Technical Manual Whole 09 - BRICK

Bricks & Pavers Technical Manual
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ADV05000 08/04

Contents 1 of 2
1.0 Bricks
1.1 Brick Properties
1.101 Brick Dimensions 1.102 Brick Strength 1.103 Water Absorption 1.104 Durability 1.105 Moisture Expansion 1.105 Efflorescence 1.105 Pitting due to Lime
1.2 Brick Masonry Design

1.201 Robustness 1.205 Masonry Strength 1.206 Durability of Masonry 1.208 Brick Ties 1.209 Movement in Masonry Walls 1.211 Thermal Properties 1.213 Masonry Design for Fire Resistance 1.214 Masonry Design for Structural Adequacy FRL 1.222 Masonry Design for Integrity FRL 1.222 Masonry Design for Insulation FRL 1.222 Effect of Recesses for Services on FRLs 1.223 Effect of Chases on Fire Rated Masonry 1.224 Options for Increasing FRLs 1.225 Acoustic Performance Rating 1.227 Weighted Sound Reduction Index (Rw) 1.227 Impact Sound Resistance 1.227 BCA Deemed to Satisfy Walls 1.230 Solid v Cavity Walls 1.230 Brick Walls with Render 1.230 Brick Walls with Plasterboard 1.231 Points to Consider When Designing Walls for Acoustic Performance 1.231 Acoustic Performance On-Site 1.232 Perimeter Acoustical Sealing 1.232 Doors 1.233 Lightweight Panels Above Doors 1.233 Air Paths Through Gaps, Cracks or Holes 1.233 Appliances 1.233 Electrical Outlets & Service Pipes
1.3 Brick Masonry Construction

1.301 Mortar 1.304 Joint Types 1.305 Joint Sizes 1.305 Weepholes 1.306 Brick Estimator 1.307 Brick Bonds 1.310 Brick Coursing Height 1.311 Brick Gauge 1.313 Blending 1.313 Brick Storage 1.314 Laying Practices 1.315 Control Joints 1.315 Damp Courses and Flashing 1.316 Cleaning of Clay Masonry
1.4 Property Tables
ADV05004 (1/2) 10/08

Contents 2 of 2
2.0 Pavers
2.1 Paver Properties
2.101 Paver Dimensions 2.102 Paving Strength 2.103 Durability 2.103 Slip Resistance 2.104 Abrasion Resistance 2.104 Moisture Expansion 2.104 Efflorescence 2.105 Pitting due to Lime 2.105 Cold Water Absorption
2.2 Pavement Design

2.201 Pavement Types 2.203 Description of Layers & Basic Engineering Design Requirements 2.203 Subgrade 2.204 Base Course 2.205 Bedding Course 2.206 Surface Course 2.207 Edge Restraints 2.209 Drainage 2.210 Paver Laying Patterns 2.212 Joints Between Pavers 2.213 Tolerance on Course Levels 2.213 Crossfalls 2.214 Steep Gradients
2.3 Pavement Construction

2.301 Paver Estimator 2.301 Subgrade Preparation 2.302 Base course Preparation for Flexible Pavements 2.302 Edge Restraints for Flexible Pavements 2.303 Bedding Course for Flexible Pavements 2.305 Paver Storage 2.305 Blending 2.306 Laying Practices 2.311 Sand Filled Joints 2.311 Mortar Filled Joints 2.311 Compaction 2.312 Trafficking After Construction 2.312 Cleaning
2.4 Property Tables
3.0 Face Brick Range 4.0 Engineered Utility Brick Range

Product Data Sheets
5.0 Paver Range 6.0 Projects In View 7.0 Reference Material

CHIPexpress Homestyle Brochures
ADV05004 (2/2) 10/08
1. Bricks
Bricks
1.1 Brick Properties
Section 1.1 Brick Properties
1.101
Section 1.1 relates to the properties of bricks made to meet the requirements of Australian Standard AS4455 Part 1 Masonry Units. This information is provided as a guide only to the properties of interest to a masonry designer or builder.
Brick Dimensions
The work size of a standard brick is: 76 mm high x 230 mm long x 110 mm wide. Some bricks are made with different work sizes. For example brick heights of 119 mm and 162 mm to match 1.5 and 2 standard size brick heights, including mortar joint, respectively. 50 mm and 90 mm high bricks, 90 mm wide bricks and 290 mm long bricks are made for different structural and aesthetic effect. Larger bricks are often used for more economical laying and as a design feature either on their own or combined with smaller bricks. In cyclonic areas larger (140 mm wide x 90 mm high x 290 mm long) hollow bricks are used to allow for reinforcement and grouting in the wall. Wider (150 mm wide) bricks can also be used in walls requiring lower sound transmission, higher fire resistance levels and higher load bearing capacity depending on the specific brick properties. Clay brick sizes may vary after they are fired but size variation between units averages out when blended properly during laying. Brick dimensions are measured by dry stacking 20 units, measuring the total length, width and height and comparing that measurement to 20 times the work size. Bricks are classified according to how much 20 bricks together deviate from 20 times the work size. For standard bricks, Dimensional Category DW1 means the height and width will differ by less than plus or minus 50 mm from 20 times the work size, and the length will differ less than plus or minus 90 mm. For standard bricks, Dimensional Category DW2 means the height and width will differ by less than plus or minus 40 mm from 20 times the work size, and the length will differ less than plus or minus 60 mm. Dimensional Category, DW0 means there are no requirements. This is usually reserved for non-standard shaped bricks and bricks that have been rumbled or otherwise distorted during the manufacturing process for aesthetic reasons.
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Brick Strength
Brick strength is defined as resistance to load per unit area and is expressed in mega Pascals (MPa).
Characteristic Unconfined Compressive Strength (fuc)

The characteristic unconfined compressive strength is used by engineers in the design of masonry to calculate the strength of a wall. Bricks in any one batch have a range of strengths that would usually follow a normal distribution. In a wall the different strength bricks contribute to the strength of the whole and the weakest brick does not determine the strength of the wall. For safety, engineering practice has been to use characteristic unconfined compressive strength. This is the strength 95% of the bricks will exceed and is typically 0.86 times the lowest unconfined compressive strength found when measuring the compressive strengths of 10 samples. Boral bricks usually have characteristic unconfined compressive strengths in the range 15 to 35 MPa.
Unconfined Compressive Strength

The unconfined compressive strength is a calculated number based on the compressive strength. To measure the compressive strength of a brick, steel platens are used above and below. This constrains the surface and where all other factors are equal, a shorter brick will have a higher compressive strength than a taller brick. To remove this test effect, the compressive strength is multiplied by a factor, which varies with the height of the brick. The resulting number is called the unconfined compressive strength and reflects the performance of the brick in a wall. Theoretically, bricks which are identical except for their height should produce the same unconfined compressive strength. This figure is not now used in masonry design, but is used to calculate Characteristic Unconfined Compressive Strength.
Compressive Strength of Bricks

Brick strength is measured according to AS4456.4 Determining Compressive Strength of Masonry Units. Individually crushing 10 bricks gives the compressive strength of each brick and the mean compressive strength of the lot. These figures are not used in masonry design, but are used to calculate Unconfined Compressive Strength.
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Water Absorption
Cold Water Absorption
The amount of water that a brick can absorb is measured by the cold water absorption test. There is no distinct relationship between water absorption and the water-tightness of walls. The results of water absorption tests are used by the brick manufacturer for quality assurance.
Initial Rate of Absorption

The initial rate of absorption (IRA) is the amount of water absorbed in one minute through the bed face of the brick. It is a measure of the bricks suction and can be used as a factor in the design of mortars that will bond strongly with units. As mortars other than the deemed to comply mortars are rarely used, the impact of the IRA is primarily on the bricklayer. Bricklayers, through practical experience, adjust the mortar, the height of a wall built in a day and the length of time before ironing the joints, according to the suction. The bond between the masonry unit and mortar is largely influenced by the capacity of the brick to absorb water and the ability of the mortar to retain the water that is needed for the proper hydration of cement. If the brick sucks the water too quickly from the mortar, the next course may not be properly bedded. If the mortar retains too much water, the units tend to float on the mortar bed, making it difficult to lay plumb walls at a reasonable rate. In either case there will be poor bond. The optimum value of IRA is considered to be between 0.5 and 1.5 kg/m2/min. However, IRAs can exceed these limits. The mortars water retentivity should be matched to the brick type where good bond strength is critical.
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Durability
Salt attack is the most common durability problem affecting bricks. In the form of a solution, salt can be absorbed into masonry. As the water evaporates, the salt is drawn towards the outside face. The evaporating water leaves the solution super-saturated so salt crystals begin to form. The salt crystals grow in the pores just below the surface and depending on the texture of the brick, the amount of salt, the rate of drying and the temperature, the salt may fill the pores, exerting very high pressures on the matrix. The energy in the constrained salt crystal increases and if sufficient pops a piece of the outer surface off and salt attack has begun. Bricks are assessed and classed into three grades according to AS/NZS4456.10 Resistance to Salt Attack. In summary the three grades of brick that can be used are as follows: Protected Grade (PRO) Suitable for use in elements above the damp-proof course in non-marine exterior environments. Elements above the damp-proof course in all exterior environments, with a waterproof coating, properly flashed junctions with other building elements and a top covering (roof or coping) protecting the masonry. General Purpose Grade (GP) Suitable for use in an external wall, excluding walls in severe marine environments or in contact with aggressive soils and environments (see AS3700 Appendix E). General purpose grade bricks can also be used in PRO applications. Exposure Grade (EXP) Suitable for use in external walls exposed to severe marine environments, i.e. up to one kilometre from a surf coast or up to 100 metres from a non-surf coast or in contact with aggressive soils and environments. The distances are specified from mean high water mark. Exposure grade bricks can also be used in PRO and GP applications. Boral bricks are classified as either EXP or GP.
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Moisture Expansion
Clay products expand over time as they absorb water into their structure. This is well known and documented and must be consider when designing brickwork. The expansion is not uniform (it is logarithmic) over time. In the first six months one quarter of the expansion occurs, one half in the first two years and three quarters in the first 5 years. The Characteristic Expansion is estimated from an accelerated test and expressed as a coefficient of expansion (em) that for Boral bricks is usually between 0.8 and 1.2 mm/m/15 years.
Efflorescence
Bricks may contain soluble salts that come to the surface when the brick dries. The source of these soluble salts is the raw materials used in the brick production process. Brick efflorescence should not be confused with the efflorescence that is seen on masonry walls after construction. This form of efflorescence is caused mainly from the raw materials and water used in the wall construction process (eg. Mortar). Brick efflorescence is usually white but there is a special form of efflorescence (known as vanadium staining) that is coloured yellow, green or reddish-brown and is therefore particularly visible on light coloured bricks. All efflorescence is more or less visible depending on the colour and surface texture of the brick. Boral bricks have a nil to slight efflorescence.
Pitting due to Lime

If brickmaking raw materials contain particles of calcium carbonate, these will be converted into quicklime in the kiln. Water subsequently combines with the quicklime to form hydrated lime and in the process expands. If lime particles are sufficiently large and sufficiently near the surface they pop off a piece of the brick, leaving a generally circular pit. Boral Bricks rarely show lime pitting.
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1.2 Brick Masonry Design
Section 1.2. Brick Masonry Design
1.201
The following design information is based on Australian Standard AS3700: 2001 Masonry Structures. Reference to Clauses and Formulae are those used in AS3700. This information is provided as a guide only to the processes involved in designing masonry. All masonry should be designed by a suitably qualified structural engineer.
Robustness
AS3700, Clause 4.6.1 requires walls to have an adequate degree of Robustness. Robustness is a minimum design requirement, and may be overridden by fire, wind, snow, earthquake or live and dead load requirements. In robustness calculations (AS3700 Clause 4.6.2), there are height, length, and panel action formulae. By reworking the standard formulae and inserting known data, it is possible to determine whether a chosen design and Boral brick will provide adequate robustness, as in the tables below and the charts on pages 1.202 to 1.204.
Table 1. Maximum Height of Isolated Piers
Pier Thickness (mm) 230 x 230 350 x 350 Maximum Height (m) 3.105 4.725
Table 2. Maximum Height of Walls with Free Ends

Maximum Wall Height (m) Wall Thickness (mm) 90 110 150 230 No Lateral Support at Top 0.54 0.66 0.90 1.38 Lateral Support at Top 2.43 2.97 4.05 6.21 Concrete Slab on Top 3.24 3.96 5.40 8.28
Table 3. Maximum Wall Length where One or Both Ends are Laterally Restrained
Maximum Wall Length (m) Wall Thickness (mm) 90 110 150 230 Lateral Support One End 1.08 1.32 1.80 2.76 Lateral Support Both Ends 3.24 3.96 5.40 8.28
In the situation depicted in Table 3 above, height is not limited although length is. This typically applies to lift shafts and stairwells. Control joints and openings greater than one fifth of the wall height are treated as free ends unless specific measures are taken to provide adequate lateral support. Where wall lengths exceed those in Table 3 above, AS 3700 Equation 4.6.2 (4) must be used to determine the maximum height for a wall of the required length. Should the initial choice of product not provide a suitable solution, then a thicker Boral brick or increased masonry width or extra restraints should be evaluated. t
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Robustness (continued)
How to Use the Boral Robustness Graphs
These charts determine the minimum brick thickness for a known wall height, length and restraint criteria.
Laterally supported one end and top laterally supported by other than concrete slab
8 7 6 5 4 3 2 1 0 1 2 3 4 5
1. Select the graph for the chosen wall restraint

F
(support) criteria. In this example there is support on one side and the top is supported by other
230mm
than a concrete slab. Typically this would be a wall supporting roof frames, joined into another
(m)
HEIGHT
WALL
150mm 110x110mm 90x90mm 110mm 90mm
wall at one end and with a door at the other end. 2. Plot the intersection of the design Wall Height and the Wall Length on the graph. (For this
6
(m)
example 3 m height x 5 m length). 3. The lines ABOVE the intersection point indicate wall thickness that are acceptable. In this example, the intersection point is just below the line for 110 mm bricks. Therefore a single leaf of 110 mm bricks would be suitable and the most economical.
WAL L
L ENGTH
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R
Robustness Limits
S
Laterally supported both ends and top laterally supported by a concrete slab
8 7 6
Laterally supported both ends and top laterally supported by other than concrete slab
150mm 110x110mm 8 7
150mm
(m)
90x90mm 5 4 3 2 1 0 1 2 3 4 5
(m)
(m)
6 5 4 3 2 1
110x110mm 90x90mm 110mm 90mm
H E IG H T
90mm
WA LL
WA LL
H E IG H T
110mm
5
(m)
WAL L
L ENGTH
WALL
LENGTH
Laterally supported both ends and top unsupported

8 7 6 5 4 3 2 1 0 1 2 3 4 5
F R R
Laterally supported one end and top unsupported

8 7 6 5 4 3 2 1 0 1 2 3 4 5
F R F
(m)
H E IGH T
WAL L
110x110mm 90x90mm 110mm 90mm
WAL L
150mm
H E IGH T
(m)
230mm 150mm 110x110mm 90x90mm 110mm 90mm 6

(m)
6
(m)
WAL L
L ENGTH
WALL
LENGTH
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S
Robustness Limits
R
Laterally supported one end and top laterally supported R by other than a concrete slab
8 7 6 5 4 3 2 1 0 1 2 3 4 5
(m)
Laterally supported one end and top laterally supported by a concrete slab
8 230mm
(m)
7 6 5 4 3 2 1 150mm 110x110mm 90x90mm 110mm 90mm
H E IG H T
(m)
WA LL
WA LL
150mm 110x110mm 90x90mm 110mm 90mm
H E IG H T
5
(m)
WAL L
L ENGTH
WALL
LENGTH
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Masonry Strength
Masonry Strength is defined as resistance to load per unit area. It must be remembered that thicker masonry will support more load than thinner masonry of the same strength.
Characteristic Compressive Strength of Masonry fm

fm = km kh fuc km is a mortar strength factor and kh is a factor for the amount of mortar joints. km is 1.4 for M3 mortar and 1.5 for the stronger M4 mortar (see AS 3700 Table 3.1 for a full list of factors). kh is 1 for 76 mm high units with 10 mm mortar beds and is 1.24 for 162 mm high bricks with 10 mm mortar beds (see AS 3700 Table 3.2 to derive factors for other unit and joint heights). In other words, a wall of double height bricks is more than 20% stronger than a wall of 76 mm high bricks of the same fuc. fuc is the characteristic unconfined compressive strength of bricks.
Characteristic Flexural Tensile Strength of Masonry fmt

In flexing, the top of the arc is in tension and the bottom of the arc is in compression. Masonry is good in compression but poor in tension. Flexural strength depends on the mortar/brick bond and for design purposes is generally taken to be zero. Using up to 0.2 MPa is permitted when designing for transient loads such as wind, earthquake, etc. Higher bending forces may be used for design but these require site testing to verify construction meets the stated values.
Characteristic Shear Strength of Masonry fms

Shear strength, like flexural strength, is related to the mortar/brick bond. For design purposes, at the damp course, it is taken to be zero unless testing shows another value. Elsewhere, mortar joints have fms values of between 0.15 and 0.35 MPa.
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Durability of Masonry
AS3700 requires masonry to be designed to continue functioning satisfactorily throughout its design life without undue maintenance. That is, all masonry materials, including bricks, mortar and all built-in components, must be sufficiently durable for the exposure classification of the site (see AS3700 Appendix E). Masonry designed to meet the requirements of AS3700 Section 5, is deemed to comply with the durability requirements and Table 5.1 defines the durability requirements for bricks, built-in components and mortar in different environments. Salt attack is the most common durability problem. In the form of a solution, salt can be absorbed into masonry. As the water evaporates, the salt is drawn towards the outside face. The evaporating water leaves the solution super-saturated so salt crystals begin to form. The salt crystals grow in the pores just below the surface and depending on the texture of the brick, the amount of salt, the rate of drying and the temperature, the salt may fill the pores, exerting very high pressures on the matrix. The energy in the constrained salt crystal increases and if sufficient pops a piece of the outer surface off and salt attack has begun. Boral bricks graded General Purpose (GP) are suitable for use in all walls, excluding external walls in severe marine environments or in all walls in contact with aggressive soils and environments. Boral bricks graded Exposure Grade (EXP) are suitable for use in all walls including external walls exposed to severe marine environments, i.e. up to 1 km from a surf coast or up to 100 m from a non surf coast or walls in contact with aggressive soils and environments. The distances are specified from mean high water mark. Walls below damp proof course often require greater durability, even if they are well away from the coast, as they may be subjected to saline, acidic or alkaline soils. If unsure of the corrosive nature of the site, an inexpensive total soluble salt content test for soil is available in most areas. Remember it is the designers responsibility to specify the appropriate durability grade of bricks, mortar and built-in components and it is the builders responsibility to order bricks, etc. of appropriate durability grade specified by the designer. Brick manufacturers cannot take any responsibility in this decision as they are not aware of the design requirements of each site. t
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Durability of Masonry (continued)

Refer to Section 1.4 Property Tables for tabulated properties of individual brick types for their salt attack resistance category. Mortar mix requirements for durability are referred in Table 11, page 1.301 of this manual and are detailed in AS3700 Table 10.1. M4 mortars are required and mortar joints must be tooled in all situations requiring exposure grade materials. Concrete floors, paths and steps are a source of sulfate salts that if dissolved in water may enter the brickwork and cause salt attack. Exposed slabs supported on external brickwork should clear the brickwork by 50 mm and incorporate a drip groove to prevent the run-off from the slab running down the brickwork. A damp proof course (usually a double layer) is also used under the slab on top of the bricks to prevent water passing through the slab into the bricks and as a slip joint to prevent a build up of forces as the concrete shrinks and the bricks expand over time. Landscaping and gardening practices are also possible sources of salt attack. Care must be taken to not bridge the damp proof course when landscaping at the base of walls. Watering gardens and lawns, against walls, may cause salts (fertilisers) to splash up on to the wall where they are absorbed and may cause salt attack.
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Brick Ties
In brick veneer construction, ties are used to pass all the lateral out-of-plane loads and forces (such as from wind) to the structural backing. In cavity brick construction ties either pass the lateral out-of-plane loads and forces to the stronger leaf or share them between the leaves. The design of ties in masonry for structural purposes must comply with AS3700 Clause 7.7 for veneer or Clause 7.8 for cavity construction. For small buildings the tie requirements are covered in AS3700 Clause 12.3.4 for brick veneer construction and Clause 12.3.3.2 for cavity brick construction. Type A ties are those that have no specific seismic design characteristics. It is difficult to find brick ties other than Type A in Australia. Ties are available in heavy, medium and light duty in galvanised steel, stainless steel and plastic. Plastic ties are usually reserved for acoustic applications. Stainless steel ties are used in situations requiring exposure grade materials or very long life. Galvanised steel ties are those most commonly used. The Newcastle (NSW) earthquake which occurred in 1989 showed masonry survived well except where the ties were deficient. Problems found included: galvanised ties rusted through; ties only built into one leaf during construction; loose ties; absent ties; and, incorrect duty ties used. Ties are required to meet the durability requirement of the site for the design life of the building. Should the design life of the building be exceeded and the ties begin to fail, they can be replaced with remedial ties but this is a very expensive process and as ties are hidden it is unlikely they will be seen until a catastrophic failure occurs. As sustainability considerations become more important, the life of buildings is likely to be extended. Properly maintained, brick buildings may last for centuries. It should be remembered that stainless steel brick ties offer a longer service life and, although more expensive as a proportion of the overall building cost, the difference is trivial.
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Movement in Masonry Walls

To allow for movements in masonry (expansion and contraction and footing movement) control joints are required. These can usually be constructed so that the expansion joint and the articulation joint are one and the same.
Expansion Joints
Expansion and contraction must be allowed for in masonry design by inserting control joints at spacings designed to suit the magnitude of the movement. Clay products expand permanently over time. This is the opposite of cement-based products, which permanently shrink. For this reason it is unwise to use clay and concrete units in the same band in a wall. If clay bricks are used in concrete framed buildings, control joint spacing and workmanship are critical, as the bricks will expand as the concrete frame shrinks. The magnitude of thermal changes varies from brick to brick depending on the many factors, however, allowing 0.008 mm/m/C is usually recommended. Expansion and contraction from wetting and drying of clay bricks is less than for concrete and calcium silicate products and usually can be ignored in brick masonry design. AS3700, Clause 4.8 requires expansion joints to be spaced to limit panel movement so that movement from both sides closes joints by less than 15 mm and joints are at least 5 mm wide when closed. This means the gap, when constructed, should be 20-25 mm. However, in most buildings articulation joints are used and these are closer than required for expansion making separate expansion joints unnecessary.
Articulation Joints
Articulation joints are vertical gaps that allow for minor footing movements, to prevent distress or significant wall cracking. Articulation joints provide the flexibility needed when building on reactive clay soils and usually are not required for masonry on stable sites (classified according to AS2870). Spacing of articulation joints depends on the site classification and the slab or footing design, but where used must be placed no closer than 0.5 metres and no further than 3 metres from all corners. The width of articulation joints depends on the height of the masonry: 10 mm for masonry up to 3 metres and 15 mm for masonry up to 6 metres high. t
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Movement in Masonry Walls (continued)

Control Joints (General)
Control joints should be used beside large openings, where wall thickness changes (except where this is for support eg. engaged piers), where wall height changes by more than 20%, at changes of level in footings and at other points of potential cracking. Control joints must not continue through bond beams. Ideally, control joints are located near a corner and concealed behind a down pipe. The bricklayer and renderer must keep the control joint clean, otherwise, bridging mortar or render will induce cracks as the masonry moves. External control joints should be finished with a soft flexible sealant to prevent moisture penetration. The design and construction of control gaps in the external leaf of a full brick wall is identical to that in brick veneer. In internal masonry, control gaps are not usually required, except at re-entrant angles in long walls. However, where an internal control joint is required the design is as for external leaves but the thermal component may be ignored in calculations. Internal control joints can usually be located at a full-height opening such as a door or window. Ties are required on both sides of a control joint, but where it is not possible to use them masonry flexible anchors (MFAs) must be used across the joint. Where MFAs are used in walls over 3 metres or in walls exposed to high winds, MFAs must be built in at half height and every seventh course (600 mm) above. MFAs are ties that are of a type that only allows movement in one plane. Unless ties are used, control joints create a free end in terms of Robustness and Fire Resistance Level calculations for structural adequacy, so their positioning is critical to the overall design of the structure. In portal frame construction, the control joint is positioned at a column so that both ends can be tied to the columns flanges. The principles of control joint
Articulation joint Articulation joints with compressible backing and mastic sealant
construction are illustrated in the adjacent figure.
Dividing wall with articulation joint and MFA's at intersection with cavity wall Brick ties on each side of articulation joint
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Thermal Properties
The initial aims of the Building Code of Australia (BCA) were to safeguard people from illness and injury and to safeguard adjacent property from building failures. Legislators subsequently determined to use the BCA for other purposes and have now added requirements for energy efficiency performance of buildings. Energy efficiency consists of three main aspects, thermal performance, hot and cold water provision and lighting. Thermal performance is the only aspect impacting on brick masonry construction. Australia is divided into 8 climatic zones. (Eastern Sydney and Perth are in Zone 5, Adelaide, Melbourne and Western Sydney are in Zone 6, Brisbane is in Zone 2 and Canberra is in Zone 7). The zones and Local Government boundaries are detailed on a map, which is available from the Australian Building Codes Board (www.abcb.gov. au) but the Local Council is able to provide the information where there is any doubt. In most cases the boundaries between zones are those between council areas. BCA Volume 1 divides buildings into three groups with different minimum energy efficiency requirements: 1. Each sole occupancy unit of a Class 2 building or Class 4 part of a building must achieve not less than 3 stars and the average for all of the sole occupancies in the building must be at least 3.5 stars for Zones 1-3 and 4 stars for Zones 4-8. Energy efficiency of buildings expressed as a Star Rating is determined using thermal calculation software that complies with the ABCB Protocol for House Energy Rating Software. 2. Class 3 and Class 5 buildings, Class 6 shops, shopping centres, restaurants and cafes, Class 8 laboratories, Class 9a clinic, day surgery or procedure unit or ward area in a health care building, Class 9b theatres, cinemas or schools and Class 9c aged care facilities must have a calculated annual energy consumption less than or equal to that calculated for a reference building. 3. Certain buildings which are designed to not have conditioned (heated or cooled) spaces such as unenclosed car parks or ambient temperature warehouses are excluded from the requirements. BCA Volume 2 requires a minimum energy efficiency for Class 1 buildings and the whole of Class 1 and attached enclosed Class 10a parts of buildings. The energy efficiency requirement is met by achieving a rating of 5 stars or by showing that heating and/or cooling loads are equal to or less than those of a reference building in the same zone. A Star Rating is determined using thermal calculation software complying with the ABCB Protocol for House Energy Rating Software. While the BCA sets these minimum requirements, State Governments may adopt these minimums or may opt for different requirements. Local authorities may adopt higher star ratings but may not opt for lower ratings than the State adopts. t
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Thermal Properties (continued)

Variations to the BCA Requirements in brief are: In the Northern Territory, Queensland and Tasmania BCA2008 Volume 2, Energy Efficiency provisions do not apply, however those of BCA 2005 Volume 2 do apply. In the Northern Territory the BCA 2008, Volume 1 Energy Efficiency provisions do not apply. In Victoria, New Class 1 buildings must have either a rainwater tank connected to all sanitary flushing systems or a solar water heater system. Sole occupancy units of a Class 2 building must achieve not less than 3 stars and the average for all of the sole occupancies in the building must be at least 5 stars. Class 4 parts of a building must achieve not less than 4 stars. In NSW the Energy Efficiency provisions of the BCA do not apply to Class 1 and 2 buildings, Class 4 parts of buildings and certain Class 10 buildings. Developments (including additions and alterations) in these classes are subject to the Building Sustainability Index (BASIX) requirements. BASIX is a piece of comprehensive sustainability rating software, which initially incorporated energy and water efficiency. It is a web-based system in which data about the development is entered and the whole has to meet targets to get Development Application (DA) approval. BASIX is aimed at achieving energy reductions and potable water savings. The reductions are on a base developed by the NSW Department of Planning before the scheme came into effect and they vary from place to place. The thermal comfort aspects of BASIX can be satisfied by following either the simplified, DIY or assessor routes. The simplified is rigid and very conservative. The DIY is conservative but allows a little more freedom. Both require direct entry of building design information into the web based forms to meet the thermal comfort targets. The assessor route is flexible but requires the services of an accredited assessor. The assessor is required to provide heating and cooling load figures for the design. Whether expressed as an energy load number or a star rating, the requirements are complex because the ratings are based on the total building design for a given site. It is important to remember that roof insulation, shading, orientation and window size and placement have a much greater impact on energy efficiency than the walls. Heat enters and leaves buildings more readily through the windows and roof and greater insulation in the roof space is usually the most cost-effective measure to increase comfort. There is no exact relationship between the walls performance and the energy ratings. The deemed to satisfy requirements in the BCA or BASIX are conservative because they consider the walls in isolation. Designs using only deemed to satisfy solutions will generally be very conservative and except for very small buildings, in most cases a professional energy rating assessor can provide cheaper building solutions, more than off-setting the cost of their services. t
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The clay brick industry through Think Brick Australia (formerly the Clay Brick and Paver Institute) sponsored a program of research at the University of Newcastle, focussed on the actual performance of clay brick masonry in buildings. The published results of this research were used by the ABCB to include heavy masonry in the deemed to satisfy provisions. The research clearly shows that heavy masonry walling has a high thermal inertia (thermal lag). That is, the effect of cavity clay masonry is to slow the transmission of heat through the wall reducing peaks and troughs in the temperature profile, ensuring a more comfortable temperature is maintained longer than would be the case otherwise. With heavy mass walling, heat is slowly absorbed during the day and slowly lost during the cool night. Most thermal requirements focus on thermal insulation, denoted as R value. When dealing with heavy mass walling R value is misleading as it assumes a steady state (constant temperature difference across the wall) which is not the case because of the day-night temperature cycle. Cavity brick houses are well known to have lower temperature fluctuation than lighter weight construction particularly when combined with a concrete slab coupled to the ground or with internal brick walls.
Decoding the BCA Deemed to Satisfy provisions
Volumes 1&2: Achieve a surface density of not less than 220 kg per square meter Two leaves of 90 mm or thicker bricks or a single leaf of 150 mm wide clay bricks or 140 mm wide clay bricks with vertical cores filled with grout at minimum 1000 mm centres with render or plasterboard and a grouted horizontal bond beam. Incorporate a cavity of 20 to 35 mm BCA Volume 1 has no deemed to satisfy provisions related to the cavity width for weatherproofing masonry. BCA Volume 2 requires masonry to have a cavity (a void between two leaves of masonry) between 35 and 65 mm for weatherproofing. Insulation in the cavity of brick masonry must provide a minimum cavity of 35 mm in Class 1 and attached Class 10a parts of buildings and 20 mm in other classes of building and prevention of moisture penetration must be maintained. Masonry that has a thermal conductivity of less than 0.8 BCA Volume 1, Specification J1.2 Materials Properties, Table 2a Thermal Conductivity of Typical Wall, Roof/Ceiling and Floor Materials, lists the thermal conductivity of 110 mm wide bricks weighing less than 3.75 kg as less than 0.78 W/m.K. All bricks manufactured by Boral, other than solid bricks, meet the requirements for the thermal conductivity to be less than 0.78 W/m.K. t
ADV1212A
1.212b

Volume 2: Tables J1.5a and J1.5b R-value requirements R-values depend on the total wall construction and are determined by adding the R-values for the individual components through the wall as shown in Specification J1.5 Wall Construction, Figure 2. Outdoor air film, indoor air film, cavities & plasterboard have the values shown in the tables. The R-values for bricks were determined long ago and a linear relationship with the density was shown. This relationship is shown in the Note 4d. Knowing the weight and the dimensions of the brick allows the density to be calculated and using the numbers given the R-value can be extrapolated for any brick. Brick weights may change over time and vary depending on the place of manufacture so it is advisable to ask your Boral Sales Representative for the latest weight of any particular brick. Note: For proper performance of walls it is critical that moisture penetration be prevented and in masonry this is best achieved by having cavities. It is critical that the cavities are not bridged and they allow moisture to drain away. For cavity (double) brick construction the insulation should hang in the cavity and should not touch either brick leaf. The insulation should also be of a closed cell type, non absorbent or be of hydrophobic material so that it does not absorb water and become saturated when the mortar droppings are flushed from the cavity during brick laying. There are types of thin reflective insulation suitable hanging in cavities and there are rigid board insulations. Boral Bricks makes no claims for or about any of the various types of insulation available. Different R-values are required of different walls in different situations and it is recommended that you consult insulation providers for their recommended types of insulation, the installation methods and techniques and the appropriate R-values for the calculations.
ADV1212B
1.213
Masonry Design for Fire Resistance

Fire Resistance Levels (FRL)
FRLs come from the Building Code of Australias (BCA) Volume 1 tables for Type A, B or C construction. The Type of construction depends on the Class of building and the number of stories or floors. FRLs for housing come from BCA Volume 2. There are three figures in the Fire Resistance Level. Eg: FRL 120/60/90 means that the wall must achieve Structural Adequacy for 120 minutes / Integrity for 60 minutes / Insulation for 90 minutes.
Structural Adequacy
This governs the walls height, length, thickness and restraints. Brick suppliers do not control the wall height, length or restraints so therefore do not control Structural Adequacy.
Integrity
This is the resistance to the passage of flame or gas. To provide integrity, walls must be structurally adequate and they must maintain insulation. Extensive fire testing of masonry has shown integrity to be closely related to structural adequacy or insulation. AS 3700 therefore allows Integrity to be equal to the lesser of the Structural Adequacy or the Insulation periods.
Insulation
This is resistance to the passage of heat through the wall. Insulation is a function of the thickness of the brick as shown in Table 5, page 1.222 of this manual.
ADV03761
1.214
Masonry Design for Structural Adequacy FRL

Structural Adequacy is a minimum provision and may be overridden by design for robustness, wind, live or earthquake loads. A fire on one side of a wall will heat that side, making it expand and lean towards the fire. When the lean or bow reaches half the thickness of the original wall, the wall becomes structurally inadequate. The formulae in AS3700, Clause 6.3.2.2 limits the panel size, depending on its restraints and thickness. The Slenderness ratio (Srf) of a proposed wall is calculated according to AS 3700 Clause 6.3.2.2. If this value is less than the maximum Srf in Table 6.1 of the Standard [or the Srf calculated from Fire Tests and AS 3700 Clause 6.3.3(b)(ii)], then the wall complies. If the Srf of the wall is greater than the maximum permissible, it must be recalculated for an increased thickness and/or extra restraints. There are 3 formulae for calculating Srf. AS 3700 Formula 6.3.2.2 (1) and (2) are the formulae for vertically spanning walls (with no support along either vertical edge). Formula (1) and (2) always govern where there is no end restraint, and often govern where walls are long, relative to their height. Projects with multiple wall lengths (eg: home units) can use this formula as a one size fits all method of calculating the wall thickness. AS 3700 Formula 6.3.2.2 (3) allows a wall to exceed the height given by formula (1) and (2) provided the top and at least one end is supported. AS 3700 Formula 6.3.2.2 (4) allows a wall to exceed the height given in formula (3) where walls are short, relative to their height (eg: a lift well or vent shaft). Short walls with no top restraint often occur in situations like portal frame factories. For cavity walls where both leaves are equally loaded (within 10 per cent of each other, including where there is no load on either leaf) the thickness is equal to two-thirds of the sum of the thicknesses of both leaves and the edge restraint condition is that for the leaf not exposed to the fire. Where one leaf is more heavily loaded than the other, the thickness and edge restraint condition is that of the more heavily loaded leaf. Where cavity walls are constructed with leaves of different masonry unit types, the structural adequacy is based on the less fire resistant material. t
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1.215
Masonry Design for Structural Adequacy FRL (continued)

Refer to the Structural Adequacy Graphs on the following pages for maximum height and length values for walls of different thicknesses and restraint conditions. An appropriately qualified engineer should check all calculations. Other loads may supersede Structural Adequacy requirements.
How to Use the Boral Structural Adequacy FRL Graphs

1.
S
Laterally supported on all sides

15 14 13
(m)
Select the graph with Structural Adequacy for the required minutes. (240 minutes for this example).
2.
Select the graph for the chosen wall restraint (support) criteria. (Support on both vertical edges, top and bottom for this example).
12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10 11 12
(m)
SUPPORTS
3.
Plot the intersection of the design Wall Height and the Wall Length on the graph. (For this
BETWEEN
230mm 150mm 110mm 90mm
example 3 m height x 5 m length). 4. The line ABOVE the intersection indicates the minimum brick thickness required for the wall. In this example, 150 mm bricks would be
HEIGHT
LENGTH
BETWEEN
SUPPORTS
suitable and the most economical.
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1.216
S
Structural Adequacy for 60 Minutes FRL

S

15 14 13
(m)
Laterally supported on three sides, one end unsupported

15 14 13
(m)
12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10 11 12
(m)
12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10 11 12
(m)
S U P PO RT S
BE T WE E N
230mm
BE T WE E N
S U P PO RT S
230mm
HEIGHT
110mm 90mm
HEIGHT
150mm
150mm 110mm 90mm
LENGTH
BETWEEN
SUPPORTS
LENGTH
BETWEEN
SUPPORTS
Laterally supported on three sides, top unsupported

15 14 13
(m )
F S S
Laterally supported one end and bottom, one end and top unsupported
15 14 13
(m )
F S F
12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 230mm 150mm 110mm 90mm 10 11 12

(m) LENGTH BETWEEN SUPPORTS
12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 230mm 150mm 110mm 90mm 10 11 12

S UP P ORTS
B ET W EE N
H E IG HT
H E IG HT
B ET W EE N
S UP P ORTS
ADV03764
1.217
S

S

15 14 13
(m)

15 14 13
(m)
12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10 11 12
(m)
12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10 11 12
(m)
S U P PO RT S
BE T WE E N
230mm
BE T WE E N
S U P PO RT S
230mm
HEIGHT
110mm 90mm
HEIGHT
150mm
150mm 110mm 90mm
LENGTH
BETWEEN
SUPPORTS
LENGTH
BETWEEN
SUPPORTS

15 14 13
(m )
F S S
15 14 13
(m )
F S F
12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 230mm 150mm 110mm 90mm 10 11 12

12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 230mm 150mm 110mm 90mm 10 11 12

S UP P ORTS
B ET W EE N
H E IG HT
H E IG HT
B ET W EE N
S UP P ORTS
ADV03765
1.218
S

S

15 14 13
(m)

15 14 13
(m)
12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10 11 12
(m)
12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10 11 12
(m)
S U P PO RT S
BE T WE E N
230mm
BE T WE E N
S U P PO RT S
230mm
HEIGHT
HEIGHT
150mm 110mm 90mm
150mm 110mm 90mm
LENGTH
BETWEEN
SUPPORTS
LENGTH
BETWEEN
SUPPORTS

15 14 13
(m )
F S S
15 14 13
(m )
F S F
12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 230mm 150mm 110mm 90mm 10 11 12

12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 230mm 150mm 110mm 90mm 10 11 12

S UP P ORTS
B ET W EE N
H E IG HT
H E IG HT
B ET W EE N
S UP P ORTS
ADV03766
1.219
S

S

15 14 13
(m)

15 14 13
(m)
12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10 11 12
(m)
12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10 11 12
(m)
S U P PO RT S
BE T WE E N
BE T WE E N
S U P PO RT S
230mm 150mm 110mm 90mm
230mm 150mm 110mm 90mm
HEIGHT
LENGTH
BETWEEN
SUPPORTS
HEIGHT
LENGTH
BETWEEN
SUPPORTS

15 14 13
(m )
F S S
15 14 13
(m )
F S F
12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 230mm 150mm 110mm 90mm 10 11 12

12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 230mm 150mm 110mm 90mm 10 11 12

S UP P ORTS
B ET W EE N
H E IG HT
H E IG HT
B ET W EE N
S UP P ORTS
ADV03767
1.220
S

S

15 14 13
(m)

15 14 13
(m)
12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10 11 12
(m)
12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10 11 12
(m)
S U P PO RT S
BE T WE E N
BE T WE E N
S U P PO RT S
230mm 150mm 110mm 90mm
230mm 150mm 110mm 90mm
HEIGHT
LENGTH
BETWEEN
SUPPORTS
HEIGHT
LENGTH
BETWEEN
SUPPORTS

15 14 13
( m )
F S S
15 14 13
( m )
F S F
12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 230mm 150mm 110mm 90mm 10 11 12

12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 230mm 150mm 110mm 90mm 10 11 12

SUPPORT S
B E TW E EN
H EI GH T
H EI GH T
B E TW E EN
SUPPORT S
ADV03768
1.221
Structural Adequacy for Panels with Unsupported Ends
This figure shows the situation where there is support top and bottom but none on the sides. This applies where there are control joints, large openings, long walls, etc. To use this graph select the desired FRL in minutes and the height of the wall. The line above the intersection shows the brick thickness required.
Maximum Wall Heights for Structural Adequacy for any Wall Length
Top and bottom supported, ends not supported.

S
(m)
6 230mm
HEIGHT WALL
4 150mm 3 110mm 90mm
MAXIMUM
0
FRL
60
F OR
90
120
180
240
STRUC TURAL (minut e s)
ADEQUAC Y
ADV03769
1.222
Masonry Design for Integrity FRL

It is impractical to provide test results for all possible wall designs, and therefore Integrity must be proved in some other way. The most practical way to prove Integrity is to prove Structural Adequacy and Insulation equal to or better than the Integrity requirement. Logically, if the wall is designed to minimise bowing it will not crack and therefore resist the passage of flame and gas for the specified time. This method is also the best way to prove Integrity even when a wall may not be required to comply with a Structural Adequacy FRL value, such as is the case with non-load bearing walls. Eg. If the BCA requires an FRL of -/90/90, the wall has no actual Structural Adequacy requirement, but to prove Integrity of 90 minutes, the wall must be structurally adequate for at least 90 minutes.
Masonry Design for Insulation FRL

Insulation is the one FRL component that a brick manufacturer does control. It is governed by the type of material and material thickness. Material thickness (t) is defined in AS3700, Clause 6.5.2 as the overall thickness for bricks with cores not more than 30% of the bricks overall volume. For cavity walls, t = the sum of material thicknesses in both leaves.
Table 5. Insulation periods for standard bricks (minutes)
Wall thickness (mm) Insulation period (minutes)
90 110 140 or 150
160 (150 plus 10 mm 180 230 render on both sides) (90/90 cavity) 180 240 240
220 (110/110 cavity) 240
60
90
120
Note: Wall thickness excludes render on side of wall exposed to fire.
Effect of Recesses for Services on FRLs

Recesses that are less than half of the masonry thickness and are less than 10,000 mm2 (0.01 m2) for both sides within any 5 m2 of the wall area do not have an effect on fire ratings. If these limits are exceeded, the masonry design thickness must be reduced by the depth of the recess.
ADV03770
1.223
Effect of Chases on Fire Rated Masonry

Structural Adequacy FRL
To assess the effect of chases on Structural Adequacy FRLs, the direction in which the wall spans must be taken into account. Walls spanning vertically may be chased vertically to full height but horizontal chases are limited in length to 4 times the walls thickness. Walls spanning vertically and horizontally may be chased either horizontally up to half the walls length or vertically up to half the walls height. If these limits are exceeded, the masonry design thickness must be reduced by the depth of the chase or, in the case of vertical chases, designed as 2 walls with unsupported ends at the chase. Horizontal chases in all walls should be kept to a bare minimum. Note: Chases affect the sound reduction capacity of walls. See Acoustic Design page 1.225 of this manual.
Integrity and Insulation FRLs

AS3700 limits the maximum depth of chase to 30 mm and the maximum area of chase to 1,000 mm2. The maximum total area of chases on both sides of any 5 m2 of wall is limited to 100,000 mm2 (0.1 m2). If these limits are exceeded, the masonry design thickness must be reduced by the depth of the chase.
ADV03771
1.224
Options for Increasing FRLs

Structural Adequacy FRLs can be increased by adding wall stiffeners, by increasing the overall thickness, by adding reinforcement or by protecting the wall, e.g. with Boral Plasterboards FireStop board, fixed to furring channels (on both sides of the wall if a fire rating is required from both sides). Note: Be careful of the effect of plasterboard on sound reduction in party walls. See Acoustic Design page 1.225 of this manual. Integrity FRLs are increased by increasing the other two FRL values to the required Integrity FRL. Insulation FRLs can be increased by adding another leaf of masonry, by rendering both sides of the wall if the fire can come from either side. Note: Only ONE thickness of render is added to the material thickness and that must be on the cold side because the render on the exposed face will drop off early in a fire.
ADV03772
1.225
ACOUSTIC DESIGn Acoustic Performance Rating

The BCA requirements are met by: 1. Testing a sample of constructed walls to verify that they meet the Weighted Standardised Level Difference (Dnt,w explained further in Acoustic Performance On-Site on page 1.231 of this manual) requirements; or 2. Constructing walls using the same materials and techniques as walls that have been constructed and tested in a laboratory and shown to meet the Weighted Sound Reduction Index (Rw) requirements; or, 3. Constructing walls using the materials and techniques in the Acceptable Construction Practice section of the BCA; and, 4. Where impact sound reduction is required, it is to be achieved by discontinuous construction, except for Class 9c buildings where there is a test; and, 5. Except where the requirements are verified by on-site testing, chasing of services into masonry walls is not allowed and electrical outlets on either side of the wall must be offset by no less than 100 mm. The BCA acoustic performance requirements in Class 1, 2, 3 and 9c buildings are shown below in the tables.
Table 6. BCA Volume 2 Requirements for walls separating (Class 1) sole occupancy units
Wall separating Sole occupancy unit- all areas except those below Sole occupancy unit- bathroom, sanitary compartment, laundry or kitchen Sole occupancy unit- all areas except those below Sole occupancy unit- habitable room except a kitchen Wall Rating Rw+Ctr 50 Rw+Ctr 50 and discontinuous construction
Northern Territory and Queensland have different requirements for acoustic performance of walls separating Class 1 buildings. The differences are; in the table above, in Row 1 the wall rating required is Rw 45 and in bottom row the rating required is Rw 50 with impact sound resistance, which may be determined by a tapping test comparing to a deemed-to-satisfy wall. t
ADV1225
1.226
Acoustic Performance Rating (continued)

Table 7. BCA Volume 1 Requirements for walls separating sole occupancy units from other parts of the building in Class 2 & 3 Buildings. Wall separating
Sole occupancy unit- all areas except those below Sole occupancy unit- all areas except those below
Wall Rating
Rw+Ctr 50 Rw+Ctr 50 and discontinuous construction Rw 50 and discontinuous construction Rw 50
Sole occupancy unit- bathroom, sanitary Sole occupancy unit- habitable room compartment, laundry or kitchen except a kitchen Sole occupancy unit- all areas Sole occupancy unit- all areas Plant room or lift shaft Stairway, public corridor, public lobby or areas of different classification
Northern Territory and Queensland have different requirements for Class 2 and 3 buildings. The requirements simply stated are that all separating walls shown in Table 7 have a rating of Rw 45, except those in row 2 where the walls must have a rating of Rw 50 and discontinuous construction or test to be no less resistant to impact noise than a deemed-to-satisfy wall (by a tapping test).
Table 8. BCA Volume 1 Requirements for walls separating sole occupancy units and other parts of the building in Class 9c Buildings (aged care facilities).
Wall separating Sole occupancy unit- all areas except those below Wall Rating Rw 45 Rw 45 and discontinuous construction or No less resistant to impact noise than a deemed-to-satisfy wall Rw 45
Sole occupancy unit- all areas
Laundry, kitchen
Bathroom, sanitary compartment (but not an associated ensuite), plant room, utilities room
Table 9. BCA Service separation* in Class 1, 2, 3 & 9c buildings.

Building service A duct, soil, waste, water supply or stormwater pipe that serves or passes through more than one unit. Adjacent room Sole occupancy unit habitable room other than a kitchen. Sole occupancy unit kitchen or non habitable room Barrier rating Rw+Ctr 40 Rw+Ctr 25
* n Class 1 buildings the requirements apply to those services that pass through more than one Dwelling. In Class 2, 3 & 9c I requirements apply to all stormwater pipes and other services that pass through more than one sole occupancy unit.
Northern Territory and Queensland have different requirements for separation of services in the table above; the requirements are respectively Rw 45 and Rw 30, which for masonry construction are roughly equivalent to the figures in the table.
ADV1226
1.227
Weighted Sound Reduction Index (Rw)

Rw is a single-number rating of the sound reduction through a wall or other building element. Since the sound reduction may be different at different frequencies, test measurements are subjected to a standard procedure that yields a single number that is about equal to the average sound reduction in the middle of the human hearing range. Two spectral corrections can be applied to Rw: C and Ctr. C compensates for medium to high frequency noise and Ctr compensates for low frequency noise. C and Ctr are both negative numbers.
Impact Sound Resistance

The BCA Amendment 14 says there is no appropriate test for impact sound reduction in walls. However, in the case of Class 9c buildings the BCA allows impact sound reduction to be demonstrated by showing a wall performs no worse than a deemed-to-satisfy wall. To achieve impact sound resistance, the BCA requires walls consist of two leaves with at least a 20 mm cavity between them and if ties are needed in masonry walls they must be of the resilient type. Except for the resilient ties in masonry walls there are to be no mechanical linkages between the walls, except at the periphery (i.e. through walls, floors and ceilings).
BCA Deemed-to-Satisfy Walls

BCA Volume 1 Amendment 14 Specification F5.2 Table 2 gives deemed-to-satisfy walls for sound insulation for walls separating sole occupancy units. BCA Volume 2 Amendment 14 Table 3.8.6.2 gives deemed-to-satisfy walls for sound insulation for walls separating two or more Class 1 Buildings. These walls are the same as those in Volume 1 except only walls achieving Rw+Ctr 50 are allowed. Deemed-to-satisfy clay brick walls are detailed on the following pages. t
ADV03775
1.228
BCA Deemed-to-Satisfy Walls (continued)

Table 10. BCA Volume 1 Amendment 14 Deemed-to-Satisfy Brick Walls
Construction Rating
Two leaves of 110 mm clay brick masonry with: (a) A cavity not less than 50 mm between leaves; and (b) 50 mm thick glass wool insulation with a density of 11 kg/m3 or 50 mm thick polyester insulation with a density of 20 kg/m3 in the cavity. Rw+Ctr50
Two leaves of 110 mm clay brick masonry with: (a) A cavity not less than 50 mm between leaves; and (b) 13 mm cement render on each outside face. Rw+Ctr50
Single leaf of 110 mm clay brick masonry with: (a) A row of 70 mm x 35 mm timber studs or 64 mm steel studs at 600 mm centres, spaced 20 mm from the masonry wall; and (b) 50 mm thick mineral insulation or glass wool insulation with a density of 11 kg/m3 positioned between studs; and, (c) one layer of 13 mm plasterboard fixed to outside face of studs and outside face of masonry. Single leaf of 90 mm clay brick masonry with: (a) A row of 70 mm x 35 mm timber studs or 64 mm steels studs at 600 mm centres, spaced 20 mm from each face of the masonry wall; and (b) 50 mm thick mineral insulation or glass wool insulation with a density of 11 kg/m3 positioned between studs in each row; and (c) one layer of 13 mm plasterboard fixed to studs on each outside face. Rw+Ctr50
Rw+Ctr50
ADV03776
1.229
BCA Deemed-to-Satisfy Walls (continued)

Table 10. BCA Volume 1 Amendment 14 Deemed-to-Satisfy Brick Walls (continued)
Construction Rating
Single leaf of 150 mm brick masonry with 13 mm cement render on each face.
Rw50
Rw50
Rw45
ADV03777
1.230
Solid v. Cavity Walls

Acoustic performance with single leaf masonry follows the Mass Law. The acoustic performance of these walls depends on their mass. More mass gives better performance, however, the relationship is logarithmic: If a 110 mm wall gives Rw = 45, a 230 mm wall of the same brick may give Rw = 57. Cavity walls behave differently because sound waves can resonate in cavities. The narrower the cavity becomes, the more resonance occurs. Insulation in the cavity helps absorb resonating sound and narrow cavities should have bond breaker board, to prevent mortar from providing a bridge for sound to travel between the leaves.
Brick Walls with Render

Render on one side of a brick wall adds 2 or 3 to the walls Rw but adding render to the second side only adds 1 to the walls Rw. The render appears to fill defects in the wall surface reducing the sound transmission, but this is a one-off benefit.
Brick Walls with Plasterboard

Cornice cement daubs, used to fix plasterboard directly to brick walls, create a small cavity in which resonance occurs. Brick walls with daub fixed plasterboard on both sides stop less noise than the same walls, bare. Adding extra daubs (halving spacing) gives lower performances, presumably due to extra bridges through the daubs. Plasterboard on furring channel is marginally better than daub fixed. A bigger cavity between the wall and the plasterboard makes it harder for resonating energy to build up pressure on the board. When standard furring channel clips are used, this system transfers vibrations to the plasterboard via the channels and clips. Boral Impact Clips (BICs) have a rubber shank on their masonry anchor that isolates the vibrations from the masonry. The use of BIC mounts can add 3 or 4 dB to the walls Rw. Polyester and glass wool in the cavity helps prevent resonance and further decreases the sound transmission. Denser grades of plasterboard and additional layers of plasterboard (fixed with grab screws and leaving no cavities) also decrease sound transmission.
ADV03778
1.231
Points to Consider When Designing Walls for Acoustic Performance

The BCA specifies minimum levels for sound isolation but experience shows that achieving the minimum standards is not always sufficient to satisfy occupants. In view of this it is recommended that architects, developers, builders, etc., consider a higher level of sound insulation, commensurate with the expectations of the end user. End user expectations are frequently related to the cost of occupying the unit. Wall design is a balance between acoustical performance, thickness, weight and cost. Frequently it is not possible to optimise one factor without seriously compromising the others.
Acoustic Performance On-Site

The Rw ratings on walling systems are obtained from tests carried out in accredited laboratories, under controlled conditions. When identical partitions in buildings are tested in-situ, it is often found that the actual result obtained, called the Weighted Standardised Level Difference (Dnt,w), is lower than the laboratory Rw. This reduction in performance can be due to rooms being too small, varying size of the element being tested, flanking paths (noise passing through other parts of the building) or background noise. The allowance in the BCA for a difference of 5 between the laboratory test and the field test is not to allow for poor construction practice. To repeat the performance in the field, attention to detail in the design and construction of the partition and its adjoining floor/ceiling and associated structure is of prime importance. Even the most basic elements, if ignored, can seriously downgrade the sound insulation performance. The most common field faults include bricklayers not completely filling all mortar joints, poor sealing between walls and other building elements, electrical power outlets being placed back to back, chasing masonry and concrete walls, leaving gaps in insulation, screwing into insulation and winding it around the screw when attaching sheet materials, not staggering joints in sheet materials and poor sealing of penetrations. Boral Bricks cannot guarantee that field performance ratings will match laboratory performance. However, with careful attention during construction of the wall, correct installation to specification and proper caulking/ sealing, the assembly should produce a field performance close to and comparable with tested values. The following items can also affect the acoustic performance on site.
ADV03779
1.232
Perimeter Acoustical Sealing

As the Rw of a wall increases, the control of flanking paths becomes more critical. Consequently, the perimeter sealing requirements for a low sound rating wall, such as Rw = 45, are much less than for a high sound rating wall, such as Rw = 60. Note: it is neither necessary, nor is it cost effective, to provide very high perimeter acoustic sealing for a low Rw wall. Effective sealants have the following properties: Good flexibility, (elastic set); Low hardness; Excellent adhesion, usually to concrete, timber, plaster and galvanised steel; Minimal shrinkage (less than 5%); Moderate density (greater than 800 kg/m3); and are, Fire rated where required (All walls required by the BCA to be sound rated also have fire ratings). All of the above properties must be maintained over the useful life of the building, that is, greater than 20 years. Note: Use of expanding foam sealants is not acceptable. Refer to the manufacturer to ensure the particular type or grade of sealant is suitable for the purpose.
Doors
Hollow, cored and even solid doors generally provide unsatisfactory sound insulation. Doors can provide direct air leaks between rooms lowering the overall Rw of the wall in which they are inserted. Where sound insulation is important, specialised heavyweight doors or, preferably, two doors separated by an absorbent lined airspace or lobby should be used.
ADV03780
1.233
Lightweight Panels Above Doors

Panels are often incorporated for aesthetic reasons, however, they should not be used unless they have an Rw equal to or better than the walls requirement.
Air Paths Through Gaps, Cracks or Holes

Seal all gaps, cracks or openings, however small, with an acoustic sealant. Holes readily conduct airborne sounds and can considerably reduce the Rw of a wall.
Appliances
Noise producing fixtures or appliances such as water closets, cisterns, water storage tanks, sluices, dishwashers, washing machines and pumps should be isolated from the structure with resilient mountings and flexible service leads and connections.
Electrical Outlets & Service Pipes

Penetrations of all sorts should be avoided but if unavoidable, seal around them effectively. If possible introduce a discontinuity in pipe work between fittings, such as a flexible connection within or on the line of a partition. Use acoustically rated boxes for all general power outlets, light switches, telephone connections, television outlets, etc. Seal the sides of electrical boxes and the perimeter of all penetrations with acoustic sealant. Offset all power outlets on either side of a wall by at least 100 mm.
ADV03781
1.3 Brick Masonry Construction
Section 1.3. Brick Masonry Construction
1.301
The following information relates to the construction of brick walls to meet AS3700, the design and aesthetic requirements.
Mortar
AS3700: 2001, Table 10.1 gives the options for mortar mixes classified as M1 to M4. M1 mortars are for restoration applications. M2 mortars are for use in interior walls above dampcourse or in exterior walls above dampcourse if more than one km from a body of salt water and 10 km from a surf coast and the wall has protection from water ingress above. M3 and M4 mortars are those most commonly used in construction. Table 11 gives the proportions of the most commonly used mortars. Other deemed-to-satisfy compositions are given in AS3700. Special mortars that are tested and shown to meet requirements are allowed with verification on site. Note: Proportions are by volume and should be measured with a bucket or gauge box, NOT A SHOVEL.
Table 11. Typical Mortar Mixes
Mortar Type M1 M2 M3 M3 M4 M4 Durability Class PRO PRO GP GP EXP EXP Mix proportions by volume Portland or Hydrated Blended Cement Lime Sand 0 1 1 1 1 1 1 2 1 0
1
Water Thickener* No No No Yes No Yes
3 9 6 5 412 4
Refer to page 1.104 for description of Durability Class. *Methylcellulose type, not air entrainers such as detergent.
Where masonry strength is crucial, trial walls should be constructed with the bricks and mortar to be used on the job, then tested before construction commences. Masonry bond strength is related to the suction of the bricks, the particle size distribution of the sand, cement content, additive contents, etc. For many jobs these panels can also be used as physical samples of the required quality of the bricklaying and cleaning. Note: AS 3700 allows the use of: Cements complying with AS 3972 or AS 1316 Lime complying with AS 1672.1 Sand that is free of any deleterious materials Water that is free from deleterious materials and Admixtures including plasticisers, air entraining agents and set retarders complying with AS1478.1, cellulose-type water thickeners, colouring pigments complying with BS EN 12878 and bonding polymers. t
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1.302
Mortar (continued)
No other material may be used until tests on masonry constructed with the mortar, made with the material or admixture shows the masonry complies with the standards requirements for compressive strength, flexural strength and durability. Deleterious materials are those reducing the strength or durability of the masonry and including anything that attacks the built-in components. This means the use of fire clay, detergent, sugar, soft drink, etc., are banned. Most of these materials severely reduce mortar strength and durability. Water thickener must be used only according to the manufacturers directions because overuse severely reduces mortar strength.
Mortar Estimator
Table 12. Estimated Material Requirements to Lay 1,000 Standard Bricks
Mix M3 M3 M4 M4 Composition (C:L:S) 1:1:6 1:0:5 1:0:4 1 : 12 : 412 40 kg bags of cement 4 4 6.5 5.3 25 kg bags of lime 2.4 0 0 1.6 Cubic metres of sand 0.64 0.64 0.64 0.64 Tonnes of damp sand 1.2 1.2 1.2 1.2
This table assumes partial filling of cores and typical site wastage. Only make sufficient mortar for immediate use. If mortar starts to set, it may be re-tempered once only. Where bricklaying is interrupted, the mortar should be covered to prevent evaporation and mixed with the trowel before continuing. t
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1.303
Mortar (continued)
Mortar Colour
The mortar colour can dramatically affect the overall look. The colour of mortar is influenced by the colour of the cement and the aggregates (sand). Many pigments are also available ranging in colour through red, yellow, brown, green, blue and black (mainly oxides but carbon black can be used to give black mortar). The cheapest way of colouring mortar is to use coloured sand. White and yellow sands are commonly available but red and brown sands are also available. Sands are normally natural materials which vary considerably even in the one deposit. To ensure colour consistency, sufficient sand from the one batch should be set aside for the whole job. Where colour is crucial to the look of the masonry, before accepting the sand, a trial wall should be built (4 bricks x 10 courses). After the mortar dries assess the colour. Where oxides or carbon black are used as colours never use more than 10% by weight of the cement content. Colours are additive in their effect and it is possible to get different shades and tones of mortar using different combinations of cement, sands and oxides.
Table 13: Typical Coloured Mortar Components
Mortar Colour Red Yellow Cream Tan Black Cement Grey Off-white or Grey Off-white Grey Grey Sand White or Yellow or Red Yellow Yellow White or Yellow Yellow Oxide Red Yellow & Brown None Brown Black
Note: The colour of mortar can be severely degraded by incorrect or poor brick cleaning.
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1.304
Joint Types
The type of joint can dramatically affect the overall look of brick masonry. Joints can be used to create a casual, rustic or formal look to brickwork. There are many different joints; the most common ones used in Australia are shown below.
Flush Joint Raked Joint Ironed Joint Struck Joint Weathered Joint
Terminology and joint preference differs in different countries and within Australia. Where there is any confusion, always use a drawing or physical sample to avoid misunderstandings. Shallow ironed joints are recommended in areas requiring exposure grade bricks and mortar. Tooling the joint to produce ironed and struck joints is equivalent to steel trowelling concrete and produces a dense smooth surface which sheds water and dirt better than other types of joint. Ironed and struck joints should always be used for bricks with straight sharp edges such as Smooth Face and Velour bricks. Raked joints may be used with any type of brick but they tend to retain dirt and may lead to streaks down the masonry in dirty environments. Raking must not come closer than 5 mm to any core. This usually limits raking to less than 10 mm, however it is best to check the bricks that are being used before raking. AS3700 specifies that joints in walls in marine, severe marine or aggressive environments or on aggressive soils must be tooled to a dense smooth surface. This precludes raking and in practice ironed joints are the only ones that consistently meet the requirement. Flush joints may be used with any type of brick. However, flush joints are particularly effective with rumbled bricks as flush joints make the joints look to be of variable thickness that gives a pleasing rustic look.
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1.305
Joint Sizes
Mortar bed joints are required to be less than 10 mm unless the design specifies another thickness. A different thickness may only be specified after the designer considers the effect on compressive and flexural strength of the masonry. During construction mortar bed joints are allowed to deviate by 3mm. Because of poor practice or lack of proper direction some slabs and footings are finished at the wrong height. Mortar joints up to 50 mm thick have been used to get the correct coursing, however, this is not allowed under AS3700. Perpends are to have a minimum design thickness of 5 mm. In structural brickwork perpends may be up to 10 mm thicker than the specified thickness but no thinner. In face brickwork perpends may deviate by 5 mm from the average width but in any one wall the maximum difference allowable between any two perpends is 8 mm. The preceding tolerances do not apply in the case of thin bed mortars and perpend tolerances do not apply where perpends are not filled with mortar.
Weepholes
Weepholes are to allow moisture that collects in the cavity to escape. Weepholes should be spaced at less than 1200 mm centres wherever flashing is built into the masonry to shed water from the cavity. Weepholes are usually empty perpends (10 mm wide) but proprietary products are available to prevent the entry of insects. In high wind areas it has been known for water to be blown up the cavity onto the inner wall and as this is very undesirable, more, narrower weepholes are usually built into the wall. It is essential that weepholes remain open and render and other applied coatings, where used, must be raked out of the joint.
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1.306
Brick Estimator
Brickwork is based on the 600 mm unit, (seven courses high and two and a half bricks long). This unit fits in with doors, windows and other building materials. The number of bricks required for a wall can be determined from the Brick Coursing Height and Brick Gauge tables on pages 1.310-1.312 of this manual. Select the height of the wall and from the following page for the brick height chosen determine the number of courses. From the next page for 230 mm long bricks or the one after for 290 mm bricks, determine the number of bricks for the length of your wall. A half brick should be calculated as 1 whole brick, due to site wastage. Multiply the number of bricks by the number of courses to give the number of bricks for the wall. Saw cutting bricks may mean getting two halves from a brick but this is not usual practice because of the cost of cutting.
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1.307
Brick bonds and other decorative effects

A bond is the pattern in which bricks are laid. The most common bond is Stretcher Bond which consists of courses of full bricks where every course is offset half a brick from the course below. When following the mortar joint, stretcher bond has the longest vertical pathway and therefore the best bend strength. Stretcher bond is used in walls one brick wide. Where walls are two or more bricks wide then stretcher bond needs ties to hold the leaves together to give it a monolithic action. To avoid the use of ties traditional practice has been to lay some of the bricks sideways. This has usually been either full courses of headers with full courses of stretcher (English) or courses of alternating header and stretcher (Flemish). A variation of Flemish Bond is Garden Wall Bond where courses are made of a header and three stretchers alternating. Corner treatment can be different in these bonds. English corners end in full stretchers or full headers, and any part brick required to make up the course is set inside the corner. Dutch corners end in the part bricks. Variations on these bonds are common in particular a header course every three or six courses with stretcher courses between. Although these bonds have traditionally been developed for thick walls, they can be used in single leaf walls as a decorative effect using cut bricks for the headers. Such walls are usually non-load bearing. Cutting costs are high but not excessive as the headers have the cut side turned in and the bricks can be bolstered. Other decorative bonds may be used in non-load bearing applications, particularly in the form of panels. The limitations are strengths lower than Stretcher Bond and the cost of cutting and slower brick laying. The decorative effect of bonds is highlighted by using a mortar in a contrasting colour to the brick. Other bonds include: Stack Bond Bricks laid horizontally in vertical columns so all vertical joints align. Soldier Stack Bond Bricks laid vertically in vertical columns so all vertical joints align. 1/3 Bond Every course is offset by 1/3 of a brick. Zigzag Bond, Vertical Zigzag Bond, 45 Stretcher Bond, Chevron Bond, Basket Weave Bond, 45 Basket Weave Bond and virtually any pattern that tessellates. t
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1.308
Brick bonds and other decorative effects (continued)

Other decorative effects are available such as: Laying bands of bricks of the same colour with different textures eg smooth faced and rock faced; Laying bands of bricks with different (contrasting or complimentary) colours; Corbelling (bricks set out from the wall); Racking (bricks set back into the wall); Quoining (corner bricks in different colours or set out from the wall); Soldiers above openings or as a single course; Copings on piers and parapet walls; Sills in different colours or textures, using sill bricks, etc.; or, In the late 1800s bricks of contrasting colours were laid in patterns such as diamonds or crosses. A more subtle effect can be made by laying bricks with different textures or corbelling the bricks in these patterns. Combinations of the above effects can be used. Eg. An American Architect specified a corbelled course with the course below to be laid in the darkest bricks selected from the packs delivered. The darker band accentuated the shadowing effect from the corbelled course. t
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1.309
Common Bond (Full Headers every 6th Course)
Brick bonds and other decorative effects (continued)

Stretcher Bond
Flemish Bond
Common Bond (Flemish every 6th Course)
English Cross or Dutch Bond
Garden Wall Bond
Stack Bond
Soldier Course (With Stretcher Bond)
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1.310
18 50 49 48 17 47 46 45 44 43 42 15 41 40 39 14 38 37 13 36 35 34 33 32 31 11 30 29 28 27 26 25 9 24 23 22 8 21 20 19 7 18 17 16 15 14 5 13 12 11 10 9 8 3 7 6 5 2 4 3 2 1 1
Brick Coursing Height

3000
36 35 34 33 23 22 21 20 19 18 17 16 12 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24
3000mm
30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
2700
32 31 30 16
2700mm
2400
29 28 27 26
2400mm
2100
25 24 23
2100mm
1800
22 21 20 19
1800mm
10
1500
18 17 16
1500mm
1200
15 14 13 12
1200mm
900
11 10 9
900mm
600
8 7 6 5 4
600mm
300
4 3 2 1
300mm
76mm
119mm
162mm
50mm
90mm
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1.311
Brick Gauge
230 mm Long Bricks
No. of Bricks Length Opening (mm) (mm) No. of Bricks Length Opening (mm) (mm) No. of Bricks Length Opening (mm) (mm) No. of Bricks Length (mm)
1 1 2
1
230 350 470 590 710 830 950 1070 1190 1310 1430 1550 1670 1790 1910 2030 2150 2270 2390 2510 2630 2750 2870 2990 3110
250 370 490 610 730 850 970 1090 1210 1330 1450 1570 1690 1810 1930 2050 2170 2290 2410 2530 2650 2770 2890 3010 3130
1312 14 14 2
1
3230 3350 3470 3590 3710 3830 3950 4070 4190 4310 4430 4550 4670 4790 4910 5030 5150 5270 5390 5510 5630 5750 5870 5990 6110
3250 3370 3490 3610 3730 3850 3970 4090 4210 4330 4450 4570 4690 4810 4930 5050 5170 5290 5410 5530 5650 5770 5890 6010 6130
26 26 2
1
6230 6350 6470 6590 6710 6830 6950 7070 7190 7310 7430 7550 7670 7790 7910 8030 8150 8270 8390 8510 8630 8750 8870 8990 9110
6250 6370 6490 6610 6730 6850 6970 7090 7210 7330 7450 7570 7690 7810 7930 8050 8170 8290 8410 8530 8650 8770 8890 9010 9130
3812 39 39 2
1
9230 9350 9470 9590 9710 9830 9950 10070 10190 10310 10430 10550 10670 10790 10910 11030 11150 11270 11390 11510 11630 11750 11870 11990 23990
2 212 3 3 2
1
27 2712 28 28 2
1
15 1512 16 16 2
1
40 4012 41 41 2
1
4 412 5 5 2
1
29 2912 30 30 2
1
17 1712 18 1812 19 1912 20 2012 21 21 2

1
42 4212 43 4312 44 4412 45 4512 46 46 2

1
6 612 7 7 2
1
31 3112 32 32 2
1
8 812 9 9 2
1
33 3312 34 34 2
1
22 2212 23 23 2
1
47 4712 48 48 2
1
10 1012 11 11 2
1
35 3512 36 36 2
1
24 2412 25 25 2
1
49 4912 50 100
12 1212 13
37 3712 38
ADV03793
1.312
Brick Gauge
290 mm Long Bricks
No. of Bricks 1 113 123 2 2 3
1
Length Opening (mm) (mm) 290 390 490 590 690 790 890 990 1090 1190 1290 1390 1490 1590 1690 1790 1890 1990 2090 2190 2290 2390 2490 2590 2690 2790 2890 2990 3090 3190 3290 3390 3490 3590 3690 3790 3890 3990 310 410 510 610 710 810 910 1010 1110 1210 1310 1410 1510 1610 1710 1810 1910 2010 2110 2210 2310 2410 2510 2610 2710 2810 2910 3010 3110 3210 3310 3410 3510 3610 3710 3810 3910 4010
No. of Bricks 1323 14 1413 14 3

2
Length Opening (mm) (mm) 4090 4190 4290 4390 4490 4590 4690 4790 4890 4990 5090 5190 5290 5390 5490 5590 5690 5790 5890 5990 6090 6190 6290 6390 6490 6590 6690 6790 6890 6990 7090 7190 7290 7390 7490 7590 7690 7790 4110 4210 4310 4410 4510 4610 4710 4810 4910 5010 5110 5210 5310 5410 5510 5610 5710 5810 5910 6010 6110 6210 6310 6410 6510 6610 6710 6810 6910 7010 7110 7210 7310 7410 7510 7610 7710 7810
No. of Bricks 2613 2623 27 27 3

1
Length (mm) 7890 7990 8090 8190 8290 8390 8490 8590 8690 8790 8890 8990 9090 9190 9290 9390 9490 9590 9690 9790 9890 9990 10090 10190 10290 10390 10490 10590 10690 10790 10890 10990 11090 11190 11290 11390 11490 11590
No. of Bricks 39 3913 3923 40 40 3

1
Length (mm) 11690 11790 11890 11990 12090 12190 12290 12390 12490 12590 12690 12790 12890 12990 13090 13190 13290 13390 13490 13590 13690 13790 13890 13990 14090 14190 14290 14390 14490 14590 14690 14790 14890 14990 29990
15 1513 1523 16 16 3
1
27 3
2
223 3 3 3
1
28 2813 28 3
2
4023 41 41 3
1
3 3
2
29 2913 2923 30 30 3
1
41 3
2
4 413 4 3
2
1623 17 17 3
1
42 4213 42 3
2
5 513 523 6 6 3
1
17 3
2
43 4313 4323 44 44 3
1
18 1813 18 3
2
3023 31 31 3
1
19 1913 1923 20 20 3
1
31 3
2
623 7 7 3
1
32 3213 32 3
2
4423 45 45 3
1
7 3
2
33 3313 3323 34 34 3
1
45 3
2
8 813 8 3
2
2023 21 21 3
1
46 4613 46 3
2
9 913 923 10 10 3
1
21 3
2
47 4713 4723 48 48 3
1
22 2213 22 3
2
3423 35 35 3
1
23 2313 2323 24 24 3
1
35 3
2
1023 11 11 3
1
36 3613 36 3
2
4823 49 49 3
1
11 3
2
37 3713 3723 38 38 3
1
49 3
2
12 1213 12 3
2
2423 25 25 3
1
50 100
13 1313
25 3
2
26
3823
ADV03794
1.313
Blending
Raw materials for brick making are from natural sources and these vary in colour within any one deposit. Brick makers blend materials to moderate the colour variation but it still occurs. Colour variation may be caused by different conditions across the kiln. No matter how well made, bricks delivered to site will have some degree of colour variation. Poorly blended bricks may show unwanted patches, streaks and bands of colour in the finished masonry. To avoid this: All bricks required for the project, or as many packs as will fit, should be delivered at one time and stored on site; and, Bricks should be drawn from at least four packs simultaneously, working down from the corners of each pack.
Brick Storage
Bricks stored on site should be covered and kept off the ground. Bricks may absorb ground water containing salts or coloured minerals creating subsequent problems with staining. Bricks when laid saturated usually produce excessive efflorescence as the masonry dries. Saturated bricks may also adversely affect the mortar bond strength. Moving bricks around the site may cause chipping and excessive movement of packs should be avoided.
ADV03795
1.314
Laying Practices
The following practices are recommended: Mortar, extruded from tapping the brick down to the string line, should be cut off with an upward stroke of the trowel. In this manner, a clean cut is made, without smearing the face of the brick. Joints should be tooled progressively as the bricks are laid, when the mortar is firm to thumb pressure. High suction bricks require joints to be tooled more frequently than low suction bricks. Tooling too late produces a burned joint, where the surface may not be smooth and dense. After allowing the mortar to undergo initial set, within a day, dry brush mortar smears, to remove any dags, and then wet brush any remaining mortar stains. Mortar that is allowed to set on the masonry face may require high-pressure water jet cleaning or more costly, risky methods of cleaning. Cavities should be kept as clear as possible from mortar droppings. Flushing out the cavity removes inadvertently dropped mortar and ensures ties are clean and flashing and damp proof courses are not bridged. It is poor practice and usually ineffective to flush large quantities of dropped mortar from cavities. Usual practice is for the bricklayer to leave out one or more bricks at the base of the wall above a flashing or the damp proof course for the washings to come out. Washings can cause serious staining where they run down over lower brickwork and should be rinsed off thoroughly each day. Scaffolding should be kept at least 150 mm from the face of the brickwork to prevent a build up of mortar droppings against the masonry. When bricklaying is interrupted by rain or rain is expected overnight, masonry should be protected by covering it. Saturated masonry will produce excessive efflorescence and may lead to staining with some bricks. Face bricks are supplied with one face and one header suitable for exposing (i.e. to be seen after laying). Face bricks with unwanted marks, chips or cracks on a header should be laid with that header inside a mortared joint. Face bricks with unwanted marks, chips or cracks on the face should be set aside by the bricklayer (or labourer) for use as commons. Boral will not be responsible for replacing bricks with unwanted marks, chips or cracks that have been laid.
ADV03796
1.315
Control Joints
Control joints must not be bridged by mortar or render. After laying the bricks or rendering, the joint must be cleaned. Lumps of mortar or render can transfer forces across the closing joint and will cause the bricks to crack (or spall). Control joints are usually constructed with a highly compressible material (in the form of a sheet or rod) inserted to keep dirt and moisture from penetrating to the cavity. For aesthetic reasons a compressible caulking material, matched to the mortar colour, is usually applied on the outside. As the joint closes, compressible caulking compounds may be extruded from the joint but incompressible ones may damage the bricks. If extruded caulking compound is considered unsightly, it can be cut out and replaced or the compound can be recessed during construction. Care must be taken when choosing a caulking compound to ensure it is a highly compressible type that will survive for the design life of the building and not discolour significantly. There are numerous suitable materials available and manufacturers recommendations should be sought. Where a control joint has flexible masonry ties built in, a piece of the compressible material must be removed to accommodate the tie.
Damp Courses and Flashing

Membrane type damp proof courses (DPC) must be laid across the full width of the wall or leaf and must project through the mortar on either side and be completely visible after laying and cleaning is complete. Recessing DPC below the edge of the brickwork so that the mortar bridges the DPC invalidates its use and is therefore entirely unacceptable. Bridged DPC may lead to rising damp, salt attack and or accelerated corrosion of the built-in components that may lead to structural failure. Recessing flashing below the mortar although common is not good practice as it allows the water that should be shed to soak into the wall below the flashing. DPC and flashing at the base of a wall may be combined. Lengths should be as long as possible but where not continuous, two adjacent pieces should overlap by at least 150 mm and if possible be sealed together. If a termite shield is used in the same joint as the DPC, the DPC material must be compatible with the termite shield or corrosion may destroy the DPC. General practice has been to recommend that flashings and DPCs be sandwiched between the mortar. There is some evidence that the common practice of laying flashings and DPC directly on the lower course of bricks and placing the mortar on top may be superior in some instances.
ADV03797
1.316
Cleaning of Clay Masonry

The Basics of Brick Cleaning
The cleaner the bricklayer leaves the wall, the easier will be the cleaning task. The majority of the mortar residues and smears should be cleaned before they set hard. However, in most cases some additional cleaning will be required to completely remove the mortar residue. Cleaning techniques may involve high-pressure water jet equipment or hand methods. Whatever technique is used, the following requirements must be observed to ensure additional staining problems are avoided.
Test Areas
Testing in one or more small areas is the safest way to determine the correct technique and chemical solution to remove mortar residues. This must occur well before final cleaning, as it will usually not be possible to assess the effectiveness of the test clean until the masonry dries.
Clean Soluble Salt Deposits First

Efflorescence, a white fluffy deposit, cannot be removed by water or acid. Dry brushing to remove the efflorescence before washing is recommended. If efflorescence is wetted, the salts go into solution and are drawn back into the brickwork and will reappear as the masonry dries. Efflorescence will eventually disappear through natural weathering. Vanadium salts produce a green or yellow efflorescence or stain (mainly seen on cream and light coloured clay bricks). Hydrochloric acid will make these stains much worse and may make them impossible to clean. Mild vanadium stains may be treated with sodium hypochlorite (household bleach). Spray or brush on dry brickwork and leave until the stain disappears, then rinse off. Proprietary mould cleaners containing sodium hypochlorite and sodium hydroxide can be used as above and have been found very effective. Proprietary brick cleaners may also be effective and should be used only according to the manufacturers instructions. Proprietary cleaners usually contain acids that must be neutralised after use with a solution of 15 grams of washing soda per litre of water. More than one chemical application may be required and the walls should be rinsed thoroughly after each treatment. t
ADV03798
1.317
Cleaning of Clay Masonry (continued)

High Pressure Cleaning
High-pressure water washing is now common for cleaning brickwork. If used the pressure must be kept below 1000 psi (7000 kPa), the nozzle must be kept 500 mm from the brick face and the nozzle must be a wide fan jet type with an angle of 15 degrees. The following practices must be observed: Cleaning should not start until the mortar has hardened. Hard lumps or persistent smears should be removed by hand. Mask adjacent materials. Do not apply the acid with the high-pressure sprayer. Use a low-pressure spray or broom it on. Clean from top to bottom in small sections. Work in the shade, ahead of the sun, if possible. DO NOT USE EXCESSIVE PRESSURE OR GET TOO CLOSE, as this will damage the face of the brick and the mortar joint. Mortar joints that are no longer smooth with sharp edges is a clear sign of excessive pressure. Excessive pressure is used to make cleaning faster; it does not do a better job of cleaning. t
ADV03799
1.318

Saturate the Wall Surface
Failure to completely saturate the surface of the wall is in itself a major cause of cleaning stains. Cleaning solutions containing dissolved mortar particles and acids will be drawn into a dry masonry wall, causing staining. Furthermore, saturating the surface of the wall keeps the acid solution on the face of the masonry where the mortar smears are present. It is not true that face saturation weakens the acid and slows the cleaning. Water should be trained on the wall until the brick suction is exhausted. The area to be cleaned must be saturated as well as all brickwork areas below. If the wall appears to be drying on the surface, reapply water until ready to apply the cleaning solution. Recommended acid strengths are based on application to a surface saturated wall. Note: This point must be strictly adhered to for bricks manufactured in Queensland. Their raw materials contain large amounts of iron oxide and failure to saturate the surface of the wall allows acid solutions to react with the iron oxide and create severe iron oxide staining. Failure to saturate the surface of the bricks manufactured in other parts of Australia can also lead to the acid reacting with iron oxide but to a much lesser degree. This form of staining is known as acid burn and is particularly visible on light coloured bricks. Acid absorption into bricks can also lead to vanadium and manganese staining. t
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1.319

Acids The Basics
The traditional masonry-cleaning chemical is hydrochloric acid, (also known as muriatic acid or spirits of salts). Its main function is to dissolve the cement in the mortar mix. It has few other uses and in many stain situations should not be used. Hydrochloric acid is a corrosive S6 poison and care must be taken when using it. If acid is splashed onto the skin it should be immediately swabbed with clean water, or more effectively, with a solution of bicarbonate of soda in water, which will neutralise the acid. The recommended acid strength for light coloured clay bricks is 1 part acid to 20 parts water and for other bricks is 1 part acid to 10 parts water. Acid takes time to dissolve the cement and should be left on for 4-6 minutes (or longer if needed) before washing off. After washing a solution of 15 g per litre of washing soda or 24 g per litre of sodium bicarbonate should be sprayed on to neutralise any remaining acid. Excess hydrochloric acid will eventually evaporate from the brickwork, however, it is likely to cause staining of the bricks and damage to built-in components. Other acids such as sulfuric acid or nitric acid will not evaporate and are not used in brick cleaning. Note: The recommended strength must be strictly adhered to. Bricks manufactured in Queensland may contain large amounts of iron oxide and the use of acid solutions stronger than 1 part acid to 20 parts water can dissolve these particles and create iron oxide staining. For light coloured bricks manufactured elsewhere the use of solutions stronger than 1 part acid to 20 parts water can lead to acid burn. Proprietary masonry cleaning solutions containing a mixture of acids are available. If used, the manufacturers recommendations must be strictly adhered to. Excessive and incorrect use of some proprietary cleaning solutions has in the past, produced very bad staining. t
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1.320

Safety Precautions
All masonry-cleaning acids are dangerous. Acids that do not dissolve cement as quickly as hydrochloric acid are not necessarily safer and can be very much more dangerous to human health. To avoid personal injury: Wear goggles, gloves and protective clothing. Always pour acids into water this avoids splashes of highly concentrated acid onto the operator. If splashed onto the body, wash with clean water and if possible, neutralise with a mixture of bicarbonate of soda and water. The manufacturers instructions and safety precautions must be strictly adhered to if proprietary cleaning products are used.
ADV03802
1.4 Clay Brick Property Tables
Escura Smooth Face

Brown
230x110x76 DW1 <30 2.9 49 190 >22 >6.6 >7.0 <1.1 EXP Nil to slight Nil to slight 90 400 1200 1150x920x775 >5.4 >5.8 <1.1 EXP Nil to slight Nil 90 340 925 1150x770x684 >5.4 >5.8 <1.1 GP Nil to slight Nil 90 340 925 1150x770x684 >6.6 >7.0 <1.1 GP Nil to slight Nil to slight 90 400 1200 1150x920x775 >5.4 >5.8 <1.1 EXP Nil to slight Nil 90 340 925 1150x770x684 >6.6 >7.0 <1.1 GP Nil to slight Nil 90 400 1200 1150x920x775 >5.4 >5.8 <1.1 GP Nil to slight Nil 90 340 1020 1150x770x684 >5.4 >5.8 <1.1 GP Nil to slight Nil 90 340 925 1150x770x684 230x110x76 DW1 <30 2.9 49 190 >15 230x110x76 DW1 <30 2.9 49 190 >15 230x110x76 DW1 <30 2.9 49 190 >22 230x110x76 DW1 <30 2.9 49 190 >15 230x110x76 DW1 <30 3 49 190 >22 230x110x76 DW1 <30 3 49 190 >15 230x110x76 DW1 <30 2.9 49 190 >15
Section 1.4 Clay Brick Property Tables
Choc Tan
Cinnamon
Cream
Flame Red
Hemp
Jute
Nevada Cream
Work size (mm) Dimensional category Perforation (%) Ave unit weight (kg) Approx number per m2 Wall surface density (kg/m2) Characteristic unconfined compressive strength of the unit (fuc) MPa Strengths of masonry (MPa) Characteristic compressive strength (fm) M3* mortar (GP) Characteristic compressive strength (fm) M4* mortar (EXP) Co-efficient of growth em (mm/m/15yrs) Salt attack resistance category Liability to effloresce Lime pitting Fire rating (FRL) minutes Insulation unrendered No per pack Pack weight (kg) Pack dimensions (mm)
Escura Smooth Face

Pearl Grey
230x110x76 DW1 <30 2.9 49 190 >15 >5.4 >5.8 <1.1 GP Nil to slight Nil 90 340 925 1150x770x684 >6.6 >7.0 <1.1 EXP Nil to slight Nil to slight 90 400 1200 1150x920x775 >5.4 >5.8 <1.1 GP Nil to slight Nil 90 340 925 1150x770x684 230x110x76 DW1 <30 2.9 49 190 >22 230x110x76 DW1 <30 2.9 49 190 >15
Melbourne Red Red Salmon Pink

230x110x76 DW1 <30 3.4 49 210 >22 >8.5 >9.0 <1.4 EXP Nil to slight Nil 90 272 950 865x710x935
Taupe
230x110x76 DW1 <30 3 49 190 >22 >6.6 >7.0 <1.1 GP Nil to slight Nil to slight 90 400 1200 1150x920x775
Terracotta
230x110x76 DW1 <30 2.9 49 190 >22 >6.6 >7.0 <1.1 GP Nil to slight Nil to slight 90 400 1200 1150x920x775
Victorian Pink
230x110x76 DW1 <30 3.4 49 210 >22 >8.5 >9.0 <1.4 EXP Nil to slight Nil 90 272 950 865x710x935
1.401
All testing is carried out in accordance with Australian Standards AS/NZS4456 test methods where applicable. Testing is carried out in NATA registered laboratories. Durability classification based on product knowledge under local climate conditions. This technical information represents average properties obtained from production lots and should not be used for specification purposes. For more detailed specification contact Boral Bricks. Unit weight quoted is an approximate weight and can vary. This information is subject to change without notice.
ADV03803
Escura Smooth Face Slimline

Brown
230x110x50 DW1 30 2 70 200 >22 >6.6 >7.0 <1.1 EXP Nil to slight Nil to slight 90 510 1100 1150x920x690 >6.6 >7.0 <1.1 GP Nil to slight Nil to slight 90 510 1100 1150x920x690 >6.6 >7.0 <1.1 EXP Nil to slight Nil to slight 90 510 1100 1150x920x690 230x110x50 DW1 30 2 70 200 >22 230x110x50 DW1 30 2 70 200 >22
Cream
Red
Escura Velour
Brown
230x110x76 DW1 <30 2.9 49 190 >22 >6.6 >7.0 <1.1 GP Nil to slight Nil to slight 90 400 1200 1150x920x775 >6.6 >7.0 <1.1 GP Nil to slight Nil to slight 90 400 1200 1150x920x775 >5.4 >5.8 <1.1 GP Nil to slight Nil 90 340 925 1150x770x684 >5.4 >5.8 <1.1 GP Nil to slight Nil 90 340 925 1150x770x684 >5.4 >5.8 <1.1 GP Nil to slight Nil 90 340 925 1150x770x684 230x110x76 DW1 <30 2.9 49 190 >22 230x110x76 DW1 <30 2.9 49 190 >15 230x110x76 DW1 <30 2.9 49 190 >15 230x110x76 DW1 <30 2.9 49 190 >15
Cream
Flame Red
Nevada Cream Pearl Grey Red
Salmon Pink
230x110x76 DW1 <30 2.9 49 190 >15
Taupe
230x110x76 DW1 <30 2.9 49 190 >22
Terracotta
230x110x76 DW1 <30 2.9 49 190 >22
230x110x76 DW1 <30 2.9 49 190 >22 >6.6 >7.0 <1.1 GP Nil to slight Nil to slight 90 400 1200 1150x920x775
>5.4 >5.8 <1.1 GP Nil to slight Nil 90 340 925 1150x770x684
>6.6 >7.0 <1.1 GP Nil to slight Nil to slight 90 400 1200 1150x920x775
>6.6 >7.0 <1.1 GP Nil to slight Nil to slight 90 400 1200 1150x920x775
1.402
ADV03804
Escura Pressed
Cream Red
Typical data for all other Boral face bricks can be found using the Reference Guides on the following pages. Look up your required product by Brick Name (page 1.404) or Range Name (page 1.405), and match the code to the corresponding Property Table Legend on page 1.406. For typical data relating to Boral clay pavers, refer to Section 2.4 Paver Property Tables page 2.401.
Work size (mm) Dimensional category Perforation (%) Ave unit weight (kg) Approx number per m2 Wall surface density (kg/m2) Characteristic unconfined compressive strength of the unit (fuc) MPa Strengths of masonry (MPa) Characteristic compressive strength (fm) M3* mortar (GP) Characteristic compressive strength (fm) M4* mortar (EXP) Co-efficient of growth em (mm/m/15yrs) Salt attack resistance category Liability to effloresce Lime pitting Fire rating (FRL) minutes Insulation unrendered No per pack Pack weight (kg) Pack dimensions (mm) >6.6 >7.0 <1.4 EXP Nil to slight Nil 90 272 1200 890x725x940 >6.6 >7.0 <1.4 EXP Nil to slight Nil 90 272 1200 890x725x940
230x110x76 DW1 Frog 4.1 49 240 >22
230x110x76 DW1 Frog 4.1 49 240 >22
Escura Dry Pressed

Red Rum
230x110x76 DW1 Frog 4.0 49 240 >15 230x110x76 DW1 Frog 4.0 49 240 >15 230x110x76 DW1 Frog 4.0 49 240 >15 230x110x76 DW1 Frog 4.0 49 240 >15 5.2 5.2 5.2 5.2 5.6 5.6 5.6 5.6 <0.7 <0.7 <0.7 <0.7 EXP GP EXP EXP Nil to slight Nil to slight Nil to slight Nil to slight Nil Nil Nil Nil 90 90 90 90 500 500 500 500 1850 1850 1850 1850 1150x900x1000 1150x900x1000 1150x900x1000 1150x900x1000
Black Beauty
Silver Shadow
Tinto Cream
1.403
ADV03805
LEGEND Listed Alphabetically by Brick Name

Brick Name Code Range Name Brick Name Code Range Name Brick Name Code
Range Name
Brick Name
Code
Range Name
NUVO HORIZON NSW NUVO OASIS HORIZON VIC ELAN NSW ELAN HORIZON NSW HORIZON NSW HORIZON NSW HORIZON NSW HORIZON NSW HORIZON VIC HORIZON NSW OASIS NUVO OASIS OASIS OASIS HORIZON VIC WOODSTOCK WOODSTOCK HORIZON VIC OASIS OASIS OASIS HORIZON NSW NUVO NUVO HORIZON VIC HORIZON VIC OASIS WOODSTOCK NUVO NUVO OASIS ELAN ELAN NUVO
Adobe Alabaster Alloy Alpine Amber Blaze Amber Blaze Amber Blaze 50mm Amethyst Antique Cream Antique Grey Antique Natural Antique Pink Argyle Arnhem Sands Ascot Bamboo Bantry Cove Beach Beach Double Height Beaumonde Bentley Bentley Double Height Berwick Rustic Bianca Bisque Bisque Double Height Blackheath Blue Rio Boulder Brown Terrain Brushwood Cameo Cascade Chestnut Chino Classic Limestone Hue Cleveland Cleveland 50mm Coco G G J M K M G G M M J D M C M G C D K G N M K J C E C J K G M G M A K J A C K WOODSTOCK HORIZON VIC ELAN ELAN ELAN ELAN HORIZON VIC WOODSTOCK WOODSTOCK HORIZON NSW WOODSTOCK WOODSTOCK OASIS HORIZON NSW OASIS HORIZON QLD NUVO HORIZON NSW NUVO NUVO HORIZON VIC ELAN NUVO WOODSTOCK WOODSTOCK HORIZON NSW OASIS HORIZON VIC ELAN OASIS HORIZON VIC NUVO HORIZON NSW WOODSTOCK WOODSTOCK WOODSTOCK ELAN ELAN HORIZON NSW L A C E C E A K L I K L J J M K G H D G A E G K L H J C N J A K M G K L C C H REVIVE REVIVE ELAN OASIS WOODSTOCK OASIS WOODSTOCK ELAN HORIZON NSW OASIS HORIZON VIC WOODSTOCK WOODSTOCK WOODSTOCK HORIZON NSW HORIZON VIC WOODSTOCK HORIZON VIC OASIS NUVO NUVO OASIS HORIZON QLD OASIS OASIS NUVO HORIZON VIC WOODSTOCK HORIZON VIC OASIS NUVO NUVO NUVO HORIZON QLD HORIZON VIC WOODSTOCK WOODSTOCK
K J K K C C E J J J J J C M K K J K L C K L C K K L H K G A C J M K G J C E G
WOODSTOCK HORIZON VIC OASIS HORIZON NSW OASIS WOODSTOCK REVIVE REVIVE WOODSTOCK HORIZON NSW OASIS NUVO WOODSTOCK ELAN WOODSTOCK HORIZON VIC HORIZON VIC NUVO NUVO WOODSTOCK ELAN WOODSTOCK HORIZON QLD HORIZON NSW ELAN ELAN HORIZON VIC OASIS OASIS WOODSTOCK WOODSTOCK HORIZON VIC WOODSTOCK HORIZON VIC NUVO HORIZON NSW HORIZON VIC HORIZON VIC WOODSTOCK
Colonial Colony Rose Coral Mist Coral Sands Coralstone Country Rose Cream Rockface Cream Texture Crestwood Delta Sands Desert Sage Domino Drysdale Duchess Dusk Eldorado Ember Glow Espresso Eucalypt Eureka Florentine Limestone Fresco Girraween Graphite Grey Nuance Grey Nuance 50mm Gypsy Rose Haze Hendra Heritage Hillview Historic Red Honeycombe Ironbark Ivory Jarosite Jarrah Kimberley Kingsley
Kingsley Double Height Kurrajong La Mesa La Mesa 50mm Labassa Labassa 50mm Lachlan Latrobe Latrobe Double Height Leura Lexington Lexington Double Height Limestone Hue Lindeman Linden Longreach Mangrove Megalong Merlot Mist Mocha Mocha 50mm Moss Mowbray Mowbray Double Height Murray River Nelson Cove Old Woodville Opal Blush Opal Cove Orient Panama Pewter Sands Port Phillip Potters Gold Potters Gold Double Height Raheen Rattan Red Cove
Red Texture No Arris Red Texture Smooth Arris Ripponlea Riverclay Rose Rose Cove Rose Double Height Rouge Rubellite Sable Sandalwood Sandhurst Sandstone Gold Sandstone Gold Double Height Sandy Bay Sandy Beach Settler Sienna Sirius Cove Slate Soft Suede Sorrell St George Stonewash Stonewash Double Height Storm Sunburst Sydney Town Tanami Tundra Vanilla Victorian Blue Victorian Blue 50mm Windorah Windsor Winter Gold Winter Gold Double Height
M M C K K J L A J J B M K L H C G C J K G K K K L G G G C J G D F K C K L
1.404
ADV03806
LEGEND Listed Alphabetically by Range Name

Brick Name Code Range Name Brick Name Code Range Name Brick Name Code
Range Name
Brick Name
Code
Range Name
ELAN ELAN ELAN ELAN ELAN ELAN ELAN ELAN ELAN ELAN ELAN ELAN ELAN ELAN ELAN ELAN ELAN ELAN Girraween Longreach St George Windorah Amber Blaze Argyle Beaumonde Berwick Rustic Brown Terrain Brushwood Colony Rose Eldorado Ember Glow Gypsy Rose Historic Red Ironbark Jarrah Kimberley Kurrajong Lachlan Mocha Old Woodville Orient Sandalwood Sandy Beach Sienna Sunburst Tanami Windsor Adobe Alloy Bamboo Blue Rio Boulder Chestnut Chino Coco Domino Espresso K K K K G K G G D D OASIS OASIS OASIS OASIS OASIS OASIS OASIS OASIS OASIS OASIS OASIS OASIS OASIS OASIS OASIS OASIS OASIS OASIS OASIS OASIS OASIS OASIS OASIS OASIS OASIS OASIS OASIS Alpine Ascot Bantry Cove Beach Beach Double Height Bianca Bisque Bisque Double Height Cameo Classic Limestone Hue Coral Mist Coralstone Desert Sage Haze Hendra Limestone Hue Linden Nelson Cove Opal Cove Riverclay Rose Cove Sable Sirius Cove Sorrell Stonewash Stonewash Double Height Tundra K K J K L K K L J J J K J J K J M J J K J J J K K L J C C C C A C G G C C G A A C A A A C A B C C G C C WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK WOODSTOCK Bentley Bentley Double Height Cascade Colonial Country Rose Crestwood Drysdale Dusk Eureka Fresco Heritage Hillview Honeycombe Kingsley Kingsley Double Height Latrobe Latrobe Double Height Lexington Lexington Double Height Mowbray Mowbray Double Height Port Phillip Potters Gold Potters Gold Double Height Rose Rose Double Height Sandhurst Sandstone Gold Sandstone Gold Double Height Settler Sydney Town Winter Gold Winter Gold Double Height K K K K Eucalypt Ivory Mangrove Merlot Mist Moss Panama Slate Soft Suede Storm Vanilla Victorian Blue Victorian Blue 50mm K K G D G G K K G G G D F Cream Rockface Cream Texture Red Texture No Arris Red Texture Smooth Arris
Amber Blaze (NSW) Amber Blaze 50mm Cleveland Cleveland 50mm Duchess Florentine Limestone Grey Nuance Grey Nuance 50mm La Mesa La Mesa 50mm Labassa Labassa 50mm Mocha 50mm Opal Blush Raheen Rattan Ripponlea Rouge
C E C E C N C E C E C E E N C C C A
HORIZON QLD HORIZON QLD HORIZON QLD HORIZON QLD
HORIZON NSW HORIZON NSW HORIZON NSW HORIZON NSW HORIZON NSW HORIZON NSW HORIZON NSW HORIZON NSW HORIZON NSW HORIZON NSW HORIZON NSW HORIZON NSW HORIZON NSW HORIZON NSW HORIZON NSW HORIZON NSW HORIZON NSW HORIZON NSW HORIZON NSW HORIZON NSW
Alabaster Amethyst Antique Cream Antique Grey Antique Natural Antique Pink Arnhem Sands Blackheath Coral Sands Delta Sands Graphite Jarosite Leura Lindeman Megalong Murray River Pewter Sands Red Cove Rubellite Sandy Bay
J J J J J J M H M M J J I J H H M H J H
HORIZON VIC HORIZON VIC HORIZON VIC HORIZON VIC HORIZON VIC HORIZON VIC HORIZON VIC HORIZON VIC HORIZON VIC HORIZON VIC HORIZON VIC HORIZON VIC HORIZON VIC HORIZON VIC HORIZON VIC HORIZON VIC HORIZON VIC HORIZON VIC HORIZON VIC HORIZON VIC HORIZON VIC HORIZON VIC HORIZON VIC HORIZON VIC HORIZON VIC
NUVO NUVO NUVO NUVO NUVO NUVO NUVO NUVO NUVO NUVO NUVO NUVO NUVO
REVIVE REVIVE REVIVE REVIVE
G G M M K L M G M M M M G M G M M K L K L K L K L G K L K L M K L G G K L
NUVO NUVO NUVO NUVO NUVO NUVO NUVO NUVO NUVO NUVO
1.405
ADV03807
Legend
A
230x110x76 DW1 <30 3.2 49 205 >22 >6.6 >7.0 <1.4 EXP Nil Nil 90 460 1518 1150 x 912 x 880 >6.6 >7.0 <1.4 GP Nil Nil 90 460 1472 1150 x 912 x 880 >8.5 >9.0 <1.4 EXP Nil to slight Nil 90 272 950 865x710x935 >6.6 >7.0 <1.4 EXP Nil to slight Nil 90 272 950 865x710x935 >5.1 >5.4 <1.4 EXP Nil to slight Nil 90 424 1000 865x730x935 >6.6 >7.0 <1.4 EXP Nil to slight Nil 90 424 925 865x710x935 >5.4 >5.8 <1.1 GP Nil to slight Nil 90 340 925 1150x770x684 230x110x76 DW1 <30 3.1 49 200 >22 230x110x76 DW1 <30 3.3 49 210 >22 230x110x76 DW1 <30 3.2 49 210 >22 230x110x50 DW1 <30 2.3 70 210 >22 230x110x50 DW1 <30 2.2 70 200 >23 230x110x76 DW1 <30 2.9 49 190 >15
For the product & range name relating to the reference codes shown below refer to the following alphabetical legend
Work size (mm) Dimensional category Perforation (%) Ave unit weight (kg) Approx number per m2 Brickwork load/m2 (kg/m2) Characteristic unconfined compressive strength of the unit (fuc) MPa Strengths of masonry (MPa) Characteristic compressive strength (fm) M3* mortar (GP) Characteristic compressive strength (fm) M4* mortar (EXP) Co-efficient of growth em (mm/m/15yrs) Salt attack resistance category Liability to effloresce Lime pitting Fire rating (FRL) minutes- Insulation Unrendered No per pack Pack weight (kg) Pack dimensions (mm)
Work size (mm) Dimensional category Perforation (%) Ave unit weight (kg) Approx number per m2 Brickwork load/m2 (kg/m2) Characteristic unconfined compressive strength of the unit (fuc) MPa Strengths of masonry (MPa) Characteristic compressive strength (fm) M3* mortar (GP) Characteristic compressive strength (fm) M4* mortar (EXP) Co-efficient of growth em (mm/m/15yrs) Salt attack resistance category Liability to effloresce Lime pitting Fire rating (FRL) minutes- Insulation Unrendered No per pack Pack weight (kg) Pack dimensions (mm) >6.6 >7.0 <1.1 GP Nil to slight Nil to slight 90 400 1200 1150x920x775 >6.6 >7.0 <1.1 EXP Nil to slight Nil to slight 90 400 1200 1150x770x685 >6.6 >7.0 <1.1 GP Nil to slight Nil to moderate 90 288 836 920x920x880 >4.4 >4.7 <1.0 EXP Nil to slight Nil to moderate 90 380 1080 1000x860x930
230x110x76 DW1 <30 2.9 49 190 >22
H
230x110x76 DW1 <30 2.9 49 190 >22 230x110x76 DW1 <30 2.9 49 190 >22 230x110x76 DW1 <30 2.9 49 185 >10
230x110x162 DW1 <30 5.8 24.5 190 >10 >5.5 >5.9 <1.0 EXP Nil to slight Nil to moderate 90 172 1050 1000x820x930
230x110x76 DW1 <30 3.0 49 190 >18 >5.9 >6.4 <1.0 EXP Nil to slight Nil to slight 90 400 1200 1150x912x770
290x90x162 DW1 <30 5.4 19.5 160 >10 >5.4 >5.8 <0.8 GP Slight Nil 60 132 713 980x770x870
1.406
ADV03808
1.407
Ratio 50% / 50% 66% / 33% 50% / 25% / 25% 25% / 25% 25% / 25% 50% / 25% / 25% 66% / 33% 33% / 33% / 33% 66% / 33% 50% / 50% 50% / 50% 50% / 25% / 25% 75% / 25% 83% / 17% 75% / 25% 33% / 33% / 33% 33% / 33% / 33% 50% / 50% 50% / 50% 85% / 15% 70% / 30% 85% / 15% 25% / 25% 25% / 25% 33% / 33% / 33% 33% / 66% 50% / 50% 85% / 15% 80% / 20% 50% / 50% 50% / 50% 33% / 33% / 33% 85% / 15% 50% / 50% 33% / 33% / 33% 85% / 15% 50% / 50% 50% / 50% 40% / 40% / 20% 85% / 15% 25% / 25% / 50% 50% / 50% 33% / 33% / 33% 33% / 33% / 33%
Boral Bricks Blends

Brand Horizon Horizon Horizon Horizon Horizon Horizon Horizon Horizon Horizon Horizon Horizon Horizon Horizon Horizon Horizon Oasis Oasis Oasis Oasis Oasis Oasis Woodstock Woodstock Woodstock Woodstock Woodstock Woodstock Woodstock Woodstock Woodstock Woodstock Woodstock Woodstock Woodstock Woodstock Woodstock Woodstock Woodstock Woodstock Woodstock Woodstock Woodstock Blend Name Brighton Sands Capes Lagoon Carrington Castlemaine Chalcedony Copeland Echo Point Galena Georges Basin Hawkesbury Hunter Manning Outback Patterson Reef Barclay Bendemeer Grange Raffia Sandstone Blush Tambo Apsley Bakehouse Gold Barweave Boyd Brunswick Carbrook Clarence Daintree Diggers Gold Dustwood Glenayr Hastings Highland Homestead Gold Macleay Mt Cotton Rywood Stockmans Wickham Wilson Woodland Blend Mix 1Coral Sands/1Delta Sands 2Sandy Bay/1Murray River 2Pink/1Cream/1Natural 1Pink/1Cream/1Natural/1Grey 2Rubellite/1Jarosite/1Graphite 2Cream/1Grey 1Sandy Bay/1Red Cove/1Murray River 2Jarosite/1Graphite 1Sandy Bay/1Red Cove 1Pink/1Cream 2Pink/1Cream/1Grey 3Pink/1Natural 5Windorah/1St George 3Cream/1Natural 1Coral Sands/1Pewter Sands/1Delta 1Sorrell/1Alpine/1Riverclay 1Linden/1Albion 1Hendra/1Ascot 5Sorrell/1Alpine 5Cameo/2Limestone Hue 5Alpine/1Sorrell 1Sandhurst/1Drysdale/1Hillview/1Crestwood 1Lexington /1Potters Gold/1Sandstone Gold 1Lexington /2 Mowbray 1Country Rose/1Cascade 5Mowbray/1Kingsley 4Bentley/1Kingsley 1Honeycombe/1Dusk 1Sandhurst/1Crestwood 1Potters Gold/1Sandstone Gold/1Winter Gold 5Lexington/1Potters Gold 1Sandhurst/1Drysdale 1Honeycombe/1Dusk/1Cascade 5Sandstone Gold/1Winter Gold 1Potters Gold/1Sandstone Gold 1Honeycombe/1Cascade 2Bentley/2Mowbray/1Kingsley 5Winter Gold/1Sandstone Gold 1Sandhurst/1Crestwood/2Hillview 1Bentley/1Mowbray 1Dusk/1Country Rose/1Cascade 1Sandhurst/1Drysdale/1Crestwood
ADV03809
2. Pavers
Pavers
2.1 Paver Properties
Section 2.1 Paver Properties
2.101
Section 2.1 relates to the properties of pavers made to meet the requirements of Australian Standard AS4455 Part 2 Pavers and Flags. This information is provided as a guide only to the properties of interest to a pavement designer or layer and does not constitute a recommendation for any type of pavement or any technique for paving. Typical properties for individual pavers can be found on the data sheets.
Paver Dimensions
Pavers can be made in any shape that tessellates but for manufacturing reasons they are usually restricted to rectangles or squares. Rectangular pavers are usually made so that two laid together with a 2-5 mm gap in between, form a square. AS4455.2 differentiates between pavers and flags in that a paver has a plan area less than 0.08 m2 (i.e. less than 280 mm x 280 mm square). Pavers being smaller than flags allow changing of levels more easily. Pavers are also easier to cut than flags to fit complex geometries such as tight re-entrant angles or curves. Pavers can be any size; however, the common work size has plan dimensions of 230 mm long x 115 wide. This size was chosen for the practical reason that pavers tend to be made in the same plants as bricks and the manufacturing machinery is designed for this size. Commonly pavers are made in 40 mm, 50 mm and 65 mm heights and because flexible pavements rely on pavers interlocking and sharing forces, a minimum thickness is required for different applications. Manufacturers specify the work size of the pavers they sell. Clay paver sizes vary when they are fired but over and undersized units average each other out when blended properly during laying. Paver dimensions are measured by dry stacking 20 units, measuring the total length and comparing that measurement to twenty times the work size. Pavers are classified according to how much they deviate from twenty times the work size. Dimensional Category, DPA1 means, for typical pavers, the height and width will differ by less than 50 mm from twenty times the work size and the length will differ less than 60 mm. Dimensional Category, DPA2 means, for typical pavers, the height and width will differ by less than 40 mm from twenty times the work size and the length will differ less than 50 mm. Dimensional Category, DP0 means there are no requirements. This is usually reserved for non-standard pavers that have been rumbled or otherwise distorted in manufacture for aesthetic reasons. DPO pavers are reserved for residential pathways. DPA1 and DPA2 pavers are specified in applications requiring tighter tolerances to share loads more effectively. This is specifically those areas where there is a higher volume of traffic or heavier loads.
ADV2101
2.102
Paving Strength
Minimum Breaking Load
The most important strength for pavers is their resistance to breaking under a bending load. This is because pavers are mainly supported from below and they are loaded from above. Bend strength is measured according to AS4456.5, where a load is applied across the middle of a paver, supported across its width 25 mm in from both ends. The test imitates the extreme case of the possible field loading, where there is no support from the sides and the bedding course has failed. Pavers in any one batch have a range of strengths that would usually follow a normal distribution. Normal practice has been to use the Minimum Breaking Load in pavement design. This is the lowest breaking load found when measuring 10 samples.
Compressive Strength of Pavers

Paver compressive strength is measured by individually crushing 10 pavers in the same way it is for bricks. This gives the compressive strength of each paver and the mean compressive strength of the lot. A factor can be applied to eliminate the test constraints to give the unconfined compressive strength of each paver, which by further mathematical treatment can give the Characteristic Unconfined Compressive Strength. While the compressive strength is critical in masonry design, it is almost never relevant in pavement design.
ADV2102
2.103
Durability
Salt attack is the most common durability problem. Salt can be absorbed into pavers in the form of a solution. As the water evaporates, the salt is drawn towards the outside face. The evaporating water leaves the solution supersaturated so salt crystals begin to form. The salt crystals grow in the pores just below the surface and depending on the texture of the paver, the amount of salt, the rate of drying and the temperature, the salt may fill the pores, exerting very high pressures on the matrix. The energy in the constrained salt crystal is large, and when a sufficient number of constrained salt crystals of large enough size are present, the energy is converted to new surface energy and movement, i.e. it pops a piece of the outer surface off, and salt attack has begun. Pavers are assessed according to AS/NZS4456.10 Resistance to Salt Attack and classed into grades. In summary the grades of paver can be used as follows: General Purpose Grade (GP) Suitable for use in all pavements not requiring Exposure Grade pavers. Exposure Grade (EXP) Suitable for use: around salt water pools; within 100 metres of a non-surf coast; within 1 kilometre of a surf coast; and in contact with aggressive soils or environments. Exposure grade pavers can also be used in GP applications. Boral provides pavers in both EXP and GP grades. Freeze-thaw is an uncommon durability problem in Australia, affecting only alpine areas. As water freezes it expands and if sufficient pressure is generated, pieces break off. Freeze-thaw resistance is determined according to an ASTM test, which is done mainly on pavers exported to Northern Asia. Although failure is due to a constrained particle in both cases, the mechanism is different and pavers that pass the salt attack test do not necessarily pass the freeze thaw test and vice versa. Should freeze-thaw resistant pavers be needed, contact your Boral sales representative so they can nominate those available.
Slip Resistance
The slip resistance of a pavement is obviously important. AS/NZS 4586:1999 Appendix A. Slip Resistance Classification of New Pedestrian Surface Materials: Wet Pendulum Test Method is used to determine paver slip/ skid resistance. The test simulates a rubber soled shoe on a wet pavement. A classification of W (low contribution of the paver to the risk of slipping when wet) is the minimum requirement for pavers, the only other acceptable classification is V (very low contribution of the paver to the risk of slipping when wet).
ADV2103
2.104
Abrasion Resistance
The abrasion resistance gives an indication of the pavers ability to withstand wear. AS/NZS 4456.9:1997 Determining Abrasion Resistance is used for testing the abrasion resistance of clay pavers. The test consists of fixing pavers over holes in the side of a rotating box filled with ball bearings. The test was designed to simulate the action of high-heeled (stiletto) shoes on pavers, which is known to be highly aggressive because of the high point loads. Abrasion resistance is only required for public area pavements and the Mean Abrasion Resistance required depends on the volume of traffic.
Moisture Expansion
Clay products expand over time as they absorb water into their structure. The expansion is not uniform and one quarter of the expansion occurs in the first six months, one half in the first two years and three-quarters in the first 5 years. The Characteristic Expansion is estimated from an accelerated test and expressed as a coefficient of expansion (em). For Boral pavers the characteristic expansion is usually between 0.8 and 1.2 mm/m. Moisture expansion is taken up in the gaps between pavers in flexible pavements however, in rigid pavements (including copers around pools) stresses are usually relieved by creep in the adhesive and it is essential the correct adhesive is used. Reducing the residual moisture expansion by storing the pavers in ambient or moist atmosphere is known as grassing the pavers. For pavers with a high moisture expansion this should be considered if using the pavers for rigid pavements where there are opposite movements in concrete shrinkage and paver expansion.
Efflorescence
Pavers may contain soluble salts that come to the surface when the paver dries. The source of the soluble salts is the raw materials used in the production process. Paver efflorescence is usually white but there is a special form of efflorescence (known as vanadium staining) that is coloured yellow, green or reddish-brown and is therefore particularly visible on light coloured pavers. Boral pavers have little to no efflorescence and paver efflorescence should not be confused with the efflorescence that is seen on pavements in some areas after laying. This form of efflorescence mainly comes from the subgrade or the base course materials used in the construction process. Frequently efflorescence comes from poorly graded bedding sand not acting as a capillary break, allowing salt laden water to be drawn up from below.
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2.105
Pitting due to Lime

If paver making raw materials contain particles of calcium carbonate, these will be converted into quicklime in the kiln. Water subsequently combines with the quicklime to form hydrated lime and in the process it expands. If lime particles are sufficiently large and sufficiently near the surface they pop off a piece of the paver, leaving a generally circular pit with a white spot in the bottom. Boral pavers rarely show lime pitting.
Cold Water Absorption

While pavers absorb water and the joints in segmental pavements allow some water to pass through the pavement, these surfaces are usually classed as impermeable in landscape design. Some special pavers are made to allow water to drain through but such permeable pavers are uncommon in Australia. Most permeable pavements are designed to allow water to penetrate through the gaps between pavers not through the paver. The amount of water that a paver can absorb is measured by the 24 hour cold-water absorption (CWA) test. The results of water absorption tests are of use to the paver manufacturer for quality assurance but are rarely of any value to anyone else. With proper drainage of the base course and attention to levels, pavers should not look continually wet in a pavement, regardless of the CWA. Sealing pavers with silicones, siliconates, urethanes, polyesters or acrylics may lower the CWA or seal the surface giving a lower test result. Sealing can be done at the manufacturing stage but the benefit to the user is hard to quantify. Sealing can give a false result in a salt attack or freeze thaw test and is specifically banned by some test methods. Sealing after the pavers are laid is generally not advised as only the top surface is sealed and water rising from below will generally bring up salts, to be deposited under the coating. If this happens it cannot be rectified in most cases. Where it is expected that grease and oil may be dropped on paving then sealing will make it easier to keep the pavement clean. Remember, no coating lasts for ever and some coatings darken over time.
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2.2 Pavement Design
Section 2.2 Pavement Design
2.201
This section contains recommendations for typical pavement systems. Local experience may support departures from these recommendations where satisfactory in-situ performance has been demonstrated over a period of time. The recommendations are not applicable for pavements on poorly drained sites and sites classified as highly reactive clay sites, extremely reactive clay sites or problem sites according to AS2870.1; engineering design is required for such sites. While rigid pavements are described below and some minor recommendations are made, both rigid pavements and water permeable pavements are beyond the scope of this manual.
Pavement Types
Pavers are used to make segmental pavements. Segmental pavements are divided into two major sub-groups, flexible and rigid. A rigid pavement relies on having a rigid layer (usually a concrete slab) to distribute the imposed loads to the subgrade, a flexible pavement does not. Pavements can be further sub-divided on their use. 1. 2. 3. 4. Pedestrian traffic only Pedestrian traffic and light vehicles (axle loads less than 3 tonnes) Pedestrian traffic and commercial vehicles (axle loads greater than 3 tonnes) Primarily vehicular traffic
Flexible Pavements are constructed in layers; subgrade, base course, bedding course and surface course. In situations where heavy vehicular traffic is expected or the subgrade is of marginal strength, an additional layer, the sub-base, may be inserted between the subgrade and the base course. On rare occasions, where the subgrade is strong rock and it is sufficiently level, the bedding course may be laid directly on the subgrade. Rigid Pavements are also constructed in layers; subgrade, rigid base course, bedding course and a surface course. The bedding course is omitted in some situations where the pavers are adhered directly to the rigid course. Rigid pavements become more common as loads increase and are usually not constructed to carry only pedestrian traffic. In some parts of Australia a significant proportion of domestic driveways are rigid segmental pavements and this trend is growing elsewhere. The decision to use a flexible or rigid pavement depends on specific site conditions and a comparative cost analysis. Boral does not recommend rigid pavements over flexible pavements or one system of rigid paving over another. Rigid pavements will not be discussed in detail in this manual. t
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Pavement Types (continued)

The Pedestrian traffic only category is typically residential paths and hard landscaped areas, paths in public gardens and parks, pedestrian areas around buildings such as offices, schools, etc. and pedestrian areas around entertainment or sporting facilities. These pavements are usually closed to all vehicles. The Pedestrian traffic and occasional light vehicles category is typically residential driveways and areas around buildings, used occasionally by light vans and utilities for deliveries or for access for maintenance work. Heavier vehicles such as those picking up full rubbish skips or delivering concrete, bricks, etc are likely to cause some damage. The Pedestrian traffic and commercial vehicles category is typically public malls, crossovers, driveways that carry occasional commercial vehicles and lightly trafficked streets. Commercial vehicles are classified as those having a gross weight equal to or greater than 3 tonnes. The Primarily vehicular traffic category is roads. Few segmentally paved roads are now constructed however; this form of construction was widespread in the past as can be seen with many surviving examples of cobbled streets. Detailed engineering design is required for roads, due to the high superimposed loads and the consequence of failure. Construction of segmentally paved roads is generally the same as for asphalt roads up to the bedding course. The bedding course and surface course construction is then generally the same as for other pavements but 65 mm or thicker pavers are used and a herringbone laying pattern is mandatory.
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Description of Layers and Basic Engineering Design Requirements

Figure 1. Typical elements of flexible pavements
Jointing sand Clay pavers Surface course Bedding course Concrete Edge Strip
Base course
Subgrade
Subgrade
The subgrade is the natural ground or constructed soil which supports the loads transmitted by the overlying pavement layers. The natural ground may be rock or soil that is sufficiently strong for the purpose. Where the natural soil is not strong enough to bear the loads, the natural soil or imported fill may be compacted to produce the desired strength. Compaction is the most cost effective measure for increasing the strength of soil. Soil strength is assessed using the Californian Bearing Ratio (CBR) test (AS 1289.6.1. Parts 1, 2 or 3). The CBR test measures the shear strength of the soil and the result is expressed as a percentage of the shear strength of a sample composed of Californian marble (or limestone) chips. The most common CBR test is the remoulded laboratory test where the sample may be tested immediately after compaction or it may be soaked to fill all pores with water before testing. Soaking represents the worst case in the field i.e. a saturated subgrade. The decision to use a soaked or un-soaked CBR in the design should reflect the expected in-service conditions. For pavements carrying only pedestrian and occasional light vehicular traffic it is usual practice to estimate the CBR from soil classification data or local knowledge. Measuring the CBR is usually restricted to situations where the potential savings from using lower grade materials or thinner layers outweighs the cost of the test. If the materials in the subgrade have a soaked CBR value less than 5% and are to carry vehicular traffic, stabilisation with cement, lime, ground granulated blast-furnace slag or the use of geotextiles or lean mix concrete should be considered. The top of the finished subgrade is calculated from the top of the pavement (minus the thickness of the pavers, bedding course and base course). The level of the top of the pavement is governed by aesthetics and practical matters such as positioning of damp-proof courses and physical termite barriers in adjacent masonry, step heights, and whether the pavement is to be flush with, above or below the surrounding landscape, etc.
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Base Course
The base course is a constructed layer which transfers the loads from the surface course to the subgrade. The thickness of the base course varies depending on the subgrade classification and the intended use. For pavements carrying loads in excess of domestic driveways, the base course should be designed on sound engineering principles. The thickness of the base course increases for lower CBR subgrades but thinner base courses may be used where the base course materials are stabilised or where a geotextile is used appropriately. The base course in a flexible pavement is made from granular material compacted in layers. Particularly for large projects, where traffic volumes and loads are expected to be high, field density testing should be used to verify that the required soil density has been achieved. The material used in the base course should conform to local requirements for base course materials for asphalt roads. Base course materials are natural or manufactured granular material which interlocks on compaction, usually being a nominal 20 mm aggregate with less than 6% clay. The top surface of the base course should be close-knit to prevent bedding course materials falling down leaving cavities under the pavers, but where such material is not available or where subgrade movement is likely a geotextile should be used.
Table 1. Typical Grading for Base Course Materials
Sieve Size 26.5 mm 19.0 mm 13.2 mm 9.5 mm 4.75 mm 2.36 mm 425 m 75 m Percent Passing 100 95-100 78-92 63-83 44-64 30-50 14-22 4-12
Stabilisation of base course materials is recommended in areas of very high rainfall, as stabilised materials are less susceptible to the effects of saturation. When resurfacing existing pavements, if the pavement is stable, then no further preparation is required as the existing pavement can usually be regarded as a suitable subgrade and base course. In rigid pavements the base course is usually a nominal 20 MPa reinforced concrete slab designed to AS 3600 Concrete Structures requirements.
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Bedding Course
The bedding course passes the loads from the pavers to the base course. It also acts as a capillary break to prevent (possibly salt laden) moisture being drawn up to the pavers and in the laying process allows pavers to settle more or less so that pavers of slightly different heights finish with the top surfaces aligned. Bedding course material should be well-graded, coarse, sharp sand (typical of a concrete sand) with less than 3% clay. Bricklaying sands, loams and fatty sands do not consolidate as do sharp sands and because of their fines content, do not provide a capillary break and so should not be used. Manufactured sands with excessive fines, (eg crusher dust or quarry fines), should not be used as they do not provide a capillary break and this results in efflorescence caused by saline ground waters.
Table 2. Typical Grading for Bedding Course Materials
Sieve Size 9.5 mm 4.75 mm 2.36 mm 1.18 mm 600 m 300 m 150 m s 75 m Percent Passing 100 90-100 75-100 55-90 35-59 8-30 0-10 0-5
The bedding course should be screeded to a nominal 25-30 mm thickness and the base course should be finished accurately enough not to need to vary this thickness. However in the event of poor workmanship, the bedding course may be varied but it must never be less than 20 mm thick and should not be more than 40 mm thick. It is most important that the bedding course is of uniform thickness. Geotextiles may be laid on top of the base course under the bedding sand. They act as a separation layer and are particularly effective in preventing the loss of bedding sand due to cracking in the base course caused by movement in subgrades. Should there be a loss of bedding sand, the pavers may subside and possibly chip or break. Geotextiles may also be effective as a drainage layer. Stabilisation of bedding course materials should be considered where the pavement is constructed on a steep slope. Stabilisation reduces the likelihood of bedding course material being flushed out leaving cavities under the pavement. In most other instances stabilisation of the base course is not recommended as it increases the cost for no commensurate benefit and in some instances leads to increased efflorescence on the laid pavement.
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Surface Course
The surface course comprises pavers. Paver thickness should be specified for all pavements. Paver durability grade should be specified only where salt attack or freeze/thaw is an issue. Paver bend strength should be specified for pavements carrying vehicles. Paver abrasion resistance should be specified for pavers in public area pavements (i.e. those with high levels of pedestrian traffic). Paver slip resistance should be specified for pavers in public areas.
Table 3. Recommended Specifications for Clay Pavers
Application Residential (domestic) pavements Pedestrian traffic only Driveway, light vehicles only Driveway, including commercial vehicles Public area pavements Pedestrian traffic only Pedestrian traffic and light vehicles (axle loads < 3 tonnes) Pedestrian traffic and commercial vehicles (axle loads > 3 tonnes) Roads General vehicular traffic on minor or local roads Minimum thickness (mm) 40 40 60 40 50 60 Minimum characteristic breaking load (kN) 2 3 5 2 3 5 Dimensional Slip resistance deviation classification DP0 DPA1 DPA1 DPA1 DPA2 DPA2 W W W W W W Mean abrasion resistance (cm2) N/A N/A N/A
Low volume: 7 Medium volume: 5.5 High volume: 3.5 (See Note 1) N/A (See Note 2)
60
DPA2
Note 1: Typical low volume pedestrian traffic is up to the level found in schools and public areas of residential complexes. Typical medium volume pedestrian traffic is found in suburban shopping precincts or sports venues. Typical high volume pedestrian traffic is found in inner city and major suburban malls and transport hubs (often over 30 000 passes per day). Note 2: Minor and local roads are those carrying up to 1000 vehicles per day (i.e. excludes collector roads).
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Edge Restraints
Edge restraints are existing structures or constructed features, which are sometimes seen as decorative features but in reality are of great structural importance. Edge restraints as the name suggests constrain lateral movement of pavers at the edge of the pavement. This combined with sand in the joints is critical in producing rotational and horizontal interlock. Failure of the edge restraint will lead to failure of the pavement. As the design load and traffic volume increase the edge restraint should be upgraded. For pavements carrying pedestrian traffic only, pavers on edge, timber on edge or mortar haunching of the edges is usually sufficient. For a driveway carrying commercial vehicles a reinforced concrete strip (beam or slab) forms a suitable edge restraint. (Such strips may be hidden by the edge pavers being bonded to it or it may be left visible as part of the pavements aesthetic). Concrete restraints should meet AS3600 requirements and should be constructed from ready mixed concrete with a minimum strength of 20 MPa.
Figure 2. Typical edge restraint systems
Paver on edge (or treated timber) set in mortar or concrete.
Hardwood on edge supported by hardwood stakes
Mortar haunch
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Figure 2. Typical edge restraint systems (continued)
Preformed concrete
Concrete poured on site (driveways mainly).
Concrete poured on site (driveways mainly)
Figure 3. Using an existing structure as an edge restraint
Damp Proof Course
150mm Mortar Bed Jointing sand Clay pavers Surface course Bedding course
Base course
Subgrade
The edge paver is set on a mortar bed (shown as grey).
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2.209
Drainage
The most common reason for the failure of pavements is inadequate sub-surface drainage. So where it is necessary, during construction install sufficient stormwater and sub-soil drainage to prevent the accumulation of water in any area excavated for the pavement. All trenches should be backfilled to ensure they perform similarly to the undisturbed ground around them. However, even where this is done effectively, after completion of the paving, water pooling on the surface may penetrate through the pavement and cause softening of the subgrade. Although pavers do not allow large amounts of water to drain through them the joints do allow water to penetrate, particularly in the early life of the pavement. Water infiltration due to poor drainage may also cause the growth of moss, mould, fungus and lichen which looks unsightly and may be slippery. Pavement design should ensure that surface water is directed to collection points where it can be discharged safely.
Figure 4. Typical drainage systems in flexible pavement
Clay pavers Surface course Bedding course
Base course PVC Pipe
Subgrade
Figure 4 shows a typical drainage arrangement in a sloping flexible pavement at a concrete, edge restraint or transverse beam. A slotted PVC pipe with a filter sock, drains water from the base course to the side and out of the pavement. A smaller PVC pipe with a filter cap drains water from the bedding course out of the pavement.
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Paver Laying Patterns

Various paving patterns can be formed and some of these are illustrated on the next page. For pavements carrying vehicles herringbone pattern (either 90 or 45) should be specified. For pavements carrying pedestrians only, the choice of pattern is a matter of personal preference. It must be remembered that some patterns require significantly more cutting than others and this may affect the cost of laying. For example, tracery pattern is developed from a unit consisting of four whole pavers and a half a paver whereas running pattern only has part pavers at each end of the pavement. When specifying the pattern it is best to remember the function, setting and size of the pavement. Pavements laid on a granular bedding course, carrying vehicular traffic must use a herringbone pattern. Herringbone patterns have contiguous pavers over the shortest distance of any pattern (i.e. no straight joint extends for more than 1 pavers) and therefore resist shunting best. Simple patterns should always be used in small spaces while large spaces can use patterns with large repeat distances to advantage. A major advantage of pavers over flags is that pavers can be formed into more complex patterns. By using different laying patterns and colours, many effects can be created. As with a carpet the effect can be a solid uniform colour, a mottle producing an overall colour impression, random coloured highlights, a polychrome patchwork, geometric patterns, etc. Some designers have used pavers to create pictures on a grand scale. Effects may also be much more subtle such as using regular arrays of similar coloured pavers to produce textural effects. t
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Paver Laying Patterns (continued)
45 Herringbone
90 Herringbone
Zig Zag
Basket weave 2 x 2
Basket weave 2 x 1 45 Basket weave ( Basket weave or Basket weave variant)
Stack
Stretcher or running
Off-set stretcher or running
45 Stack
Mixed stack and running
Tracery
Off-set stack
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Joints Between Pavers

Pavers laid on bedding sand should have gaps of 2-3 mm left between them for the jointing sand. To be effective, gaps should never be less than 1 mm nor more than 5 mm. After laying the pavers jointing sand is spread over and broomed into the gaps. A plate vibrator is then passed over the surface, levelling the pavers and vibrating sand down into the gaps while settling and compressing the pavers into the bedding sand. At the same time some of the bedding sand is forced up into the joints. Sand filled joints are essential as the sand interlocks the pavers so that imposed forces are shared between adjacent pavers. Interlock is of three types; vertical, horizontal and rotational. Vertical interlock ensures a paver does not slide down relative to its neighbours by sharing loads between neighbouring pavers. Rotational interlock ensures that a paver loaded at one side does not rotate. Pavers need space to rotate so edge restraints and proper filling of the joints prevent movement that would otherwise allow pavers to rotate. The sand moves the point at which the pavers would rotate (i.e. the hinge) to the top of the joint and prevents the top edges of adjacent pavers coming into contact. Pavers contacting their neighbours are very likely to chip when loaded. Horizontal interlock is provided by the laying pattern. Wheeled traffic pushes the pavers and where straight lines occur in the laying pattern the pavers can move past each other (this is called shunting). Where the pavement carries wheeled traffic a herringbone pattern (either 45 or 90) is recommended. There seems to be no difference in the performance of the different styles of herringbone or in orientation relative to the traffic. For pavements only carrying pedestrian traffic, horizontal interlock is required to a much lower degree and a wide range of decorative laying patterns may be used. Gaps between pavers that are too narrow (<1 mm) do not allow sufficient sand for effective interlock. Jointing sands should be rounded, free flowing sand, typically dune sand.
Table 4. Typical Grading for Jointing Sands
Sieve Size 2.36 mm 1.18 mm 600 m 300 m 150 m 75 m Percent Passing 100 75-95 50-80 20-45 5-15 0-5
Typical gradings for jointing sands overlap typical gradings for bedding sands and so one sand may be suitable for both requirements. Bedding and jointing sands are frequently whatever is readily available in the local area and may not meet the typical gradings above. Proprietary jointing sands containing various additives are available, but their cost usually limits them to specialised uses.
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Tolerance on Course Levels

Subgrade should be finished to +0, -25 mm of the design level. Where the pavers are laid on bedding sand the base course (and where used the sub-base) should be finished to +0, -25 mm except where it abuts existing structures where +0, -10 mm is appropriate and in any 3 metre length the surface should not be higher or lower than 10 mm from the average (taking into account any falls). Bedding courses should be finished to the thickness required to bring the surface course to the design level, taking into account the thickness of the surface course and compaction as the pavers are vibrated to settle them into the bedding course. This will depend on the bedding course materials and its moisture content. Where local experience is not available the required thickness should be established by trial. Surface courses should be finished to 6 mm of the design level, except where it abuts a kerb or drainage channel where it should be finished to +6, -0 mm. In all cases there should be less than 3 mm difference between adjoining pavers.
Crossfalls
A 1:60 crossfall is normally satisfactory for drainage. Crossfalls should not be less than 1% (1:100) unless specific measures have been taken to ensure water does not build up on the pavement e.g. covering it with a roof. The general rule is that the broader the paved area the greater the crossfall. Crossfalls are sometimes restricted by the sites landform and some pooling of water in heavy rain may be acceptable.
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Steep Gradients
Even on the best constructed pavements, water running over or dripping or splashing onto steeply sloping pavements may wash out the jointing sand, particularly early in the life of the pavement. Localised rutting (usually from inadequate subgrade or base course preparation), loss of bedding sand (usually from poor sub-surface drainage), and localised movement (usually at or near poor edge restraints) can also lead to loss of the jointing sand. For pavements carrying wheeled traffic (such as driveways) this is a particular problem as it may result in the pavers chipping or shunting (moving laterally). To avoid shunting and chipping pavers, maintaining the jointing sand and using a restraint system are essential. Rigid pavement with the pavers adhered directly to a concrete slab and the joints filled with mortar or grout has been used successfully as an alternative. Maintaining the jointing sand is as simple as sweeping more sand over when needed. Proprietary jointing sands are available containing cement, mineral and polymeric binders. The additives bond the sand together and this has been shown to be beneficial on steeply sloping pavements because the sand does not wash out as easily, but beware of potential staining problems. Use only as directed by the manufacturer and construct a small trial area to test if there are any problems in use. The principle of restraint systems is to subdivide the pavement into (typically 5 metre) sections restrained at the periphery. Because the section length is short the potential for movement is reduced. A typical restraint system uses a plain concrete transverse beam. Concrete beams should be designed to AS3600 requirements and be constructed from ready mixed concrete with a minimum strength of 20 MPa.
Figure 5. Typical plain concrete transverse beam for a steep single residence driveway
PVC Pipe Clay pavers Surface course Bedding course
Base course
Subgrade
The depth of the concrete beam depends on the soil type. Typically for a single residence driveway on clay, the beam is 250 300 mm deep. The pavers are adhered to the beam typically with a 1:4 cement to sand mortar with additives to enhance bonding or the pavers are pressed into wet low slump concrete. An exposed plain or exposed aggregate concrete beam can be used instead of having pavers bonded to it.
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2.3 Pavement Construction
Section 2.3 Pavement Construction
2.301
Each job is different and the descriptions below may or may not be suitable in any particular instance. The steps in the construction of the pavement may vary in their order. For example, edge restraints for a heavy duty driveway will usually be constructed between the preparation of the subgrade and the base course but may be constructed between the preparation of the base course and the bedding course. However, for light duty driveways edge restraints may be put in after preparation of the base course and for domestic pathways professional paviours almost always put in edge restraints after laying the surface course. For an amateur it is best to construct the edge restraints early.
Paver Estimator
Pavers can be different sizes and shapes and pavements can be any size and shape. The more complex the pavements shape usually the more cutting and therefore the more pavers required. For regular pavements, determine the number of pavers for the length of the pavement and the number of rows for the width of the pavement. Half pavers should be calculated as a whole paver, due to site wastage. Multiply the number of pavers by the number of rows to give the number of pavers for the pavement. Saw cutting pavers is usual practice but that does not mean two pieces will be obtained from any paver. For complex pavements, draw the pavement accurately to scale on squared paper and work out the approximate area and multiply this area by the factor in the relevant paver property table. Always allow some excess pavers for site wastage.
Subgrade Preparation
The subgrade should be prepared to the design profile. The prepared area should be wider than the pavement, extending beyond the rear edge of the edge restraints or up to existing structures. Unsuitable material including the topsoil, roots and other organic matter should be removed from the subgrade. Proof rolling may be used to identify areas of unstable subgrade, which should be removed or compacted to achieve the desired strength. Observing a loaded truck slowly crossing the area will generally show areas of unstable subgrade. The subgrade should be excavated, compacted, trimmed or built up with compacted base course material as necessary to within +0mm, -25 mm of the design level. The most common reason for the failure of pavements is inadequate subsurface drainage and so, where necessary, install sufficient stormwater and subsoil drainage to prevent the accumulation of water in any area excavated for the pavement. Water accumulating in this location could reduce the stability of the whole structure or bring efflorescing salts to the pavement surface and detract from appearance or durability. All trenches should be backfilled to ensure they perform similarly to the undisturbed ground around them.
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Base course Preparation for Flexible Pavements

The base course is made from granular material (usually called road base) compacted in layers. The thickness of the layers and the number of passes of the compactor should be matched to the capability of the compaction device. For large machinery it is usual to compact in 150 mm layers but for a vibrating plate compactor layers less than 100 mm are usual. The number of passes of the compactor varies but for a vibrating plate compactor three passes is usually satisfactory for domestic pavements carrying only pedestrian traffic. In typical domestic pavements 100 mm of compacted base course is usually sufficient. The base course should be screeded and compacted to the design profile (+0, -25 mm except where it abuts existing structures where +0, -10 mm is appropriate). The top surface should be closed after compaction but if holes are apparent because of the nature of the material used, fines can be screeded on and compacted into the surface to fill any voids. Where stabilised base course is required, in most circumstances it is best to purchase it ready mixed, just before use. Cement stabilised materials may set if not used within a few hours and if a delay is expected slower setting materials and retarders are available. Mixing on site should only be done in a concrete mixer as it is difficult to get an even distribution of the binder by hand mixing.
Edge Restraints for Flexible Pavements

All edges of all pavements must be restrained to prevent lateral movement of the pavers and consequent loss of interlock. The size and strength of the restraints must be adequate to support the intended loads. The shape and style of the restraints must prevent the escape of bedding course material from beneath the pavers and must be aesthetically pleasing. Edge restraints should be formed before compacting adjacent pavement layers. However, adjacent layers may first be compacted then some compacted material may be carefully cut and removed for the haunch1 if the haunch material is initially fluid e.g. concrete or mortar. Concrete and mortar haunching, and concrete beams and slabs should be mature before vibration and compaction of the surface course is undertaken. As a minimum, haunching must continue down to the underside of the bedding course. As haunching is usually a barrier to water movement, drainage should be provided through the haunching to prevent the build up of water in the bedding course.
1 haunch is that part of an arch between the crown and the springing line, in effect, a half an arch. Because of A its shape, in paving haunch has come to mean the material supporting the side of the pavement. Haunching is an alternate form of haunch.
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2.303
Bedding Course for Flexible Pavements

Bedding course material should be well-graded, coarse, sharp sand (typical of a concrete sand). Bricklaying sands, loams and fatty sands do not consolidate as do sharp sands and because of their fines content do not provide a capillary break and thus should not be used. Manufactured sands with excessive fines, (crusher dust), should not be used as they do not provide a capillary break and this results in efflorescence on the pavers. The moisture content of the bedding course should be uniform, so stockpiled material should be covered before use. Waterproof membranes beneath the bedding course are not advised except where the paving is completely under cover. A waterproof membrane will prevent salt laden water being drawn up to the surface limiting efflorescence but it is unnecessary with a properly chosen base course material. The reason for not using a waterproof membrane is that it traps water causing the base course to become saturated and this can lead to pumping, the loss of fines and the eventual breakdown of the pavement. Where the surface of the base course is not densely compacted or where movement may occur in the sub-grade opening up cracks in the base course (i.e. where bedding sand may be lost), the use of geotextiles is usually beneficial. Geotextiles are tough, polymeric felts with holes small enough to prevent the sand penetrating. Other cloths are generally not suitable. Cement-stabilised bedding sands are not recommended where well-graded bedding sand is available. If poor quality bedding sands must be used very lean cement stabilisation may be appropriate. Adding two to four per cent cement (by volume) to the bedding sand is usually satisfactory. Where the slope of a pavement exceeds 1:15 cement stabilising the bedding sand is practical and should prevent water scouring out the sand. For driveways with a sloping pavement having a length greater than 5 metres, a transverse concrete beam running between edge restraints should also be used. A capping course of pavers is bonded onto the top surface of the beam and the pavers, up slope from the beam, are then laid on cement-stabilised sand. (See Section 2.214 for more information on flexibly paved sloping driveways.) The bedding course should be screeded to 25 -30 mm thick. The base course should be finished accurately enough to not need to vary this thickness, however, the bedding course may not be less than 20 mm thick and not more than 40 mm thick. t
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Bedding Course for Flexible Pavements (continued)

Either of the following installation procedures is acceptable: Spread the material loose and screed to the final level plus an amount to accommodate the reduction in thickness that will occur when the pavers are vibrated; or, Spread the material loose and screed to the final level. Vibrate and compact this sand using the same vibrating plate compactor as that used for vibrating the pavers. Finally spread and screed a thin layer to form a loose surface onto which the pavers can be laid. In either method the sand should be disturbed as little as possible before laying the pavers. Any disturbance may lead to final surface undulations. Gaps between edge restraints or at the intersection with other pavements should be sealed to avoid loss of bedding sand. Screeding is usually done by placing rails (sometimes called trammels) made of pieces of timber or pipe at the right level and dragging a piece of straight timber or aluminium over them levelling the sand. After removing the rails there is a depression in the sand and that is usually filled by the paviour trowelling on some sand as the pavers are laid. Where the edge restraints are in place and sufficiently close together, a screed can be made from a piece of timber notched to fit within the restraints or a piece cut to fit between the restraints then a second, longer piece of wood is nailed to the top of the first piece of timber. The timber is drawn along the restraints levelling the sand between them.
Figure 6. Screeding bedding sand
Edge restraint set to concrete level
Screed Bed
Trammel
Where the slope of the pavement changes direction, screed to an apex or v then flatten the apex with a trowel or fill and smooth the depression so the directional change is over as many pavers as possible and the height difference between neighbouring pavers is minimised.
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Paver Storage
Pavers stored on site should be covered and kept off the ground. Saturated pavers may adversely affect the bond strength in rigid pavements or where pavers are adhered to cross beams. Store pavers away from where saw cutting of bricks and pavers is being conducted, and away from cement and other materials which may stain them. Moving pavers around the site may cause chipping, so excessive movement of packs should be avoided.
Blending
Some colour variation is inevitable in clay pavers. Colour variation when poorly handled may lead to unwanted patches, streaks and bands of colour in the finished pavement. The raw materials for paver making are natural clays and shales and these vary in colour within any one deposit. Paver makers blend materials to moderate the colour variation and tightly control the conditions in the kiln but no matter how well made, pavers delivered to site will have some degree of colour variation. To minimise colour variation and the visible effects of it, the following is recommended: All pavers of the one colour required to complete a pavement should be ordered at the one time; All pavers required for the project, but in any case as many packs as will fit, should be delivered at one time and stored on site; Pavers should be drawn from as many packs as possible, simultaneously, working down from the corners of each pack; and, Edge pavers of the same colour as the bulk of the pavement should be selected at the same time as those in the adjacent pavement. Those requiring cutting should then be marked up, cut and positioned. Selecting all edge pavers separately for cutting may produce an undesirable effect. Pavers are supplied with one face suitable for exposing (i.e. to be seen after laying). On some pavers both faces are suitable for exposing but they may look different. The paviour should ensure where two sides are different the pavers are laid to produce the aesthetic required. Two faced pavers that have unwanted marks, chips or cracks on one face should be turned over, exposing the good face in the pavement. Single sided pavers that have unwanted marks, chips or cracks on the face or any paver with significant edge damage should be set aside by the paviour (or labourer) for cutting pieces. Boral will not be responsible for replacing pavers with unwanted marks, chips or cracks that have been laid.
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Laying Practices
Pavers being a regular form are usually laid in regular patterns containing straight lines. These lines are critical to the look of the pavement and are marked out with stringlines which are used to set out the pavers. Judging the line(s) to use requires an assessment of the pattern and the site. Where there is a strong central line in the pavement this is usually critical and a stringline would be placed on that line and set out would be from that line. Pavements abutting existing structures usually follow their lines and gauging should be done from them. Edges or ends of pavers are usually aligned with the stringline but in the case of 45 herringbone corners are aligned to it. While experienced paviours gauge by eye it is usual practice to place stringlines at regular intervals (10 rows in pavements on sand bedding courses) to check the pattern is regular. If the line of the pavers has deviated from the stringline it is usually necessary to remove a few rows of pavers and relay them making adjustments to the joint width to return to the correct alignment. Depending on the magnitude of the misalignment, realigning may need the removal and relaying of three or four rows. Pavers are usually laid from one side or from the centreline. 90 herringbone is usually laid from a corner or sometimes from the centre of one side advancing out in the shape of a triangle. Whole pavers are laid first followed by part pavers.
Pavers on Sand Bedding Courses

Pavers must be laid so that there is a joint of 2 to 5 mm between them. Pavers should never be butted up against each other. Where joints are too narrow insufficient sand will fill them and it is likely the pavers will contact each other which will lead to chipping of corners and edges and may lead to rutting, shunting and the failure of the pavement. Laying is usually forward from the laid pavers and not from the sand in front. Where laying from the front must be done the bedding sand should be compacted and only a thin screed layer left loose on top and where possible boards should be used to minimise the disturbance and prevent the need to re-screed the sand. Pavers should be placed in the correct position without regard to their neighbours, leaving gaps where a full paver will not fit. Small amounts of sand may be trowelled on to adjust the level if needed. This is particularly the case where two or more different types of paver are used in the one pavement.
Pavers with Mortared Joints

Mortared joints in pavements are usually 10 mm and laying is from the side or front of the pavers. Good brick laying techniques should be used including laying to stringlines or using levels to ensure pavers are to the required level. It is usually easier to lay part pavers at the same time as laying whole pavers. Careful mortar preparation, clean working and fully bedding and filling all joints are important. t
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Laying Practices (continued) Laying Part Pavers

Whole (and damaged or part) pavers are held over the holes left after laying the whole pavers and the piece required to fill that hole is marked directly on the paver. Where this is not possible carefully measure the piece required and transfer the measurements to a paver. Note: Do not forget the gap for the jointing sand. Pavers should always be cut using a masonry saw as this is the only way to get an accurate cut. For small jobs done by nonprofessional paviours, because of the cost of hiring a masonry saw, masonry wheels or blades on angle grinders and bolsters are frequently used but the accuracy of the cut suffers. It must be remembered that many pavers are very dense and may break into many pieces if hit with a bolster. It is always better to have two larger cut pavers than one whole paver and one small piece. Cut pavers should always be greater than one third of the area of the paver when cut across the paver or greater than one quarter of the area of the paver when cut diagonally. For cutting dense hard materials, masonry saw blades without teeth are preferred. For cutting softer materials toothed masonry saw blades are preferred. Obviously a professional paviour will require two blades if they lay concrete and clay pavers. Toothed blades used to cut hard pavers usually wear faster than smooth blades.
Laying Pavers on Curves and Around Obstacles

The smaller rectangular or square objects are the tighter the curve they can follow. If you do not mind the look of v shaped joints, with no gap at the base and a 20 mm gap at the top, standard pavers can form a circle 3.5 metres in diameter. Few people want such wide v shaped joints (which also have to be mortar filled because sand will wash out) and so it is common practice to cut pavers to suit the curve.
Figure 7: Curve formed without cutting pavers Curves formed by cutting one or two sides of the pavers.
To minimise cutting some paviours cut only one side of the paver or cut every second paver. If only one side of each paver is cut, the joints do not point to a common centre so the curve has a skewed appearance. Curves formed of alternating uncut and double-cut pavers also have an unusual appearance. It is a matter for each individual to decide if they find the aesthetic acceptable, particularly around tight curves such as manhole covers or trees. t
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Laying Practices (continued)

Figure 8. Manhole cover detail
Figure 8 shows a soldier course of double-cut, tapered pavers in a circle around a manhole cover, set in a 45 herringbone pavement. Note the small pieces of paver needed to maintain the pattern and fit the circular inclusion. It is almost impossible to eliminate these smaller pieces but judicious use of half pavers will allow an increase in the size of the smaller cuts giving the pavement greater stability in this area.
Corners in Header Courses

A soldier course or a single or double stretcher course is often used around paving as a border. For corners that are not right angles a properly cut mitre is essential to avoid an overhang. At right angled corners in a soldier course a mitred joint is recommended. t
Figure 9. Non-right angle corners
Unmitred 45 angle
Mitred 45 angle
Figure 10. Right angle corners in double stretcher course
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Figure 11. Corners in soldier course
Figure 12. Treatment of right angled service covers
In Figure 12, note on the left hand cover the use of two larger cut pavers in the top, bottom and left hand sides to replace the one thin sliver in the soldier course as shown on the right hand side. Around both edge courses in the body of the paving, note the use of half pavers (dark brown) to avoid the use of a small triangular piece at the edge of the soldier or stretcher course. Small pieces of paver as shown on the right hand side of the right hand cover should be avoided. This half paver technique should also be used adjacent to borders around any 45 pattern. t
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Figure 13. Treatment of recessed covers
For recessed covers, pavers should be cut and fitted to maintain the pattern. Small pieces inside the recess are not a problem as they are restrained by the edge and the pieces are normally glued to the cover. To maintain the pattern outside the cover it can be necessary to use small pieces of paver. It is usual to remove the bedding sand under these pieces and replace it with mortar for stability. Warnings: 1. Cutting pavers produces a very fine dust (becoming a mud when using a proper water cooled masonry saw). Pavers contain crystalline silica and dust from dry cutting is hazardous to your health if breathed in. 2. The residue from cutting forms a hard, solid mud which in sufficient quantities will block drains. It is advisable to have a container under the drain on a brick saw bench to act as a sediment trap. The sediment should be removed periodically throughout the cutting and disposed of properly. Allowing this sediment to flow into drains or water courses attracts a fine in most jurisdictions. 3. The residue from cutting and the spray from the saw can get into the pores of bricks, pavers and other materials leaving a permanent stain. This should be prevented by careful placement of the saw but should this happen the only technique known to have been successful in removing the stain from bricks and pavers is to rub the stain with a firm cloth with a paste of sand blasting grit (glass fragments). This is very time-consuming, physically hard work and not guaranteed to work. It may harm the bricks or pavers and should always be tried on a small inconspicuous area first to test the effect.
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Sand Filled Joints

Joint-filling sand should be spread over the surface of the pavers and swept into the joints. Sand should be dry to flow into and fill joints effectively. Damp sand should not be used as the joints will not be filled effectively. Sands containing clay should not be used as they are likely to stain the surface of the pavers. Commercially prepared stabilised, jointing sands are available and although more costly than bulk sand may be better in some instances. The manufacturers advice should be sought on the proper use of these sands as improper use may lead to staining of the pavers.
Mortar Filled Joints

Mortared joints are now rare in large pavements, however where mortared joints are used they should be finished as an ironed joint. Mortar smears on such pavements will usually require cleaning and the same precautions and techniques as used to clean bricks apply. Mortar composition must be carefully controlled to achieve good bonding and prevent excessive shrinkage.
Compaction
Compaction is necessary for all pavements laid on sand base courses and should follow laying and joint filling as soon as possible but should not occur closer than one metre to the unrestrained working edge of the pavement under construction. No area of paving should be left uncompacted at the completion of the days work, apart from the edge strip of the laying face. Compaction should be carried out using a vibrating plate compactor with a plan area of not less than 0.25 m2 or a rubber-rolled mechanical vibrator. Vibrating plate compactors should be fitted with a glider attachment but where not available the plate may be wrapped in carpet or a carpet square or a sheet of plywood can be laid over the pavers to protect them from damage during compaction. The area to be compacted should be swept clean of joint filling sand and then receive at least two passes of the vibrating plate compactor. The joints should then be topped up by sweeping joint filling sand over the area prior to a final compaction consisting of at least two more passes of the vibrating plate compactor. Compaction should continue until the tops of all pavers are in the same plane. No paver should be more than 3 mm out of plane with its neighbours. The jointing sand will continue to settle over the ensuing weeks, and should be topped-up by brooming sand over empty joints until they are filled. Vibration for this topping up is not required.
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Trafficking After Construction

Flexible pavements may be trafficked immediately after construction depending on the nature and age of the edge restraints. Where edge restraints are constructed with cement, traffic should be restricted until they gain sufficient strength.
Cleaning
In most cases cleaning pavements after construction is as simple as picking up and sweeping off the sand, paver pieces etc. In some instances there is mortar to clean up. Cleaning mortar off pavers is best done when fresh as it is easier and less likely to create problems. Hosing, vacuuming or blowing of any pavement with sand filled joints is not recommended for the first three months of its life. Hand brooming is recommended in this time. If jointing sand is removed broom more on to top up the joints. High pressure water or steam cleaning is not recommended for householders and should only be done by trained professionals. High pressure water is the basis of a cutting technique, used for cutting stone, glass, concrete, tiles, pavers, and some metals. Incorrect use of high pressure will damage the face of the pavers. Small, cheap, high pressure cleaners, capable of exceeding 15 MPa (2200 PSI), are now commonly available and incorrectly used they will damage pavements. Clay pavers do not change colour in service. Changes in colour are usually related to the build-up of dirt, coloured materials on the surface (red wine, tannins, grease, food, tyre marks, etc.), growths (lichen, moss and algae), salts (efflorescence) or physical damage. Colour change in one area and not another is usually an indicator of the source of the problem. All pavements are subject to spillages and soiling and a build-up of dirt and grime. Frequent sweeping and washing reduces the effect of dirt and grime and maintains the attractiveness of a pavement. Washing with detergents and liquid household bleach (sodium hypochlorite) will not damage the pavers but remember incorrect use of these chemicals has severe environmental consequences and in some areas there are penalties for putting them into the stormwater system. Where grease or oil (including greasy food) will be spilled on the pavement, such as around barbecues, outside take-away food shops, around public eating places, driveways, etc., using dark coloured pavers makes the problem less noticeable. Sealers can be used to prevent or minimise absorption into the pavers and make removal by washing with detergent easier. Prevention is the only 100% cure but it should be remembered that weathering and bacterial action will eventually remove the residue once the cause is removed. t
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Cleaning (continued) Efflorescence

This is a powdery deposit of salts (usually white or yellow), often found on the surface of clay pavers after rain. The source of this stain could be the pavers but almost always it comes from the soil under the pavement, or from cement (if the soil was stabilised), or both. Dry brushing to remove the efflorescence before washing is recommended. If efflorescence is wetted, the salts go into solution and are drawn back into the pavers and will reappear as the pavement dries. Efflorescence will eventually disappear through natural weathering.
White scum
Do not confuse white scum with efflorescence. White scum is a thin white film on the surface of pavers. This film is invisible when the pavers are wet but shows up as the surface begins to dry. Scum often appears after an attempted removal of mortar stains or after the sanding of the joints with sand that has a high clay content. White scum is particularly difficult to remove. Water, detergents or hydrochloric acid often do not have any effect on it. However scrubbing with a proprietary brick cleaner will often improve the appearance of pavements affected by this stain.
Dirt and grime

Frequent sweeping and hosing will usually ensure a clean pavement. It this is not enough, washing with a detergent or a proprietary cleaner may be required.
Vanadium stains
Vanadium salts produce a green or yellow efflorescence which is mainly seen on cream and light coloured clay pavers. Hydrochloric acid will make these stains much worse and may make them impossible to clean. Vanadium stains will disappear in time but in most cases they are easy to clean. Mild vanadium stains may be treated with sodium hypochlorite (household bleach). Spray or brush it on the dry pavers and leave until the stain disappears, then rinse off. Proprietary mould cleaners containing sodium hypochlorite and sodium hydroxide can be used as above and have been found very effective. Proprietary brick cleaners may also be effective and should only be used according to the manufacturers instructions. t
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Cleaning (continued) Fresh mortar stains

While the mortar is soft, lightly cover it with damp clean sand. Dune sand is best but it is very important that the sand has no clay in it. Sweep the sand towards the edge of the pavement. Repeat if needed. Follow this with a light covering of dry clean sand and sweep towards the edge. Any sticky wet mortar residues that escaped the wet sanding will be removed by the dry sand. The next day after the pavement has dried, some mortar residue may still be visible as a faint white film. Smooth pavers may be carefully wiped with a cloth to take off most of the remaining film but the film will generally weather away if left untouched. Some efflorescence will appear as the pavement dries but it is not damaging to the pavers. Follow the instructions above to deal with the efflorescence.
Oil and bitumen

These stains usually need two treatments with a commercial emulsifying agent. First, mix the emulsifier with kerosene to remove the stain. Then clean the kerosene off with the emulsifier mixed only with water. When dealing with petroleum, asphalt and bituminous emulsion, scrape off the excess material and scrub the surface with scouring powder and water. Chilling the surface with ice or solid carbon dioxide can cause brittleness in the asphalt and assist removal. For petrol or lubricating oil stains, free oil must be mopped up immediately with an absorbent material such as paper towelling. Wiping should be avoided as it spreads the stain and tends to force the oil into the pavement. Hardened oil must be scraped off. The area affected should then be covered with a dry absorbent material such as diatomaceous earth, fine white clay, kaolin or whiting and the procedure repeated until there is no further improvement. Subsequently use detergent to clean up, and rinse well with clean water.
Food stains and tyre marks

Scrub with a full-strength commercial detergent and rinse well. t
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Cleaning (continued) Hardened mortar stains

In mortar the cement binds the sand particles to each other and to other surfaces. Cleaning starts with breaking down these bonds and in general this requires the use of hydrochloric acid. Recommended acid strengths are based on application to a surface saturated paver. The recommended acid strength for light coloured clay pavers is 1 part acid to 20 parts water and for other pavers is 1 part acid to 10 parts water. Stronger acid solutions do not work more effectively and will cause staining. Hydrochloric acid is a corrosive S6 poison and care must be taken when using it. To avoid personal injury: Wear goggles, gloves and protective clothing. Always pour acids into water this avoids splashes of highly concentrated acid onto the operator. If splashed onto the body, wash with clean water and if possible, neutralise with a mixture of bicarbonate of soda and water. Before attempting to clean off mortar, make sure any efflorescence and particularly any vanadium stains are removed, then using a piece of wood or paver, knock off any mortar lumps. The next step is to fully saturate the pavers with water. This does not dilute the acid, rather it keeps it on the surface where the mortar is. Failure to completely saturate the surface of the pavers allows cleaning solutions, containing dissolved mortar and acids, to be drawn into the pavers, causing staining. Note: Saturating pavers and using the correct strength of hydrochloric acid solution must be strictly adhered to for pavers manufactured in Queensland. Their raw materials contain large amounts of iron oxide and failure to saturate the surface or using strong acid solutions allows acid to react with the iron oxide and create severe iron oxide staining. Failure to do this with pavers manufactured in other parts of Australia may lead to the acid reacting with iron oxide but to a much lesser degree. This form of staining is known as acid burn and is particularly visible on light coloured pavers. Acid absorption into bricks can also lead to vanadium and manganese staining. Next apply the acid solution with a stiff bristled (not wire) brush and scrub vigorously. Acid takes time to dissolve the cement and scrubbing may take 4-6 minutes (or longer). Work at an area no larger than one square metre at a time and as soon as the pavers are clean wash down thoroughly. After washing, a solution of 15 g per litre of washing soda or 24 g per litre of sodium bicarbonate should be sprayed on to neutralise any remaining acid. (Continue spraying until no bubbling occurs). Excess hydrochloric acid will eventually evaporate; however, it is likely to cause staining. Other acids such as sulfuric acid or nitric acid will not evaporate and are not used in cleaning. High-pressure water jet cleaning is not recommended for pavements with sanded joints as it will remove the sand. If a high-pressure water jet cleaner is used on pavers, with mortared or grouted joints, be careful not to damage the pavers. Keep the pressure below 1200 psi (8000 kPa), use a wide fan jet nozzle, keeping it at least 500 mm from the surface and work at an angle not vertically. t
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Cleaning (continued) Fungi, moulds, moss and lichens

These are common, particularly in shady or damp parts of the pavement. They sometimes appear as localised dark stains or patches of green, giving a dirty and unsightly appearance. Alternatively these growths may add to the appearance of the pavement. They will not damage the pavement but may cause it to become slippery. To remove these growths, vigorously brush the effected area when it is dry. Highpressure water may also be used following the precautions above. Although the problem may appear to be gone, the cause is still present and it is recommended that a poison be applied. Copper sulphate solution or sodium hypochlorite (liquid household bleach) generally work well if used as directed on the container. Proprietary herbicides and fungicides are available from plant nurseries, however, some of these may discolour the pavement. Check their effect on a small part of the pavement before proceeding to clean the whole area. Follow the manufacturers directions and avoid nearby garden plants or lawn, especially on the lower side of the paved area being treated.
Chewing gum
In large areas, wire brushes free from rust should remove the majority of chewing gum. This may require several attempts and the wire may leave traces of steel on the paver which in time will rust leaving a stain. Careful application of high-pressure water jets can also be successful. For smaller areas freeze each piece of chewing gum with a carbon dioxide aerosol or dry ice. The chewing gum can then be chipped off with a scraper.
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2.4 Clay Paver Property Tables
Section 2.4 Clay Paver Property Tables
Clay Paver Range

Coffee 228x113x40 DPA1 2.0 38 <0.9 >5.0 <4.5 W GP No Nil to slight Nil 550 1100 1150x680x790 228x113x40 DPA1 2.0 38 <0.9 >5.5 <4.5 W GP No Nil to slight Nil 550 1100 1150x680x790 228x113x40 DPA1 2.0 38 <0.9 >4.5 <4.5 W GP No Nil to slight Nil 550 1100 1150x680x790 228x113x40 DPA1 2.0 38 <0.9 >5.5 <4.5 W GP No Nil to slight Nil 550 1100 1150x680x790 228x113x40 DPA1 2.0 38 <0.9 >5.0 <4.5 W GP No Nil to slight Nil 550 1100 1150x680x790 228x113x40 DPA1 2.0 38 <0.9 >6.5 <7.0 W GP No Nil to slight Nil 550 1100 1150x680x790 228x113x40 DPA1 2.0 38 <0.9 >5.0 <6.0 W GP No Nil to slight Nil 550 1100 1150x680x790 228x113x40 DPA1 2.0 38 <0.9 >4.0 <8.0 W GP No Nil to slight Nil 550 1100 1150x680x790 228x113x40 DPA1 2.0 38 <0.9 >3.5 <6.0 W GP No Nil to slight Nil 550 1100 1150x680x790 Morocco Merino Rumba Tan Garnet Onyx Opal Zircon
PAVESCAPE
SUMMERSET
Birch
Work size (mm) Dimensional category Ave unit weight (kg) Approx number per m2 Co-efficient of growth em (mm/m/15yrs) Minimum breaking load (kN) Mean Abrasion Index (cm3) Slip resistance classification Salt attack resistance category Salt safe Liability to effloresce Lime pitting No per pack Pack weight (kg) Pack dimensions (mm)
Autumn Cream 228x113x40 DPA1 2.0 38 <0.9 >3.5 <4.5 W GP No Nil to slight Nil 550 1100 1150x680x790
228x113x40 DPA1 2.0 38 <0.9 >4.5 <4.5 W GP No Nil to slight Nil 550 1100 1150x680x790
Clay Paver Range

Cream 230x114x50 DPA2 2.8 37 <1.0 >6.5 <2.5 V GP No Slight Nil 510 1428 1150x905x600 230x114x50 DPA2 2.8 37 <1.0 >10 <2.0 V GP No Slight Nil 510 1428 1150x905x600 230x113x50 DPA2 2.8 37 <1.0 >6.5 <2.0 V GP No Nil to slight Nil 510 1428 1150x905x600 Red Resort Cream Resort Ironstone 230x113x50 DPA2 2.8 37 <1.0 >7.5 <2.0 V GP No Nil to slight Nil 510 1428 1150x905x600 Resort Terracotta 230x113x50 DPA2 2.8 37 <1.0 >7.0 <2.0 V GP No Nil to slight Nil 510 1428 1150x905x600
BRINGELLY
Tan Blend 230x114x50 DPA2 2.8 37 <1.0 >7.0 <2.5 V GP No Slight Nil 510 1428 1150x905x600 Terracotta 230x114x50 DPA2 2.8 37 <1.0 >9.0 <2.0 V GP No Slight Nil 510 1428 1150x905x600
Almond
Ash
Work size (mm) Dimensional category Ave unit weight (kg) Approx number per m2 Co-efficient of growth em (mm/m/15yrs) Minimum breaking load (kN) Mean Abrasion Index (cm3) Slip resistance classification Salt attack resistance category Salt safe Liability to effloresce Lime pitting No per pack Pack weight (kg) Pack dimensions (mm)
230x114x50 DPA2 2.8 37 <1.0 >10 <2.0 V GP No Slight Nil 510 1428 1150x905x600
230x114x50 DPA2 2.8 37 <1.0 >10 <2.0 V GP No Slight Nil 510 1428 1150x905x600
All testing is carried out in accordance with Australian Standards AS/NZS4456 & 4586, ASTM C67 test methods where applicable. Testing is carried out in NATA registered laboratories. Durability classification based on product knowledge under local climate conditions. This technical information represents average properties obtained from production lots and should not be used for specification purposes. For more detailed specification contact Boral Bricks. Unit weight quoted is an approximate weight and can vary. This information is subject to change without notice.
2.401
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3. Face Brick Range
Face Brick Range
4. Engineered Utility Brick Range
Engineered Utility Brick Range
Section 4. Product Data Sheet
Standard Commercial Common

NSW
TYPICAL PROPERTIES Dimensions Work Size (LxWxH mm) Dimensional Category Average Unit Weight (kg) Approximate number per m2 Lime Pitting No. per pack # Pack Weight (kg) # Pack Dimensions (LxWxH mm) # Wall Surface Density (kg/m2) Characteristic Unconfined Compressive Strength (fuc MPa) Coefficient of Expansion (mm/m/15 years) Salt Attack Resistance Category Liability to Effloresce Weighted Sound Reduction Index Rw (C,Ctr) Unrendered Rendered (one side) Rendered (both sides) Fire Resistance Level Insulation (minutes) Unrendered Rendered (both sides) Unrendered (Structural Adequacy/Integrity/Insulation)^
^ Assumes FRL for fully supported single skin wall up to 3.0m height. All testing is carried out in accordance with Australian Standards AS/NZS4456 test methods where applicable. Testing is carried out in NATA registered laboratories Durability classification based on product knowledge under local climate conditions. This technical information represents average properties obtained from production lots and should not be used for specification purposes. For more detailed specification contact Boral Bricks. Unit weight quoted is an approximate weight and can vary. This information is subject to change without notice.
BADGERYS CREEK BRINGELLY KEMPSEY
230x110x76 DW1 3.0 49 Nil to Slight 320 928 920x920x880 400 1200 1150x770x912 182 >22 >18 <1.1 <0.9 GP Nil to slight 46 (-2, -5) 48 (-2, -5) 50 (-2, -5) 90 120 90/90/90
# Pack size of 320 cannot be handled by a forklift with tines, however will be placed on pallets on request.

FIRE RESISTANCE & SOUND TRANSMISSION FOR TYPICAL WALL APPLICATIONS
Fire Resistance Levels (FRL) The Building Code (BCA) Section C defines the type and class of buildings and designates three fire resistance levels. These levels are structural adequacy, integrity and insulation, and are written in the form 60/60/60. Information on how to calculate these is provided in the Clay Brick and Paver Institute (CBPI) publication, Manual 5: Fire Resistance Levels for Clay Brick Walls available at www.thinkbrick.com.au The figures below provide typical wall examples. Weighted Sound Reduction Index (Rw) The Rw has two reduction figures to account for high range noise (C) and low range noise (Ctr). The reduction figures are added to the Rw and are written Rw (C,Ctr). Note: S = Supported. Indicating moment is passed to a transverse structure such as a concrete slab, braced roofing trusses, a perpendicular wall, etc.
110mm
S S
FRL for Insulation FRL for wall height up to 3.0 metres
90 minutes 90/90/90
S
FRL for Insulation FRL for Integrity is the lower of the FRLs for Insulation or Structural Adequacy 240 minutes
110mm 110mm
For both leaves equally loaded (10%) FRL for Structural Adequacy wall height up to 3.3 metres wall height up to 4.1 metres
240 minutes 90 minutes
S S
For both leaves unequally loaded (i.e. >10% variance) FRL for Structural Adequacy wall height up to 2.5 metres 240 minutes wall height up to 3.0 metres 90 minutes Sound reduction of a wall consisting of two leaves 110mm brick with a 50mm cavity Rendered both sides Rw + Ctr 50 & impact attenuation Unrendered with 50mm glass wool insulation with a density of 11 kg/m3 Rw + Ctr 50 & impact attenuation Unrendered with 50mm polyester insulation with a density of 20 kg/m3 Rw + Ctr 50 & impact attenuation
All masonry walls should be designed by a qualified structural engineer. Variation in colour, texture and size is a natural characteristic of clay products. Copyright Boral Bricks Pty Ltd all rights reserved 2008. Boral Bricks Pty Ltd ABN 66 082 448 342.
Boral Clay Bricks and Pavers

Phone 13 30 35 Fax 1300 363 035 Email bricks@boral.com.au www.boral.com.au
ADV03813NSW
Jumbo Common
NSW
TYPICAL PROPERTIES Dimensions Work Size (LxWxH mm) Dimensional Category Average Unit Weight (kg) Approximate number per m2 Lime Pitting No. per pack Pack Weight (kg) Pack Dimensions (LxWxH mm) Wall Surface Density (kg/m2) Characteristic Unconfined Compressive Strength (fuc MPa) Coefficient of Expansion (mm/m/15 years) Salt Attack Resistance Category Liability to Effloresce Weighted Sound Reduction Index Rw (C,Ctr) Unrendered Rendered (one side) Rendered (both sides) Fire Resistance Level Insulation (minutes) Unrendered Rendered (both sides) Unrendered (Structural Adequacy/Integrity/Insulation)^
BADGERYS CREEK BRINGELLY
230x110x119 DW2 4.3 32.5 Nil to Slight 192 245 864 1152 920x920x880 1150x770x833 180 >22 <1.1 GP Nil to slight 46 (-2, -5) 48 (-2, -5) 50 (-2, -5) 90 120 90/90/90 4.5
Jumbo Common
110mm
S S
90 minutes 90/90/90
S
FRL for Insulation FRL for Integrity is the lower of the FRLs for Insulation or Structural Adequacy
110mm
240 minutes
110mm
S S

ADV03815NSW
Double Height Common

NSW
^ Assumes FRL for fully supported single skin wall up to 3.0m height. This technical information is subject to change without notice. All testing is carried out in accordance with Australian Standards AS/NZS4456 test methods where applicable. Testing is carried out in NATA registered laboratories Durability classification based on product knowledge under local climate conditions. This technical information represents average properties obtained from production lots and should not be used for specification purposes. For more detailed specification contact Boral Bricks. Unit weight quoted is an approximate weight and can vary. This information is subject to change without notice.
BADGERYS CREEK BRINGELLY KEMPSEY
230x110x162 DW1 5.7 24.5 Nil to Slight 160 172 992 1100 920x920x880 935x830x995 180 >22 <1.1 GP Nil to slight 46 (-2, -5) 48 (-2, -5) 50 (-2, -5) 90 120 90/90/90 6.0
200 1200 1150x972x770 >18 <0.9

110mm
S
FRL for Insulation 90 minutes 90/90/90
FRL for wall height up to 3.0 metres
S
110mm
240 minutes
110mm
S S

ADV03817NSW
Scratch Face Common

NSW
230x110x76 DW1 2.9 49 Nil to Slight 320 928 920x920x880 180 >22 <1.1 GP Nil to slight 46 (-2, -5) 48 (-2, -5) 50 (-2, -5) 90 120 90/90/90
Scratch Face Common

110mm
S
S
110mm 110mm
S S

ADV05177NSW
PartyWall Brick
NSW
PW76 PW119
230x150x119 6.0 32.5 180 1080 1150x750x952
PartyWall Brick
PartyWall PW76
150mm
S S
120 minutes 120/120/120
PartyWall PW119
150mm
S S
120 minutes 120/120/120

ADV03819
Special Paint Grade Brick

NSW
BRINGELLY KEMPSEY
230x110x76 DW2 3 49 Nil to Slight 400 1240 1150x770x912 180 >22 <1.1 GP Nil to slight 46 (-2, -5) 48 (-2, -5) 49 (-2, -5) 90 120 90/90/90 >18 <0.9
Special Paint Grade Brick

110mm
S S
90 minutes 90/90/90
S
110mm 110mm
S S

ADV03821NSW
Coastal Common
NSW
BRINGELLY KEMPSEY
230x110x76 DW1 2.9 49 Nil to Slight 400 1200 1150x912x770 180 >22 <1.1 EXP Nil to slight 46 (-2, -5) 48 (-2, -5) 49 (-2, -5) 90 120 90/90/90 >18 <0.9
Coastal Common
110mm
S S
90 minutes 90/90/90
S
110mm 110mm
S S

ADV03823NSW
Coastal Jumbo Common

NSW
230x110x119 DW1 4.5 32.5 Nil to Slight 235 1100 1150x833x770 180 >18 <0.9 EXP Nil to slight 46 (-2, -5) 48 (-2, -5) 49 (-2, -5) 90 120 90/90/90
Coastal Jumbo Common

110mm
S S
90 minutes 90/90/90
S
110mm
240 minutes
110mm
S S

ADV03825NSW
Coastal Double Height Common

NSW
230x110x162 DW1 6.0 24.5 Nil to Slight 172 1200 1150x972x770 180 >18 <0.9 EXP Nil to slight 46 (-2, -5) 48 (-2, -5) 49 (-2, -5) 90 120 90/90/90
Coastal Double Height Common

110mm
S
S
110mm
240 minutes
110mm
S S

ADV03827NSW

VIC
TYPICAL PROPERTIES Dimensions Work Size (LxWxH mm) Dimensional Category Average Unit Weight (kg) Approximate number per m2 Lime Pitting No. per pack # Wall Surface Density (kg/m2) Characteristic Unconfined Compressive Strength (fuc MPa) Coefficient of Expansion (mm/m/15 years) Salt Attack Resistance Category Liability to Effloresce weighted Sound Reduction Index Rw (C,Ctr) Unrendered Rendered (one side) Rendered (both sides) Fire Resistance Level Insulation (minutes) Unrendered Rendered (both sides) Unrendered (Structural Adequacy/Integrity/Insulation)^
ALbuRY SCORESbY ThOmASTOwn
2.9 Nil to Slight 340 190 >15 <1.1 GP Nil to slight
230x110x76 DW1 3.2 49 Nil 460 205 >22 <1.4 EXP Nil 46 (-2, -5) 48 (-2, -5) 50 (-2, -5) 90 120 90/90/90
3.3
272 210
EXP Nil to slight

FIRE RESISTAnCE & SOunD TRAnSmISSIOn FOR TYPICAL wALL APPLICATIOnS
Fire Resistance Levels (FRL) The Building Code (BCA) Section C defines the type and class of buildings and designates three fire resistance levels. These levels are structural adequacy, integrity and insulation, and are written in the form 60/60/60. Information on how to calculate these is provided in the Clay Brick and Paver Institute (CBPI) publication, Manual 5: Fire Resistance Levels for Clay Brick Walls available at www.thinkbrick.com.au The figures below provide typical wall examples. weighted Sound Reduction Index (Rw) The Rw has two reduction figures to account for high range noise (C) and low range noise (Ctr). The reduction figures are added to the Rw and are written Rw (C,Ctr). note: S = Supported. Indicating moment is passed to a transverse structure such as a concrete slab, braced roofing trusses, a perpendicular wall, etc.
110mm
S S
90 minutes 90/90/90
S
110mm 110mm
S S

ADV03812VIC
Jumbo Common
VIC
TYPICAL PROPERTIES Dimensions Work Size (LxWxH mm) Dimensional Category Average Unit Weight (kg) Approximate number per m2 Lime Pitting No. per pack Wall Surface Density (kg/m2) Characteristic Unconfined Compressive Strength (fuc MPa) Coefficient of Expansion (mm/m/15 years) Salt Attack Resistance Category Liability to Effloresce weighted Sound Reduction Index Rw (C,Ctr) Unrendered Rendered (one side) Rendered (both sides) Fire Resistance Level Insulation (minutes) Unrendered Rendered (both sides) Unrendered (Structural Adequacy/Integrity/Insulation)^
ALbuRY SCORESbY
230x110x119 DW2 4.5 32.5 Nil to Slight 230 180 >22 <1.1 GP Nil to slight 46 (-2, -5) 48 (-2, -5) 50 (-2, -5) 90 120 90/90/90 305
Jumbo Common
FIRE RESISTAnCE & SOunD TRAnSmISSIOn FOR TYPICAL wALL APPLICATIOnS
Fire Resistance Levels (FRL) The Building Code (BCA) Section C defines the type and class of buildings and designates three fire resistance levels. These levels are structural adequacy, integrity and insulation, and are written in the form 60/60/60. Information on how to calculate these is provided in the Clay Brick and Paver Institute (CBPI) publication, Manual 5: Fire Resistance Levels for Clay Brick Walls available at www.thinkbrick.com.au The figures below provide typical wall examples. weighted Sound Reduction Index (Rw) The Rw has two reduction figures to account for high range noise (C) and low range noise (Ctr). The reduction figures are added to the Rw and are written Rw (C,Ctr). note: S = Supported. Indicating moment is passed to a transverse structure such as a concrete slab, braced roofing trusses, a perpendicular wall, etc.
110mm
S S
90 minutes 90/90/90
S
110mm
240 minutes
110mm
S S

ADV03814VIC
Purpose Made Common

QLD
TYPICAL PROPERTIES Dimensions Work Size (LxWxH mm) Dimensional Category Average Unit Weight (kg) Approximate number per m2 Lime Pitting No. per pack Pack Weight (kg) Pack Dimensions (LxWxH mm) Wall Surface Density (kg/m2) Characteristic Unconfined Compressive Strength (f'uc MPa) Coefficient of Expansion (mm/m/15 years) Salt Attack Resistance Category Liability to Effloresce Weighted Sound Reduction Index Rw (C,Ctr) Unrendered Rendered (one side) Rendered (both sides) Fire Resistance Level Insulation (minutes) Unrendered Rendered (both sides) Unrendered (Structural Adequacy/Integrity/Insulation)^
^ Assumes FRL for fully supported single skin wall up to 3.0m height. All testing is carried out in accordance with Australian Standards AS/NZS4456 test methods where applicable. Testing is carried out in NATA registered laboratories. Durability classification based on product knowledge under local climate conditions. This technical information represents average properties obtained from production lots and should not be used for specification purposes. For more detailed specification contact Boral Bricks. Unit weight quoted is an approximate weight and can vary. This information is subject to change without notice.
Purpose Made Common

110mm
S S
90 minutes 90/90/90
S
110mm 110mm
S S

ADV03813QLD

QLD
TYPICAL PROPERTIES Dimensions Work Size (LxWxH mm) Dimensional Category Average Unit Weight (kg) Approximate number per m2 Lime Pitting No. per pack Pack Weight (kg) Pack Dimensions (LxWxH mm) Wall Surface Density (kg/m2) Characteristic Unconfined Compressive Strength (f'uc MPa) Coefficient of Expansion (mm/m/15 years) Salt Attack Resistance Category Liability to Effloresce Weighted Sound Reduction Index Rw (C,Ctr) Unrendered Rendered (one side) Rendered (both sides) Fire Resistance Level Insulation (minutes) Unrendered Rendered (both sides) Unrendered (Structural Adequacy/Integrity/Insulation)^
^ Assumes FRL for fully supported single skin wall up to 3.0m height. All testing is carried out in accordance with Australian Standards AS/NZS4456 test methods where applicable. Testing is carried out in NATA registered laboratories. Durability classification based on product knowledge under local climate conditions. This technical information represents average properties obtained from production lots and should not be used for specification purposes. For more detailed specification contact Boral Bricks. Unit weight quoted is an approximate weight and can vary. This information is subject to change without notice.
230x110x162 DW1 5.8 24.5 Nil to Slight 172 1050 930x820x1000 180 >10 <1.1 GP Nil to slight 46 (-2, -5) 48 (-2, -5) 49 (-2, -5) 90 120 90/90/90

110mm
S
S
110mm
240 minutes
110mm
S S

ADV03827QLD
5. Paver Range
Paver Range
6. Projects in View
Projects in View
Projects In View
Issue 13 March 08
Issue 14 July 08
Issu
e 12
Nove
mb
er 07
12:
PIV
PRO JEC
TS
IN V
IEW
13:
PIV
Bricks
PROJECTS IN VIEW
14:
PIV
PROJEC
Combining with cultur kids e
TS IN VIEW
rs delive ign ll des galore Wa efits ben

A shining star in Jamisontown
Wall-to-wall opportunities at Interchange Park

and Maso nry team
up at Oakle igh Centr e
lk on A wa
the
side style
lity h qua Hig
, too rdable affo thats sing hou
A Renaissance in retirement Carpark honours local heritage

A honey of a projec t
living
ont forefr ign the s at tion des litie qua ice Sta Civic of Pol
th twelv to the turing nry. lcome PIV fea Maso We and n of Bricks editio tan bricks Clay Green estate chooses choc Boral
iration adm than more acts e attr Centr
Rousing interest in Rouse Discovering Masonry
Hill
Welcome to the thirteenth edition of PIV featuring Boral Clay Bricks and Masonry.
W nt NS Pyrmo Contents lex, VIC W Comp le VIC Jamisontown, NSW ment enham Springva 01ulwuy NS Contents 05 Shaula Apartments, Altona Perfo , Pak Apart n, Pem 05 rming Arts SA Village, Tarneit, VIC Life ice Statio nia lage, 02 Beeke Centre Carpark, Port Willunga, 01 Carlisle Homes Display Cardi epers Inn 06 Esplanade & Prima Pol NSW ment Vil 06 ry Schoo Creek, NSW gvale & Information Centre, Wilton, Retire 03 Oakle 02 Bingara Gorge Sales 07 Interchange Park, Eastern l igh Centr Sprin 04 Rouse Grove Bay, QLD 07 e for Intell Village, Complex, Shepparton, VIC Hill Town Point RetirementNelsons Moreton ectua Village 03 Renaissance Victoria 08 Harmonylly DisabRetirement Centre 05 Disco 08 led Citize NSW Concord, NSW very Hous ns Ryde Hospital Mental Health Precinct, e 04 Concord rth 06 Logis tics Build y, No ing, Caulfi iversit eld Medi ont VIC e Un ari cal Centr Verm e ion, Macqu W ents Cont llys Walkway, Pavilion Extens e, Minto NS Wa Centr orts 01 ution ont Sp e VIC Verm Distrib 02 ouse nbourn n, Cra Wareh 03 Statio Police
04
Welcome to the fourteenth edition of PIV featuring Boral Clay Bricks and Maso nry.
Boral Timbe r Woodhead 08 Lighte Project, ning the Pernod Ricar load on 09 Harris d Head Office energy and on Schoo water at l Kempsey
07
PIV, Borals publication profiling a range of architecturally-inspired projects featuring Borals bricks, blocks, pavers and retaining walls, is full of the latest public and private sector commercial projects, designs, and ideas. PIV also features industry news, events and more, to keep you constantly up to date. Subscription to PIV is FREE. Subscribe on-line, and you will ensure that PIV is emailed directly to you. There are benefits to subscribing you not only have the latest information delivered direct to your desktop, but as a PIV subscriber, you will also have access to additional un-published photography and direct links to product information. Visit www.boral.com.au/piv to subscribe and access previous editions.
Subscribe by registering online at:
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If you have a project that you would like us to consider for inclusion in PIV please call your Boral Clay Bricks & Pavers sales representative, or phone our contact centre on
13 30 35
ADV05003 10/08
7. Reference Material
Reference Material
Free Clay Brick and Paver Samples
Free face samples

Professionally present your project concept to your client with actual clay brick and paver colour and texture samples. This special service enables you to select and receive facing samples by express courier to your door.
NSW and Queensland chip sizes Bricks Pavers 115mm x 76mm x 10mm 115mm x 114mm x 10mm
10mm 115mm 76mm 115mm 114mm 10mm
Bricks
Pavers
Victoria chip sizes Bricks Pavers 230mm x 76mm x 10mm 230mm x 114mm x 40mm / 50mm (full size)
10mm 40mm / 50mm 230mm 76mm 230mm 114mm
Bricks
Pavers
Contact the Boral CHIPexpress service
Phone Fax Email Web
13 30 35 1300 36 30 35 Using fax order forms provided bricks@boral.com.au www.boral.com.au/bricks
ADV05001 10/08
Fax Order Form

Clay Bricks & Pavers
Name Project Detached home Villa / townhouses High rise med. density
Fax this form to Boral Bricks CHIPexpress
1300 36 30 35
CHIPexpress samples can also be ordered by calling
Commercial (provide description below)
13 30 35
Company Address or emailing your request to
bricks@boral.com.au
Please send more order forms
Phone Fax Email Special delivery instructions
Clay brick and paver samples required
1. 2. 3. 4. 5.
Brochures required
1. 2. 3. 4. 5.
ADV05002 08/04

Technical Manual Whole 09 - BRICK

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Technical Manual Whole 09 - BRICK

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Bricks & Pavers Technical Manual

Issued to Company Address

Fax Phone Catalogue number Issue date Boral Representative

Bricks & Pavers Technical Manual

1.2 Brick Masonry Design

1.3 Brick Masonry Construction

1.4 Property Tables

ADV05004 (1/2) 10/08

Bricks & Pavers Technical Manual

2.2 Pavement Design

2.3 Pavement Construction

2.4 Property Tables

3.0 Face Brick Range 4.0 Engineered Utility Brick Range

5.0 Paver Range 6.0 Projects In View 7.0 Reference Material

1.1 Brick Properties

Bricks & Pavers Technical Manual

Section 1.1 Brick Properties

Bricks & Pavers Technical Manual

Section 1.1 Brick Properties

Characteristic Unconfined Compressive Strength (fuc)

Unconfined Compressive Strength

Compressive Strength of Bricks

Bricks & Pavers Technical Manual

Section 1.1 Brick Properties

Initial Rate of Absorption

Bricks & Pavers Technical Manual

Section 1.1 Brick Properties

Bricks & Pavers Technical Manual

Section 1.1 Brick Properties

Pitting due to Lime

1.2 Brick Masonry Design

Bricks & Pavers Technical Manual

Section 1.2. Brick Masonry Design

Table 2. Maximum Height of Walls with Free Ends

Bricks & Pavers Technical Manual

Section 1.2. Brick Masonry Design

1. Select the graph for the chosen wall restraint

150mm 110x110mm 90x90mm 110mm 90mm

Bricks & Pavers Technical Manual

Section 1.2. Brick Masonry Design

110x110mm 90x90mm 110mm 90mm

Laterally supported both ends and top unsupported

Laterally supported one end and top unsupported

110x110mm 90x90mm 110mm 90mm

230mm 150mm 110x110mm 90x90mm 110mm 90mm 6

Bricks & Pavers Technical Manual

Section 1.2. Brick Masonry Design

7 6 5 4 3 2 1 150mm 110x110mm 90x90mm 110mm 90mm

150mm 110x110mm 90x90mm 110mm 90mm

Bricks & Pavers Technical Manual

Section 1.2. Brick Masonry Design

Characteristic Compressive Strength of Masonry fm

Characteristic Flexural Tensile Strength of Masonry fmt

Characteristic Shear Strength of Masonry fms

Bricks & Pavers Technical Manual

Section 1.2. Brick Masonry Design

Bricks & Pavers Technical Manual

Section 1.2. Brick Masonry Design

Durability of Masonry (continued)

Bricks & Pavers Technical Manual

Section 1.2. Brick Masonry Design

Bricks & Pavers Technical Manual

Section 1.2. Brick Masonry Design