National Masonry Design Guide Book 2 SQLD PDF

Masonry Blocks & Bricks

Design Guide SQLD & NSW

Blocks & Bricks
About National Masonry® National Masonry® Construction Solutions

National Masonry® has quickly established itself as the industry leader with National Masonry® offers a comprehensive range of proven products and systems
exceptional product quality and outstanding customer service with a clear vision including Masonry Blocks, Masonry Bricks, Fire and Acoustic Wall Systems,
of customers for life. We are obsessed with ensuring every customer has a Segmental Block Retaining Walls and Segmental Paving Products.
memorable experience with us and to leave you with no doubt that you have
made the right choice.
What’s in this Guide
National Masonry , the new benchmark in masonry.
® The National Masonry® Blocks and Brick Design Guide (this book) has been prepared
as a comprehensive South QLD and NSW Reference Guide. It does not attempt to cover
all the requirements of the Codes and Standards which apply to masonry construction,
Pallet Return but as an overview of considerations. All structural detailing should be checked and
approved by a structural engineer before construction. National Masonry® reserves the
All pallets remain the property of National Masonry® right to change the contents of this guide without notice. Please note that this guide is
based on products that are available at the time of publication from National Masonry®
South QLD and NSW Regions. Different products and specifications may apply to
National Masonry Products sourced from other regions.
Additional Assistance and Information

• Contact Details: Please refer to the outside back cover of this publication for National
Masonry® contact details.
• Colour and Texture Variation: The supply of raw materials can vary over time. In
Call to Arrange
NATIONALPickup
MASONRY addition, variation can occur between product types and production batches. Also
please recognise that the printed colours in this brochure are only a guide. Please,
Call your local branch during office hours. always ask to see a sample of your colour/texture choice before specifying
or ordering.
1800 066 089 • Terms and Conditions of Sale: For a full set of Terms and Conditions of Sale please
contact your nearest National Masonry® sales office.
Online Booking Pickup For technical support and sales office details please refer to the outside back cover.
Use our Pallet Collection Form on our website. Overview

For External and Internal Walls.
www.nationalmasonry.com.au
Designer Range
• 9 Contemporary Colours.
• 5 Innovative Textures — Smooth, Honed, Polished, Shot-Blast or Split Face.
• Suitable for loadbearing and non-loadbearing walls.
Standard Grey Block

Hollow Concrete Block suitable for loadbearing and non-loadbearing applications.
Heavy Duty Block

Grey Concrete Blocks - up to a 50Mpa Strength Rating.
Core-Fill Block
Grey Concrete Block or Designer Range coloured and textured finishes for reinforced
retaining walls and loadbearing walls requiring increased robustness.
Concrete Brick
Speed-E Brick and Rippa Brick (162mm height) in Concrete material for good fire
performance and loadbearing characteristics.
Product Disclaimer: Concrete Blocks, Bricks, Pavers and Retaining Wall products supplied by
National Masonry® are manufactured using raw materials that inherently vary in nature. Whilst
all effort is made to produce uniformity in our range of products, variation in colour, texture,
and finish can be present. The dimensional characteristics of all products are nominal and
variations in length, height, and width can occur from unit to unit which needs to be taken into
consideration when installing these products.
2
Contents
Installation & Maintenance........................................................................................4 Designer Range......................................................................................................12

Face Blockwork Design Considerations.............................................................4 Architectural Designer Blocks & Bricks Overview ............................................12
Sizes..........................................................................................................4 Colour Range.................................................................................................12
Material and Dimensional Variation...................................................................4 Designer Range Series 100, 200 and 300 Smooth, Honed, Shot-blast and
Modular Planning.............................................................................................4 Polished Face................................................................................................12
Module Selection........................................................................................4 Designer Range Split Face - Series 100 and 200............................................12
Face Blockwork Design Considerations.............................................................4 Smooth Face.................................................................................................13
Setout of Face Blockwork............................................................................4 Shot-blast Face..............................................................................................13
Colour and Texture Selection.......................................................................4 Honed Face...................................................................................................13
Mortar Selection.........................................................................................4 Polished Face................................................................................................13
Copings, Sills, Parapets...............................................................................4 Split Face......................................................................................................13
In-built Elements........................................................................................4 Designer Range - ULTRA BRICK............................................................................14
Protecting Face Masonry.............................................................................4 Designer Range - Breeze Blocks...........................................................................15
Blockwork Mortar Joints...................................................................................5 Designer Range Blocks...........................................................................................16
Joint Finishing.................................................................................................5 Smooth, Shot-Blast, Honed and Polished Face ................................................16
Ironed Joint................................................................................................5 Split Face......................................................................................................18
Flush Joint.................................................................................................5 Installation Details...................................................................................................18
Raked Joint................................................................................................5 Series 100 Installation Details.........................................................................18
Brickwork Design Considerations......................................................................5 Series 150 Installation Details.........................................................................19
Sizes..........................................................................................................5 Series 200 Installation Details.........................................................................20
Modular Planning.............................................................................................6 100mm Series (ƒ’uc = 15MPa)............................................................................21
Mortar Joints...................................................................................................6 120mm Series 2 hour insulation FRL (ƒ’uc = 15MPa)...........................................21
Control Joints..................................................................................................7 Grey Blocks............................................................................................................21
Mortar Mixes for Concrete Block and Brick........................................................8 150mm Series 2 hour insulation FRL (ƒ’uc = 15MPa)...........................................22
Sand...............................................................................................................8 200mm Series 2 hour insulation FRL (ƒ’uc = 15MPa unless noted).......................23
Mortar for Laying National Masonry Designer Range........................................8
® 300mm Series 2 hour insulation FRL (ƒ’uc = 15MPa unless noted) or insulation FRL
(ƒ’uc = 15MPa)....................................................................................................25
Other Admixtures.............................................................................................8
Heavy Duty available up to a 50Mpa strength rating........................................26
Reinforced Core-Fill Masonry Walls...................................................................9
Speed Blox - Perp Free Block.........................................................................26
Grout Filling.....................................................................................................9
Core Filled - Designer Range...................................................................................28
Grout for Core Filling...................................................................................9
Core-Fill Reinforced Retaining Walls................................................................28
Grouting.....................................................................................................9
Smooth, Shot-Blast, Honed and Polished Face ................................................28
Grout for Designer Range............................................................................9
Split Face......................................................................................................29
Construction Considerations.............................................................................9
Core Filled - Grey Block..........................................................................................30
Mortar Deposits..........................................................................................9
Core-fill block - Standard Grey Block Series 150, 200 and 300........................30
Scaffolding.................................................................................................9
150mm Series 2 hour insulation FRL (ƒ’uc = 15MPa)...........................................30
Concrete Droppings....................................................................................9
Speed Blox - Perp Free Block.........................................................................31
Coping & Flashing......................................................................................9
200mm Series 2 hour insulation FRL (ƒ’uc = 15MPa)...........................................31
Blending ...................................................................................................9
Core Filled - Grey Block..........................................................................................32
Rain Interruptions and Masonry Storage......................................................9
300mm Series 2 hour insulation FRL (ƒ’uc = 15MPa unless noted) or insulation FRL
Sealing of Designer Masonry.......................................................................9
(ƒ’uc = 15MPa)....................................................................................................33
Cleaning Concrete Masonry............................................................................10
Typical Component Usage - Core Filled...........................................................34
Good Building Practice..............................................................................10
Concrete Bricks.............................................................................................35
Removal of Mortar Stains with Hand Tools..................................................10
Concrete Bricks......................................................................................................35
Pressure Cleaning..........................................................................................10
Acid Treatments.............................................................................................10
Procedures for Acid Cleaning....................................................................10
Other Stains..................................................................................................10
Timber (Tannin).........................................................................................10
Clay or Loam Stains..................................................................................10
Mosses, Moulds and Lichens....................................................................10
Efflorescence.................................................................................................11
Safety Precautions and Warnings....................................................................11
3
Installation & Maintenance
Face Blockwork Design Considerations Nominal widths of doors and windows are also based on this module, e.g. 900mm
wide single door; and 1200mm,1800mm or 2400mm windows and doors.
Sizes The preferred way of dimensioning drawings is to show the ‘Nominal Sizes’ on
Blocks have a face dimension (nominal) of 400mm long x 200mm high. Because an openings. However, because the blocks are made 10mm shorter than the nominal (or
allowance is made for 10mm wide mortar joints, the actual face size of the block is modular) size, the actual openings will be different. Openings include one more mortar
390mm x 190mm. There are 12.5 blocks per m2. joint than units. For this reason, window and door frames are manufactured to suit
openings which are 10mm wider than the module, e.g. 910mm 1210mm, 1810mm,
1 metre 2410mm.
Note also that the length of piers and walls is 10mm less than the modules, i.e. 890,
1790 etc., due to the omission of the last vertical joint at the end of the pier/wall.
Face Blockwork Design Considerations

The following items should be considered carefully during the design stage to maximise
1 metre the long-term beauty and to minimise the need for maintenance of face masonry.
Setout of Face Blockwork

When designing with split face blocks, special consideration should be given to the
distances between openings and between corners and openings to facilitate the
bolstering of block ends where required.
12.5 blocks/m 2
Colour and Texture Selection
Fig B1 — Typical Block Dimensions The colour and texture of the unit should take into account the location of the
masonry and the building. Dark coloured units can mask unsightly staining from dirt
National Masonry® Grey Concrete Blocks are available in thicknesses of 90mm (100 and pollution. On the other hand, darker units can accentuate the presence of any
Series), 110mm (120 Series), 140mm (150 Series), 190mm (200 Series) and 290mm efflorescence or calcium carbonate caused by poor construction detailing, materials or
(300 Series). cleaning.
National Masonry® Queensland offers many ‘fractional’ sized blocks to reduce the need
for on-site cutting. However to maintain better colour consistency with coloured blocks, Mortar Selection
part size blocks for these applications are best prepared on-site by cutting or splitting Less staining and more aesthetically pleasing walls are achieved by ensuring the
from full size blocks. mortar colour is similar to the masonry unit. The colour of mortar is determined by the
Other block types such as lintel blocks, capping pieces, corner returns are made in colour of the cement and sand used, and by the use or not of different iron oxides. For
various product ranges. colours other than greys, off-white cement and clean sand will assist colour matching.
National Masonry® Queensland also manufacturers a range of Concrete Bricks. Our Construction of sample walls is recommended to determine the appropriate mortar
ULTRA Brick is made to a standard 76mm height in a range of colours and finishes. colour. Staining on light coloured units can be reduced by the use of off-white cements.
Our Speed-E Bricks are made in both a standard 76mm height and a 162mm height
to match two standard size brick courses. National Masonry® concrete Rippa Brick are Copings, Sills, Parapets
also made in a 162mm height to match two standard size brick courses. Sills should shed stormwater from the masonry by projecting at least 30mm beyond
Core-Fill Blocks for reinforced wall construction are made in thicknesses of 140mm the wall face. Copings or parapets should also shed water by having a ‘fall’ towards the
(Series 150), 190mm (Series 200), and 290mm (Series 300). unexposed (inner) face. Copings and parapets should be covered with a metal capping
Before specifying your choice, please contact your local National Masonry® sales office to prevent any water from penetrating the wall.
to confirm availability in your region.
In-built Elements
Where there are in-built elements (e.g. signage support frames etc.) they should slope
Material and Dimensional Variation away from the masonry. The soffit of major elements, such as balconies, should be
Concrete Blocks are formed in steel moulds using relatively stable materials enabling provided with a drip mould.
the size of individual units to be controlled to within small tolerances. The code for
concrete masonry units, AS/NZS4455.1, permits a general tolerance of ±3mm on the Protecting Face Masonry
overall dimension of each unit.
The additive used in the manufacture of Designer Range and its mortar is designed to
reduce water absorption, reduce mould growth and lower the risk of staining.
Modular Planning National Masonry® recommends that all Designer Range should be sealed with a
The concrete block was one of the first building components to be designed with quality penetrating sealer following installation, to manufacturer’s guidelines.
modular construction in mind. Originally it was based on a 4 inch module (as it remains
in the USA) but when the metric system was adopted in Australia during the 1970’s,
this was changed to a 100mm module.
Module Selection
For greatest ease and efficiency when constructing with masonry blockwork, it is
recommended to plan a building using a 200mm module, as a significant reduction in
the number of ‘special’ or cut blocks can be achieved.
Providing the design of a building is based on this module, cutting of blocks can
generally be avoided. Coloured face blocks are generally made in only full length units
(390mm) with part sizes (halves, etc) being cut on-site when required (or factory cut to
order) from the full length units, to maintain colour consistency.
Note: All saw grindings must be washed off the cut blocks as they are cementitious.
They are invisible while wet, but if allowed to dry, they appear as a pastel colour and
are difficult to move.
Most building materials work to a 600mm module. Blocks can also work to a 300mm
module by using part sizes, which include half height blocks, (e.g. A skirting course of
half height blocks and 5 courses of full blocks = 2100mm to suit typical door head
height).
4
Blockwork Mortar Joints Brickwork Design Considerations

Hollow blocks are normally laid with face shell bedding, i.e. there are two strips of
mortar which are laid over the face shells with no mortar being laid on the web (except Sizes
at corner construction). These two strips of mortar are continued up the vertical (or The dimensions of standard brick are: 76mm high x 230mm long x 110mm thick.
perpend) joints. Refer to Fig B2. National Masonry® Queensland manufactures a range of Concrete Bricks and Blocks in
various modular sizes to complement standard blockwork and brickwork construction.
National Masonry’s ULTRA BRICK comes 76 mm high x 230mm long x 110mm wide.
This Brick range offers 8 different colour options and 4 possible finishes.
National Masonry® Speed-E Brick comes in both a standard 76mm high x 230mm long
x 110mm wide as well as a double height 162mm high x 230mm long x 110mm wide.
Speed-E bricks are more cost effective laying system compared to clay bricks.
National Masonry® Concrete Rippa Bricks are also 162mm high x 390mm long x
110mm wide to match two standard size brick course (including mortar). They are
generally used to construct one lead of a wall. These are faster option to lay and more
Fig B2 — Applying Mortar cost effective when compared to clay bricks.
Table B2 — Brick Quantities per Square Metre
(No allowance for wastage)
Joint Finishing Face Size Bricks per m2
AS3700, Clause 4.9.2 requires mortar joints in ‘exposure environments’ to be ironed.
76 x 230 50
Ironed Joint 162 x 230 25
The preferred finish for mortar joints in face blockwork is an ironed finish which
provides the following benefits: 162 x 390 15
• The ironing tool compresses the mortar at the face of the masonry, making it denser
and more durable; and Additional information is provided on individual product pages in the following sections
• The mortar is pushed against the top and bottom faces of the blocks, improving the of this guide.
bond between the mortar and block.
• The finish is obtained by ironing the joints with an ironing tool when the mortar is
firm to touch (about 20 to 30 minutes after laying) and then lightly scraping off the
surplus mortar with a trowel, or by lightly brushing. Refer to Fig B3.
• The ironing tool should be made of 12mm diameter round rod and be more than
400mm long to ensure that a straight joint is produced.
Side
Fig B3 — Ironed Joint

Ironed joints are the preferred finish in Designer Blockwork.
Flush Joint
Where a plaster or textured coating is to be applied to the blockwork, a flush joint may
be used. Rub surface with a piece of block when the mortar is firm to provide a flat
surface for the coating.
Fig B4— Flush Joint (side)
Raked Joint
Although the raked joint is sometimes used in face brickwork for aesthetic reasons, it
should NOT be used with hollow blocks which are not to be rendered. This is to avoid:
• Reducing the face shell mortar width; and
• Adversely affecting the weatherproofing.
IMPORTANT: Because acid cannot be used to dissolve mortar without affecting the
masonry units’ appearance, mortar smears should be cleaned off face blockwork
before it sets hard onto the face.
5
Table B1 — Brickwork Dimensions

(with 10mm mortar joints) Table B1 — Brickwork Dimensions (with 10mm mortar joints)
Brickwork Opening Brickwork Opening Brickwork Opening Brickwork Height (mm)
Number of Bricks Brick Length (mm) Brick Length (mm) Brick Length (mm) Brick Height (mm)
230 290 390 76 162
5 1190 1210 1490 1510 1990 2010 429 857
10 2390 2410 2990 3010 3990 4010 857 1714
15 3590 3610 4490 4510 5990 6010 1286 2572
20 4790 4810 5990 6010 7990 8010 1714 3428
25 5990 6010 7490 7510 9990 10010 2143 4286
50 11990 - 14990 - 19990 - 4286 8572
100 23990 - 29990 - 39990 - 8572 17144
Modular Planning 600mm

Standard size bricks, as with most building materials, work to a 600mm module.
In standard height bricks, this module is 7 bricks high x 2.5 bricks long
(for standard length brick).
600mm
600mm
600mm
Fig B7. 600mm Module for

Double Height/Standard Length Brick
Mortar Joints
Fig B5. 600mm Module for Mortar joints (both bed and perpend) are usually specified as 10mm in thickness. Any
Standard Height/Standard Length Brick raking, if specified, should not exceed 10mm depth and should not penetrate closer
than 5mm to any core or perforation in cored units. Tooling of joints is particularly
beneficial in improving durability and must always be carried out as specified. Joint
In one-and-a-half height bricks, this module is 1 standard height course plus 4 courses finishing options are illustrated in Fig B8.
of brick-and-a-half high x 2.5 bricks long (for standard length brick)
600mm
600mm Shallow Deep Weather Struck

Ironed Ironed Struck Flush
Fig B8 — Joint Finishing Options
Fig B6. 600mm Module for

One-and-a-Half Height/Standard Length Brick
In double height bricks, it is 1 standard course plus 3 courses of double height brick x
2.5 bricks long (for standard length brick).
6
Control Joints Table B3 — Control Joint Spacing
(Contraction Joints) Product Spacing

Concrete Masonry blocks will contract as they cure. They will expand as they take up
water and then contract again as they dry. Concrete units will also expand as they get Dense-Weight Masonry (Standard Concrete) 7 metres
hot and again contract as they cool.
Masonry Blocks can encounter problems of cracking due to shrinkage of masonry Lightweight Masonry (< 1500 kg/m3) 6 metres
units, thermal movement and differential settlement of foundations. Control Joints such
as contraction joints can be used to counter these problems. Note Joint width is 10mm for panels up to 6000mm long. For panels over 6000mm
Control joints are constructed and spaced to allow for these movements. Control joints and up to 8000mm, joint width is 14mm. Joint sealants should be applied towards the
should be used beside large openings, at changes in wall height, changes in wall end of construction to minimise the effect of panel movement.
thickness (other than at piers), control joints in floor and roof slabs, at T-Junctions or at
any other points of potential cracking. Colour matched or paintable Joint width (see Note above)
Table B3 details the recommended maximum control joint spacings for non-reinforced
concrete walls. 10mm
The design and construction of control gaps in the external leaf of a full brick wall is Sealant
identical to that in a brick veneer wall. Except at re-entrant angles in long walls, control
gaps are not usually required in internal brick masonry. Where an internal gap is
required, it can usually be located at a full-height opening such as a door or window.
Open cell polyurethane
Brush on primer 1 to 8 hours foam backing rod
before inserting sealant
National Masonry® supply the following options for control joints:
150mm Series 2 hour insulation FRL (ƒ’uc = 15MPa)

Image Product Name Dimensions Notes Weight per unit (kg) Units per pallet
190
15.09 Control Joint 390x190x140 10.4 120

390
140
190
15.10 Control Joint Half 190x190x140 8.6 240
190
140
200mm Series 2 hour insulation FRL (ƒ’uc = 15MPa unless noted)

20.09 Full Control Joint 390x190x190 1 pallet = 72 x 20.09 and 20.10 (Sold in pairs) 14.2 72
190
390
190
190
20.10 Control Joint Half 190x190x190 1 pallet = 72 x 20.09 and 20.10 (Sold in pairs) 8.5 72
190
190
7
Mortar Mixes for Concrete Block and Brick Sand

The three principal functions of mortar are: The sand used in making the mortar for concrete blocks and bricks should not be
• To provide an even bedding for blocks and allow level coursing by taking the same as commonly used for clay bricks. “Brickie’s Loam” contains clay particles,
up small variations in unit height; which make the mortar more workable, but also can cause some additional shrinkage
in the mortar. Concrete masonry units tend to shrink so if used with a mortar with high
• To transmit compressive loads; and
shrinkage, cracking of the joints may result.
• To hold the blocks together in the wall by bonding to them, so that tensile
and shear force can be carried - often referred to as ‘bond strength’. For this reason, mortar for concrete blockwork and brickwork should be prepared with
This is particularly important so that units on top of the wall are not easily dislodged. clean sharp sand, such as pit sand, or plasterer’s sand. Tests have shown that the sand
can contain up to 10% fines but it should not contain clay particles. Lime or Methyl
In order to provide a good bond between the units and the mortar,
cellulose, can be added to increase workability. These additives or lime must not be
the following guidelines should be followed:
used in mortar used for laying Designer Range products.
• An appropriate mortar mix should be selected (refer to Tables B4 and B5 together
with the following section on ‘Mortar for Laying Designer Range).
• The mortar should be batched accurately using some consistent form Mortar for Laying National Masonry® Designer Range
of volume measurement. The additive used in the manufacture of Designer Range and its mortar is designed to
• The sand used in the mortar should be clean pit sand or plasterer’s sand. Clayey reduce water absorption, reduce mould growth and lower the risk of staining.
loam or sand containing organic impurities will affect the mortar strength and should Designer Range can be laid in convention mortar, however for the best result, Designer
not be used. Sand should be well washed to ensure it is free of salt. (Sand supplies Range should be laid in mortar containing Designer Range Additive. Refer to Table B4
of a suitable standard are normally readily available in Queensland). and B5 for mortar mixture details.
• Mortar should be discarded and not retempered, after the initial set of the cement Lime or plasticisers must NOT be added to mortar with Designer Range additive.
has taken place.
Other Admixtures
Additives may be used with products other than Designer Range, however caution
should always be exercised when using lime replacing additives such as plasticisers
or workability agents. They should be cellulose based, and only be used if specified
by the architect or engineer and then strictly in accordance with the manufacturer’s
instructions. Detergent and air entrainers should never be used.
Table B4 — Mortar Mixes
Mix Proportions by Volume

(See AS3700-2011: Table 11.1) Designer Range Methyl Cellulose Minimum Mortar Where Used (exposure)
Additive Additive Classification (See AS3700-2011: Table 5.1)
G.P. Portland
Lime Sand
Cement
1 — 5 Yes No M3
Designer Range products
1 — 4 Yes No M4
1 1 6 No No
M3 General purpose with moderate exposure
1 — 5 No Yes
1 0.5 4.5 No No Structural blockwork and severe exposure
M4 (marine and industrial environments). External walls
1 — 4 No Yes adjacent to seafront, below damp-proof course, fences.
NOTES: Methyl Cellulose water thickener is used to prevent the rapid drying out of the mortar thus improving its workability as well as increasing bond strength. It does not
have the detrimental effect of the plasticiser or detergent admixtures which generally reduce bond strength. Methyl Cellulose can cause long delays in drying in moist basement
environments.
Approximate Material Quantities for 1m3 of Mortar
Mortar Classification Grey Block Designer Range
Mix in 1 : 1 : 6 proportions Mix in 1 : 5 proportions

M3
Should be used in following exposures:
• Located within 100m to 1km of non-surf coast or 1km to Cement: 14 bags (20kg each) Cement: 16 bags (20kg each)
10km of surf coast and above damp proof course.
• In contact with ground in non-aggressive soils. Lime: 5 bags (20kg each) Designer Range additive: 8 litres
• In fresh water.
NOTE: Designer Range mortar should
• in domestic BBQs and incinerators.
be made with off-white cement and Sand: 1.2m3 * Sand: 1.2m3 *
oxide to match the colour of the
face block or brick.
Mix in 1 : 0.5 : 4.5 proportions Mix in 1 : 4 proportions
M4
Should be used in following exposures: Cement: 18 bags (20kg each) Cement: 20 bags (20kg each)
• Located within 100m of non surf coast or 1km of surf
coast and above damp proof course.
• In contact with ground in aggressive soils. Lime: 3 bags (20kg each) Designer Range additive: 8 litres
• In tidal and splash zones.
Sand*: 1.2m3 * Sand#: 1.2m3 *
* 20% extra sand included for bulking

# Use Brickie sand
8
Reinforced Core-Fill Masonry Walls Grout for Designer Range

Concrete blocks (140, 190, and 290mm) have large cores which facilitate the Due to the high hydrostatic pressure at the bottom of freshly grouted cores, water will
placement of steel reinforcing rods and the pouring/ pumping of grout (grout is highly seep out of the wall. This MUST be cleaned off. The admixture used with Designer
workable concrete). Range will increase the time for the grout to firm and dry, therefore more care must
be used inspecting and cleaning any seepage on the surface of these walls. Clean all
If a wall is reinforced with bars spaced at 800mm centres or less and fully grouted, the
grout spills before they set.
wall is referred to as ‘reinforced masonry’. These walls can have similar strength and
‘flexure’ characteristics to reinforced insitu concrete walls. For added protection against efflorescence caused by the leaching of lime from
blockfill, National Masonry recommends BASF MASTERPEL 240 or EQUIVALENT added
Partially reinforced block walls are only grout filled where the reinforcement is placed,
to your blockfill mix. This is not supplied by National Masonry and would need to be
usually in bond beams and vertically in cores.
requested from your blockfill supplier.
All reinforced walls must be designed by a structural engineer.
All core-filled walls must be cleaned thoroughly immediately following filling to ensure
lime leaching from the core-fill through unprotected capillary pores does not stain the
Grout Filling surface of the Blockwork.
Grout for Core Filling Construction Considerations

The correct grout specification (mix design) is critical to achieving the structural design
of a reinforced wall. The grout used to fill the cores of blockwork walls should be Mortar Deposits
specified as follow:
Mortar extruded from masonry joints during laying should be cut off with an upward
• Grout to comply with AS3700 Clause 10.7. stroke of the trowel. In this way a clean cut can be made without smearing the face
• Characteristic Compressive Strength 20MPa. of the unit. On completion of laying and tooling, any mortar smears which may be
• Cement content not less than 300kg/m3. on the face of the work should be removed, firstly with dry brushing and secondly, if
• Round aggregate (if any) not more than 10mm. necessary, by wet brushing. Do not allow mortar smears and dags to set on the face
• Clean sand (1.2m) of the masonry. If these mortar deposits are allowed to set on face masonry, high
pressure water jets or in extreme cases a diluted acid solution might be needed to
• A pouring consistency which ensures that the cores are completely filled and the
remove mortar stains. See ‘Cleaning Face Concrete Masonry’ before testing either
reinforcement completely surrounded without segregation of the constituents.
water jets or acid solutions. Acid cleaning should be avoided as face concrete blocks
can be discoloured.
The approximate number of blocks filled per cubic metre of grout is shown in Table B6.
(Based on 10mm rounded aggregate and 300kg/m3 cement.) Scaffolding
Table B6 Scaffolding planks should be placed with a clearance of at least 150mm to the wall.
Blocks Filled per cubic metre of Grout This gap allows mortar droppings to fall clear of the plank instead of splattering on
Blocks Filled per m3 of Grout the plank and building, disfiguring the wall. At the end of each day’s work or when
Block Type rain interrupts work, the plank nearest the wall should be propped on edge to prevent
(approximate)
mortar from being splattered onto the wall by overnight rain.
15.42 Channel 190
15.01 Standard 230 Concrete Droppings
15.48 H-Block 210 Masonry, supporting reinforced concrete slabs and beams is frequently disfigured by
20.01 Standard 150 droppings from the concrete pour. If such deposits are allowed to set it is sometimes
20.42 Channel 120 impossible to rectify the damage. Protection is best achieved by covering the walls with
20.142 Split Face 125 plastic sheeting. Where this is not done, any concrete on the wall must be thoroughly
cleaned off before it sets.
20.48 H-Block 125
30.48 H-Block 69 Coping & Flashing
40.925 Pier Block 50 Walls and parapets should have protection such as flashings or capping to the top
of the surface. A common source of staining and efflorescence of masonry is water
Grouting entering the walls and cavities at this point via exposed horizontal surface. If this is not
Grout may be mixed on site and poured from buckets into hoppers placed on top of possible the top of the blockwork should be sealed using a waterproofing membrane
the wall. Alternatively, for larger jobs, the grout may be delivered by transit mixer and before capping is bedded to waterproof the top surface.
pumped into the cores, using a small nozzle on the hose.
Before commencing placement of the grout, it is important that the cores should be Blending
clean and free of mortar ‘dags’ projecting into the core. A steel rod is pushed down the National Masonry® strongly recommends “blending” - drawing product across multiple
core to knock off these ‘dags’ and to break up any mortar that has dropped onto the pallets on-site - to obtain a consistent finish and mitigate colour variations.
footing. The cores are then hosed or swept out from the bottom of each core through
the ‘clean-out’ space. The vertical steel rods are tied to the starter bars, and then the Rain Interruptions and Masonry Storage
clean-out blocks are covered with formwork, ready for grouting. An alternative method,
which may be used in low height walls, is to leave a gap in the mortar bed at the All Masonry blocks and bricks must be kept dry on site, before use as well as when
bottom of each core and to hose out the dropped mortar and dags before the mortar freshly laid. Overnight or when rain interrupts blocklaying, its good practice to cover
has set. masonry products with a plastic sheet as to prevent moisture entering the cores.
Failing to do this will increase the likelihood of efflorescence.
In hot weather it may be necessary to hose the cores out with water in order to cool
the blocks and so prevent ‘flash-setting’ of the grout. If so, this hosing should be If masonry blocks or bricks obtain to much moisture, the solution of mortar takes in
completed at least 30 minutes before the grout is placed. carbon dioxide from the atmosphere and precipitates calcium carbonate. This whitish
stain is very disfiguring and not easily removed from the blockwork.
Because of the high pressures developed at the bottom of the cores when they are
filled, grouting in lifts of more than 1.2 metres should not be attempted in one pour.
Sealing of Designer Masonry
Where the lift is more than 1.2 metres, it is preferable to fill the cores in two stages at
least 30 minutes apart. Its highly recommended that all Designer Range Blocks or Bricks should be cleaned
and sealed with a quality penetrating sealer after installation. Applying a sealer,
When grouting Series 150 blocks, lifts should be reduced to 800mm (4 courses) to
as per installation instructions, will protect the product from the inside. Generally
ensure no voids are left in the wall.
characteristics of the surface colour and surface texture remain unchanged maintaining
the same look after the sealing process but with the added protection against common
spills or staining and the likelihood or severity of efflorescence.
9
Cleaning Concrete Masonry Acid Treatments

Only if hand cleaning and pressure washing methods have failed to fully remove mortar
Good Building Practice stains, should acid treatments be considered for cleaning of concrete blockwork.
Block layers must exercise extra care when laying face concrete masonry to minimise Note Acids react with and dissolve cement, lime and oxide colourants in concrete
mortar staining. blocks and mortar joints and are thus capable of etching, fading and streaking the
Block layers should: masonry finish. When acid is applied to dry blockwork without pre-wetting, it is drawn
• Keep face blocks as clean as possible while laying and tooling; in below the surface it is intended to clean. Salts may appear when the masonry dries
out.
• Keep unused pallets of blocks and tops of unfinished walls covered during rain to
prevent water penetration and excessive efflorescence; If it is considered necessary to use an acid for general cleaning, it should only be used
• Clean any dags and mortar smears before they set hard. Remaining stains could be after trialing in an inconspicuous area as outlined under ‘Essential Preliminaries’ and
removed following the procedures set out below. strictly in accordance with the following procedures.
Hydrochloric acid (otherwise known as Muriatic Acid or Spirits of Salts) can be tested
Removal of Mortar Stains with Hand Tools at a strength of 1 part acid to 20 parts water. A less aggressive alternative is powdered
After using a bucket and brush, remove any remaining mortar dags and smears by Citric Acid which can be used at strengths up to 1 Part acid to 10 parts water (by
rubbing the surface with a piece of ‘like coloured’ block or a piece of wood if cleaning volume).
polished masonry (to prevent scratching). Careful use of a paint scraper, wide bladed
chisel or wire brush can be helpful in removing mortar buildup. However care must be Procedures for Acid Cleaning
taken not to scratch or damage the masonry surface. 1. Remove mortar dags and smears as described under ‘Hand Tools’;
2. Working from the top of the wall down in vertical ‘runs’, thoroughly pre-wet (SOAK)
Pressure Cleaning an area of blockwork of approximately 2m2 at a time;
3. Apply dilute acid to the water-soaked area by brush or broom with a horizontally
This cleaning method is not a substitute for good building practice and hand cleaning
(sideways) action to prevent runs and streaks;
methods. It should only be used after these procedures have been carried out if further
cleaning is required. 4. Within 2 to 3 minutes, rinse this area from top to bottom under tap pressure only;
5. Pressure clean this area thoroughly, gently and evenly, as outlined previously;
Essential Preliminaries:
6. Repeat steps 1 to 5 as necessary to achieve the best compromise between
Thoroughly remove mortar smears and dags back to a flat surface with hand tools cleaning and damage caused by excessive treatment.
as outlined above. Hand cleaning must not leave any thickness of mortar, otherwise
pressure cleaning will damage the masonry face and mortar joints before removing the
thickness of mortar. Other Stains
Allow the mortar to harden for a minimum of seven days prior to pressure cleaning.
Timber (Tannin)
Carry out a pressure cleaning trial on a typical but inconspicuous area and allow it to
These can usually be removed by the application of a chlorine solution, preferably
dry to determine:
Sodium Hypochlorite (household bleach), onto the dry surface. Re-apply as necessary
• The effectiveness of this cleaning method; and to achieve the desired result.
• That marking, damage or erosion of the surface has not been caused before
proceeding with the general cleaning. Clay or Loam Stains
NOTE: If there is no inconspicuous area, a small wall could be constructed for this
If not too severe and intransigent, these stains may be removed with a solution of 50ml
purpose.
household detergent and 500 grams of oxalic acid dissolved in 4 litres of warm water.
Pressure cleaning may be carried out with pressure not exceeding 7MPa (1000 psi) Lightly pre-wet then apply the above solution with a nylon brush. Rinse off and repeat
and volume not exceeding 20 litres/minute and fan jet of a minimum 40 degree width, as necessary. Pressure cleaning as outlined previously may be of assistance.
held not closer than 500mm from the wall. Cleaning should be continuous and even.
The pressure jet should never be stationary and should not ‘needle’ or zero in on Mosses, Moulds and Lichens
mortar stains as surface erosion will almost certainly occur.
1. T hese commonly appear as a green to black area, often with a hair like growth,
NOTE: If this method is not totally successful, further hand cleaning and scraping around damp areas such as taps, gutter overflow areas, south facing walls, etc.
should be carried out prior to further pressure cleaning. 2. Scrape off any thickness of moss/mould/lichen;
Caution: High pressure water blasting can cause personal injury and damage masonry. 3. Pre-wet the mouldy area;
Mortar joints can be blown out and face blockwork marked and eroded. 4. Apply a chlorine solution, preferably Sodium Hypochlorite (household bleach),
Zero degree or needle jets, narrow fan jets and turbo jets should not be used on at sufficient strength to kill mould within approximately 1 hour;
blockwork because all concentrate the water pressure on too small an area which can 5. Scrubbing with a stiff brush or broom will normally assist;
cause damage. 6. Thoroughly flush the surface. If mould remains, repeat steps 1 to 3 as necessary to
Minimal pressure should be used to avoid mortar blowouts and/or damage to the face kill and remove the mould;
of units. 7. Pressure cleaning, as outlined previously, may assist.
Experienced operators should carry out pressure cleaning in accordance with the above
recommendations after appropriate trials have taken place.
10
Efflorescence
The term efflorescence is given to a white powdery deposit that forms on the surfaces
of porous building materials such as masonry units, mortar and concrete. The
temporary appearance of efflorescence is common on new masonry. For efflorescence
to occur, three conditions must be present:
• There must be soluble or semi soluble salts present;
• There must be water entering the masonry; and
• The masonry must be able to dry out.
The absence of any of the above three conditions will prevent efflorescence. Any
situation which allows water to enter the wall is likely to promote efflorescence. The
most common causes are:
• Poor building practice such as partially built walls left uncovered during rain. Delays
in installation of window sills and downpipes can exacerbate this problem, allowing
rainwater to enter block cavities and leach free lime to the surface;
• Poor storage of masonry units on site. Before units are placed in the wall they can
absorb ground salts and excessive water in the stockpiled masonry and can mobilise
latent salts. It is desirable to store masonry off the ground and loosely cover with a
waterproof membrane during rain;
• Poor or missing copings and flashings;
• Excessively raked joints which allow water to enter the bed face of the masonry
(ironed joints are recommended); and
• The use of air entraining agents in the mortar which makes the mortar act like a
sponge;
• Good laying practice and site procedures are necessary for keeping efflorescence
to a reasonable level. Care should also be taken to ensure that excessive lime is not
used in mortar joints.
In conjunction with dry brushing, the cleaning methods outlined previously will usually
remove most ‘normal’ levels of efflorescence. It is important to remove as much
efflorescence as possible with DRY brushing because powder efflorescence is water
soluble. Wet brushing can dissolve the powder and the dry block can re-absorb it. If
high levels of efflorescence are present on walls exposed to continual wetting from rain
or other sources of dampness over an extended period, calcification or hardening of
the lime tends to take place. The powdery lime gradually becomes a very hard film of
calcium carbonate. If this occurs, it will almost certainly require professional advice and
specialised cleaning methods for its removal.
Wall sealers also help to prevent future efflorescence, mould growth and general
staining by reducing water absorption from rain.
National Masonry® recommends that all Designer Range should be sealed with a
quality penetrating sealer following installation, to manufacturer’s guidelines.
Safety Precautions and Warnings

When using chemicals, care must be taken to avoid damage to adjacent materials and
finished surfaces. Masking and plastic sheeting may be necessary;
To avoid personal injury, wear protective clothing and vapour cartridge breathing mask-
particularly in confined areas, as recommended by chemical manufacturers;
NEVER mix chemicals with which you are unfamiliar, particularly chlorine and acid - it
emits deadly chlorine gas. Follow the chemical manufacturer’s recommendations;
Dilute acid by adding acid to water. Never add water to acid;
Harsh acidic chemicals should never be used for the cleaning of blockwork; and
Chemical wastes must not be allowed to run down drains and storm water outlets in
accordance with Environmental Protection Regulations.
11
Designer Range
Architectural Designer Blocks & Bricks Overview Colour Range

National Masonry’s Designer Range has the leading range of decorative masonry Using a bespoke combination of fine sands, aggregates, and Bayferrox® Pigments,
blocks and bricks available. Blocks are available in Nine contemporary colours in either National Masonry® create a solid fine textured masonry block with crisp sharp lines
a smooth face, honed, shot-blast, polished or split face finishes. Bricks are available and rich colours. The use of natural raw materials gives the product its own character
in eight colours in either smooth face, honed, shot-blast or polished finishes. Whether which cannot be matched by other more artificially processed building materials.
large or small National Masonry’s range of decorative blocks or bricks will give your
next project the winning edge. Benefits
• Tetxures to reflect a wide range of styles
Five Innovative Textures • Suitable for load bearing and non-loading applications
Smooth Face – A finely textured finish created through the standard moulding process. • Low to zero maintenance required
Both faces are suitable for face block work. Care is required when laying 2 face walls
• High Fire Protection
as variation in width of up to +/- 2mm may be present.
• Excellent thermal and acoustic performance
• Manufactured locally by National Masonry® to strict Australian Standards
Value Added Finishes
• Sika® additive to reduce water absorption
Value added finished masonry is supplied as a single face product. When only one face
• Bayferrox® colour pigments provide long lasting finish
is value added, the back side of the block may not be suitable as a face finish due to
the value adding process. If both faces are value added, both faces will be suitable for
a face work but care will be required when laying as there may be 2-5mm difference
Where to use
in the width of the individual blocks due to the honing / polishing process. • Suitable for load bearing and non-loading applications
Our New ULTRA BRICK with both Smooth and Value Added Finishes extend our range • External and internal walls for both residential and commercial projects
even further to provide a premium look in a traditional brick size. • Retaining Walls
• Feature Walls
Important Designer Range Information • Can be core filled for reinforced concrete wall applications
Which colour
Lead Time
Available in 9 unique and contemporary colours. Customised colours are also possible.
Lead times apply to all coloured blocks and bricks. Longer lead times apply to Honed,
Please note that extended lead times and minimum order quantities may apply.
Polished, and Shot-Blast Finishes as the product must be cured to harden sufficiently
before processing.
Part size blocks are best cut/bolstered on-site to maintain colour consistency.
Part size blocks can be made-to-order. Alabaster Pearl Grey Platinum Charcoal Wilderness Terrain Coco Paperbark Almond
Contact National Masonry® for further details.

Designer Range Series 100, 150, 200 and 300 Smooth,
Colour and Texture Variation
Honed, Shot-blast and Polished Face
Some variation in colour may occur due to natural variations in raw materials. Colour
variation can also occur from batch to batch making it essential to order all product
Introduction
requirements at the same time. National Masonry® recommends part size blocks are
cut on site to maintain colour consistency. Blocks can be cut to order. Series 100 (90mm thickness), Series 150 (140mm thickness), Series 200 (190mm
thickness) and Series 300 (290mm thickness) are suitable for internal and external
Blending walls in loadbearing and non-loadbearing applications.
To obtain a consistent finish and mitigate colour variation, National Masonry® strongly
Face textures
recommends “blending” which is drawing product from multiple pallets on-site.
Series 100, 200, and 300 Designer Range blocks are available with the following face
Blocks & Bricks Storage texture finishes:
Blocks and bricks must be kept dry on site before use and when laid. Freshly laid • Smooth Face
walls must be covered overnight and when rain interrupts work in order to prevent • Honed Face
moisture entering the cores of the blocks. Failing to do this will increase the likelihood • Shot-Blast Face
of efflorescence. • Polished Face
• Ends - Honed, Polished or Shot-blast finishes
Mortar
Coloured Designer Range blocks and bricks contain an efflorescence inhibitor (Tech- Designer Range Split Face - Series 100 and 200
Dry®). To complete the system, an additive must be used in mortar mix. National Designer Range Split Face is suitable for internal and external walls in loadbearing and
Masonry® supply and recommend TECH-DRYAD Mortar Additive. The consumption of non- loadbearing applications.
additive varies significantly, 20 litres of mortar additive may lay approximately 1000-
1500 Tech Dry Blocks. Designer Range Split Face is produced in two block thicknesses, Series 100 (90mm
thickness) and Series 200 (190mm thickness).
Sealing
Face textures
All Designer Range blocks and bricks should be cleaned and sealed with a quality
penetrating sealer after installation. Failure to do so dramatically increases the Split Face - The splitting process produces a bold textured surface resulting in
likelihood and severity of efflorescence and general staining. characteristics much like split natural stone.
12
Five Innovative Textures
Smooth Face
A finely textured finish created
through the standard moulding
process.
Shot-blast Face
This process subtly exposes
the aggregates, producing a
weathered, sawn stone-like finish.
Honed Face
The honed process grinds 2-3mm
from the block surface, producing a
matt exposed-aggregate finish.
Polished Face
This involves producing a denser
block which is honed and then
buffed. This enriches the colour of
the aggregates.
Split Face
The splitting process produces a
bold textured, exposed aggregate
finish.
13
Designer Range - ULTRA BRICK
Not just another brick, the ULTRA BRICK has been designed and engineered from A finish for every style
the ground up delivering a premium pressed brick with a finish to suit any budget.
A bespoke mix of raw materials have been combined with the latest pressing Finish Description
technology to produce a brick that is perfect in shape, consistency, durability, and
easy to lay. Delivering crisp lines, rich colour and texture, the ULTRA BRICK is the brick Smooth
range for the 21st Century. The smooth face texture uses the
finest grade of sand and world class
Benefits pigments to prove a rich finely texture
solid colour finish.
• Finely texture surface with Bayferrox® pigments for vibrant long lasting colour
• Sika® additive to reduce likelihood of efflorescence
Honed
• No need to paint or render
• Non combustible The honed finish has its own special blend
• Won’t rot, rust, or delaminate of materials. These bricks have the face
• Manufactured locally by National Masonry® carefully ground exposing the premium
selected aggregates producing an elegant
Where to use honed finish.
• External and internal walls Polished

• Feature walls
• Fences The polished finish takes the honed
product and using diamond polishing
stones buffs the honed finish to a
Which colour glass like finish.
Available in 8 modern colours
Shot-blast
This process subtly exposes the
Alabaster Pearl Grey Platinum Charcoal Terrain Coco Paperbark Almond aggregates, producing a weathered,
Available in 4 finishes sawn stone-like finish.
Smooth Honed Shot-blast Polished
Premium look. Ultra results.
14
Designer Range - Breeze Blocks
The National Masonry® Breeze Block collection has revitalised a 1970’s icon into a Fresh contemporary designs
modern day contemporary classic. Brimming with sharp lines, vibrant texture, and rich
colour, these modern day classics will compliment a diverse range of projects. National Rhombus Tetra
Masonry® Breeze Blocks can create unique walling and feature solutions that provide
permeability of light and air that are aesthetic in character with the durability and
practicality that you come to expect in a masonry unit. These crafted units are finished
with a lightly honed face leaving no doubt they are a premium architectural finished
product that are at home in the most humble of applications through to striking
features in a modern master piece.
Benefits
• Two contemporary designs
• Durable masonry construction
• Versatile
• Non flammable
• Lightweight
• Lightly honed finish
• Bayferrox® colour pigments provide long lasting finish
Where to use
• Suitable for indoor & outdoor applications
• Can use horizontal & vertically
• Privacy screen
• Room partition
• Patios & outdoor living areas
• Features
• Increase light or ventilation
Which colour
Pearl Grey Charcoal
Let in light and air
15
Designer Range Blocks
Smooth, Shot-Blast, Honed and Polished Face

Weight per Units per
Image Product Name Dimensions LxHxW Available Finishes Available Colours
unit (kg) pallet
Alabaster, Pearl Grey, Platinum,

190
Smooth Face, Shot-blast Face, Honed
10.01 Standard 390x190x90 Charcoal, Wilderness, Terrain, 10.3 195
Face, Polished Face
Coco, Paperbark, Almond
390
90

10.03 Half Length 190x190x90 Charcoal, Wilderness, Terrain, 5.5 360
190
190 Face, Polished Face

90

190
10.31 Solid 390x190x90 Charcoal, Wilderness, Terrain, 14.8 156
Face, Polished Face
390
90

90
10.71 Standard Half Length 390x90x90 Charcoal, Wilderness, Terrain, 5.3 390
390
Face, Polished Face
90

190
12.702 Three Quarter Length 290x190x110 Charcoal, Wilderness, Terrain, 8.6 200
290
Face, Polished Face
110

190

110

190
Face, Polished Face
390
110

190
Face, Polished Face
140
390

190 Smooth Face, Shot-blast Face, Honed
Face, Polished Face
290
140

190
Face, Polished Face
140 190

190
Shot-blast Face, Honed Face, Polished
15.42 Full Length Channel 390x190x140 Charcoal, Wilderness, Terrain, 12.5 144
Face
140
390
190
15.48 Full Length H Block 390x190x140 Smooth Face Charcoal, Wilderness, Terrain, 12.6 144
390
140

190
Face, Polished Face
190
390

190
Face, Polished Face

190
290
16

unit (kg) pallet

190
Face, Polished Face
190 190

20.42 Channel# 390x190x190 Charcoal, Wilderness, Terrain, 15.9 108
190
Face
190
390
190
20.48 H Block* 390x190x190 Smooth Face Charcoal, Wilderness, Terrain, 13.2 108
190
390

20.71 Standard Half Height 390x90x140 Charcoal, Wilderness, Terrain, 7.6 216
90

190

30.01 Standard* 390x290x190 Smooth Face Charcoal, Wilderness, Terrain, 20.82 72
190
290
390

190
290
390

30.925 Standard# 390x290x190 Charcoal, Wilderness, Terrain, 20.27 72
190
Face
290
390

40
Standard Smooth Face, Shot-blast Face,
50.31 Capping Tile 390x40x190 Charcoal, Wilderness, Terrain, 6.6 270
390
Honed Face, Polished Face
190

110
230
76
ULTRA BRICK 230x76x110 Smooth, Honed, Shot-blast, Polished Charocal, Terrain, Coco, Paperbark, 3.8 500
Almond
Breeze
Rhombus 390x190x140 n/a Charcoal, Pearl Grey 12.2 108
190
140
390 Block
Breeze
Tetra 390x190x140 n/a Charcoal, Pearl Grey 12.2 108
190
140
390 Block
Find detailed information and download more guides at our website - www.nationalmasonry.com.au
17
Split Face
Image Product Name Dimensions LxHxW Available Colours Available Finishes
unit (kg) pallet

10.101 Standard 390x190x95 Split Face Charcoal, Wilderness, Terrain, 14.8 108
190

390
95

90
10.109 Standard Half Height 390x90x90 Split Face Charcoal, Wilderness, Terrain, 8.0 216
390
90

190
190
390

190
20.123 Half Length 190x190x190 Split Face Charcoal, Wilderness, Terrain, 11.1 180
190 190

90
390
190

20.139 Corner Return Half 390x190x190 Split Face Charcoal, Wilderness, Terrain, 18.9 90
190
190
390

190
190 190

20.142 Full Length Channel 390x190x190 Split Face Charcoal, Wilderness, Terrain, 17.0 108
190
190
390
Installation Details
Series 100 Installation Details

10.101 10.01 cut 10.01
10.101 bolstered
10.101 on-site 10.01 on-site
10.101 10.01
295mm 290mm 10.01 cut

on-site
95mm
10.101
10.01
10.101 10.01
10.101 10.01
295mm 290mm
90mm
10.101 bolstered on-site
95mm 95mm Fig C2 — Corner Bonding Detail
Utilising Cut-On-Site Corner Block
Fig C1 — Corner Bonding Detail
Using Bolstered-On-Site Split Face Block
18
15.01 cut on-site to 15.01

maintain bond
15.01
15.01
340mm
15.01
15.01 cut
15.01 on-site to
maintain
340mm bond
Fig C9 — Corner Bonding Details
Full block 3/4 block 3/4 block Full block
1/2
block
1/2
block
Cut block in half
Remove remainder
of centre web
20.13 Lay end down

Half Lintel
Fig C10 — Face Lintel Detail with 1800mm Opening for Series 150 or 200 Blocks
19
20.121
Cut
45mm A B
195mm Split
Cut one block per course to

340mm length to maintain
1/2 bond pattern
20.121
20.121 20.139
Split End
20.121
20.121
20.121
20.121
B
20.121 20.121
20.121
20.121
20.121
A Cut one block per course to

20.139 340mm length to maintain
Split End 1/2 bond pattern
Fig C11 — Corner Bonding Details Fig C12 — Alternative Corner Bonding Details
Series 200 Split or Smooth Face Designer Range Blocks Series 200 Split or Smooth Face Designer Range Blocks
For window heights For window heights

900mm or 1500mm 1200mm or 1800mm 80mm
20.40 20.40
Sill Sill
40mm
10.71
10.01
10.01 10.101 cut in half, laid
with cut end down.
10.71 80 x 40mm bevel cut
on top.
20.01 Flashing Flashing
20.121
20.01
20.01
Fig C13 — Sill Detail - Single Skin Wall Fig C14 — Sill Detail - Single Skin Wall
Series 200 Feature Face Designer Block Series 200 Split Face Designer Block
20
Grey Blocks
Concrete Grey Blocks

Concrete Grey Blocks are manufactured utilising recycled ash to provide a lightweight, high strength product. Concrete Grey Blocks are commonly used for construction on
houses, schools, and various commercial projects. Choosing the right Concrete Grey Block is important. Before selecting, you should ensure this product meets your projects
requirements. Certain Concrete Grey Blocks are lightweight, heavy duty and/or fire rated. Please check the Additional Information. Please consult National Masonry® if you are
unsure on the best Concrete Grey Block for your construction needs.
Popular Products
20.01 20.03 20.42 20.45 20.48 20.71

Standard Half Channel Cleanout H Block Standard Half Height
100 Series
100mm Series (ƒ’uc = 15MPa)

Image Product Name Dimensions LxHxW Notes Weight per unit (kg) Units per pallet
190
10.01 Standard 390x190x90 8.5 195

390
90
190
290
10.02 Three Quarters 290x190x90 6.7 240
90
10.03 Half 190x190x90 4.4 360

190
190
90
190
10.31 Solid 390x190x90 12.4 156

390
90
90
390
10.71 Standard Half Height 390x90x90 4.0 390
90
120 Series

12.703 Thick Half Wall 190x190x110 Not sold separately 6.3 n/a
190
190
110
190
12.709 Thickwall 390x190x110 Pallet contains 10 x 12.703 11.31 150

390
110
21
150 Series

190
15.01 Standard 390x190x140 10.9 144

390
140
190
15.02 Three Quarter 290x190x140 8.9 160

290
140
190
15.03 Half 190x190x140 5.7 240
140 190
190
15.09 Control Joint 390x190x140 10.4 120

390
140
190
190
140
190
15.12 Lintel 390x190x140 16.2 120

390
140
190
15.20 Knockout Bond Beam 390x190x140 10.6 120

390
140
190
15.22 Seven Eighths 340x190x140 9.7 125

340
140
190
15.25 Corner Return 390x190x190 12.9 105

390
190
190
15.42 Channel 390x190x140 10.5 144

390
140
390
15.45 Cleanout 390x140x190 9.9 120

140
190
190
15.48 H Block 390x190x140 11.4 144

390
140
190
15.703 Thick Wall Half 190x190x140 Not sold separately 8.5 n/a
140 190
190
15.709 Thick Wall 390x190x140 Pallet contains 10 x 15.703 15.3 120

390
140
22
150 Series

90
390
140
40
390
50.31 Capping Tile 390x40x190 5.7 270
190
50.45 Biscuit & Spring 4.1 120
200 Series
200mm Series 2 hour insulation FRL (ƒ’uc = 15MPa unless noted)

190
20.01 Standard 390x190x190 13.29 108

390
190

190
290
190
190
20.03 Half 190x190x190 7.3 180
190 190
190
20.04 Quarter 190x190x90 4.4 360
190
90
190
390
190
190
190
190
190
20.13 Half Lintel 190x190x190 8.2 220
190 190
190
20.18 Deep Lintel 390x190x190 12.5 125

390
190
23
200 Series

190

390
190
20.21 Knockout Bond Corner 390x190x190 13.63 108

190
390
190
20.22 Seven Eighths 340x190x190 12.74 108

190
340
190
20.25 Three Quarter Lintel 290x190x190 10.0 165

190
290
190
40
190
90
20.40 Half Height Sill 190x90x190 4.48 360
190
20.42 Channel 390x190x190 13.09 108

190
390
190
390
20.45 Cleanout 390x190x190 11.62 108

190
190
190
20.48 H Block 390x190x190 11.73 108

390
190
190
390
190
20.60 Bonded PR 390x190x390 17.9 60
390

90
390
190
20.140 Standard 390x140x190 11.0 108

140
390
190
210 190
10
20.748 Squint 290x190x190 10.2 90

190
290
90
190
20.925 Single Core 390x190x190 16.6 108

390
190
40
390
50.31 Capping Tile 390x40x190 5.7 270
190
24
300 Series
300mm Series 2 hour insulation FRL (ƒ’uc = 15MPa unless noted) or insulation FRL (ƒ’uc = 15MPa)
30.01 Standard 390x190x290 18.9 72

190
390
290
190
30.02 Three Quarter 290x190x290 14.3 80
290 290
30.03 Half 290x190x190 9.4 144

190
290
190
190 30.04 Quarter 290x190x90 6.7 240

290
90
30.18 Deep Lintel 390x190x290 17.1 85

190
390
290
390
30.45 Cleanout 390x190x290 16.65 60

290
190
190
30.48 H Block 390x190x290 14.52 72
390
290
30.925 Standard 390x190x290 17.5 72

190
390
290
190
40.925 400 Pier Block 390x190x390 23.9 54
390 390
40
390
50.31 Capping Tile 390x40x190 5.7 270
190
25
Heavy Duty
Heavy Duty available up to a 50Mpa strength rating

190
20.01 Standard 390x190x190 13.29 108

390
190

190
290
190
190
20.03 Half 190x190x190 7.3 180
190 190
190
20.13 Half Lintel 190x190x190 8.2 220
190 190
20.22 Seven Eighths 340x190x190 12.74 108

190
340
190
390
20.45 Cleanout 390x190x190 11.62 108

190
190
190
20.48 H Block 390x190x190 11.73 108

390
190
Speed Blox
Speed Blox - Perp Free Block

20.03SB Half 200x190x190 7.1 165

190
200
190
190
20.21SB Full Length Corner 400x190x190 14.8 90

400
190
190
20.48SB H Block 400x190x190 13.1 90

400
190
26
National Masonry®
National Masonry Designer Range: Charcoal - Polished
National Masonry Designer Range: Charcoal Shot Blast

27
Core Filled - Designer Range
Core-Fill Reinforced Retaining Walls Which colour

Designer Range colours and textures or standard grey blocks Available in 9 unique and contemporary colours. Customised colours are also possible.
Please note that extended lead times and minimum order quantities may apply.
Core-fill Block
For construction of reinforced masonry retaining walls and loadbearing walls requiring
increased robustness characteristics.
Alabaster Pearl Grey Platinum Charcoal Wilderness Terrain Coco Paperbark Almond
Available in standard grey or Designer Range colours.
Available with smooth, honed, polished, shot-blast and split face textured finishes. Installation considerations
Hydrostatic pressure at the bottom of a freshly grouted core is very high, forcing water
Introduction to seep out of the wall. This must be cleaned off. The admixture used with Designer
National Masonry feature face core-fill blocks are designed for the construction Range will increase the time for the grout to firm and dry, therefore more care must
of reinforced masonry retaining walls and loadbearing walls requiring increased be used inspecting and cleaning any seepage on the surface of these walls. Pours of
robustness characteristics and where a feature face is required. 1.2M max. Lift are recommended.
Face textures Availability

Core-fill block is available with the following face texture finishes: Lead times apply to all coloured blocks.
• Smooth face Part size blocks are best cut/bolstered on-site to maintain colour consistency.
• Honed face Part size blocks can be made - to - order.
• Shot-blast face Contact National Masonry for further details.
• Polished face
• Split face
• Ends - Honed, Polished or Shot-blast

unit (kg) pallet

190
Face, Polished Face
190
390

190
Face, Polished Face

190
290

190
Face, Polished Face
190 190

20.42 Channel# 390x190x190 Charcoal, Wilderness, Terrain, 15.9 108
190
Face
190
390
190
20.48 H Block* 390x190x190 Smooth Face Charcoal, Wilderness, Terrain, 13.2 108
190
390

20.71 Standard Half Height 390x90x140 Charcoal, Wilderness, Terrain, 7.6 216
90

190

190
290
390

190
290
390

30.925 Standard# 390x290x190 Charcoal, Wilderness, Terrain, 20.27 72
190
Face
290
390
28
Core Filled - Designer Range
Split Face
Image Product Name Dimensions LxHxW Available Colours Available Finishes
unit (kg) pallet

190
190
390

190
190 190

90
390
190

20.139 Corner Return Half 390x190x190 Split Face Charcoal, Wilderness, Terrain, 18.9 90
190
190
390

190
190 190

20.142 Full Length Channel 390x190x190 Split Face Charcoal, Wilderness, Terrain, 17.0 108
190
190
390
National Masonry Designer Range: Charcoal - Polished

29
Core Filled - Grey Block
Core-fill block - Standard Grey Block Series 150, 200 and 300
Introduction
National masonry core-fill block is designed for the construction of reinforced masonry retaining walls and loadbearing basement walls requiring increased robustness
characteristics.
Construction considerations
Before commencing placement of the grout, it is important that the cores should be clean and free of mortar ‘dags’ projecting into the core. A steel rod is pushed down the core
to knock off these ‘dags’ and to break up any mortar that has dropped onto the footing. The cores are then hosed or swept out from the bottom of each core through the ‘clean-
out’ space. The vertical steel rods are tied to the starter bars, and then the clean-out blocks are covered with formwork, ready for grouting. An alternative method, which may be
used in low height walls, is to leave a gap in the mortar bed at the bottom of each core and to hose out the dropped mortar and dags before the mortar has set.
When grouting series 150 blocks, lifts should be reduced to 800mm (4 courses) to ensure no voids are left in the wall.

190
15.01 Standard 390x190x140 10.9 144

390
140
190
15.02 Three Quarter 290x190x140 8.9 160

290
140
190
15.03 Half 190x190x140 5.7 240
140 190
190
15.09 Control Joint 390x190x140 10.4 120

390
140
190
190
140
190
15.12 Lintel 390x190x140 16.2 120

390
140
190

390
140
190
15.22 Seven Eighths 340x190x140 9.7 125

340
140
190
15.25 Corner Return 390x190x190 12.9 105

390
190
190
15.42 Channel 390x190x140 10.5 144

390
140
390
15.45 Cleanout 390x140x190 9.9 120

140
190
190
15.48 H Block 390x190x140 11.4 144

390
140
30

190
15.703 Thick Wall Half 190x190x140 Not sold separately 8.5 n/a
140 190
190
15.709 Thick Wall 390x190x140 Pallet contains 10 x 15.703 15.3 120

390
140
90
390
140

190
20.01 Standard 390x190x190 13.29 108

390
190

190
290
190
190
20.03 Half 190x190x190 7.3 180
190 190
190
20.04 Quarter 190x190x90 4.4 360
190
90
190
390
190
190
190
190
190
20.13 Half Lintel 190x190x190 8.2 220
190 190
190
20.18 Deep Lintel 390x190x190 12.5 125

390
190
190

390
190
20.21 Knockout Bond Corner 390x190x190 13.63 108

190
390
190
20.22 Seven Eighths 340x190x190 12.74 108

190
340
190
31

20.25 Three Quarter Lintel 290x190x190 10.0 165

190
290
190
20.42 Channel 390x190x190 13.09 108

190
390
190
390
20.45 Cleanout 390x190x190 11.62 108

190
190
190
20.48 H Block 390x190x190 11.73 108

390
190
190
390
190
20.60 Bonded PR 390x190x390 17.9 60
390

90
390
190
20.140 Standard 390x140x190 11.0 108

140
390
190
210 190
10
20.748 Squint 290x190x190 10.2 90

190
290
90
190
20.925 Single Core 390x190x190 16.6 108

390
190
32
300mm Series 2 hour insulation FRL (ƒ’uc = 15MPa unless noted) or insulation FRL (ƒ’uc = 15MPa)
30.01 Standard 390x190x290 18.9 72

190
390
290
190
30.02 Three Quarter 290x190x290 14.3 80
290 290
30.03 Half 290x190x190 9.4 144

190
290
190
30.18 Deep Lintel 390x190x290 17.1 85

190
390
290
390
30.45 Cleanout 390x190x290 16.65 60

290
190
190
30.48 H Block 390x190x290 14.52 72
390
290
30.925 Standard 390x190x290 17.5 72

190
390
290
190
40.925 400 Pier Block 390x190x390 23.9 54
390 390
Speed Blox - Perp Free Block

20.03SB Half 200x190x190 7.1 165

190
200
190
190
20.21SB Full Length Corner 400x190x190 14.8 90

400
190
190
20.48SB H Block 400x190x190 13.1 90

400
190
33
Typical Component Usage - Core Filled
15.48 15.22
15.48
15.48
15.22
15.48
15.48
15.48
15.25
15.48
15.48
Fig E1 — Corner Bonding Detail

for Series 150 Core-Fill Block
10.02
30.48
48
30.48
20.01
20.48
30.03 20.48
10.02
20.48
30.48
30.48
20.48 20.01
20.48
20.48
30.18
onding and End Detail Fig E2 - Corner Bonding Detail

es Core-Fill Block for Series 200 Core-Fill Block
10.02
30.48
30.48
30.48
30.18 20.01
20.48
30.03 20.48
10.02
30.48
30.48
20.48 20.01
30.48
30.03 20.48
30.18
Fig E3 - Corner Bonding and End Detail Fig E2 - Corner Bonding Detail
for 300 Series Core-Fill Block for Series 200 Core-Fill Block
34
Concrete Bricks
Concrete Bricks
Introduction
National Masonry® Concrete Brick is a 162mm height block which equals two courses
of standard height brick (including mortar) making these blocks ideal for use in
conjunction with standard height face brick veneer construction.
Concrete Brick combines strength, durability and ease of construction to provide highly
cost effective solutions for every-day construction applications.
Applications
Concrete Brick is generally used to construct one leaf of a masonry wall in conjunction 2 courses of
with standard height face brick veneer.
Rippa/Speed- standard brick +
E = 162mm mortar = 162mm
Colours
Concrete Brick is available in Natural Grey, and can also be made-to-order in any of the
Designer Range colours. For colour information, refer to the Designer Range section of
this guide.
ULTRA Brick available in 8 colours.
Alabaster Pearl Grey Platinum Charcoal Terrain Coco Paperbark Almond

Fig D1 — Rippa/Speed-E Coursing
Additional Information
Please refer to National Masonry Design Guide - Structural, Fire and Acoustic
performance information.
Availability
• No minimum order quantities apply to Natural Grey Bricks.
• Lead time 0-2 weeks.
• Contact National Masonry® for further details.
Natural Grey Bricks

Image Product Name Dimensions LxHxW Series Notes
unit (kg) pallet
110
230
76
12.715 Speed-E Common 230x76x110 Bricks 3.4 600
Speed-E Double Height -

12.796 230x162x110 Bricks 6.9 250
162
110
230 Loadbearing
Speed-E Double Height - NON

12.796 230x162x110 Bricks Non loadbearing 4.4 300
162
110
230 Loadbearing
162
12.162.01 Standard Rippa 390x162x110 Bricks 9.25 180

390
110
162
12.162.11 Universal Rippa 390x162x110 Bricks (1 in 5 with 12.162.01) 8.0 180

390
110

unit (kg) pallet

110
230
76
ULTRA BRICK 230x76x110 Smooth, Honed, Shot-blast, Polished Charocal, Terrain, Coco, Paperbark, 3.8 500
Almond
35
All pallets remain the property
NATIONAL of National Masonry®
MASONRY
Online Booking Pickup Call to Arrange Pickup
Use our Pallet Collection Form on our website. Call your local branch during office hours.
www.nationalmasonry.com.au 1800 066 089
To find your closest National Masonry® stockist, to receive brochures or to learn more about our products,
call us or visit our website at www.nationalmasonry.com.au
South Queensland Gold Coast North Queensland New South Wales Victoria
62 Industrial Avenue, 663 Pine Ridge Road, 6 David Muir Street, 65 Burleigh Street, Riding Boundary Road,
Wacol Biggera Waters Slade Point Toronto Deer Park
Brisbane QLD 4076 Gold Coast QLD 4216 Mackay QLD 4740 Lake Macquarie NSW 2283 Melbourne VIC 3023
Phone: (07) 3271 9292 Phone: (07) 5552 3300 Phone: (07) 4955 1155 Phone: (02) 4088 1888 Phone: (03) 9361 6400
Fax: (07) 3271 1815 Fax: (07) 5552 3399 Fax: (07) 4955 4130 Fax: (02) 4088 1899 Fax: (03) 9363 6008
[email protected] [email protected] [email protected] [email protected] [email protected]
Colour variations occur from batch to batch. Colours shown are indicative only and should not be used for final selection. Products ordered should be chosen from actual samples current at the time of order and are subject to availability. Photographs in this brochure are only representative of National Masonry®
products and the appearance and effect that may be achieved by their use. Samples, brochures and displays should be viewed as a guide only. Customers should ensure all delivered products are acceptable, and any concerns about products are made prior to laying. All prices are subject to availability and can be
withdrawn or varied without notice. © Copyright National Masonry Pty Ltd– all rights reserved 2013. Gardenwall® & Keystone Elite133® are registered trademarks of Keystone® Retaining Wall Systems Inc, use under licence by National Masonry®. National Masonry®, the National Masonry® logo, nationalmasonry.com.
au, If these and other National Masonry Pty Ltd trade marked terms are marked on their first occurrence in this information with a trade mark symbol (® or ™), these symbols indicate Australian registered or common law trade marks owned by National Masonry® Pty Ltd at the time this information was published.
Such trade marks may also be registered or common law trade marks in other countries. Other product, company or service names may be trade marks or service marks of others. National Masonry Pty Ltd ABN 94 155 064 136. Correct as at 15/12/17. NAT0119 SQLD Design Guide - Masonry Blocks & Bricks v14.

National Masonry Design Guide Book 2 SQLD PDF

Uploaded by

Copyright:

Available Formats

National Masonry Design Guide Book 2 SQLD PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

National Masonry Design Guide Book 2 SQLD PDF

Uploaded by

Copyright:

Available Formats

Masonry Blocks & Bricks

Design Guide SQLD & NSW

About National Masonry® National Masonry® Construction Solutions

Additional Assistance and Information

Use our Pallet Collection Form on our website. Overview

Standard Grey Block

Heavy Duty Block

Installation & Maintenance........................................................................................4 Designer Range......................................................................................................12

Face Blockwork Design Considerations

Setout of Face Blockwork

Blockwork Mortar Joints Brickwork Design Considerations

Fig B3 — Ironed Joint

Fig B4— Flush Joint (side)

Table B1 — Brickwork Dimensions

Brickwork Opening Brickwork Opening Brickwork Opening Brickwork Height (mm)

230 290 390 76 162

5 1190 1210 1490 1510 1990 2010 429 857

10 2390 2410 2990 3010 3990 4010 857 1714

15 3590 3610 4490 4510 5990 6010 1286 2572

20 4790 4810 5990 6010 7990 8010 1714 3428

25 5990 6010 7490 7510 9990 10010 2143 4286

50 11990 - 14990 - 19990 - 4286 8572

100 23990 - 29990 - 39990 - 8572 17144

Modular Planning 600mm

Fig B7. 600mm Module for

600mm Shallow Deep Weather Struck

Fig B6. 600mm Module for

Control Joints Table B3 — Control Joint Spacing

(Contraction Joints) Product Spacing

National Masonry® supply the following options for control joints:

150mm Series 2 hour insulation FRL (ƒ’uc = 15MPa)

15.09 Control Joint 390x190x140 10.4 120

200mm Series 2 hour insulation FRL (ƒ’uc = 15MPa unless noted)

Mortar Mixes for Concrete Block and Brick Sand

Mix Proportions by Volume

Mortar Classification Grey Block Designer Range

Mix in 1 : 1 : 6 proportions Mix in 1 : 5 proportions

* 20% extra sand included for bulking

Reinforced Core-Fill Masonry Walls Grout for Designer Range

Grout for Core Filling Construction Considerations

Cleaning Concrete Masonry Acid Treatments

Safety Precautions and Warnings

Architectural Designer Blocks & Bricks Overview Colour Range

Contact National Masonry® for further details.

• External and internal walls Polished

Smooth Honed Shot-blast Polished

Premium look. Ultra results.

Pearl Grey Charcoal

Let in light and air

Smooth, Shot-Blast, Honed and Polished Face

Alabaster, Pearl Grey, Platinum,

Alabaster, Pearl Grey, Platinum,

190 Face, Polished Face

Alabaster, Pearl Grey, Platinum,

Alabaster, Pearl Grey, Platinum,

Alabaster, Pearl Grey, Platinum,

Alabaster, Pearl Grey, Platinum,

190 Face, Polished Face

Alabaster, Pearl Grey, Platinum,