Masonry Homes Construction Manual PDF

CBI 3321 3323 4261 4263 4264 4711
March 2009
Masonry Homes
Construction ManuaL
Timeless elegance , todays technology

The look that only solid masonry can deliver
Safer, healthier homes
Masonry homes provide New Zealanders with the age

old benefits of solid masonry construction, along with
the strength, simplicity and good looks of a modern
building method.
Many building technologies try to imitate the solid good
looks of masonry construction. Firth masonry provides
the components that deliver the real thing - from solid
walls, to a range of interior and exterior finishes to suit
every taste. Firth masonry products will provide enduring
quality and looks for a masonry home, all for not much
more than you would pay for a home built using a
lightweight imitation system.
Naturally solid masonry homes are completely fire

resistant and they are also healthier. One of the problems
with well sealed light timber frame houses that rely on
keeping heated or cooled air inside, is the condensation
that builds up from cooking, showering, even breathing
the major benefit with masonry construction is that it is
durable and will not rot. Because comfort temperatures
are achieved through radiant heat from masonry walls,
Firth masonry can provide homes with better ventilation.
This means that the low humidity environment possible
in a masonry home can lead to a lower number of
dust mites and consequently reduce the incidence of
asthma.
Cool in Summer, warm in Winter
Tranquility and peace
With Firth HotBloc , the thermal mass of the unit is in

the interior of the house wall. This effectively stores heat
from solar and off peak heating/cooling applications.
Heat from solar gains can be absorbed by the walls
without great changes in the interior temperature. When
the gains stop, the warm walls conduct heat back to the
interior air to make up for the losses, to the outside. The
more mass, the more heat storage and the longer the
indoor temperature can be maintained. In summer the
reverse happens. The masonry is cooled by the night
time temperatures and then as the outside temperature
increases, the inside temperature is maintained by
giving off coolness (absorbing the heat).
The same high density makes masonry homes

comfortable to live in makes it quiet and peaceful inside.
A masonry home is inherently quiet. Its thick solid walls
provide superior built-in sound insulation, without the
expense and effort of additional soundproofing often
needed by timber framed walls.
Finishing touches
In conjunction with the range of low maintenance
landscaping products available from Firth, you can
complete the picture with coloured concrete, exposed
aggregate driveways, pavers and retaining wall options
to suit every home style.
Masonry Construction Manual
contents
SECTION 1 PLANNING AND DESIGN CONSIDERATIONS
1.1 Structural Masonry Homes . . . . . . . . . . . . . . . . . . . . . 2
1.2 Design Considerations and
Scope of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Geotechnical Report . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Insulation of Masonry . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.6 "R" Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.7 Specification of Firth HotBloc . . . . . . . . . . . . . . . . . . 3
1.8 Modular Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.9 Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.10 Suspended Concrete Floors . . . . . . . . . . . . . . . . . . . 4
1.11 Internal Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.12 Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6.8 Concrete Topping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

6.9 Topping Reinforcement . . . . . . . . . . . . . . . . . . . . . . . 13
6.10 Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.11 Penetrations in the Floor . . . . . . . . . . . . . . . . . . . . 14
6.12 Balconies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.13 Waterproofing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 7 - SERVICES
7.1 Locations of Services . . . . . . . . . . . . . . . . . . . . . . . . 15
7.2 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.3 Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.4 Services on Strapped and Lined Walls . . . . . . . . . . 16
7.5 Future Proofing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 8 - STAIRCASES
8.1 Cast-in-situ Staircases . . . . . . . . . . . . . . . . . . . . . . . 17
SECTION 2 FOOTINGS AND FOUNDATIONS
8.2 Precast Staircases . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Conventional Footings . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.2 RibRaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 9 - ROOF CONNECTION
SECTION 3 WALL INSTALLATION

3.1 Starter Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 First Course . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Running Bond . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Tooling of Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Washouts/Cleanouts . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.6 Bond beams and Lintels . . . . . . . . . . . . . . . . . . . . . . . 8
3.7 Temporary Bracing . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.8 Consideration of Weather . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 4 BLOCKFILL FOR GROUTING OF MASONRY
4.1 Filling Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2 Blockfilling Procedures . . . . . . . . . . . . . . . . . . . . . . 10
4.3 Vibration of Blockfill . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.4 Filling Under Windows . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 5 CONTROL JOINTS
5.1 Location of Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2 Reinforcement through Control Joints . . . . . . . . . . 11
5.3 Sealing of Control Joint . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION 6 S USPENDED CONCRETE FLOORS
6.1 Types of Concrete Floors . . . . . . . . . . . . . . . . . . . . . 12
6.2 Flooring Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.3 Prestressed Flat Slab Flooring System . . . . . . . . . . 12
6.4 Rib aqnd Infill Flooring System . . . . . . . . . . . . . . . . 12
6.5 Construction Considerations . . . . . . . . . . . . . . . . . . 12
6.6 Placing the Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.7 Temporary Propping . . . . . . . . . . . . . . . . . . . . . . . . . 13
Masonry Homes Construction Manual - V1 2008
9.1 Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

9.2 Metal Straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SECTION 10
WINDOWINSTALLATION
Window Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SECTION 11
WATER PROOFING/COATING SYSTEMS
11.1 Dry Blockwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
11.2 Cleaning Blockwork . . . . . . . . . . . . . . . . . . . . . . . . . 20
11.3 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SECTION 12
EXTERNAL COATING SYSTEMS
12.1 Acrylic Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
12.2 High-build Elastomeric Coatings . . . . . . . . . . . . . . 21
12.3 Solid Plaster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
12.4 Modified Plaster . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
12.5 Clear Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
12.6 Cement Based Paints . . . . . . . . . . . . . . . . . . . . . . . 21
SECTION 13
INTERNAL COATING SYSTEMS
13.1 Exposed Blockwork . . . . . . . . . . . . . . . . . . . . . . . . . 22
13.2 Paint Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
13.3 Strapped and Lined . . . . . . . . . . . . . . . . . . . . . . . . . 22
13.4 Plasterboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
13.5 Tiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
13.6 Plaster Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SECTION 14
CONSTRUCTION DETAILS
Construction Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1
SECTION 1 - PLANNINGANDDESIGNCONSIDERATIONS
1.1 Structural Masonry Homes
1.3 Geotechnical Report
Masonry homes can be some of the most stunning and

comfortable houses on the market, but as with any
building they require careful planning before construction
begins. While it is possible to alter once construction has
started, it usually is more difficult than with traditional
timber frame construction.
A geotechnical report on the site is very good insurance

for the future and is strongly recommended prior to
construction. It would provide information about the site
and the support capabilities of the ground.
1.2 Design Considerations & Scope of this Manual

This document is intended as a guide only to assist
Architects, Designers and Engineers who are
appropriately experienced and qualified, in the design of
concrete masonry residential buildings.
Architects, Designers, Engineers and Builders should
be familiar with and make reference to NZS 4229:1999
Concrete Masonry Buildings Not Requiring Specific
Engineering Design in conjunction with their use of this
Manual. The Architect, Designer and Builder should also
be familiar with the principles for dealing with external
moisture under Compliance Document E2/AS1 issued
by the Department of Building & Housing for timber
frame structures. Though this does not apply directly
to concrete masonry structures, similar principles
are employed. Details for guidance in applying these
principles to masonry construction can be found in two
publications:
C
oncrete Masonry - a guide to weathertight
construction, available for free download from the
NZ Concrete Masonry Associations website
www.nzcma.org.nz
Weathertight Solutions Volume 4- Masonry, details for
junctions and openings in masonry walls. Available
from Branz.
In all cases the Architect or Designer should provide
sufficient detailing within the Plans to be submitted
for Building Consent, so that sound structural and
weathertight construction details are unambiguous to
both Territorial Authorities and the Builder.
This document is also intended as a guide for Builders and
Masons constructing structural blockwork for masonry
homes. It is to be used in conjunction with NZS 4229:1999
Concrete Masonry Buildings Not Requiring Specific
Engineering Design and NZS 4210:2001 Masonry
Construction Materials and Workmanship. Persons
engaged in the construction of structural masonry homes
should ensure that they comply with the requirements of
Clause 1.5 Workmanship of NZS 4210:2001.
The Builder should ensure that copies of NZS 4229:1999 and
NZS 4210:2001 are available for ready reference on site.
2
1.4 Insulation of Masonry

Concrete masonry has inherent thermal storage
properties making it the ideal construction material for
comfort. However, by itself, it does not have the required
insulation to comply with the New Zealand Building Code
(Clause H1).
Firth HotBloc, shown below, being the premium
Concrete Masonry Unit (CMU) on the market, provides
the simplest means of compliance as the insulation is
l Polystyrene Insulation
Outer side of wallg

Figure 1 Firth HotBloc 20 Series Hot-Std
built in. It affords the structural strength of standard
masonry (see 1.5 Engineering below) as well as providing
options to exceed the R-values stipulated in the Building
Code for solid construction, refer section 1.6.
Other methods involve adding insulation to the outer
surfaces of the wall (where it can be easily damaged) or
to the interior of the wall (reducing the thermal storage
benefits).
To make the most of the thermal properties of masonry
and concrete, contact the Cement and Concrete
Association to obtain a copy of their booklet Designing
Comfortable Homes.
1.5 Engineering
NZS 4229:1999 Concrete Masonry Buildings not
Requiring Specific Engineering Design covers the nonspecific design of residential masonry buildings. (This
is the masonry equivalent of NZS 3604:1999 Timber
Framed Buildings.) This Standard details the bracing
requirements, lintel sizes, footing widths etc. and should
cover most simple buildings.
Occasionally there will be areas of the house that fall

outside the Standard and a structural engineer will be
required. This does not necessarily mean that the entire
building must be engineer designed simply the areas
that fall outside the scope of the Standard.
When designing a building in Firth Hotbloc, it is important
to consider the reduction in grout space caused by the
presence of the internal polystyrene biscuit. The 20
Series Hotbloc typically has a 30mm thick polystyrene
biscuit, and the 25 Series approximately 80mm thick.
When designing using the non specific design Standard
NZS4229:1999, both the 20 and 25 Series Hotbloc
should be considered equivalent to a 15 Series block
when considering bracing demand, bracing capacity, and
reinforcement required.
1.6 R Values for Firth HotBloc in Solid Walls as part
of the Building External Envelope
The R-values of various HotBloc solutions areR0.7
20 series HotBloc, fully filled,
R1.16 25 series HotBloc, fully filled,

R1.2
5 series HotBloc, fully filled and interior lined

2
with glue fixed gib board.
Importantly the R-values are obtained without the use of

surface insulation, a unique feature to structural masonry
homes built with Firth HotBloc.
1.7 Specification of Firth HotBloc in Structural Design
to comply with NZS 4229:1999 and NZS 4230:2004
Architects, designers and engineers may design to
the requirements of NZS 4229:1999 or NZS 4230:2004
Design of Reinforced Masonry Structures, where Firth
HotBloc is substituted for a conventional block within
the limitations of clause 1.5.
The acceptable solution H1/AS1 of the Building Code

clause H1- Energy efficiency, recognizes the benefits
of thermal mass for solid masonry construction by
allowing lower R-values than for non solid (timber frame)
construction.
Schedule Method
Table 2(b) identifies the minimum R-values required if
the schedule method is used. When using this table it is
important to recognize the limitations to use the tables
in particular the area of glazing. The new insulation
requirements of H1 became effective from:
31st October 2007 for zone 3
30th June 2008 for zone 2
30th September 2008 for zone 1
20 Series HotBloc, R0.7 Hot-STD

Structural equivalent = 15 series
Calculation Method
Lower R-values than are tabled in Table 2(b) of H1/AS1,
can be, however, any reduction in R-value provided in one
element must be compensated by an increase in another
element. The process used to demonstrate equivalence
is referred to as the calculation method and is described
in section 3.2 of NZS4218. 20 Series Hotbloc can only be
used under the calculation method.
Post September 2008, the R-values required for masonry
walls are:
R0.8 for zone 1
R1.0 for zone 2, however this can be reduced to R0.9 if
R0.31 glazing is used.
R1.2 for zone 3, however this can be reduced to R 1.0 if
R0.31 glazing is used.
25 Series HotBloc, R1.16 Hot-STD

Structural equivalent = 15 series
3
1.8 Modular Layout
1.9 Services
Designing wall dimensions to equal a multiple of the

Concrete Masonry Unit (CMU) being used saves time and
money by eliminating cutting. It also adds predictability
and discipline to both design and construction. As
such, dimensioning the design to fit the module is
recommended. The critical dimensions are wall height,
wall length, opening size and opening position.
Typically services are placed in ducts in the cores of the

masonry blocks. It is very difficult to do this after the
walls are filled with blockfill, and as such, the locations
for services need to be finalised before construction
begins. This rule is relaxed where the masonry walls are
to be strapped and lined with GIB plasterboard as the
services can be placed within the resulting cavity at any
stage after filling with blockfill.
The standard CMU is 390mm long, and 190mm high with

an allowance for a 10mm mortar joint on each dimension
(i.e. 400mm long, and 200mm high). When using a
standard HotBloc a module of 400mm long by 200mm
high is normally adopted. Where necessary, a half block
(190mm long) will be inserted to meet a specific length
requirement. An example would be to make wall lengths
1200mm rather than 1189mm, as would be common
in timber frame construction. Off-module dimensions
require the blocklayer to cut the blocks, increasing
costs. See the diagram below for an explanation of the
importance of keeping the design to a modular layout.
Just as important is ensuring that the lintels and bond
beams are only 190mm or 390mm deep. This eases
construction and therefore keeps costs down.
1200
When using a suspended concrete floor in two-storey

construction, a false ceiling can be taken advantage of
to allow services to be carried within this space. It also
makes sense to position the upper service room over the
lower one to reduce the distance services are required to
travel through the building.
1.10 Suspended Concrete Floors
The most common types of residential suspended
concrete flooring systems are suitable up to 8m spans.
However, this shouldnt limit the design of the building
as there are commercial flooring systems that will easily
span 15m or more if necessary. These can be up to
300mm-400mm thick and typically require an increase
in wall reinforcement and footing requirements.
2000
1400
The Modular Correct

no cutting required
Another approach for solid filled walls is to leave a

vertical core empty in order to place services within the
wall. The bracing panels will be affected in this area
so this needs to be decided upon before the bracing
calculations are completed.
800
The Modular-Correct no cutting required
1900
1300
The Modular Incorrect

shaded portion = cut block
1100
700
The Modular-Incorrect shaded portion-cut block

4
All suspended concrete floor types need to be supported

at the ends of the individual spans by a concrete masonry
wall. Timber should never be used to support these
floors.
1.11 Internal Walls

Masonry homes do not need every internal wall
to be masonry. It is common to only use masonry
where necessary due to bracing or other structural
requirements (such as supporting the concrete midfloor)
Options for internal walls are 15 Series Masonry Units or
timber partition walls, this choice maybe influenced by
the desired finish required.
1.12 Openings
Masonry lintels consist of a reinforcing cage within a
masonry shell (usually 190mm or 390mm deep). These
can span relatively large distances. For most situations,
masonry lintels will suffice and the tables in NZS
4229:1999 detail the reinforcing requirements. However,
where the lintel falls outside the scope of that Standard,
(i.e. the load acting on the lintel being too great for the
particular span), the lintel can be constructed from cast
insitu reinforced concrete or with a precast beam such
as Interspan. Both of these types will require specific
engineering design.
SECTION 2 - FOOTINGS AND FOUNDATIONS

2.1 Conventional footings
Conventional footings consist either of strip (or ring)
footings or edge-thickened slab. Strip footings are made
up of a small masonry wall (typically one or two courses)
supported on a footing strip in an excavated trench.
This footing strip can vary in width upward from 300mm
depending on the design of the house. Edge thickened
slabs combine the footing strip and slab into one without
the need for a masonry footing wall. The edges of the
concrete floor slab are thickened to support the building
walls. Both types of footings require excavation and are
therefore weather dependent.
Following completion of the excavation of the footings
trench or trenches, the reinforcement steel needs to
be placed in accordance with the job drawings. The
stirrups are then tied to the main bars. NZS 3604 sets
out the minimum cover requirements for steel in various
scenarios.
When the concrete is poured for the footings, it is very
critical that the concrete is placed in such a manner to
avoid segregation (separation) of the concrete or changes
to the location of the reinforcement. For construction
details refer to Section 14.
2.2 RibRaft
This system combines the footing and concrete floor into
one and is one of New Zealands most effective residential
and light commercial flooring solutions.
specific design details, but also contains details that will

assist a designer in carrying out a specific design of a
RibRaft floor.
A basic overview and step-by-step construction guide
is provided in the Firth RibRaft Flooring Solutions
brochure. For an in-depth explanation of the non-specific
construction and design issues associated with RibRaft
construction see the RibRaft Manual.
The RibRaft system is most economic on flat sites but
there is also a range of details available to allow RibRaft
to be used on a sloping site. The use of these alternative
details require specific design.
The non-specific design consists of an 85mm thick top
slab supported by a grid of ribs normally 100mm wide
at a maximum spacing of 1200mmx1200mm centres.
The overall depth is 305mm. Edge beams and ribs under
loadbearing walls are 300mm wide to provide for the
extra load carried by these members. Construction is
directly on levelled ground covered with a DPM (damp
proof membrane).
Polystyrene waffle pods 1100mm square and 220mm
thick are placed directly on levelled ground. These are
arranged in such a way that a reinforced concrete floor
slab with a grid of reinforced concrete ribs and edge
beams is formed when concrete is placed onto them.
Pods may be cut to suit specific layout architecture and
also to accommodate services.
The RibRaft Manual can be obtained from Firth through

Firth Information Service on 0800 800 576 or through
www.firth.co.nz. This document covers not only the non-
SECTION 3 - WALL INSTALLATION

3.1 Starter Bars
10mm 3mm as per NZS 4210:2001.
Starter bars are the steel reinforcing bars that connect

the masonry wall to the floor. The number of bars and
their location is defined by the construction drawings or
NZS 4229:1999. The starter bars should be central to the
grouted cavity. When using HotBloc consideration must
be made of the polystyrene thickness. It is important to
confirm that the starter bars are in the correct location
before pouring the concrete and then again once the
concrete has been placed, but before the concrete
sets. This allows any bars that were moved during the
concrete placing to be corrected. If the bars are not
located accurately then they will not fit correctly into
the block cores which then would affect the structural
performance of the wall. Unless specifically instructed
by the Architect or Engineer, it is not acceptable to crank
the bars on site to their correct alignment.
All mortar either site mixed or premixed must meet a 28

day compressive strength of not less than 12.5MPa.
For internal walls, correction of a bar location is a simple

process of grinding the bar off flush with the slab then
drilling and epoxying a starter bar in the correct location.
An engineer should be involved to ensure that the
procedure is undertaken correctly.
Vertical Reinforcement
3.2 First Course

Laying Surface
Surfaces for the blocks to be laid upon must be level,
clean but slightly rough. This roughness is necessary
to create a good bond between the mortar and base.
Usually the finish achieved with a wood float is adequate.
It is uncommon but if the floor is finished too smooth,
roughness can be achieved with a scabbling gun (a
compressed air gun with steel fingers) to chip the
surface of the concrete. Once an adequate surface has
been prepared the first course of blocks can be laid. It is
common for a bond beam block to be inverted and placed
at the site of the starter bars for the first course to allow
easy construction of the washouts.
3.3 Running Bond

The CMUs should be laid in straight uniform courses
unless specified in the construction drawings. Running
bond is the strongest type of laying configuration. This is
where the blocks are offset horizontally by one half block
from one course to the next. Other bond patterns are used
to achieve particular aesthetics but unless specifically
engineered, running bond should be used.
Wall Reinforcement
The reinforcement requirement for the wall is specified
in NZS 4229:1999 or by Specific Design and is usually
detailed in the construction drawings.
The vertical bars need to be tied to the starter bars with

at least 600mm lapping.
Note that where Firth HotBloc is being laid then the
vertical reinforcement must be placed central to the
remaining grout space (the polystyrene biscuit will take
up some space normally filled with grout in a conventional
CMU) and not central to the overall block width.
Horizontal Reinforcement
The horizontal steel is placed in a course of knock-in
bond beam or depressed web CMUs. To ensure correct
placement within the wall cavity, the horizontal steel is
then tied to the vertical steel.
3.4 Tooling of Joints
HotBloc
Another aspect of masonry construction that is

commonly overlooked (particularly when a plaster finish
is required) is tooling of the mortar joints, this is when
a special tool is used to compress mortar into the joint.
Tooling is important as it contributes to the structural
strength and water resistance properties of the wall.
HotBloc with its integral insulation is installed virtually

the same as a traditional CMUs. The only difference is
that the polystyrene biscuit is to be placed towards the
outside face of the wall and the position of the starter
bars needs to be modified to ensure they are central in
the grouted cavity.
Tooling to a depth of 6mm is allowable. The

reconsolidation of the joint after the initial water loss
is seen as being vital. When a plastered finish is to be
applied, it is common to strike the mortar joint flush
to make a smooth surface for the plasterer. The joint
should still be tooled.
Mortar
Laying the first course should be done ensuring all blocks
are level. The first course mortar joint maybe up to 20mm
to achieve levelling. All subsequent mortar joints shall be
Often tooling is carried out too early. The mortar should

be thumb nail hard before tooling. After tooling and
when the mortar is sufficiently set, the work should be
lightly brushed down with a soft bristle brush to remove
7
any particles of mortar sticking to the block face. Rubbing

the face of the blockwork with a cut-off piece of masonry
will also remove any overhang of mortar.
Stage 1
Unit
As laid wet
Unit
Stage 2
Unit
Evaporation of water from
mortar creates crack
Unit
Stage 3
Unit
Tooling in semi-hard condition
remoulds the mortar and
eliminates the crack
Unit
Tooling of joints
Sometimes tooling of the joints pushes mortar into the
block cavity (see picture above, right). This either falls
to the bottom or hangs on and causes an intrusion. The
intrusions may partially block off the cavity and not allow
the blockfill to reach the lower parts of the wall. This is
very likely where horizontal steel is placed in the wall. As
such the mortar intrusions must be removed while still
workable.
Any mortar that has fallen to the bottom of the wall will
interfere with the bond between the blockfill and starter
bars and the blockfill and the base. For the wall to
perform as designed the base must be clean.
3.5 Washouts/Cleanouts
the formwork in place with wire ties around the base of

the vertical steel. This will allow the blockfill to finish
flush with the outside face of the blocks. It is important to
ensure that the formwork is braced adequately to prevent
blow out under grout pressure. Often small gaps are left
in the formwork at the washouts to allow the blockfill to
flow out. These are to confirm that the blockfill has fully
filled the wall and are plugged once confirmation has
been made.
For exposed blockwork or architectural masonry,
however, it is recommended to remove the entire face
shell of a block rather than cut a section of the face.
Following cleaning out and inspection, the face can then
be mortared back in place and braced before blockfilling
commences.
3.6 Bond beams and Lintels
Masonry
The two most common bond beams or masonry lintel
types are either 190mm or 390mm deep. The 190mm
deep version is simply one course of CMUs and most
commonly only used as a bond beam below concrete
mid-floors. The 390mm deep version is formed using
two courses of knock-in bond beam or depressed web
CMUs, with the top one inverted to create a larger cavity
for the reinforcement steel. The steel is placed in before
the top course is laid.
To enable cleaning of all debris from the base of the wall,

washouts or cleanouts are used. These are openings or
inspection ports at least 100mm height x 75mm width
cut into the face of blocks at the base of the vertical
reinforcement bars. A common method is to use
inverted bond beam blocks at these locations to allow
simple removal of the face shell portions. Inspection of
the steel and concrete junctions can also be made at
these openings to confirm compliance with the relevant
requirements.
Where non-standard dimensions are required, it is usual

to place other courses in between the two standard bond
beam courses. This however, does affect the placement
of the steel.
Once inspections are complete, the washouts should be

blocked off with formwork. A common method is to hold
For non-standard bond beams, the stirrups are tied to

the bottom bar(s) and this is placed into the bottom bond
Reinforcement
The steel is formed into a cage made up of the top bar(s)
and the bottom bar(s) separated by the stirrups (or links).
The cage is placed and tied to the vertical steel where
appropriate and the top bond beam course is laid.
beam course. The intermediate bond beam courses are

then laid, threading the stirrups through. Before the
top course is laid, the top steel bar(s) are tied to the
stirrups.
Where the lintel coincides with the bond beam, the two
are simply combined. If the longitudinal steel requirement
in the lintel exceeds that in the bond beam, then the steel
in the bond beam at this location will be that required
in the lintel and vice versa (the stirrup requirements are
unchanged). In most single storey applications, the bond
beam reinforcement exceeds that required in the lintels
and the only difference is the spacing of the stirrups
over the openings. (However it is crucial to check the job
drawings for reinforcement requirements).
Temporary Supports
Often it is necessary to support lintels with timber
framing (props) until the blockfill has gained sufficient
strength. Refer to the photograph above right.
3.7 Temporary bracing
The need for temporary bracing of the masonry wall
during construction is often overlooked (see photograph
above). An unfilled wall is very susceptible to failure from
strong winds. Typically walls over 1m in height are at
significant risk. It is important to take some measures to

brace the wall in order to prevent its premature failure.
Typically bracing at 3m centres is recommended in line
on both sides of the wall.
Bracing may also be required to ensure that the pressure
from the blockfilling operation does not alter the wall
positions. This is particularly critical on tall narrow
sections of walls. The blockfill procedure creates large
hydrostatic pressures and where there is little blockwork
to resist, it will force blocks to move, some-times even
causing face shells of blocks to be blown out.
3.8 Consideration of Weather
Generally masonry construction should not be carried
out when the air temperature drops below 4C, unless
the following precautions are taken:
(a) Water used for mixing mortar is heated.
(b) M
asonry is protected for not less than 24 hours after
laying by covers, blankets, heated enclosures, or the
like to ensure that the mortar can gain sufficient
strength without freezing or harmful effect from cold
winds.
(c) N
o frozen materials nor materials containing ice
shall be used.
When the air temperature rises above 27C or there is a
drying wind even when the temperature may be lower, it
may be necessary to take some additional precautions:
(a) Lightly dampening the CMUs before laying.
(b) K
eeping the mortar moist and not spreading it on the
wall more than two unit lengths ahead of the units
being placed.
(c) P
reventing both the mortar and the grout from drying
out so rapidly that it cannot cure properly. This is
most important during the first 24 hours.
SECTION 4 - BLOCKFILL for grouting of masonry

It is vital that a blockfill mix is used and not a standard
concrete mix. The blockfill is far more fluid and will flow
to all required parts of the wall, whereas the standard
concrete mix is comparatively stiff. As the cores of the
block are relatively small, the standard concrete mix is
prone to blocking the cores and not filling the lower parts
of the wall. Watering down of a standard concrete mix
should never be done, as it reduces the concrete strength
and increases the amount of shrinkage. Firth blockfill
is designed to have the required strength and to flow
easily into the cores to be filled. Grouting must always be
carried out by a competent experienced professional.
4.1 Filling Options
There are two types of grouting that are in common design.
Partial Filling
This is where only the vertical cores containing
reinforcement and the bond beam are filled with blockfill.
All others cores are left empty. This is common where
the weight of the wall is required to be kept to a minimum
usually because of earthquake loads. This is the cheaper
option in terms of materials as less concrete is used but
is more difficult to achieve on site. There are many
methods for blocking off the cores that are not to be filled.
Two common methods are using the knock-in biscuits
from the bond beam units and laying them over the cores
or using dampcourse laid across the hollow cores in
order to prevent the blockfill entering them.
Solid Filling
This is where the whole wall is filled with blockfill,
creating one solid mass. This is used where the design
specified for horizontal steel other than in the bond beam
(usually at half-height of the wall), or where the simplest
construction approach is preferred. The hydrostatic
pressures when solid filling a wall can be quite
significant, and time should be allowed for the lower half
of the wall to solidify slightly before filling the upper part
of the wall. In the unlikely event of a fire, a solid filled wall
will provide additional protection to the polystyrene in a
HotBloc unit.
4.2.1 High lift grouting with expansive admixture

This allows pours up to 3.6m in height and uses an
admixture to provide expansion after placement of
the grout and before initial set occurs. The expansion
compensates for water loss and plastic settlement.
Grout is placed in the cells in a semi continuous operation
allowing for consolidation as work proceeds.
4.2.2 The low lift grouting method
This is similar to the high lift with expansive admixture
method but allows the blockfill to solidify fully before the
next lift is placed. Maximum height of pour is 1.2m per
lift. Again the blockfill should be mechanically vibrated
into place.
4.2.3 High lift with reduced compaction
This is grouting the wall to a maximum height of 2.4m in
a continuous pour, with thorough mechanical vibration
during the pour.
4.3 Vibration of Blockfill
It is strongly recommended that all blockfill be placed
in combination with mechanical vibration. Failing this,
the walls should at least be rodded with a bar 16mm in
diameter or greater to ensure the blockfill has reached
all parts of the wall (see photograph below). Where
services have been installed in the wall, it is critical to
ensure blockfill has made it past these intrusions.
4.4 Filling Under Windows
A simple method for ensuring that the blockfill gets into
the required cores under window openings is to leave
out one or more sill blocks. The pump operator can then
grout from the sill and once complete, the sill blocks can
be mortared back into place.
4.2 Blockfilling Procedures

Once all the washouts have been blocked off and the
required inspections made, the wall can be filled. A
common practice is to lightly dampen the block cavities
immediately prior to grouting. This is to ensure that the
blockfill is not dried out by the blocks sucking out the
water and therefore reducing its flowing ability. There
are three procedures for grouting as detailed in NZS
4210:2001.
10
SECTION 5 - CONTROL JOINTS

Wall reinforcement
R16 lapping bars 800 long,
Concrete masonrydebonded
in common
5.2 Reinforcement through Control Joints
one with
side other
with building
Debonded length of bar
grease
or plastic
tape by changes
materials, is subject
to movements
caused
Reinforcement in lintels and bond beams shall continue
in moisture content and temperature. Since masonry will
through the control joints but all other horizontal
have a high moisture content initially, it loses moisture
reinforcement shall be discontinuous at the control joints.
with time and consequently shrinks. It is usual to include
The detail below is as per NZS 4229:1999. This ensures
shrinkage control joints in the design of the concrete
that any movement in the wall will not be restricted by
masonry.
the reinforcement.
5.1 Location of Joints

The spacing of control joints is specified as a maximum
of 6m in NZS 4229:1999 unless specific design for
Vertical
reinforcement
shrinkage has
been undertaken.
The location of control
Wall reinforcement
joints is influenced by:
(a) M
ajor changes in wall height
R16 lapping bars 800 long,

debonded one side with
grease or plastic tape
Wall reinforcement
Filler strip and sealant
Figure 13.2 - Control joint detail (see 13.1.13)

(b) Changes in wall thickness
(c) Wall intersections
Vertical reinforcement
(d) Opening locations.

The diagrams below are taken from NZS 4229:1999
Figure 13.2 - Control joint detail (see 13.1.13)
Control Joint Detail
5.3 Sealing of Control Joints
5.2m
600
600
ol joint detail (see 13.1.13)
Less than
6m
5.2m
Control joints
Less than
6m
Control joints will always undergo some movement and

therefore it is necessary on exterior walls to form a
suitable detail to allow for the sealingLessofthanthe control joint
6m
3.2m max.
against weather penetration.
The weatherproof coating
will also need particular care over the control joint to
ensure that the expected movement is tolerated.
Less than
6m
Less than
6m
Less than
6m
3.2m max.
Control joints
3.2m max.
3.2m max.
Note that reputable plaster-coating systems

manufacturers will have a proprietary solution for the
sealing of control joints.Control
It isjointsimportant to follow the
Figure
13.1
Location
of
control
joints
for shrinkage (see
13.1.1)
complete detail of your selected
manufacturers
plaster
Less than
6m
and coating
system.
Control joints
Less than
6m
Location of control joints for shrinkage
Figure 13.1 - Location

Less than of control joints for shrinkage (see 13.1.1)
ss than
6m
3.2m max.
6m
3.2m max.
Control joints
Less than
6m
of control
joints
for shrinkage
f control joints Location
for shrinkage
(see
13.1.1)
11
SECTION 6 - SUSPENDED CONCRETE FLOORS

Suspended concrete floors differ from timber floors in
many ways. They are quieter, stronger, provide greater
fire protection, and where large spans are required or
where supporting walls are retaining fill, are usually
cheaper. Most builders are impressed with the speed of
installation of a suspended concrete flooring system.
6.3 Prestressed Flat Slab Flooring System

Prestressed Flat Slabs come as 240mm or 1200mm wide
and 75mm thick (other widths are possible if required).
The topping depth varies from 75mm 130mm. Props
as required on the suppliers drawing must be in place
before the slabs are placed.
6.1 Types of Concrete Floors

There are two types of suspended concrete floors. One
being precast and the other being steel tray. Both of
these are placed on the supporting walls and a topping
slab of concrete is then poured. This manual will focus
on precast flooring systems, as they are more common.
For information on the tray type of system, contact
Dimond Industries. The main types of precast flooring
systems used in a structural masonry system are Flat
Slabs, or Rib and Infill systems. They can accommodate
clear spans of up to approximately 8m. Manufacturers
can provide an engineering service as part of the supply
of these units. If there are any technical questions about
these floors, contact your nearest manufacturer or www.
precastnz.org.nz
The precast concrete floors are connected to walls by
starter bars extending from the wall, and cast into the
topping concrete. The flooring units should only be placed
after the Blockfill has been poured and allowed to set.
6.2 Flooring Systems
Both these flooring systems below are designed to
be composite floors made up of prestressed concrete
panels/beams with a concrete topping poured on site. The
units are available in lengths to suit the project design
and must be placed as per the construction drawings
prepared by the supplier. The units are uniquely identified
for this purpose.
These systems are also designed to span between
supporting walls. As such, the units are deliberately
made discontinuous over concrete walls. The topping is
continuous across the entire floor. Timber walls should
not be load bearing under concrete suspended floors and
should never be used to support either of these flooring
systems.
Section of Beam Infill Floor

6.4 Rib and Infill Flooring System
The Rib and Infill system comes as a series of beams
200mm wide by 100mm (usually) placed at 800mm
centres. Timber planks are placed between the beams
to act as permanent formwork for the concrete topping.
Props as required on the suppliers drawing must be in
place before the 200mm wide ribs are placed.
6.5 Construction Considerations
Concrete floor units are heavy, so suitable lifting
equipment will be required, in the form of a crane or a
Hiab. Site access is a consideration, the further away
from the building the crane has to park, the larger it has
to be. However, in most residential situations the sites
can be serviced with a Hiab.
6.6 Placing the Units
It is important to place the flooring units as required
by the precast manufacturers drawings. Seating on
blockwork is important. Too much seating on one end
will mean not enough at the other, causing an overload
of the supporting walls in compression. A good way to
allow easy movement of the units once in place is to
use a plastic bearing strip. This allows the units to be
located accurately before the topping is poured, as the
units can be shifted on the plastic instead of damaging
the blockwork and/or units themselves. Once the topping
is poured everything is locked in place.
Section of Prestressed Concrete Propped Floor

12
6.8 Concrete Topping

These flooring systems derive a large portion of their
spanning capabilities from the concrete topping. This
topping varies in thickness from 70mm to 130mm. Until
this topping has gained sufficient strength (14 28 days
after pouring) some propping will be necessary. Refer
to the construction drawings prepared by the precast
manufacturer, for the location of the propping.
It is important to locate the units next to each other in the

manner detailed in the construction drawings. Flat Slabs
should be butted hard against each other so there is no
gap between units. This will minimise concrete leakage
when the topping is poured. Rib units have a small
amount of tolerance because of the timber infill planks.
However, these timber planks require close alignment to
minimise concrete leakage.
6.7 Temporary Propping
Before erecting, props must be installed at the positions
and precamber levels as shown in the manufacturers
drawings. The props must be levelled to an accuracy of
3mm, must be adequate to safely carry the construction
loads with out settlement and must be well braced in
each direction. The photograph below shows timber
props. These must be designed with suitable top and
bottom bearing plates and bracing.
The perimeter boxing can be placed once the units are

located accurately. This can be set to a height so that
it can be used as screed railing. It is essential to cure
the topping correctly to ensure it reaches the required
strength. Insufficient curing of the floor may result in
greater deflections than designed for.
6.9 Topping Reinforcement

The flooring units are cast with pretensioning reinforcing
strands. The reinforcement requirements in the topping
will be detailed on the precast manufacturers drawings,
as will any extra bars for cantilevered balconies etc. It is
important that the reinforcement mesh is supported on
mesh chairs to ensure correct location within the topping.
Any supplementary reinforcement should be tied to the
mesh either under or on top, depending on the thickness
of the topping.
The reinforcement from the lower storey wall needs to be
tied into the topping. For walls that are supporting units
on both sides, the starter bars should bend alternate
directions. Refer to the photograph below.
The props may be removed once the concrete topping has

reached a compressive strength of 15MPa. This is usually
around two weeks. An initial settlement may occur once
the props are removed. The amount of initial and long
term settlement depends on the overall depth and span
of the floor system. The manufacturer can advise what
this long term deflection can be.
13
6.10 Services
It is possible to place services in the topping. Usually
this is limited to 40mm diameter waste pipes. A thicker
topping to accommodate the pipes will normally be used
(up to 20mm thicker).
6.12 Balconies
It is beyond the scope of this document to provide detailing
for balconies.
Balconies are to be specifically designed by the precast
floor manufacture and engineer.
6.11 Penetrations in the Floor
When penetrations are required in the floor due to
services, the precast manufacturer must be informed
before the units are made, this ensures that the
pretensioning strands are unaffected. It is not
recommended that the units are cut on site unless
specifically instructed by the precast manufacturer.
14
6.13 Waterproofing
Any suspended floor exposed to the weather will require
waterproofing on the surface to prevent penetration of
moisture to a habitable room or garage below. Refer to
the manufacturer for details.
Installation of services into a masonry home is a simple
exercise. Exactly the same planning is required as for a
conventional timber frame building. Changes are difficult
to achieve after the grouting of masonry walls.
SECTION 7 - SERVICES
7.1 Locations of Services
Methods of installing plumbing and electrical lines
depend on whether they are run through, within or
alongside the concrete masonry wall. Penetrations are
necessary primarily to allow services to pass directly
through the wall. Lines that run parallel to the wall can
reside either within the masonry cores themselves or in
the cavity created if the wall is to be strapped and lined.
Any openings required in the face shell shall be formed
with drills and saws. The use of hammers can crack
adjacent block faces and/or disturb mortar joints, both of
which can then leak.
Penetrations
Holes penetrating straight through a concrete masonry
wall can be created as the wall is assembled or after
assembly. During construction holes are left in the
designated locations by cutting sections of the blocks
before they are laid. An alternative is to drill through the
wall after wall assembly. The advantage of this is that
the blocklaying is uninterrupted and allows for delays
in deciding precise locations for the penetrations. With
either method, it is important to avoid the masonry webs
and to seal around the holes before blockfilling.
Services within Masonry Cores
If the interior of the wall is to be plastered or left exposed,
the services must be placed within the cores of the wall.
Provision must be made for the services as the masonry
is installed. Either the blocklayer or the service installer
will make cut-outs in the block face shells where the
electrical flush boxes and other service mounts will be
fixed. After the wall is completed, the electrician will pull
wires, install boxes and other fixtures. In partially filled

masonry, good planning will see the services installed in
a hollow core of the block wall.
7.2 Electrical
The location of all electrical fittings needs to be confirmed
prior to grouting. Electrical cable is usually run through
PVC conduit that has been placed inside the block wall
prior to grouting. It is not good practice to place more
than one conduit within a single vertical core that is to be
filled with grout.
The length of conduit and the number of bends should be
kept to a minimum so as to not affect the installation of
the cables within the conduit. With long, twisting conduits
the friction can make it difficult to pull the wires/cables
through.
The locations of the flush boxes should be marked out
on the masonry wall prior to grouting. Then the face
shell of the masonry block is cut out or drilled out and
the conduit is placed within the core of the masonry wall
extending out the wall at the location of the flush box.
The hole is then sealed around the conduit and the wall
is then grouted. Once the wall is grouted, the face of the
masonry unit can be cut for the installation of the flush
box.
In this photograph, the flush box is visible in the finished
wall. Switchplate fixing is identical to that on a timber
frame wall.
7.3 Plumbing
Consideration needs to be given to upstairs bathroom
facilities and their location relative to external walls.
15
Where necessary it is possible to leave a core of the

masonry blocks empty during pouring so that the
waste pipes can be run inside the blockwork. This gives
excellent noise dampening properties. This needs to be
coordinated with the Architect or Engineer to ensure that
the structural performance of the wall is unaffected.
For upstairs bathrooms and toilets located away from

external walls, plumbing needs to be routed to these
When the wall is to be strapped and lined, the services

can simply be placed in the cavity between the masonry
and the lining. This is very similar to that in traditional
timber frame construction.
7.5 Future Proofing
Data cabling offers many advantages over conventional
electrical cabling. With this type of system, the entire
houses lights, curtains, alarm systems, and heating can
be controlled from one point.
Installation of data cables is very similar to electrical
cables but there are a few minor points to consider:
Where

any data cables run parallel to electrical cables,
maintain at least 300mm separation. This is to stop
any electromagnetic interference of the transmission
of data as with any type of construction.
W
hen data and electrical cables have to cross, make
sure they are at right angles to each other.
walls. With a Prestressed Flat Slab floor the pipes can

be placed within a false ceiling as it is not practical to
run the large diameter toilet waste pipes in the concrete
floor. Rib and Infill floors can have an advantage in this
situation, as the beams create a natural 100mm deep
space when using a plasterboard ceiling. The pipes must
run parallel to the Rib Infill beams, as it is not possible to
core through a beam without compromising strength.
In some situations, data cabling can reduce the number of

wires required to manage the houses electrical systems.
Traditional cabling requires an individual wire for each
electrical item to be controlled. With data cabling, a
single control panel is capable of controlling the entire
house.
7.4 Services on Strapped and Lined Walls
16
SECTION 8 - STAIRCASES
One of the benefits of solid structural masonry
construction is the lack of foot impact noise from
concrete suspended floors and the all round quietness
provided by the downstairs concrete walls. This effect
can be continued with a concrete staircase. There are
a number of options available for the type of concrete
staircase used and how it is installed.
8.1 Cast-in-situ Staircases
A cast-in-situ staircase is where the staircase shape
is boxed on site, the steel is placed, and concrete is
poured. A stiff concrete mix is used to ensure that the
concrete does not slump to the bottom. Advantages with
this system are that the staircase can be installed at any
stage of the construction and any inaccuracies in wall or
floor construction can be easily accommodated.
This type of construction works well when staircases
have short spans or there is an unusual shape to be
formed. It is important to ensure that the surface of the
staircase is finished smooth enough to be used bare even
if the stairs are to be covered, as it is easier to make the
concrete smooth before it has cured, grinding off the
surplus dags can be an expensive exercise.
8.2 Precast Staircases

Precast staircases can be an economic solution when
longer spans are required. This type of staircase offers
great speed of construction and can also be made with
a finished (exposed) surface. A greater accuracy in
construction of the supporting walls is required.
One type of staircase is called monolithic, where the
staircase is cast in one large unit. It is wise to consider
the site access with this type, as the staircase requires
heavy lifting equipment to install. Good construction
planning can allow installation at the same time as the
suspended concrete floor, requiring a crane to visit the
site only once. Usually starter bars cast into the staircase
extend from the ends of the staircase, to tie into the
topping concrete of the suspended concrete floor.
Another type of precast staircase is made up of separate
components beams which support individual risers
and treads, and can be installed at virtually any stage
once the supporting walls have been grouted. As the
components are relatively lightweight, most often they
can be manhandled into place.
17
SECTION 9 - ROOF CONNECTION

The two most popular methods of roof connection are
by top plate and metal strap. Either one can be used
in almost any circumstance. The top plate requires
more material, but leaves greater flexibility for the roof
members to be placed. It also leaves a nailing surface
along the top of the wall, which is useful if a trim is to be
installed. Metal straps can provide a stronger connection
and for high-wind areas are often compulsory. They also
leave the concrete masonry surface uninterrupted to the
roofline (good for plastering).
the plate in place. These bolts are suspended in the bond
9.1 Top Plate
to the roofing members. The straps are positioned in the
This is the most common approach where a wooden

plate is installed along the top of the wall and the roofing
members attach to it conventionally. Anchor bolts hold
beam prior to the wall being filled and upon grouting they
lock into place. The top plates are drilled and screwed
into place. As with any timber/masonry connection, the
top plate needs to be protected from moisture by DPC or
similar.
9.2 Metal straps
Metal straps or hurricane straps can also connect the wall
blockfill at the design locations of the roofing members.
The roof is built on top of the wall with each strap nailed
to its representative member.
SECTION 10 - WINDOW INSTALLATION

In general the most critical aspect of masonry
construction is the installation of windows. If a house is
going to leak, it is most likely to be caused by inadequate
sealing around window frames. Masonry homes are just
as prone to leaking around windows as any other home if
incorrect installation techniques are used.
The Architect or Designer should carefully select a sealing
and coating system from a reputable manufacturer. The
directions of that manufacturer should be carefully
followed, at all times.
The four Ds for weather tightness design are,
deflection, drainage, drying and durability. Penetrations
through masonry walls may employ the Ds by1. deflection are building elements that shelter the wall
or divert water away from critical junctions such as
eaves, drip moulds and sealants.
Details which employ these principles are summarized

in two publications C
oncrete Masonry- a guide to weathertight
construction, available for free download from the
NZ Concrete Masonry Associations website
www.nzcma.org.nz
W
eathertight Solutions Volume 4- Masonry, details for
junctions and openings in masonry walls. Available
from Branz.
An illustration of a typical construction sequence is as
follows.
Flush any block joints around the window opening with
mortar. This removes any recesses in the surface that
would require excess sealant to be applied.
2. drainage is achieved by ensuring that any water that

gets in is drained back out generally through an
unsealed joint along the bottom.
3. The unsealed bottom edge allows some circulation of
air to aid drying.
4. Air seals installed around the inside edges of the
openings restrict the passage of air through joints and
prevent water being carried to the interior.
18
Apply a waterproofing membrane around head, jamb,

and sill. This waterproofing membrane should cover the
entire thickness of the wall and be extended a minimum
of 50mm on the exterior face around the penetration.
B: apply a flexible seal to the gap between the top and

sides of window frame and masonry wall. Do not seal
along the bottom of the window frame.
Fit joinery leaving a 5mm gap between the window frame

and masonry rebate.
Ensure that the window frame is located accurately and

square in the opening. This will ensure a uniform gap
around the frame for further application of sealant.
With the paint system, it is very important that the

paint coat is applied over the flexible sealant up to the
joinery. This provides one extra defence against moisture
ingress. The Architect or Designer should fully detail the
weatherproofing procedures for window openings.
Ensure that all paint, sealants and coatings are
compatible. The use of one selected, reputable
manufacturers products and system is strongly
recommended.
A: Once the window is fixed and square install backing

rod and foam airseal to the interior of the jonery.
19
SECTION 11 - WATERPROOFING/COATING SYSTEMS

External waterproofing systems are one of the most
critical aspects of the construction and also have a large
visual impact. Coating of a masonry home is a simple
process but there are a few areas that need special
attention before applying the coating.
11.1 Dry Blockwork
Before coating, the blockwork must be dry. AS/NZS
2311:2000 provides a guideline for recommended
drying times for recently constructed masonry. The
recommended times are 8 weeks for solid-filled
construction and 4 weeks for partial-filled construction.
Wet concrete masonry units shrink when drying. This
movement is minute but is still significant if a brittle
coating (such as plaster) is applied to wet blocks.
Cracking is likely to occur in the plaster due to the block
movement.
The following conditions have the most influence on
shrinking:
Masonry units stored on site and not covered are laid
wet.
Signficant rainfall occurring
(especially during winter).
during
blocklaying
Insufficient time to allow drying prior to applying the

coating.
Once sufficient drying has occurred the exterior coating

should be applied as soon as practical to prevent further
moisture entering the masonry.
11.2 Cleaning Blockwork
Ensure the blockwork is clean and free from surplus
mortar/grout. All mortar joints should be free from
dags and blocks should have smooth clean surfaces. A
common practice is to brush the surface of the wall down
with a wire brush or rub a piece of masonry on it to clean
the wall.
11.3 Application
It is strongly recommended that an accredited applicator
of the coating chosen for the job is hired. They have the
know how and can deal with problems, if they arise,
better than anyone. The accredited applicator normally
has the manufacturers guarantee as support should
anything go wrong.
It is vitally important to follow the coating manufacturers
application instructions. Incorrect application may lead
to the coating not providing the waterproofing expected.
In multicoated systems, do not change from one brand to
another from one layer to the next. Each manufacturer
will have ensured that reaction occurs with the mixing of
their products. This cannot always be guaranteed when
products from different manufacturers are mixed.
Firth does not claim to be the expert in the application

of coatings on masonry. It is strongly recommended
that the manufacturer of the preferred coating(s) be
consulted for advice in this area.
20
SECTION 12 - EXTERNAL COATING SYSTEMS

12.1 Acrylic Paint
Good quality acrylic paint acts as a moisture barrier but
not a vapour barrier. This allows the blocks to breathe
removing any trapped water vapour while at the same time
stopping moisture from rain from entering the blocks.
Paint like this has no rendering ability so it is usually
applied over a skim coat of sand-cement plaster but can
be applied directly to blockwork if that look is desired.
If this type of coating is to be used, it is recommended
that three coats be applied, or in accordance with the
manufacturers specification.
12.2 High-build Elastomeric Coatings
High-build elastomeric coatings are similar to a very
thick acrylic paint. Using the latest paint and polymer
technology they offer a coating system that can have a
variety of looks, ranging from conventional paint look
to a textured plaster finish. These are recommended
as a coating system for masonry, as they have a great
amount of flexibility and can cope with small amounts of
movement that may occur.
12.3 Solid Plaster
Sand-cement plaster is the traditional method of coating
masonry and it is usually coated with one of the above
treatments for waterproofing.
The first treatment for the dry masonry surface is the
application of a scratch or splatter coat. This is a sandcement slurry that is splattered onto the wall, creating a
rougher surface for the main plaster coat to bond to. The
plaster needs to adhere to the wall or there is potential
for what is called drummy plaster to occur. This is a
condition where the plaster coat has not broken but has
de-bonded from the masonry and when tapped it makes
a slight hollow sound. After this preparation coat, it is
common for two or three coats of plaster to be trowelled
on. It is even possible to spray the plaster on which
speeds up the process. The top coat of the plaster can be

coloured to match the paint just like an undercoat.
There is a wide range of surface finishes available. This
can range from an undulating finish (achieving a rough
country look) to straight plaster finishes (the smoothest
type of finish available). The undulating plaster is usually
the most cost effective, as it requires less labour to
create. Other thinner coating systems cannot achieve
this undulating appearance.
12.4 Modified Plaster
These are typically acrylic-based proprietary coating
systems developed for use on masonry structures. They
are designed to provide a substantial look while offering
protection from ingress of moisture. They are applied in a
similar manner to solid plaster, but refer to the relevant
manufacturer for their recommendations.
12.5 Clear Sealants
Other types of coatings basically rely on their inherent
thickness and elasticity to provide long term protection.
But thick coatings are easily seen, defeating the purpose
of using a clear sealant that uncoated look. Refer to the
clear sealant manufacturer for suitability, application and
maintenance information.
12.6 Cement Based Paints
It is not recommend to use cement-based paints directly
on blockwork. These paints are very brittle and once
wall movement occurs, cracking of the coating is almost
inevitable.
21
SECTION 13 - INTERNAL COATING SYSTEMS

The choice of internal linings is basically limitless. As it
has almost no impact on the structure, any type of finish
can be accommodated.
13.1 Exposed Blockwork
Exposed blockwork (fair faced) has found new favour
with the architectural community. This is the cheapest
option. Internally there is no issue with leaving the
blockwork uncoated as the waterproofing is provided
from the outside. Where a fair faced finish is desired in a
wet area such as a bathroom, a suitable sealing system
may be selected. Refer to the sealant manufacturers
recommendations prior to use.
13.2 Paint Finish
Where strapping and lining is used the thermal mass of
the masonry wall is isolated from the interior and the heat
storage capacity of solid construction is compromised.
Guidance on R-values required for strapped and lined
construction can be found in the Firth publication,
Masonry Insulation Solutions.
13.4 Plasterboard
Blockwork with GIB plasterboard glued directly to the
masonry is a quick and economic method of coating
the walls. This gives the GIB plasterboard wall a
much more solid feel as there is no cavity and ensures
that that thermal mass befits of solid construction are
maintained.
This method does rely on a well maintained external
waterproof coating.
Paint over bare blockwork is a relatively low cost solution.
This provides a uniform colour to the wall and still allows
Consult your GIB plasterboard supplier to determine

when the glue fixed GIB plasterboard method should be
used.
the mortar joints to be seen. It is important that the walls

are as dry as possible before applying the paint. If any
excess moisture is trapped, it is likely to bubble the paint
over time. In order to hide the block lines, a high-build
elastomeric coating with a levelling coat can be used.
13.3 Strapped and Lined
This method involves fixing strapping to the block wall and
fixing GIB plasterboard to it. The cavity can be utilised
as service channels. This method may also incorporate
insultation, however with HotBloc there is no need to
use this type of construction for insulation. Strapping
and lining comes into its own is that it allows relatively
easy installation of electrical services at a later date if
the owner wishes to upgrade the services.
22
13.5 Tiling
The basic requirements for tiling do not change from wet
areas to dry areas but there are some requirements that
need to be followed in order to get a quality job. The basic
requirements are:
Blockwork needs to be flush-jointed in order to
provide a flat surface for tile adhesive application or an
adhesive designed for application directly to blockwork
needs to be used.
If tiling over a control joint in the blockwork, a control
joint in the tiles must also be provided, as any movement
that occurs in the block wall will be reflected in the
tiling.
It is of utmost importance to ensure that blockwork
is dry before application of tiles as any shrinkage
movement will reflect cracks in the surface due to
their brittle nature.
13.6 Plaster finish
The same procedure applies as for the application of
external plaster. First a splatter coat is applied followed
by the topcoat(s).
23
SECTION 14 - CONSTRUCTION DETAILS

This section illustrates typical construction details.
Other sources of information include
NZS 4229 which provides details on retaining walls,
foundations, bond beams and wall to floor and wall to
roof details.
24
Weathertight Solution Volume 4 produced by BRANZ.

This document provides numerous illustrations of
details to ensure weathertightness. This document is
available from BRANZ as a hard copy or a CD containing
CAD drawings.
Grade 300 40 bar dia

min.lap
For Technical Advice: Ph. 0800 800 576
Slab Foundation With Insulation
Standard Edge Beam Detail
100_standard_edge .dwg
Firth RibRaft Floor System
Vapour barrier
Sand blinding
Firth Raft
2009 . The copyright of this document is

the property of Firth and shall not be
reproduced, copied, loaned or disposed of
directly, or indirectly, nor used for any
purpose other than that for which it is
specifically furnished without prior consent.
Firth RibRaft polystyrene pod installation in

accordance to Firth RibRaft construction details
2HD12
300
665 mesh
HD12
Vertical reinforcement central

to the resultant grout cavity
Grout 17.5 MPa

(except sea spray zones 25 MPa)
Horizontal reinforcement
Interior plaster/finish as
specified
Detail:100_standard_edge
Disclaimer: This information is intended solely as a guide for use of Firt h

products. Before using a Firth product you should ensure that the product is
suitable for use in the specific application. Nothing in this information
constitutes a statement of fitness for particular purpose - appropriate expert
advice should always be obtained. Firth makes no warranty regarding the use
of this information with non-Firth product.
Notes:
Refer to NZS 4229 or specific design for
masonry wall reinforcement details.
Refer to specific design for dimension &
x
reinforcing of RibRaft floor system.
Ground
clearance
per E2/AS1
Polystyrene insulation
Exterior plaster/finish as specified

with applied waterproof coating
Firth HotBloc
Standard Edge Beam Detail
305mm
25
100
www.firth.co.nz
Scale 1:10
February 2009
Ground
Clearance
per E2/AS1
D12
Strip Footing Detail
Firth HotBloc
102_strip_footing .dwg
Note:
Refer to NZS 4229:1999 or specific
design for dimension, reinforcing, and
ground clearances
See Note
Type 20.45 blocks must be laid

within finished floor level
tolerances
Exterior plaster/finish as
specified with applied
waterproofing
min.lap
Polystyrene
Firth HotBloc
Strip Footing Detail
See Note

Optional additional layer of

insulation
75mm minimum granular fill
Damp proof membrane

See Note
Concrete (17.5 MPa)
Reinforcing mesh
100mm slab
Vertical reinforcement central to

cavity
Grout 17.5 MPa

(Except sea spray zones 25MPa)
specified
Detail:102_strip_footing
D12 ties @ 600 ctrs.

(lap 600 min.)
See Note
26
102
www.firth.co.nz
Scale 1:10
February 2009
Edge Thickened Slab Detail
Firth HotBloc
D12
See Note
See Note
200 x 200 haunch
75mm minimum granular fill
Damp proof membrane
Concrete (17.5 MPa)
Reinforcing mesh
100mm slab
Vertical reinforcement central to cavity
Grout 17.5 MPa

(except sea spray zones 25MPa)
Horizontal reinforcement
specified
Detail:103_edge_thickened
103_edge_thickened .dwg


Note
Refer to NZS 4229 or specific design for dimension, reinforcing, and ground clearances
D12 ties @ 600

ctrs.
(lap 600 min.)
Ground
clearence
per E2/AS1
Finished
floor level

Polystyrene
Firth HotBloc

min.lap
Edge Thickened Slab Detail
See
Note
See Note
27
103
www.firth.co.nz
Scale 1:10
February 2009
28
Basement
Firth HotBloc
Slotted drain to fall to outfall

drain
Filter frabric
Continuous damp-proof
membrane to wall and under
floor
Membrane protection
Granular drainage metal
Base course
Site concrete
(tidy slab)
104_basement .dwg


Damp-proof membrane
Concrete floor slab and footing

reinforcing not shown for clarity
100mm rebate
Concrete masonry
specified
75mm end Seating
Bedding: Mortar seating for precast flooring
Block wall grouted to this level before

placing precast flooring
Precast flooring
Varies with span and loading
Vertical reinforcing central to cavity

Box and form upstand for wall above as
required
Mesh size appropriate to topping thickness
Interior plaster/finish as specified
Detail:104_basement
Note: refer to NZS 4229 or specific design for masonry reinforcing
HotBloc bond-beam
Starters D12@600 cts.

(lap 600 min.)
Firth HotBloc
Polystyrene
Exterior plaster/finish as specified with applied

waterproof coating
Optional surface
water channel
Basement
104
www.firth.co.nz
Scale 1:20
February 2009
29
200_sample_resident .dwg
Sample Residential Construction
Firth HotBloc
D.P.C.
Lintel reinforcing to
NZS 4229 or specific
design to NZS 4230
Top plate as specified by NZS

4229 or specific design

Detail:200_sample_resident

Reinforcing each side of

opening. Refer to NZS 4229.
Polystyrene in Firth HotBloc

to be placed to the external
face
Sample Residential Construction
200
www.firth.co.nz
Scale 1:10
February 2009
30
Typical Lintel & Bond Beam
Firth HotBloc
201_typical_lintel .dwg
Firth HotBloc

Detail:201_typical_lintel

390mm deep lintel reinforce to

NZS 4229 or specific design
Continuous horizontal steel and ties in

concrete filled bond-beam
Typical Lintel & Bond Beam
201
www.firth.co.nz
Scale 1:10
February 2009
31
Holding bolts
D.P.C.
Sealant
Roofing underlay
Sloping Soffit and Ceiling
Firth HotBloc
specified
Selected trim
Ceiling
Insulation
300_sloping_soffit .dwg


Detail:300_sloping_soffit
Notes:
1. Reinforcement not shown for clarity
2. Fix rafter to top plate with approved mechanical fix
3. Refer clause E2/AS1 section 8 of the NZ Building Code for full weathertightness
detailing of the roof structure and eaves
Firth HotBloc

Birdsmouth
200x50 timber plate
Sloping Soffit and Ceiling
300
www.firth.co.nz
Scale 1:10
February 2009
32
Holding bolts
specified
Selected trim
Ceiling
Insulation.
Detail:301_horizontal_soff
301_horizontal_soff .dwg


Notes:
2. Fix truss to top plate with approved mechanical fix
Firth Hotbloc

Horizontal Soffit And Ceiling
Firth HotBloc
Roofing underlay
Sealant
200x50 timber plate
Horizontal Soffit And Ceiling
301
www.firth.co.nz
Scale 1:10
February 2009
33
Roofing underlay
Gable End Connection
Firth HotBloc
specified
Selected trim
Ceiling
Insulation
Detail:302_gable_end_con
302_gable_end_con .dwg


Notes:
2. Fix truss/rafter to top plate with approved mechanical fix
Firth HotBloc
Exterior plaster finish as specified

with applied waterproofing
Holding bolts
D.P.C.
Sealant
200x50 timber plate
Gable End Connection
302
www.firth.co.nz
Scale 1:10
February 2009
34
Roofing underlay
D.P.C.
Sealant
Sarked Celing Over Rafters
Firth HotBloc
specified
Sarked ceiling
Insulation
Detail:303_sarked_ceiling
303_sarked_ceiling .dwg


Notes:
2. Fix rafter to top plate with approved mechanical fix
Firth HotBloc

Holding bolts
Birdsmouth
Timber plate
Sarked Celing Over Rafters
303
www.firth.co.nz
Scale 1:10
17 October 2008
35
304_sloping_soffit .dwg
Sloping Soffit With Horizontal Trusses
Firth HotBloc
Insulation
specified
Selected trim
Ceiling


Detail:304_sloping_soffit
Notes:
Firth HotBloc
Exterior plaster finish as specified

D.P.C.
Holding bolts
Sealant
Timber plate
Roofing underlay
Sloping Soffit With Horizontal Trusses
304
www.firth.co.nz
Scale 1:10
February 2009
36
305_truss_roof_fix .dwg
Truss Roof Fixing With Top Plate
Firth HotBloc
specified
D.P.C.
Selected trim
Ceiling
Insulation.
Detail:305_truss_roof_fix


Notes:
Firth HotBloc

Holding bolts
Box soffit alternative.
Sealant
75x50 nog
200x50 timber plate
Roofing underlay
Truss Roof Fixing With Top Plate
305
www.firth.co.nz
Scale 1:10
February 2009
37
401_internal_gutter .dwg
Internal Gutter On Parapet Wall
Waterproof
membrane dressed
and chased into
mortar bed
Plaster
High build acrylic

paint system

Flashing Detail
Chase cut
Masonry units
Flexible paintable sealer
Detail:401_internal_gutter

Note: Reinforcement not shown for clarity.
specified
D.P.C.
Timber joist
Waterproof membrane on
plywood base
Chase cut (see flashing detail)
Apply proprietary waterproofing

membrane to blockwork prior to
plaster
Top flashing
Bevelled top plate to provide fall

DPC
Internal Gutter Detail
Firth HotBloc
Firth HoBloc
Polystyrene
insulation
waterproof coating
70mm cover from

block top
Building wrap
Internal Gutter On Parapet Wall
401
www.firth.co.nz
Scale 1:10
February 2009
38
20
Parapet Wall Waterproofing
specified
D.P.C.
Timber joist
Metal flashing note: stainless

may be required, see NZS 3604
durability section
Chase cut (see detail)

plaster
Top flashing

DPC
400_parapet_wall .dwg
Flashing
Plaster
400
www.firth.co.nz
Scale 1:10
February 2009
High build acrylic

paint system

Flashing Detail
Chase cut
Masonry units
Detail:400_parapet_wall

Parapet Wall Detail
Firth HotBloc
Firth HotBloc
Polystyrene
insulation
waterproof coating
Roofing underlay turned

up behind flashing
70mm cover from

block top
Building wrap
Parapet Wall Waterproofing
75 min
39
75mm end
specified
402_precast_deck .dwg
Precast Flooring Deck Waterproofing Detail
Firth HotBloc

Chase cut
Masonry
units

Flashing Detail
402
www.firth.co.nz
Scale 1:10
17 October 2008
Waterproof
membrane
dressed and
chased into mortar
bed
Plaster
High build acrylic

paint system
Detail:402_precast_deck
Flexible paintable
sealer
Block wall grouted to this level

before placing precast flooring.
75mm precast
flooring

membrane to concrete surface
and blockwork upstand
Vertical reinforcing

plaster
Top flashing

DPC
Precast flooring Deck Waterproofing Detail
Firth HotBloc bond-beam.
D12 starters @ 600 ctrs.

(lap 600 min.)
Mortar seating for

precast flooring
waterproof coating
70mm cover from

block top
Building wrap
Precast Flooring Deck Waterproofing Detail
40
Plaster/finish as specified
Flashing
Plaster
403
www.firth.co.nz
Scale 1:10
February 2009
High build acrylic

paint system

Flashing Detail
Chase cut
Masonry units
Detail:403_cross-section

Note:
x
Reinforcement not shown for clarity.
x
Bolt details as per NZS4229
403_cross-section .dwg
Cross-section Wall To Roof Junction
Parapet Wall Detail
Firth HotBloc
Firth HotBloc
D.P.C.
Polystyrene insulation (not

required if an interior wall)
Purlin
Roof cladding
Metal flashing note: stainless

may be required, see NZS 3604
durability section
Rafter
20
Exterior plaster/finish as specified with

applied waterproof coating
See note
specified
Roofing underlay turned

up behind flashing
Firth HotBloc
Cross-section Wall To Roof Junction
75 min
Ecofoam
Eco foam beneath sill
Packing
Window
Jamb liner
Backing rod
501_window_head .dwg
Backing rod
Window Head And Sill Detail
Firth HotBloc
Internal finish as specified
5mm min gap

5mm min gap
41
50
Protruding sill block

Applied waterproof membrane
Leave 4-5mm gap between

aluminium and plaster
10mm min cover
Proprietary waterproofing
system to all reveals prior to
window installation

aluminium and plaster and seal
with approved sealant
(Head and stiles only)
Aluminum angle 20mm x 20mm
For plaster finish, form a drip

edge
specified with applied water
proof coating
Rebated block
Detail:501_window_head

5mm min gap
50
501
www.firth.co.nz
Scale 1:5
February 2009
On Conventional Footing
Sliding/French Door Details
Firth HotBloc

(paint coating) with 50mm cover
to block face
15 slope to sill
Tiled sill
Sealant
waterproof coating
Rebated block
Sliding/French Door Details
503_sliding_french .dwg
Firth HotBloc
50
42
5mm min
Rebate to suit
sill profile

Concrete slab
Selected timber sill board

Compressible cell foam air seal
Selected aluminium sliding door

section
Detail:503_sliding_french

5 10
503
www.firth.co.nz
Scale 1:5
February 2009
Packing
Window
Ecofoam
Eco foam beneath sill
Firth HotBloc
Backing rod
Internal finish as specified
5mm min gap

502_window_head .dwg
Backing rod
5mm min gap
43

Protruding sill block

5mm min gap

aluminium and plaster
10mm min cover
Proprietary waterproofing
system to all reveals prior to
window installation

aluminium and plaster and seal
with approved sealant
(Head and stiles only)
Aluminum angle 20mm x 20mm
For plaster finish, form a drip

edge
specified with applied water
proof coating
Rebated block
Detail:502_window_head
502
www.firth.co.nz
Scale 1:5
February 2009
44
specified
D.P.C.
Ramset fixings
505_interior_door .dwg
Interior Door Jamb/head Details
Firth Grey Masonry
Interior Timber Jamb Detail
Firth 15 Series Block
specified
Architrave
Planted stop
Stop
Bead of flexible
paintable sealer
90x20 door frame wedge&fixed

under by door stop

Interior Timber Head Detail
Note: reinforcement not shown for clarity.
Door
Ex 200x50 timber machined to

180mm
Detail:505_interior_door

Interior Door Jamb/head Details
505
www.firth.co.nz
Scale 1:5
February 2009
45
506_meter_box .dwg
Ecofoam continuous to all sides
Firth HotBloc
Meter Box
Metal meter box
Modified silicon sealant

between angle and DPC
for head and sides
Metal angle
Water proof coating
Firth concrete masonry
specified
2-5mm gap beween angle and

DPC. Do not seal at bottom
Meter Box
Cross-fall 5

Backing rod continuous to all

sides
Applied waterproofing
membrane
Metal meter box

QRWWRVFDOH
Meter Box At Head
QRWWRVFDOH
Ecofoam around all sides of

meter box to form airseal
Backing rod
Selected Interior finish
Rebate block
Detail:506_meter_box
506
www.firth.co.nz
Scale 1:5
February 2009
46
Pipe Penetration
Firth HotBloc
507_pipe_penetrate .dwg
Pipe penetration to
be sealed with tape
to building wrap
Flexible sealant to
perimeter of hole
Pipe to slope down to the

outside
Gasket sleeve for pipes up to

40mm diameter
Waterproof coating
Exterior plaster/finsh as
specified
Pipe Penetration


Interior finish as specified
Pipe laid to fall to outside if

possible
Firth HotBloc
Detail:507_pipe_penetrate
507
www.firth.co.nz
Scale 1:5
February 2009
47
601_precast_interm .dwg
Precast Flooring Intermediate Support
Precast Flooring
specified

Block grouted to this level prior

to placing precast flooring
75 precast flooring
Varies with span and loading
Mesh size appropriate to

topping thickness
Block work above with wall

reinforcement continued through
floor if required
Detail:601_precast_interm

All reinforcing to engineering

design
Bond beam
Mortar seating for

precast flooring
25mm min. Cover
Bend starters alternatively into

topping
Precast Flooring Intermediate Support
601
www.firth.co.nz
Scale 1:10
17 October 2008
IMPORTANT NOTICE
This Manual has been prepared by Fletcher Concrete & Infrastructure Limited trading as Firth as part of its Firth
Industries Division (Firth), solely to provide general information on Masonry Construction and not as specific advice
to any particular recipient or person. Notwithstanding the contents of this Manual, Masonry Construction should be
undertaken in accordance with the New Zealand Building Code, all relevant statutory and regulatory requirements and
all relevant New Zealand Standards. Any person contemplating the construction of a structural masonry home should
carry out their own investigations and inquiries as to their specific requirements.
The information contained in this Manual is believed to be correct at the time it was prepared but no representation
or warranty, expressed or implied (other than as may be implied by law) is made by Firth, its officers, employees or
agents as to its accuracy, reliability or completeness.
To the fullest extent permitted by law, Firth excludes all liability for:
any negligent misstatement, error or omission in relation to the information and/or recommendations contained in
this Manual; and
any damages, losses, costs, or expenses including, without limitation, direct, indirect, special or consequential
damages (including but not limited to damages arising from negligence) arising from or in connection to with any
access to, use of or reliance on the contents of this manual.
Further, successful Masonry Construction is dependent upon numerous factors outside Firths control for example,
quality of workmanship, particular design requirements and non-Firth products etc. Firth will not be liable in relation
to any of these factors.
Firth is not under any obligation to update any information and/or recommendations contained in this Manual or to
notify any person should any such information and/or recommendations cease to be correct after the date this Manual
is published.
If you are using this Manual for business purposes, you agree that the provisions of the Consumer Guarantees Act
1993 will not apply, to the extent that contracting out is permitted by that Act.
HotBloc and RibRaft are registered trademarks of Fletcher Building Ltd or its subsidiaries.
References
Various portions of this Manual were prepared with the assistance of CCANZ, NCMA, and NZCMA. The three documents
used were The New Zealand Concrete Masonry Manual from the Cement and Concrete Association of New Zealand,
ResTek2 from the National Concrete Masonry Association from the USA and Concrete Masonry a Guide to
Weathertight Construction produced by BRANZ and funded by the Department of Building and Housing, Building
Research and NZCMA Inc.
48
SustainabilitY: The Firth Concrete & Concrete Masonry sustainability lifecycle

4 Environmentally compliant manufacturing plants
n
4 Surplus water and some aggregates recycled
n
4 Low transport impacts
n
4 Leftover concrete returned from construction sites
n
4 Passive solar heated thermal mass makes completed buildings
n
more energy-efficient
4
n
4
n
4
n
4
n
4
n
4
n
Most wash water returned from construction sites
For
Highly durable, low maintenance buildings and no rot
contribution to building a
more
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Masonry Homes Construction Manual PDF

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CBI 3321 3323 4261 4263 4264 4711

Timeless elegance , todays technology

Safer, healthier homes

Masonry homes provide New Zealanders with the age

Naturally solid masonry homes are completely fire

Cool in Summer, warm in Winter

Tranquility and peace

With Firth HotBloc , the thermal mass of the unit is in

The same high density makes masonry homes

6.8 Concrete Topping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SECTION 2 FOOTINGS AND FOUNDATIONS

8.2 Precast Staircases . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.1 Conventional Footings . . . . . . . . . . . . . . . . . . . . . . . . . 6

SECTION 9 - ROOF CONNECTION

SECTION 3 WALL INSTALLATION

9.1 Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.3 Geotechnical Report

Masonry homes can be some of the most stunning and

A geotechnical report on the site is very good insurance

1.2 Design Considerations & Scope of this Manual

1.4 Insulation of Masonry

Outer side of wallg

Occasionally there will be areas of the house that fall

The R-values of various HotBloc solutions areR0.7

20 series HotBloc, fully filled,

R1.16 25 series HotBloc, fully filled,

 5 series HotBloc, fully filled and interior lined

Importantly the R-values are obtained without the use of

The acceptable solution H1/AS1 of the Building Code

20 Series HotBloc, R0.7 Hot-STD

25 Series HotBloc, R1.16 Hot-STD

1.8 Modular Layout

Designing wall dimensions to equal a multiple of the

Typically services are placed in ducts in the cores of the

The standard CMU is 390mm long, and 190mm high with

When using a suspended concrete floor in two-storey

The Modular Correct

Another approach for solid filled walls is to leave a

The Modular-Correct no cutting required

The Modular Incorrect

The Modular-Incorrect shaded portion-cut block

All suspended concrete floor types need to be supported

1.11 Internal Walls

Masonry Homes Construction Manual - V1 2008

SECTION 2 - FOOTINGS AND FOUNDATIONS

specific design details, but also contains details that will

The RibRaft Manual can be obtained from Firth through

Masonry Homes Construction Manual - V1 2008

SECTION 3 - WALL INSTALLATION

10mm 3mm as per NZS 4210:2001.

Starter bars are the steel reinforcing bars that connect

All mortar either site mixed or premixed must meet a 28

For internal walls, correction of a bar location is a simple

3.2 First Course

3.3 Running Bond

The vertical bars need to be tied to the starter bars with

Another aspect of masonry construction that is

HotBloc with its integral insulation is installed virtually

Tooling to a depth of 6mm is allowable. The

5 series HotBloc, fully filled and interior lined

(c) Wall intersections

(d) Opening locations.

2. drainage is achieved by ensuring that any water that