Class Day TwelveClass Day Twelve

Chapter 8Brick Masonry

History of Brick MasonryHistory of Brick Masonry

AA No one really knows the age of brick No one really knows the age of brick masonry.masonry.

BB Common sense would dictateCommon sense would dictate that the lack of that the lack of construction materials for shelter in lands where construction materials for shelter in lands where no natural stone was available, would lead to no natural stone was available, would lead to innovations with whatever material is at hand innovations with whatever material is at hand

CC Where there was land there was soil, and if Where there was land there was soil, and if there was water there was mud. And there was water there was mud. And soil particles soil particles stick together and form a hard massstick together and form a hard mass when the sun when the sun dries the moisture.dries the moisture.

DD Mud bricksMud bricks were molded by hand and were molded by hand and allowed to dryallowed to dry in the sun, and stockpiled for future in the sun, and stockpiled for future use. Small units were easily handled.use. Small units were easily handled.

EE Mud bricks were stacked with mud mortarMud bricks were stacked with mud mortar, , which varied in thickness to accommodate which varied in thickness to accommodate irregular shapes.irregular shapes.

FF It was learned that the best bricks were made It was learned that the best bricks were made of soil that had very tiny particles and became of soil that had very tiny particles and became sticky when wet. sticky when wet. The material we call clayThe material we call clay. .

GG In the southwest regions of North America, In the southwest regions of North America, “Adobe” bricks were made of a clay“Adobe” bricks were made of a clay that has come that has come to be known as adobe clay, which was particularly to be known as adobe clay, which was particularly good for making mud bricks. Adobe was further good for making mud bricks. Adobe was further strengthened by strengthened by adding short strands of straw to adding short strands of straw to the mixthe mix. Adobe bricks are still made and used . Adobe bricks are still made and used today.today.

HH Consistency of sizeConsistency of size did not become did not become prevalent until units were cast into molds, which prevalent until units were cast into molds, which greatly facilitated ease of assembly.greatly facilitated ease of assembly.

II The industrial revolution of the late 1800s The industrial revolution of the late 1800s brought about the brought about the firing of masonry in kilnsfiring of masonry in kilns, which , which made the units very hard and strong.made the units very hard and strong.

JJ In the early 1900s other materials surpassed In the early 1900s other materials surpassed brick in use because of strength requirements for brick in use because of strength requirements for buildings too tall and heavy to be supported by a buildings too tall and heavy to be supported by a “mass” type wall.“mass” type wall.

K K But brick has and intimacy about itBut brick has and intimacy about it that that remains a warm and friendly material for use in remains a warm and friendly material for use in construction of residences and office buildingsconstruction of residences and office buildings

BRICK MORTARBRICK MORTAR

AA Mortar is a vital part of brick construction.Mortar is a vital part of brick construction.

BB As bricks are made of clay, then fired in a As bricks are made of clay, then fired in a furnace to remove the moisture and make them furnace to remove the moisture and make them hard, hard, they are impossible to make in exact, they are impossible to make in exact, consistent size – but in modern day it is closeconsistent size – but in modern day it is close..

CC In early times, mortar was used as a cushion In early times, mortar was used as a cushion to align the assembly process to maintain square to align the assembly process to maintain square and plumb in a structure. and plumb in a structure. Additional strength in Additional strength in the mortar mix was not necessary because it was the mortar mix was not necessary because it was made of the same material as brick.made of the same material as brick.

DD But since fired bricks are much stronger than But since fired bricks are much stronger than the original sun-dried clay, the original sun-dried clay, the strength of mortar the strength of mortar was improved to make stronger buildings. was improved to make stronger buildings.

EE With the development of With the development of natural cement for natural cement for the manufacture of concretethe manufacture of concrete, it became a natural , it became a natural matrix for masonry mortar.matrix for masonry mortar.

FF Mortar is a mix much like concrete; which Mortar is a mix much like concrete; which consists of stone aggregates held together by a consists of stone aggregates held together by a matrix. In the case of concrete, that consists of a matrix. In the case of concrete, that consists of a gradation of large rocks, smaller rocks, and still gradation of large rocks, smaller rocks, and still smaller particles (sand) – smaller particles (sand) – all mixed consistently all mixed consistently and held together by a paste of cement and water, and held together by a paste of cement and water, which hardens by a chemical process called which hardens by a chemical process called hydration.hydration.

GG Masonry mortar is a mixture of sand, cement, Masonry mortar is a mixture of sand, cement, and water, with the addition of lime to lend and water, with the addition of lime to lend smoothness and workability to the mix.smoothness and workability to the mix.

Mortar FunctionsMortar Functions

Provides for full bearing of weightProvides for full bearing of weight

Maintains the strength of the masonry wallMaintains the strength of the masonry wall

Seals against moisture and verminSeals against moisture and vermin

Bonds the masonry units togetherBonds the masonry units together

It should be a part of theIt should be a part of the

aesthetic value of aaesthetic value of a

building.building.

MAKING BRICKSMAKING BRICKS

AA Early molding of bricks was done by shaping Early molding of bricks was done by shaping a mass of mud by hand.a mass of mud by hand.

BB Then individual single molds made of wood Then individual single molds made of wood increased production and consistency of size.increased production and consistency of size.

CC Then Then multiple molds made of wood increased multiple molds made of wood increased production even more.production even more.

DD Today, very sophisticated methods exist for Today, very sophisticated methods exist for shaping bricks by shaping bricks by extruding clay through a steel extruding clay through a steel form, then cutting to individual units with wire.form, then cutting to individual units with wire.

Wood molds for making brickWood molds for making brick

EE The making of bricks became more The making of bricks became more sophisticated with units extruded and wire cut, sophisticated with units extruded and wire cut, then fired in gas kilns. Production and quality of then fired in gas kilns. Production and quality of units increased tremendously.units increased tremendously.

FF The The color of bricks up until approximately 20 color of bricks up until approximately 20 years ago depended upon the color of clay, which years ago depended upon the color of clay, which was found in large deposits in the ground.was found in large deposits in the ground.

GG Constant use of brick as a veneer in Constant use of brick as a veneer in residential and commercial construction as residential and commercial construction as population grew, population grew, led to depletion of consistent led to depletion of consistent color clay deposits.color clay deposits.

HH Now, nearly all brick used in residential Now, nearly all brick used in residential construction are made of any clay, but construction are made of any clay, but given their given their color by a slurry mix that is applied to the units color by a slurry mix that is applied to the units before firingbefore firing. .

Basic types of brick:Basic types of brick:

Common brickCommon brick: Units made of clay where : Units made of clay where color and surface finish are not a factor, color and surface finish are not a factor, because of use as a “backup” structural because of use as a “backup” structural material in an area where it will never be seen.material in an area where it will never be seen.

Face brickFace brick: Units made where appearance is : Units made where appearance is the main consideration. Face brick for the main consideration. Face brick for commercial use is still made with specific commercial use is still made with specific colors of clay. colors of clay.

Special bricks may be made for specific Special bricks may be made for specific purposes. Should an Architect desire a purposes. Should an Architect desire a special shape to be used in creating an special shape to be used in creating an unusual desired effect in a design, brick unusual desired effect in a design, brick companies will custom make the units.companies will custom make the units.

Fire brickFire brick is made of a specific type of white is made of a specific type of white clay, with special additives for use in the clay, with special additives for use in the firebox of fireplaces, ovens, kilns, and other firebox of fireplaces, ovens, kilns, and other firing mechanisms.firing mechanisms.

Bricks, generally are made with holes (except Bricks, generally are made with holes (except fire brick) to reduce the weight of material not fire brick) to reduce the weight of material not needed for structure, and to provide a method needed for structure, and to provide a method for additional adherence of mortar. for additional adherence of mortar.

Bricks made of the same material as concrete Bricks made of the same material as concrete masonry units are available on a limited masonry units are available on a limited basis, but have never been accepted for basis, but have never been accepted for widespread use.widespread use.

BRICK SHAPES AND SIZESBRICK SHAPES AND SIZES

The text shows a chart with 12 sizes of bricks, but The text shows a chart with 12 sizes of bricks, but all available sizes and shapes are not listed. all available sizes and shapes are not listed.

Two shapes of brick are commonly used, but Two shapes of brick are commonly used, but many others are made for specific purpose. many others are made for specific purpose.

Modular BrickModular Brick – nominally lay 8” long, 4” – nominally lay 8” long, 4” thick, & 3 courses high = 8”. Texas Tech uses thick, & 3 courses high = 8”. Texas Tech uses modular brick. For use where strength and modular brick. For use where strength and appearance is important.appearance is important.

King Size BrickKing Size Brick – nominally lay 10” long, 3” – nominally lay 10” long, 3” thick, & 2 ½” high. For use as a veneer where thick, & 2 ½” high. For use as a veneer where economy is the main concern.economy is the main concern.

Eight modular size bricks are required to lay Eight modular size bricks are required to lay one square foot of surface wall, but it takes only one square foot of surface wall, but it takes only 5.4 king size bricks for the same area. So, king 5.4 king size bricks for the same area. So, king size brick are made strictly for economy.size brick are made strictly for economy.

Bricks shapes made for appearance:Bricks shapes made for appearance:

Roman brickRoman brick – basically 12” long, 4” thick, 1 – basically 12” long, 4” thick, 1 ½” high.½” high.

Norman brickNorman brick – basically 12” long, 4” thick, 3 – basically 12” long, 4” thick, 3 courses = 8” high.courses = 8” high.

Big JohnsBig Johns – basically 12” long, 4” thick, 4” – basically 12” long, 4” thick, 4” high.high.

BRICK ARRANGEMENT TERMINOLOGYBRICK ARRANGEMENT TERMINOLOGY

AA Bricks are laid in a variety of arrangementsBricks are laid in a variety of arrangements, , mostly today for the sake of appearance. In earlier mostly today for the sake of appearance. In earlier times when a wall consisted of several layers times when a wall consisted of several layers thickness, bricks were turned endways through thickness, bricks were turned endways through the wall for structural bond. Named patterns the wall for structural bond. Named patterns evolved in the process, such as English bond, evolved in the process, such as English bond, Flemish bond, etc. Flemish bond, etc.

BB Common course pattern for structure and Common course pattern for structure and appearance:appearance:

StretcherStretcher – – Bricks laid flat end to end.Bricks laid flat end to end.SoldierSoldier – – Laid vertically so the outside long Laid vertically so the outside long

edge shows. edge shows. RowlockRowlock - - Laid so the end shows, Laid so the end shows,

vertically.vertically.HeaderHeader – – Laid so the end shows, Laid so the end shows,

horizontallyhorizontally

Basic Brickwork TerminologyBasic Brickwork Terminology

BedJoint

HeadJoint

Course - horizontal layer of brick

Brickwork TerminologyBrickwork Terminology

Header - Bonds two wythes together Wythe: vertical layer 1 unit thick

Soldier - Laid on its end, face parallel

Rowlock - laid on face, end visible

Stretcher - long dimension horizontal & face parallel to the wall

Brick Masonry - Sizes and ShapesBrick Masonry - Sizes and Shapes

There is There is NoNo standard size standard size

Normal coursing - 3 modular bricks = 8”Normal coursing - 3 modular bricks = 8”

Larger sizes availableLarger sizes available

Custom shapes & colors are availableCustom shapes & colors are available

Masonry JointsMasonry Joints

Various tools are used Various tools are used to treat the surface to treat the surface finish of mortar joints.finish of mortar joints.

Some are done to Some are done to repel water, but most repel water, but most are done for are done for

appearanceappearance..

Concave

Flush

Raked

Stripped

Struck

Weathered

Vee

Concave joints done primarily for weather proofing

Raked joints are made primarily for appearance

In the category of the Earnheardts, Emmet Smith, Tiger In the category of the Earnheardts, Emmet Smith, Tiger Woods, etc, this man is the world champion bricklayer of Woods, etc, this man is the world champion bricklayer of 2004. 2004. In a contest in Las Vegas, Bob Bol laid 765 bricks in In a contest in Las Vegas, Bob Bol laid 765 bricks in ONE HOURONE HOUR. . That’s 12.75 bricks per minuteThat’s 12.75 bricks per minute – or – or one brick one brick every 5 seconds.every 5 seconds.

He won a prize of $2,000.He won a prize of $2,000.