Designer Block. Architectural Feature Masonry New South Wales

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1 Designer Block Architectural Feature Masonry New South Wales

2 Designer Block Commercial New South Wales Boral Masonry has been supplying coloured and textured blocks for over 25 years to the Australian architectural community. To meet the need of popular composite building styles that require varying finishes and materials, Boral Masonry in consultation with designers have developed a palette of 4 contemporary colours and 5 bold textures. The Designer Block TM range also utilises the latest pre-sealing technology to reduce water absorption, and hence reduce the possibility of efflorescence, mould or mildew staining. 01

3 Designer Block Colours and Textures New South Wales Essential Colours Smooth Face Shot-Blast Face Honed Face Polished Face Split Face Alabaster Almond Pearl Grey Charcoal Five Innovative Textures Smooth Face A finely textured finish created through the standard moulding process. Shot-Blast Face This process subtly exposes the aggregates, producing a weathered, sawn stone-like finish. Honed Face The honing process grinds 2-3mm from the block surface, producing a matt exposed-aggregate finish. Polished Face This involves producing a denser block which is honed and then buffed. Polishing enriches the colour of the aggregates. The finely finished polished surface is ideal for feature walls, trims and banding. Split Face The splitting process produces a bold textured, exposed aggregate finish. Designer Block Material Qualities Material Quantities for a 1 bag mix of Mortar M3 Mortar Mix (general purpose) One 20kg bag of Off-White cement and oxide# 100kg clean sand. (18 5.6kg) 0.1kg of Dynex or similar methyl cellulose plasticiser. This yields 0.08 cubic metres and will lay 60 to 70 Designer Blocks M4 Mortar Mix (exposure grade) One 20kg of Off-White cement and oxide# 80kg clean sand. (14 5.7kg) 0.1kg of Dynex or similar methyl cellulose plasticiser. This yields 0.06 cubic metres and will lay 45 to 55 Designer Blocks Notes One cubic metre of mortar will lay approximately 800 blocks. Twenty percent extra sand included for bulking. Masonry Units Boral Designer Block is manufactured in accordance with the provisions of Australian Standard AS/NZS4455:1997. Mortar Mortar mix options in AS3700 include cement; lime and sand in 1:1:6 proportions for M3 (general) and in 1:0.5:4.5 proportions for M4 (Exposure Grade). While these make better mortar, the adjacent mixes, without lime, are more common. Cement is now usually supplied in 20kg bags. The adjacent mixes are based on one 20kg bag per mix. Block Laying When core filling Designer Block walls, some seepage may occur due to high hydrostatic pressure. Ensure it is cleaned off before it dries, otherwise staining will occur. It is essential that the block work is kept clean from mortar smears. This will eliminate the need for aggressive acid based cleaning solutions which can damage the face or change the colour of the concrete blocks. #Oxide quantities below are approximate and assume sand is near white. Trial batches should be made and assessed for colour-match for blocks when dry. Contrasting mortar colour is not recommended due to difficulty of cleaning smears. Alabaster White oxide 0.8kg Almond Yellow oxide 0.1kg Pearl Grey Black oxide 0.01kg Charcoal Black oxide 0.5kg Joints should be finished with an ironing rod to make them smooth, dense and more water resistant. Raked joints are NOT recommended. Please refer to page 06 for Component range details and see back page for product lead times and additional information. 02

4 Designer Block Residential New South Wales Above Harry Seidler and Associates, used Split Face Designer Block to impart a warm texture both inside and outside this Birchgrove home. Above and Top Right Micheal Fountain Architects MFA used different surface finishes to create unique spaces in this Pittwater home. The rugged Split Face texture of the entry (above) contrasts with the finer Honed finish of the formal living room (top right). Above T.J. Antiohos and Associates combined Polished Charcoal blocks with white timber detailing in this unique residence. 03

5 Designer Block Commercial New South Wales This Page Ellington is a contemporary apartment development consisting of three four-storey buildings. Arkhefield Architects combined full and half height Split Face units for the exterior to create a wall that had a large, rough and uniform texture. Helping to emphasise the exterior s clean architectural lines is the Designer Block Alabaster colour. 04

6 Designer Block Commercial New South Wales Left Honed Designer Block creates an impressive blade wall in the Ultimo Community Centre, designed by Lawrence Nield and Partners Australia. Below Architects Woods Bagot used polished Alabaster bands with Split Face Designer Block panels in the design of Discovery House in Canberra. Designer Block provided the flexibility to achieve different textural finishes within the one modular material. Left and Above The most striking features of Prior + Cheney Architects design, were two dramatically curved walls that enclose and protect the entry forecourt from the elements. Designer Block TM Alabaster Smooth was predominantly used for this Beaconsfield Community Centre in Melbourne, Victoria. 05

7 Designer Block Component Range New South Wales Component Range Corner Bonding Detail Smooth, Shot-Blast, Honed and Polished Designer Block Split Face Designer Block (1 unit in 3 is half solid, for on-site bolstering for corners) Full Full* Recessed Web* 295mm Bolstered on-site to 295mm 95mm Full Recessed Web* 295mm mm 95mm Bolstered on-site Series 100 Corner Victorian Sill* Capping 40 (1 unit in 4 is half solid, for on-site bolstering for corners) *Made to order only. All these products are available in Honed, Shot-Blast or Polished finish. For corner applications, these products are available with the face and one end Honed, Shot-Blast or Polished, with the exception of capping. Split Face Designer Block 145mm 45mm Bolstered on-site to 345mm Series 150 Corner Full Half High* 45mm A B Cut Smooth face 200mm do not need special corner units 195mm Split Cut one block per course to 340mm length to maintain 1/2 bond pattern 145 Full* Recessed Web* B Full Recessed Web A Cut one block per course to 340mm length to maintain 1/2 bond pattern *Made to order only. Series 200 Corner Please refer to page 02 for detailed information on material quantities. For further information on corner detailing, please call the Specifier Line on or contact your local Boral Masonry sales office. 06

8 Designer Block Designer Block Additional Information Block Laying Masonry walls are to be constructed in accordance with AS3700:2001. Stock Colours and Textures Lead times apply to all coloured blocks. Longer lead times apply to Honed, Polished and Shot-Blast finishes as the product must be cured for four weeks to harden sufficiently before processing. Boral recommends part size blocks are cut/bolstered on site to maintain colour consistency. Textures Finishes including Honing, Polishing and Shot-Blasting are produced on a made to order basis. Lead times apply as the product must be cured for four weeks to harden sufficiently before processing. Contact your nearest Boral Masonry office for approximate lead times and premiums on special textured finishes. Designer Block is available standard with one face. Additional faces can be made to order on honed, polished, and shotblast finishes. A surcharge may apply. Not all finishes are available in all regions. Colour and Texture Variations The colours shown in this brochure are provided as an indication of the colours and textures available. Some variations in colour may occur due to changes in raw materials. In addition variation can occur between production batches. Brochure Colours The printed colours in this brochure are only a guide. Please ask to see a sample of your chosen colour/texture before specifying or ordering. Construction Notes 1. Blocks must be kept dry on site before use and when laid. Freshly laid walls must be covered overnight and when rain interrupts work in order to prevent moisture entering the cores of the blocks. 2. Do not put mortar on the web of the blocks. 3. Ensure that perpends are buttered on each side with a void in the middle. The mortar joints should be well ironed to provide a tight sealed joint. 4. Ensure mortar smears are removed before mortar sets as acid cleaning later can discolour the masonry. 5. It is important that retaining walls have good drainage behind the wall. 6. For non-grouted masonry, a horizontal weep hole at the floor joint of each core should be provided to drain water that may be trapped inside the blocks. Partially fill the bottom course blocks with 20mm blue metal or similar drainage material to prevent mortar droppings from blocking the weep holes. Boral Masonry reserves the right to change the details in this publication without notice. For a full set of Terms and Conditions of Sale please contact your nearest Boral Masonry sales office. Front Cover The Designer Block, in Alabaster with a Polished Smooth Face finish, has been used here by Wilson Davis Series Architects for the Harbord Open Plan Living project in NSW. Designer Block is a registered trademark of Boral Masonry Limited. Boral Masonry All Rights Reserved Boral Masonry Limited ABN Orders, product samples and sales enquiries NSW Clunies Ross Street, Prospect NSW 2148 Tel (02) Fax (02) For technical assistance: Call Specifier Line on Visit V010607