Design of Adhered Masonry Veneers for Multi-storey Buildings

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1 Design of Adhered Masonry Veneers for Multi-storey Buildings Presented by Dr. Mark D. Hagel, PhD., P.Eng Executive Director at the Alberta Masonry Council

2 Mark Hagel PhD. in civil engineering, BSc. in civil engineering, BSc. in actuarial science & applied math.

3 Mark Hagel Technical Services Engineer

4 Mark Hagel Building Envelope / Structural Engineer at HY

5 St. Pancreas Station - London Casaloma - Toronto

6 Outline Review of adhered masonry veneers (natural stone, manufactured stone and thin brick veneers). Adhered stone bond test program. (The why behind AMC recommendations). Design and detailing of adhered stone and adhered thin brick veneers above 10 over wood-stud and steel-stud structural backings. Design and detailing of adhered stone and adhered thin brick veneers over exterior insulation.

7 Types of Stone

8 Natural Stone Sedimentary: Metamorphic: 1. Limestone 2. Sandstone 1. Marble 2. Quartz-based 3. Slate 1. Smooth 2. Machine Tooled 3. Split face / Rock face 4. Chat sawn / Shot sawn 1. Smooth 2. Machine Tooled Igneous: 1. Granite 2. Basalt 1. Sawn 2. Honed 3. Polish 4. Machined

9 Natural Stone Varying physical properties depending on type (limestone, sandstone, etc) Compressive strength Modulus of rupture Freeze-thaw tests

10 Manufactured Stone Stone fabricated from lightweight concrete or calcium silicate to replicate all forms and finishes of natural stone. More consistent physical properties than natural stone (standardized by ASTM- C1670).

11 Types of Installation of Thin Stone Modular or Individual Unit Modular Unit (Dry Stack) Individual Unit (Jointed)

12 Thin Brick Veneer Units Typically ¾ (19 mm) but can be 3/8 (10 mm) to 1 1/8 (31 mm) thick. Can be extruded and fired as thin brick or cut after firing from solid units. Product cost the same cost or more less expensive than full brick because manufacturing cost (either cutting or cost of firing) are equal or more. Labour may be less expensive with full brick as masons can lay full bed more quickly.

13 ADHERED Stone Veneer

14 Adhered Thin Stone Veneer Natural Stone

15 Adhered Thin Stone Veneer Natural Stone

16 Adhered Thin Stone Veneer Manufactured

17 Adhered Thin Stone Veneer Manufactured

18 ADHERED Thin Brick

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21 Adhered Thin Brick Veneer

22 Adhered Thin Brick Veneer

23 Design Literature Available ASTM C , Standard Practice for Installation Methods for Adhered Manufactured Stone Masonry Veneer. ASTM C , Standard Specification for Adhered Manufactured Stone Masonry Veneer Units/. Brick Institute of America Thin Brick Veneer Tech note 28C/. CSA-A Annex A (removed from 2014 edition).

24 AMC - Adhered Stone Bond Testing

25 Failure Modes in the Field : Setting Bed / Stone Unit Interface

26 Failure Modes in the Field : Setting Bed / Stone Unit Interface

27 Failure Modes in the Field : Setting Bed / Scratch Coat Interface

28 Failure Modes in the Field : Setting Bed / Scratch Coat Interface

29 Shear Bond Test Setup

30 Shear Bond Test Type N Shear Bond Strength = 8.3 psi No useful information from this failure mode Shear Bond Strength = 14.0 psi Shear bond that should be the outcome of a ASTM-C482 Shear bond test

31 Shear Bond Test Type S Shear Bond Strength = 23.3 psi Shear Bond Strength = 23.1 psi

32 Shear Bond Test Polymer Modified Stone Veneer Mortar Matching Mortar Block Shear Bond Strength = 36.8 psi Shear Bond Strength = 33.4 psi

33 Shear Bond Test Thinset Mortar, Type N Mortar Block Shear Bond Strength = 78.7 psi Shear Bond Strength = 91.1 psi

34 Shear Bond Test Thinset Mortar, Structural Water Resistive Barrier, Type N Mortar Block Shear Bond Strength = 65.7 psi Shear Bond Strength = 79.6 psi

35 Shear Bond Test Thinset Mortar Water Barrier and Cement Board

36 Adhered Stone Testing Results To Date

37 Adhered Stone Testing Results To Date

38 Design of Adhered Stone Veneer Four Cases Stone trim (not a full wall, typically less than 6 in height i.e. corners, columns, or features). Walls 10 (3.2m) or less in height. Walls Greater than 10 in height. Adhered masonry veneers over exterior insulation.

39 Case 1 Stone Trim

40 CRU Adhered Stone Trim

41 Single Family Residence Adhered Stone Trim

42 Drystack Manufactured Stone or Natural Stone Veneers and Thin Brick Veneers Use pre-bagged Type S mortar for jointed or drystack applications. Drainmat optional. Low risk of water ingress and low risk of injury if debonding of units occurs.

43 Case 2-10 (3 m) Above Grade or Less

44 CRU Adhered Stone 10

45 Single Family Residence Adhered 10

46 Drystack Manufactured Stone or Natural Stone Veneers and Thin Brick Veneers Use pre-bagged Type S mortar or Polymer Modified Stone Veneer mortar for jointed or drystack applications. Drain mat recommended.

47 Case 3 - Walls over 10 (3 m) in Height

48 CRU Adhered Stone Above 10

49 Single Family Residence Adhered Stone Above 10

50 Movement Joints Above 10

51 Back-up Wall Deflection Structural engineers typically design this deflection, D for a limit of h/360 ( 3 / 8 in 10 feet). Brick Institute of America (BIA) Full bed brick veneer recommends h/480 to prevent cracking in brick veneer ( 1 / 4 in 10 feet). Direct adhered ceramic tile and thin brick design guide recommends deflection limit of h/600 i.e. ( 3 / 16 in 10 feet). D = h / 600

52 Drystack Adhered Stone Veneers

53 Drystack Manufactured Stone or Natural Stone Veneers and Thin Brick Veneers Use Laticrete Hi-bond Masonry Veneer Mortar, Flexbond exterior grade Modified Dry-set cement mortar or equivalent meeting all requirements of ANSI-A118.4 or ANSI-A118.15).

54 Drystack Manufactured Stone or Natural Stone Veneers and Thin Brick Veneers

55 Drystack Manufactured Stone or Natural Stone Veneers and Thin Brick Veneers

56 Drystack Manufactured Stone or Natural Stone Veneers and Thin Brick Veneers

57 Drystack Manufactured Stone or Natural Stone Veneers and Thin Brick Veneers

58 Drystack Manufactured Stone or Natural Stone Veneers and Thin Brick Veneers

59 Drystack Manufactured Stone or Natural Stone Veneers and Thin Brick Veneers

60 Jointed Adhered Masonry Veneers

61 Natural And Manufactured Stone and Thin Brick Veneers If Grout bagging is used for filling joints this is essentially a drystack application: Use Laticrete Hi-bond Masonry Veneer Mortar, Flexbond exterior grade Modified Dry-set cement mortar or equivalent meeting all requirements of ANSI-A118.4 or ANSI-A118.15).

62 Grout-Bag Installation of Adhered Thin Stone

63 Installation of Adhered Thin Brick Grout Bagged

64 Installation of Adhered Thin Brick Grout Bagged

65 Adhered Masonry Veneer Installed Like Traditional Stone Tied Masonry

66 Individual Units (Jointed) - Traditional Installation Method With Pre-bagged Type S Mortar and Ties

67 Individual Units (Jointed) - Traditional Installation Method With Pre-bagged Type S Mortar and Ties

68 Replicate Traditional Composite Stone Wall Mechanical Anchorage

69 Replicate Traditional Composite Stone Wall Mechanical Anchorage

70 Adhered Stone Installed Like Traditional Stone Masonry The ties should help better anchor the veneer to the wall. However, testing is still underway to conclude that this is an adequate substitute for modified dry-set cement mortars (thinset mortars). Until further research confirms, installations above 20 recommend to use thinset mortars.

71 Replicate Traditional Composite Stone Wall Mechanical Anchorage

72 Replicate Traditional Composite Stone Wall Mechanical Anchorage

73 Replicate Traditional Composite Stone Wall Mechanical Anchorage

74 Replicate Traditional Composite Stone Wall Mechanical Anchorage

75 Replicate Traditional Composite Stone Wall Mechanical Anchorage

76 Mechanical Anchorage Of Thin Brick

77 Mechanical Anchorage of Adhered Thin Brick Modular Panels Corner Detail

78 Mechanical Anchorage of Adhered Thin Brick Modular Panel with Built-in Drainage

79 Mechanical Anchorage of Adhered Thin Brick Great for interior applications can get much more consistent mortar joints more easily. May not be best suited for exterior applications: 1. Steel and aluminum are thermal bridges with high thermal transmittance. 2. The light gauge metals can warp with temperature fluctuations referred to as oil canning. 3. The mill galvanized light gauge steel is not that corrosion resistant and the thin gauge steel is not well protected.

80 Installation of Thin Stone Veneer Over Rigid Insulation

81 Building Stone Institute (BSI) Rigid foam board cannot transfer the weight of the adhered stone veneer directly to the stud backup or foundation. The thicker the layer of foam, the more extreme the bending component will be. If such an installation cannot be avoided, consult an engineer to design appropriate anchors in order to avoid sagging or racking that can produce cracks in the veneer.

82 Adhered Masonry Veneers Over Exterior Insulation Long Fasteners

83 Wood Stud Backup Wall

84 Adhered Masonry Veneers Over Exterior Insulation Less Than 1-½ Long Fasteners

85 Adhered Masonry Veneers Over Exterior Insulation Less Than 1-½ Long Fasteners

86 Adhered Masonry Veneers Over Exterior Insulation Less Than 1-½ Long Fasteners

87 Adhered Masonry Veneers Over Exterior Insulation Less Than 1-½ Long Fasteners

88 Adhered Masonry Veneers Over Exterior Insulation Less Than 1-½ Long Fasteners

89 Steel Stud Backup Wall

90 Adhered Masonry Veneers Over Exterior Insulation Greater Than 1-½ Long Fasteners

91 Adhered Masonry Veneers Over Exterior Insulation Greater Than 1-½ Long Fasteners

92 Adhered Masonry Veneers over Exterior Insulation Greater Than 1-½ Long Fasteners

93 Adhered Masonry Veneers Over Exterior Insulation Greater Than 1-½ Long Fasteners

94 Adhered Masonry Veneers Over Exterior Insulation On Z-bars

95 Adhered Masonry Veneers Over Exterior Insulation Greater Than 1-½ Z-bars

96 Adhered Masonry Veneers Over Exterior Insulation Greater Than 1-½ Z-bars

97 Adhered Masonry Veneers Over Exterior Insulation Greater Than 1-½ Z-bars

98 Adhered Masonry Veneers Over Exterior Insulation Greater Than 1-½ Z-bars

99 Adhered Masonry Veneers Over Exterior Insulation Greater Than 1-½ Z-bars

100 Insulation Embedded Thin Masonry Veneers

101 Insulation Embedded Thin Masonry Veneers Ideal for thin clay brick, concrete brick or concrete masonry units or jointed random ashlar manufactured stone. Less ideal for drystack manufactured stone.

102 Insulation Embedded Thin Masonry Veneers Provides approximately R12. Drained both back and front side. Mechanically fastened with stainless steel ties. Shelf angle at base for extra support.

103 Insulation Embedded Stone Veneer Jointed Random Ashlar Simulated Drystack

104 Insulation Embedded Thin Brick Veneers

105 Insulation Embedded Thin Concrete Brick Veneers

106 Insulation Embedded Thin Concrete Masonry

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111 AMC Design Aids

112 Design Aids Architects and Architectural Technologists 2D and 3D details Sample specifications Fire rating Tables STC ratings for block

113 Design Aids Engineers and Engineering Technologists 2D and 3D details structural details. Weblink to MASS software. EXCEL design Sheets for engineers available on request (tie design, shelf angle design, column / pilaster design, wall design.

114 Design Aids Adhered Stone Details

115 Design Aids R-Value Calculator

116 About AMC

117 Alberta Masonry Council To improve the longevity of architecture in Alberta through the aesthetic and stable appeal of masonry design.

118 Masonry Products are Green Building Materials Cement products reduce green house gases - they absorb carbon dioxide (CO 2 )over time. Manufactured stone products, mortar, scratch coat and cement boards all absorb CO 2 over their service life.

119 Masonry Products are Green Building Materials Masonry products are also modular and very recyclable. They produce less construction waste for land fills and are cradle - cradle NOT cradle to grave.

120 AMC Supplier Members