MASONRY WORK

Prof. Prahlad
NICMAR university, Pune
AUTOCLAVED AERATED CONCRETE BLOCK
MASONRY WORK
1 IS 2185 (Part-1): CONCRETE MASONRY UNITS — SPECIFICATION:
2005 HOLLOW AND SOLID CONCRETE BLOCKS
2 IS 2185 (Part-2): CONCRETE MASONRY UNITS — SPECIFICATION:
1983 HOLLOW AND SOLID LIGHTWEIGHT CONCRETE
BLOCKS
3 IS 2185 (Part-3): CONCRETE MASONRY UNITS — SPECIFICATION:
1984 AUTOCLAVED CELLULAR (AERATED ) CONCRETE
BLOCKS
4 IS 2572: 2005 CONSTRUCTION OF HOLLOW AND SOLID
CONCRETE BLOCK MASONRY — CODE OF
PRACTICE
Terminology
Autoclaved -Steam curing of concrete Products, sand lime bricks, asbestos
cement products, hydrous calcium silicate insulation Products, or cement in
an autoclave at maximum ambient temperatures generally between 1700C to
2150C.
Block - A concrete masonry unit, any one of the external dimensions of which
is greater than the corresponding dimension of a brick as specified in IS :
3952-1978 and of such size and mass as to permit it to be handled by one
man. Furthermore, to avoid confusion with slabs and Panels, the height of the
block shall not exceed either its length or six times its width.
Block Density - The density calculated by dividing the mass of a block by the
overall volume, including holes or cavities and end recesses..
Drying Shrinkage - The difference between the length of specimen which has
been immersed in water and then subsequently dried to constant length, all
under specified conditions; expressed as a percentage of the dry length of the
specimen.
Gross Area-The total area occupied by a block on its loading face, including
areas of the cavities and end recesses.
Height -The vertical dimension of the exposed face of a block, excluding any
tongue or other device designed to provide mechanical keying
Length - The horizontal dimension of the exposed face of a block excluding
any tongue or other device designed to provide mechanical keying.
Width -The external dimension of a block at the bedding plane, measured at
right angles to the length and height of the block

Dimensions & Tolerances

• Autoclave Aerated Concrete Block shall be referred to by its normal
dimension the term ‘normal’ means that the dimension includes the
thickness of the mortar joints. The actual dimension shall be 10mm short
of the normal dimension
• The normal dimension of the concrete block shall be as follows
– Length : 400, 500 or 600 mm
– Height : 200, 250 or 300 mm
– Width : 100, 150, 200 or 250 mm
• In addition, Autoclave Aerated Concrete Block shall be manufactured in
half length of 200, 250 or 300 mm correspond to the full lengths
• The maximum variation in the length of the Autoclave Aerated
Concrete Block shall not be more than plus/minus 5mm and
maximum variation in the height and width of Autoclave Aerated
Concrete Block, not more than plus/minus 3mm
• The faces of Autoclave Aerated Concrete Block shall be flat &
Rectangular, opposite faces shall be parallel and all arises shall be
square. The bedding surfaces shall be at right angle to the face of
the Blocks
Physical properties of AAC block
Sampling and Testing
 In any consignment, all the blocks of the same size and from the same
batch of manufacture shall be grouped together into a minimum number
of groups of 10000 blocks or less. Each such group shall constitute a lot

 From each lot, a sample of 24 blocks shall be selected at random. The

required numbers of Blocks shall be taken at regular intervals during the
loading of the vehicle or unloading the vehicles depending on whether
sample is taken before delivery or after delivery. When this is not
practicable sample shall be taken from the stack in which case the
required number of blocks shall be taken at random from across the top of
the stacks, the sides accessible and from the interior of the stacks by
opening trenches from the top

 The sample of blocks shall be marked for future identification of the

consignment it represents. The blocks shall be kept under cover and
protected from extreme conditions of temperature, relative humidity and
wind until they are required for test
 All the 24 Blocks shall be checked for dimensions and inspected for visual
defects.
 Out of the 24 blocks, 12 blocks shall be subjected to the test for
compressive strength, 3 blocks to the test for density, 3 blocks to the test
for thermal conductivity and 3 blocks to the test for drying shrinkage.
 The remaining 3 blocks shall be reserved for re-test for drying shrinkage if
a need arises

Criteria for conformity

 All Autoclave Aerated Concrete Block shall be sound, free of cracks or
other defects which interfere with the proper placing of block units, impair
the strength or performance of the construction
 Where block units are to be used in exposed wall construction, the face or
faces that are to be exposed shall be free of chips, cracks or other
imperfections except that if not more than 5% of a consignment contains
slight cracks or small chippings not larger than 25mm, this shall not be
deemed grounds for rejection
 The number of blocks with dimensions outside the tolerance limit and or
with visual defects, among those inspected, shall not be more than two
 For density, the mean value shall be within the range specified
in Table
 For thermal conductivity, the mean value shall be equal to or
less than the value specified in Table
 The min. compressive strength being the average of twelve
block units shall be as prescribed in table
 The drying shrinkage shall be not more than 0.05% for grade
–1 block and 0.10% for grade-2 block when tested
 The Block density shall conform to the requirements specified
in table
HOLLOW AND SOLID CONCRETE BLOCKS
Terminology
• Face Shells — The two outer plates of the hollow concrete block.
These are connected together by webs.
• Gross Area — The total area occupied by a block on its bedding
face, including areas of the cavities and end recesses.
Hollow (Open or Closed Cavity) Block — A block having one or more
large holes or. cavities which - either pass through the block (open
cavity) or do not effectively pass through the block (closed cavity) and
having the solid material between 50 and 75 percent of the total
volume of the block calculated from the overall dimensions.
Length — The horizontal dimension of the exposed face of a block,
excluding any tongue or other device designed to provide mechanical
keying.
Moisture Movement — The difference between the length of the
specimen when dried to constant length and when subsequently
immersed in water, all under specified conditions, expressed as a
percentage of the dry length of the specimen.
‘Solid Block — A block which has solid material not less than 75
percent of the total volume of-the block calculated from the overall
dimensions.
Webs — The solid sections of the hollow concrete blocks which
connect the face shells.
Width — The external dimension of a block at the bedding
plane, measured at right angles to the length and height of the
block.

DIMENSIONS AND TOLERANCES

The nominal dimensions of concrete block shall be as follows:
Length : 400, 500 or 600 mm
Height : 200 or 100 mm
Width : 50,75, 100, 150,200, 250 or 300 mm.
The variation in the length of the units shall not be more than ±
5 mm and variation in height and width of units, not more than ±
3 mm
The hollow (open and closed cavity) and solid concrete blocks
shall conform to the following three grades:
Sampling and Testing
 a sample of 20 blocks shall be taken from every lot / consignment of 5000
blocks or part thereof from the same grade, size and same batch of
manufacture.
 The sample of blocks shall be marked for future identification of the
consignment it represents.
 The blocks shall be kept under cover and protected from extreme
conditions of temperature, relative humidity and wind until they are
required for test.
 All the 20 blocks shall be checked for dimensions and inspected for visual
defects
 Out of the 20 blocks, 3 blocks shall be subjected to the test for block
density
 8 blocks to the test for compressive strength
 3 blocks to the test for water absorption and
 3 blocks to the test for drying shrinkage and later to the test for moisture

movement .

 The remaining 3 blocks shall be reserved for retest for drying shrinkage

and moisture movement, if a need arises.

 Compressive Strength: The minimum compressive strength at 28 days

being the average of eight units,

 The water absorption, being the average of three units and shall not be

more than 10 percent by mass.

 The drying shrinkage of the units when unrestrained being the average of

three units, and shall not exceed 0.06 percent.

 The moisture movement of the dried blocks on immersion in water, being

the average of three units, and shall not exceed 0.09 percent.

 Blocks Density: as per the values given in above table

 Masonry work

NECESSARY INFORMATION

• Layout plans showing the watls, position of doors, windows and other openings, stairs,

columns, etc.

• Detailed dirnensions of the structure with details of sections, showing reinforced bands, ties,

etc.

• Full details of architectural features, mouldings and other special work such as fittings

attached to or embedded in the masonry.

• Details of fixing of door and window frames to masonry wall.

• Location and other details of service lines, such as-for water supply, drainage, sewerage,

electrical installations, telephone, cable TV, etc.

• The grade of blocks.

Mortar
 Hollow concrete blocks shall be embedded with a mortar
which is relatively weaker than the mix used for making blocks
in order to avoid the formation of cracks.
 A rich or strong mortar tends to make a wall too rigid thus
localizing the effects of minor movements due to temperature
and moisture variations resulting in cracking of the blocks.
 The recommended proportions of mortar measured by
volume are given in below Table
• All mortar shall be prepared in accordance with IS 2250.
STORAGE AND HANDLING
The blocks shall be stored in such a way as to avoid any contact with moisture on the
site. They shall be stock-piled on planks or other supports free from contact with the
ground and covered to protect against wetting. The block shall be handled with care
and damaged units shall be rejected

PREPARATORY WORK
The blocks need not be wetted before or during laying in the walls. In case the climatic
conditions so require, the top and the sides of the blocks may only be slightly
moistened so as to prevent absorption of water from the mortar and ensure the
development of the required bond with the mortar

LAYING CONCRETE BLOCK MASONRY

 The nominal thickness of load bearing masonry built witb holicmv concrete blocks
shall be not less than 200 mm
 The minimum nominal thickness of non- Ioad-bearing internal partitions shall be
100 mm
 The minimum nominal thickness of external panel walls in framed construction
shall preferably be not less than 200 mm
 Hollow concrete block walls shall preferably be planned on the basis of modular
co-ordination with a view to making the maximum use of full and half-length units.
The cutting of units at the site shall be restricted to the minimum. Attention shall
be paid to modular co-ordination while fixing the overall length and height of the
wall. All horizontal dimensions shall be in multiples of nominal half-length of the
units and all vertical dimensions shall be multiples of full-height units.

Foundation and Basement

 For single storeyed houses, the hollow of blocks in the foundation and
basement masonry shall be filled up with sand and only the top foundation
course shall be of solid blocks.
 But for two or more storeyed houses generally solid concrete blocks should
preferably be used in foundation courses, plinth, and basement walls. If hollow
blocks are used, their hollows must be filled up with concrete comprising one
part of cement, three parts of sand and six parts of gravel or crushed stone of
5 to 20 mm size.
 In damp soils to prevent the rise of moisture from the ground due to capillary
action, the foundation and basement masonry shall be laid in richer mortar.
 In addition, a damp-proof course shall be provided which may consist of a 25
mm layer of I :2 cement mortar, or an approved type of bituminous course.
Masonry in Superstructure
 Hollow concrete block masonry in superstructure shall be laid in composite mortar
comprising one part of cement, one part of lime and nine to ten parts of sand
depending upon the grading of sand
 Lesser proportion of sand should be adopted if the sand to be used is either not
properly graded or is rather fine.
 The first course of concrete masonry, shall be laid with great care, making sure that
it is properly aligned, Ievelled and plumbed, as this will assist the mason in laying
succeeding courses to obtain a straight and truly vertical wall.
 Before laying the first course, the alignment of the wall shall be marked on the
foundation footings. The blocks for this course shall first be laid dry, that is without
mortar over the footing, along a string lightly stretched between properly located
corners of the wall in order to determine the correct position of the blocks
including those of the cross-walls joining it and also adjust their spacing
 When the blocks are set in proper position, the two corner blocks should be
removed, a full mortar bed spread on the footing and these blocks laid back in
place truly level and plumb.
 The string shall then be stretched tightly along the faces of two corner blocks and
the faces of intermediate one adjusted to coincide with the line. Thereafter each
block shall be removed and relaid over a bed of mortar. After every three or four
blocks have been laid, their correct alignment, level and verticality shall be
carefully checked.
 For the subsequent courses, mortar shall be spread over the entire top surface of
the block including front and rear shells as well as the webs to a uniform layer of
one centimeter thickness.
 Normally full mortar bedding shall be adopted as it enables fulle utilization of the
load carrying capacity of the blocks. But where the walls carry light loads, such as
panel walls, in a framed structure ‘face shell’ bedding may be used.
 In this type of bedding the mortar is spread only over the front and rear shells and
not on the webs.
 For vertical joints, the mortar shall be applied on “the vertical edges of the front
and rear shells of the blocks. The mortar may be applied either to the unit already
placed on the wall or to the next unit to be laid alongside of it. But it will be more
convenient to apply mortar on the edges of the succeeding unit when it is
standing vertically and then placing it horizontally well-pressed against the
previously laid unit. However, whatever the method used for applying mortar, care
must be taken to produce well-compacted vertical joints.
 Mortar shall not be spread so much ahead of the actual laying of the units that it
tends to stiffen and lose its plasticity, thereby resulting in poor bond. For most of
the work, the joints, both horizontal and vertical, shall be 1cm thick
 The mortar shall be raked out from the joint with a trowel to a depth of about 1 cm as each
course is laid so as to ensure good bond for the plaster.
 The construction of the walls may be started either at corners first or started from one end
proceeding in other direction. If the corners of the wall are built first, they shall be built four
or five courses higher than the centre of the wall. As each course is laid at the corner, it shall
be checked for alignment and level and for each plumb. Each block shall be carefully checked
with a level or straightedge to make certain that the faces of the block are all in the same
plane. This precaution is necessary to ensure truly straight and vertical walls.
 When filling the wall between the corners, a mason’s line shall be stretched from corner to
corner for each course and the top outside edge of each block shall be laid to this line. The
manner of handling or Gripping the block shall be such as to position the block properly with
minimum adjustment.
 As each block is Iaid, excess mortar extruding from the joints shall be cut off with the trowel
and thrown back on the mortar bed to be reworked into fresh mortar. If the work is
progressing rapidly, the extruded mortar from the joints may be applied to the vertical face
shells of the block just laid.
 When installing the closure block, all edges of the opening and all four vertical edges of the
closure block shall be buttered with mortar. The closure block shall be carefully lowered into
place. If any of the mortar falls out leaving an open joint, the closure block shall be removed,
fresh mortar applied and the operation repeated.
Provision for Door and Window Frames

 A course of solid concrele block masonry shall be provided under doors and

window openings over a 100 mm thick precast concrete fill-block. The solid coarse

shall extend for atleast 200 mm beyond the opening on either side should be

reinforced with two numbers high strength deformed steel bars of 10 mm

diameter

 For jambs of doors and windows where hollow blocks are used the hollow core

adjacent to the joints shall be filled with concrete mix of 1:3:6 are reinforced with

single high strength deformed steel bars of 10 mm diameter for each jamb.

 Mild steel bar holdfasts should be so fastened to the door and window frames that

these occur at block course level and their ends be embedded in a hollow which

shall be filled up with 1 :3:6 cement concrete