MASONRY

STRUCTURAL MATERIALS RESEARCH CATALOGUE STUDIO 703

CONTRIBUTORS ARCH 3501 - ARCHITECTURAL DESIGN STUDIO 4

Marshall Drennan and Cody Johnson COLLEGE OF ARCHITECTURE

TEXAS TECH UNIVERSITY - FALL 2008
 MASONRY
History - 00

History and Architects

 History MASONRY
History - 03

Masonry is one of if not the oldest style of construction. The pyramids and stone hendge are
thought to be the oldest existing structures in the world. Masonry has been used throughout time
for nearly every precident and has preformed many different uses.
Hisory of masonry
 History MASONRY
History - 04

Masonry has preformed many different uses throught history. its solidity has made it a form of
protection such as in the great wall of china, while its compressive force has made it used to
erect tall alters to gods.
Hisory of masonry
 The arch MASONRY
History - 05

The arch is a construction form that transitions forces outward through its form to its base while
in compression. the romans where one of the first cultures to use and master the form of the
arch and its spanning capabilities. Traditionaly arches where always constructed out of masonry.
In order for masonry to span its greatest distance it must b built in the form of an arch.
Hisory of masonry: the arch
 Architects MASONRY
History - 01

Antonio Gaudi was an architect and master mason in spain. His works are constructed entirely
out of masonry. Among his most famous works would be Sagrada Familia. Which is still under-
construction after 100 years.
Hisory of masonry: architects
 Architects MASONRY
History - 02

Eladio Dieste was an architect and master mason in uraguay in the late 20th century. His design
for the tower of the obrero church is what gave us the design for the cantalivered stair. Dieste
has taken contemporary masonry to a new level with the works that he has created.
Hisory of masonry: architects
 EQUIPMENT MASONRY
EQUIPMENT - 00
Materials Necessary for Masonry Construcition
Structural Research Materials Catalogue
 Brick MASONRY
EQUIPMENT - 01

There are many different kinds of bricks out in the world. All are good with compression but
some are stronger than others and some are even designed differently. The differences can be
caused by many different factors such as: the chemical composition of the clay used ot make
the brick, how hot and long the bricks are fired, and even how they are cooled. Also, some
bricks are made with holes in them to make them lighter or for a place for a tensional steel rod to
pass through the structure.

For our project we chose a simple paving brick that is smaller than normal brick which allowed
us to make smaller structures even though we were using real brick blocks. Being able to use
the real bricks was a very good learning experience.
Materials Necessary for Masonry Construction
 Mortar MASONRY
EQUIPMENT - 02

Mortar is the glue that holds the masonry material together. Just like bricks there are many
different kinds of mortar to choose from. The mortar that is used needs to be strong enough
for whatever kind of load that it will be used for. Some mortars are only good for small garden
walls while other mortars are specifically designed for enormous loads. The mortar starts out in
a liquid state and has to dry to a state where it is expected to be just as compressively strong as
the bricks it holds together. Also, some mortars dont have any sand which must be added later
to the mixture. the ratios for the mortar sand ratio vary but in out test we found that 1:2 worked
best. When adding water to the mortar mixture one only wants to add just enough to where if
the mixture was stirred in the bucket it would be easy to stir but the mixture would not fall flat
after the stirring.
Materials Necessary for Masonry Construction
 Framework MASONRY
(Wood) EQUIPMENT - 03

Frame work could be made of a few other materials but wood is usually chosen. Wood is
the preferred framework because ti is quick and easy to work with, especially as a temporary
structure. The framework is what is required to hold up whatever one is building so that the
mortar has time to dry. In this case of an arch the framework is also necessary to hold all the
parts up until the structure is complete because an arch requires all parts to be in place before it
can be successful. Wood also comes in many shapes and sizes (refer to the wood chapter for
specifics). For larger arches the solid wood support is not recommended and never really used.
Instead the frame is made of wood trusses with an outer curved section to hold up the masonry
work. Once the masonry has been placed and the mortar has had time to dry then framework
can be taken away leaving a very strong compressive structure.
Materials Necessary for Masonry Construction
 Re-Bar MASONRY
EQUIPMENT - 04

Re-Bar is metal tubes that are used to give a compressive material such as mortar or concrete
tensile strength. Usually the Steel is concealed which gives an aesthetic quality to the com-
pressive form making it look as though it is defying its fundamental propertires. Re-bar is tied
together using small thin strips of metal and a special tool almost like a twist tie to seal the bread
wrapping. Re-Bar is definately not always necessary in masonry construction but is used at
times when needed.
Materials Necessary for Masonry Construction
 Tools MASONRY
EQUIPMENT - 05

On our first attempts at masonry construction we tried the use of wooden sticks to stir and apply
the mortar. These worked okay at first but then we began to mix larger batches and need better
application. The sticks often broke in the mixing of the mortar and worse yet when trying to ap-
ply mortar to the bricks it often prefered to stick to the wood. We then invested in a trowel. This
is a tool specifically designed for masonry construction and mortar application. The trowel, even
though not a mixer, worked very well for mixing the mortar because it easily went to the bottom
of the bucket and would not break. But, best of all the trowel was perfect for applying mortar.
We could gather a large amount of mortar on the trowel and it would slide right off like it was on
ice. The trowel made work much easier, quicker, and more efficient.
Materials Necessary for Masonry Construction
 Tools MASONRY
(Cont.) EQUIPMENT - 06

There needs to be some kind of container that is used to mix the mortar on large scale projects
it isnt usually a bucket but a portable cement mixer that keeps the morter ready for use and
mixed easily by just pouring in the ingredients. However, we chose to go the hard way and use
a home depot five gallon bucket and a trowel. there are also attachments to a drill that could be
used to mix the mortar in a bucket or wheel barrow for you.

The last tool necessary is the special tool designed to twist the re-bar ties. The re-bar ties have
a loop on each end and you thread the tool through both loops and then just spin it around until
it gets tight around the re-bar. We had to be careful through because the tool was so efficient
that we broke many of the ties by spinning them too tight.
Materials Necessary for Masonry Construction
 Process of MASONRY
Construction CONSTRUCTION - 00

The Method Used in Masonry Construction

Structural Materials Research Catalogue
 Buying MASONRY
Materials CONSTRUCTION - 01

Construction materials seem cheap at first but when you end up having to buy a whole lot of
them the cost really adds up. Home Depot and Lowes dont ever have any “extra” bricks to give
away. However, we found out from Fred that Acme and other brick supply stores around lub-
bock will practically give away there left overs or wrong color bricks, especially to needy archi-
tecture students. Anyway, finding leftovers and asking politely is a much cheaper way of getting
small amounts of construction material than going to a store such as home depot.
The Method Used in Masonry Construction
 Making MASONRY
Formwork CONSTRUCTION - 02

The Frame work is a very important part of the construction process. we used plywood, two by
fours and re-bar in our framework. We cut the plywood with a jigsaw once we had drawn on the
catenary arch adn then connected the two sides with two by fours running through the center.
We then made stands for the cantilevered steps. Also, we had to cut our strips of re-bar to size
so they would fit inside the steps without poking out.
The Method Used in Masonry Construction
 Preparing MASONRY
the Site CONSTRUCTION - 03

For our construction sites we chose open spaces that were relatively out of the flow of traffic,
clean, and especially that were flat and level. We then cleared away all debree and put down
paper under our projects to protect the ground from falling mortar and so that we wouldnt actu-
ally attach our projects to the ground. Picking the site is very important because you dont want
the project to be too succeptable to the weather, or people who might intentionally knock it over.
The Method Used in Masonry Construction
 Mixing MASONRY
the Mortar CONSTRUCTION - 04

The mortar was one of the most difficult parts to get right. First of all the sand mortar ratio had
to be right, but in the structural mortar which we used at the end luckily the sand was already
mixed in. To mix the mortar all was had were hand tools such as a trowel and wood sticks. This
really wore out our arms because of all the difiicult mixing. However towards the end of the
projects it was almost insticnt on how much water to add and exaclty what would be the right
consistency for the type of brick laying we were doing.
The Method Used in Masonry Construction
 Laying MASONRY
Brick CONSTRUCTION - 05

Laying brick was more tricky than we though it would originally be. One key is to make sure that
there is plenty of mortar so that the brick actually pushes it out of the sides. This ensures that
the whole brick on the bottom is covered. The trowel also works best so that the mortar only
sticks to the bricks instead of what you are using to apply it, which can take the applied mortar
right back off the brick. we were trying to use our hands to make sure that the bricks stayed
clean but that is something that comes better with experience.
The Method Used in Masonry Construction
 Wait MASONRY
to Dry CONSTRUCTION - 06

It is important to make sure that each part is properly dry before taking any of the formwork out.
for the arched part we waited until it was about mid way done through the drying process of
24-36 hours and pulled the formwork out so that the compressive forces could get dried into the
mortar. But, we waited until the bricks were completely dry before removing the support for the
cantilevered step because we didnt want it to be able to move at all. also the steps have very
thick applications of mortar which will cause a longer drying time.
The Method Used in Masonry Construction
 MASONRY
FAILURES - 00

Failures
 Attempt one MASONRY
FAILURES - 01

This was our first attempt at an arch. This blind attempt ended in a failure of the arch due to the
construction technique. bricks where not allined in a fassion as to transition forces from the top
to the base, there where no pinicals to hold the base of the arch from expanding and no definant
keystone to contain the forces of compression.
Failure attempt one at arch construction
 Attempt two MASONRY
FAILURES - 02

Attempt two at arch construction ended in a failure. Learning from the first arch we built in a
mannor that the forces would run down from the key stone to the base. This arch was also
constructed in the cantinary style. This attempt failed due to the absense of a pinacle to hold
the base from flairing out under pressure and from being built on its side and then stood, the
standing required forces to be applyed in a way that the form was not ment to withstand therefor
busting the morter joints.
Failure attempt two at arch construction
 Attempt Three MASONRY
FAILURES - 03

For our third attempt we constructed the arch on a standing framework. pinicals where also
added so that the bottom of the bricks would not push out under compression. This arch failed
due to a weak morter joint. the arch stood but once we applyed force to the top of the arch a
morter joint in the bricks cracked and the arch crumbled under the pressure.
Failure attempt three at arch construction
 Corner detail MASONRY
FAILURES - 04

The corner detail failed due to the type of morter uses. After the bricks had dryed they where
able to be pulled apart easily. From this initial test and first construction with bricks we learned
the importance of morter strenght in masonry construction.
Failure corner detail of brick
 Success MASONRY
Models SUCCESSES - 00

The Succesful Models that Led to our Final Project

Structural Materials Research Catalogue
 Arch MASONRY
(Construction) SUCCESSES - 01

We finally had success on our arch. we were able to achieve this success by waiting 2 hours
before we removed the formwork which allowed the mortar to have time to set up while still
allowing it to dry under pressure. the other secret that we learned was to build it standing up
with formwork instead of trying to cheat the system by building it on its side on the ground then
standing it up.
The Succesful Models that led to the Final Project
 Arch MASONRY
(Weight Held) SUCCESSES - 02

The arch was able to hold one of our classmates, Jasmine, with no problem at all. It could not,
however, hold Marshall (230 lbs). The point at which it faled was the single layer on the top
where it bowed at and broke at the mortar seems. We concluded that our final project woudl
have pleant of strength with the better mortar and the thinest point being 5 layers of brick thick.
The Succesful Models that led to the Final Project
 Cantilevered MASONRY
Step SUCCESSES - 03

(Construction)

To test the cantilevered step idea we built a model and used rebar in between to layers of brick
running diganollay through the steps. we chose this patter because it gave each step two
pieces of re-bar going into them and then the re-bar would travel all the way to the other side to
help balance out the forces from side to side.
The Succesful Models that led to the Final Project
 Cantilevered MASONRY
Step SUCCESSES - 04

(Weight Held)

The step was able to hold Marshall (230 lbs) standing on the ver edge of one of the steps no
problem. Then i tried to jump on it and thats when it broke. We deduced that it would still be
very structurally sound for our final project because the mortar was not as strong as the struc-
tural mortar and it had to dry during a day that saw eight inches of rain. the new steps are still
standing even with people jumping on them.
The Succesful Models that led to the Final Project
 MASONRY
FINAL PROJECT - 00

The Arch Final Project

 Design MASONRY
FINAL PROJECT - 01

The origional design for the final structure came from this origional sketch of a cantalivered stair
spanning by use of an arch. The cantaliver came from a design by Eladio Dieste (reference ar-
chitects page) in which a cantalivered spiral stair case lines a tower. As we progressed in design
the model progressed into an eight foot span at 4 feet above the ground. with stair steps up the
sides and cantalivered stairs at the top.
Final project design of the structure
 Materials MASONRY
FINAL PROJECT - 02

For materials for the final project we used garden brick, plywood sheets to make the frame, two
by four’s to create a brase for the cantalivers, rebar, and 80 pound bags of type S construction
morter.
Final project materials used in construction
 Preparation MASONRY
FINAL PROJECT - 03

Prior to construction wooden framework had to be prepaired. Using the catnary arch we cut the
main framework. Then four braces where constructed to hold the cantalivered stairs in place
while their morter dried.
Final project Preperation prior to construction
 Construction MASONRY
FINAL PROJECT - 04

After the initial framwork was erected construction began by laying one brick at a time and ap-
plying morter. The design called for a double layered arch with a flemish bond of bricks on the
outside pinicals.
Final project Construction
 Construction MASONRY
FINAL PROJECT - 05

As the arch approched the keystone a single brick was too thin and two bricks where too thick.
to properly have a keystone we had to cut bricks to the proper size using a hammer. Above the
keystone the flemish bond continues from the pinicals above the arch to provide extra support.
Final project Construction of the keystone
 Construction MASONRY
FINAL PROJECT - 06

The support braces where cut to exactly the height of the base of the cantalivered stair. Each
step had rebar inbetween the morter and extruded away from the arch. Four butraces where
placed at the base of the arch so that when weight is applyed to the cantalivers the arch would
not fall to that side.
Final project Construction of the cantalivered stair
 Testing MASONRY
FINAL PROJECT - 07

After letting the morter dry for two days we removed the framework, to test we placed controled
weight with our hands on different locations on the arch to make sure there is no structural fail-
ure. We then proceded to walk on the arch and it proved that it could hold the wight of a person.
Final project testing for stability
 Testing MASONRY
FINAL PROJECT - 08

The arch proved to be stronger than anticipated and held the weight of seven men without any
signs of structural failure.
Final project testing for stability