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Lecture Six

Masonry Construction Patterns

Masonry Construction Terminology

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Arch: An opening made of bricks or one or more stones. Arches can be used to allow much greater opening widths than are possible with lintels. 1) Round arches: were developed by the Romans (basically a semi-circle) 2) Peaked arches: were developed in Islamic architecture, and used also in the gothic context. 3) Flat arches: made form a large stone or stones, or bricks laid obliquely, with a keystone

Lintel-a flat arch: A horizontal device used to support the wall over an opening (usually a doorway). Usually lintels are large stones that are wider than the openings.

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Vault- an extended archway (e.g.- the vaulted ceiling of a cathedral) 1) A simple extended arch is called a barrel, or wagon vault. 2) Two intersecting barrel vaults form a groin vault, which has a peak at the center.

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Column: free standing vertical support design

Pier: vertical support design inset into a wall

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Stress and Strain: 1) Stress is the resistance of the material to a load applied over a unit area (it is given in units of psi or kg.cm2) 2) Strain is the linear distortion of a material under stress (i.e. the amount that a beam shrinks when under compression). It is dimensionless. 3) Shear: shear is the tendency of layers of molecules to slip sideways in relation to one another. The ability to resist this slippage is called shear strength.

Bonding of masonry; Mortar is the term used to describe the material used between bricks, and sometimes stone. MORTAR HAS NO ADHESIVE EFFECT on the bricks (or stones), although it does bond to the bricks or stones. It gives no tensile strength to the wall. What makes masonry walls stable is gravity. What mortar is used for, is to seat the bricks against each other (i.e. to provide an even bed, and to fill in any holes or inconsistencies so that water is kept out).

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Constituents of mortar are as follows: 1) Portland cement 2) Lime 3) Sand 4) Water 5) Color dies can be added for effect 6) Also, admixtures are available to increase waterproofing, and bonding.

Thrust: When an opening is made in a masonry wall, the force of gravity from above the opening must be directed away from the opening (through an arch or lintel). When this vertical force is transferred into a horizontal force, we call it thrust. Thrust is resisted in one of the following ways: 1) Weight of the adjoining wall 2) Buttressing 3) Tie rod 4) Compression ring (in domes)

Brick

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The three basic types of brick are as follows: 1) Burned clay brick (what we usually think of when we say brick) 2) Cementitious brick of sand-lime, cement (what we generally think of as paving bricks) 3) Adobe brick (sun dried brick which is generally not used in this climate) For the purposes of this lecture, we will concentrate on the first of these types.

Burned clay brick, process of manufacture: 1) Four types of forming: a. Soft mud process: mud is poured into individual molds. This is the least accurate method for consistent quality. b. Stiff mud process: when dryish, clay is pressed into molds under high pressure. c. Repressed: bricks are dry pressed twice. It is the strongest brick with the most consistent quality.

2) The bricks are then burned dry, achieving maximum hardness and durability.

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Nomenclature of burned clay bricks Sizes: When we hear the word brick we usually think of the modular brick, which is 2x4x8. The smallest common brick is the Roman brick at 1x4x12. The largest common brick is the jumbo brick at 4x8x12. This volume is the upper limit for burned clay bricks, because large bricks are subject to distortion during the burning process.

Brick shapes: 1) Bull nose: refers to a rounded corner on a brick. Bricks with two rounded corners are double bull nose. 2) Hollow brick refers to a brick with a hole (or holes) through it in the long direction. It has almost the strength of a solid brick, but is lighter. The disadvantage is the open end. 3) Cored brick, like hollow brick had a hole or holes through it, but in the short direction, which leaves the ends closed. 4) Frogged brick has a slight depression on the flat sides (those with the greatest area), also in order to save weight.

Brick position: Non-structural veneer brick walls are common and are only 4 thick. They must be tied to some other structure. Structural masonry walls constructed of brick are at least 8 thick. Bricks are laid in different directions in the wall for different functions. The different positions have, accordingly, different names.

The most common positions for bricks in walls: 1) Stretcher: the brick sits only in one vertical layer (in modular brick, the 2x8 is exposed horizontally). 2) Header: end on, it ties the stretchers together (in modular brick, 2x4 side is exposed horizontally). 3) Bull header: header turned sideways, ties stretchers together (in a modular brick, the 4x8 side is exposed horizontally). 4) Bullstretcher: half a layer (in a modular brick, the 4x8 side is exposed horizontally). 5) Bar: a half brick used to complete a corner.

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Brick quality depends on the location of the brick in the furnace when it was burned. The basic quality categories for bricks: 1) Clinker brick: closest to the fire, these bricks are the hardest and the most durable. They are, however, the most unattractive, and are generally not used in places where the brick is to be exposed. 2) Soft brick: furthest from the fire, and the softest bricks. Soft bricks can only be used for backing (that is, in the interior of a thick wall). 3) Face brick: intermediate in distance from the fire, as well as in hardness, and appearance. They are good for all applications. Appearance of burned clay brick Color: Color in brick is not a result of dyes, but rather a result of the clay used in the composition of the brick. Since red, brown and gray are the colors of clay, some combination of these can be used in determining the color of the brick. Surface finish: a. If not treated in any way, bricks will adopt the common smooth finish. b. If, however, a texture is desired, the bricks can be combed before burning. c. Ceramic or enameled glazed finishes are also a common addition to bricks, especially in pools, hospital, etc. d. Salt glazing also exists as a faster, cheaper method of glazing brick. Mortar joints: Mortar joints can be made to various thicknesses between 1/8 and . The different common mortar joint finished: 1) Flush joint: excess mortar is scraped away with the flat of the trowel, until the

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In ceramic finish walls, mortar joints are kept to the minimum 1/8, but typical brick walls have mortar joints of or . While the mortar is still wet, it is tooled to give different appearances.

mortar is flush with the brick. 2) Raked joint: the tip of the trowel is used until the mortar is set back about from the brick. 3) Stripped joint: wood inserts are used to form a joint similar to raked joint, but flat edged. 4) Weathered joint: mortar is set back from the top brick, and slopes down to meet the bottom brick (this is an expensive procedure). 5) Concave joints: are formed with a special tool, and are like raked joints. 6) Struck joint: flat joints set far into the wall, these are only used in interior functions. 7) Combinations of the above can also be used (i.e. different horizontal and vertical joints).

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Brick Bonds: Every horizontal layer of bricks is called a course. Different methods and assemblies of brick walls have evolved, giving a different appearance to the finished wall. These assemblies are called bonds, and are named according to the arrangement of bricks in the courses.

Veneer wall bond types: 1) Stretcher bond: consists of a single layer of stretchers, each course is offset by half the length of a brick with respect to the adjoining courses. 2) Stack bond: consists of a single layer of stretchers or bull stretchers, with no offset (i.e. vertical joints are continuous for the full height of the wall).

Structural wall bond types: 1) Common bond (American bond): Offset stretchers (basically two layers of stretcher bond), tied together every sixth course by a layer of headers. 2) English bond: A course of stretchers alternates with a course of headers. 3) Flemish bond: Within each course, stretchers alternate with headers. 4) Header bond: Headers in every course. Expensive and time consuming, this is only used for effect.

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Decorative patterns: Commonly you find decorative patterns in floors, but they also exist in walls (see Curie gymnasium). Herringbone, diagonals, and basketweave are common decorative patterns. Colored bricks are also often used in decorative patterns.

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