REINFORCED CONCRETE MASONRY CONSTRUCTION INSPECTOR S HANDBOOK 8 th EDITION MASONRY INSTITUTE OF AMERICA
REINFORCED CONCRETE MASONRY CONSTRUCTION INSPECTOR S HANDBOOK 8 th EDITION John Chrysler, P.E. Executive Director Masonry Institute of America Based on previous editions developed by: James E. Amrhein, S.E. and Michael W. Merrigan, P.E. Published by MASONRY INSTITUTE OF AMERICA (800) 221-4000 www.masonryinstitute.org in cooperation with INTERNATIONAL CODE COUNCIL 500 New Jersey Avenue, NW, 6th Floor Washington, DC 20001-2070 www.iccsafe.org (888) 422-7233 iii
REINFORCED CONCRETE MASONRY CONSTRUCTION INSPECTOR S HANDBOOK 8 th EDITION ISBN: 978-0-940116-56-6 Cover Design: Illustrator: Typesetting: International Code Council Thomas Escobar Thomas Escobar/Luis Dominguez COPYRIGHT 2013 MASONRY INSTITUTE OF AMERICA Portions of this publication are reproduced, with permission, from the 2012 International Building Code, copyright International Code Council, TMS 402-11/ACI 530-11/ASCE 5-11 Building Code Requirements for Masonry Structures and TMS 602-11/ACI 530.1-11/ASCE 6-11 Specification for Masonry Structures, copyright The Masonry Society, American Concrete Institute, American Society of Civil Engineers. In this publication the Masonry Standards Joint Committee s (MSJC) Building Code Requirements for Masonry Structures (TMS 402-11/ACI 530-11/ASCE 5-11 is hereafter referred to as the MSJC Code, and the MSJC s Specification for Masonry Structures (TMS 602-11/ACI 530.1-11/ASCE 6-11) is hereafter referred to as the MSJC Specification. This book was prepared in keeping with current information and practice for the present state of the art of masonry design and construction. iv
The author, publisher and all organizations and individuals who have contributed to this book cannot assume or accept any responsibility or liability, including liability for negligence, for errors or oversights in this data and information and in the use of such information. ALL RIGHTS RESERVED: This publication is a copyright work owned by the Masonry Institute of America and the International Code Council. Without advance written permission from the copyright owners, no part of this book may be reproduced, distributed or transmitted in any form or by any means, including, without limitation, electronic, optical or mechanical means (by way of example and no limitation, photocopying, or recording by or in an information storage and retrieval system). For information on permission to copy material exceeding fair use, please contact: Masonry Institute of America, P.O. Box 3905, Torrance, CA 90510-3905, Phone: 800-221-4000 or ICC Publications, 500 New Jersey Avenue, NW, 6th Floor, Washington, DC 20001-2070, Phone: 888-ICC-SAFE (422-7233). Information contained in this document has been obtained by the Masonry Institute of America (MIA) from sources believed to be reliable. Neither MIA nor its authors shall be responsible for any errors, omissions, or damages arising out of this information. This work is published with the understanding that MIA and its authors are supplying information but are not attempting to render professional services. If such services are required, the assistance of an appropriate professional should be sought. Trademarks: International Code Council, the ICC logo, the International Building Code are trademarks of the International Code Council, Inc. First Printing: August 2013 Printed in the United States of America MIA 206-13 08-13 1.5M v
Reinforced Concrete Masonry Construction Inspector's Handbook vi
Table of Contents TABLE OF CONTENTS Acknowledgements----------------------------------------------------xv Masonry Institute of America--------------------------------------xvi International Code Council----------------------------------------xvii Masonry Standards Joint Committee---------------------------xix The Masonry Society--------------------------------------------------xx American Concrete Institute----------------------------------------xx American Society of Civil Engineers-----------------------------xx CHAPTER 1. INTRODUCTION-----------------------------------------------1 1.1 General----------------------------------------------------------1 1.2 The Inspector---------------------------------------------------2 1.3 Responsibilities and Duties---------------------------------3 1.4 Equipment and Materials for the Inspector-------------4 1.5 Terminology-----------------------------------------------------5 CHAPTER 2. MATERIALS---------------------------------------------------25 2.1 General--------------------------------------------------------25 2.2 Material--------------------------------------------------------25 2.2.1 Concrete Masonry Units-----------------------------26 2.2.2 Clay Masonry Units-----------------------------------26 2.2.3 AAC Masonry Units-----------------------------------27 2.2.4 Stone Masonry Units---------------------------------27 2.2.5 Ceramic Tile--------------------------------------------28 2.2.6 Glass Unit Masonry-----------------------------------29 2.2.7 Mortar----------------------------------------------------29 2.2.8 Grout-----------------------------------------------------30 2.2.9 Reinforcement-----------------------------------------30 2.2.10 Other Standards---------------------------------------33 vii
Reinforced Concrete Masonry Construction Inspector's Handbook 2.3 Concrete Masonry Units-----------------------------------35 2.3.1 General--------------------------------------------------35 2.3.2 Dimensions---------------------------------------------35 2.3.3 Wide Selection of Units------------------------------36 2.3.4 Component Units -------------------------------------38 2.3.5 Storing Masonry Units--------------------------------39 2.4 Cementitious Materials-------------------------------------40 2.4.1 Portland Cement--------------------------------------41 2.4.2 Plastic Cement-----------------------------------------41 2.4.3 Mortar Cement-----------------------------------------42 2.4.4 Masonry Cement--------------------------------------42 2.4.5 Lime------------------------------------------------------42 2.5 Aggregates for Mortar and Grout------------------------44 2.6 Reinforcing Steel--------------------------------------------45 2.6.1 General--------------------------------------------------45 2.6.2 Reinforcing Bars---------------------------------------48 2.6.3 Identification Marks-----------------------------------49 2.6.4 Overall Bar Diameters-------------------------------49 2.7 Joint Reinforcing Steel-------------------------------------50 2.7.1 General--------------------------------------------------50 2.7.2 Description----------------------------------------------51 2.7.3 Configuration and Size of Longitudinal and Cross Wires---------------------------------------51 2.7.4 Material Requirements-------------------------------52 2.7.5 Fabrication----------------------------------------------52 2.8 Water-----------------------------------------------------------53 2.9 Additives and Admixtures----------------------------------53 2.10 Mortar----------------------------------------------------------54 2.10.1 General--------------------------------------------------54 2.10.2 Proportions of Mortar---------------------------------55 2.10.3 Mortar Aggregate Sand----------------------------57 2.10.4 Mixing----------------------------------------------------58 2.10.5 Pre-Blended Mortar-----------------------------------60 2.10.6 Retempering-------------------------------------------61 2.10.7 Color------------------------------------------------------61 2.10.8 Proprietary Mortars-----------------------------------63 2.10.9 Mortar Admixtures------------------------------------63 2.11 Grout------------------------------------------------------------63 2.11.1 General--------------------------------------------------63 viii
Table of Contents 2.11.2 Type of Grout-------------------------------------------64 2.11.3 Proportions---------------------------------------------65 2.11.4 Aggregate for Grout----------------------------------66 2.11.5 Mixing----------------------------------------------------66 2.11.6 Grout Admixtures--------------------------------------66 2.11.7 Anti-Freeze Compounds----------------------------69 2.11.8 Ready Mixed Grout-----------------------------------69 2.11.9 Grout Demonstration Panel-------------------------70 2.11.10 Self-Consolidating Grout (SCG)-------------------70 CHAPTER 3. QUALITY CONTROL, SAMPLING AND TESTING--------------------------------------------------------75 3.1 Quality Control-----------------------------------------------75 3.2 Sampling and Testing---------------------------------------76 3.2.1 Cone Penetration Test for Consistency of Mortar ------------------------------------------------76 3.2.2 Field Test for Mortar Strength-----------------------78 3.2.3 Field Tests for Grout----------------------------------78 3.3 Concrete Masonry Units-----------------------------------83 3.4 Prism Testing-------------------------------------------------84 3.4.1 General--------------------------------------------------84 3.4.2 Standard Prism Tests---------------------------------86 3.4.3 Tests of Masonry Prisms----------------------------87 3.4.4 Specified Compressive Strength, f m -------------88 3.5 Level of Inspection------------------------------------------97 3.5.1 Quality Assurance Level A--------------------------97 3.5.2 Quality Assurance Level B--------------------------98 3.5.3 Quality Assurance Level C------------------------101 3.6 Core Testing-------------------------------------------------103 3.7 Summary-----------------------------------------------------105 CHAPTER 4. GENERAL CONSTRUCTION PRACTICE AND LAYOUT------------------------------------------------111 4.1 General-------------------------------------------------------111 4.2 Materials, Handling, Storage and Preparation------111 4.3 Mortar Joints-------------------------------------------------115 ix
Reinforced Concrete Masonry Construction Inspector's Handbook 4.4 Preparation of Foundation and Site--------------------118 4.5 Placement and Layout------------------------------------120 4.5.1 General------------------------------------------------120 4.5.2 Installation---------------------------------------------121 4.5.3 Typical Layout of CMU Walls---------------------136 4.6 Racking and Toothing-------------------------------------149 CHAPTER 5. REINFORCING STEEL----------------------------------151 5.1 General-------------------------------------------------------151 5.2 Maximum Size/Amount of Reinforcing Steel--------151 5.2.1 Maximum Size/Amount of Reinforcing Steel Allowable Stress Design-------------------152 5.2.2 Maximum Size/Amount of Reinforcing Steel Strength Design-----------------------------153 5.3 Spacing of Steel in Walls---------------------------------154 5.4 Clearances of Steel in Masonry------------------------157 5.5 Securing Reinforcing Steel------------------------------163 5.6 Location Tolerances of Bars-----------------------------164 5.7 Lap Splices, Reinforcing Bars---------------------------167 5.8 Joint Reinforcement---------------------------------------171 5.8.1 Lap Splices, Joint Reinforcement----------------171 5.8.2 Coverage and Layout of Joint Reinforcing Steel------------------------------------172 5.9 Hooks and Bends in Reinforcing Bars----------------176 5.10 Anchorage of Shear Reinforcing Steel----------------178 5.11 Column Reinforcement-----------------------------------183 5.11.1 Vertical Reinforcement-----------------------------183 5.11.2 Lightly Loaded Columns---------------------------184 5.11.3 Reinforcing Tie Details-----------------------------185 5.11.4 Projecting Wall Columns or Pilasters-----------193 5.11.5 Flush Wall Columns, Pilasters and Compression Steel at End of Walls-------------195 5.11.6 Ties on Compression Steel in Beams----------196 5.11.7 Anchor Bolts------------------------------------------197 x
Table of Contents CHAPTER 6. GROUTING OF CONCRETE MASONRY WALLS----------------------------------------------------205 6.1 General-------------------------------------------------------205 6.2 Mortar Protrusions-----------------------------------------205 6.3 Grout Slump-------------------------------------------------206 6.4 Grouting Limitations---------------------------------------207 6.5 Low Lift Grouting------------------------------------------210 6.6 High Lift Grouting-----------------------------------------213 6.7 Cleanouts----------------------------------------------------218 6.8 Consolidation of Grout------------------------------------219 6.9 Grout Barriers ----------------------------------------------220 6.10 Use of Aluminum Equipment----------------------------220 6.11 Pumping Grout---------------------------------------------221 6.12 Grout Demonstration Panel-----------------------------222 CHAPTER 7. SPECIAL PROVISIONS FOR SEISMIC DESIGN AND CONSTRUCTION-----------------------223 7.1 General-------------------------------------------------------223 7.2 IBC Seismic Design Categories------------------------224 7.2.1 Seismic Design Category A-----------------------225 7.2.2 Seismic Design Category B-----------------------228 7.2.3 Seismic Design Category C-----------------------228 7.2.4 Seismic Design Category D-----------------------233 7.2.5 Seismic Design Categories E and F------------236 CHAPTER 8. PRESTRESSED MASONRY----------------------------237 8.1 General-------------------------------------------------------237 8.2 Materials-----------------------------------------------------241 8.3 Construction-------------------------------------------------247 CHAPTER 9. SPECIAL TOPICS OR CONDITIONS----------------253 9.1 Bracing of Walls--------------------------------------------253 9.2 Pipes and Conduits Embedded in Masonry---------255 xi
Reinforced Concrete Masonry Construction Inspector's Handbook 9.3 Adjacent Work----------------------------------------------255 9.4 Intersecting Structural Elements-----------------------256 9.4.1 Wall to Wall--------------------------------------------256 9.4.2 Wall to Floor or Roof--------------------------------261 9.5 Multiwythe Walls-------------------------------------------263 9.5.1 General------------------------------------------------263 9.5.2 Metal Ties for Cavity Wall Construction--------265 9.5.3 Metal Ties for Grouted Multiwythe Construction------------------------------------------268 CHAPTER 10. MOVEMENT JOINTS AND CRACK CONTROL-----------------------------------------------269 10.1 General-------------------------------------------------------269 10.2 Jointing; Control Joints and Expansion Joints------270 10.2.1 Sources of Movement------------------------------270 10.2.2 Properties Affecting Concrete Masonry Units-270 10.2.3 Environmental Factors-----------------------------270 10.2.4 Design/Construction Deficiencies---------------271 10.3 Crack Control-----------------------------------------------271 10.4 Control Joints-----------------------------------------------272 10.5 Expansion Joints-------------------------------------------279 10.6 Summary-----------------------------------------------------279 10.7 Crack Repair------------------------------------------------280 CHAPTER 11. CONSTRUCTION IN SEVERE WEATHER CONDITIONS----------------------------------------------281 11.1 Cold Weather Masonry Construction-----------------281 11.1.1 General------------------------------------------------281 11.1.2 Construction------------------------------------------281 11.1.3 Placing Grout and Protection of Grouted Masonry-----------------------------------------------282 11.1.4 Protection---------------------------------------------283 11.1.5 Summary of Recommended Cold Weather Practices-----------------------------------284 11.2 Hot Weather Masonry Construction-------------------287 11.2.1 General------------------------------------------------287 xii
Table of Contents 11.2.2 Performance------------------------------------------287 11.2.3 Handling and Selection of Materials------------288 11.2.4 Construction Procedure----------------------------289 11.2.5 Summary of Recommended Hot Weather Practices-----------------------------------291 11.3 Wet Weather Masonry Construction------------------292 11.3.1 General------------------------------------------------292 11.3.2 Performance------------------------------------------292 11.3.3 Construction Procedures--------------------------293 11.3.4 Protection of Masonry------------------------------293 CHAPTER 12. MASONRY INSPECTION CHECKLIST-----------295 12.1 General--------------------------------------------------295 12.2 Inspector s Checklist--------------------------------------295 12.2.1 Pre Construction Verification--------------------295 12.2.2 Start Up Observations-----------------------------296 12.2.3 Pre Placement Observations--------------------297 12.2.4 Workmanship-----------------------------------------299 12.2.5 Construction Details--------------------------------303 CHAPTER 13. MASONRY UNITS--------------------------------------309 13.1 ICC-ES Evaluation Reports-----------------------------309 13.2 Typical Concrete Masonry Units-----------------------310 13.2.1 Precision Units---------------------------------------310 13.2.2 Slumped Blocks--------------------------------------310 13.2.3 Custom Face Units----------------------------------330 13.2.4 Split Face Units--------------------------------------331 13.2.5 Ground Faced (Burnished) Units----------------333 13.2.6 Special Proprietary Units--------------------------333 13.3 Length, Height and Quantities in Concrete Masonry Walls----------------------------------------------334 13.3.1 Length and Height of Walls------------------------334 13.3.2 Quantities of Materials-----------------------------337 CHAPTER 14. GLOSSARY OF TERMS------------------------------339 xiii
Reinforced Concrete Masonry Construction Inspector's Handbook CHAPTER 15. REFERENCES-------------------------------------------367 CHAPTER 16. INDEX-------------------------------------------------------371 xiv
Acknowledgements ACKNOWLEDGEMENTS The Masonry Institute of America appreciates the past review and suggestions received by the American Construction Inspectors Association and its Board of Registered Construction Inspectors. Input from James E. Amrhein and Donald A. Wakefield in previous editions of this book are incorporated into this edition. Special appreciation is extended to those who have reviewed this and previous editions of this book. Their suggestions have contributed to technical content and editorial correctness. Reviewers include Gregg Borchelt, James Feagin, William Fitzjohn, Phillip Samblanet, Kurt Siggard, Roger Utesch and Dan Zechmeister The Masonry Institute of America and the author also acknowledge the expertise of staff which include Thomas Escobar, Design Director; Luis Dominguez, Production Manager and Debby Chrysler, Proofing Specialist for their input which makes this publication the most recognized reference for concrete masonry inspection. xv
Reinforced Concrete Masonry Construction Inspector's Handbook MASONRY INSTITUTE OF AMERICA The Masonry Institute of America, founded in 1957 under the name of Masonry Research, is a promotional, technical research organization established to improve and extend the use of masonry. The Masonry Institute of America is supported by the California masonry contractors through labor agreement contracts between the unions and contractors. The Masonry Institute of America is active in California and throughout the United States promoting new ideas and masonry work, improving national and local building codes, conducting research projects, presenting design, construction and inspection seminars and writing technical and non-technical papers, all for the purpose of improving the masonry industry. The Masonry Institute of America does not engage in the practice of architectural or engineering design or construction nor does it sell masonry materials. xvi
International Code Council INTERNATIONAL CODE COUNCIL The International Code Council (ICC) was established in 1994 as a non-profit organization dedicated to developing a single set of comprehensive and coordinated national model construction codes. The founders of the ICC are Building Officials and Code Administrators International, Inc. (BOCA), International Conference of Building Officials (ICBO), and Southern Building Code Congress International, Inc. (SBCCI). Since the early part of the last century, these non-profit organizations developed three separate sets of model codes used throughout the United States. Although regional code development has been effective and responsive to our country s needs, the time came for a single set of codes. The nation s three model code groups responded by creating the International Code Council and by developing codes without regional limitations; the International Codes. The ICC has developed and made available an impressive inventory of comprehensive and coordinated International Codes, including: International Building Code International Residential Code for One- and Two- Family Dwellings International Fire Code International Energy Conservation Code International Plumbing Code International Private Sewage Disposal Code International Mechanical Code International Fuel Gas Code International Wildland-Urban Interface Code International Existing Building Code ICC Performance Code for Buildings and Facilities International Property Maintenance Code xvii
Reinforced Concrete Masonry Construction Inspector's Handbook International Zoning Code International Green Construction Code TM International Swimming Pool and Spa Code TM The International Code Council offers unmatched technical, educational and informational products and services in support of the International Codes, with more than 250 highly qualified staff members at 16 offices throughout the United States and in Latin America. Some of the products and services readily available to code users include: Code application assistance Educational programs Certification programs Technical handbooks and workbooks Plan review Automated products Monthly magazines and newsletters Publication of proposed code changes Training and informational videos xviii
Masonry Standards Joint Committee MASONRY STANDARDS JOINT COMMITTEE The Masonry Standards Joint Committee (MSJC) is an organization comprised of volunteers who through background, use, and education have established experience in the manufacturing of masonry units and materials and the design and construction of masonry structures. Working under its three sponsoring organizations, The Masonry Society (TMS), the American Concrete Institute (ACI), and the American Society of Civil Engineers (ASCE) the Committee has been charged with developing and maintaining consensus standards suitable for adoption into model building codes. Since The Masonry Society has received ANSI accreditation, TMS has become the lead sponsor in the production of the MSJC Code and Specification. In the pursuit of its goals, Committee activities include: 1. Evaluate and ballot proposed changes to existing standards of the Committee. 2. Develop and ballot new standards for masonry. 3. Resolve negative votes from ballot items. 4. Identify areas of needed research. 5. Monitor international standards In this publication the term MSJC Code refers to Building Code Requirements for Masonry Structures (TMS 402-11/ACI 530-11/ASCE 5-11) and the term MSJC Specification refers to Specification for Masonry Structures (TMS 602-11/ACI 530.1-11/ASCE 6-11). xix
Reinforced Concrete Masonry Construction Inspector's Handbook Advancing the knowledge of masonry THE MASONRY SOCIETY The Masonry Society (TMS), founded in 1977, is an international gathering of people interested in masonry. It is a professional, technical, and educational association dedicated to the advancement of knowledge on masonry. TMS members are design engineers, architects, builders, researchers, educators, building officials, material suppliers, manufacturers, and others who want to contribute to and benefit from the global pool of knowledge on masonry. AMERICAN CONCRETE INSTITUTE The American Concrete Institute (ACI) is a nonprofit technical and educational society founded in 1904 with 99 chapters and 20,000 members spanning 108 countries. As ACI moves into its second century of progress through knowledge, it has retained the same basic mission: Provide knowledge and information for the best use of concrete. AMERICAN SOCIETY OF CIVIL ENGINEERS The American Society of Civil Engineers (ASCE) was founded in 1852 and currently represents 140,000 members of the civil engineering profession worldwide and is America s oldest national engineering society. ASCE s vision is to position engineers as industry leaders building a better quality of life. To provide essential value to members, their careers, partners and the public, ASCE develops leadership, advances technology, advocates lifelong learning, and promotes the profession. xx