Constructing Durable Masonry
SCOPE
IMPORTANT
SAFETY INFORMATION
When handling and using
cement or fresh concrete, avoid
skin contact. Wear suitable
protective clothing.
Cement
and Concrete
Association of
Australia
The Association is a non-profit
organisation sponsored by the
cement industry in Australia to
provide information on the many
uses of cement and concrete.
This Guide is distributed by the
Association for that purpose.
Since the information provided
is intended for general
guidance only and in no way
replaces the services of
professional consultants on
particular projects, no legal
liability can be accepted by
the Association for its use.
JULY 1999 B2
Page 1 of 2
CONCRETE
This data sheet sets out practices to be followed when
constructing masonry to ensure the durability of the
resulting wall. For guidance on checking the plans and
specification to see that all required information is
included and that appropriate materials have been
specified see Concrete Data ‘Durable Masonry
Specification Checklist’.
INTRODUCTION
Although the process of ensuring
masonry elements are durable and don’t
suffer deterioration during their life
begins at the design and specification
stages, it is the construction phase that is
crucial to achieving the objective. This
data sheet outlines the steps that should be followed
during construction to produce durable masonry.
ORDERING MATERIALS
Orders for materials should comply with the
requirements as set out in the plans and specification.
When placing orders, ensure that the supplier attaches
any required test certificates and documentation to
confirm that the specified material has been supplied.
data
STORAGE OF MATERIALS ON SITE
Generally, materials should be ordered and supplied
so they are incorporated into the structure as soon as
possible after delivery. Long storage periods should be
avoided. Materials should be stored on site so as to
prevent deterioration or contamination. Particular
requirements for some materials include:
Cement and Lime Store in bags off the ground in a
dry environment, eg waterproof shed. Minimise air
circulation around bags. Keep different Types of
cement, eg Type GP (General purpose portland) and
Type GB (General purpose blended) in separate
stacks so they are not used interchangeably. Use on a
‘first-in/first-out’ basis.
Masonry units Masonry units should be stored on
pallets in the wrapping as delivered from the
manufacturer. When the units are taken from the pallet
they should be stacked off the ground on a clean, firm
surface.
Reinforcement Reinforcement should be stored off the
ground and supported at sufficient points along its
length to avoid bending or distorting the bars. It should
be protected from contamination by oil, paint or other
coatings that can reduce the bond.
CONCRETE
data MIXING MORTAR
■ Batch by volume Ingredients should be measured
accurately by volume. Volume batching does not
mean by ‘shovelful’ as a shovelful of cement and a
shovelful of sand (usually damp) are not equal in
volume.
■ Use only specified materials Don’t add ‘fire clay’ or
‘brickies loam’ to the mix. These reduce the bond of
the mortar.
■ Do not use additives to replace lime Lime makes
the mortar creamier and easier to use, improves
bond and minimises cracking.
■ Beware of overdosing with admixtures Chemical
admixtures have their place but must be used with
care. It is not true in this case that more is better.
Overdosing will lead to a dramatic loss of bond and
resulting poor performance of the masonry.
■ Mix in a mechanical mixer Mortar should be mixed
in a tilting drum or a ‘cement-mixer’. Hand mixing,
eg in a wheelbarrow, should be used only in special
circumstances.
■ Adding materials to mixer A small amount of
mixing water is placed in the mixer followed by the
sand, cement and lime. More water is then slowly
added to create a thick creamy mortar.
■ Mix for a sufficient period of time Each batch
should be mixed for two to three minutes to ensure a
uniform distribution of materials.
■ Use promptly Mortars should be used within half an
hour of mixing. Do not add water to mortar which
has stiffened to restore workability as this will reduce
the quality of the mortar and impair the masonry
Cement performance.
and Concrete
Association of
Australia
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helen rix d e s i g n
LAYING UNITS
Units must be laid in the specified bonding pattern
with the appropriate bedding. Solid and cored units
are laid on full bedding and hollow units on face-shell
bedding. Vertical joints in fully-bedded masonry should
be completely filled with mortar. Check the specification
for face-shell bedded masonry.
Mortar joints should be tooled to give a dense,
water-shedding surface. Joints should not be raked in
other than mild environments. Note that AS 3700 lists a
number of restrictions when raking joints, for example
stipulating that joints in hollow-unit, ungrouted masonry
must not be raked.
WALL TIES AND OTHER COMPONENTS
Wall ties and other components should be incorporated
into the construction as specified and, if appropriate, in
accordance with the manufacturer’s instructions. Ensure
that wall ties are properly bedded and fixed to
supporting members.
PROTECTION OF NEWLY-LAID MASONRY
Newly-laid masonry should be protected from rain by
covering the top of the construction with plastic
sheeting. Mortar joints should be protected from
premature drying out by wrapping the masonry in
plastic sheeting and shading the walls where possible.
Do not add water to mortar which has
stiffened to restore workability as this
will reduce the quality of the mortar
and impair the masonry performance.