Brick Work in Construction of Residential Building G+10

CHAPTER - 1

INTRODUCTION

1.1 GENERAL

Bricks are small rectangular blocks that can be used to form parts of buildings,
typically walls. The use of bricks dates back to before 7,000 BC, when the
earliest bricks were formed from hand-moulded mud and dried in the sun. During
the Industrial Revolution, mass-produced bricks became a common alternative to stone,
which could be more expensive, less predictable and more difficult to handle.

Bricks are still in common use today for the construction of walls and paving and
for more complex features such as columns, arches, fireplaces and chimneys. They
remain popular because they are relatively small and easy to handle, can be extremely
strong in compression, are durable and low maintenance, they can be built up
into complex shapes and can be visually attractive.

However, more recently, other materials have been developed that can be used as
alternatives for building walls or for cladding facades and for some building types,
particularly larger buildings, bricks can be seen as time consuming, expensive (although
this is disputed by the Brick Development Association), structurally limiting, and
requiring too much on-site labour. Some of these difficulties have been overcome by
the introduction of reinforcement systems and by the development of pre-fabricated brick
panels

1.2 Classification of Bricks

Bricks can be of many types depending on –
1. Quality

2. Building Process

3. Manufacturing Method

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4. Raw Material

1.2.1 Classification of Bricks as Per Common Practice:

Bricks, which are used in construction works, are burnt bricks. They are
classified into four categories on the basis of its manufacturing and preparation, as
given below.

1. First class bricks

2. Second class bricks
3. Third class bricks
4. Fourth class bricks

1. First Class Bricks:

These bricks are table moulded and of standard shape and they are burnt in kilns.
The surface and edges of the bricks are sharp, square, smooth, and straight. They comply
with all the qualities of good bricks. These bricks are used for superior work of permanent
nature.

It is generally used-

 in a building of long durability, say 100 years

 for building exposes to a corrosive environment
 for making coarse aggregates of concrete. The absorption capacity is less than 10%,
crushing strength is, 280kg/cm2 (mean) where it is 245 kg/cm2 (minimum). It does
not have efflorescence. It emits a metallic sound when struck by another similar brick
or struck by a hammer.

2. Second Class Bricks:

These bricks are ground moulded and they are burnt in kilns. The surface of these
bricks is somewhat rough and shape is also slightly irregular. These bricks may have hair
cracks and their edges may not be sharp and uniform. These bricks are commonly used
at places where brick work is to be provided with a coat of plaster. It has a regular shape;
efflorescence is not appreciable. The absorption capacity is more than 10% but less than
15%. Crushing strength is 175kg/cm2 (mean) where the minimum is 154 kg/cm2. It emits
a metallic sound when struck by another similar brick or struck by a hammer. It is hard
enough to resist any fingernail expression on the brick surface if one tries to do with a N

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thumbnail. It is used for the construction of one-storied buildings, temporary shed when
intended durability is not more than 15 years.

3. Third Class Bricks:

These bricks are ground moluded and they are burnt in clamps. These bricks are
not hard and they have rough surfaces with irregular and distorted edges. These bricks
give dull sound when struck together. They are used for unimportant and temporary
structures and at places where rainfall is not heavy.
It has extensive efflorescence. The texture is non-uniform. The absorption
capacity is more than 15% but less than 20%. The crushing strength is 140kg/cm2 (mean)
where the minimum crushing strength is 105kg/cm2. It emits a dull or blunt sound when
struck by another similar brick or struck by a hammer. It leaves fingernail expression
when one tries to do with the thumbnail.

4. Fourth Class Bricks:

These are over burnt bricks with irregular shape and dark color. These bricks are
used as aggregate for concrete in foundations, floors, roads etc., because of the fact that
the over burnt bricks have a compact structure and hence they are sometimes found to be
stronger than even the first-class bricks.

1.2.2 Classification of Bricks Based on Building Process

On the basis of the building process Bricks are of following kinds:

1. Unburnt Bricks: These are half burnt bricks. The color is yellow. The strength is low.
They are used as surki in lime terracing. They are used as soiling under RCC footing or
basement. Such bricks should not be exposed to rainwater.

2. Burnt Bricks: Burnt bricks are made by burning them in the kiln. First class, Second-
Class, Third-Class bricks are burnt bricks.

3. Over Burnt or Jhama Brick: It is often known as the vitrified brick as it is fired at
high temperature and for a longer period of time than conventional bricks. As a result,
the shape is distorted. The absorption capacity is high. The strength is higher or
equivalent to first class bricks. It is used as lime concrete for the foundation. It is also

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used as coarse aggregate in the concrete of slab and beam which will not come in contact
with water.

1.2.3 Classification of Bricks Based on Manufacturing Method

On the basis of manufacturing method bricks are of the following kinds:

1. Extruded Brick: It is created by forcing clay and water into a steel die, with a very
regular shape and size, then cutting the resulting column into shorter units with wires
before firing. It is used in constructions with limited budgets. It has three or four holes
constituting up to 25% volume of the brick.

2. Molded Brick: It is shaped in molds by hand rather being in the machine. Molded
bricks between 50-65mm are available instantly. Other size and shapes are available in
6-8 weeks after the order.

3. Dry pressed Brick: It is the traditional types of bricks which are made by compressing
clay into molds. It has a deep frog in one bedding surface and shallow frog in another.

1.2.4 Classification of Bricks Based on Raw Materials

On the basis of raw materials bricks are of the following kinds:

1. Burnt Clay Brick: It is obtained by pressing the clay in molds and fried and dried in
kilns. It is the most used bricks. It requires plastering when used in construction works.

2. Fly ash clay Brick: It is manufactured when fly ash and clay are molded in 1000
degree Celsius. It contains a high volume of calcium oxide in fly ash. That is why usually
described as self-cementing. It usually expands when coming into contact with moisture.
It is less porous than clay bricks. It proved a smooth surface so it doesn’t need plastering.

3. Concrete Brick: It is made of concrete. It is the least used bricks. It has low
compression strength and is of low quality. These bricks are used above and below the
damp proof course. These bricks are used can be used for facades, fences and internal
brickworks because of their sound reductions and heat resistance qualities. It is also

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called mortar brick. It can be of different colors if the pigment is added during
manufacturing. It should not be used below ground.

4. Sand-lime Brick: Sand, fly ash and lime are mixed and molded under pressure. During
wet mixing, a chemical reaction takes place to bond the mixtures. Then they are placed
in the molds. The color is greyish as it offers something of an aesthetic view. It offers a
smoother finish and uniform appearance than the clay bricks. As a result, it also doesn’t
require plastering. It is used as a load bearing members as it is immensely strong.

5. Firebrick: It is also known as refractory bricks. It is manufactured from a specially

designed earth. After burning, it can withstand very high temperature without affecting
its shape, size, and strength. It is used for the lining of chimney and furnaces where the
usual temperature is expected to be very high.

Fig: 1.1 Brick work

1.3 Characteristics of Good Bricks
The characteristics of a good brick are

1. Size and Shape: The bricks should have uniform size and plane, rectangular surfaces
with parallel sides and sharp straight edges.

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2. Color: The brick should have a uniform deep red or cherry color as indicative of
uniformity in chemical composition and thoroughness in the burning of the brick.

3. Texture and Compactness: The surfaces should not be too smooth to cause slipping
of mortar. The brick should have precompact and uniform texture. A fractured surface
should not show fissures, holes grits or lumps of lime.

4. Hardness and Soundness: The brick should be so hard that when scratched by a
finger nail no impression is made. When two bricks are struck together, a metallic sound
should be produced.

5. Water Absorption: Water Absorption should not exceed 20 per cent of its dry weight
when kept immersed in water for 24 hours.

6. Crushing Strength: Crushing strength should not be less than 50 N/mm2.

1.4 Properties of Cement Bricks

Architects and structural engineers design buildings with concrete blocks (also
known as concrete masonry units, or CMUs) for a number of important properties: high
structural capacity, resistance to fire, resistance to water, variety of aesthetic possibilities
and insulating and acoustical advantages. In many cases, this minimum-maintenance
material may provide the most economical way to meet certain requirements of building
codes or the specialized needs of a client. ASTM International's Publication C140 - 09a,
"Standard Test Methods for Sampling and Testing Concrete Masonry Units and Related
Units," ensures that each concrete block meets minimum design expectations.

1. Structural Properties
While concrete blocks vary by type, their primary structural property is
compressive strength. The American Concrete Institute's (ACI) Publication 318,
"Building Code Requirements for Structural Concrete," contains the structural property
standards for concrete and 7-day and 28-day testing methods used to ensure that the
concrete blocks manufactured meet or exceed building codes throughout the United
States. ACI's 228.1R-03, "In-Place Methods to Estimate Concrete Strength," outlines the
standard in-place strength tests that estimate concrete strength during construction or
estimate concrete strength during the evaluation of existing concrete block structures.

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Inserting rebar (steel rods) into the cells (the openings in blocks--most blocks have holes
for ease of construction) or solid grouting the cells produces a significantly stronger
concrete block

2. Water Resistance
Permeability and porosity vary by unit type, but generally concrete blocks absorb
water. A mixture of course and fine particle material during manufacture produces a
significantly more waterproof concrete block wall. The amount of cement used in the
manufacture of concrete blocks affects the block's permeability; a mixture rich in cement
produces a less permeable block. Facing the blocks with a mixture of cement and fine
sand, using waterproof compounds during manufacture, or applying one of the various
washes available after erecting the blocks prevents the penetration of water.

3. Fire Resistance
Fireproof properties vary by coverage area and unit type. ACI's 216.1-97/TMS
0216.1-97, "Standard Method for Determining Fire Resistance of Concrete and Masonry,
Construction Assemblies," provides information on the fire-resistance rating, sometimes
called the fire rating, of concrete blocks. This document contains various tables that
include the fireproof values for the various aggregate-type concrete blocks, utilized in
restrained or unrestrained conditions, and their corresponding fire ratings. Utilizing
concrete blocks in any building design significantly increases its fire code rating.

4. Aesthetic Properties
The aesthetic properties of concrete blocks, once utilitarian and gray, have
become more important. Concrete block manufacturers now produce concrete blocks in
a wide range of colors, textures and finishes that architects utilize to great effect,
depending on the building design. Concrete block manufacturers develop new concrete
block shapes and sizes to meet an ever-evolving construction market.

5. Insulating Properties
The insulating properties of various concrete blocks vary by manufacturer, and
are dependent on the density of the block. Thermal conductivity tests performed by
manufacturers determines the insulating properties. By reducing the concrete block

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density by volume and producing a lower-weight block, manufacturers increase the heat-
insulating properties of the blocks. Solid grouting the cells of concrete blocks increases
the insulating properties of a concrete block wall.

6. Acoustic Properties
The acoustic properties of any concrete block structure depend on the form of
construction, the junctions and connections between the blocks and the properties of the
materials used during manufacture of the blocks. Following concrete block installation
recommendations as provided by the ACI and other organizations significantly increases
acoustic control within the building.

1.5 Masonry
It is an assembly or combination of small building units made of bricks or stones
or concrete. Normally the masonry units are laid with cement mortar, which binds them
together to create a structure. Masonry construction can provide beautiful walls and
floors at economical prices Masonry consists entirely or partially of hollow or solid units
which is laid closely in mortar.

1.5.1 Stone Masonry

Stone masonry is made of stone units bonded together with mortar. Stone
masonry is used for the construction of walls, columns, lintels, arches, beams, etc., of a
building. Stones are abundantly available in nature and when cut and dressed to proper
shapes, they provide an economical material for the construction of various parts of
building. The materials used for stone masonry are stone and mortar.

1.5.2 Types of stone masonry

Rubble masonry

It is rough, uneven building stone set in mortar, but not laid in regular courses. It may
appear as the outer surface of a wall or may fill the core of a wall which is faced with
unit masonry such as brick or cut stone. This consists of blocks of stones either undressed
or roughly dressed and having wider joints.

 Random rubble masonry

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 Coursed
 Square rubble masonry
 Coursed
 Uncoursed
 Polygonal rubble masonry
 Flint rubble masonry
 Dry rubble masonry

1.6 General principles to be followed in the construction of masonry:

1. The stone used shall be hard, durable, and tough. All stones should be laid on its natural
bed.
2. The pressure acting on the stones should not act parallel to the bedding planes. This
will try to split the stones. Sometimes stones used in corbels are laid with pressure acting
parallel to bedding planes.
3. The bond stones and headers should not be of dumb-bell shape.
4. Large flat stones should be laid under the ends of girders, roof trusses, etc.
5. In all slopping retaining walls, the beds of the stones and the plan of the courses should
be at right angles to the slope.
6. All laid fine dressed stone work should be protected against damage during further
construction by means of wooden boxes.
7. Jambs for door and window openings should be made of quoins which are equal in
height to the course. They should be in breadth equal to at least 1½ times the height of
the course and their length should be at least twice the height.
8. All the surfaces should be kept wet while the work is in progress and also till the mortar
has set.
9. Double scaffolding will be used wherever it is difficult to fit in the stones later on.
10. All the portions of the masonry should be raised uniformly. Wherever this is not
possible, the stone work built earlier should be raked (stepped) so that the new work can
be bonded well with the old.
11. Sufficient through stones should be used and they should form ¼th of the area in
elevation.

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12. The hearting of the masonry should be properly packed with mortar and chips, if
necessary, to avoid any hollows or very thick mortar joints.
13. Vertical faces of the masonry walls should be checked with a plumb rule and the
battered faces should be tested with wooden template corresponding to the batter and a
plumb rule to ensure a constant batter.
14. The stones used in the masonry should be wetted before use to avoid moisture being
sucked from the mortar.

1.7 Bonds
Bond is the arrangement of bricks or stones in each course, so as to ensure the
greatest possible interlocking and to avoid the continuity of vertical joints in two
successive courses, both on the face and in the body of a wall.

1.7.1 Objectives of Bonds

1. The primary objective of providing a bond is to break the continuity of the vertical
joints in the successive courses both in the length and thickness of masonry structure. As
a result, the structure will act as a bounded mass and its load will be transmitted uniformly
to the foundations.
1. To ensure longitudinal and lateral strength of the structure.
2. To provide pleasing appearance by laying bricks symmetrically.
3. To do masonry work quickly by engaging more masons on a job at a time.

1.7.2 Types of Bonds

1. Header Bond
2. Stretcher Bond
3. English Bond
4. Flemish Bond
A. Double Flemish Bond
B. Single Flemish Bond
5. Raking Bond
A. Herring Bone Bond
B. Diagonal Bond
6. Zig-Zag Bond

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1. Header Bond
A header is the shorter face of the brick as seen in the elevation. In header bond
brick masonry, all the bricks are arranged in the header courses. This type of bond is
useful for the construction of one brick thick walls.
2.Stretcher Bond
A stretcher is the longer face of the brick as seen in the elevation. In stretcher
bond masonry all the bricks are arranged in stretcher courses. However, care should be
taken to break vertical joints. This type of construction is useful for the construction half
brick thick partition wall.

Fig: 1.2 Stretcher Bond

3. English Bond
The bond, in which headers and stretchers are laid in alternate courses.
The following are the salient features of English bond:
1. Headers and stretchers are laid in alternate courses.
2. In each heading course, a queen closer is placed next to quoin header and the
remaining bricks are laid as headers.
3. Every alternate header in a course comes centrally over the joint between two
stretchers in the course below.
4. The same course will show headers or stretchers on face and back, if the thickness of
the wall is an even multiple of half bricks
5. The same course will show headers on the face and stretchers on the back and vice
versa, if the thickness of the wall is an odd multiple of half brick.
6. The middle portion of the thicker walls consists entirely of headers.
7. Every transverse joint is continuous from face to face.

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4. Flemish Bond
In this type of bond each course comprises of alternate header and stretcher. The
alternate courses start with stretcher and header. To break the vertical joints queen closers
are required, if a course starts with header. Every header is centrally supported on the
stretcher below it.
Flemish bonds may be further classified as
 Double Flemish Bond
 Single Flemish Bond
In case of Double Flemish bond, both faces of the wall have Flemish look, i.e., each
course consist of alternate header and stretcher, whereas Single Flemish bond outer faces
of walls have Flemish look whereas inner faces have look of English bond. Construction
of Flemish bond needs greater skill. It gives more pleasing appearance. But it is not as
strong as English bond. If only pointing is to be used for finished wall, Flemish bond
may be used to get good aesthetic view. If plastering is going to be used, it is better to
use English bond.

5. Raking Bond
The bond in which all the bricks are laid at an angle other than 90º to the facing
and backing of the wall is known as Raking bond. This bond is used for doing inner
filling of walls at suitable intervals to improve their longitudinal strength. The angle of
rake between any two adjacent courses should be 90 º to attain maximum transverse
strength of the wall. This bond can also be used as paving in case of brick floors.

6. Zig-Zag bond
This is similar to herring-bone bond with the only difference that in this case the
bricks are laid in a zig-zag fashion. This is commonly adopted in brick paved flooring.

1.8 Types of Masonry walls

1. Load Bearing Masonry Walls

Load bearing masonry walls are constructed with bricks, stones, or concrete
blocks. These walls directly transfer loads from the roof to the foundation. These walls
can be exterior as well as interior walls. The construction system with load bearing walls

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are economical than the system with framed structures. The thickness of load bearing
walls is based on the quantity of load from roof it has to bear. For example, a load bearing
wall with just a ground floor can have its outer walls of 230mm, while with one or more
floors above it, based on occupancy type, its thickness may be increased. The load
bearing walls can be reinforced or unreinforced masonry walls.

Fig:1.3 Load Bearing Wall

2. Reinforced Masonry Walls
Reinforced masonry walls can be load bearing walls or non-load bearing walls.
The use of reinforcement in walls helps it to withstand tension forces and heavy
compressive loads. The un-reinforced masonry walls are prone to cracks and failure
under heavy compressive loads and during earthquakes. They have little ability to
withstand lateral forces during heavy rain and wind. Cracks also develop in un-reinforced
masonry walls due to earth pressure or differential settlement of foundations. To
overcome such problems, reinforced masonry walls are used. Reinforcement in walls is
at required intervals both horizontally and vertically is used. The size of reinforcement,
their quantity and spacing are determined based on the loads on the walls and structural
conditions.

3. Hollow Masonry Walls

Hollow or Cavity masonry walls are used to prevent moisture reaching the
interior of the building by providing hollow space between outside and inside face of the
wall. This wall also helps in temperature control inside the building from outside wall as
the hollow space restricts heat to pass through the wall. When the wall is exposed to

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moisture for a sustained period and penetrates through the outer face, the water reaches
the cavity or the hollow space and flows down. Then they are drained through the weep
holes to the exterior of the building. These hollow spaces may be coated with water
repellent coating or damp-proofing to further reduce the ingress of moisture.

4. Composite Masonry Walls

These walls are constructed with two or more units such as stones or bricks and
hollow bricks. This type of masonry wall construction is done for better appearance with
economy. In composite masonry walls, two Wythes of masonry units are constructed
bonding with each other. While one Wythe can be brick or stone masonry while the
others can be hollow bricks. A Wythe is a continuous vertical section of masonry one
unit in thickness. These Wythe are interconnected either by horizontal joint
reinforcement or by using steel ties.

5. Post-tensioned Masonry Walls

Post-tensioned masonry walls are constructed to strengthen the masonry walls
against the forces that may induce tension in the wall such as earthquake forces or wind
forces. These walls are constructed from the foundation level and post-tensioning rods
are anchored into the foundation. These rods are run vertically between the wythes or in
the core of concrete masonry units. After the masonry wall construction is completed and
cured, these rods are tensioned and anchored on the steel place at the top of the wall.

1.8.1 Mortar
The paste obtained by mixing a binding material and a fine aggregate in suitable
proportions in addition to water is known as Mortar. Cement and Lime are used as
binding materials and Sand, Surkhi, Cinder, etc. are used as fine aggregates. The mortars
are named according to the type of binding material used in their preparation such as,
cement mortar, lime mortar, etc. The mortar prepared from simple earth is known as
"Mud Mortar". The mortar not only acts as a cementing bed between any two courses of
bricks but also, gives strength to the structure by holding the individual bricks together
to act as a homogenous mass.

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1.9 Difference between Red Bricks and Solid Concrete Blocks

Red bricks are one of the oldest and extensively used building material that is primarily
made from clay. Solid concrete blocks, on the other hand, are precast concrete blocks
manufactured from cement and fine aggregates.
The important difference between red bricks and solid concrete blocks are tabulated
below.

S. No Parameters Red Bricks Cement Concrete Bricks

1. Raw Materials Red bricks use the Solid Concrete blocks use
following raw materials: the following raw materials:
Lime Clay or Alumina, Ordinary Portland Cement,
Sand, Iron Oxide, Sand, Gravel, Water. In
Magnesia. The sand certain situations, fly ash
used for red brick can be used instead of fine
manufacture is mostly sand.
obtained locally.

Properties Red bricks are available Standard sizes of solid

in modular sizes of 190 concrete blocks are of
x 90 x 90mm and 190 x length 400, 500 or 600 mm
90 x 40mm. And also, in and height of 200, 100mm
non-modular sizes of and the width from 50, 75,
230 x 110 x 70 mm and 100, 150, 200, 250 or 300
230 x 110 x 30mm millimeters. The dimension
differs from manufacturer to
manufacturer.

Compressive The compressive The compressive strength of

Strength strength varies from one solid concrete block varies
class to another and based on the grade of
hence lies in the range cement used. Its

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between 3.5 to compressive strength varies
35N/mm2. from 4 to 5 N/mm2.

Dry Density The dry density also The dry density of the solid
varies depending on the concrete block is depended
class of brick. It on the grade of block. This
normally ranges from ranges from 1800 to 2500
1600 to 1920 kg/m3 kg/m3

Water The water absorption of Solid concrete blocks must

Absorption red bricks is not have a water absorption
recommended to be less value not greater than 10%
than 20% of its weight of its weight

Thermal The thermal Solid concrete blocks

Conductivity conductivity of red usually have a thermal
bricks is advised to have conductivity in the range 0.7
a value in the range of to 1.28W/mK.
0.6 to 1 W/mK.

Environmental The mortar consumed by Solid concrete blocks have

Impact red bricks is high due to flat and even surface that
its irregular surface hence demand less mortar
compared to redbrick.

Water Usage Curing requires more Solid concrete blocks

water require 7 to 14 days of
curing which demand high
amount of water compared
to red bricks.

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Cost Red bricks alone is The solid concrete blocks
cheap. But overall cost cost high as individual
including the cost of pieces. It consumes less
mortar and construction mortar. It has the advantage
is high as it demands that the same wall area can
more mortar. be constructed with less
number of solid concrete
blocks than red bricks.

Uses Red bricks can be used Solid concrete blocks are

as a structural material employed in construction to
for the construction of act both as load bearing and
structures like buildings, non-load bearing in walls,
foundations, arches, panel wall and partition
pavement, and bridges. walls. This can also be used
These can be also used as backing for piers,
for aesthetic purposes retaining walls, other facing
like landscaping, facing materials, chimneys, fire
works and many other places and garden walls etc.
architectural purposes.

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CHAPTER 2
LITERATURE REVIEW
1. Umme sameen et.al 2017

Generally conventional bricks of Bangladesh are sintered at 950o to 1050°C temperature.

These bricks have compressive strength between 2600 and 3000 psi. To lower the
sintering temperature, waste glass powder (borosilicate glass, colored glass, and soda
lime glass) was used in the production of bricks and sintering temperature was
successfully lowered to 650°C. Among the glass powder used, soda lime glass produced
the best result. Compressive strength of the brick made with 50% soda lime glass was
around 31.36 MPa (4550 psi), which was much higher than that of conventional brick.
Higher percentage of soda lime glass resulted in degraded quality of bricks. Other
physical properties of bricks like bulk density, apparent porosity, water absorption and
shrinkage were also better than those of conventional one. Longevity of bricks increases
when they contain both glassy and crystalline phases. While conventional bricks possess
no or less amount of glassy phase, XRD patterns of the prepared brick sample showed
prominent glassy phase along with crystalline phase in it.

2. N. Gawali, Chetan 2012

Brick is the most important building construction material which is widely used
in residential and commercial structures. In load bearing structure the most important
component of masonry walls is nothing but a brick. In this we studied about the different
types of fly ash bricks, various ingredient materials and their proportion, Partial
replacement of cement and lime with granite powder and their effects on different
properties like compressive strength and water absorption. From this study, it has been
Concluded that use of granite powder as a partial replacement of cement is economical,
ecofriendly, and cost-effective.

3. Shalini Kashyap et.al07 July 2020

Hollow fly ash concrete blocks have been utilized as a development material in
numerous immature and creating nations. Hollow fly ash concrete blocks are set up

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without planning details and rules in the majority of the districts, by straightforward
blending of fly ash, concrete and total in a customary way by nearby makers. Past
investigations have indicated a huge variety in the mechanical properties of hollow fly
ash concrete blocks gathered from various locales. In this examination, various
procedures were utilized to improve the mechanical properties of Hollow fly ash concrete
blocks. Concrete and fly ash were utilized to grow new blend plans. Results indicated a
checked increment in the compressive quality of the recently fabricated Hollow fly ash
concrete blocks as contrasted and the ordinary blocks. Other mechanical properties
including the water retention and modulus of crack of the recently produced Hollow fly
ash concrete blocks additionally improved.

4. V. Jayanthi et.al December, 2018

From the industrial activities, an enormous number of solid wastes is generated,
which can cause adverse effects on the environment. Among these wastes, steel scrap is
one of the important solid wastes which is obtained from the lathe industries, disposed
of an open ground makes an unhealthy environment and soil contamination. The past
studies confirm the utilization of steel scrap wastes used in the construction industry as
well as in transportation and highway industry. This project emphasis on the innovative
use of steel scrap in the manufacturing of soil cement reinforced bricks.
To study the properties of soil cement reinforced bricks, compressive strength test, water
absorption test and weight comparison were performed on bricks with different
proportions of steel scraps. From the results, it is observed that the compressive strength
of brick increased and the water absorption rate is decreased upon increasing the
percentage of steel scrap content.

5. Somu S Krishna et.al

Bricks are the major construction material, as it is made from clay which is
abundantly available in nature. Bricks helps to regulate the interior temperatures by its
unique feature of absorbing heat and slow-release rate. But on the other side, the amount
of air pollutants produced from the brick kilns in India are approximately 0.94 million
tons of particulate matter (PM); 3.9 million tons of CO and 127 million tons of CO2 per
year. In this research work, ecofriendly soil cement bricks are made with varying cement
content and various tests were conducted regarding compressive strength, hardness,

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water absorption, efflorescence and soundness of bricks. These are cost effective, energy
efficient materials compared to the normally clay burnt bricks and fly ash bricks.

6. H. Maizir et.al 30 September to 2 October 2019

Cellular Lightweight Concrete (CLC) brick is a material composition for wall

building made of Portland cement, water, and fine aggregate blended with a foaming
agent. The weight of the brick is light due to the air cavities formed in the CLC brick.
The number composition of sand and cement in the CLC brick could improve the strength
of the bricks. Thus, it is essential to find out the sand and cement consumption in order
to improve the rate of brick strength. The study aims to improve the strength of the CLC
bricks with different composition of the material and to find out the index properties of
the CLC bricks with the variable component of the materials. The study used an
experimental work in the material laboratory with two variations of the material
composition. The first variation is mixing concrete for the ratio of cement and sand of
1:2, while the second variation is mixing concrete for cement and sand ratio of 2:3. The
wet density of the CLC brick is about 800-900kg/m3, and the average compressive
strength test was conducted at ages 3, 7, 14, and 28 days for each test. Three identical
specimens were prepared for each test. The study resulted in the 28-day strength of the
CLC brick with a mass ratio of cement to sand 1:2 of 0.52 MPa, and the strength of the
CLC brick with a mass ratio of cement to sand 2:3 was 0.68 MPa. The first variation was
lower by 24.5% than the second variation in terms of strength.

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CHAPTER 3
METHODOLOGY

3.1 How to Make Cement Bricks

The small-scale manufacture of concrete bricks and blocks for masonry is well
suited to small businesses. Production can be carried out in the open, the process is simple
and equipment does not require high capital investment. The aim of this publication is to
provide the information needed to set up and run a block yard to manufacture concrete
bricks and blocks on a small scale. The publication is intended mainly for development
agencies, local authorities, builders’ associations, housing consultants, trainers, etc. but
could be of use to entrepreneurs and block yard managers. Aspects dealt with include the
feasibility study, selecting and establishing a site, selection of equipment, materials for
block making, trial mixes and production. This publication focuses on technical
information. Topics outside the scope of this leaflet are:

• Detailed cost analysis

• Manufacture of paving blocks

Bricks and blocks are masonry units and are referred to as such in SABS standards. Units
may be solid or hollow. The difference between bricks and blocks is one of size. In this
pamphlet “block” is used throughout, but the same principles apply to brick.

3.2 Feasibility Study

It is easy to make a concrete block. The successful block yard must however make
blocks of uniform quality and sell them at a price high enough to cover costs and make
a reasonable profit. Before you start a block yard, it is essential therefore to investigate
the economic feasibility of the venture. Determine first what demand there is for blocks
in your area (how many per month) and find out if there would be competition from other
block yards.

Then estimate costs based on various methods of production and output

Factors which influence unit cost include:
• Purchase price or rental of site

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• Cost of site improvements: fencing, paved areas for production and stockpiles,
pathways, roadways, and buildings.
• Cost of equipment: concrete mixer, blockmaking machine, miscellaneous equipment,
e.g. wheelbarrows, trolleys and tools.
• Cost of services: water and electricity
• Material costs (See section 7.2 for mix ratios. As a first estimate, assume that 1 m3 of
loose aggregate will yield 0,7 m3 of concrete volume.)
• Wastage
• Maintenance costs of site and equipment
• Output: number of blocks per day – dimensions of block, solid or hollow.
• Labor costs
• Cost of finance

3.3 Selecting a Site

In selecting a site, consider location, access, ground slope and size. Each of these is
discussed below

3.3.1. Location

This should be considered in relation to:

• Supply of raw materials
• Market for blocks
• Location of the labour force
• Security of the area
• Availability of services such as roads, water, sewerage, and electricity

3.3.2. Access
The site must be accessible to trucks delivering aggregates and cement and
collecting finished blocks.

3.3.3. Ground Slope

Ideally, the site should be level or nearly so. Steep slopes make handling and
production difficult. Terracing a steep slope is expensive and could involve ongoing
maintenance.

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3.3.4 Size
The site should be big enough for aggregate stockpiles, cement storage,
production (slab or stationary machine), block stacking, staff facilities, an office and on-
site access.

3.4 Establishing the Site

The site should have provision for stockpiling aggregates and storing cement, a
production area, a stacking area, staff facilities, an office, and access between different
areas and facilities. Each of these is discussed below. Aggregate stockpiles Aggregates
must be stockpiled in such a way to: prevent contamination by soil or leaves, ensure
different aggregates are kept separate and rainwater can drain away. Ideally therefore,
aggregates should be stockpiled on a concrete slab. If this is not done, the layer of
aggregates in contact with the soil should not be used for production. Aggregates must
not be stockpiled under trees. Partitions should be erected between different types of
aggregate. Stockpiles should be on a slight slope so that rainwater does not collect in the
aggregates.

3.5 Cement Store

Cement must be kept dry while it is being stored. The best way to store cement is
in a silo. For most small-scale block yards however, cement will be delivered in bags.
Cement in bags should preferably be stored in a weather-proof room. Bags should be
stacked on a plastic tarpaulin or on closely spaced wooden strips so that they do not
absorb damp from the floor. The storeroom should be big enough to hold at least a week’s
supply of cement. If it is not possible to provide a storeroom, cement in bags should be
stored in stacks raised above the ground and completely covered with waterproof
tarpaulins

3.6 Block Making Equipment

There are two basic types of equipment, depending on the method of moulding
the blocks
• Stationary machines that mould blocks, one or more at a time, on pallets.
• “Egg-layer” machines that mould blocks on a concrete slab.
Some advantages and disadvantages of stationary and “egg-layer” machines. For both
types, equipment available includes small hand operated devices, which have limited

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output, and a range of electrically powered machines of high output. Detailed information
on the output and price of specific machines should be obtained from manufacturers and
suppliers. A list of suppliers is available from Cement & Concrete.

3.6.1 Concrete Mixer

It is possible to make blocks on a small scale without a concrete mixer. Hand
mixing has the advantage of reducing the amount of capital required and providing
employment, but may limit output and may not always be thorough. Hand mixing should
be done with shovels on a concrete slab or flat steel sheet. Never mix directly on the
ground because this results in contamination of the mix. A pan mixer is the only type of
machine mixer suitable for block yards. Pan mixers, with a forced mixing action, can
cope with the semi-dry mixes used for making blocks. Drum mixers do not work because
they cannot mix the semi-dry concrete. The output of the mixer should match that of the
blockmaking machine. A mixer of adequate capacity for making hollow units may have
insufficient capacity for solid units.

3.6.2 Miscellaneous equipment

This includes wheelbarrows, batching containers, trolleys (for moving blocks), shovels,
hosepipes, and plastic sheeting,

Materials for block making

3.7 Cement
All cement must meet the requirements of IS 4031 part 6 for Common cement or
IS 4031 for Masonry cement and the National Regulator for Compulsory Standards
(NRCS) requirements as detailed in NRCS VC9085. Bags should be clearly marked with
the strength grade, notation indicating composition and a Letter of Authority (LOA)
number issued by the NRCS. An LOA is issued for each cement type from each source.

Note: That Masonry cements complying with IS 4031 part 6 are not permitted to
be used in concrete. Masonry cements are therefore not suitable for use in making
concrete bricks and blocks. Cement strength class should be 42,5N or higher because the
concrete must develop strength as rapidly as possible.

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3.8 Aggregates
Sand and stone are used for most block production. Clinker or hard-burnt ash
often contains harmful impurities and should not be used as aggregate unless it is found
to be acceptable by laboratory test. Good quality clinker can be used instead of sand or
stone but blending with sand or stone may be necessary. Sand and stone are fragments
of rock and differ only in size. Sand particles will pass through a sieve with 4,75 mm
square openings. Stone particles will not because they are too large. All aggregates
should be clean and not contain organic matter such as roots or humus.

Aggregates should not contain more than a very small fraction of clay.

The following aggregates may be considered:

• Fine sand with particles mainly smaller than 1 mm: pit, Fine River, or dune sand
• Coarse sand with the biggest particles approximately 5 mm in size: crusher, pit or coarse
river sand.
• Stone with a maximum size of 13 mm for bricks or solid blocks or 10 mm for hollow
blocks.
It is normally possible to make blocks with coarse sand on its own. Alternatively,
combinations of aggregates may be used:
• A blend of coarse sand and fine sand
• A blend of fine sand and stone
• A blend of fine sand, coarse sand and stone for small-scale production, the best
aggregate or combination of aggregates is normally found by trial and error.

3.9 Water
Water that is fit for drinking is suitable. Most river and borehole water may be used.

3.10 Trial Mixes

The aim is to find a mix that will produce blocks that have an acceptable texture and are
strong enough but as cheap as possible. Because cement is more expensive than
aggregates, the lower the cement content the cheaper the block.

Strength of well cured blocks depends on:

• Aggregate: cement ratio
• Degree of compaction

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• Type (solid or hollow) and size of block

3.10.1 The degree of compaction depends on:

• Overall grading of the aggregates

• Particle shape of aggregates
• Aggregate: cement ratio
• Water content
• Compactive effort

It can be seen that strength depends on a number of interrelated factors. It is

therefore not possible to design a mix in a laboratory. Instead, a trial-and-error process,
using the equipment of the block yard, is followed. This process aims to arrive at the best
combination of aggregates and the right aggregate: cement ratio.

3.11 Starting Points

The following starting points are suggested.

3.11.1 Aggregates

First try coarse sand only. Then try replacing some of this by fine sand and some
by stone, if these materials are available. Alternatively, if coarse sand is not available,
try different blends of fine sand and stone.

3.11.2 Aggregate: cement ratio

Try 6:1, 8:1 and 10:1 by loose volumes (230, 300 and 380 ℓ of aggregate respectively
per 50 kg bag of cement).

3.11.3 Trials

For each combination, make up a batch of concrete with optimum water content and,
Using the yard’s block making equipment, mould some blocks. Because block density is
a good indicator of strength, blocks can be assessed by weighing them as soon as they
are demoulded. Adjust the mix until the heaviest block is achieved. The next step in
assessment of strength is to look out for breakages to corners and edges of cured blocks.
(If blocks break when handled, they are clearly too weak.) Strength can also be assessed
by knocking together two blocks, after curing and drying out. A ringing sound indicates

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good strength while a hollow thud probably means that the blocks are too weak. Ideally,
blocks should be laboratory tested for strength. The National Building Regulations
require nominal strengths of 7 MPa for solid units and 3,5 MPa for hollow units for single
storey houses and buildings. Also assess the surface texture of the blocks. If the texture
is too smooth, reduce the amount of fine material in the mix; if it is too coarse, increase
the amount of fine material.

3.12 Production
To minimize breakages in cold weather, increase the cement content of the mix
or the curing period before moving blocks.

3.12.1 Ordering and Stockpiling Materials

Aggregates and cement should be ordered in good time. Stocks should be
sufficient to prevent stoppages due to lack of material. As a rough guide, using an
aggregate: cement ratio of 8:1 by loose volumes, three and a half bags of cement and a
cubic meter of aggregate will be enough to make about 400 bricks. The number of blocks
produced from the same quantity of material will depend on block size and whether they
are solid or hollow. Aggregates must be stockpiled in such a way that contamination is
prevented and mixing of different types is prevented Cement must be stored in such a
manner that it is kept dry Cement in bags should be used within one month of being
delivered.

3.12.2 Batching
Cement, if supplied in bags, should preferably be batched by the full bag. Cement
supplied in bulk may be weighed (preferable) or batched by loose volume (not
recommended). It is important to batch all materials accurately. Batching containers, e.g.,
wheelbarrows, buckets, drums, and wooden boxes, should be loosely filled to the brim
and struck off flush with it. To avoid errors, there should be enough containers for a full
batch to be made without using any container more than once. Dented or broken
containers must not be used. The amount of water to be added to the mix is judged by
eye and by doing some simple tests (see Water content below). Time can be saved if,
once the approximate quantity of water per batch is known, about 90% of this is measured
out and added to the mix at the start of mixing. The rest of the water can then be judged
by eye and by test.

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3.12.3 Water content

Water content is critical. The mixture must be wet enough to bind together when
compacted, but it should not be so wet that the blocks slump (sag) when the mould is
removed. A common mistake is the use of mixes that are too dry, resulting in incomplete
compaction. The moisture content should be as high as possible as this allows better
compaction and thus gives the best strength. Moisture content is approximately right
when ripple marks form on a steel rod or the back of a shovel when it is rubbed against
some of the mixture. The water content is just over optimum when ripple marks start
appearing on blocks when they are demoulded.

3.12.4 Mixing
Hand mixing should be done, using shovels, on a level concrete slab or steel plate.
First spread the sand out 50 to 100 mm thick. Then distribute the cement, and stone if
any, evenly over the sand. Mix aggregate and cement until the color is uniform. Spread
the mixture out, sprinkle water over the surface and mix. Continue with this process until
the right amount of water has been mixed in for machine mixing, first mix aggregate and
cement then add water gradually while mixing until water content is correct.

Fig: 3.1 Mixing of Bricks

3.12.5 Moulding

Hand operated machines should be used as instructed by the manufacturer. The

mould of a powered machine should be filled until approximately six to eight cycles of
compaction are required to bring the compacting head to its stops. Too little or poor
compaction should be avoided as it results in greatly reduced strengths. Demoulding

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removal of the mould should be done carefully so that the fresh blocks are not damaged.
Fresh blocks should be protected from rain (with plastic sheets or any suitable covering)
and from the drying effects of the sun and wind until curing starts. In some cases, it may
be necessary to protect blocks from frost damage. Covering with plastic sheeting with
the edges held down is normally sufficient. To minimize breakages in cold weather it
may be necessary to increase the cement content of the mix, or the curing period before
moving blocks

Fig: 3.2 Moulding of Bricks

3.12.6 Curing
Curing is the process of maintaining a satisfactory moisture content and a
favorable temperature in the blocks to ensure hydration of the cement and development
of optimum strength. In the South African climate, it is normally sufficient to cover
blocks with plastic sheeting to prevent moisture loss (or to spray blocks with water,
provided block surfaces do not dry out and the water does not freeze). The day after
production, blocks should be removed from the production slab or pallets and stored in
the stacking area, ready for curing. Stacks should be carefully built to avoid chipping
edges and corners.

Blocks should be cured for at least seven days.

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Fig: 3.3 Curing of Bricks

3.13 Quality control

Three aspects should be monitored to ensure quality masonry units: strength,
dimensions, and shrinkage.

3.13.1 Strength
Quality of blocks should be controlled so that strengths are adequate (to avoid
breakages and rejection by customers) and mixes are as economical as possible. Ideally,
blocks should be regularly tested for strength and mixes and production processes
modified if necessary. If testing is impracticable or unaffordable, block strength should
be continually assessed by noting whether corners and edges, or even whole blocks, tend
to break in handling. Strength can also be assessed by knocking two mature bricks
together Assessment testing as described above is inherently inaccurate and so it is
recommended that the blocks are tested for strength in a compression testing machine.

3.13.2 Dimensions
The length and width of the units are determined by the mould and will not vary
greatly. However, the height can vary and should be monitored using a simple gauge.
Units of inconsistent height will lead to difficulties in the construction of masonry and
possible rain penetration.

3.13.3 Shrinkage
Concrete masonry units shrink slightly after manufacture. In order to avoid this
happening in the wall, blocks should be allowed to dry out for at least seven days before
being used for construction.

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3.14 Tests on Bricks

To know the quality of bricks following 7 tests can be performed
In these tests some are performed in laboratory and the rest are on field.
• Compressive strength test
• Water Absorption test
• Efflorescence test
• Hardness test
• Size, Shape and Color test
• Soundness test
• Structure test

3.14.1Compressive strength test:

This test is done to know the compressive strength of brick. It is also called
crushing strength of brick. Generally, 5 specimens of bricks are taken to laboratory for
testing and tested one by one. In this test a brick specimen is put on crushing machine
and applied pressure till it breaks. The ultimate pressure at which brick is crushed is
considered. All five brick specimens are tested one by one and average result is taken as
brick’s compressive/crushing strength.

Fig: 3.4 Compressive Strength

REULTS: Compressive strength of brick are following:

1) Compressive strength of first-class Common building brick is 175 kg/cm2,

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2) Compressive strength of second-class brick is 110 kg/cm2,

3) Compressive strength of sun-dried brick is 25 – 45 kg/cm2,

3.14.2Water Absorption test:

In this test bricks are weighed in dry condition and let them immersed in fresh
water for 24 hours. After 24 hours of immersion those are taken out from water and wipe
out with cloth. Then brick is weighed in wet condition. The difference between weights
is the water absorbed by brick. The percentage of water absorption is then calculated.
The less water absorbed by brick the greater its quality.
Results: Good quality brick does not absorb more than 10% water of its own weight.

Fig:3.5 Water Absorption

3.14.3 Efflorescence Test:

The presence of alkalies in bricks is harmful and they form a grey or white layer
on brick surface by absorbing moisture. To find out the presence of alkalis in bricks this
test is performed. In this test a brick is immersed in fresh water for 24 hours and then it’s
taken out from water and allowed to dry in shade. If the whitish layer is not visible on
surface it proofs that absence of alkalis in brick. If the whitish layer visible about 10% of
brick surface, then the presence of alkalis is in acceptable range. If that is about 50% of

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surface then it is moderate. If the alkalies’ presence is over 50% then the brick is severely
affected by alkalies.

Results: No efflorescence visible on all bricks.

If that is about 50% of surface area then it is moderate. If the alkali’s presence is
over 50% of the brick surface area, then the brick is severely affected by alkalies.

3.14.4 Hardness Test:

In this test a scratch is made and on brick surface with a hard thing. If that does
not leave any impression on brick then that is good quality brick. Determined by using
drop test.

RESULTS: When bricks are dropped from the height of 1 to 1.2m (4 feet), it should not
crack or break.
This ensures the durability and quality of bricks.

3.14.5 Size, Shape, and Color Test:

In this test randomly collected 20 bricks are staked along lengthwise, width wise
and height wise and then those are measured to know the variation of sizes as per
standard. Bricks are closely viewed to check if its edges are sharp and straight and
uniform in shape. A good quality brick should have bright and uniform color throughout.

RESULTS: Outer Wall brick Size 30 x20 x10cm, Inner Wall Size: 40 x20 x20 cm

3.14.6 Soundness Test:

In this test two bricks are held by both hands and struck with one another. If the
bricks give clear metallic ringing sound and do not break then those are good quality
bricks. Hence cement bricks are heavy this test is performed by trowel.

RESULTS: By striking the two bricks it gave metallic sound.

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Fig: 3.6 Soundness Test

3.14.7 Structure Test:

In this test a brick is broken or a broken brick is collected and closely observed.
If there are any flows, cracks or holes present on that broken face then that is not good
quality brick.

Fig:3.7 Verifying the Quality of bricks

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CHAPTER-4

ESTIMATION OF BRICK WORK

Brick is most commonly used building material and used for constructing walls,
roofs, paving floors, etc. The term brick is referred as a rectangular unit composed of
clay. Bricks are available in different classes and sizes. The sizes of brick may vary
according to the region. To know about Brickwork calculation, learn some basic info on
Bricks.

4.1. No. Of Bricks required for 1 Cubic Meter or 1m3. (Brickwork Calculation)

 Calculate the Volume of Single brick:

Standard Size of Brick is varied according to the region. The size of brick is 30cm x
20cm x 20cm for outer wall and 40cm x20cm x10cm for inner wall.

 Unit Conversion

Converting Cm to m for ease in calculation.

Volume of outer wall Brick = 30cm x 20cm x 20cm= 0.3m x 0.2m x 0.2m
Volume of Inner wall Brick = 40cm x 20cm x 10cm= 0.4m x 0.2m x 0.1m
Volume of Brick in Cu.m (outer) =0.012 cu.m
Volume of Brick in Cu.m (Inner) =0.008 cu.m

Volume required for one Cu.m or 1m3 (1m x 1m x 1m)

Total Volume Required = 1Cu.m or 1m3

Volume of Each brick (outer) = 0.012 m3

Volume of Each brick (inner) = 0.008 m3
No. of Bricks in 1m3 (outer) = 1/0.012 = 84 Bricks

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No. of Bricks in 1m3 (inner) = 1/0.008 = 125 Bricks

Hence: 84, 125 (outer, inner) bricks are required for 1 cubic metre or 1m3 of bricks.

4.2 Calculation of Number of Bricks required in a wall

Bricks are bonded each other using 1:6 Cement Masonry. We generally adopt 10-
16mm of thickness between each layer of Bricks. Therefore, the standard thickness of
Cement Masonry layer in Brickwork is 0.39″ or 10mm
 Adding mortar thickness to brick
Outer Size of brick is 30cm x 20cm x 20cm
Inner Size of brick is 40cm x 20cm x 10cm

Fig: 4.1 Setting and Adding of Thickness of the Brick

Outer wall brick

Add 1 cm to all sides of brick (30 cm+1cm, 20 cm+1cm, 20 cm+1cm)
The size of brick with mortar thickness is 31 cm x 21 cm x 21 cm
Unit Conversion cm to ft (1.01706 x 0.688976 x 0.688976)

Inner wall brick

Add 1 cm to all sides of brick (40 cm+1cm, 20 cm+1cm, 10 cm+1cm)
The size of brick with mortar thickness is 41 cm x 21 cm x 11 cm
Unit Conversion cm to ft (1.34514 x 0.688976 x 0.328084)
Consider Front face area of the brickwork in calculating the no. of bricks

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From Fig: Front face area of brickwork = L x D

Fig: 4.2 Front face of brickwork

4.3 Calculate the Bricks in Each Room

Fig: 4.3 Typical Floor Plane

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Area of Bed Room

Outer Wall
1)2 (5.60 x 3) =33.6 m2
2)3.81 x 3=11.43 m2
3)2 (4.22 x 3) =25.32 m2

Inner Wall

1)3.39 x 3=10.17 m2
2)3(3.39 x 3) =30.51 m2
3)2 (4.06 x 3) =24.36 m2

Area of Drawing room

2 (4.27 x 3) =25.62 m2

Area of Living or Dining Room

5.70 x 3=17.1 m2

Inner Wall
3.70 x 3=11.1 m2

Area of Kitchen Room

2 (3.68 x 3) =22.08 m2

Inner Wall
2.87 x 3=8.61 m2

Area of Puja Room

1.43 x 3=4.29 m2

Inner Wall
2 (1.33 x 3)=7.98 m2

Area of Toilets
1)1.37 x 3=4.11 m2
2)1.53 x 3=4.59 m2
3)1.54 x 3=4.62 m2

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Inner Wall
2.34 x 3=7.02 m2
Total Area of outer brick work =152.76m2

Fig: 4.4 Sample of Outer Brick

Total area of inner brick work =99.75m2

Fig: 4.5 Sample of Inner Wall Brick

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Dimensions of RCC Bed in Brickwork calculation:

The length of bed goes up to the length of brick work and bed is attached to
Columns for transferring the vertical load.
Depth or thickness of the bed may vary between 0.0762 m to 0.1016 m (Refer
above fig)

Fig: 4.6 RCC BED FOR 1m

(Let us consider the maximum i.e., 0.1016 m or 11 cm)

The length and Depth of Bed is 5.60 m x 0.1016 m [Front Face area]
Front face area of bed for outer brick (L x D) = 5.60 m x0.1016 m = 0.56896 m2
There are 7 beds in Outer brickwork = 7×0.56896 m2= 3.98272 m2
There are 7 beds in Inner brickwork = 7×0.56896 m2= 3.98272 m2

Dimensions of Doors, Windows, and Ventilators Area Calculation

Doors
3(0.9144 m × 2.032 m) =5.574 m2 (W×D)

Windows
4 (0.9m × 1.2 m) = 4.32 m2 (W×D)

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Fig: 4.7 Doors, Windows, and Ventilator

Ventilators
5 (0.45 m × 0.6 m) = 1.35 m2
Total Area = 59.67 m2
Deduct the area of RCC Bed, Doors, Windows, and Ventilators from the above wall
area for Brickwork calculation
Outer Wall Area – Deduct Area
152.76m2 – 3.98272 m2 + 59.67 m2 = 89.10728 m2
Front face Area of Each brick (0.31 × 0.21) = 0.0651 m2
Total No. of Bricks for outer wall = 89.10728/0.0651 = 2100 Bricks required
There are 22 Flats in each Floor i.e.
2100 x 22=46200 no’s
Inner Wall
Inner wall - Deduct the area of RCC Bed
99.75m2 - 3.98272 m2 =95.76728 m2
Front face Area of Each brick (0.41 m × 0.21 m) = 0.0861 m2
Total No. of Bricks for inner wall = 95.76728 m2/0.0861m2 = 2230 Bricks required

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2230 x 22 =49060 no’s

Total Number of Bricks for outer walls in G+10 building:
No. of Bricks for one floor x 10
46200x10 = 462000 no’s of Bricks required.
Total No. of Bricks for inner walls in G+10 building:
No. of Bricks for one floor x 10
49060 x 10 = 490600 no’s of Bricks required.

Total no of Bricks Required = 952600 no’s

Calculation of Cement Mortar (1:6)

Volume of cement in m3 = (1×1.33) / 7 = 0.19m3 Volume of 1 bag of cement = (Weight
/Density) = 50 / 1440 = 0.0347 m3
No. of cement bags needed = 0.19 / 0.0347 = 5.48 bags.
Approximately = 6 bags

Fig: 4.8 cement mortar

 Density of cement = 1440 Kg/m3

 Which means for 1m3 = 1440 Kgs required.

Amount of Sand required for mortar:

• Similarly, as Cement, Sand is calculated in terms of m3

• The Amount of Sand required for Brick masonry = Dry volume of mortar x 6/7 =
1.33 x 6/7 = 1.14m3
• In terms of Kgs, Density of Sand = 1600 Kgs/m3
• For 1.14 = 1.14x 1600 = 1824 Kgs

Department of Civil Engineering, ATRI 42

Brick Work in Construction of Residential Building G+10

CONCLUSION
1. The Brick v/s block debate is a very close one and anyone who is about to get a
construction started with have to deal with the comparing of pros and cons of both.
However, a lot depends on place, budget, and situation of the builder.

2. For some, brick masonry constructions are necessary because they ultimately want
lesser maintenance even when the cost of building is higher. Some people, on the other
side would prefer less cost of construction and regular renovations to keep the blocks
well maintained.

3. Cement bricks play a very important role in the world of construction. They are
sustainable, durable, and require little to no maintenance.

4. They are low maintenance because they do not need painting and will not wear or chip
down. Cement bricks product your house from damage during harsh environment
conditions. Furthermore, they are termite proof and fireproof as well.

5. The best thing about cement bricks is that they are perfect for cold weather because
they retain heat and remain warm for a long period.

6. Making of red bricks is not so eco-friendly it seems but the same can be said about the
blocks not being up for the purpose of recycle. Red brick-kilns remain under the scrutiny
of government and NGT while concrete block industry is on the rise at many places.

Department of Civil Engineering, ATRI 43

Brick Work in Construction of Residential Building G+10

REFERENCES

1. Efflorescence and Stains on Brick Walls, Guide to Good Building, Dept. of

Environment, Her Majesty's Stationery Office, London, No.75, 1972,1972

2. Brickwork: Efflorescence, Structural Clay Products, Great Britain, No.5, January

1974,1974

3. Bricks - Their Properties and Use, The Brick Development Association, Lancaster,
England, Published by the Construction Press Ltd., 1974,1974

4. Differential Movements in Buildings Clad with Clay Bricks 1. The Magnitude of

Differential Movements, Notes on the Science of Building, Commonwealth
Experimental Building Station, Australia, No.134, 1974,1974

5. Differential Movements in Buildings Clad with Clay Bricks, 2. The Design of

Expansion Gaps, Notes on the Science of Building, Commonwealth Building Station,
Australia, No.135, 1975,1975

6. Permanent Expansion of Clay Bricks: a Chronological Summary of the Publication of

Information for the Construction Industry, Brick Development Research Institute,
Techniques 5, University of Melbourne, Australia, August 1977,1977

7. Brick Masonry Cavity Walls: Detailing, Technical Notes on Brick Construction, Brick
Institute of America, No.21 B, January-February 1978,1978

8. Sulphate Attack on Brick Work, BRE Digest, Her Majesty Stationery Office, London,
1979,1979

9. Frost Durability of Clay Bricks - Evaluation Criteria and Quality Control, Proceedings
of the CBAC/DBR Manufacturers' Symposium, Proceedings No.8, Division of Building
Research, NRCC, NRCC 23294, 7-8 March 1984,1984

Department of Civil Engineering, ATRI 44

Brick Work in Construction of Residential Building G+10

10. Allen, D.E, Damage to Brick and Stone Veneer on Tall Buildings, Division of
Building Research, NRCC, Building Practice Note No.7, 1978, pp.1,1978

IS: 2185- 1967 (Hollow cement concrete blocks)

IS: 4860-1968 (Specification for acid-resistant bricks)

IS: 5779-1986 (Specification for burnt clay soling bricks)

IS: 2691-1988 (Specification for burnt clay facing bricks)

Department of Civil Engineering, ATRI 45