mortarless masonry_symposium_2010-03-30
TRANSCRIPT
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
“Design and Construction ofMortarless Interlocking Masonry”
Prepared by:
Jesse Edwards, Mina Gayed, Michael Pyra, & Tisbeth Rodriguez
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Goals Part I
– Introduction: what is mortarless masonry?– Why was it introduced and what are its
benefits?– Currently available systems– Design example
Part II– Construction aspects
• Applications and limitations
– Productivity and cost comparisons– Case study
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Introduction: What is mortarless masonry?
Eliminates the use of mortar in head and bed joints
Geometric interlocking mechanisms
Reinforced and grouted Post-tensioned and surface
bonded Manufactured with tighter
tolerances for alignment
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Current Systems AvailableName of System (Country, Year)
Block Type (Material)
Interlocking Mechanism
Reinforcement Type
Haener (USA, 1975) Hollow (concrete)
Nibs in bed joint, T&G in head joint
Vertical & horizontal
Sparlock (Canada, 1986)
Hollow (concrete)
Geometric interlocking and
stackingVertical
Mecano (Peru, 1998) Hollow (concrete) No interlocking* Vertical &
horizontal
Sparfil (Canada, 1989)
Hollow (light- weight
concrete)No interlocking* None
Whelan-Hatzinikolas-Drexel
(USA, 1992)Hollow
(concrete)Rounded dovetail lug on head joint Vertical
Azar (Canada, 1997*)
Hollow (concrete)
3 mechanisms: web key, head and bed
joint face shell interlocking
Vertical & horizontal
Silblock (India, 1999) Solid (concrete) Geometric
interlocking Vertical
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Masonry Statistics
60% of traditional masonry construction is skilled labour
Average age of a skilled mason in the U.S.A. and Canada is 56 years old. (National Concrete Masonry
Association)
– Influx of young skilled masons in industry is decreasing
Traditional crew consists of 3 masons and 1 labourer; the crew is reversed for mortarless masonry
Ex: Construction of house foundation– 3 unskilled labourers can construct a 1,200 block foundation in
4-5 hours Up to 10X faster than traditional masonry and cast in place concrete!
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Some Benefits
Significant labour savings Contractors win owners win Multitude of applications: commercial,
industrial, and residential projects All weather construction Fuels masonry growth in
the building sector Establish masonry as
a competitive material!!
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Design Aspects Given a shear wall:
– 200 mm block, fully grouted– 3.2 m long and 10.0 m high– Dead load: 300 kN– Shear: 200 kN & moment of 1200 kN-m
Given a flexure wall:– 200 mm block, fully grouted– 4.0 m high– Dead load: 150 kN/m– Live load: 100 kN/m
Design with 30 MPa blocks for both the traditional and Azar systems using vertical reinforcement of 15M bars @ 400 c/c
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Design AspectsShear Wall Flexure Wall (per meter)
Traditional Mortarless Traditional Mortarless
Axial Resistance (kN) 3348 4315 1047 1348
Moment Strength (kN-m) 1660 1680 19.5 22.3
Shear Reinforcement Yes (15M at 600mm c/c) No N/A N/A
Diagonal Shear (kN) 270 480 N/A N/A
Sliding Shear (kN) 542 542 115 115
Mortarless masonry is equal to or exceeds traditional masonry strength!
Note: Mortarless values are based on Azar Block design.
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
PART II - Construction
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
“Traditional” Applications
The North American market: – Haener: individual consumer use (primarily
Los Angeles), variable commercial applications
– Sparlock: firewall construction– Azar: house foundations and firewall
construction The untapped potential of these systems is
huge Large industrial and commercial applications
of these systems have only become more common in the last decade
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Integrated Systems
Integrated Masonry Systems Inc. (IMSI): cavities for insulation and electrical wires
Durisol and Faswall: Portland cement and mineralized wood fibre for high R-value and ease of handling
Primarily residential applications
IMSI
Faswall
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Limitations
Regional building code restrictions– Ex: Azar Block review by the Canadian
Construction Materials Center (CCMC) for compliance with NBCC:
• Buildings up to 3 storeys and an area of 600 m²• Wall construction must be fully grouted• Basement walls cannot exceed 2.5 m in height• Exterior above-grade walls and interior load-
bearing walls are limited to 20 times the wall thickness
Challenges posed by high initial settlement and attaining plumb
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Productivity and Cost Comparison
Two identical commercial buildings in Edmonton, AB; one built traditionally and the other with the Azar system: – 15 m (W) x 50 m (L) x 4 m (H)– 200 mm x 200 mm x 400 mm units– 20M vertical bars at 600 mm spacing– Grouted every third core (Azar fully grouted)– Traditional team: 3M-1L (30 blocks/hr)– Azar team: 1M-3L (300 blocks/hr)
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Productivity and Cost Comparison
Time = 1377 hrs (34.4 wks) Time = 505 hrs (12.6 wks)
$141,174
$212,511
$888
MaterialLabourEquipment
$189,360
$76,073
$2,536
MaterialLabourEquipment
$141,174
$189,360 TraditionalAzar $212,511
$76,073
TraditionalAzar
Material Comparison Labour Comparison
Traditional Construction = $354,573 Azar Mortarless System = $267,969
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
2,952 sq. ft. residence
Built in 2006 FlexLock Wall
System Post-tensioned walls
Case Study: Magnolia, Texas
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Case Study: Magnolia, Texas
Laying the First Two Courses
Dry-Stacking the Walls
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Case Study: Magnolia, Texas
Pouring the Bond Beam Tensioning the Wall
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Case Study: Magnolia, Texas FlexLock performed a comparative cost
analysis based on installed cost of standard 8" masonry in the region:– Total masonry costs declined by 24%– Productivity increased by 120%.
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Condos in Bois-Franc Community, Montreal
Constructed using the Sparlock Interlocking Building System
Mortarless Construction in Canada
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Besser Proneq machine shop in Quebec City
Sparlock blocks use for the building envelope
Mortarless Construction in Canada
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Conclusion
The structural capacity of mortarless blocks is comparable to standard concrete masonry units
Not suitable for all applications Mortarless construction is more efficient and
cost-effective than conventional masonry Mortarless units are becoming more readily
available and have been implemented in many projects around the world
MCAA Chair in Masonry Systems | 2nd Masonry Mini Symposium | University of Alberta | March 30, 2010
Questions?
Sacsahuaman, Peru -1423 A.D.
“ Arguably, the biggest change in the world of concrete masonry units is the mortarless system.”
(Masonry Magazine)