam or other deleterious substances.
• Fine aggregates (aggregates smaller than 6mm () in size) consist of sand, stone
screenings or other inert materials of similar characteristics.
• Specs: 80 to 95% shall pass a No. 4 wire cloth sieve and not more than 30% nor less
than 10% shall pass a No. 50 sieve.
B. AGGREGATES
• Coarse aggregate (aggregate larger than in size) consists of crushed stones, gravel or other
inert materials of similar characteristics.
• Coarse aggregates should be well graded in size to a size which will readily pass between all
reinforcing bars and between reinforcement and forms but not exceed 25mm (1") in size for
reinforced beams, floor slabs, & thin walls.
• They may range up to 50mm (2) for less highly reinforced parts of the structures such as
footings, thick walls, and massive work.
B. AGGREGATES
Special aggregates, such as cinders, blast furnace slag, expanded shale or clay, perlite, vermiculite,
and sawdust, may produce: lightweight, nailable concrete thermal insulating concrete.
C. WATER
- should be free from oil, acid, alkali, vegetable mat or other deleterious substances - should be
reasonably clear and clean.
- The use of sea or brackish water is not allowed. Water combines with the cement to form a paste
which coats and surrounds the inert particles of aggregates.
- Upon hardening, it binds the entire mass together.
-The strength of the mixture therefore depends directly upon the strength of the paste. If there be an
excess of water the paste becomes thin and weak, and its holding power is reduced.
C. WATER
-The water-cement ratio is the amount of water used per bag of cement.
-This usually varies from 5 to 7 gallons, with 6.5 gallons as average for ordinary job conditions. The
less water used in mixing, the better the quality of concrete.
-The ideal mix is one that is plastic and workable. It should not be too dry that it becomes too difficult
to place in the forms, nor too wet that separation of the ingredients result
3.10 ADMIXTURES
Admixtures may be grouped into three categories:
• those for mixing into concrete those for mixing into mortar
• those for surface application or finish.
Admixtures come in powder, paste, and liquid form, and are usually patented and sold under trademark
names.
3.10 ADMIXTURES
Concrete admixtures include:
a. Accelerators -to speed up. setting time, to develop earlier strength, and to reduce length of time for
protection, Principal ingredients are calcium chloride. Maximum amount added is 2 lbs. per bag of
cement.
Disadvantages: they increase the expansion and contraction of concrete, reduce resistance to sulfate
attack, and increases efflorescence and corrosion of high tension steels.
b. Retarders-to slow down the hydration of the cement during very hot weather, Principal ingredients
include zinc oxide, calcium lignosulfonate, derivatives of adipic acid.
Disadvantages may cause some loss of early strength and will therefore requiré careful control and
more frequent slump tests, also reduces the expansion and contraction of concrete.
3.10 ADMIXTURIS
c. Air-entraining agents - introduce minute air bubbles to greatly increase the resistance of concrete
to freezing and thawing, increase plasticity and reduce bleeding. Addition of air-entraining admixtures
is usually in the proportion of 3 to 6% of the volume of concrete. They are manufactured from such
ingredients as rosin, beef tallow, stereates, foaming agents (soap).
Disadvantages: These require careful control and more frequent slump tests. They may also cause
some loss of strength.
d. Inert, finely divided powders such as powdered glass, silica sand, stone dust, hydrated lime
- are added to improve workability, used as per manufacturer's directions. Hydrated lime is usually in
the proportion of 10 to 15% of the cement by volume.
3.10 ADMIXTURES
e. Waterproofing (permeability reducing) compounds - reduce the capillary attraction of the voids
in the concrete or mortar, but while it may decrease water absorption of the concrete or mortar, it does
not render concrete waterproof. They are manufactured from stearic acid or its compounds, mainly
calcium steareate, and include asphalt emulsions. They are introduced usually in the amounts of 0.1 to
4.0% of the weight of cement.
3.10 ADMIXURES
f. Colored pigments are mainly to used to give color to concrete floors. There are two types:
• Dry-cast, broadcast or dust on, for surface coloring. They are dusted on, usually in two coats,
after all surface water has disappeared. The surface is then finished with a steel trowel
• Integral colors, for body coloring Integral color pigments are incorporated in the mortar topping.
They are mixed dry with the cementi and aggregate before water is added Amount of color
pigment required is not more than 10% of the cement by weight, generally 3 to 6 lbs. per bag of
cement
3.10 ADMIXTURES
Admixtures for mixing into mortar include:
• Accelerators
• plasticizing agents (correctly called water-reducing agents) to lower water cement ratio and
make the mix more workable
• . waterproofing agents, and
• . color pigment
Surface application finishes for concrete consist of:
• hardeners
• . color pigments
• special aggregates
• . sealers
• abrasive materials
• waterproofing agents, and
• fillers and patchers.
3.11 FORMS
A. LUMBER FORMS
• Lumber used in form construction should only be partially seasoned.
• Kiln-dried lumber has a tendency to swell when soaked by the concrete, and this swelling causes
bulging and distortion of the forms.
Green lumber, on the other hand, dries out and shrinks if allowed to stand too long before the concrete
is placed. This tendency of green lumber to check and warp may, however, be prevented to some
extent by keeping the boards thoroughly saturated with water.
3.11 FORMS
A. LUMBER FORMS
When using natural, well seasoned lumber, care should be taken not to drive the work up too close,
since forms should always be left in a position to experience some slight swelling without any
undesirable results
3.11 FORMS
A. LUMBER FORMS
• Sheathing lumber dressed at least ono side and both edges even are used where the removal
and cleaning of the forms are necessary for re-use
• Sheathing lumber dressed on all four sides shall be used in face work where smooth and true
surface is important.
• Tongue-and-groove lumber will achieve light joints between boards in floor and wall panel
construction. Simply dressing the lumbor true to edge form square of butt joints in the forms for
columns, beams, and girders.
3.11 FORMS
A. LUMBER FORMS
Use nails sparingly in the construction of forms because unnecessary nailing not only adds to the labor
of wrecking but also renders the lumber unfit for continued use. Where nails must be used, leave the
head protruding so that they may be withdrawn without injury to the lumber.
3.11 FORMS
A. LUMBER FORMS
All forms for concrete require a coating of some lubricant to prevent concrete from adhering to the wood
and thus make a rough, unpleasant appearance. Crude oil and petroline preserve the forms against
damage by alternate wetting and drying. The forms should preferably be oiled before they are set in
place. Oil should not be used, however, on forms against surfaces which are to be plastered, as oil
prevents adhesion of the plaster. In such cases, wetting with water will be sufficient.
3.11 FORMS
A. LUMBER FORMS
The inside of forms which have been used once and are to be used again shall be coated an approved
soap or other approved material, or thoroughly wetted before concreting. No application of soap or
other material should be made to forms after the reinforcements are in place.
The forms should be durable and rigid, and should be well braced so that bulging or twisting cannot
occur. The joints should be made tight enough to prevent leakage of the mortar.
3.11 FORMS
B. PLYWOOD FORMS
Works best where a smooth surface is required. The plywood should be waterproof, Grade "A" and at
least 12mm (4") thick.
C. STEEL FORMS
Steel forms may be in the form of pans for concrete joist construction or steel decking or corrugated
steel for concrete slabs and slab and-joist construction.
D. PLASTIC FORMS
Polystyrene forms are now available for concrete work.
4. PROCESSED CONCRETE
4.01 TYPES OF PROCESSED CONCRETE
A. "AEROCRETE"
• This is a light-weight, expanded structural concrete produced by adding a small amount of
metallic aluminum powder to the mixture of Portland cement and sand of cinders.
• On the addition of water, a gas is generated which expands the wet mix and forms small air cells
throughout the material.
• It is used for structural floor and roof slabs, partition blocks for sound proofing, wall insulation, in
rooms of refrigerator plants, lightweight fill on top of structural floor and roof slabs.
• In addition to its light weight, it has excellent fire-resistive qualities.
• GUNITE is used for encasing structural steel, when reinforced, for floor and roof slabs and
curtain walls. Ideal for swimming pool construction.
• The cost of raw aggregates is higher than for gravel, rock, and sand because of small production
facilities and the additional processing that is sometimes necessary.
• Concrete using lightweight aggregate should not weigh more than 75% of ordinary concrete.
Since the aggregates compromise about 50 percent of the usual mixes, its weight should not
be more than 50 percent of that of rock or gravel aggregates for the same volume. Grade rock,
gravel aggregates weigh a little less than 100 lbs. per cu ft. thus a good lightweight aggregate
should weigh less than 50 lbs. per cubic foot.
Perlite is useful where maximum strength is not required, as in precast slabs and blocks and in floor
fill, fireproofing and plaster.
MANSORY
-a proportioned mixture of siliceous materials (sand, crushed stone) and cement (lime, Portland)
which, after being prepared in a plastic state with water, hardens into a stonelike mass.
• Mortar is cement mix used to glue masonry units to each other, or other surface finishing
materials like tiles, bricks,stones to a receiving structure like a wall or floor.
- For rubble stonework, 1:4 will be much stronger than lime mortar. For the top surface of floors
and walks, use 1: 1 to 1-1/2
- Mortar made with fine sand requires a much larger quantity of cement to obtain a given
strength than mortar made with coarse sand.
-Mortar may be mixed by hand or mechanical mixers, the latter being preferred for large quantities.
-When the mixing is done by hand, it should be done on platforms made watertight to prevent the loss
of cement.
-The cement and sand should be mixed dry in small batches in the proportions required on a clean
platform.
-Water is added and the whole remixed until it is homogeneous in color and leaves the mixing hoe
clean when drawn out.
-Mortar should never be retempered after it has begun to set.
1.02 PLASTER
- is a mortar of cementitious material ( lime, gypsum or cement), sand and water which is
applied in coats (layers) to masonry surfaces, lath or various types of plaster board to give a
hard finish surface to interior or exterior walls and ceilings.
- the word "plaster" refers to gypsum plaster and the words gypsum and plaster are often used
interchangeably.
• Fiber or hair is sometimes added to the mixture to give increased strength as when used for
the first coat.
• Plastering is done according to two basic methods: two-coat and three-coat. A three-coat job
consists of:a first binding coal called scratch coal a second straightening coat called the brown-
coat and a final coat called the finish coat.
In the two-coat work, the scratch and brown coats are combined into one.
LIME PLASTER
Lime putty (hydrated lime and water;none hydraulic), mixed on the job with sand and gypsum plaster,
used for two and three-coat finish surfaces for interior walls and ceilings.
Scratch coat :1 part lime putty, 1 part Portland cement or Keene's cement, 2-3/4 parts sand by
weight.
Brown coat 1 part lime putty. ipart Portland cement or Keene's cement, 3 parts sand by weight.
• Finish coat:
Hard finish: 1 part lime pulty, 1/3 gypsum plaster by volume
Sand float : 1 part lime putty, gypsum plaster, 2 parts sand by volume
DIVISION 4: MASONRY
1.03 TYPES OF PLASTER AND THEIR USES
B. GYPSUM PLASTER
• Gypsum plaster Plaster of Paris mixed with clay, lime and other materials in combinations
covered by trademarks or patents Mixed on the job with water, sand, lime putty, hair or fiber for
two or three coat finish surfaces for interior walls and ceilings; or used dry as ingredient for
hard or sand float finish with lime plaster (see above)
• High-strength gypsum plaster. Same as gypsum plaster but mixed to meet established
standards. Mixed on the job with water, sand, lime putty hair or fiber for two and three-coat
finish surfaces for both exteriors and interiors.
Gypsum Plaster
Scratch and brown coats 2 parts sand by weight
Hard finis gypsum plaster by volume
1 part high-strength gypsum plaster to
1/4 lime putty to 1 part high-strength
B. GYPSUM PLASTER
Fibered gypsum plaster Gypsum plaster premixed with fibers. Mixed on the job with water and sand
for scratch coat for three-coat plastering job
• Prepared gypsum plaster Gypsum plaster mixed with fine white sand. Used for two and three-coat
finish surfaces for interior walls and ceilings.
- Scratch and brown coats: mix per manufacturer's instructions.
- Finish coat: Any type of final coat plaster (gypsum, Keene's cement, lime or prepared finish coat)
• Bonding plaster, Gypsum plaster mixed with ingredients develop more adhesive strength in
combinations covered by trademarks or patents. Used for Interior finish for smooth concrete
walls or callings Mix and apply as per manufacturer's directions
• Lightweight gypsum plaster fire-resistant plaster Gypsum plaster mixed on the job with water,
perlite, vermiculite or other suitable mineral aggregate Lightweight gypsum plaster is used
when weight is important, and for fire-proofing other materials such as steel. Applied on lath.
For Interior use only
• Scratch and brown coats 100 b
• 2 sand, 2 cu.ft. perlite or vermiculite per of plaster
Brown coat:
• 3 sand, 3 cu I. perlite or vermiculite per 100 lb. of plaster
Finish coat:
Hard finish
DIVISION 4: MASONRY
• In three-coat plastering work, the scratch and brown coals are thick at minimum; the finish coat is
1/8" with a minimum of 1/16" at any point.
For two-coat work, the base coat is 1 1/2%" and the finish coat is the same as three-coat work.
1.03 TYPES OF PLASTER AND THEIR USES
D. "SGRAFFITO"
• The word sgraffito comes from the Italian language and is derived from graffiare ("to scratch"),
ultimately from the Greek yodgev (gráphein, "to write). Related terms include graffito and
graffiti. (Wikipedia)
• is highly decorative type of plaster work developed in Italy during the Renaissance. This type
of technique consists of applying two or three thin coats of plaster different colors and then
cutting away certain areas of one or two coats to produce a three-dimensional colored design.
2. UNIT MASONRY
2.01 DEFINITION:
• Masonry - is a built-up construction or combination of building materials as clay, concrete, or
stone set in mortar, or plain concrete.
2. UNIT MASONRY
2.01 DEFINITION:
MASONRY TERMS:
a. Bed The horizontal surfaces on which the stones or bricks of walls lie in the courses.
b. Course-A continuous layer of bricks, stones, or other masonry units
c. Wythe or Tier-Each continuous, vertical section of the wall, one masonry unit thick
d. Bond That connection between bricks, stones or other masonry units formed by lapping them one
upon another carrying up the work, so as to form an inseparable mass of building, by preventing the
vertical joints falling over each other (also called a breaking joint).
e Stretcher A brick or block masonry laid lengthwise of a wall
f. Header A brick or block masonry extending over the thickness of the wall
g. Heading course - A course in which the bricks or other masonry units are all headers.
h. Soldier A unit laid on its end with its face perpendicular to the face of the wall
i. Quoins-The corner stones at the angles of buildings, usually rusticated so as to project from the
normal surface of the wall.
j. Bond Stones Stones running through the thickness of the wall at right angles to its face, in order to
bind it together.
k. Blocking or Blocking Course - A course of stones placed on top of cornice crowning the walls
2. UNIT MASONRY
2.02 STONE
• Stone, together with wood and clay, are the basic building material of man. The history of
architecture until as late as 1900 was largely the history of stone in architecture,
• Stone was the structural material, the exterior and interior finishing material, the flooring
material and in many cases the roofing materiál.
• It was also used for all types of sculpture, statuary, and decorative and ornamental
applications. Today, stone is largely used as a surface finishing material for both the exterior
and interior of buildings.
2. UNIT MASONRY
2.02 STONE
They are commonly classified as:
a. Rubble Stone. Stone delivered from the quarries rough and irregular shape.
b. Dimension Stone. Stone cut into specific size, squared to dimensions, and to a specific thickness.
2.02 STONE
STONEWORK The types of stonework are based on the shape and the surface treatment of
finish of the stone
a. Rubble work. Masonry of rough, undressed stones when only the roughest irregularities are
knocked off, it is called scabbled rubble, and when the stones in each course are rudely dressed to a
nearly uniform height, range rubble
b. Random work. Stones fitted together at random without any attempt to lay them in course.
c. Ashlar, Squared stones in regular courses, in contradistinction to rubble work.
d. Ranged work or coursed ashlar - Uniform courses with stones uniform in size.
e. Broken range ashlar - Course laid with the horizontal joints uninterrupted, but the width of the
courses and the tength of the stones are varied to produce a wall with a less regular pattern.
2. UNIT MASONRY
2.02 STONE
STONEWOR
• Ashlar - Random course their rectangular shape and are laid on horizontal beds but no effort is
made to continue the horizontal beds through in an uninterrupted manner. Large stones
combine with small ones in a convenient and, if possible, an interesting manner.
• Rustic or Rock work- Courses of stone face which is jagged, so as to present a rough surface.
• Rustication occurs when heavier stones or areas of stone project from the normal face of the
surrounding wall or of the joint themselves.
2.03 BRICK
- are structural units of clay or shale formed while plastic and subsequently fired
- The manufacture of brick consists essentially of screening grinding, or working the clay to the
desired consistency for moulding, whether by hand or machine.
- After moulding the bricks are dried and then burned in kilns for many hours at high
temperatures, approximately 2000 F These processes punty the raw products, make it uniform
and homogeneous, burn out all combustible matter, and result in a product which is both stable
and physically permanent Standard size of brick is 3:3/4 x 2 1/4 x 8
The types of bricks most frequently used in architecture are Common or building brick. Used for all
purposes, including facing
b. Facing brick. Specially processed to give certain specific surface characteristics. Used for exposed
masonry surfaces.
C. Glazed brick. These have a smooth outer surface with a dull satin or high gloss finish. They are
load bearing, fire resisting, and Impérvious. They are usually formed with vertical hollow cores
through the body with scoring on the back. d. Fire (refractory) brick. These are ordinarily made from a
mixture of fint clay and plastic clay, and are used for the lining of furnaces, fireplaces, and chimneys.
• Mortar joints between brick courses are usually from 4.5mm (3/16") to 12mm (1").
2. UNIT MASONRY
2.04 CONCRETE HOLLOW BLOCK
• Concrete Hollow Block (CHB) is a hollow masonry unit, with two or three cells or cores, made
of the following ingredients: water, Portland cement, and vanous types of aggregate such as
sand, gravel, and crushed stone.
• Lightweight concrete hollow blocks are also manufactured with such aggregates as cinders,
expanded slag, expanded shale or clay. Expanded blast furnace slag rates the highest in fire
resistance, and due to its cellular structure, has high sound and thermal insulation quality
• These are manufactured by machine-mixing the ingredients, pouring the mix into molds, and
curing the block by air drying. A steam-and-pressure curing process is also used which can
produce concrete hollow block in a few hours.
2. UNIT MASONRY
2.04 CONCRETE HOLLOW BLOCK
• Standard CHB sizes are from thicknesses of 100mm (4"), 150mm (6") and 200mm (8") x
height of 200mm (8") x length of 400mm (16").
• CHB of 100mm (4") thickness should be used only for interior partition walls where weather-
tightness is not required.
2. UNIT MASONRY
2.04 CONCRETE HOLLOW BLOCK (PLATE NO.2-PR)
• The different types of concrete hollow block include:
A STRETCHERS
B. HEADER
C. CORNER BLOCKS
D. JAMB BLOCKS
E BEAM OR LINTEL BLOCKS
2. UNIT MASONRY
2.04 CONCRETE HOLLOW BLOCK
• Concrete hollow blocks should be laid on a full bed mortar with horizontal and vertical joints
10mm (3/8") thick.
• Reinforcement for 100mm (4") and 150mm (6") thick wall shall be 10mm2 vertical bars at
600mm on centers and 10mm horizontal bars every third course
• Reinforcement for 200mm (8) thick walls shall be 12mm vertical bars at 600mm on center and
12mm horizontal bars every third course
• All horizontal reinforcement shall be tied to the vertical reinforcement at their intersections.
• Dowel bars should be placed into the piers, columns. slabs, leaving 20 bar diameters exposed
to splice with the reinforcement of the hollow blocks.
2. UNIT MASONRY
2.04 CONCRETE HOLLOW BLOCK
- Block cells with reinforcement are filled with cement mortar.
- Concrete hollow block walls should have a reinforced concrete lintel or beam block course
every twelfth course, and a concrete column stiffener at every 4.80 meters length.
2. UNIT MASONRY
2.05 "DURISOL" BLOCK
2. UNIT MASONRY
2.07 STRUCTURAL CLAY TILE
Structural clay tile are hollow masonry units, open at two ends with interior webs or partitions 19mm
(4) to 25mm (1") dividing the block into longitudinal cells.
In its manufacture, the various shapes of clay tile are formed through special dies and then wire-cut
into the required lengths.
It may have a smooth or scored (grooved) surface. Structural clay tile is classified into:
Load-bearing wail tile, 300mm x 300mm x 300mm (12 x 12" x 12")
b. Non-load bearing, fireproofing, partition, and furring tile, 100mm (4") or 125mm (5") x 200mm x
300mm
2. UNIT MASONRY
3. 2.06 PLASTER BLOCK
- also known as gypsum partition blocks are usually made of gypsum, vegetable
fibers as binders, and reinforcement used for lightweight, fire-resistant interior partitions and for
furring and fireproofing columns.
- Gypsum hollow blocks are manufactured in units of 75mm (3"), 100mm (4") or 150mm (8)
thicknesses, x 300mm (12") height x (9) 700mm (30) length.
- Gypsum solid block is manufactured only with a 50mm (2") thickness.
METALS
DIVISION 5: METALS
1. TYPES OF METALS
1.01 ALUMINUM
• is a soft, nonmagnetic silvery metal
• characterized by its light weight (1/3 that of iron, brass or copper)
• low melting point
• high thermal and electrical conductivity (surpassed only by silver and copper)
• moderately high coefficient of expansion
1. TYPES OF METALS
• readily combines with oxygen to form aluminum oxide, a transparent film that makes it corrosion
resistant
• is readily attacked by alkalis, hydrochloric acid and other dilute acids.
• is subject to galvanic action and should therefore be electrically insulated from direct contact with
metals other than zinc, cadmium, magnesium and nonmagnetic stainless steel.
• is easily worked: can be hot or cold rolled, extruded, forged, pressed, drawn, molded, stamped, bent
and shaped.
• can be riveted, bolted, welded, brazed and soldered.
EXTRUSION
- is the process of shaping material by forcing it to flow through
a shaped opening in a die.
- Extruded material emerges as an elongated piece with the same
profile as the die opening.
- However, these products are not fabricated from pure aluminum but in alloy combination with iron, silicon,
copper, manganese, magnesium, zinc, chromium and nickel in small quantities to give strength and other
desirable characteristics but often reduces its corrosion resistance.
STRUCTURAL ALUMINUM - When aluminum is used as a structural material, important factors, arising
from its physical and chemical characteristics, are considered:
- Aluminum can be extruded; therefore, a structural
shape can be produced economically to meet the
specified structural design requirements.
- Very corrosion resistant aluminum alloys are available;
requiring no painting and the thickness of sections can
be reduced since a safety margin is not necessary to
cover loss of strength due to corrosion
ALUMINUM PANELS AND SANDWICH PANELS -are pre-fabricated units, generally manufactured:
- using dimensions of modular and non-modular window-width for building exterior, and
- in 600mm, 900mm, and 1200mm widths for interior partitions and dividers.
Panels for the exterior of buildings primarily consist of :
- an aluminum exterior facing which may be an aluminum casting
- an extrusion or sheet material which has been pressed, stamped or formed into specially design
shapes.
ALUMINUM PANELS AND SANDWICH PANELS - A sandwich panel comprises a system of construction
called skin construction.
A cellular core of aluminum or other material has a skin of
aluminum applied and bonded to both sides. thereby forming a
unified whole in which all the components work as one.
ELECTROLYTIC FINISHES Commonly referred to as anodized finishes, these finishes are based on the
specific ability of aluminum to develop a protective coating of oxide on its surface.
The coating formed may be transparent or opaque. It is hard,
yet when colored finishes are desired, it is porous enough to absorb
dyes until the final treatment which seals the surface.
Of the colors used in anodic treatments, architectural gold has
proven to be one of the most stable from the standpoint of fade
resistance. Others are blue and, more recently, brown and black
ELECTROPLATING. Aluminum can be covered with a protective or decorative film or another metal, usually
by electrodeposition. In the case of copper and nickel, the coating should be complete and unbroken;
otherwise there will be galvanic action which is destructive to aluminum.
PAINT - Paint, lacquer and enamel can be applied as finishes to aluminum surfaces
that have been prepared by a suitable chemical treatment finish. Lead base paints
must not be used on aluminum.
1.02 IRON
Pure iron is:
• tough,
• malleable silvery-white metal that IS
• soft and ductile as copper
• it is easily magnetized
• is the most magnetically permeable of the metals
• it oxidizes rapidly in air and is readily attacked by most acids.
• can be hardened by heating and sudden cooling
• and made more pliable or more workable by heating and slow cooling.
• At very low temperatures is very brittle
• at red heat it is soft, and at white heat it can be welded.
As pure iron passes through these temperature ranges, it undergoes changes in its structure and properties
that are vitally important in the preparation of steel (an iron-carbonalloy).
The commercial form in which iron is first prepared is crude or pig iron. This impure form which contains 3% to
4% carbon and varying amount of phosphorous, silicon, sulfur, and manganese, is the starting point from
which all other kinds of iron and iron alloys (or steel) are produced.
The key to the various types of iron and steel is the carbon-iron relationship.
A. CAST IRON
- is an iron-carbon alloy that contains more than 1.7% carbon
- is poured while molten into forms
- it can be easily cast into any shape, but it is too hard and brittle to be shaped by hammering, rolling, or
pressing.
- Cast iron is used in the architectural field mainly for piping and fittings, ornamental ironwork,
hardware, as the base metal for porcelain enameled plumbing fixtures, and for miscellaneous casting
such as floor and wall brackets for railings, vents, circular stairs manhole covers, and gratings
The types of cast iron generally used are gray cast iron and malleable cast iron. Cast irons find their largest
use in heavy machinery and industry because it has significant compressive strength and the ability to absorb
energy and stop vibration.
B. WROUGHT IRON
• is almost pure iron with less than 0.1% carbon, usually not more than 0.05%.
• contains 2.5%, of slag (iron silicate) in purely physical association, not alloyed.
• Wrought iron is soft, malleable, tough, fatigue-resistant, and resistant to progressive corrosion.
• It has good machinability and can be forged, bent, rolled, drawn, and spun. It can be welded by any of
the commonly used procedures. Wrought iron is available in the form of pipes, plates, sheets, special
shapes, and bars.
• Wrought iron is now used in the architectural field primarily in the form of genuine wrought iron pipe,
chain, sheet, and ornamental ironwork. Wrought iron pipe is used extensively for plumbing, heating,
and air conditioning where a corrosion resistant, tough, durable material is required.
• Because it is intrinsically related to classical architecture and requires high skilled craftsmanship,
wrought ironwork today is used only in furniture, railing, fences, grilles, and small decorative objects.
1.03 STEEL
• The word "steel" refers usually to plain carbon steels which is defined as alloys of iron and carbon whi
do not contain more than 2% carbon and which are made in malleable or ingot form.
• In the plain or straight carbon steels the iron is always in excess of 95%.
• phosphorus, sulfur, oxygen and nitrogen are present, the last three as impurities.
• Manganese, silicon, aluminum, copper and nickel may also be present either as residual impurities or
as elements deliberately added in small quantities to control the properties of the steel.
• Carbon steel can be wrought, rolled, cast, and welded, but not extruded.
A. WROUGHT CARBON STEEL
Structural steel. This is a medium carbon steel with its carbon content controlled to give both the strength
and ductility necessary for its use.
Structural steel is available in angles, channels, I-beams, H columns, T shapes, Z shapes, plates, round pipe
columns, sheet piling, open web joists, and light steel framing shapes.
Corrugated steel. This is rigidized sheet fabricated from low-carbon cold or hot rolled steel sheets which
are either galvanized or covered with some type of bituminous coating. If galvanized, corrugated steel is
silvery in color and has a glittering frosted surface. It is generally available in 18, 20, 22, 24, and 26 gauge sheet
and strip.
Steel Mesh and Wire Cloth. They are used for concrete reinforcement, lath for plaster, stucco, and
cement, fencing, insect screens
B. . ALLOY STEEL
• steels to which manganese, silicon, aluminum, titanium, and molybdenum have been added in
sufficient quantity to produce properties unobtainable in carbon steels in cast, rolled or heat-
treated form.
The alloying elements are added to increase the following properties:
✓strength
✓hardness
✓ease and depth of hardenability
✓performance at high or low temperatures
✓electromagnetic properties
✓wear resistance
✓electrical conductivity or resistivity.
➢ High-strength low-alloy steels are a group of trade name steels with improved mechanical
properties and resistance to atmospheric corrosion, They are being increasingly used as reinforcing for
pre stressed concrete, high strength bolts, special structural steels and cables for elevators, etc.
➢ Stainless steels generally used in architecture are highly alloyed steels that contain more than 10%
chromium. They are characterized by their resistance to heat, oxidation and corrosion. They are used
where corrosion resistance, durability, and minimum of maintenance is necessary principally for
exterior and interior wall finishes, doors, windows, trims, railings, signs and letters, appliances, etc.
1.04 COPPER
• is ductile, malleable, nonmagnetic metal with a characteristic bright, reddish brown color.
• has the highest electrical and thermal conductivity of any substances except silver.
• Copper useful alloys have enough strength for minor structural work
• easily worked.
• It is attacked by alkalis and many of the common acids.
• It is highly resistant to corrosion by air and salt water.
• On exposure it soon reacts to form a surface layer of an insoluble green salt which retards further
corrosion; this green color on copper is known as its patina.
• Copper can be cast, drawn, extruded, hot and cold worked, spun, hammered, punched, welded,
brazed, and soldered.
• The galvanic action of copper must be considered when copper is used in architecture. When in
contact with many of the common construction materials and in the presence of an electrolyte; it will
corrode these materials near the area of contact.
• The copper itself, being cathode, will not corrode. Therefore a careful check should be made of the
methods of attachment, support and securing into place.
• As copper is one of the best electrical conductors, it finds tremendous use in the entire electrical field,
from very fine wires to bus bars.
• Copper sheet and strip are used for roofing and flashing.
1.05 TIN
• is a soft, ductile, malleable, bluish-white metal.
• Because it is normally covered with a thin film of stannic oxide, it resists corrosion by air, moisture,
sulfur dioxide, hydrogen sulfide (which usually tarnishes and corrodes other metals).
• takes a highly reflective polish and has the ability to wet other metals.
• The main use of the tin is in metallic form of either pure tin or tin-containing alloys for protective
coatings on stronger metals.
• Architectural uses of tin include bronzes, brasses, terneplate, mirrors, gilding, solders, hardware and
fusible alloys.
1.06 ZINC
• is medium hard, bluish-white metal
• is characterized by brittleness and low strength.
• is readily attacked by acids and alkalis.
• It is resistant to corrosion by water. On exposure to air, a film of zinc carbonate or oxide forms which
protects zinc from further oxidation.
• The most important uses of zinc are
• as protective coatings (galvanizing) on iron and steel
• as die-casting metal, and
• as an alloying element in brasses.
Galvanizing is the process whereby a protective coat of zinc is applied to steel and iron to
protect them against corrosion. The advantage of coating them with zinc is that, should the iron or steel
become exposed through wear, aging or discontinuities, galvanic reaction between the coating and the base
metal causes the zinc to corrode and form compounds which cover and continue to protect the iron and steel
for as long as any zinc remains.
Hot-dip galvanizing- metal parts are fully submerged in a bath of molten zinc.
Zinc plating-(also known as electro galvanising) is a process where zinc is applied by using a current of
electricity. While is does provide some rust protection, its thinner coating is not as rust resistant as hot dip
galvanising. Its main advantage is it is cheaper and easier to weld.
• The most common galvanized material used in architecture is galvanized iron (steel) sheet and strip.
• Galvanized sheets become defaced and discolored when subjected to dampness and extremes of
temperature.
• If the sheets are piled flat in the open or tightly bundled in a warehouse, the zinc coating can also be
damaged by the consequent absence of oxygen and carbon dioxide between two sheets. This absence
prevents the formation of a protective film of zinc carbonate; instead zinc hydroxide forms and
destroys the galvanizing.
1.07 BRASS
• fundamentally an alloy of copper and zinc with small quantities of other elements sometimes added to
give the special qualities.
• The copper-zinc proportions may vary from 95% copper and 5% zinc to 55% copper and 45% zinc.
• As a class, brass alloys are less hard and strong than steels (iron-base alloys) but are superior in
workability and resistance to corrosion.
• All brasses react with other metals. When brass is used in direct contact with any other metal, a careful
check should be made of its position on the galvanic series.
• Brass should not come into direct contact with iron, steel or stainless, aluminum, zinc or magnesium if
there is an electrolyte present or the possibility of one forming at the point of contact.
• In architecture, brasses are used for doors, windows, door and window frames, and for ornamental
metalwork such as railings, trims, grilles, etc.
• They are also used extensively for finish hardware, plating of hardware, and other miscellaneous
accessories such as screws, nuts and bolts, anchors, etc.
1.08 BRONZE
• True bronze is an alloy of copper and tin which varies only slightly from 90% copper and 10% tin
composition.
• This bronze is a rich golden-brown metal, originally worked by forging and particularly suited for
casting since it is corrosion resistant, dense and hard enough to take an impression of a mold of any
delicacy whatever.
• The term "bronze" however, is no longer used in this limited sense. In commercial practice the terms
"brass" and "bronze" may be used without much regard for their original meanings.
• The term "bronze" now usually has a prefix and indicates alloys of copper with silicon, manganese,
aluminum, and other elements with or without zinc, e.g. silicon bronze.
• A few brasses are known as bronzes because they have the characteristic bronze color.
• Of the three types of so-called bronzes in architectural work, only one is true bronze. This is the
statuary bronze, which consist usually of 97% copper, 2% tin and 1% zinc.
• As for the others, architectural bronze is really a leaded brass, and commercial bronze is one of the
more commonly used brasses (90% copper and 10% zinc).
• The architectural uses of bronze are confined to statuary, plaques, medallions and other
ornamentation, and miscellaneous rough and finish hardware.
1.09 CHROMIUM
• is a steel-white metal which takes a brilliant polish and is harder than cobalt or nickel.
• It is nonmagnetic at ordinary temperatures but becomes magnetic at 13°F.
• It does not tarnish in air, resists oxidizing agents, is soluble in acids and strong alkalis.
• The principal use of chromium is an alloying ingredient in ferrous and nonferrous metallurgy.
• Chromium plating is one of the most commonly encountered usage of this material in architecture. It
gives a thin, hard, bright, wear resistant surface which sheds water when highly polished. The metals
that can be plated with chromium include aluminum, copper, iron, magnesium, nickel, titanium, zinc
and their alloys. The chromium is electro deposited as a thin layer of pure metal.
1.10 NICKEL
• is an inert silvery metal
• is resistant to strong alkalis and to most acids.
• It resembles iron in strength and toughness and copper in its resistance to oxidation and corrosion.
• Nickel takes a high polish and can be hot and cold rolled forged, bent, extruded, spun, punched and
drawn.
• When alloyed with other metals, nickel imparts its qualities of strength, hardness, toughness, ductility,
corrosion resistance, and strength at high temperatures to the resulting material. The major use of
nickel therefore is in alloys
• Another important use of nickel is as protective or decorative coating for other metals. It can be
applied to the following base metals and their alloys: aluminum, brass, copper, iron, magnesium, steel,
tin, and zinc.
1.11 LEAD
• Lead is a blue-gray, soft, very heavy metal (the heaviest of the common metals). It is extremely
workable, has good corrosion resistance, is easily recovered from scrap materials, and is relatively
impenetrable to radiation. The corrosion resistance of lead arises from the fact that metallic lead does
not react with many compounds or solutions, and with certain others it forms compounds which act as
protective coatings against further corrosion.
• Lead is available (1) extruded in the forms of pipe, rod, wire, ribbon, etc. (2) rolled into sheet, foil, strip,
(3) cast. There are several grades of lead metal of which corroding lead, chemical lead and common
desilverized lead are of interest to the architect. Corroding lead is used for fine white lead paints, red
lead, litharge (see PAINT). Chemical lead and common desilverized are used for sheet, pipe, powdered
lead, ribbon lead and alloys.
• Lead also finds many uses in rough hardware items such as expansion shields for securing bolts,
screws, and other accessories in masonry, washers, lead-headed nails, etc.
2. METHODS OF JOINING METALS
2.01 SOLDERING
• is a method to join metals, to make electrical connections, to seal joints hermetically with another
lower melting metal or alloy called the solder.
• Since the temperatures used are comparatively low, there is no alloying action between the solder and
the metals being joined, which are usually stronger than the solder itself.
• Soldered joints have very little tensile, shear or impact strength; therefore this method should not be
used where a strong joint is required.
• Solders are mostly alloys of tin and lead in various proportions with small percentages of other
elements added to give special characteristics. They can be divided into the following major types:
- tin-lead
- tin-lead-antimony
- silver-lead.
• Tin-lead solder of the 50% tin, 50% lead variety is the most commonly used general purpose of solder.
• Some tin-lead are used for coating the metals before soldering. This is known as pre tinning.
A. METAL BATH DIP: defined as a metal-joining process where the workpieces to be joined are immersed
in a pot of molten solder.
Because of the relatively low melting temperature of the soldér (between 350 and 600 degrees F), only
adhesion between the solder and the workpieces results.
A flux or metal cleaner is used to prepare the workpiece for bonding with the solder.
Typically, dip soldering is an automated process used extensively in the electronics assembly industry.
B. SOLDERING IRON -In this method the iron piece is preheated and applied to the joint along with the
solder and the flux (the flux is a substance used in soldering to clean the surfaces of the metals to be joined
and to aid fluidity); the heat from the iron forms the soldered joint.
C. TORCH -The parts to be soldered are heated by the torch flame and then the solder and flux are applied.
This method is limited to metals which can be heated without altering their characteristics.
D. SWEAT METHOD
• The heating of the metals to be joined causes the solder to run into the joint. This is the method used
for joining copper tubing and fittings.
• Fluxes for soldering are generally of three types: corrosive, neutral and noncorrosive.
• Corrosive fluxes are known as acid type and salt type fluxes and include chlorides of zinc, ammonium,
calcium, magnesium, aluminum and other metal. Care should always be taken with the corrosive
fluxes. The residue must be quickly removed, as it is not only corrosive to the metal being joined, but it
is also electrically conductive as a rule and therefore cannot be used for most electrical work.
• Neutral fluxes are mild in type and are used for easily soldered metals such as copper, brass, lead, and
tin plate.
• Stearic acid is a typical neutral flux.
• Noncorrosive fluxes leaves residues which are noncorrosive and nonconductive and therefore need not
be removed. Rosin is the principal flux of this type.
• Noncorrosive fluxes are weak their fluxing action and their use are limited to the easily soldered base
metals.
2.02 BRAZING
• Brazing is a type of soldering in which the operating temperatures are higher (but lower than in
welding) and in which stronger and higher melting alloys are used to fill the joints, which consequently
are stronger than ordinary soldered joints. The bond is obtained by alloying between the brazing
material and the surface of the joined metals.
• Brazing is generally used where the shape and position of the joint or the composition of the metal or
metals are not adaptable to welding. In brazing the type of metal to be joined, the brazing material,
and their color are equally important because galvanic action, strength of the joint, matching of colors
play a significant part in the finished product.
• Brazing materials fall into six major types: aluminum-silicon, copper phosphorous, silver, copper, and
copper-zinc, magnesium, and heat resistant alloys. Each type is particularly suited to a certain group of
metals. The brazing materials are prepared by melting and mixing together the metallic ingredients to
fixed and controlled proportions.
2.03 WELDING
• Welding is the process by which two metals are so joined that there is an actual union of the
interatomic bonds. This may be brought about by close contact, heating, pressure, adding molten
metal, or combinations of these methods. The resulting joints are as strong or stronger than the metals
joined.
• Welding may be divided into two general types: pressure welding in which pressure and heat make the
weld; and fusion welding, in which the heat and added metal make the weld. In fusion welding the
methods of heating are gas flame and electric arc. The gas flame now generally used is acetylene mixed
with oxygen. It will deliver about 5500 F of heat which is sufficient to melt the welding rod and the
surrounding metal and then fuse them together. In electric-arc method, when the welding rod (or
electrode) is brought near the joint of the metals to be welded, an electric arc is formed which melts
and fuses the metal and the welding rod.
2.04 RIVETS
• Rivets are devices used to join or fasten the metals. The rivet, a metal cylinder or rod which has a head
at one end, is inserted through holes in the materials being joined, and then the protruding end is
flattened to tie the two pieces of material together.
The first pair of numbers refer to the spacing of the wires: the second pair refers to the gauge of the
longitudinal and transverse wires respectively. Thus, for example, a 6 x 6 - 10/10 mesh (read it six six-ten ten)
will be both No. 10 gauge wires spaced 6 apart bothways (the smaller the gauge number the heavier the
wire). Welded wire fabric is available in rolls 5 or 6 ft. wide, 150, 200, and 300 ft. long.
3.04 LATHS
In addition to the various meshes mentioned above, permanent centering or self-centering laths are
produced in many forms. These laths are furnished either in flat or segmental sheets, pressed into a series of
solid ribs, between which the metal is stamped, perforated or deformed into an open mesh-work. These laths
are furnished painted or galvanized, and in open-hearth mild steel or in special copper bearing or alloy steels,
e.g. "RIBPLEX", "HYRIB".