MASONRY WORKS (BRICKS, BLOCKS & SIPOREX) QUALITY ASSURANCE MANUAL THIS PRODUCT IS THE COPYRIGHT OF QUALCON QUALCON ENGINEERING SOLUTIONS PVT LTD. 14, C-1, Shri Ganeshkrupa Society, Paramhans Nagar, Paud Road, Kothrud, Pune-411038 Email: - info@qualconsolutions.com Telephone No.91 9021923390 / 9422320284 1 Qualeon/QAM/Masonry/RO/28 Dec 2011MASONRY WORKS 1. General: There are several types of masonry units, such as clay bricks, concrete blocks, lime based bricks, burnt clay fly ash, fly ash bricks, stones ete, Therefore the choice of masonry unit becomes relevant. 1.1. Types of brieks: The following are the Indian Standards covering various bricks. a) Clay bricks: IS 1077:1992, IS 2180:1988, IS 2222:1991, IS 2691:1988, IS 3952: 1988, 186165:1992. 'b) Calcium silicate (sand lime) bricks IS 4139:1989. ©) Sand Time and Fly ash lime bricks IS 12894: 1990, 2. Bricks: Shall be hand made or machine moulded, Reference may be made to IS 2117:1991 for guide on hand made common burnt clay building bricks. For semi mechanized process reference may be made to IS 11650:1991. Bricks strength varies with state to state, ranging from 30 to 200 Kg f/sq em. 2.1: Classification of bricks: Common burnt clay bricks are classified on the basis of compressive strength as given below. Class Designation ‘Average Compressive Strengths Nisq mm Kg fisq em 35 35 350 30 30 300 25 25 250 20 20 200 175 175 175 15 1 150 125 12.5 125 10 10 100 15 78 5 5 3 50 3.5 3.5 38 IS 2180:1988 covers burnt clay bricks of higher strength 40 and above (for heavy duty) the bricks shall be free from cracks and flaws. They shall have smooth rectangular faces with sharp corners and shall be uniform in color. 2.2: Tolerance on brick dimensions shall be (4) 3% for designation 100 and above: (#) 8% for lower designations below 100. Sampling and testing shall be as per IS 5454:1978 and IS 3495:1992 respectively 2.3: ize of bricks: Bricks shall have the following dimen 2.3.1; Modular bricks a) 190 x 90 x 90mm. b) 190.x 90 x 40mm 2 Qualeon/QAM/Masonry/R0/28 Dee 20112.3.2: Non modular bricks a) 230 x 110.x 70mm b) 230.x 110 x 30mm. 2.4: Sand Lime Brieks: These bricks shall have same size as clay bricks. Bricks shall be of four classes as given below: a) Class 75. Average compressive strength 7.5 to 10.0 N/sq mm. b) Class 100, Average compressive strength 10.0 to 15.0 N/sq mm ©) Class 150. Average compressive strength 15.0 to 20.0 N/sq mm. 4) Class 200.Average compressive strength 20.0 N / sq mm and above. 2.5: Fly Ash Lime Bricks: (1S4139:1989, 12894:1990) 1 Size 230 x 150 x 80mm & 230 x 100 x 75mm, 2.5.2 Physical properties a) Average compressive strength 8 N/sq mm to 12.5 N/sq mm (as against 3.5N/sq mm for hand made clay bricks) b) Water absorption 8 ~ 12% (as against 15 - 20% for clay bricks) ©) Efflorescence: nill d) Density 1700kg/Cum 2.5.3 Approximate Mix proportions a. Fly ash 60% b. Lime 15% ¢. Gypsum / Cement 10% 4d. Quarry Dust 15% ¢, Water 10% to 15% 2.5.4 Fly Ash bricks advantages. a) Due to heavy strength, practically no breakages during transport and handling. b) Due to uniform size of bricks. Mortar quantity for joints and plaster reduces by 40 - 50 ©) Due to less water absorption, seepage of water through bricks is considerably reduced 4) Plaster of Paris / Gypsum plaster can be directly applied on these bricks. Without backing coat of plaster. ¢) These bricks do not require soaking in water for 24hrs. 3. Sampling and Testing of common burnt Clay Bricks Checking of tolerances: 20 whole bricks selected at random, arranged on an average surface, in contact with each other and in a straight line. Total length measured of assembled bricks at one streteh. Their dimensions measured as above shall be within following limits a) Modular bricks 3 Qualeon/QAM/Masonry/R0/28 Dec 2011i) Length (380 + 8 cm) ii) Width (180 + 4 em) ili) Height (180 + 4m) or (80 + 4em) b) Non modular bricks i) Length (460 + 8 cm) ii) Width (220 + 4 em) iii) Height (140 + 4 em) or (60. 4 cm) 3.2: Sampling and criteria for conformity: The sampling shall be at random and brick shall be stored in dry place. The sample size shall be as below: a) Brick class 100: lot size more than 50000 bricks, sample size 20 bricks b) Brick class 75, 50, 35 lot size more than 100000 bricks, sample size 20 bricks. c) Recommended sample sizes from trucks refer table no. 1 3.3: Tests: 3.3.1: Compressive strength: 5 bricks shall be tested. The average compressive strength shall be as per class designation. The compressive strength of the individual brick shall not be less than 20% of specified value. During testing the brick shall be placed with flat faces horizontal with the frog with mortar upside. Load shall be applied at uniform rate of 140 kgf/ sq em. 3.3.2: Water absorption: 5 bricks shall be tested. Average water absorption by brick shall not exceed 20% by weight up to class 12.5 and 15% by weight for higher classes. 3.3.3: Efflorescence: 5 bricks shall be tested. The efflorescence shall be nil to moderate. For nil to no deposit, for slight not more than 10% area of brick covered with salt and for moderate, a heavy deposit covering up to 50% of brick surface. No heavy deposit bricks are acceptable. 4. Siporex Block: This is basically light weight construction material having dry density of 550kg / Cu mtr, Also blocks of density 450kg / Cu mtr can be made. The compressive strength is 35kg / sq cm. The standard sizes are as below: a) 075 x 240 x 650mm b) 100 x 240 x 650mm ©) 125 x 240 x 630mm 4) 150 x 240 x 650mm €) 200 x 240 x 650mm £) Siporex wall panels length 3 mtr, width 600mm, thickness 075 & 100mm. 2) Siporex slabs length Imtr to 4 mtr, width 600mm, thickness 125 & 150mm. Concrete Masonry Units- Hollow and Solid Concrete Blocks Conerete blocks may be solid or hollow. The various types of blocks are concrete masonry unit IS 2185 (part 1) 1979, Hollow and Solid concrete blocks IS 2185(part 2) 1983, Hollow And Solid light weight conerete blocks IS 2185 (part 3) 1984. The blocks shall be hand 4 Qualcon/QAM/Masonry/R0/28 Dee 2011made or machine made. To avoid confusion with slabs and panels, the height of block shall not exceed either its length or six times its width. Hollow block have one or more large holes or cavities which either pass through the block (open cavity) or do not pass through the block (closed cavity) and having the solid material between 50 and 75% of total volume of the block calculated from the over all dimensions. 5.1: Nominal dimensions: The term nominal means that the dimension includes the thickness of mortar joint. Actual dimensions (length and depth only) shall be 10mm short of nominal dimensions. The same shall be as below a) Length: 400, 500 or 600mm b) Width: 50, 75, 100, 15, 200, 250 or 300mm ) Height: 200 or 100 mm 5.2: Tolerances: The variations in the length of the units shall not be more than (+) Smm and variation in height and width of units not more than (+) 3mm. face shells and webs shall increase in thickness from bottom to the top of unit. Depending upon the moulds used, the face shells and webs shall be flared and tapered or straight tapered, the former providing a wider surface for mortar. The thickness of face shell and web shall be not less than the values given in table no Sr. Nominal Face Shell | Thickness | Total Web Thickness Per Course No. | loci: Width of Web In Any 200mm Length of Wall ( (Min) 1 | _ 100 or less 25 25 2 | _100- 150 25 30 3 150 - 200 2 30 4 | Over 200 30 J 38 5.3: Classification of bloci efer table 2 5.3.1: Hollow (open & closed cavity) a) Grade A. For load bearing units, density 1500 kg/cu mtr. Average compressive strength shall be 3.5, 4.5, 5.5, 7, 7.0, 8.5, 10.0, 12.5 and 15.0 N/sq mm b) Grade B. These are also used as load bearing units and shall density between 1100 to 1500 kg / cu mtr. The minimum average compressive strength of 3.5 & 5.0 N/ sq mm. Solid concrete block Grade C. These are used as load bearing units and have density not less than 1800kg/ cu mtr, The minimum average compressive strength of 4.0 & 5.0 N/ sq mm, 5.4: Manufacture of blocks- 5.4.1 — Cement — 43 grade OPC conforming to 1S 8112or Portland slag cement conforming to IS 455, Portland pozzolana cement fly ash based conforming to IS 1484 (part 1) or any 5 Qualcon/QAM/Masonry/R0/28 Dec 2011other IS based cement when cement conforming to IS 269 or IS 8122 or IS 12269 is used, replacement of cement by fly ash conforming to IS 3812 (Part 1) may be permitted up to a limit of 25%. Ensure that blending of fly ash with cement is as intimate as possible to achieve uniformity. 5.4.2 — Aggregates shall be clean & free from deleterious material & shall conform to IS 383. 5.4.3 — Fly Ash — Fly ash conforming to IS 3812 (Part 2) may be used for part replacement of fine aggregate up to a limit of 20% 5.4.4 — Water — Water shall be free from matter harmful to concrete or reinforcement. The water shall conform to IS 456. 5.4.5 — Additives or Admixtures - The same may be added either else additives to cement during manufacture or as admixture to concrete mix. The same can be accelerating, water reducing, ait- entraining, super plasticizer, water proofing or coloring pigments etc. 5.4.6 — Mix- The concrete mix shall NOT be richer than 1 part by volume of cement to 6 parts by volume of combined aggregate before mixing. The amount of water required for ‘mix will depend to an extent on the type of machine on which blocks are produced. 5.4.7 — Mixing - Accurate batching & mixing done in a mixer until the mass is uniform in color & consistency. 5.4.8 - Placing & Compaction — The block should be compactive by vibro- compaction & finished to proper size without broken edges. Handle carefully to avoid damage. The blocks shall be protected until they are sufficiently hardened before starting curing. 5.4.9 — Curing- Hardened block shall be cured as per IS 456 or by mist or by steam. 5.4.10 — Drying — After curing blocks shall be dried for a period of 4 weeks before being used for work. The blocks shall be stacked with voids horizontal to facilitate air passage Ensure that blocks have been thoroughly dried & allowed to complete their initial drying shrinkage before supplying to the work site, 5.4.11 — Surface Texture & Finish — A variety of surface texture ranging from very fine close texture to a coarse open texture by the proper selection, grading & proportioning of aggregates at the time of manufacture. Textures by wire brushing / combing while units are still green. If intended to plaster, block shall be sufficiently rough surface to give good key to plaster. 5.5 — Physical requirements ~ 5.5.1 — General - All units free of cracks. Minor chipping during handling shall not be grounds for rejection, Units used in exposed walls shall be free of chips, cracks or other 6 Qualeon/QAM/Masonry/R0/28 Dec 2011imperfections, except that if not more than 5% of consignment contains slight cracks or small chippings not larger than 25 mm, this shall not be ground for rejection. ~ Sampling — A sample of 20 blocks shall be taken by every lot / consignment of 5000 blocks or part thereof from the same grade, size & same batch of manufacturer, 5.5.3 - Number of test - All 20 blocks checked for dimensions & visual defects. Out of 20 blocks 3 tested for density, 8 for CS, 3 for water absorption, 3 for drying shrinkage & later for moisture movement. The last 3 reserved for retest for drying shrinkage or moisture movement if needed. 5.5.4 — Dimensions — 20 full size units measured for length, width & height. Core units for minimum thickness of face shells & web. Over all dimension up to 1 mm & face shell / web up to point 0.5 mm. Length on longitudinal centre line of each face, width across top & bottom bearing at mid length & height on both faces at mid length. Face ~ shell thickness & web thickness measured at the thinnest point of each element 15 mm above mortar-bed plane. If opposite face-shells differ in thickness by less than 3 mm their ‘measurements shall be average. The report shall show average dimensions of 20 samples. 5.5.5 — Block Density — The average of 3 blocks conforming to as shown in classification of blocks. = Compressive Strength — Min. CS at 28 days being the average of 8 units & min. CS at 28 days of individual units when tested shall be as per table above. 5.5.7 — Water Absorption - Average of 3 units shall not be more than 10% by mass. 5.5.8 ~ Drying Shrinkage — Average of 3 units when unrestrained shall not exceed 0.06%. 5.5.9 — Moisture Movement — Average of 3 units shall not exceed 0.09% 5.5.10 - Independent Test ~ If the purchaser or his representative requires independent test, the sample shall be taken before or immediately after delivery at the option of the purchaser & the test shall be carried out as above. 6, Masonry Construction Materials 6.1 Cement - Complying with any Indian standards may be used. When cement conforming I$ 269 or IS 8112 or IS 12269 is used, replacement of cement by fly ash conforming to IS 3812 (Part 1) may be permitted up to the limit of 25%. However ensure that blending of fly ash with cement is as intimate as possible to achieve maximum uniformity. Recommended to use 43 grade cement and not more than 8 weeks old. 6.2. Fly ash — Conforming IS 3812 may be used for part replacement of cement. If followed, it must be mixer mixed only. 7 Qualcon/QAM/Masonry/RO/28 Dee 20116.3 Natural Sand ~ 6.3.1Grading of Sand - The particle size grading of sand for use in mortars shall be within the limits as specified in Table below: GRADING OF SAND FOR USE IN MASONRY MORTARS IS Sieve Designation Percentage Passing Ref to Method OF [See IS: 460 (part 1) By Mass Test 1978*] @ Q) @) 4.75 mm 100 IS: 2386 (part 1)-1963+ 2.36 mm 90 t0 100 118mm 7010 100 600 micron 4010 100 300 micron 51070 150 micron O10 15 * specification fr test sieves: part I Wire cloth test sieves (second revision) + Methods of est for agarcgates for concrete: Part I particle size & shape a) Asand whose grading falls outside the specified limits due to excess or deficiency of coarse or fine particles may be processed to comply with the standard by screening through a suitably sized sieve & / or blending with required quantities of suitable sizes of sand particles, Based on test results & in the light of practical experience with the use of local materials, deviation in grading of sand given in a) may be considered by the engineer-in- charge, ) The various sizes of particles of which the sand is composed shall be uniformly distributed throughout the mass. c) The required grading may often be obtained by screening &/ or by blending together either natural sands or crushed stone screenings, which are, by themselves unsuitable. 6.3.2 SAMPLING AND TESTING: a) Sampling ~ The method of sampling shall be in accordance with IS: 2430-1969*. The amount of material required for each test shall be as specified in relevant parts of IS : 2386- 1963+ b) Testing ~ Any test which the purchaser or his representative may require in connection with this standard shall be carried out in accordance with the relevant parts of IS: 2386 ~ 1963+. Unless otherwise stated in the enquiry or order, duplicate tests shall be made to all cases & the results of both tests reported. ©) If further confirmation as to the satisfactory nature of the material is required, compressive test on cement mortar cubes (1:6) may be made in accordance with IS : 2250- 1981+ using the supplied material in place of standard sand & the strength value so g Qualcon/QAM/Masonry/R0/28 Dec 2011obtained shall be compared with that of another mortar made with a sand of acceptable & comparable quality 4) Silt content not to exceed 15% by volume in 15 minutes. ¢) Fineness Modulus shalll be between 1.5 & 2.5. 4) Screen size for sieving -8 holes’ sq cm (48 holes /sq inch) 6.4 Crushed Sand: a) % passing 75 micron sieve shall not exceed 15% by volume. b) Fineness Modulus shall be between 1.4 & 2.4. ©) Screen size for sieving -8 holes/ sq cm (48 holes /sq inch) 6.5 Water: Only potable water to be used Ref IS 456. 6.6 Metal Reinforcement; Conforming IS: 432 for MS, IS: 1786 for Tor, IS: 1566 for steel fabric, IS: 412 for expanded metal Design Consideration a) Selection of Bricks : Depending upon Internal / external/below or above foundations, load / non-lad bearing, resistance to water, free standing wall etc, b) Guidelines for approximate design of non load bearing wall: Reference Annexure ~ A. ©) Selection of mortar: Mortar makes up approximately 7% of total volume of a masonry wall. There are several properties of mortar that can influence bond strength and durability ‘The most important property of mortar is bond strength. Thus it is eritical that this bond be complete, strong and durable, This bond provides resistance to tensile stress and seals against the penetration of moisture. Hence complete and intimate contact between the mortar and unit is important. In aligning the masonry tapping the unit to level will increase bond strength by 50 to 100% overhand pressure alone. Mortars should typically be weaker than the masonry unit, so that any cracks will occur in the mortar joints where they can be easily repaired. To generally conform to IS 2250, Ref is made to IS 1905 for suitability of combination of various types of mortar with grades of Bricks., for different strength required by masonry, Strength of Commonly used Cement Sand (IS 2116) Mortar for Masonry is as below: i. 14, 7.5 Nimm? 1:5, SNémm? iii,1:6, 3 Nimm? iv. 1:8, 0.7 N/mm? 4) Types of Bonds & their suitability, Refer annexure ~ B ©) Thickness of joint: Size of mortar joint, affects the ultimate compressive load capacity. A typical 10mm bed joint load capacity will probably be well over twice the value obtained when the mortar is tested as a 2" cube. Bed joint should not thicker than 9 Qualcon/QAM/Masonry/R0/28 Dec 201112mm (maximum).Same is measured as” equals to four times the actual thickness of Brick plus 3 Cm”, £) Finishing of joints: By jointing or by pointing. 2) Workmanship, chases ete: refer Annexure ~ C (for all masonry works) h) Cheeklists: i, For material, lab test and documentation sheet 2.1. ii, For masonry work sheet 2.2 For acceptance criteria for masonry work sheet 2.3 iv.For IS Code under reference sheet 2.4 Equipment & Tools: a) Tools: Line string, Plumb bob, Level Tube, Measuring tape, Spirit level, Trowel, Mallet, Spade etc b) Equipment: Tower crane (more than 5 Floors), MS Tray, Mixer (size as required), Measuring Box, ete c) Scaffolding: Internal work (metal ghodi), External work double scaffolding or equivalent, Scaffolding planks. d) Safety equipment (mandatory) Masonry Construction 9.1 Before construction a) Cleaning of slab surface including chipping of mortar ete. b) Line / layout done in whole flat with reference to reference line / by engineer. c) Electrical conduits drop in beam bottom cleaned and fish line pulled through. 4) Unloading (around column and or on beam) and stacking (max loading 300 kg/sq mtr) on slab done. ¢) Wetting / soaking of bricks or sprinkling on blocks done. £) Silt percentage checked and found within permissible li g) Sieving of sand done (if required) h) Accountability list filled -y axis and checked 9.2 During Work a) Bricks from same supplier to be used in one panel wall. b) Mortar proportion as agreed. ©) If using fly ash, mechanical mixer with weigh batcher used. 4) Slab surface made moist, preferably bonding agent or with cement slurry 1:4 (after hacking). 10 Qualeon/QAM/Masonry/R0/28 Dee 2011¢) Mark line and level on each column through out the area so that the same level will be maintained all over. 4) Do peri of each wall, along with checking of plumb or line / if beam is bulged ete. g) Difference more than +12 mm may need chiseling (if required for beams). h) Bottom PCC thickness adjusted in such a way that, the last layer touching beam bottom will haye a full brick or block. i) Level correction always in level of first layer done, In case mortar thickness is more than 25mm, the same made up by PCC. Bricks with 20mm deep frog, laid with frog-down. Bricks with 10 mm deep frog shall be either frog-up or frog-down. Bricks once laid over mortar, to be hammered with hammer to increase Bond (recommended). j) Mortar dashed on column surface (as work progresses) for bonding with RCC work (with in specified time for bonding) k) Key provided for joining old / new and cross walls as specified. 1) Hollow box type features finished from inside (bottom and sides upto 12 inches) and providing with 2 spouts. m) No chipping of slab / beam for door frame fixing, 1n) Pre checking of door frames (fitted during or after masonry) No crack / bend in frame. ii, Recommended without horn iii, Bituminous paint on all surfaces touching masonry or conerete iv, Primer / multani matti on exposed surfaces y, MS (primer applied) / GI holdfast 3nos each side fixed (min 250mm long), fixed with 2 no screws (no nails). vi, At RCC column door frame anchored (with holdfast straight / L / U type) with plumbing nails. Bottom spacer of MS (primer applied) / wooden. Notel: Fixing of Frames a) ~ Where door or window frames of timber are fixed in the openings, the fixing shall be done generally with hold-fasts of adequate size & strength securely embedded in the brickwork or in chases later filled up by cement mortar or conerete. Hold-fasts shall be fixed in the brickwork for a sufficient length & then turn up at ends into a cross joint, thus avoiding indiscriminate cutting of bricks. Iron hold-fasts shall be given a protective coat of bitumen to avoid rusting. Wood-work faces in contact with brickwork shall be treated with wood preservative to prevent attack from insects & termites. b) — Fixing of steel doors & windows shall be done in accordance with IS 1081: 1960, ©) ~ Fixing of timber doors & windows shall be done in accordance with IS 4913 : 1968 Wl Qualcon/QAM/Masonry/R0/28 Dee 20114) — The frames shall preferably be fixed simultaneously as the masonry work proceeds, as this construction will ensure proper bond without gaps between the masonry & the frames. Note2: Provision for Door and Window Frames (SP 62) Door & window frames shall be attached to the surrounc masonry either by conventional method or by 200 mm flooring nails with screwed end fixed directly into the block, after the frame has been edged into the opening at every nailing position. The number of nails depends on the dimensions of the frames. The nails shall be spaced at a ‘maximum of 400 mm apart & the first nail shall not be farther than 200 mm. from the comer. ) For frame fixing later, an opening in masonry 15mm more than door/window size. p) Door Frame may be fitted during masonry in progress or after masonry work using M 15. Door frames with masonry walls up to 450mm long, to be anchored with RCC member for stability (Recommended). q) RCC band (M 15) 75/100mm thick at point 0.9 mtr interval for 100mm wall and at 1.20 mtr interval for 150mm thick wall. 1) PCC band 75 / 100mm thick at sill level ,provided through out for 6 inch’s / 9 inch’s external brick walls (recommended to provide two numbers 8 dia bars to reduce cracks. Bars lapping length min 300mm, s) PCC band 75/100mm thick provided at parapet top. 0) Mortar to be used within 90 mins of preparation. uu) Max height of masonry construction not more than 1,0 mtr in 1 day (4””, 6” & 97) v) Lintel bearing as specified (min 6” to 9”) anchoring of lintel reinforcement with column if required, using epoxy grout \w) Mortar joints staggered max thickness 10 to 12 mm, x) Raking of all joints min depth 5 to 7mm (for plaster bonding) y) Over size metal packing or conerete wedges (300mm C/C) at concrete and masonry joint. 2) If needed last layer made up after 2-3 days using M 15 etc. 9.3 Additional points for concrete blocks masonry (solid / hollow) a) Nocut block at top b) Hollow block laid, with web bed thickness more at top(if applicable) ©) If using hollow block, at sill level provide solid block/PCC filled d) _Nosill for solid block, level difference ifany made up by PCC 12 Qualcon/QAM/Masonry/RO/28 Dec 2011©) For hollow block at door frame for holdfast provide solid block/PCC filled f) For Architrave etc, block at anchor fastener must be solid block / PCC filled 9.4 After Masonry Works a) Masonry damaged while fixing door frames b) DOC marked on wall, to monitor curing done satisfactory for 7 days ©) Cheek window location (fixed distance) and all jambs in plumb d) Bottom de shuttering of local chajja, 7 days after constructing masonry over it. 10. Inspection of Workmanship A close supervision while the work is in progress will ensure a better quality work with the materials available for use. The following shall be observed at the time of inspection: a) All loose materials, dirt and set lumps of mortar which may be lying over the surface over which brickwork is to be freshly started, shall be removed with a wire brush, b) All bricks shall be thoroughly soaked/ wetted in clean water immediately before use. c) The surface over which the brickwork is to be started shall be slightly wetted. 4) The first course itself shall be made horizontal by providing enough mortar in the bed joint to fill up any undulations in the bed course €) Plastic mortar results in thorough bedding of the brick & more complete filling of the joints which ensure greater strength. Care shall be taken to see that the required quantity of water is added to the mortar at the mixing platform itself & not over the courses. ) All the joints shall, as far as possible, be thin & the specifications mentioned in clause 7d above, in this regard shall be strictly adhered to. g) Care shall be taken to see that there is no through joints & the lap is not less than half, the width of the brick, & that all the vertical joints are properly filled with mortar. hh) The verticality of the walls & horizontality of the courses shall be checked very often with plumb bob & spirit level respectively. i) No portion of the work shall be left more than | m lower than the other. Where the masonry of one part has to be delayed the work shall be ‘raked back” suitably at an angle not exceeding 45° according to bond & not toothed. j) Where plastering is required to be done all the vertical as well as horizontal joints shall be raked to a depth of about 10 mm ( max) while the mortar is wet, & this will ensure Satisfactory adhesion between the plaster & brickwork. k) Care shall be taken to ensure that the brickwork is kept wet for seven days commencing from 24 hours after the course is laid, 13 Qualcon/QAM/Masonry/R0/28 Dec 201111. Recommendation for masonry considering Earth Quake 1, Internal walls (max. length 3.65 mtr) every 8" course & external wall every 6" course provide 2 no. 6mm at all courses. 2. The reinforcement so placed should be tide to RCC columns at both ends. 3, For long wall spans more than 3.65mtr reinforcement should be placed after fewer courses. 1.1 Miscellaneous (recommendation) a) Stacking 50 bricks long, 10 bricks height placed on edge. Width of each stack 6 to 8 bricks. Distance between two stacks min 0.8 mts. b) Expansion joint for long compound walls: recommended to provide expansion joint 25mm wide at every 30 mir / change of directions. c) Fly ash max replacement 20% in cement. Half briek wall for water tank or for long length walls, provide two bars of 6mm MS provided at every third course, 12. Treatment of Cracks across Walls — 12.1 — These cracks are more or less diagonal cracks & either follows the vertical & horizontal joints alternately or pass straight down through alternate vertical joints & the intervening bricks & mortar beds. In these cases one of the following methods may be adopted: a) If the cracks are of such nature that they are likely to encourage the penetration of rain if they are not repaired, it is necessary to cut & replace the racked bricks, b) If the cracks are wide, the two portions can be stitched by inserting bond stone or precast reinforced concrete blocks at suitable intervals. The cracks shall then be grouted. Sufficient care has to be taken in preparing the precast concrete blocks so that the patched surface will match with the surrounding surface. In repairing cracks with mortar itis important to secure satisfactory adhesion between the masonry of the existing work & the new bricks & also not to use too strong a mortar mix. Otherwise shrinkage of the new rich mortar may cause a fresh crack to develop, To promote adhesion, the brickwork shall be wetted before the mortar is filled 12.2~ Ifa number cracks of have appeared in a single wall & the cracks cross each other these cracks can not be effectively repaired. The walls in such cases have no strength. & it is advisable to dismantle the entire wall & reconstruct the same, supporting the structure above in a suitable manner. 12.3 In case the diagonal cracks have occurred in a localized place of the wall, the brickwork at the damaged place & around shall be dismantled & rebuilt. While dismantling such portions, care shall be taken to relieve the load on the wall by providing props at suitable places. The props or supports for the structure above the work under repair shall not be removed till the rebuilt masonry has attained enough strength, 4 Qualcon/QAM/Masonry/RO/28 Dec 201112.4 Surface eracks ~ Where the mortar in the joints has become damaged without dislocating the brickwork, which may be due to initial usage of poor mortar, improper filling or action of frost or fire ‘or unknown elements of nature, the joints shall be raked thoroughly to a depth of at least 20 mm & the raked joints caulked with mortar & the brickwork pointed. Care shall be taken to avoid the usage of a strong mortar for caulking purposes. The patch work shall be properly cured 13. Drywall Partition System- 13.1 Drywall partition system — ‘A GypWall™ drywall partition system is a light weight drywall system consisting of Gypsteel ULTRA™ Gl frames with Gypboard / Gyproc plasterboard screw fixed on either side with drywall screws. The key benefits of a Gypwall™ drywall partition system are a) Lightweight — 8 to 10 times lighter than comparable masonry systems b) Speed of installation — 3 to 4 times faster than comparable masonry systems ©) Aesthetic appeal ~ Seamless & crack free surfaces allowing ease of decoration with paint, tiles or wall paper 4) Excellent performance in terms of fire rating, thermal & sound insulation ©) Dry construction — Clean, dry & dust free work environment ) Flexibility in creating & dividing spaces according to your needs 13.1.1 Gypwall Classic Featuring Gypboard Plain board+ Gypsteel ULTRA metal framing systems «Light weight (starts from 19k /m? ); non load bearing © Thinner than conventional partitions (minimum 75 mm) * Fire resistance up to 60 minutes Smooth flush seamless surface on finish 13.1.2. Gypwall Robust Featuring Gyproe Duraline + Gypsteel ULTRA metal framing systems © High impact resistance ~ Severe duty ratings as per BS 5234 — part Il © Robust walls enabling heavy weight applications up to 120 kg, © Excellent sound insulation up to STC 47 with single layer boarding * Fire rating of 60 minutes for a 98 mm GypWall Robust 15 Qualcon/QAM/Masonry/R0/28 Dec 2011«Recommended for drywall partitions in heavy traffic applications like educational institutes, hospitals & industrial applications 13.1.3 Gypwall Fire Resist Featuring Gyproe Fireline board + Gypsteel ULTRA metal framing, systems. ‘Fire resistance from 1 hour to 4 hours ‘¢ Systems with glass wool / mineral wool insulation can provide STC ratings up to 60 © Can take any type of surface decoration «Recommended for drywall partitions in areas like server rooms,corridors, spandrels, industrial partitions, room to room partitions in hotels & hospitals 13.1.4 GypWall Hydro Featuring Gyproc Moisture Resistant board + Gypsteel ULTRA metal framing systems © Absorb less than 5% water by weight in total immersion test of 2 hours (BS ~ 1230, part 1) © Excellent tile backer as ceramic tiles up to 12.5 mm thick & 32kg/m? can be fixed using 3 mm thin bed ceramic adhesive Can be painted with PU, epoxy & other specialized coatings for better finish as per manufacturers recommendations © Conforms to class 1 for fire resistance (surface spread of flame — Nil) * Recommended for drywall partitions in high humid areas like bathrooms, toilets & kitchen areas 16 Qualcon/QAM/Masonry/R0/28 Dec 2011ANNEXURE-A Guidelines for approximate design of non load bearing wall: Table 1- Partition Walls — 1.1 —These are internal walls usually subjected to much smaller lateral forces. Behavior of such wall is similar to that of panel wall & these could, therefore, be designed on similar lines. However, in view of smaller lateral loads, ordinarily these could be apportioned empirically as follows a) Walls with adequate lateral restraint at both ends but not at the top : 1) The panel may be of any height, provided the length does not exceed 40 times the thickness or 2) The panel may be of any length, provided the height does not exceed 15 times the thickness (that is, it may be considered as a free standing wall): or 3) Where the length of the panel is over 40 times & less than 60 times the thickness, the height plus twice the length may not exceed 135 times the thickness; b) Walls with adequate lateral restraint at both ends at the top: 1) The panel may be of any height, provided the length does not exceed 40 times the thickness: or 2) The panel may be of any length, provided the height does not exceed 30 times the thickness: or 3) Where the length of the panel is over 40 times & less than 110 times the thickness, the length plus three times the height should not exceed 200 times the thickness & ©) When walls have adequate lateral resistant at the top but not at the ends, the panel may be of any length, provided the height does not exceed 30 times the thickness, 4d) Strength of bricks used in partition walls should not be less than 3.5 N/sqmm or the strength of masonry units used in adjoining masonry, which ever is less. Grade of mortar should not be less than M2 (2 N/sq mm). Note should not usually exceed 18 for walls built in coment mortar. The British Standard Code of Practice - 111 Specifies that the slenderness 7 Qualcon/QAM/Masonry/R0/28 Dec 2011ANNEXURE - B 1-TYPES OF BONDS: 1.1 -General - ‘The primary object of a bond is to give strength to masonry. In brickwork, the cross joints in any course shall not be nearer than a quarter of'a brick length from those in the course below it. The types of bonds generally in use, their characteristics and situations of use are described below. ~ English Bond (see fig. 1) The bricks in the facing are laid in alternate courses of headers & stretches. The header course is commenced with a quoin header followed by a queen closure & continued ssive headers, The stretcher course is formed by stretchers having a minimum ly to the with st lap of one quarter their length over the header. The bond contributes substan strength of brickwork & may be particularly suitable for carrying heavy loads. FIG. 1 ENGLISH BON! 1.3 - Double Flemish Bond (see fig. 2) The courses both in the facing & backing are formed with alternating stretcher & headers. In order to obtain the lap, which is equal to one-quarter of the length of bricks, a queen closer is introduced next to the quoin header in alternate courses, the intervening ones commencing with a stretcher, & every header will obtain a location that is central with respect to the stretcher above or below ‘The appearance on the face may be considered as more uniform than in English bond, It requires less number of facing bricks than English bond & hence may be more economical where brickwork is faced with special facing bricks & exposed to view. 18 Qualeon/QAM/Masonry/RO/28 Dec 2011FIG. 2 DOUBLE FLEMISH BOND Flemish bond & the backing in English appearance of Flemish bond with the trength over Double Flemish bond is FIG. 3 SINGLE FLEMISH BOND 19 Qualcon/QAM/Masonry/RO/28 Dec 20111,5 — Garden Wall Bond (see fig = 4 & 5) English garden wall bond consists of a header course with the necessary queen closure next to quoin header to three or sometimes even five stretcher courses running in es with overlap of half-brick between stretcher over stretcher. Flemish garden wall bond consists of one header to three or five stretchers in si throughout the length of these courses. ‘One brick thick walls are easier to construct with these bonds than with pure Flemish or English bonds & save facing bricks considerably in the case of exposed. COURSE ‘A’ COURSE ‘C’ COURSE ‘BY pReBomE FIG.4 ENGLISH GARDEN WALL BOND, 20 Qualcon/QAM/Masonry/R0/28 Dec 2011FIG. 5 FLEMISH GARDEN WALL BOND COURSE ‘C Qualcon/QAM/Masonry/R0/28 Dec 2011 2 FIG. 6 AMERICAN BOND1.7 - Stretcher Bond (see fig -7) courses & the overlap is usually half brick & bat With as In this bond all the courses are stretcher is obtained by commencing each alternate course with a hal ight variation at the quoin the overlap may be varied to % or ¥ brick & the bond is then known as ‘Raking Stretcher Bond” This is generally used in ¥ brick thick leaves of cavity walls. SLATE CLOSURE 10 JAMB. [ TTT ee PLAN OF COURSE ‘B’ PLAN OF COURSE ‘A’ I I Or ELEVATION [NOTE—Use of stretcher bond in cavity wall construction is ilusteated bere, FIG, 7 STRECTHER BOND Qualeon/QAM/Masonry/R0/28 Dec 20111,8 — Header Bond (see fig- 8) The facing of this bond has all the courses as headers only & the overlap, which is half the width of the brick, is obtained by introducing a three quarter bat in each alternate course at quoins. This bond is used for walls curved in plan for better alignment; & preferably in foundation footings of brick masonry for better transverse distribution. PLAN OF COURSE ‘B” PLAN OF COURSE ‘A’ LLLL ELEVATION FIG. 8 HEADER BOND 23 Qualcon/QAM/Masonry/R0/28 Dec 2011ANNEXURE - C 1, Workmanship L.1- Bedding of Masonry Units - Masonry units shall be laid on a full bed of mortar with frog, if any, upward such that cross-joints & wall joints are completely filled with mortar. Masonry units which are moved after initial placement shall be re-laid in fresh mortar, discarding the disturbed mortar, 1.2 Verticality & Alignment — All masonry shall be built true & plumb within the tolerances prescribed below; care shall be taken to keep the perpends properly aligned: a) Deviation in verticality in total height of any wall of a building more than one storey in height shall not exceed 12.5 mm b) Deviation from position shown on plan of any brickwork shall not exceed 12.5 mm ©) Relative displacement between load bearing walls in adjacent storey’s intended to be in vertical alignment shall not exceed 6 mm. 4) Deviation of bed-joint from horizontal in a length of 12 m shall not exceed 6 mm subject to a maximum deviation of 12 mm ©) Deviation from the specified thickness of bed joints, cross-joints & perpends shall not exceed one-fifth of the specified thickness. 2. Chases, Recesses & Holes 2.1 - Vertical chases shall not be closer than 2 m in any stretch of wall & shall not be located within 345 mm of an opening or within 230 mm of a cross wall that serves as a stiffening wall for stability. Width of a vertical chase shall not exceed thickness of wall in which it occurs, 2.2 - When unavoidable horizontal chases of width not exceeding 60 mm in a wall having slenderness ratio not exceeding 15 may be provided. These shall be located in the upper or lower middle third height of wall at a distance not less than 600 mm from a lateral support. No horizontal chase shall exceed 1 m in length & there shall not be more than 2 chases in any one wall. Horizontal chases shall have minimum mutual separation distance of 500 mm, Sum of lengths of all chases & recesses in any horizontal plane shall not exceed one- fourth the length of the wall 2.3 As far as possible chases, recesses & holes in masonry should be left (inserting sleeves, where necessary) at the time of construction of masonry so as to obviate subsequent cutting. If cutting is unavoidable, it should be done without damage to the surrounding or residual masonry. It is desirable to use such tools for cutting which depend upon rotary & not on heavy impact for cutting action 2.4—No chase, recess or hole shall be provided in half-brick load bearing wall, excepting the minimum number of holes needed for scaffolding. Electrical chasing for half Brick wall to be done after plaster only. 24 Qualcon/QAM/Masonry/R0/28 Dec 2011Table No.1 No. OF FOR CHARACTERISTICS FOR DIMENSIONAL, BRICKS SPECIFIED FOR CHARACTERSTICS ee INDIVIDUAL BRICK For the group of 20 bricks No of - A Bricks to be | Permissible defects mn No. of Bricks to be selected sample selected 2001 to tate0 20 1 40 10001 to 35 000 a a “ 35001 to 0000 50 3 80 Table No.2 Type Grade | Density of block ~ Min Av ‘Min Compressive Kem? Compressive strength of strength of units | individual units | N/mm? N/mm? | AG.5) 35 - 28 | AGS) 45 3.6 Hollow (open | A(S.5) . 35 44 &closed | A(7.0) | N* a 7.0 | 5.6 cavity) load | A(8.5) 85 | 7.0 bearing unit | A(10.0) 10.0 8.0 | A(2.5) 12.5 10.0 A(15.0) 15.0 12.0 BG.5) | Less than 1500 but 35 28 B(5.0) | not less than 1100 5.0 4.0 Solid load | C(4.0) | Not less than 1800 40 32 bearing unit | C(3.0) 5.0 40 i 25 Qualeon/QAM/Masonry/R0/28 Dec 2011Acceptance Criteria for Masonry Works __[ form no. 2.3 Ri - 28/12/2011 [Sr.No Description Recommended | Acceptance Tolerance - Tolerances _ i Plumb 1 External Walls (3 floors) 12mm 1.2 | External wall openings #12mm 13 (Door / Window) 1.4 | Internal Walls 5mm 15 | Door Jambs +5mm 1.6 | Window Jambs 25mm 2 Workmanship(Deviation) 2.1 | Horizontal bed-joint 6mm 2.2 | Vertical Joint £10mm, 23 | Joint thickness 43mm 24 | Cross wall joint 43mm 3 Room Dimensions 3.1 | Length 10mm 3.2 | Breadth 10mm 133 Diagonal +12mm 4 Lintel Level (Bottom) +10mm 5 Level: Window bottom sill! | 12mm parapet wall top. 6 Location Door/ Window, — | 15mm. (Distance from side wall) 7 Last (top) layer touching | 40 mm beam bottom, max permitted | (no gap) gap Last layer 26 Qualeon/QAM/Masonry/R0/28 Dec 2011*, Form No. 2.4 List of IS Codes Reference eal IS Code No Description 12894 4139 1077, 2222,2691, 3952, 6165 11650 2180 5454, 3495 2185 (Part 1) 2185 (Part 2) 2185 (Part 3) 311s 1725 269,455,1489,6452,6909,8112, 8041,8042,8043,12269,12600 3812 383 456 9103 2645 2250 12 1635 Sand lime bricks &efly ash lime bricks Calcium silicate (sand lime) For clay bricks Semi mechanized process for manufacture of clay bricks. clay bricks of higher strength 40 & above sampling & testing hollow & solid conerete block hollow & solid light weight conerete block autoclaved cellular aerated conerete block lime based blocks soil based blocks (Cement) (Cement) Fly ash Aggregate Concrete Admixture Water proofing agent Requirements of various mortars. Building lime Slaking of lime 27 Qualcon/QAM/Masonry/R0/28 Dec 2011