MORTER LESS CONSTRUCTION DETAILS

7/28/2019 MORTER LESS CONSTRUCTION DETAILS

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mortarlessA masonry wall system specifically developed for

load bearing structures.

Substantial savings possible in both time and cost.

Completed buildings superior.


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200 mortarless product range:There are only four basic products in the 200 mortarless

product range:

The stretcher block for the bulk of any wall.

The full end block for every course at a corner and foralternate courses at ends of walls.

The half end block for alternate courses at ends ofwalls.

The plastic connectorone for every block.


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Stretcher block

Dimensions: 400 long x 200 wide x 200 high


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Full end block



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Half end block



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Connector

Secures blocks end to end resists hydrostatic forces when wallis being filled with grout.

Helps align blocks in any course.

Helps position and align blocks in the overlying course.

Secures vertical and horizontal reinforcement in correct location.

Helps stabilise walls during construction.


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Mortarless walls are always reinforced and fully

grouted with core-fill concrete.


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Constructing mortarless walls: Accurately set out and install vertical starter bars


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Always set first course in a mortar bed to accommodate

irregularities in the footings or base slab and to provide full width

bearing. Simple packing or wedging may also be used in

certain applications.


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When first course is laid, install plastic connectors and andcommence laying subsequent courses working from each endand using a string line and spirit level to maintain straightnessand plumb.

(Note that laying is a two handed operation. (With lighter blocksthis means less strain on the wrists.)


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Note horizontal bar snugly fits into

notches in connectors and this helps

secure blocks in horizontal alignmentduring construction.

By correctly positioning the horizontal

bars during construction of the wall, the

vertical bars can readily be inserted in

their correct position to comply with the

structural design requirements.


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Continue constructing the wall to a height of about 1.6 to 2mand then install vertical bars in the specified locations prior togrouting.

Rod grout to remove any trapped air. Finish grout below top ofblock if wall is to continue on, or finish flush if wall is up toheight.


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Proceed with the next lift of wall in the same way.

Construct insitu slabs or install precast slabs as per the

structural details. Anchor slab reinforcement into walls and vice

versa for ductile connections.


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Mortarless masonry is a strong, solid, load bearingwall system

The floor slabs and roof slabs (either pre-cast or castinsitu) are supported directly on the walls.


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Walls can be designed to resist all axial loads and shear loads.

Walls can also be designed to resist both transverse and in-plane bending moments, hence many lintel beams can simply

be incorporated in the design of the walls:


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MEP services can be installed as the work proceeds. This

saves much of the chasing in normally required.


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Concrete framed buildings: Masonry construction is widely used throughout the world,

however in many parts of the world including India, masonry is

merely used as infill for walling.

Building are constructed with concrete columns, beams andslabs and the masonry walls are installed as cladding elements.


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Residential development with masonry infill walls


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Masonry infill walls


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Advantages of mortarless: Substantially reduced construction time and cost.

Unskilled labour used for much of the construction effort

Not weather dependent mortarless can be laid in the rain

Greatly reduced mess on site

Certainty of reinforcing bar positioning

Proper cover to reinforcement

No mortar dags or droppings to clean out of cores

No clean-out blocks required, hence no shutters

Solid construction - concrete filled walls

Reduced thickness of cement plaster finishes Ductile constructionreadily designed for earthquake loads

Walls, footings and slabs fully tied - stronger buildings

More even distribution of loads to the foundation


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MEP services can be installed as the wall is being constructed

eliminating the need for much of the chasing-in normally

required. Design made easy by the tables provided

Simplicity of detailing

Professional technical support provided to specifiers and users.

Severe damage to villas under construction that could have been avoided with mortarless


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Detailing mortarless walls: When detailing any project for mortarless it is preferable to set

the buildings out in 200mm increments both horizontally andvertically.

Preferably set out all openings (doors, windows etc) to also suitthe 200mm module.

If the builder is unfamiliar with mortarless it is advisable toelevate the walls, or at least some typical walls. This will reducethe possibility of the builder making mistakes on site.

Most walls will have typical reinforcement specified (e.g. N12-800 vertical and horizontal bars throughout). On any wallelevations therefore it should only be necessary to show theadditional bars trimming openings etc.


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Example of plan showing setout of walls and starter bars


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Example of wall elevation drawing showing additional bars


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Show typical details for corners, wall intersections etc.

Preferably provide a starter bar set-out plan for each level. This

will minimise the risk of bars beings installed in the wrong

locations, or bars being omitted.

Adequately detail any mortarless lintels or beams with specialreinforcement.

Show any special details for wall/slab junctions etc.


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Designing mortarless walls:

Design manuals are provided on the mortarless websitewww.mortarless.com.au. At present the manuals providecomprehensive design aids for design in accordance with AS3700 and BS 5628.

BS 5628 Design Manual Part 1 provides a detailed look at the

three parts of the Code, establishes the applicability of the Codeto the design of mortarless masonry, and provides thebackground information on the Code rules that were used in thepreparation of the design aids in Part 2.

Part 2 contains the various design aids for the mortarlessproducts generally available. It is essential to check that anyparticular mortarless product selected for a project in the designphase is readily available for the project.
http://www.mortarless.com.au/http://www.mortarless.com.au/http://www.mortarless.com.au/


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Worked example for wall in compression:Clear height of wall = H = 3200

Length of wall = L = 7000

Design load on wall = 294 kN/m

Concrete slabs top and bottom, therefore enhanced lateral restraint

top and bottom, therefore av = 0.75

e = 30mm (eccentricity calculated as shown in Part 2a Section 2)

If in doubt as to whether length or height governs the design of the

wall in compression, use the table in Part 2a Section 2 Page 4to determine. In this case height clearly governs the design.


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Select 200 mortarless Grade 20 non-chamfered blocks for the

project.

From Table CH200-20-1, maximum design load in compression =(375+263)/2 = 314kN (interpolation for 30mm eccentricity),

therefore the wall is adequate for the maximum design load of

294kN.

The above worked example shows how quick and easy it is tocheck the adequacy of a load bearing wall in compression.


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Designing for earthquake

Ductile construction helps minimise the design requirements.

Horizontal and vertical regularity is also an important factor for

earthquake design.

Any load bearing masonry structures in excess of 3 storeysgenerally have to be in reinforced masonry construction. This

means that there is an even stronger case formortarlessconstruction in buildings of 4 or more storeys if they are of load

bearing wall construction.


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Cost comparison - case study:

This case study is for the Al Ghadeer villa in Abu Dhabi, UAE.Several demonstration villas were constructed for comparisonpurposes primarily to study the construction process, theconstruction time, the construction cost, and all aspects of thefinished villa.

The demonstration villas included several different metal studframing systems, a plastic framing system, load bearingmortarless, and load bearing precast concrete.

Load bearing mortarless was selected by the developer, Sorouh

Real Estate, as one of the preferred systems to be used in thedevelopment which comprised approximately 4,500 villas.


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Mortarless demonstration villa nearing completion (Al Ghadeer project)


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Al Naboudah, one of the major builders in the UAE, prepared atender for construction of at 500 villas in the Al Ghadeer project.

They tendered for construction of the villas in any of three

different structural framing systems: Post and beam (concrete frame) with masonry infill walls

Load bearing mortarless

Load bearing precast concrete

Their tender prices for the structural shells were as follows: Post & Beam UAE 403,429 dhs

MortarlessUAE 329,940 dhs Precast UAE 400,262 dhs

The load bearing mortarless structure was found to be at least18% less than the other two framing systems.

The Al Naboudah priced BoQ summary sheet follows:


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Photo Gallery Mortarless projects under construction:


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Blocks F to W were constructed with mortarless common walls


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Load bearing masonry buildings in Australia:


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Thank you

Documents

MORTER LESS CONSTRUCTION DETAILS