BRICK & BLOCK

Chapter 4

Jul-21 CEM 1
MASONRY
 Masonry construction = masonry units + mortar.
 Units are laid together to form a structure.
 2 types (based on location):
Exterior type, Interior type.
 2 types (based on structural requirement):
Load bearing, Non-loading bearing.
 2 types (based on method of construction):
Solid wall / Hollow wall, Framed wall.

Jul-21 CEM 2
 Exterior type

Interior type

Jul-21 CEM 3
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Jul-21 CEM 7
 WALL CHARACTERISTICS

 Good resistance to fire but poor

insulating against heat (transfer
heat).
 Poor resistance to water penetration
but good against heat transfer.
 Changes in temperature and
moisture.
Jul-21 CEM 8
MASONRY BUILT AS:

 Single-wythe wall

 Double-wythe wall

Jul-21 CEM 9
Jul-21 CEM 10
 TYPES OF
CLAY

SURFACE FIRE
SHALES
CLAYS CLAYS

Jul-21 CEM 11
 STIFF-
MUD
PROCESS

BRICK
MANUFACTURE

DRY
SOFT-MUD
PRESS
PROCESS
PROCESS
Jul-21 CEM 12
MORTAR

 Mortar is a plastic mixture of

cementitious materials, sand and water.
 Capable of binding together individual.
 Applied to any materials used for
bedding, jointing and rendering
brickwork, stonework and concrete
block work.

Jul-21 CEM 13
 MIXING MORTAR

1) Put cement and sand 2) Dry mix cement and sand

3) Sand and cement mixing

adding with water

4) Cement and sand is shoveling 5) Cement and sand mixing ridges

Jul-21 CEM 14
FUNCTION OF MORTAR

 To bond individual unit together (single larger

unit).
 Serves bedding material – allow level
placement.
 Responsible for the strength characteristic.
 Used to project some aesthetic features (color
and appearance).

Jul-21 CEM 15
TYPES OF MORTAR

 Lime + sand + water = lime mortar

 Lime + sand + water + cement =

cement-lime mortar/cement mortar

Jul-21 CEM 16
TYPES OF MIXING

1. Ready-mixed mortar

2. Paddle-type mixer.

Jul-21 CEM 17
PROCEDURE MIXING MORTAR
(Paddle Type)
1. Place all the mixing water.
2. Add cement to the mixer.
3. Mix at low speed for 30 seconds.
4. Add lime and sand while the mixing is
running.
5. Mix at medium speed for 30 seconds.
6. Rest for 1 ½ minutes.
7. Run the mixer for 1 minutes at medium
speed and dump the mortar out.
Jul-21 CEM 18
Jul-21 CEM 19
CLAY BRICKS PROPERTIES

1. Small solid block usually rectangular.

2. Structural clay tile
a) Hollow clay unit

b) Larger than a brick

c) Develop for use where lightweight

masonry is required

Jul-21 CEM 20
CLAY BRICKS

 Clay bricks continue to be the most

important building units.

 Raw materials are clay or shale.

 Efficient material to use in terms of their

energy consumption.

 Strong and durable.

Jul-21 CEM 21
Raw materials and manufacture

 Clay bricks are made by shaping suitable

clays and shales to units of standard size.

 Fire to temperature in the range 900-1200ºc

 The fire product is a ceramic composed

predominantly of:
silica SiO2 (generally between 55 and 65% by
weight) + alumina Al2O3 (10 to 25%) + 25%
of other constituents
Jul-21 CEM 22
Raw materials and manufacture (cont’d)

 Sand facing and face textures may be applied

before firing, and key slots formed for plaster
finishes.

 Many bricks are perforated and pressed bricks

commonly have frogs; both feature reduce
brick weight.

Jul-21 CEM 23
Raw materials and manufacture (cont’d)

 Normal size of building bricks is 215mm x

102.5mm x 65mm.
 Allowing for 10mm mortar joints, this
correspond to the standard format or
‘coordinating size’ of 225mm x 112.5mm x
75mm.
 Some bricks are also available in a metric
modular format.

Jul-21 CEM 24
Jul-21 CEM 25
Application

 External and internal load bearing walls

 Load bearing piers and columns
 Partition walls
 Party walls
 Cladding and facings
 Foundations
 Perimeter and garden walls
 Paving and floorings

Jul-21 CEM 26
 Clay
composition
variety
at different
Chemical geological
analysis period, from Bricks a differ in
& Minerological sticky their
examination can mud to shale properties
identified colour, texture,
the presence of strength,
chemical& clay density &
mineral durability
in the raw mat.

Other minerals:
Potash, lime,
Clay for Only 30-40% of
brick
soda,
magnesium and
brick- making clay are
clay minerals
iron making
Clay minerals:
Size < 2microns,
the amount
& particle size
Clays are
present in the
hydrated
clay
Aluminosilicate
affect the
s
cohesiveness,
(kaolinite, llite,
forming
montmorillonite) Too much clay- characteristics,
high drying drying & firing
shrinkage; properties of the
adding sand can clay
Jul-21 reduce
C E M it 27
Grades and Types
 Bricks may be classified into different types,
according to their uses.
1. Building bricks
 For construction and structural material.
 Manufactured in 3 grades: grade SW ‘severe
weathering’ (highest min compressive strength
requirement and lowest maximum water absorption),
grade MW ‘moderate weathering’, and grade NW
‘negligible weathering’ ( lowest minimum compressive
strength requirement and no limit on the water
absorption). This grading depends on some physical
requirements ( minimum compressive strength,
maximum water absorption, and maximum saturation
coefficient)

Jul-21 CEM 28
Grades and Types (cont’d)
2. Facing bricks
 For facing purposes (available in all sizes and colors,
smooth, fine, medium, or coarse textured)
 Manufactured in 3 types: type FBS (face brick standard),
type FBX (face brick extra), and type FBA (face brick
architecture).

3. Floor bricks
 For used on finished floor surfaces (smooth, dense, highly
resistant to abrasion)
 The appearance of a finish floor depends on the color,
texture, and bond pattern of bricks.

Jul-21 CEM 29
Calcium Silicate Brick

 Consists of 90% - 95% sand

(majority passing 1.15mm sieve)

 Lime
(aggregate lime ratio by weight of 10-20:1)

 Water

Jul-21 CEM 30
Manufacturing

Mixing of sand, lime,

Mixing pigments and water

Pressed under very

Pressing high pressure to
gives shape &
compaction

High pressure steam

Autoclave curing combining
lime & sand to form
calcium silicates

Jul-21 CEM 31
Properties
SIZE
 Standard brick dimension are 215 x 102.5 x
65mm

ABSORPTION
 Varies between about 6% and 16% by weight

DENSITY
 Varies between about 1700kg m³ & 2100kg m³
depending on the composition of the brick &
manufacturer

Jul-21 CEM 32
Properties

STRENGTH

 Range of mean compressive strengths for

bricks in general use is 14-27.5Nmm-2
depending on the quality of brick being
produced.
 Although strengths greater than 48.5mm-2 can
be achieve by some manufacturer.

Jul-21 CEM 33
Properties (cont’d)

DRYING SHRINKAGE
 Calcium silicate brick shrinks on drying out in
a similar manner to concrete products although
the magnitude of this drying shrinkage, 0.01%
- 0.04% is about half that associate with the
latter.

FROST RESISTANCE
 The effect of repeated freezing & thawing on
the integrity of calcium silicate brick is slight
depends on class of bricks.

Jul-21 CEM 34
Properties (cont’d)

EXPANSION

 Expansion occurs with temperature change, the

coefficient of thermal expansion being in the 8
– 10 x 10-6k-1, with the actual value
depending on the aggregate used & the mix
proportion.

Jul-21 CEM 35
 Hardness
Size
& Strength
Shape

Characteristics
Durability of good Colour
bricks

Water Fire
Absorption Resistance
Texture

Jul-21 CEM 36
 Explanation
1.Size – the bricks should have uniform size and plane,
rectangular in shape with smooth surface.
2. Colour – the bricks should have a uniform deep red or
cherry colour as indicative of uniformity in chemical
composition and thoroughness in the burning of the
brick.
3. Strength – adequate strength for sustaining loads. E.g.
load of bearing walls, sufficient strength to carry loads
Min compressive Max water absorption
Bricks
strength
Class A 70 N/mm² 4.5 %

Class B 50 N/mm² 7.0%

Jul-21 CEM 37
Explanation
4. Hardness – not easily scratched and break.
5.Fire resistance – ordinary bricks can resist high
temperature up to 1500ºF.
6.Texture – the bricks should have precompact and
uniform texture. Not show fissures or lumps of lime
7. Water absorption – a good bricks should not absorb
more than 20 % of water by weight, when placed in
water for 24 hours.
8. Durability – be able to resist weathering action.
(alternate wetting and drying).

Jul-21 CEM 38
 Types of clay bricks

Common bricks
-General multi purpose
-There are ordinary bricks
Which are not designed to to give attractive appearance,
provide good finished
Appearance or high
strength
Engineering bricks
Facing bricks
-These are designed
-There are designed
primarily for strength
and durability.
hence they are free
-They are usually for high
from imperfections
density and well fired.
such as cracks

Jul-21 CEM 39
 Manufacture of clay bricks

4.Burning 5.Bricks

1.Clay
3.Drying
preparation

2.Moulding

Jul-21 CEM 40
 Manufacture of clay bricks (cont.)

 Clay preparation

Clay is prepared by crushing, grinding and

mixing with small quantities of sand, ash
and lime until it is of a uniform
consistency. Water may be added to
increase plasticity (tempering).

Jul-21 CEM 41
 Manufacture of clay bricks (cont.)
 Moulding
a. Semi dry process.
b. Stiff plastic.
c. Wire cut
d. Soft mud.

a. Semi – dry process

-suitable for clay, moisture content 10 %
- no drying is needed
- compacted into mould under high pressure.

Jul-21 CEM 42
Plastic moulding

Jul-21 CEM 43
 Manufacture of clay bricks (cont.)

b. Stiff plastic process

- moisture c. of 15 % & high pressure.

c. Wire cut process

-moisture c. 20 % & homogenous materials.

d. Soft mud process

-moisture c. of up to 30 %( more soft).
-sanded to prevent sticks.
-very soft, similar process.

Jul-21 CEM 44
 Manufacture of clay bricks (cont.)
 Drying
o is essentially evaporation of moisture either is a
normal atmosphere or with controlled, humidity
and temperature.

o drying is done prior to burning of bricks.

o artificial drying, this is done by drying bricks in

chamber. Hot flue gases may be used to heart
these chambers.
o Maintained at 120ºC, within 1 to 3 days.

Jul-21 CEM 45
Method of drying bricks

Jul-21 CEM 46
 Manufacture of clay bricks (cont.)
 Burning
The burning of clay may be divided into 3 main stages.

a. Dehydration(400 - 650ºC)
- evaporation of free water.
b. Oxidation period(650 - 900º)
- burning of carbonaceous matter.
c. Vitrification
-(900-1100º) for low melting clay.
-(1000-1250º) for high melting clay.

The process is done inside the kiln burning.

Jul-21 CEM 47
Jul-21 CEM 48
 Test on bricks
WATER ABSORPTION TEST

 5 whole bricks are selected at random.

 Oven- dried at 100ºC for 48 hours
 Cooled to room temperature and weight ( dry weight)
 Dry specimens are immersed in water and boiled for 5 hours in order
to ensure maximum possible penetration of water.
 Allowed to cool still submerged in water for 16 -19 hours.
 They are then removed, the surface wiped off & weight
(weight of wet brick)
 Average of 5 bricks, taken final result.
 (wt wet brick - wt dry brick) kg x 100 = ?
wt dry brick

Formula (w² - w¹) kg x 100 % = ?

w¹

Jul-21 CEM 49
Test on bricks
Efflorescene test

 Not less than 5 bricks selected.

 Each brick is placed on end in a shallow flat bottom dish
containing distilled water, depth immersion less than 2.5
cm.
 Put in warm (18ºC - 30ºC), well ventilated room until all
the water in the dish absorb by the bricks.
 Water absorb ( bricks dry) dishes.
 Time bricks examined for efflorescence.
 Reported ‘nil’ , ‘slight’ , ‘moderate’ , ‘heavy’.
 Not more 10 %, bricks covered with thin deposit of
salts.
 Covering up 50 % - flaking.
Jul-21 CEM 50
Test on bricks
Compressive Strength Test
 For bricks without frogs.
 Soaked in water 24 hours, removed, drain for 5 minutes.
 Tested under the compression testing machine.
 Filled with mortar prior to testing.
 The composition of mortar is usually 1 : 1.5 cement / sand mix
 Fill the frogs with mortar
 Cure it under damp sacking for 24 hours.
 Transfer it to a curing tank.
 Tester after 7 days under the compressive testing machine.
 Engineering bricks strength 50 – 70 N/ mm ².

Jul-21 CEM 51
Ingredients of good bricks

Jul-21 CEM 52
Function of ingredients
1. Silica
Free silica ( sand), if added to clay is suitable proprtion makes
a brick hard and prevents it from warping and shrinking on drying.
If present in greater proportion makes a brick brittle.

2. Alumina
Is main constituent of every clay. On the addition of water clay
become plastic and can be moulded into and shape. In absence of
sand , purely clay will develop cracks due to shrinkage on drying
and burning. A good brick earth should contain about 20% of
alumina.

3.Lime
It helps to lower the fusion temperature. It helps silica to fuse at
lower temperature and thus helps to bind the particles together. It
also prevents shrinkage of raw bricks.

Jul-21 CEM 53
Harmful ingredient
1. Alkali
The alkali's lower the fuse on temperature and melts the bricks,
changes its shape or get twisted. Also these salt have hygroscopic
action. E.g. They absorb moisture present in the atmosphere and
keeps the wall damp. Once the moisture evaporates they leave
behind grey or white deposits of these salts and spoil the
appearances of a building.

2.Iron pyrites
During burning, iron pyrites due to high temperature oxidize,
decompose and disintegrate brick into pieces.
3. Organic matter
Although the presence of organic matter in a brick helps its
burning, this causes porosity in the bricks. The presence, such as
roots, dry leaves in brick should be avoided.
Jul-21 CEM 54
 Difference between clay bricks &
cement sand bricks

Clay bricks Cement bricks

Are made by Are made from

OPC, sand, water
pressing a prepared mixed together into a
sample into a mould, mould, compacting it
extracting the formed and extracting the
unit immediately and formed unit once it has
heating it in order to gained enough strength
sinter the clay. and properly cured.

Jul-21 CEM 55
 Forms of bricks

Jul-21 CEM 56
 Types of blocks

Hollow blocks Solid blocks Cellular blocks

Blocks containing cavities -Blocks containing -Blocks containing cavities
which fully penetrate no formed cavities which do not
the block fully penetrate
the block

Jul-21 CEM 57
 THANK YOU

Jul-21 CEM 58