ABM Terengganu Training Presentation April 2008

CONSTRUCTION PROCEDUREFOR

CONCRETE MASONRY WALLS

AKADEMI BINAAN NEGARAWILAYAH TIMUR

08 APRIL 2008

integrated brickworks sdn bhd Incorporated in 1972 Pioneering producer of high quality concrete masonry Factories use dedicated state-of-the-art plants

Industry milestones: Wrapped and palletised product packaging Truck-mounted cranes Introduced Segmental Retaining Walls Introduced architectural concrete masonry SIRIM and BOMBA certification

Our Production Facility

Factory set up on 16-acre site near Port Dickson 2 high-capacity plants operational Dedicated high-tech automated dry-cast systems Customised product curing chambers Fully-equipped laboratory for QC and QA Ample product storage capacity

Our Products and ServicesConcrete Masonry Units

Load-bearing MasonryAcoustic MasonryInterlocking Masonry

Architectural MasonryFluted BlockSplitblox

Segmental Retaining Wall SystemsKeystoneCountry Manor

Services ProvidedDesign Assistance, Cost Estimations, Project & Site Advisory, Product & Installation Training

Product ApplicationsConcrete Masonry Units – Load Bearing

Product ApplicationsConcrete Masonry

Product ApplicationsConcrete Masonry – Acoustic Masonry

Product ApplicationsArchitectural Concrete Masonry

Product ApplicationsKeystone Retaining Wall Systems

Product ApplicationsKeystone Country Manor

CONCRETE MASONRY

What is aConcrete Masonry

Unit?

Modular System ~ IBS componentInternational Usage and AcceptanceHollow cores provide improved insulation, reduced

weight and reinforcement channelsRange of basic and special units for plumbing,

corners, lintels, vertical/horizontal steel reinforcementLoad-bearing masonry structures built with

reinforcing steel for columns and tie-beamsCompleted walls can be fair-faceWalls can be plastered, painted, coatedModular Units include Architectural Masonry

CONCRETE MASONRY

CONCRETE MASONRYCONCRETE MASONRY UNITS

(CMU)

Modular Coordination

CMU WALL CONSTRUCTION

(Fair-face)

Mortar

CMU InstallationMaterials

Storage,Handling

Protection

SitePreparation

Services

Tools,Equipments, Material

Mixing Mortar

Tools

Cleaning & PatchingOf Mortar Joints

WallFoundation

WallIntersections

Door & Window Openings

Wall Corners

Electricity

Plumbing

ReinforcedWall

Wall Block Patterns

UnreinforcedWall

VerticalReinforcement

Columns andPilasters

Lintels & Sills

Door & Window Frames

Horizontal Reinforcement

CMU WALLS

Non-Load Bearing Structures

Load Bearing Structures

MODULAR CONCRETE MASONRY STRUCTURES

Modular DesignsUtilise modular coordinationLimits the variety of componentsReduces or eliminates customisingUse industrial mass-produced IBS components

Modular Designs, Methods and Systems:

Modular Methods and SystemsIncreases speed and efficiencyReduce wastagesLower costs

CONCRETE MASONRY UNIT MODULES

CMUs use a basic grid of 200mm x 200mm

CMU module sizing (inclusive 10mm mortar joints):

Full Block 200mm (H) x 400mm (W)

Half Block 200mm (H) x 200mm (W)

CMUs for reinforcement and services conform to above (for

bond beams, lintels, plumbing, corners, etc)

Special applications and designs may require ¼ and ¾ sized

units, half-height units or others, which can also be available

CONCRETE MASONRY WALL

1. Keep the CMUs dry2. Check for tools, materials and equipment3. Prepare the base or wall foundation4. Locate wall ends or corners5. Install alignment string lines6. Prepare mortar mix7. Lay the first course8. Install the last unit or Closure Block9. Continue laying second and upper courses10. Tool the mortar joints11. Clean the wall and patch the mortar joints as necessary.12. Cover the unfinished wall for continuation next day.

INSTALLATION GUIDELINES

Step 1: Keep the CMUs clean and dry

Masonry units at-site are to be kept clean and dry before use.Store the stocks on planks, pallets, etc to keep them above ground, and, where possible, covered to keep off rain.

INSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS


Step 1: Keep the CMUs clean and dry

Masonry units at-site are to be kept clean and dry before use.Store the stocks on planks, pallets, etc to keep them above ground, and, where possible, covered to keep off rain.

CMUs are to be installed in dry condition for the most effective bonding strength of the mortar joints.



Step 2: To lay the FIRST COURSEEnsure the foundation face is clean and ready to receive mortar bedding for the base of the wall.Check and make good the bedding face level and alignment.Set out the wall ends, and install string lines for level and alignment.

CONCRETE MASONRY WALLINSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLS

Step 2: To lay the FIRST COURSEEnsure the foundation face is clean and ready to receive mortar bedding for the base of the wall.Check and make good the bedding face level and alignment.Set out the wall ends, and install string lines for level and alignment.Install the wall end or corner blocks in mortar to correct level, alignment and plumb.


Step 2: To lay the FIRST COURSEEnsure the foundation face is clean and ready to receive mortar bedding for the base of the wall.Check and make good the bedding face level and alignment.Set out the wall ends, and install string lines for level and alignment.Install the wall end or corner blocks in mortar to correct level, alignment and plumb.Do a test run by placing blocks without mortar in between the two end blocks to confirm.


Step 2: Lay the FIRST COURSE (cont)Spread a full mortar bed on the foundation, and check for alignment and thickness.


Step 2: Lay the FIRST COURSE (cont)Spread a full mortar bed on the foundation, and check for alignment and thickness.Install blocks by buttering mortar to the ends of the face shells for the vertical joints, and pressing them into the mortar bed and butting them against the block adjacent, ensuring 10mm thick mortar joints.


Step 2: Lay the FIRST COURSE (cont)Spread a full mortar bed on the foundation, and check for alignment and thickness.Install blocks by buttering mortar to the ends of the face shells for the vertical joints, and pressing them into the mortar bed and butting them against the block adjacent, ensuring 10mm thick mortar joints.Adjust the blocks to the string line for level, alignment and spacing by tapping with a small hammer.It is important to lay the first course carefully, as mistakes in alignment, level or plumb will lead to bigger problems the higher the wall is built.


Step 3: Install the CLOSURE BLOCKCheck the opening for the last unit (Closure Block) in the course to ensure the last block fits.Butter mortar to the block for the vertical joint, and lower the block into the opening vertically from above. Adjust for joint thickness, alignment, plumb and level.


Step 3: Install the CLOSURE BLOCKCheck the opening for the last unit (Closure Block) in the course to ensure the last block fits.Butter mortar to the block for the vertical joint, and lower the block into the opening vertically from above. Adjust for joint thickness, alignment, plumb and level.Mortar for the final vertical joint is to be packed in from above, ensuring a well-filled mortar joint.


Step 4: Lay the SECOND COURSELay the corner or end blocks first to level, alignment and plumb, and install a string line.



Step 4: Lay the SECOND COURSELay the corner or end blocks first to level, alignment and plumb, and install a string line.Butter mortar to the horizontal face shells of the blocks in the first course.Next, butter mortar for vertical joints to the ends of the blocks to be laid, and lay them to the string line, with the necessary adjustment to level, plumb and alignment.



Step 4: Lay the SECOND COURSELay the corner or end blocks first to level, alignment and plumb, and install a string line.Butter mortar to the horizontal face shells of the blocks in the first course.Next, butter mortar for vertical joints to the ends of the blocks to be laid, and lay them to the string line, with the necessary adjustment to level, plumb and alignment.Remove excess mortar extruded from the joints.Do NOT use dead mortar.Do NOT adjust the block after the mortar has stiffened.



Step 5: Lay the THIRD and SUBSEQUENT COURSESTo continue installation of blocks in wall to completion, repeat the procedures as given above.

Closure Blocks should be staggered throughout the wall length.

Protect the uncompleted wall for continuing work the next day, by covering open cores from rain, and, if appropriate, protect the lower wall sections from mud splashes.



This fundamental 5 part installation guideline provides for the successful installation of a well constructed concrete masonry wall.

Adhering to this guideline will result in walls built to high workmanship, meeting the structural and aesthetic requirements of clients, architects and engineers.

CONCRETE MASONRY WALLINSTALLATION PROCEDURE TO CONSTRUCT UNREINFORCED CONCRETE MASONRY WALLSSUMMARY

THANK YOU

CONCRETE MASONRY UNITS (CMU)

Modular Coordination

CMU WALL CONSTRUCTION

(Fair-face)

Mortar

CMU InstallationMaterials

Storage,Handling

Protection

SitePreparation

Services

Tools,Equipments, Material

Mixing Mortar

Tools

Cleaning & PatchingOf Mortar Joints

WallFoundation

WallIntersections

Door & Window Openings

Wall Corners

Electricity

Plumbing

ReinforcedWall

Wall Block Patterns

UnreinforcedWall

VerticalReinforcement

Columns andPilasters

Lintels & Sills

Door & Window Frames

Horizontal Reinforcement

CMU WALLS

Non-Load Bearing Structures

Load Bearing Structures

ABM Terengganu Training Presentation April 2008

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Transcript of ABM Terengganu Training Presentation April 2008