Construction and Materials – III (AR-351)

Lecture # 1 (Week 1)
CONCRETE MASONRY, Building Elements, Perforations and Tiles

Department of Architecture and Planning, NED University of Engineering

& Technology, Karachi

Course Facilitator:
Fariha Tahseen
E-mail: [email protected]

Hydraulic concrete block making machine

Lecture – 1: CONCRETE MASONRY October 2020 (Online Teaching)

COURSE OBJECTIVES:
To study the properties of traditional and contemporary materials, their selection
criteria and use in construction, structural and non-structural as well as in interior and
exterior of the buildings. To be able to critically analyze the properties of materials,
appropriateness of their application, application methods and their response to the
specific environment.

CREDIT HOURS:
Theory: 1 credit hour (Total Marks 50, Sessional 35 and Final 15)
Practical: 2 credit hours (Total Marks 100, Sessional 70, and Final 30)

COURSE CONTENTS:
1. Concrete Masonry Units, Building Elements, Perforations and Tiles. (2 weeks)
2. Masonry Wall Construction (2 Weeks)
3. Steel Frame Construction (1 Week)
4. Light Gauge Steel Frame Construction (1 Week)
5. Wood Frame Construction (1 Week)
6. Building Finishes (Wall, Flooring and Ceiling) (3 Weeks)

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TEXT BOOKS FOR REFERENCE

•N.L.Arora& B.R. Gupta, Building Construction, 2018-19 Edition, SatyaPrakashan, Year

2009-10

•Edward Allen & Joseph Iano, Fundamentals of Building Construction, Fifth Edition, 2009,
Wiley P.

•Francis D. K. Ching, Construction Illustrated, Wiley Publishers.

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COURSE LEARNING OUTCOME AND ITS MAPPING WITH

PROGRAMME LEARNING OUTCOME

At the end of the course, the student will be able to:

1. Understand and compare physical properties, characteristics, advantages and disadvantages

of conventional building materials

2. Understand various mode of construction techniques by using concrete, steel and wood

3. Draw sectional details of various building construction details.

4. Acquaint with knowledge and understanding about external building finishes as well as
internal finishes (specially for walls, floors and ceilings)

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Lecture Contents
•Manufacture of Concrete Masonry Units

•Standard Concrete Block

•Decorative Concrete Masonry Units

•The Economy of Concrete Masonry Construction

•Other Types of Masonry Units

•Locally Available Concrete Masonry Units; Envicrete

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Concrete masonry units (CMUs) are manufactured

in three basic forms;

Solid bricks
Large hollow units (commonly referred
as concrete blocks
Less commonly, larger solid units
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Manufacture of Concrete Masonry Unit

Manufactured by vibrating a stiff concrete mixture into metal molds.

Then immediately turning out the wet blocks or bricks onto a rack so
that the mold can be used at the rate of 1000 or more units per hour.

Cured at an accelerated rate by subjecting them to atmospheric

pressure (or high pressure for faster curing)

Units are bundled on wooden pallets for shipping to the construction

site.
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Video

Mixer Machine Hydraulic press Machine

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Concrete masonry units are made in variety of sizes…

American standard concrete blocks and half blocks. Each full block is nominally 8
inches (200 mm) high and 16 inches (400 mm) long.
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Standard Concrete Block

Innumerable special sizes, shapes, and patterns are available
world wide.
Usually concrete masonry units are based on 8 inch cubic module.
The most common block is nominally 6 x 8 x 12 inches.
The actual size of the block is 65/8 x 75/8 x 115/8 inches that allows mortar
joint 3/8 inch.
The standard block is designed to be lifted with two hands (as compared to
brick which is designed to be laid with one).
Its double cube proportions work well for running bond strechers,
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Concrete masonry units are made in variety of shapes…

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The use of control joint unit is to control shrinkage cracking.

Bond beam units have space for horizontal

reinforcing bars and grout and are used to tie a
wall together horizontally. They are also used
for reinforced block lintels.

A blocks are used to build walls with vertical

reinforcing bars grouted into the cores.

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Concrete masonry units are made in variety of

densities using industrial wastes such as…

Cinders is concrete block made of fly ash or bottom ash

(byproduct of coal combustion). Partly burnt coal.

Pumice is a very light and porous volcanic rock formed

when a gas-rich froth of glassy lava solidifies rapidly.

Blast Furnace Slag is formed when iron ore or iron

pellets, coke (petroleum byproduct) and a flux (either
limestone or dolomite) are melted together in a blast furnace.

Expanded light weight aggregate rather

than crushed stone or gravel
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Heavier Blocks (with greater density) are;

Denser and typically yield higher compressive strength than lighter blocks
Less expensive to manufacture
Absorbs moisture less readily
Have better resistance to sound transmission
More resistant to abuse
BUT
Greater weight makes heavier blocks more expensive to ship and more labor intensive and
expensive for masons to lay up.
Lower thermal resistance and lower fire resistance.
Medium weight blocks are probably the most common weight classification
specified, although the availability of blocks of different weights varies with regional
differences in building practices.
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Concrete masonry units are made in variety of surface

textures and colors… special shapes are relatively easy to produce if a
sufficient number of units will be produced to amortize the expense of the mold.

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Decorative concrete masonry units, also called architectural concrete masonry

units, are easily and economically manufactured in an unending variety of surface
patterns, textures, and colors intended for exposed use in exterior and interior
walls.

Mold costs for producing special units are low when spread across the number of
units required for a medium sized to large building.

Many of the textured concrete

masonry units that are now
considered standard originated
as special designs created by
architects for particular buildings.

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Split face Concrete Block Wall

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Fluted Face Concrete Block Wall

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angular face Concrete Block

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Ribbed split face Concrete Block

ribbed face Concrete Block

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Although concrete masonry units can be cut with a

diamond bladed power saw, it is more economical and
produces better results if the designers layout buildings
of concrete masonry in dimensional units that
correspond to the module of the block.

Nominal 4, 6 and 12 inch block thicknesses are also

common, as is a solid concrete brick that is identical in
size and proportion to a modular clay brick.

A handy feature of the standard 8 inch block height is

that it corresponds exactly to three courses of ordinary
clay or concrete brick work, or two courses of oversize
bricks, making it easy to interweave block work and
brick work in composite walls.

Concrete Block Cutter Machine

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Laying a Concrete Masonry Wall

The first course of blocks for a lead is laid in

the mortar. Mortar for the head joint is
A bed of mortar is spread on the footing applied to the end of each block with the
trowel before the block is laid.
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As each new course is started on the lead, its height

Mortar is normally applied only to the
is meticulously checked with either a folding rule
face shells of the block and not to the
or a story pole marked with the height of each
webs.
course
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A soft brush removes mortar crumbs

The joints of the lead are tooled to a
after tooling.
concave profile.

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A meson’s line is stretched taut The courses of blocks between the leads are laid
between the leads on line blocks rapidly by aligning each block with the stretched
line. The mason has laid bed joint mortar and
“buttered” the head joints for a number of blocks.

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Video

The last block to be installed in each course of infill Both ends of the closer blocks are also
blocks, the closer, must be inserted between blocks that buttered with mortar, and the block is
have already been laid. The bed and head joint of the lowered carefully into position.
already laid bricks are buttered.
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Concrete masonry is often reinforced with steel to

increase its load bearing capacity, resistance to
cracking and seismic forces.

Horizontal Reinforcement
Joint reinforcement: if stronger horizontal reinforcing is required, bond beam blocks or
special blocks with channeled webs allow heavier reinforcing bars to be placed in the horizontal
direction and embedded in grout.

Welded grids; small diameter steel rods are laid into the mortar bed joints at the desired
vertical intervals.

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Vertical Reinforcement
Vertical block cores are easily reinforced
by inserting bars and grouting.
In most cases only those cores that
contain reinforcing bars are grouted, but
sometimes all the vertical cores are
filled, whether or not they contain bars,
for added strength.

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Surface Bonding
Surface bonding of concrete masonry walls has found application in certain low rise buildings
where the cost or availability of skilled labor is a problem.

The blocks are laid without mortar, course upon course, to make a wall.

Then a thin layer of a special cementitious compound containing short fibers of alkali resistant
glass is applied to each side of the wall with plastering tools.

After it has cured, this surface bonding compound joins the block securely to one another both
in tension and in compression.

It also serves as a surface finish whose appearance resembles stucco.

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Lintels for Concrete Block Walls

A steel lintel for a broad opening is made up

of a wide-flange section welded to a plate.

A reinforced block lintel is composed of

bond beam units.

A precast reinforced concrete lintel.

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Economy of Concrete Masonry Construction

Concrete masonry is a versatile building material, and walls built from
it are usually more economical than comparable ones made of brick or
stone masonry.

The concrete blocks themselves are cheaper on a volumetric basis and are made into a
wall much more quickly because of their larger size.

Concrete blocks can be produced to required degrees of strength, and because their
hollow cores allow for the easy insertion of reinforcing steel and grout, they are widely
used in bearing wall construction.

Concrete blocks can also be used for the back up wythe behind a brick or stone facing.

Block walls also accept plaster, stucco, or tile work directly, without the need for metal
lath.
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 Construction and Materials – III (AR-351)

Lecture # 1 (Week 2)
CONCRETE MASONRY, Building Elements, Perforations and Tiles

Department of Architecture and Planning, NED University of Engineering

& Technology, Karachi

Course Facilitator:
Fariha Tahseen
E-mail: [email protected]

Hydraulic concrete block making machine

Lecture – 1: CONCRETE MASONRY October 2020 (Online Teaching)

Other types of Masonry Units

Hollow blocks of cast Gypsum
Fire Clay Blocks
Structural glazed facing tile
Structural terracotta (Glazed or unglazed)
Glass Blocks

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Hollow blocks of cast Gypsum

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Structural Glazed Facing Tiles of Clay

Remain in use, especially for partitions, where their durable, easily cleaned surfaces are
advantageous, as in public corridors, toilet rooms, institutional kitchens, locker and shower
rooms, and industrial plants.

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Terracotta
Hollow
blocks

Terracotta Face Tiles

Glazed or unglazed molded
decorative units of fired clay.

Terracotta Façade Panels

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Terracotta
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Video

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Glass Blocks
Available in many textures and in clear, heat absorbing, and reflective
glass.

Glass blocks are non absorbent.

When glass masonry walls are constructed, the mortar stiffens more
slowly than it does with more absorbent units of clay or concrete, so
temporary spacers are inserted between units to maintain proper
spacing until the mortar sets up.
Video

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Locally Available varieties in

Concrete Block

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Thickness Hollow Concrete Block

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Thickness Solid Concrete Block

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Standard
Finish

Pigmented
Finish

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Fair Face
Finish

Split
Finish

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SPLIT BLOCKS

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Concrete masonry units are made in variety of colors…

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SOLID BLOCK
DESCRIPTION
Solid Blocks are ideal for load bearing applications reducing the cost of steel + RCC. Solid
blocks are available in various grades and sizes for a multitude of applications.
STANDARD DENSE – High density/strength, load bearing block for internal and
external use. May or may not require plaster / paint.
FILLER – “Open Texture” block for normal load bearing use. Requires plaster or rendering.
FAIR FACED / PIGMENTED – “Smooth Finished” block for load bearing application. Does not require
plaster or paint. Maintenance free.
STRENGTH
Architectural masonry blocks, fair face and pigmented blocks 1500 psi ± 5% Standard/Filler blocks 1000
psi ± 5% Standard Dense 1500psi or higher if required.
AVAILABLE COLOURS
Varying shades of Brindle, Charcoal, Grey, Mud, Terracotta, and Yellow.
BASIC APPLICATIONS
Boundary walls.
Partition walls.
Load bearing walls.
Facades and elevations.
Interior & exterior walls.
Landscaping decorative and featured walls.
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LIGHT WEIGHT BLOCK APPLICATION

Driveways.
Patios.
Car porches.
Parking areas.
Residential streets.
Landscaping.
Parks.
Pedestrian malls.
Walkways and footpaths.
Medians.
Airports.
Ports.
Loading docks.
Heavy traffic areas.

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HOLLOW SPLIT BLOCK

DESCRIPTION
Two different types of blocks, Hollow blocks and envistone veneer.
Give advantage in terms of cost savings and time.
Used as smooth face from one side and stone finish from the other.
Since this is a complete hollow block, therefore it eliminates the requirement for first making a
wall and then cladding it. It can be ideally used for exterior shell of buildings where stone finish is
required on the outside and interior surface is required to be smooth. This smooth surface can be
plastered and or painted if required. Hollow Split blocks can be used on their own or combined
with other Envicrete products to design attractive and practical wall surfaces.
STRENGTH
Architectural masonry 1000 psi ± 5% (Based on net area).
BASIC APPLICATIONS
Boundary walls.
Partition walls.
Load bearing walls.
Facades and elevations.
interior & exterior walls.
Landscaping decorative and featured walls.
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KEY STONE

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KERB BLOCK

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PAVERS

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HEAVY DUTY PAVERS

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PRE CAST WALL PANEL

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CEMENT BOARD

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Cement Board is specially designed for use in applications where impact

resistance is required in a high humid environment.

It is a versatile, economic building board substitute of plywood, cement-

bonded particle board, gypsum boards or magnesium boards.

It is light weight, robust and moisture resistant.

Product Application: Internal Ceiling, External Ceiling partition walls,

general external walls/ wet areas, raised floors and elevated floors.

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Ratio:4:1 •

4 Trolley Sand , 1
pack Cement

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FRAMING
PIECES

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The shapes ,sizes and patterns are in a great variety for decoration and
daily use purposes .

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CONCRETE TILES:
• Cement-based concrete is a strong material. While it’s commonly
used for commercial purposes to withstand wear and tear better
than ceramic and hardwoods, tiles manufactured from concrete are
endlessly customizable from a design aspect and have found their
place in residential homes for centuries.

• It has no fixed sizes.

• They are manufactured in accordance to the design and desire of the

customer.

• The thickness of these tiles varies from ½” – 2 ½”.

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• Price Range:
▫ Grey base Rs.85 per sq. ft
▫ White base Rs.100 per sq. ft
▫ Pigmented base is Rs.110 per sq. ft

• Installation Mechanism:
▫ For installation of these tiles 1 ½’ base wall is required to provide
strength to the walls of the façade.

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Concrete Jalis

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Insulated Concrete Tiles

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Textured Brick Concrete Tiles

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Concrete Tiles Used in Façade

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Concrete block used in AKU

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Different Sizes, Patterns and Colours Mostly

Used in Outdoor Facades

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Angle Triangled Blocks

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Hollow concrete blocks

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Hexagon Shaped Concrete Tiles

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Concrete tiles used in stairs, steps and outdoor use

They have a standard set of of 18

colors including White, Black,
Blue , Yellow, Red, Brown, Grey,
Green etc.

They experiment with colors by

playing with different shades
and produce new colors by using
pigment oxides.

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References:

Fundamentals of Building Construction

Materials & Methods
By
Edward ALLEN & Joseph IANO

www.envicrete.com

https://www.terracotta-panel.com/rainscreen

Market Visits to Thallas (NEPA, Orangi, Lasbela), Terrazo and Concrete Technologies
(D.H.A)

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