This is a companion program to Moisture Control for Masonry, and therefore will not address the important topic of moisture. This program analyzes a masonry wall from the vantage point of quality control in both design and construction. It covers ASTM standards, brick and block selection, mortar types, and a detailed discussion of movement control for masonry. The program also looks at acceptable tolerances in materials and workmanship.
2. International Union International
of Bricklayers and Masonry
Allied Craftworkers Institute
LIFELONG LEARNING
Pre-job and apprentice training
Journeyman upgrade training
Safety, scaffold, OSHA training
Craftworker
certification training
Supervisor certification
Sustainable Masonry
Certification Program
Contractor College
7. International Union International
of Bricklayers and Masonry
Allied Craftworkers Institute
BAC CONTRACTORS
IMI-TRAINED CRAFTWORKERS
8. Course Evaluations
In order to maintain high-quality learning experiences, please
access the evaluation for this course by logging into CES
Discovery and clicking on the Course Evaluation link on the
left side of the page.
22. BRICK PROPERTIES
Recommendation:
5-25 g/min/30 in 2
Not a requirement
in ASTM or MSJC
Consider high IRA
brick for cold weather
construction
Consider low IRA
brick for hot weather
construction
INITIAL RATE OF ABSORPTION (IRA)
26. MOISTURE RESISTANCE
REQUIRED by Code
Air space
Flashing
Weep holes
OPTIONAL
Air Barrier *
Mortar Dropping
Collection Device
(MDCD)
*depending on project location
53. MORTAR
ASTM C 270
Mortar Options:
- Portland Cement and Lime
- Masonry Cement
- Mortar Cement
Mortar Types: M, S, N,
and O
Mortar Quality Control
ASTM C 270 MASONRY MORTARS
54. MORTAR
M a S o N w O r K
ASTM C 270 MASONRY MORTARS
56. MORTAR
M S N O K
1:¼:3¾ 1:½:4½ 1:1:6 1:2:9 1:3:12
general ratio
cement : lime : sand
Refer to ASTM C 270 for acceptable ranges
PROPORTION RULES-OF-THUMB
69. MOVEMENT CONTROL
Temperature changes
Moisture changes
Elastic deflection
Plastic deformation
Soil movements
Crystallization
BUILDING MOVEMENTS
70. MOVEMENT CONTROL
Brick expands
Concrete block
shrinks
BUILDING MOVEMENTS
71. MOVEMENT CONTROL
Expansion Joint
or
Masonry Exp. Joint
BRICK
NOT
Control Joint nor CJ
Control Joint
BLOCK
NOT
Expansion Joint
BUILDING MOVEMENTS
72. MOVEMENT CONTROL
architectural precast shrinkage
brick (clay) expansion
calcium silicate expansion
cast stone shrinkage
concrete masonry unit shrinkage
EIFS shrinkage
stone expansion
terra cotta expansion
tile (ceramic) expansion
brick (fly ash) ?
73. MOVEMENT CONTROL
1.2 Contract documents
1.2.2 “Show all code-required items
on the project drawings including…
(h) provision for dimensional changes
resulting from elastic deformation,
creep, shrinkage, temperature, and
moisture.”
3.3 F.7 Movement Joints
“Indicate type and location of
movement joints on the project
drawings.”
DRAWING REQUIREMENTS
77. MOVEMENT CONTROL
OPENINGS < 6’, CJ
REQUIRED @ ONE SIDE
OPENINGS > 6’, CJ
REQUIRED @ BOTH
SIDES
MJ @ PILASTERS
& INSIDE CORNERS
MOVEMENT JOINT LOCATIONS
82. MOVEMENT CONTROL
OPENINGS < 6’, CJ
REQUIRED @ ONE SIDE
OPENINGS > 6’, CJ
REQUIRED @ BOTH
SIDES
MJ @ PILASTERS
& INSIDE CORNERS
ALIGN MJ W/ JAMB
OR HEADER
MOVEMENT JOINT LOCATIONS
83. OPENINGS < 6’, CJ
REQUIRED @ ONE SIDE
OPENINGS > 6’, CJ
REQUIRED @ BOTH
SIDES
MJ @ PILASTERS
& INSIDE CORNERS
ALIGN MJ W/ JAMB
OR HEADER
SHORTER WALLS MAY
REQUIRE CJ SPACING
1½ x WALL HEIGHT
MOVEMENT JOINT LOCATIONS
84. MOVEMENT CONTROL
MOVEMENT MOVEMENT MOVEMENT
JOINT FLUSH JOINTS AT END JOINT BETWEEN
WITH OPENING OF LINTEL OPENINGS
MOVEMENT JOINT LOCATIONS
107. ASTM C476-10 GROUT TYPE & PROPORTIONS
4. Grout Type and Proportions
4.1 Type
4.1.1 Fine grout Fine aggregate
4.1.2 Coarse grout Coarse and Fine aggregates
4.2 Proportions of Ingredients
4.2.1 Conventional Grout
4.2.1.1 Table 1
4.2.1.2 Specified Compressive Strength 2,000 psi at 28 days
Per astm c1019
4.2.2 Self-consolidating Grout
2,000 psi at 28 days
4.2.2.1 Specified Compressive Strength Per astm c1019
24-30 in. slump flow;
Vsi < 1
108. ASTM C476-10 GROUT TYPE & PROPORTIONS
MSJC 2008 Specification for Masonry Structures
“Grout compressive strength equals or exceeds f’m but not less than 2000 psi.”
(Article 1.4 B.2.a.3)b) and 1.4 B.2.b.3)b))
“Grout compressive strength equals or exceeds f’aac but compressive strength is
not less than 2000 psi.” (Article 1.4 B.c.3)b))
“unless otherwise required, provide grout that conforms to the requirements of
ASTM C 476, or ” (Article 2.2 A.1)
“…attains the specified compressive strength or 2000 psi, whichever is greater,
at 28 days when tested…” (for self-consolidating grout) (Article 2.2 A).2)
ASTM C 476-10 Standard Specification for Grout for Masonry
“…and shall have a minimum compressive strength of 2000 psi at 28
days.”
(Section 4.2.1.1 (Conventional grout))
…”The grout shall have a minimum compressive strength of 2000 psi at
28 days.” (Section 4.2.2.1 (Self-consolidating grout))
110. ASTM C476-10 MEASUREMENT & PRODUCTION
5. Measurement and Production
5.1 Measurement of Materials Volume to batch weight conversions
5.2 Production Methods
5.2.1 Grout Mat’ls Mixed w/ Water @ Job Site
5.2.1.1 Conventional Grout mech. Mixer, 5 minutes min.;
5.2.1.2 SCG continuous mixer per mixer
manuf’r recommendations
5.2.2 Ready-Mixed Grout
Transported to Job Site
adjust slump as necessary
5.2.2.1 Conventional Grout by remixing for at least 1 min.
5.2.2.2 SCG
add water per scg
Manuf'r recommendations
111. ASTM C1019-09
STANDARD TEST METHOD FOR
SAMPLING AND TESTING GROUT
112. ASTM C1019-09 SCOPE; SIGNIFICANCE & USE
1. Scope
1.1 This test method covers
procedures for both field and
laboratory sampling and
compression testing of grout used
in masonry construction.
3. Significance & Use
3.1 Grout used in masonry is a fluid
mixture of cementitious materials
and aggregate with a high water
content for ease of placement.
3.1.1 During construction,
grout is placed within or
between absorptive masonry
units. Excess water must be
removed from the grout
specimens in order to provide
compressive strength test
results more nearly indicative of
the grout strength in the wall.
113. ASTM C1019-09 TEST SPECIMENS
PROCEDURES
5. Test Specimens
5.1 Each grout specimen shall
have a square cross section,
3 in. or larger on the sides and
twice as high as its width.
5.2 Test at least three specimens
at each age specified.
EXAMPLE: IF SPECIMENS ARE TO BE
TESTED AT 7, 14, AND 28 DAYS, THEN
MAKE 9 SPECIMENS.
Note 4: frequency of sampling and
age of test is to be determined by
the specifier, and is usually found
in the construction documents; for
example, one set of specimens may
be specified for every 5,000 s.f. of
wall.
115. ASTM C1019-09 SCOPE
6. Grout Specimen Molds
6.1 Molds from Masonry Units
6.1.1 Select a level location where the molds
remain undisturbed for up to 48 hours.
6.1.2 The construction of the mold shall simulate
the in-situ construction. If the grout is
placed between two different types of
masonry units, both types shall be used
to construct the mold.
6.1.3 Form a space with a square cross-section,
3 in. or larger on each side and twice as high 5% tolerance on dims.
as its width, by stacking masonry units of
the same type and moisture condition as
those being used in the construction. The
surface of the unit in contact with the grout
specimen shall not have been previously
used to mold specimens. Place non-
absorbent block, cut to proper size and of
the proper thickness or quantity, at the bottom
of the space to achieve the necessary height
of specimen.
117. ASTM C1019-09 SAMPLING GROUT
7. Sampling Grout field technician aci or ncma certified, or equal
7.1 Size of Sample sample used for slump & comp. strength 1/2 ft3 min.
7.2 Procedure 2 or more portions mid-discharge,
7.2.1 Field Sampling spaced < 15 min. apart
7.2.2 Laboratory Sampling entire mixed batch of grout is sample
7.3 Place the grout sample in a non-
absorptive container, cover the top to
protect sample from the sun, wind,
and any other sources of rapid
evaporation /contamination. Remix
to ensure uniformity prior to filling
molds.
118. ASTM C1019-09 TEMPERATURE & SLUMP TEST
8. Temperature and Slump Test
8.1 Measure and record the
temperature of the grout sample in
accordance w/ ASTM C1064
8.2 Begin filling the slump cone within 5
min. of obtaining the final portion of
the sample.
8.3 For conventional grout, measure
and record the slump in accordance
w/ ASTM C143
8.4 For SCG, measure and record the
slump flow and VSI in accordance w/
ASTM C1611
119. SLUMP TEST, CONVENTIONAL GROUT
Filling Slump Cone
Slump cones are for testing grout
consistency prior to grouting.
Hold cone firmly
in position so grout
does not escape
while filling the cone.
120. SLUMP TEST, CONVENTIONAL GROUT
Filling Slump Cone
Fill the bottom 1/3
and rod 25 times
with the puddle rod.
Straight in and
Straight out… do not
1/3
stir.
121. SLUMP TEST, CONVENTIONAL GROUT
Filling Slump Cone
Fill the middle 1/3
and rod 25 times.
Penetrate bottom
1/3 only slightly.
2/3
122. SLUMP TEST, CONVENTIONAL GROUT
Filling Slump Cone
Fill the top 1/3
and rod 25 times.
Penetrate middle 3/3
1/3 only slightly.
123. SLUMP TEST, CONVENTIONAL GROUT
Remove Slump Cone
Lift the cone slowly
and straight up.
Do not twist or turn.
Grout should slump
8 to 11 inches.
124. SLUMP vs. SLUMP FLOW
Conventional Grout
ASTM C 143
8 - 11” slump
SCG
ASTM C1611
24” to 30” slump flow
VSI < 1
125. ASTM C1019-09 COMPRESSIVE TEST SPECIMEN
9. Compressive Test Specimen
9.1 Begin filling molds within 15 min. of
obtaining final portion of sample.
9.2 - 9.5 describe procedures for
conventional grout; see next slide.
For SCG, fill mold w/ grout in one
layer and do not rod.
9.6 Protect specimens from freezing
and variations in temp. Record max.
& min. temps prior to time
specimens are placed in final curing
environment.
Note 9: if storage temps are < 60ºF
or > 80ºF, resulting compressive
strengths will likely be affected.
126. ASTM C1019-09 COMPRESSIVE TEST SPECIMEN, CONVENTIONAL GROUT
1. Masonry pinwheel 2. Line face of units 3. Fill bottom layer w/ grout 4. Rod 15 times w/ tamping rod
5. Fill top layer w/ grout 6. Rod 15 times w/ tamping rod 7. Strike off top surface 8. Cover w/ absorbent cloth
9. Within 30 minutes, 10. Fill depression caused by 11. Strike off top surface 12. Cover w/ absorbent cloth;
remove cloth initial water loss do not disturb specimen
until molds are removed
13. Remove molds 24-48 hours after making specimen
127. ASTM C1019-09 COMPRESSIVE TEST SPECIMEN
9. Compressive Test Specimen
9.1 Begin filling molds within 15 min. of
obtaining final portion of sample.
9.2 - 9.5 describe procedures for
conventional grout; see next slide.
For SCG, fill mold w/ grout in one
layer and do not rod.
9.6 Protect specimens from freezing
and variations in temp. Record max.
& min. temps prior to time
specimens are placed in final curing
environment.
128. ASTM C1019-09 COMPRESSIVE TEST SPECIMEN, SCG
1. Masonry pinwheel 2. Line face of units 3. Fill to top w/ SCG
4. Strike off top surface 5. Cover w/ absorbent cloth 6. Within 30 minutes, remove cloth
7. Fill depression caused by 8. Strike off top surface 9. Cover w/ absorbent cloth;
initial water loss do not disturb specimen
until molds are removed
10. Remove molds 24-48 hours after making specimen
129. ASTM C1019-09 ALTERNATIVE METHODS
6. Grout Specimen Molds
6.2 Alternative Methods - … used
only with approval of the
specifier.
Note 7: fill compartments in
slotted corrugated cardboard
boxes specifically manufactured
to provide grout specimens.
130. Understand Grout Pours and Lifts
Often confused or used interchangeably. MSJC Definitions:
Grout Pour – The total height of masonry to be grouted prior to erection of
additional masonry. A grout pour consists of one or more grout lifts.
Grout lift – An increment of grout height within a total grout pour. A grout
pour consists of one or more grout lifts.
Maximum pour height – function of grout type (fine or coarse), minimum grout
space dimensions, use of cleanouts, conventional grout or SCG. Maximum
pour heights are established by MSJC Table 7.
Maximum lift height – default is 5’, may increase to 12’-8” under some
circumstances. SCG may be increased to pour height under some
circumstances.
131. Tip 10 – Understand Grout Pours and Lifts
1999 MSJC – 5’ lift height limitation.
2002 MSJC – demonstration panel option permitting
any construction procedures that produce proper
installation.
2005 MSJC – lift height increased to 12’-8” subject
to conditions.
2008 MSJC – Self-consolidating grout provisions
132. Understand Grout Pours and Lifts
Grout lift height –
A.) Where the following conditions are met, place grout in lifts not
exceeding 12.67 ft
1.The masonry has cured for at least 4 hours.
2. The grout slump is maintained between 10 and 11 in.
3. No intermediate reinforced bond beams are placed
between the top and the bottom of the pour height.
B.) As above but intermediate bond beam, then lift height can extend
to the bottom of the bond beam but not to exceed 12.67’.
C.) Otherwise, place grout in lifts not exceeding 5 ft.
D.) Demonstration panel option may result in increases.
E.) SCG may, under some circumstances be permitted to have the
grout lift equal the pour height.
159. STOP GROUT 1” FROM TOP OF
POUR TO CREATE SHEAR KEY
GROUT IN BOND BEAMS & REINFORCED
VERTICAL CELLS PLACED IN TOP OF WALL
AFTER WALL HAS BEEN LAID UP
VERTICAL REINFORCEMENT FOR
CLOSED-END CONCRETE MASONRY
UNITS CAN BE SET AFTER WALL HAS
BEEN LAID.
REBAR POSITIONER, WALL TIE, OPTION 1: U-BLOCK
OR OTHER DEVICE TO POSTION UNITS W/ SOLID
VERTICAL REINFORCEMENT BOTTOM AT BOND
BEAM COURSE
CELLS CONTAINING
REINFORCEMENT ARE
FILLED SOLIDLY W/ GROUT;
VERTICAL CELLS SHOULD
PROVIDE A CONTINUOUS
HORIZONTAL CAVITY FREE OF MORTAR
REINFORCEMENT DROPPINGS
PLACED IN BOND
BEAMS AS WALL IS
LAID UP
NOTE: GROUT PLACED IN
POURS & LIFTS NOT TO
EXCEED 5 FT. CONSOLIDATE
LIFTS OVER 12” USING MECH.
VIBRATION. LIFTS LESS THAN
12” MAY BE PUDDLED.
OPTION 2: STANDARD CMU W/
CROSS WEBS KNOCKED OUT
AT BOND BEAM COURSE
METAL LATH, MESH, OR WIRE SCREEN
PLACED IN MORTAR JOINTS UNDER KNOCK-
OUT BOND BEAM COURSES TO PREVENT
FILLING OF UNGROUTED CELLS
LOW LIFT GROUTING PROCEDURES
DETAIL 02.410.0131 REV. 06/30/10
160. STOP GROUT 1” FROM TOP OF
POUR TO CREATE SHEAR KEY
GROUT IN BOND BEAMS & REINFORCED
VERTICAL CELLS PLACED IN TOP OF WALL
AFTER WALL HAS BEEN LAID UP
VERTICAL REINFORCEMENT FOR
CLOSED-END CONCRETE MASONRY
UNITS CAN BE SET AFTER WALL HAS OPTION 1: U-BLOCK
BEEN LAID. UNITS W/ SOLID
BOTTOM AT BOND
REBAR POSITIONER, WALL TIE, BEAM COURSE
OR OTHER DEVICE TO POSTION
VERTICAL REINFORCEMENT CELLS CONTAINING
REINFORCEMENT ARE
HORIZONTAL FILLED SOLIDLY W/ GROUT;
REINFORCEMENT VERTICAL CELLS SHOULD
PLACED IN BOND PROVIDE A CONTINUOUS
BEAMS AS WALL IS CAVITY FREE OF MORTAR
LAID UP DROPPINGS
NOTE: GROUT LIFTS
NOT TO EXCEED 5 FT.
SEE STRUCTURAL
DWGS FOR MAX.
HEIGHT OF POUR.
MECH. CONSOLIDATE & CLEANOUT OPENINGS @ BASE OF
RECONSOLIDATE VERTICALLY REINF. CELLS, 32” O.C.
GROUT MAX. SPACING FOR SOLID GROUTED
WALLS. REMOVE MORTAR
DROPPINGS THROUGH CLEANOUTS
AND VERIFY PLACEMENT & LOCATION
OF VERTICAL REINF.; FORM OVER
OPEN’GS BEFORE PLACING GROUT
OPTION 2: STANDARD CMU W/
CROSS WEBS KNOCKED OUT
AT BOND BEAM COURSE
METAL LATH, MESH, OR WIRE SCREEN
PLACED IN MORTAR JOINTS UNDER KNOCK-
OUT BOND BEAM COURSES TO PREVENT
FILLING OF UNGROUTED CELLS
HIGH LIFT GROUTING PROCEDURES
DIAGRAM 02.410.0131 REV. 07/06/10
167. PLACE REINFORCING
AND INSPECT WALL
FOR OBSTRUCTIONS
CUT PORTION OF
FACE SHELL TO REINSERT FACE
CREATE CLEANOUT SHELL AND
MORTAR IN PLACE
BRACE CLEANOUT
AND PLACE GROUT
REMOVE
BRACING
BLOCK CLEANOUT
DIAGRAM 02.410.0111 REV. 06/12/09
168. CUT FACE SHELL
FOR CLEANOUT
GROUT &
REINFORCEMENT
WOOD BRACING
BLOCK CLEANOUT
DIAGRAM 02.410.0112 REV. 06/12/09
169. CUT WEDGE-SHAPED
PORTION OF FACE SHELL
TO CREATE CLEANOUT
MORTAR FACE SHELL
EDGES IF NECESSARY
REINSERT FACE SHELL
PIECE TO RESIST
GROUT PRESSURE
CLEANOUT
BLOCK CLEANOUT
DIAGRAM 02.410.013 REV. 06/12/09
170. 2. PLACE ACRYLIC
GROUT STOP
INTEGRALLY BRACED
AGAINST INSIDE OF
FACE SHELL
1. CUT OUT
PORTION OF FACE
SHELL
4. PLACE REBAR
& GROUT
3. HAND-TIGHTEN 5. REMOVE ACRYLIC
BRACE AND BREAK OFF
PLASTIC BRACE
BLOCK CLEANOUT
DIAGRAM 02.410.0114 REV. 06/12/09
171. Give the Contractor Some Latitude
Give the contractor some latitude in the….
Selection of Fine or Coarse Grout
Technical considerations
Grout space dimensions
Pour height limitations
Compressive strength independent of type
Fine Grout might
be better suited Coarse or Fine Grout
here here
Constructability considerations
Ease of use/Personal preference
Cost implications – material, placement
Issues related to pour height (next slide)
172. VERTICAL REINFORCEMENT
AS REQ’D
HORIZONTAL JOINT
REINFORCEMENT
GROUT AS REQ’D
DOWELS MAY BE BENT
UP TO 1” LATERALLY
PER 6” VERTICALLY
CMU SHOWN IN
LONGITUDINAL
SECTION
FOUNDATION
FOUNDATION DOWEL ALIGNMENT
DETAIL 02.010.0301 REV. 02/22/09
174. MINIMUM DISTANCE FROM ANY
PROTRUSION:
1/2” MIN. FOR COURSE GROUT
1/4” MIN. FOR FINE GROUT
REINFORCEMENT PLACEMENT TOLERANCE
DIAGRAM 02.410.0123 REV. 02/22/09
175. ±1/2” IF d ≤ 8” ±2”
±1” IF 8”< d ≤ 24”
±1¼” IF d > 24”
d
SPACING OF VERTICAL REINFORCEMENT
REINFORCEMENT PLACEMENT TOLERANCE
DIAGRAM 02.410.0122 REV. 02/24/09
176. EXTERIOR
FACE OF WALL INTERIOR
FACE OF WALL
FACE
2db MIN. 1/2” MIN.
EXTERIOR
FACE
5/8” MIN. 2db MIN.
INTERIOR
HORIZONTAL JOINT
REINFORCEMENT
W/ db DIAMETER
HORIZONTAL JOINT REINFORCEMENT TOLERANCE
DIAGRAM 02.410.0124 REV. 02/22/09
190. CONSTRUCTION TOLERANCES
L
d
I
C
L
d
L = LENGTH OF WALL WHEN L < 10’-0”
d < 1/4“
d = ALLOWABLE
VARIATION FROM
PLAN AT ANY POINT WHEN L < 20’-0”
d < 3/8“
WHEN L > 20’-0”
d < 1/2“
ALLOWABLE VARIATIONS FOR OUT-OF-LINE
191. CONSTRUCTION TOLERANCES
I
C
L
D D
H = WALL HEIGHT
D = ALLOWABLE
VARIATION FROM
PLUMB AT ANY POINT
WHEN H < 10’-0”
D < 1/4“
WHEN H < 20’-0”
D < 3/8“
H
WHEN H > 20’-0”
D < 1/2“
ALLOWABLE VARIATIONS FOR OUT-OF-PLUMB
192. CONSTRUCTION TOLERANCES
≥20’-0”
I
C
L
≤10’-0”
1/4”
1/2”
1/2”
1/4”
ALLOWABLE VARIATIONS FOR OUT-OF-LEVEL
193. THEREFORE WHEN WE BUILD,
LET US THINK THAT WE BUILD FOR EVER.
LET IT NOT BE FOR PRESENT DELIGHT,
NOR FOR PRESENT USE ALONE;
LET IT BE SUCH WORK AS
OUR DESCENDANTS WILL THANK US FOR.
AND LET US THINK
AS WE LAY STONE UPON STONE,
THAT A TIME IS TO COME
WHEN THOSE STONES WILL BE HELD SACRED
BECAUSE OUR HANDS HAVE TOUCHED THEM,
AND THAT MEN WILL SAY
AS THEY LOOK UPON THE LABOUR
AND WROUGHT SUBSTANCE OF THEM,
[my descendant]
“SEE! THIS OUR FATHERS DID FOR US.”
John Ruskin, 1849 The Seven Lamps of Architecture
194. BENEFITS OF BUILDING WITH MASONRY
Beauty
Versatility of Design
Contextual / Relatable
Ease of Construction
Structural
Fire & Impact Resistant
Durable / Low Maintenance
Economical
Sustainable
Energy Efficient
High Performance
Acoustic
Qualified Local Labor
195. International Union International
of Bricklayers and Masonry
Allied Craftworkers Institute
BAC CONTRACTORS
IMI-TRAINED CRAFTWORKERS