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Thebuildingof masonry
KonradZilch, Martin Schdtz
Thestandardof workmanship is a criticalfactor mixeris employed. Mixinginstructions should tool matchesthe widthof the walland is pulled
that determines the load-carrying capacityand be attachedto the machinein a placewhere alongthe bed joint,therebydepositinga con-
serviceability of masonry, especially because, they'areclearlyvisible.Therawmaterials should stantamountof mortarontothe bed joint
in contrastto reinforcedconcrete,timbe.ror be mixeduntitthemortarhasan evenconsis- througha slit.Thismakesit possibleto applya
steel,all the importantstructuraland building tencythat is suitablefor the intendedjob. bed jointof constantthicknessup to 1Om long
sciencetasksare in thiscasefulfilledby one Premixedmortarsare becomingincreasingly acrossthe fullwidthof the wall in one opera-
singlebuildingmaterial. popularas an aid to rationalization and for tion.
Therefore,DIN 1053part 1 includesa separate ensuringconstantmortarqualityin termsof Thin-bedmortarsrequirethe useof toothed
sectiondevotedto the buildingof masonry. consistency, workability, strengthetc. trowelsor mortarrollers,whichguaranteea
The aim of this sectionis notonlyto guarantee Accordingto theformof supply,we distinguish consistentapplicationof the mortarjLlst1 mm
thatthe aforementioned tasksare fulfilled,but betweenpremixeddry modar,premixed"coarse thick.The masonryunitis frequentlymerely
alsothatthe appearanceand aestheticsof stuff"and ready'mixedmortar(includingmulti- dippedin the mortarandthenlaid.A com-
masonryconstructions complywithcertain chambersilomortar). On site,onlythe required parativelylargeamountof wateris extracted
standards, In addition, thesepracticalconsid- amountof waterneedsto be addedto pre- fromthe "green"mortarin the caseof high
erationsare intendedto resistthe undermining mixeddry moftaror multi-chamber silomoftar, absorbencymasonryunits,whichmeansthat
of qualitystandardsas a resultof the growing or the requiredamountof waterplus cementto the hardeningprocessof the mortarmay not
pressureon costsand time,as well as the premixed"coarsestuff".No aggregates,addi- be completedbecausethis requiresa
declinein standardsof trainingevidenton site. tivesor admixturesmay be mixedintopre- certainminimumamountof water.The mortar
Consequently, the parameters for carefulplan- mixedmoftars.Premixeddry mortarand pre- driesout and the resultis pooradhesion
ningand buildingof masonryensurethatthe mixed"coarsestuff"are preparedon site in a betweenmasonryunitand mortar.Thiscan
practicalrealization is as freefromflawsas mixer,but ready-mixedmortaris delivered be preventedby adequateprewettingof high
possible. readyto use in a workableconsistency(see absorbencymasonryunitsor by mixingan
In the end,rationalization measuressuch as "Mortarsfor masonry"). additiveintothe mortarto increasethe water
buildingwith large-format units,withoutmortar Differenttypesand groupsof mortarsmay only retentioncapacity.The recommendations of
or with kit-typeelementsand so on, can lead be preparedand usedtogetheron site if mis- the mortarsuppliershouldbe followedin the
to moreeconomicmasonryonly if special takesin identificationcan be ruledout.This is caseof premixedmortars.
reouirements are olacedon the standardof particularly
so in the caseof normalmortarsof Anotheradvantageof prewettingor using
workmanshio of the wall. mortargroupsll and lla becausethey lookvery water-retention additivesis that leachingof
similar. water-soluble saltsfromthe cementin the
Mortarnormallycontainscementas the bind- mortaris reducedor prevented.As the water
Mixingand using mortar on site ingagent,whichundergoes an alkalinere- evaporates, the saltscauseefflorescence on
actionin the presenceof wateror moisture. the surfaceof the masonryunitswhich,
Mixingmortar Therefore,protectskinand eyes.Uponcontact althoughharmless,is unattractive and there-
lf mortaris to be mixedon site.the cement, withthe skin,rinsewithwater,uponcontact fore mustbe removedby repeatedbrushing
admixturesand additivesmustbe storedin a withlhe eyes,consulta doctorwithoutdelay. (see"Buildingand cleaningfacingmasonry").
dry placeprotectedfromthe weather.Aggre- As mortarhardensit loseswaterand so is
gatesmustbe storedundercleanconditions subjectedto evermoresevereconditionsby
so thatthey cannotbe contaminated by salts, Using mortar the masonryunits.Therefore,everytype of
loam,organicsubstancesor largestones. Thetrowelis stillthe besttoolfor layingsmall- pretreatment and subsequenttreatmentof the
Gaugingthe quantitiesof mortaringredients and medium-format masonryunits.Thetrian- masonry,e.g. prewettingthe masonryunits,
mustbe carriedout usingscalesor suitable gulartrowelhas a favourablecentreof gravity protectingthe newlybuiltmasonryagainstrain,
containers, e.g. bucketsor gaugeboxeswith and puts lessstrainon the bricklayer's wrist strongsunlightand prematuredrying-outby
volumetricgradations,but neverwith shovels, than.thesquaretrowel.The advantageof the coveringit withplasticsheeting, or spraying
in orderto guaranteea consistentmortarmix. latteris, however,that ii is easierto lay and the new masonrywithwater,benefitsthe
Forsmallamounts,mixingis carriedout manu- spreadlargeramountsof mortarevenly. qualityof the mortarand hencethe masonry.
ally in a tub with a sandshovelor - particularly The magonryand moftarindustrieshavede- This is particularly true in the first3-4 daysafter
withthin-bedmortars- with a mixingblade velopedthe so-calledmortarsledgefor econ- l a y i n g[ 1 6 4 ] .
attachedto an electric,drill.As a rule,however, omic construction with large-format masonry
a suitablysizedelectrictilt or non-tiltdrum unitsas wellas for one-brick-thick walls.This
14
and qualitytests
Suitability
Joint
Joint
mm
Protecting masonry against moisture on the masonryand to damage(e.9.spalling Quality control of prescribed masonry (RM)
causedby the formationof saltcrystals)[54, Suitabilityand qualitytestsare not requiredfor
Masonry unitsareusuallydelivered wrappedin 164,2141. prescribedmasonrybecausethistype of
plasticsheetingon palletsand henceare pro- masonryis basedon manyyearsof experience
tectedagainstsaturationup to the time of lay- of usinga "prescribed"combination of stan-
ing.As saturatedmasonryunitsdo not develop Suitabilityand qualitytests dard masonryunitsand standardmortar.. The .
adequateadhesionto the mortarand,further- buildingcontractormustcheckthatthe details
more,increasethe energyrequiredfor drying Accordingto DIN 1053,the properties of the on the deliveryslip or the packagingof mason-
outthe primarystructure,bricksand blocks buildingmaterials mustbe verified. This ry unitsfor prescribedmasonrymatchthoseon
awaitlnglaying,as well as the unprotected requirement is fulfilledby suitabilityand quality the buildingauthoritydocumentation. Mortar
toosand sidesof individual elements suchas tests.The suitabilitytest stipulateswhetherthe mixedon sitefor prescribedmasonryrnustbe
walls,spandrelpanelsand openings,mustbe typesand quantitiesof certainraw materials checkedregularly duringconstruction against'
protectedagainstprolongedrainfallby means aresuitablefor the production of a building tableA.1 of DIN 1053part 1 (seeLable2.1,25)
or plasticsheeting.
of tarpaulins Theseshould. materialwith definedproperties,e.g. strength, or usinga suitability testto ensurethatthe mix-
be securedagainstupliftby way of battens grossdensityetc.Thistest is carriedout ing ratiois beingmaintained. Forpremixed
naileddownor by heavymaterials.In addition, beforethe actualproduction of the building mortars,the detailsof the type of mortarand
temporarydrainagemeasuresshouldbe taken materialor the buildingof the masonry.The mortargroupon the deliveryslip or packaging
beneathroofguttersif the rainwaterdownpipes qualitytest is carriedout on randomsamples mustbe comparedwiththe technicaldocu-
havenotyet beenconnectedin orderto pre- of the buildingmaterialproducedfor useon mentation, and the gradenumberand the
ventlocalsaturationof the masonry.Following the buildingsiteand simultaneously withthe supplyingworkscomparedwiththe order.
theserecommendations will ensurethatthere actualconstruction, in orderto verifythatthe Mortarsof groupllla mustundergoa com-
is no damageto the masonryin the formof, for intendedmaterialpropertieshavebeen pressivestrengthtest accordingto DIN 18555
example,shrinkagecracks,efflorescence or achieved.The qualitycontrolof masonryunits part 3 carriedout on threeprismsfromthree
reducedstrength[175]. is carriedout withinthe scopeof the manu- differentmix batchesper storey,but at least
facturer'sown qualitycontrolmeasures,and every10 m3of mortar,and be checkedagainst
thoseof outsidecentres,at regularintervals. the requirements of Dl-N1053parl 1 tableA.2.
Layingduring cold weather The requirements for this are stipulatedin the Buildings withmorethansixfullmasonry
individualstandards coveringthe different storeysrequirea qualitytestto be carriedout
Masonrymay be builtduringfrostyconditions typesof masonryunits.The manufacturer's per storey,but at leastfor every20 msof mor-
onlyif certainprotectivemeasuresare carried ownqualitycontrolduringproduction include tar, evenfor normalmortarsof groupsll, lla
out.Theseincludecoveringthe aggregatefor constantmonitoringof the productionprocess and lll as wellas for lightweight andthin-bed
the mortarwith insulatingblanketsfor the tem- to guaranteethatthe masonryunitsproduced mortars.Thistakesaecount.ofthe higher
peraturerangefromOto +5'C; coveringthe complywiththe criticalteohnicalparameters. requirements placedon the load-carrying
masonry unitswaitingto be laidwithinsulating Monitoringby approvedoutsidecentrestakes capacityof such masonryand henceon the
blanketsfor the temperaturerangefrom-5 to the formof checkingthe manufacturer's quality requiredconsistencyof the mortarproperties
0"C;heatingthe mixingwaterand the aggre- controlmeasures duringproduction and en. in the lowerstoreys.As the increasedrequire-
gateandworkingin tentsor protectiveshelters. suringthatthe personnel and equipment used mentsdo not applyto the top threestoreys,
As the temperaturedropsstillfufther,develop- meetthe requiredstandards. this extraqualitytest is unnecessary for those
mentof the mortarstrengthslowsdownand In the caseof mortars,a suitabilitytest accord- sroreys,
practicallycomesto a haltat about-10'C. ingto DIN1053part1 appendixA.5 is neces-
Wheneveipossible,masonryshouldnot be saryonly if the serviceability of the aggregate
builtat such lowtemperatures. hasto be verifiedor if admixturesand addi- Quality control of masonry according to
Frozenbuildingmaterialsmay not be usedat tivesare to be used. suitability test (EM)
'1053part2
anytemperature. Furthermore,newlybuilt Furthermore, the suitabilitytest needsto be Suitability testsaccordingto DIN
masonry, delicateelements and columnsin carriedout as a preliminary testfor premixed are required to establishthe strength classof
particular,shouldbe protectedagainstfrost mortars,includinglightweight andthin-bed masonryaccordingto suitability test.This
and precipitation by a coveringof insulating modarsonlyfor structureswith morethansix involvesallocati;rgthe masonryto a strength
blankets.If suchmeasuresare not carriedout, fullmasonrystoreys(see2.1.28). classby way of a compressivestrengthtest
no furthermasonryunitsmay be laid on The buildingcontractoris responsiblefor car- carriedout on test samplesaccordingto DIN
masonryalreadyfrozen.Sectionsof masonry ryingout on-sitequalitytestsfor mortarwithin 18554part1 and the subsequent issueof a
damagedby frostmustbe removedbefore the scopeof checkingand assessing the qua- classification Thismustbe provided
certificate.
workcontinues,On no accountuse antifreeze lityof prescribedmasonry(RM)or masonry to the buildingsitepriorto commencing con-
agentsor de-icingsaltsbecausethis can lead accordingto suitability test (EM). structionworkwithsuch masonry.The suitabil-
to efflorescence (e.9.saltdeposits)appearing itytest mustbe carriedout by an approved
Thebuildingof masonry
146
walls
Junctionswithintersecting
Butt-iointed junctions
Thebuttjointtechnique enablesthejunctions
to be simplified. In thismethodthewallsare
butt-jointed withouttakingaccountof the bond-
ing rules.Consequenily, they may be offsetlat-
erally (see'fig. 2.5.2).A tension-resistant con-
nectionis achievedby anchors(forwhicha
structural analysisis required)placedin the
bedjoints.lf the wallsare not builtsimultane-
ously,thenthe anchorsare leftprojectingand
bentasideuntilrequiredin orderto prevent
injuries (seefig.2.5.q.
Thebuttjointtechniquemay be usedonlyfor
internalwalls;externalcornersshouldalways
be formedas fullybondedjunctions.Buttjoints
arefullyfilledwithmortarin everycourseto
ensureadequatetransferof compressionand
continuity of the acousticinsulationproperties
of thewall.Theanchorsareto be designed
according to DIN1045section19.8.3in sucha
waythat 1/100of the verticalloadof the load- 2.5.4 Butt-jointedjunctionwith varioustypes of anchors
bearingwall can be transferredat eachof the
third-points of the wall height.Undersuch con-
ditions,the supportedwall can be analysedas
beingsupported on threeor foursides.The
anchorsmay be distributedoverthe heightof
the storeyto avoidan accumulation at third-
points,e.g.in all or alternate bed joints.
It is recommended thatwallssuppoftedon only
twosidesbe connectedto intersecting walls Perforatedflat bar
withnon-structural anchors.
Inthe structuralanalysisof the walls,only rec- Masonryanchor
tangularand notcompoundcross-sections may
be useddesoitethe inclusion of anchors. Mild steelto DIN 488
Thebestanchorshaveprovedto be perforated
flat barsof stalnlesssteelmeasuring300 x 22 x Wiretie
0.75mm or pairsof V4Asteelwireties (as
usedfor twin-leafwalls).
147
Thebuildingof masonry
Wall Horizontaland inclinedchasesrr Vertical chases and recesses Verticalchasesand recessesbuilt in masonrybond
thickness cut subsequently
The useof the buttjointtechniquehas several the masonry.At the very least,the arrangement To simplifystructuralanalysis,DIN 1053part 1
importantadvantagesfor on-siteoperations of chasesand recessesshouldbe checkedfor table10 specifies maximumdimensions for
and the laterbehaviourof the walls: theirstructuralimplications priorto construction. chasesand recesses.lf thesedimensions are
Plannedchasesand recessesformedwithin not exceeded,the effectof suchchasesand
'The wallscan be builtseparately without the masonrybond,or providedin the formof recesseson the load-carrying capacityof a
inconvenient toothingin oneoperation. The channelblocks,or serviceductor pre-chased wallis so minorthattheycan be ignoredwhen
omissionof toothingspeedsup operations units(see"Specialformats,specialunits"), designing the masonry(seetable2.5.5andfig.
quiteconsiderably. In addition,theflushwall shouldbe takenintoaccounton the working 2.5.6).In addition,an analysisis notnecessary
surfacesand avoidanceof shortreturns drawings.As a rule,theseare moreaccurate for verticalchasesand recessesifthe reduc-
easesthe erectionand movementof working and lesstime-consuming and costlythanchas- tion in the cross-section - per m of wall length
platformsand scaffolds. es cut subsequently. Whencuttingchases,it - is no morethan6% and the wall is not
' Theflushwall connectionmeansthatfewer mustbe ensuredthatthe intendeddimensions assumedto be supportedon threeor four
make-upunitsare requiredand thereare no are not exceeded.Chasesand recessescan sides.In thiscase,a residual wallthickness
bondingproblemsat intersections. considerablylowerthe load-carrying capacity accordingto DIN1053part1 table10 column
'The two intersecting wallscan be builtwith of a wall becausebesidesreducingthe cross- 8 and a minimumspacingaccordingto column
differentcourseheightswithoutbonding sectiontheyalsodecrease,in particular,the 9 mustbe maintained (seetable2.5.5).lf the
problems, i.e.its is easyto combinewallsof bendingstrengthof the walland alterthe dimensionsof the chasesand recessesdiffer
unitswith differentheightsand formats(but eccentricityin the remainderof the wall. fromthe valuesgivenin the tablesor fromthe
stillcomplyingwiththe "octametric" system). Verticalchasesin wallsspanningin onedirec- extrarequirement for verticalchases,they
. The buttjointtechniqueavoidsthe creationof tion onlyreducethe cross-sectional area;their mustbe takenintoaccountin the designof the
thermalbridgesat junctionsbetweeninternal influenceon the load-carrying capacityof the masonry.As the requirements of table 10
wallswithhighbulkdensityand external walls wallis henceof onlyminorlmportance. On the appearvery complicatedfor the practically
witha lowerbulk density. otherhand,verticalchasesin wallsspanningin mindeddespitethe graphicpresentation in fig.
' The use of differenttypesof masonryunitsin two directions,whoseincreasein load-carrying 2.5.6,thefollowing recommendations should
the two wallsmeansthatthe effectsof long- capacityis due to lateralrestraintand henceis be adheredto duringconstruction:
termdeformations are lesscriticalbecause relianton horizontal bendingmoments, can ' Chasesand recessesshouldbe positioned
the anchorspreservea certainverticaldefor- havea severeeffecton the horizontalsoan. well clearof heavilyloadedsectionsof
mationcapabilitywhileat the sametime pro- Therefore, theirinfluenceis takenintoaccount masonry, e.g.bearingsbeneathlintels, open-
vidinga tension-and compression-resistant whendetermining whethera wall is supported ings.Theyshouldnotbe positioned in piers
connection betweenthewalls171,211,2141. on threeor foursidesby usingonlythe resid- and chimneyjambs.
ualwallthicknessin the designof the section . The deothof a chaseor recessshouldbe as
adjacentto a verticalchase,or by assumingan smallas possible, max.30 mm,in ordernot
Chases and recesses unsupported edgeat thisposition. We also to weakenthe cross-section morethannec-
assumean unsupported edge if the residual essary,
Chasesand recessesare requiredfor all types wallthicknessis lessthan halfthe totalwall . Horizontalchasesshouldonlybe positioned
of buildingservices, e.g.heating, waterand thickness or < 115 mm. immediately belowfloor/roofsoffitsor immedi-
wastewaterpipes,electriccables,ventilation Horizontal chasesshouldbe avoidedif oossi- atelyabovefloorlevelbecausein these
ducts.Owingto theirsignificance for the stabil- ble becausetheyreducethe cross-sectional zonessuch chaseshavevery littleinfluence
ity of a wall,drawingsshowingthe sizesand area,and hencethe bendingstrength, along on the loadbearingbehaviourof the wall (sta-
positionsof chasesand recessesshouldbe theirfulllength.At the sametime,theyhavean bilityagainstbuckling).
providedat an earlystageso thatthey can be unfavourable effecton the eccentricitvin the . Walls< 175mm thickshouldnot be chasedif
takenintoaccountin the structuralanalvsisof restof the wall. at all possible.
148
I
!
L
facingmasonry
Buildingandcleaning
149
Thebuildingof masonry
2.5.7 Formingflushand
"buckethandle"
joints
2mm
150
/
Jointdesign
2.5.8 Pointing
151
Thebuildingof masonry
ffi
\kp
Preformedsealinggaskets
Jointsmay be filledwithpreformed sealing
materialpropertiesand differentloadson the
innerand outerleaves.The advicebelow
shouldbe followedwhen designingmovement
& gasketsmadefromopen-cellplastic.foam jointsin outerleavesof masonry:
impregnatedwith a specialbitumenor poly-
' Verlicalmovementjointsare requiredat the
ffi acrylate.Therefore, the gasketsremainperma-
nentlyelastic,do not crackor becomebrittle, cornersof buildingsand alsoin longwallsat
ffi
W
alkalinesolutions.
radiationand
and are resistantto ultraviolet
The preforrnedgasketis
squeezedtogetherbeforebeing inserted,and
a spacingof max.6.0 m for lightweightcon-
creteunits,max.8.0 m for calciumsilicate
units,and 1O-16m for claybrickwork. These
152
fixingsin masonry
Mechanical
differentfiguresdo not representdifferent of the trowelor rolleror sledgeshouldmatch 2.5.10 Examplesof plasticand injectionanchors
standardsbut arethe resultof the different the thicknessof the wall.Whenusinga trowel, coveredby buildingauthoritycertificates[15]
deformation propertiesof thesefacingmater- thethin-bedmortaris onlyappliedto the bed
ilil
ials.lf a facadeis takenaroundthe cornerof jointtwo or threebricksaheadof the brick
the buildingwithouta joint,the returnshould beinglaid,butwhenusinga rolleror sledge,
notbe longerthan5.0 m. In the caseof lintels rationalizationmeasuresdictatethatthe mortar
ww
overlargewindowand dooropenings,move- be appliedto thewholelengthof wall.The
mentjointsarepositioned in linewiththewin- rollercan alsobe usedto placea glassfibre
dow and doorrevealsaboveand belowthe mat betweentwo layersof thin-bedmortar
openrngs. eachapprox.1 mm thick.Thehightearing
. Horizontal movementjointsare required resistanceof the rnatincreasesthe compres-
beneathparapetsand roofoverhangs,below sivestrengthof the masonryand the adhesive
balconyfloorsand beams,belowjoistsand shearstrengthbetweengaugedbricksand Plasticwall plugs
purlins, beneathwindowsandthresholds, mortar.
and belowsupportsfor outerleaveswhen Afterthe gaugedbrick is laid,the facesand
theyare morethan6.0 m highwith an outer edgesare alignedaccuratelybeforetappingit
leaf< 115 mm thick,and whentheyare more intoplacewitha rubberhammer. Anythin-bed
than12.0m highwithan outerleaf> 115 mm mortarthat squeezesout is trimmedoff with a
thick. metalspatulaonce it hasstartedto harden.At
the sametime,anyflaws,e.g.unfilledper-
Thewidthof the jointdependson the antici- pendsor bed jointsor damagededges,are
pateddeformation of the componentsand the madegood.
deformability
of the materialto be usedto seal Fromtimeto time,aftera brick is laid it should
thejoint.Thewidthis usuallyfiveto seven be removedagainimmediately in orderto
timesthe changein lengthto be accommo- checkwhethera completebed of mortaris
datedby the joint.Jointwidthsof 15-25mm beingachievedwiththe respectivemethodof
arenormallychosenand the jointsspacedto application.
suitthiswidth.Widerjointsare difficultto seal
propeny.
Mechanicalfixings in masonry
153
Thebuildingof masonry
approvedfor fixingsin masonry(seefig. 2.5.10). geometryand the shapeof the substrate(see Anchors for autoclavedaeratedconcrete
Thereare alsospecialanchorsfor fixingther- f i g .2 . 5 . 1 1 ) . Plasticexpansionand injectionanchorswitha
mal insulationcompositesystemsand for cylindricaldrilledholeare not suitablefor auto-
anchoringwalltiesfor twin-leafmasonryand lnjectionanchors clavedaeratedconcretebecausethis material
facingmasonry.Theseanchorsystemsare in are insertedintothe wall beforeofferingup the is verysoft,is damagedby the expansion
turn basedon the plasticexpansionanchors itemto be attachedand up to now haveonly forcesand alsocannotaccommodateany
andthe injectionanchors.Finally,
thereare beenapprovedfor fixingsin hollowmasonry significantbondingforces.Therefore, special
specialwall plugsfor autoclavedaeratedcon- unrts. anchorshavebeendevelopedfor fixingsin
crete,whichpermitcomponentsto be attached Theywork by way of the bond betweenthe autoclavedaeratedconcrete.Theyare
to thisverysoftrnaterial. anchoror anchorsleeveand the substrate.The anchoredby way of conicaldrilledundercuts
bond is achievedby way of an injectedgrout virtuallywithoutany compression due to
Plasticanchors basedon rapid-hardening cementor artificial expansion,or injection,or a special?rfoflge:
can be usedfor fixingsin concreteas well as resin.However,injectionanchorsfittedin voids mentwhichallowslow expansionforcesto be
in masonryof solidand perforatedunits.They alsotransfer thetensionviathe mechanical transferred, thanksto a suitablesurfacedesign
are normallyinsertedthroughthe itemto be interlockof the injectedgroutforcedintothe and partialcompactionof the autoclavedaer-
fixedand intothe wall.The anchorsconsistof v o i d( s e ef i g .2 . 5 . 1 1 ) . ated concrete(seefig. 2.5.12).Thefixingof
a plasticsleeve,designednotto turnin the Whenusingrapid-hardening cement,the mor- componentssubjectedto heavyor dynamic
hole,and an associated screwor nail.The tar is mixedwith a prescribedamountof water loadsmay requirethe useof boltspassed
minimumdepthof anchorage is markedon beforebeingforcedintothe void by a hand- throughthe aeratedconcretewall.
the olasticsleeve.A collarat the outerend of operatedpump.The resultis thatthe void in In thiscasethewallis drilledrightthroughto
thesleeveprevents the anchorbeingpushed the masonryis moreor lessfilled.Theamount matchthe diameterof the boltand a wider
toofar intothe holeduringassembly. of mortarrequiredis minimized by using pocketformedon the rearface.The itemto be
The geometryand lengthof the screwor nail anchorssurrounded by a polyamidemesh. fixed is fittedoverthe bolt,whichpasses
are matchedto the internalgeometryand Injectionanchorsbasedon aftificialresincon- throughthe wall and is securedon the rear
lengthof the sleeveso thatthe anchoris prop- sistof a meshsleeveand a threadedbar with face,and pressedup againstthe autoclaved
erlyexpandedoncethe screwor nailis in nut and centeringring,or a metalsleevewith aeratedconcrete.Largewashersor anchor
place.However, expandingplasticanchors internalthread,plusthe artificialresinmortar. olatesare fittedto the bolton bothsidesof the
withnailsmayonlybe usedfor fixingfacades The separatecomponents,resinand hardener, wallto distributethe load
in concreteand solidmasonryunits. areforcedthrougha mixingtube and injected
Plasticanchorsmay not be usedfor pureaxial - thoroughly mixed- intothe meshsleeve.The lnstallinganchors
tension,butonlyfor inclinedtensionat an threadedbar or the sleevewith internalthread Anchorsrequirethe holeto be carefully drilled;
angleof at least10'. In solidmaterialstheten- is subsequently pushedintothe meshsleeve. lackof carewhen drillingcan leadto an over-
sionis transferredby friction.The expanded Anchoring thewallplugin theweb of a mason- sizehole,whichresultsin a rapiddecreasein
partof the anchoris pressedagainstthe side ry unitrequires the drilledholeto be carefully the pull-outstrengthof the fixing.Holesfor
of the drilledholeand henceactivatesthe fric- cleanedby brushingand compressed air in anchorsin masonrycan be drilledwith a nor-
tion.In hollowmasonryunitsthetensionis also orderto guaranteean adequatebondto trans- mal rotarydrill,a percussiondrill (rotationplus
transferredby the interlockbetweenthe anchor fer thetension. rapidpercussion action)or a hammerdrill
1U
measures
Rationalization
155
Thebuildingof masonry
2.5.14 Workinghoursguidancefigures[h/m3] be considered as loadbearing. Thegainin mortarfrom 50 l/m3for a thick joint to 5 l/msfor
floorareawhen usingmasonrywallswiththese a thinjoint.Moreover,the applicationof a con-
Conventional minimumthicknessesis aoprox.5-7o/o aom- stantbed of modarusinga modarsledgeor
- masonry paredto the commonwallthicknesses of 240- specialtrowel,and the resultinglayingof a row
2 D F/ 3 D F 365 mm. In addition,fewermasonryunitsand of masonryunits,achievesa time savingof up
/q
4.60 h/m' lessmortarare required.Furthermore, thin 1o25o/o.The bricklayers workin pairs,,one
masonryis moreflexibleand thereforeless spreading thethin-bedmortaralongthewall
4.O liableto crackthanthickermasonry, in which withthe mortarsledgeor specialtrowel,and
the structuralstressesare lower.The use of a the otherlayingrowsof masonryunitsin the
3.5 skimcoat insteadof 15-20mm "normalplaster" preparedmortarbed [75;.
can alsoachievean additional gainin floor in masonryconstruction
Furtherrationalization
areaamounting to approx.2% dependingon can be achievedby usingthevariousspecial
the sizeof the room.However,masonrywalls unitsand specialcomponentsproducedby the
2.5 with largeslenderness ratioscall for the use of masonryindustry(see"Specialformats,spe-
masonryunitswith high strengthand high cialunits").Theaimhere,in padicular, is to
2.0
grossdensity,as well as high-quality mortar integrateothermaterials- steeland concrete-
gauged elements ( M Gl l l ,M G l l l a ,D M ) .T h ea c t u abl u i l d i n o
gf requiredfor structuralreasonsintoan essen-
999 x 623 x 300 mm masonryat an optimizedcost is lessa question tiallyhomogeneous masonryconstruction,
of optimizingthe loadbearingstructurethana while reducingthe workrequiredto integrate
matterfor rationalized buildingoperations, the suchmaterials.
useof large-format masonryunitsand special
buildingmethods(e.9.prefabricated construc-
t i o n )[ 1 3 9 ,1 4 0 ] . The quantitiesof materialsand numberof
working hours required
can be determinedtheoretically but are subject
Rational laying techniques to considerable fluctuationinpractice.Organi-
The aim of rationalbricklayingis to minimize zationon the buildingsite is criticalfor this.To
the numberof operationsto be carriedout by calculate the numberof unitsrequired, it is
the bricklayer whenbuildinga wall,and at the important,for example,to knowwhetherthe
sametimeto adaptthe ergonomicsof the work unitswill be cut on sitewith a hammeror witha
to meetthe needsof the bricklayerbetter, saw.The amountof mortarrequiredis,for
The handlingof the masonryunitsthemselves example,approx.25-30o/o lowerfor masonry'
is crucialto manualbricklaying. for
Therefore, ' withoutmortarto the perpendsthanfor mason-
example, the calciumsilicateindustryhas ry with mortarto the perpends.In Germany,
developed grip aidswithgrip bar andthumb- comprehensive guidancefiguresfor working
holeespeciallyfor theirheavyblocksfor brick- hourshavebeenpublishedby the Federal
layersto be ableto handlethe blockseasily. Committeefor Performance-linked Pay.These
The bricklayerno longerhasto relyon the fric- includeancillaryworksuch as instruction, mix-:
tion betweenhisfingersand the surfaceof the ing mortar,movingscaffolds,settingout and
masonryunitto grip it. Apartfromthat,there buildingopenings, cleaningtheworkplace etc.
are also blockswith grip aids at the bottomfor Thefiguresclearlyrevealthe influences of the
whenthe bricklayerhasto workon sections sizeof the masonryunit;whetherbricklayingis
m o r e t h a n lm h i g h . carriedout by handor witha handlingdevice;
Above'acertainweight,handlingdevicesare the use of thin-bedmortarand the omissionof
usedto reducethe physicalstrainof lifting mortarto the perpends(seefig.2.5.14).The
such heavymasonryunits.At the sametime, speeding-upof operationswhen usinglarge-
productivityis improved(see"Large-format formatinsteadof small-format unitscan be
elements"). Furtherrationalization measuresfor attributedto the sizeof the unitsbut alsothe
bricklayingare the useof masonrywithoutmor- techniqueof layingrowsof unitsin thin-bed
tar to the perpends(see"Layingwithoutmortar modar.The economicadvantagegrowswith
to the perpends"), the useof thin-bedmasonry the manufacturing accuracyof the masonry
and the omissionof bondedintersections unitsbecauseas deviationsdiminishso the
betweenwalls(see"Butt-jointed junctions"). mortarbed can be reducedto a minimum:sav-
Buildingwallswithoutmortarto the perpends ings in time and materialsarethe result.At the
involvesusingmasonryunitswith an integral sametime,the wall becomesmorehomoge-
tongueand groovesystem,whichcan then be neous- withallthe advantages thisimpliesin
interlocked withoutusingmortar.Tiltedbricks termsof structure and buildingscience.
areavoidedby guidingeachtongueand
groovetogether, whichhelpsproducea.plane Organizing thebuitding site andbtuitding
wall surface.The construction of masonrywith operations
conventional 10-12mm perpendsand bed Rationalconstruction of masonryalsomeans
jointsmeansthat 55% of the bricklayer's time is carefulplanningof siteand operationsin order
spentwiththe mortar.The use of the thin-bed to avoidframeworkconditionsthat makeit
techniquein conjunction withtongueand unnecessarily Thisincludesthe right
difficult.
groovemasonryunitscutsthe consumption of use of personnel;choiceof materials; timely
156
I
measures
Rationalization
2.5.15 Installation
drawingsfor modularmasonry
Gable wall
6029+ 6029+
o'-l
6 s z t o+
t
yY $N
(,O
-13710+ o
2982+
.* 26T0 +
= ^ - ^ - + q9J 2
_ 7595
6 1 5+
^-^-
-
---- 3300 1200| 3300 I N
3900 3900 |
-- 7800 |
2.5.16 Prefabricatedsyslemwalls
missible weight- includinglevelsof moisture bricklayerdespitethe fact that improvedpro- bondingbecausethe lowernumberof per-
commonon site- for masonryunitswhen lay- ductivityis expectedfroma smallernumberof pends(andfrequently the useof perpends
ing by hand,Themaximum weightlimitsare bricklayers. Theuseof a handlingdevicein a withoutmortar)meansfeweropporiunities for
mandatoryand are stipulatedin an information two-manteamonly contributes to moreratronal compensation alongthe lengthof the wall.This
sheetpublishedby the Bau-Berufsgenossen- masonryconstruction whenthe perpends limitsthe load-carryingcapacityof the mason-
schaften(Building Employers' LiabilityInsur- makeuse of the tongueand groovesystem ry.
anceAssociations) [132],and are basedon withoutmodar(becauseseveralunitsare Consequently, large-formatunitsmustbe di-
extensiveergonomicstudies.The informa,tion grippedsimultaneously), whentheteamis fully videdwith a bolsterchiselor a mason'sham-
sheetdistinguishes betweenthe one-handand familiarwiththis systemand eachother,and meror betterstill- especially
for thin-bed
the two-handlift. whena continuoustransportchainfrompro- masonry- by accuratesawing.Handsawswith
The one-handliftmeansthatthe masonryunit ductionto placementis guaranteed. Therefore, a hardenedblade,diamondcuttingdiscs,
can be pickedup withone handand laidwith- the groupsof masonryunitsshouldbe aligned bandsawsor chainsawsmay be used.Clean
outunnecessary physicalstrain.Themaximum in rowswiththe tongueand grooveend faces edgescan be producedwiththe aid of guides
permissible weightof a unltis 7.5 kg for a grip interlocking so thatthey can be readilylifted and templates.Cutiingdiscsgenerallylast
widthof up to 70 mm, and 6.0 kg for a grip intoplaceby the handlingdevice.Thefastest longerthan bandsawsor chainsaws.
w i d t ho f u p t o 1 1 5m m . workingtimesareachievedwhenthe groupsof
Thetwo-handlift meansthatthe masonryunit masonryunitsare stackedbetweenthe han-
exceedsthe maximumvaluesfor the one-hand dlingdeviceandthe bricklayer. Modular
However, masonry
it
lift.The maximumweightof a unitis 25 kg. shouldbe notedthat a concentratedThe ideaof modularmasonrywas developed
arrange-
Suchunitsmustbe providedwithgripaidsor by the calciumsilicateand autoclavedaerated
mentof masonryunitsand handlingdevice
be designedin sucha way thattheycan be placesa heavyloadon the floorwhichmay
concreteindustries. The benefitthat modular
grippedin bothhandsusingsuitabletoolsand masonrybringsto rationalization
needto be carriedby temporaryadditional is thatthe
laidmanually, Heavyunitsshouldbe liftedand large-format
supportsbeneaththe floor.Adequatecircula- masonryunitsfor eachwallare
laidby meansof a handlingdevice. deliveredto siteas factory-made
tion zonesare necessaryin orderto be ableto wall "kits",
movethe handlingdevicefromplaceto place.
includingall make-upand complementary
Masonryunit handlingdevices units,togetherwith computer-produced
This is helpedby usingbutt-jointed wall inter- instal-
Theuseof liftingequipment or handling lationdrawingsfor a fixedprice(see2.5.15).
sections,whichavoidthe needfor projecting
devicesis necessaryfor masonryunitformats ln addition,the manufacturer
rackingor toothedreturns,so that crosswalls of the masonry
largerthan16 DFfor 240mm thickwallsand can be builtat a laterdate. unitsprovidesthethin-bedmortar,handling
10 DFfor 365 mm thickwallsor for masonry devicesand accessories.
unitsweighingmorethan25 kg.Travelling Thecuttingof large-formatmasonryunits Thedesignof thewalls(dimensions, layout
mini-cranes with a load-carryingcapacityof up The productionof propermasonrybonds,as and sizesof openings)mustbe coordinated
to 300 kg situatedon the respectivefloorare well as the needto constructgivenwall and withthe buildingsystemor the large-format
increasingly beingemployedfor thiswork. columnsizes,makesit necessary to divide, unitsin orderto minimize the numberof precut
Depending on the sizeof the units,up to five cut and bevellarge-format units.Whilesmall- make-upand complementary unitsand hence
large-format unitscan be grippedand laidside formatunitscan be cut with a brickor scutch the cost of materials.Flatpanelsof masonry
by sidein one lift,i.e.approx.1 m2of wallarea hammer, thisis nota suitablemethodfor large- withoutinterruptionsin cellularconstruction are
can be producedin two lifts.Handlingdevices formatunitsbecauseit wouldcreatetoo much advantageous.
are normallyusedin conjunctionwiththe two- unnecessary wastage.Moreover,cuttingwith a The installation drawingsand instructions sim-
manteamsdescribedabove.Theyconsider- hammeror similartoolis inaccurate. In mason- plifyand acceleratethe erectionof masonry
ablyrelievethe physicalstrainon the individual ry of large-formatunitsthis leadsto incorrect unitsdeliveredas kits.This leadsto a
158
Rationalization
measures
159