- 1. Overview
- 2. Manufacturing process (generic template)
- 3. Properties and performance parameters
- 4. Types and classifications
- 5. Common failures and troubleshooting
- 6. QA/QC checklist (site and lab)
- 7. Design and detailing notes
- 8. Sample specification (short form)
- 9. BOQ template (standard items)
- 10. Lab test matrix
- 11. Tests for aggregates (when used)
- 12. Durability, fire, and thermal data (typical)
- 13. Limitations
- 14. Consultant checklist
- 15. References
- Disclaimer
Purpose: master reference for Masonry & Walling Systems. Use the TOC to jump to process, properties, types, failures, QA/QC, design, specs, BOQ, and references.
1. Overview
This master page defines the common structure and acceptance bands for masonry systems used in SpecX. Apply this pattern to Brick Masonry, Block Masonry (AAC/CLC/Concrete), Mortars, Plasters, and Pointing.
2. Manufacturing process (generic template)
Stage | Description | Control parameter |
Raw materials | Soil / cement / aggregates / admixtures | Purity, gradation, moisture |
Processing | Mixing / pugging / moulding / autoclaving | Uniformity, reaction control |
Curing | Air / water / steam / autoclave | Temperature, duration |
Finishing | Cutting / sorting / grading | Size tolerance, surface finish |
3. Properties and performance parameters
Property | Test method | Acceptance criteria (typical) | Reference |
Compressive strength | IS 3495 (brick) / IS 2185 (block) | As per grade/class | IS 1077 / IS 2185 |
Water absorption | IS 3495 Part 2 | <= 20% (brick) / <= 10% (dense block) | — |
Density | IS 2386 Part 3 | Brick ~ 1800–2000 kg/m3; AAC ~ 550–650 kg/m3 | — |
Dimensional tolerance | Vernier/steel scale | +/- 3 mm (L/W/H) typical | IS 1077 / IS 2185 |
Thermal conductivity | ASTM C177 | Brick ~ 0.6–1.2 W/mK; AAC ~ 0.16–0.20 W/mK | — |
Efflorescence | Visual | Nil to slight | IS 3495 Part 3 |
4. Types and classifications
Type | Material | Density (kg/m3) | Strength (MPa) | Typical use |
Clay brick | Burnt clay | ~ 1800 | 7–10 | General masonry |
Fly ash brick | Fly ash + lime | ~ 1600 | 10–12 | Sustainable option |
AAC block | Cement + fly ash + aluminum powder | ~ 550 | 3–4 | Lightweight walls |
CLC block | Cement + foam agent | ~ 800 | 3–5 | Non-load-bearing walls |
Concrete block | Cement + aggregate | ~ 2000 | 10–15 | Load-bearing walls |
5. Common failures and troubleshooting
Issue | Likely cause | Prevention / solution |
Efflorescence | Soluble salts in brick/mortar; rising damp | Low-salt materials; effective DPC; breathable coatings |
Wall cracks | Thermal/settlement movement; missing joints | Provide vertical joints every ~ 6 m; detail around openings |
Bulging | Weak mortar; poor bonding | Strengthen mix; control alignment; add ties |
Plinth dampness | Missing/failed DPC; poor drainage | DPC membrane; improve site drainage |
Hollow plaster | Poor key; suction not controlled | Bond coat; PMM; correct pre-wetting |
6. QA/QC checklist (site and lab)
Stage | Checkpoint | Method | Acceptance |
Pre-execution | Brick/block MTCs and tests | Review reports | Grade/class OK |
Sand grading | Sieve analysis | Zone II (IS 383) | |
Water quality | IS 3025 | pH 6.5–8.5 | |
During work | Mortar proportion | Random sample | Within +/- 5% |
Joint thickness | Vernier gauge | Brick 10 +/- 2 mm; AAC 3–4 mm | |
Plumb and alignment | Plumb bob/laser | +/- 3 mm per 2 m | |
Post work | Compressive strength | Lab | >= design grade |
Ponding (wet areas) | Visual | 72 h no leakage |
7. Design and detailing notes
Aspect | Guidance |
Control joints | ~ 6 m spacing; 10–12 mm gap; sealant filled |
Bonding with RCC | Galvanized mesh or shear key; starter bars |
Reinforced brick/blockwork | 6 mm bars every 3–4 courses for long walls as needed |
Mortar thickness | Brick 10 mm; AAC thin-bed 3–4 mm |
DPC level | >= 150 mm above finished ground level |
Seismic detailing | RCC bands at sill, lintel, and roof levels |
8. Sample specification (short form)
Item: Brick masonry 230 mm thick using first-class burnt clay bricks in cement mortar 1:6, including raking joints, scaffolding, curing, and required reinforcement. Standards: IS 1077, IS 2212, IS 2250. Rate includes materials, labour, equipment, curing, waste, and scaffolding.
9. BOQ template (standard items)
Sl. No. | Description | Unit | Qty | Rate | Amount |
1 | Brick masonry 230 mm thick in CM 1:6 | m3 | — | — | — |
2 | AAC block masonry 200 mm with thin joint adhesive | m2 | — | — | — |
3 | External plaster 20 mm CM 1:4 (2 coats) | m2 | — | — | — |
4 | Internal plaster 12 mm CM 1:6 (2 coats) | m2 | — | — | — |
5 | Pointing flush finish with PMM 1:3 | m | — | — | — |
10. Lab test matrix
Test | Frequency | Standard | Acceptance |
Compressive strength (brick/block) | ~ 1 per 5000 units | IS 3495 / IS 2185 | As per class |
Water absorption | ~ 1 per 10000 units | IS 3495 Part 2 | <= 20% (brick) |
Efflorescence | 1 per batch | IS 3495 Part 3 | Nil to slight |
Mortar cube strength | 1 set per day | IS 4031 | >= 5 MPa (CM 1:6 typical) |
Plaster adhesion (pull-off) | 1 per 200 m2 | ASTM C952 | >= 0.5 N/mm2 |
11. Tests for aggregates (when used)
Test | Standard | Limit |
Sieve analysis | IS 2386 Part 1 | Zone II |
Specific gravity | IS 2386 Part 3 | 2.60–2.75 |
Water absorption | IS 2386 Part 3 | <= 2% |
Deleterious materials | IS 2386 Part 2 | <= 5% |
12. Durability, fire, and thermal data (typical)
Parameter | Typical range | Remark |
Fire resistance | ~ 2–4 h (230 mm brick wall) | Per IS 3809 |
Thermal conductivity | Brick ~ 0.6–1.2 W/mK; AAC ~ 0.16–0.20 W/mK | Function of density |
Sound reduction index (STC) | ~ 45–55 dB | AAC generally lower than brick |
13. Limitations
- Brickwork: higher self-weight, slower execution, higher water absorption
- Dense concrete blocks: lower insulation performance
- Efflorescence and shrinkage cracks possible without proper detailing and curing
14. Consultant checklist
- Verify all material test certificates and mock-up approvals
- Ensure DPC and control joints in drawings and execution
- Enforce curing records (>= 7 days typical for CM plasters/mortars)
- Require photo records at pre-, mid-, and post-work stages
15. References
- IS 1077: Common burnt clay building bricks
- IS 3495: Methods of testing bricks
- IS 2185 (Part 3): AAC blocks
- IS 2212: Brickwork practice
- IS 2250: Masonry mortars
- IS 1661: Plastering practice
- IS 1905: Structural masonry design
Disclaimer
Conix is an industry initiative & a neutral resource, compiled from industry references and best practices. It is not brand-specific. Always cross-check with project requirements and local codes before finalizing specifications.