technical manual bricks

ADV05000 08/04

Bricks & Pavers Technical ManualRegistration Form

Issued to

Company

Address

Fax

Phone

Catalogue number

Issue date

Boral Representative

Update record

Date Item Actioned by

ADV05004 (1/2) 10/08

1.0 Bricks1.1 Brick Properties

1.101 Brick Dimensions

1.102 Brick Strength

1.103 Water Absorption

1.104 Durability

1.105 Moisture Expansion

1.105 Efflorescence

1.105 Pitting due to Lime

1.2 Brick Masonry Design

1.201 Robustness

1.205 Masonry Strength

1.206 Durability of Masonry

1.208 Brick Ties

1.209 Movement in Masonry Walls

1.211 Thermal Properties

1.213 Masonry Design for Fire Resistance

1.214 Masonry Design for Structural Adequacy FRL

1.222 Masonry Design for Integrity FRL

1.222 Masonry Design for Insulation FRL

1.222 Effect of Recesses for Services on FRL’s

1.223 Effect of Chases on Fire Rated Masonry

1.224 Options for Increasing FRL’s

1.225 Acoustic Performance Rating

1.227 Weighted Sound Reduction Index (Rw)

1.227 Impact Sound Resistance

1.227 BCA Deemed to Satisfy Walls

1.230 Solid v Cavity Walls

1.230 Brick Walls with Render

1.230 Brick Walls with Plasterboard

1.231 Points to Consider When Designing Walls for Acoustic Performance

1.231 Acoustic Performance On-Site

1.232 Perimeter Acoustical Sealing

1.232 Doors

1.233 Lightweight Panels Above Doors

1.233 Air Paths Through Gaps, Cracks or Holes

1.233 Appliances

1.233 Electrical Outlets & Service Pipes

1.3 Brick Masonry Construction

1.301 Mortar

1.304 Joint Types

1.305 Joint Sizes

1.305 Weepholes

1.306 Brick Estimator

1.307 Brick Bonds

1.310 Brick Coursing Height

1.311 Brick Gauge

1.313 Blending

1.313 Brick Storage

1.314 Laying Practices

1.315 Control Joints

1.315 Damp Courses and Flashing

1.316 Cleaning of Clay Masonry

1.4 Property Tables

Bricks & Pavers Technical ManualContents 1 of 2

ADV05004 (2/2) 10/08

2.0 Pavers2.1 Paver Properties

2.101 Paver Dimensions

2.102 Paving Strength

2.103 Durability

2.103 Slip Resistance

2.104 Abrasion Resistance

2.104 Moisture Expansion

2.104 Efflorescence

2.105 Pitting due to Lime

2.105 Cold Water Absorption

2.2 Pavement Design

2.201 Pavement Types

2.203 Description of Layers & Basic Engineering Design Requirements

2.203 Subgrade

2.204 Base Course

2.205 Bedding Course

2.206 Surface Course

2.207 Edge Restraints

2.209 Drainage

2.210 Paver Laying Patterns

2.212 Joints Between Pavers

2.213 Tolerance on Course Levels

2.213 Crossfalls

2.214 Steep Gradients

2.3 Pavement Construction

2.301 Paver Estimator

2.301 Subgrade Preparation

2.302 Base course Preparation for Flexible Pavements

2.302 Edge Restraints for Flexible Pavements

2.303 Bedding Course for Flexible Pavements

2.305 Paver Storage

2.305 Blending

2.306 Laying Practices

2.311 Sand Filled Joints

2.311 Mortar Filled Joints

2.311 Compaction

2.312 Trafficking After Construction

2.312 Cleaning

2.4 Property Tables

Bricks & Pavers Technical ManualContents 2 of 2

7.0 Reference MaterialCHIPexpress® Homestyle Brochures

6.0 Projects In View

4.0 Engineered Utility Brick RangeProduct Data Sheets

5.0 Paver Range

3.0 Face Brick Range

1. Bricks

1 Bricks

1.1 Brick Properties

Section 1.1 relates to the properties of bricks made to meet the requirements of Australian Standard AS4455

Part 1 Masonry Units. This information is provided as a guide only to the properties of interest to a masonry

designer or builder.

Brick Dimensions

The work size of a standard brick is: 76 mm high x 230 mm long x 110 mm wide.

Some bricks are made with different work sizes. For example brick heights of 119 mm and 162 mm to match 1.5

and 2 standard size brick heights, including mortar joint, respectively. 50 mm and 90 mm high bricks, 90 mm wide

bricks and 290 mm long bricks are made for different structural and aesthetic effect. Larger bricks are often used

for more economical laying and as a design feature either on their own or combined with smaller bricks.

In cyclonic areas larger (140 mm wide x 90 mm high x 290 mm long) hollow bricks are used to allow for

reinforcement and grouting in the wall. Wider (150 mm wide) bricks can also be used in walls requiring lower

sound transmission, higher fire resistance levels and higher load bearing capacity depending on the specific brick

properties.

Clay brick sizes may vary after they are fired but size variation between units averages out when blended

properly during laying. Brick dimensions are measured by dry stacking 20 units, measuring the total length, width

and height and comparing that measurement to 20 times the work size.

Bricks are classified according to how much 20 bricks together deviate from 20 times the work size.

• Forstandardbricks,DimensionalCategoryDW1meanstheheightandwidthwilldifferbylessthanplusor

minus 50 mm from 20 times the work size, and the length will differ less than plus or minus 90 mm.

• Forstandardbricks,DimensionalCategoryDW2meanstheheightandwidthwilldifferbylessthanplusor

minus 40 mm from 20 times the work size, and the length will differ less than plus or minus 60 mm.

• DimensionalCategory,DW0means there are no requirements. This is usually reserved for non-standard

shaped bricks and bricks that have been rumbled or otherwise distorted during the manufacturing process

for aesthetic reasons. ■

Bricks & Pavers Technical Manual

Section 1.1 Brick Properties 1.101

ADV03743

Brick Strength

Brick strength is defined as resistance to load per unit area and is expressed in mega Pascals (MPa).

Characteristic Unconfined Compressive Strength (f’uc)

The characteristic unconfined compressive strength is used by engineers in the design of masonry to calculate

the strength of a wall. Bricks in any one batch have a range of strengths that would usually follow a normal

distribution. In a wall the different strength bricks contribute to the strength of the whole and the weakest brick

does not determine the strength of the wall. For safety, engineering practice has been to use characteristic

unconfined compressive strength. This is the strength 95% of the bricks will exceed and is typically 0.86 times

the lowest unconfined compressive strength found when measuring the compressive strengths of 10 samples.

Boral bricks usually have characteristic unconfined compressive strengths in the range 15 to 35 MPa.

Unconfined Compressive Strength

The unconfined compressive strength is a calculated number based on the compressive strength. To measure the

compressive strength of a brick, steel platens are used above and below. This constrains the surface and where

all other factors are equal, a shorter brick will have a higher compressive strength than a taller brick. To remove

this test effect, the compressive strength is multiplied by a factor, which varies with the height of the brick. The

resulting number is called the unconfined compressive strength and reflects the performance of the brick in a

wall. Theoretically, bricks which are identical except for their height should produce the same unconfined

compressive strength. This figure is not now used in masonry design, but is used to calculate Characteristic

Unconfined Compressive Strength.

Compressive Strength of Bricks

Brick strength is measured according to AS4456.4 Determining Compressive Strength of Masonry Units.

Individually crushing 10 bricks gives the compressive strength of each brick and the mean compressive strength

of the lot. These figures are not used in masonry design, but are used to calculate Unconfined Compressive

Strength. ■



ADV03744

Water Absorption

Cold Water Absorption

The amount of water that a brick can absorb is measured by the cold water absorption test. There is no distinct

relationshipbetweenwaterabsorptionandthewater-tightnessofwalls.Theresultsofwaterabsorptiontests

are used by the brick manufacturer for quality assurance.

Initial Rate of Absorption

The initial rate of absorption (IRA) is the amount of water absorbed in one minute through the bed face of the

brick. It is a measure of the brick’s ‘suction’ and can be used as a factor in the design of mortars that will bond

strongly with units. As mortars other than the ‘deemed to comply’ mortars are rarely used, the impact of the IRA

is primarily on the bricklayer. Bricklayers, through practical experience, adjust the mortar, the height of a wall

built in a day and the length of time before ironing the joints, according to the suction.

The bond between the masonry unit and mortar is largely influenced by the capacity of the brick to absorb water

and the ability of the mortar to retain the water that is needed for the proper hydration of cement. If the brick

sucks the water too quickly from the mortar, the next course may not be properly bedded. If the mortar retains

too much water, the units tend to float on the mortar bed, making it difficult to lay plumb walls at a reasonable

rate. In either case there will be poor bond.

The optimum value of IRA is considered to be between 0.5 and 1.5 kg/m2/min. However, IRAs can exceed

these limits. The mortar’s water retentivity should be matched to the brick type where good bond strength is

critical. ■



ADV03745

Durability

Salt attack is the most common durability problem affecting bricks. In the form of a solution, salt can be

absorbed into masonry. As the water evaporates, the salt is drawn towards the outside face. The evaporating

waterleavesthesolutionsuper-saturatedsosaltcrystalsbegintoform.Thesaltcrystalsgrowintheporesjust

below the surface and depending on the texture of the brick, the amount of salt, the rate of drying and the

temperature, the salt may fill the pores, exerting very high pressures on the matrix. The energy in the constrained

salt crystal increases and if sufficient ‘pops’ a piece of the outer surface off and salt attack has begun.

Bricks are assessed and classed into three grades according to AS/NZS4456.10 Resistance to Salt Attack. In

summary the three grades of brick that can be used are as follows:

• ProtectedGrade(PRO)

Suitableforuseinelementsabovethedamp-proofcourseinnon-marineexteriorenvironments.Elements

above the damp-proof course in all exterior environments, with a waterproof coating, properly flashed

junctions with other building elements and a top covering (roof or coping) protecting the masonry.

• GeneralPurposeGrade(GP)

Suitable for use in an external wall, excludingwalls in severe marine environments or in contact with

aggressivesoilsandenvironments(seeAS3700AppendixE).Generalpurposegradebrickscanalsobeused

in PRO applications.

• ExposureGrade(EXP)

Suitable for use in external walls exposed to severe marine environments, i.e. up to one kilometre from a

surfcoastorupto100metresfromanon-surfcoastorincontactwithaggressivesoilsandenvironments.

Thedistancesarespecifiedfrommeanhighwatermark.ExposuregradebrickscanalsobeusedinPROand

GPapplications.

BoralbricksareclassifiedaseitherEXPorGP.■



ADV03746

Moisture Expansion

Clay products expand over time as they absorb water into their structure. This is well known and documented

and must be consider when designing brickwork. The expansion is not uniform (it is logarithmic) over time. In

the first six months one quarter of the expansion occurs, one half in the first two years and three quarters in the

first5years.TheCharacteristicExpansionisestimatedfromanacceleratedtestandexpressedasacoefficient

of expansion (em) that for Boral bricks is usually between 0.8 and 1.2 mm/m/15 years. ■

Efflorescence

Bricks may contain soluble salts that come to the surface when the brick dries. The source of these soluble salts

is the raw materials used in the brick production process.

Brick efflorescence should not be confused with the efflorescence that is seen on masonry walls after

construction. This form of efflorescence is caused mainly from the raw materials and water used in the wall

construction process (eg. Mortar).

Brick efflorescence is usually white but there is a special form of efflorescence (known as vanadium staining)

that is coloured yellow, green or reddish-brown and is therefore particularly visible on light coloured bricks.

All efflorescence is more or less visible depending on the colour and surface texture of the brick.

Boral bricks have a nil to slight efflorescence. ■

Pitting due to Lime

If brickmaking raw materials contain particles of calcium carbonate, these will be converted into quicklime in

the kiln. Water subsequently combines with the quicklime to form hydrated lime and in the process expands.

If lime particles are sufficiently large and sufficiently near the surface they ‘pop’ off a piece of the brick, leaving

a generally circular pit.

Boral Bricks rarely show lime pitting. ■



ADV03747

1.2 Brick Masonry Design

The following design information is based on Australian Standard AS3700: 2001 Masonry Structures. Reference

to ‘Clauses’ and ‘Formulae’ are those used in AS3700. This information is provided as a guide only to the

processes involved in designing masonry. All masonry should be designed by a suitably qualified structural

engineer.

Robustness

AS3700, Clause 4.6.1 requires walls to have an adequate degree of ‘Robustness’. Robustness is a minimum

design requirement, and may be overridden by fire, wind, snow, earthquake or live and dead load requirements.

In robustness calculations (AS3700 Clause 4.6.2), there are height, length, and panel action formulae. By reworking

the standard formulae and inserting known data, it is possible to determine whether a chosen design and Boral brick

will provide adequate robustness, as in the tables below and the charts on pages 1.202 to 1.204.


Section 1.2. Brick Masonry Design 1.201

ADV03749

Maximum Wall Length (m)

Wall Thickness (mm) Lateral Support One End Lateral Support Both Ends

90 1.08 3.24

110 1.32 3.96

150 1.80 5.40

230 2.76 8.28

Table 3. Maximum Wall Length where One or Both Ends are Laterally Restrained

Table 2. Maximum Height of Walls with Free Ends

Maximum Wall Height (m)

Wall Thickness (mm) No Lateral Support at Top Lateral Support at Top Concrete Slab on Top

90 0.54 2.43 3.24

110 0.66 2.97 3.96

150 0.90 4.05 5.40

230 1.38 6.21 8.28

Pier Thickness (mm) Maximum Height (m)

230 x 230 3.105

350 x 350 4.725

Table 1. Maximum Height of Isolated Piers

In the situation depicted in Table 3 above, height is not limited although length is. This typically applies to lift

shafts and stairwells. Control joints and openings greater than one fifth of the wall height are treated as free

ends unless specific measures are taken to provide adequate lateral support.

WherewalllengthsexceedthoseinTable3above,AS3700Equation4.6.2(4)mustbeusedtodeterminethemaximum

height for a wall of the required length. Should the initial choice of product not provide a suitable solution, then a thicker

Boral brick or increased masonry width or extra restraints should be evaluated. t

Robustness (continued)

How to Use the Boral Robustness Graphs

These charts determine the minimum brick thickness for a known wall height, length and restraint criteria.



ADV03750

1. Select the graph for the chosen wall restraint

(support) criteria. In this example there is support

on one side and the top is supported by other

than a concrete slab. Typically this would be a

wall supporting roof frames, joined into another

wall at one end and with a door at the other

end.

2. Plot the intersection of the design Wall Height

and the Wall Length on the graph. (For this

example 3 m height x 5 m length).

3. ThelinesABOVEtheintersectionpointindicate

wall thickness that are acceptable. In this

example, the intersection point is just below the

line for 110 mm bricks. Therefore a single leaf of

110 mm bricks would be suitable and the most

economical.

8

7

6

5

4

3

2

1

01 22 3 4 5 6 7 8

WA

LL

H

EI

GH

T

(m

)

W A L L L E N G T H ( m )

230mm

90x90mm110mm90mm

150mm110x110mm

FR

S

R

Laterally supported one end and top laterally supported by other than concrete slab

Robustness Limits



ADV03751

8

7

6

5

4

3

2

1

01 22 3 4 5 6 7 8

WA

LL

H

EI

GH

T

(m

)


90x90mm

110mm

90mm

150mm

110x110mm

RR

R

R

Laterally supported both ends and top laterally supported by a concrete slab

8

7

6

5

4

3

2

1

01 22 3 4 5 6 7 8

WA

LL

H

EI

GH

T

(m

)


90x90mm110mm

90mm

150mm

110x110mm

RR

S

R

Laterally supported both ends and top laterally supported by other than concrete slab

8

7

6

5

4

3

2

1

01 22 3 4 5 6 7 8

WA

LL

H

EI

GH

T

(m

)


90x90mm110mm90mm

150mm

110x110mm

RR

F

R

Laterally supported both ends and top unsupported

8

7

6

5

4

3

2

1

01 22 3 4 5 6 7 8

WA

LL

H

EI

GH

T

(m

)


230mm

90x90mm110mm90mm

150mm110x110mm

FR

F

R

Laterally supported one end and top unsupported

ADV03752

1.204


Section 1.2. Brick Masonry Design

Robustness Limits

8

7

6

5

4

3

2

1

01 22 3 4 5 6 7 8

WA

LL

H

EI

GH

T

(m

)


90x90mm110mm

90mm

150mm

110x110mm

FR

R

R

Laterally supported one end and top laterally supported by a concrete slab

8

7

6

5

4

3

2

1

01 22 3 4 5 6 7 8

WA

LL

H

EI

GH

T

(m

)


230mm

90x90mm110mm90mm

150mm110x110mm

FR

S

R

Laterally supported one end and top laterally supported by other than a concrete slab

Masonry Strength

Masonry Strength is defined as resistance to load per unit area. It must be remembered that thicker masonry

will support more load than thinner masonry of the same strength.

Characteristic Compressive Strength of Masonry – f’m

f’m = km kh √f‘uc

km is a mortar strength factor and kh is a factor for the amount of mortar joints.

km is 1.4 for M3 mortar and 1.5 for the stronger M4 mortar (see AS 3700 Table 3.1 for a full list of factors).

kh is 1 for 76 mm high units with 10 mm mortar beds and is 1.24 for 162 mm high bricks with 10 mm mortar

beds (see AS 3700 Table 3.2 to derive factors for other unit and joint heights). In other words, a wall of

double height bricks is more than 20% stronger than a wall of 76 mm high bricks of the same f‘uc.

f’uc is the characteristic unconfined compressive strength of bricks.

Characteristic Flexural Tensile Strength of Masonry – f’mt

In flexing, the top of the arc is in tension and the bottom of the arc is in compression. Masonry is good in

compression but poor in tension. Flexural strength depends on the mortar/brick bond and for design purposes is

generally taken to be zero. Using up to 0.2 MPa is permitted when designing for transient loads such as wind,

earthquake, etc. Higher bending forces may be used for design but these require site testing to verify construction

meets the stated values.

Characteristic Shear Strength of Masonry – f‘ms

Shear strength, like flexural strength, is related to the mortar/brick bond. For design purposes, at the damp

course,itistakentobezerounlesstestingshowsanothervalue.Elsewhere,mortarjointshavef’ms values of

between 0.15 and 0.35 MPa. ■



ADV03753

Durability of Masonry

AS3700 requires masonry to be designed to continue functioning satisfactorily throughout its design life without

unduemaintenance.Thatis,allmasonrymaterials,includingbricks,mortarandallbuilt-incomponents,mustbe

sufficientlydurable for theexposureclassificationof thesite (seeAS3700AppendixE).Masonrydesigned to

meet the requirements of AS3700 Section 5, is deemed to comply with the durability requirements and Table 5.1

definesthedurabilityrequirementsforbricks,built-incomponentsandmortarindifferentenvironments.

Salt attack is the most common durability problem. In the form of a solution, salt can be absorbed into masonry.

As the water evaporates, the salt is drawn towards the outside face. The evaporating water leaves the solution

super-saturatedsosaltcrystalsbegintoform.Thesaltcrystalsgrowinthepores justbelowthesurfaceand

depending on the texture of the brick, the amount of salt, the rate of drying and the temperature, the salt may

fill the pores, exerting very high pressures on the matrix. The energy in the constrained salt crystal increases and

if sufficient ‘pops’ a piece of the outer surface off and salt attack has begun.

Boralbricksgraded‘GeneralPurpose’(GP)aresuitableforuseinallwalls,excludingexternal walls in severe

marine environments or in all walls in contact with aggressive soils and environments.

Boralbricksgraded‘ExposureGrade’(EXP)aresuitableforuseinallwallsincludingexternal walls exposed to

severe marine environments, i.e. up to 1 km from a surf coast or up to 100 m from a non surf coast or walls in

contact with aggressive soils and environments. The distances are specified from mean high water mark.

Walls below damp proof course often require greater durability, even if they are well away from the coast, as

they may be subjected to saline, acidic or alkaline soils. If unsure of the corrosive nature of the site, an

inexpensive total soluble salt content test for soil is available in most areas. Remember it is the designer’s

responsibilitytospecifytheappropriatedurabilitygradeofbricks,mortarandbuilt-incomponentsanditisthe

builder’s responsibility to order bricks, etc. of appropriate durability grade specified by the designer. Brick

manufacturers cannot take any responsibility in this decision as they are not aware of the design requirements

of each site. t



ADV03754

Durability of Masonry (continued)

Refer to Section 1.4 Property Tables for tabulated properties of individual brick types for their salt attack

resistance category.

Mortar mix requirements for durability are referred in Table 11, page 1.301 of this manual and are detailed in

AS3700 Table 10.1.

M4 mortars are required and mortar joints must be tooled in all situations requiring exposure grade materials.

Concrete floors, paths and steps are a source of sulfate salts that if dissolved in water may enter the brickwork and

cause salt attack. Exposed slabs supported on external brickwork should clear the brickwork by 50 mm and

incorporateadripgroovetopreventtherun-offfromtheslabrunningdownthebrickwork.Adampproofcourse

(usually a double layer) is also used under the slab on top of the bricks to prevent water passing through the slab

into the bricks and as a slip joint to prevent a build up of forces as the concrete shrinks and the bricks expand

over time.

Landscaping and gardening practices are also possible sources of salt attack. Care must be taken to not bridge

the damp proof course when landscaping at the base of walls. Watering gardens and lawns, against walls, may

cause salts (fertilisers) to splash up on to the wall where they are absorbed and may cause salt attack. ■



ADV03755

Brick Ties

Inbrickveneerconstruction, tiesareused topassall the lateralout-of-plane loadsand forces (suchas from

wind) tothestructuralbacking. Incavitybrickconstructiontieseitherpassthe lateralout-of-plane loadsand

forces to the stronger leaf or share them between the leaves.

The design of ties in masonry for structural purposes must comply with AS3700 Clause 7.7 for veneer or Clause

7.8 for cavity construction. For small buildings the tie requirements are covered in AS3700 Clause 12.3.4 for brick

veneer construction and Clause 12.3.3.2 for cavity brick construction.

Type A ties are those that have no specific seismic design characteristics. It is difficult to find brick ties other

than Type A in Australia. Ties are available in heavy, medium and light duty in galvanised steel, stainless steel

and plastic. Plastic ties are usually reserved for acoustic applications. Stainless steel ties are used in situations

requiringexposuregradematerialsorverylonglife.Galvanisedsteeltiesarethosemostcommonlyused.

The Newcastle (NSW) earthquake which occurred in 1989 showed masonry survived well except where the ties

were deficient. Problems found included:

• galvanisedtiesrustedthrough;

• tiesonlybuiltintooneleafduringconstruction;

• looseties;

• absentties;and,

• incorrectdutytiesused.

Ties are required to meet the durability requirement of the site for the design life of the building. Should the

design life of the building be exceeded and the ties begin to fail, they can be replaced with remedial ties but

this is a very expensive process and as ties are hidden it is unlikely they will be seen until a catastrophic failure

occurs. As sustainability considerations become more important, the life of buildings is likely to be extended.

Properly maintained, brick buildings may last for centuries. It should be remembered that stainless steel brick

ties offer a longer service life and, although more expensive as a proportion of the overall building cost, the

difference is trivial. ■



ADV03756

Movement in Masonry Walls

To allow for movements in masonry (expansion and contraction and footing movement) control joints are

required. These can usually be constructed so that the expansion joint and the articulation joint are one and

the same.

Expansion Joints

Expansion and contraction must be allowed for in masonry design by inserting control joints at spacings

designed to suit the magnitude of the movement.

Clayproductsexpandpermanentlyovertime.Thisistheoppositeofcement-basedproducts,whichpermanently

shrink. For this reason it is unwise to use clay and concrete units in the same band in a wall. If clay bricks are

used in concrete framed buildings, control joint spacing and workmanship are critical, as the bricks will expand

as the concrete frame shrinks.

The magnitude of thermal changes varies from brick to brick depending on the many factors, however, allowing

0.008mm/m/°C isusually recommended.Expansionandcontractionfromwettinganddryingofclaybricks is

less than for concrete and calcium silicate products and usually can be ignored in brick masonry design.

AS3700, Clause 4.8 requires expansion joints to be spaced to limit panel movement so that movement from both

sides closes joints by less than 15 mm and joints are at least 5 mm wide when closed. This means the gap, when

constructed,shouldbe20-25mm.However,inmostbuildingsarticulationjointsareusedandthesearecloser

than required for expansion making separate expansion joints unnecessary.

Articulation Joints

Articulation joints are vertical gaps that allow for minor footing movements, to prevent distress or significant

wall cracking. Articulation joints provide the flexibility needed when building on reactive clay soils and usually

are not required for masonry on stable sites (classified according to AS2870). Spacing of articulation joints

depends on the site classification and the slab or footing design, but where used must be placed no closer than

0.5 metres and no further than 3 metres from all corners. The width of articulation joints depends on the height

of the masonry: 10 mm for masonry up to 3 metres and 15 mm for masonry up to 6 metres high. t



ADV03757

Movement in Masonry Walls (continued)

Control Joints (General)

Control joints should be used beside large openings, where wall thickness changes (except where this is for

support eg. engaged piers), where wall height changes by more than 20%, at changes of level in footings and

at other points of potential cracking. Control joints must not continue through bond beams.

Ideally, control joints are located near a corner and concealed behind a down pipe. The bricklayer and renderer

must keep the control joint clean, otherwise, bridging mortar or render will induce cracks as the masonry moves.

Externalcontroljointsshouldbefinishedwithasoftflexiblesealanttopreventmoisturepenetration.

The design and construction of control gaps in the external leaf of a full brick wall is identical to that in brick

veneer. In internalmasonry, control gaps are not usually required, except at re-entrant angles in longwalls.

However, where an internal control joint is required the design is as for external leaves but the thermal

componentmaybeignoredincalculations.Internalcontroljointscanusuallybelocatedatafull-heightopening

such as a door or window.

Ties are required on both sides of a control joint, but where it is not possible to use them masonry flexible

anchors (MFAs) must be used across the joint. Where MFAs are used in walls over 3 metres or in walls exposed

to high winds, MFAs must be built in at half height and every seventh course (600 mm) above. MFAs are ties that

are of a type that only allows movement in one plane. Unless ties are used, control joints create a ‘free end’ in

terms of Robustness and Fire Resistance Level calculations for structural adequacy, so their positioning is critical

to the overall design of the structure. In

portal frame construction, the control

joint is positioned at a column so that

both ends can be tied to the column’s

flanges.

The principles of control joint

construction are illustrated in the

adjacent figure. ■



ADV03758

Articulation joints with compressible backing and mastic sealant

Dividing wall with articulation joint and M F A's at intersection with cavity wall

Brick ties on each side of articulation joint

Articulation joint

Thermal Properties

The initial aims of the Building Code of Australia (BCA) were to safeguard people from illness and injury and to

safeguard adjacent property from building failures. Legislators subsequently determined to use the BCA for other

purposesandhavenowaddedrequirementsforenergyefficiencyperformanceofbuildings.‘Energyefficiency’

consists of three main aspects, thermal performance, hot and cold water provision and lighting. Thermal

performance is the only aspect impacting on brick masonry construction.

Australia isdivided into8climatic zones. (EasternSydneyandPerthare inZone5,Adelaide,Melbourneand

WesternSydneyareinZone6,BrisbaneisinZone2andCanberraisinZone7).ThezonesandLocalGovernment

boundaries are detailed on a map, which is available from the Australian Building Codes Board (www.abcb.gov.

au) but the Local Council is able to provide the information where there is any doubt. In most cases the

boundaries between zones are those between council areas.

BCA Volume 1 divides buildings into three groups with different minimum energy efficiency requirements:

1. EachsoleoccupancyunitofaClass2buildingorClass4partofabuildingmustachievenotlessthan3stars

andtheaverageforallofthesoleoccupanciesinthebuildingmustbeatleast3.5starsforZones1-3and

4starsforZones4-8.Energyefficiencyofbuildingsexpressedasa‘StarRating’isdeterminedusingthermal

calculationsoftwarethatcomplieswiththeABCBProtocolforHouseEnergyRatingSoftware.

2. Class 3 and Class 5 buildings, Class 6 shops, shopping centres, restaurants and cafes, Class 8 laboratories,

Class 9a clinic, day surgery or procedure unit or ward area in a health care building, Class 9b theatres,

cinemas or schools and Class 9c aged care facilities must have a calculated annual energy consumption less

than or equal to that calculated for a reference building.

3. Certain buildings which are designed to not have conditioned (heated or cooled) spaces such as unenclosed

car parks or ambient temperature warehouses are excluded from the requirements.

BCA Volume 2 requires a minimum energy efficiency for Class 1 buildings and the whole of Class 1 and attached

enclosed Class 10a parts of buildings. The energy efficiency requirement is met by achieving a rating of 5 stars

or by showing that heating and/or cooling loads are equal to or less than those of a reference building in the

same zone. A ‘Star Rating’ is determined using thermal calculation software complying with the ABCB Protocol

forHouseEnergyRatingSoftware.

WhiletheBCAsetstheseminimumrequirements,StateGovernmentsmayadopttheseminimumsormayoptfor

different requirements. Local authorities may adopt higher star ratings but may not opt for lower ratings than

the State adopts. t


Section 1.2. Brick Masonry Design 1.211a

ADV1211A


1.211b

ADV1211B


Thermal Properties (continued)

Variations to the BCA Requirements in brief are:

In the Northern Territory, Queensland and Tasmania BCA2008 Volume 2, Energy Efficiency provisions do not

apply, however those of BCA 2005 Volume 2 do apply.

IntheNorthernTerritorytheBCA2008,Volume1EnergyEfficiencyprovisionsdonotapply.

In Victoria, New Class 1 buildings must have either a rainwater tank connected to all sanitary flushing systems

or a solar water heater system.

Sole occupancy units of a Class 2 building must achieve not less than 3 stars and the average for all of the sole

occupancies in the building must be at least 5 stars.

Class 4 parts of a building must achieve not less than 4 stars.

InNSWtheEnergyEfficiencyprovisionsof theBCAdonotapply toClass1and2buildings,Class4partsof

buildingsandcertainClass10buildings.Developments(includingadditionsandalterations)intheseclassesare

subject to the Building Sustainability Index (BASIX) requirements. BASIX is a piece of comprehensive

sustainabilityratingsoftware,whichinitiallyincorporatedenergyandwaterefficiency.Itisaweb-basedsystem

in which data about the development is entered and the whole has to meet targets to get Development

Application (DA) approval. BASIX is aimed at achieving energy reductions and potable water savings. The

reductionsareonabasedevelopedbytheNSWDepartmentofPlanningbeforetheschemecameintoeffect

andtheyvaryfromplacetoplace.ThethermalcomfortaspectsofBASIXcanbesatisfiedbyfollowingeitherthe

‘simplified’,‘DIY’or‘assessor’routes.The‘simplified’isrigidandveryconservative.The‘DIY’isconservative

but allows a little more freedom. Both require direct entry of building design information into the web based

forms to meet the thermal comfort targets. The ‘assessor’ route is flexible but requires the services of an

accredited assessor. The assessor is required to provide heating and cooling load figures for the design.

Whether expressed as an energy load number or a star rating, the requirements are complex because the ratings

are based on the total building design for a given site. It is important to remember that roof insulation, shading,

orientation and window size and placement have a much greater impact on energy efficiency than the walls.

Heat enters and leaves buildings more readily through the windows and roof and greater insulation in the roof

space isusually themostcost-effectivemeasureto increasecomfort.There isnoexact relationshipbetween

thewalls’performanceand theenergy ratings.Thedeemed tosatisfy requirements in theBCAorBASIXare

conservativebecausetheyconsiderthewallsinisolation.Designsusingonlydeemedtosatisfysolutionswill

generally be very conservative and except for very small buildings, in most cases a professional energy rating

assessorcanprovidecheaperbuildingsolutions,morethanoff-settingthecostoftheirservices.t


ADV1212A

1.212aSection 1.2. Brick Masonry Design


The clay brick industry through Think Brick Australia (formerly the Clay Brick and Paver Institute) sponsored a

program of research at the University of Newcastle, focussed on the actual performance of clay brick masonry

in buildings. The published results of this research were used by the ABCB to include heavy masonry in the

deemed to satisfy provisions. The research clearly shows that heavy masonry walling has a high thermal inertia

(thermal lag). That is, the effect of cavity clay masonry is to slow the transmission of heat through the wall

reducing peaks and troughs in the temperature profile, ensuring a more comfortable temperature is maintained

longer than would be the case otherwise. With heavy mass walling, heat is slowly absorbed during the day and

slowly lost during the cool night. Most thermal requirements focus on thermal insulation, denoted as ‘R’ value.

When dealing with heavy mass walling ‘R’ value is misleading as it assumes a steady state (constant

temperaturedifferenceacrossthewall)whichisnotthecasebecauseoftheday-nighttemperaturecycle.Cavity

brick houses are well known to have lower temperature fluctuation than lighter weight construction particularly

when combined with a concrete slab coupled to the ground or with internal brick walls.

Decoding the BCA Deemed to Satisfy provisions

Volumes 1&2:

• ‘Achieveasurfacedensityofnotlessthan220kgpersquaremeter’

Two leaves of 90 mm or thicker bricks or a single leaf of 150 mm wide clay bricks or 140 mm wide clay bricks

with vertical cores filled with grout at minimum 1000 mm centres with render or plasterboard and a grouted

horizontal bond beam.

• ‘Incorporateacavityof20to35mm’

BCA Volume 1 has no deemed to satisfy provisions related to the cavity width for weatherproofing masonry.

BCA Volume 2 requires masonry to have a cavity (a void between two leaves of masonry) between 35 and

65 mm for weatherproofing. Insulation in the cavity of brick masonry must provide a minimum cavity of 35

mm in Class 1 and attached Class 10a parts of buildings and 20 mm in other classes of building and

prevention of moisture penetration must be maintained.

• ‘Masonrythathasathermalconductivityoflessthan0.8’

BCA Volume 1, Specification J1.2 ‘Materials Properties’, Table 2a ‘Thermal Conductivity of Typical Wall,

Roof/Ceiling and Floor Materials’, lists the thermal conductivity of 110 mm wide bricks weighing less than

3.75 kg as less than 0.78 W/m.K. All bricks manufactured by Boral, other than solid bricks, meet the

requirements for the thermal conductivity to be less than 0.78 W/m.K. t


• Volume2:TablesJ1.5aandJ1.5bR-valuerequirements

R-valuesdependonthetotalwallconstructionandaredeterminedbyaddingtheR-valuesfortheindividual

components through the wall as shown in Specification J1.5 Wall Construction, Figure 2.

Outdoorairfilm,indoorairfilm,cavities&plasterboardhavethevaluesshowninthetables.TheR-valuesfor

bricks were determined long ago and a linear relationship with the density was shown. This relationship is

shown in the Note 4d. Knowing the weight and the dimensions of the brick allows the density to be calculated

andusingthenumbersgiventheR-valuecanbeextrapolatedforanybrick.Brickweightsmaychangeovertime

and vary depending on the place of manufacture so it is advisable to ask your Boral Sales Representative for the

latest weight of any particular brick.

Note: For proper performance of walls it is critical that moisture penetration be prevented and in masonry this

is best achieved by having cavities. It is critical that the cavities are not bridged and they allow moisture to drain

away. For cavity (double) brick construction the insulation should hang in the cavity and should not touch either

brick leaf. The insulation should also be of a closed cell type, non absorbent or be of hydrophobic material so

that it does not absorb water and become saturated when the mortar droppings are flushed from the cavity

during brick laying. There are types of thin reflective insulation suitable hanging in cavities and there are rigid

board insulations. Boral Bricks makes no claims for or about any of the various types of insulation available.

DifferentR-valuesarerequiredofdifferentwallsindifferentsituationsanditisrecommendedthatyouconsult

insulation providers for their recommended types of insulation, the installation methods and techniques and the

appropriateR-valuesforthecalculations.■


Section 1.2. Brick Masonry Design 1.212b

ADV1212B

Masonry Design for Fire Resistance

Fire Resistance Levels (FRL)

FRLs come from the Building Code of Australia’s (BCA) Volume 1 tables for Type A, B or C construction. The Type of

construction depends on the Class of building and the number of stories or floors. FRLs for housing come from BCA

Volume 2.

There are three figures in the Fire Resistance Level.

Eg:FRL120/60/90meansthatthewallmustachieveStructuralAdequacyfor120minutes/Integrityfor60minutes/

Insulation for 90 minutes.

Structural Adequacy

This governs the wall’s height, length, thickness and restraints. Brick suppliers do not control the wall height,

length or restraints so therefore do not control Structural Adequacy.

Integrity

This is the resistance to the passage of flame or gas. To provide ‘integrity’, walls must be structurally adequate

andtheymustmaintaininsulation.Extensivefiretestingofmasonryhasshownintegritytobecloselyrelatedto

structural adequacy or insulation. AS 3700 therefore allows Integrity to be equal to the lesser of the Structural

Adequacy or the Insulation periods.

Insulation

This is resistance to the passage of heat through the wall. Insulation is a function of the thickness of the brick

as shown in Table 5, page 1.222 of this manual. ■



ADV03761

Masonry Design for Structural Adequacy FRL

Structural Adequacy is a minimum provision and may be over ridden by design for robustness, wind, live or

earthquake loads.

A fire on one side of a wall will heat that side, making it expand and lean towards the fire. When the lean or

bow reaches half the thickness of the original wall, the wall becomes structurally inadequate. The formulae in

AS3700, Clause 6.3.2.2 limits the panel size, depending on its restraints and thickness.

The Slenderness ratio (Srf) of a proposed wall is calculated according to AS 3700 Clause 6.3.2.2. If this value is

less than the maximum Srf in Table 6.1 of the Standard [or the Srf calculated from Fire Tests and AS 3700 Clause

6.3.3(b)(ii)], then the wall complies. If the Srf of the wall is greater than the maximum permissible, it must be

recalculated for an increased thickness and/or extra restraints.

There are 3 formulae for calculating Srf.

AS 3700 Formula 6.3.2.2 (1) and (2) are the formulae for vertically spanning walls (with no support along either

vertical edge).

Formula (1) and (2) always govern where there is no end restraint, and often govern where walls are long,

relative to their height. Projects with multiple wall lengths (eg: home units) can use this formula as a ‘one size

fits all’ method of calculating the wall thickness.

AS 3700 Formula 6.3.2.2 (3) allows a wall to exceed the height given by formula (1) and (2) provided the top and

at least one end is supported.

AS 3700 Formula 6.3.2.2 (4) allows a wall to exceed the height given in formula (3) where walls are short,

relative to their height (eg: a lift well or vent shaft). Short walls with no top restraint often occur in situations

like portal frame factories.

For cavity walls where both leaves are equally loaded (within 10 per cent of each other, including where there

isnoloadoneitherleaf)thethicknessisequaltotwo-thirdsofthesumofthethicknessesofbothleavesand

the edge restraint condition is that for the leaf not exposed to the fire. Where one leaf is more heavily loaded

than the other, the thickness and edge restraint condition is that of the more heavily loaded leaf. Where cavity

walls are constructed with leaves of different masonry unit types, the structural adequacy is based on the less

fire resistant material. t



ADV03762

Masonry Design for Structural Adequacy FRL (continued)

RefertotheStructuralAdequacyGraphsonthefollowingpagesformaximumheightandlengthvaluesforwalls

of different thicknesses and restraint conditions.

An appropriately qualified engineer should check all calculations. Other loads may supersede Structural

Adequacy requirements.

How to Use the Boral Structural Adequacy FRL Graphs



ADV03763

1. Select the graph with Structural Adequacy for

the required minutes. (240 minutes for this

example).

2. Select the graph for the chosen wall restraint

(support) criteria. (Support on both vertical

edges, top and bottom for this example).

3. Plot the intersection of the design Wall Height

and the Wall Length on the graph. (For this

example 3 m height x 5 m length).

4. The line ABOVE the intersection indicates the

minimum brick thickness required for the wall.

In this example, 150 mm bricks would be

suitable and the most economical.

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

01 2 3 4 5 6 7 12111098

HE

IG

HT

B

ET

WE

EN

S

UP

PO

RT

S

(m

)

L E N G T H B E T W E E N S U P P O R T S ( m )

110mm90mm

150mm

230mm

SS

S

S

Laterally supported on all sides

ADV03764

1.216



Structural Adequacy for 60 Minutes FRL

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

01 2 3 4 5 6 7 12111098

HE

IG

HT

B

ET

WE

EN

S

UP

PO

RT

S

(m

)


110mm90mm

150mm

230mm

SS

S

S


15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

01 2 3 4 5 6 7 12111098

HE

IG

HT

B

ET

WE

EN

S

UP

PO

RT

S

(m

)


110mm90mm

150mm

230mm

FS

S

S

Laterally supported on three sides, one end unsupported

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

01 2 3 4 5 6 7 12111098

HE

IG

HT

B

ET

WE

EN

S

UP

PO

RT

S

(m

)


110mm90mm

150mm230mm

SS

F

S

Laterally supported on three sides, top unsupported

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

01 2 3 4 5 6 7 12111098

HE

IG

HT

B

ET

WE

EN

S

UP

PO

RT

S

(m

)


110mm90mm

150mm230mm

FS

F

S

Laterally supported one end and bottom, one end and top unsupported

ADV03765

1.217




15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

01 2 3 4 5 6 7 12111098

HE

IG

HT

B

ET

WE

EN

S

UP

PO

RT

S

(m

)


110mm90mm

150mm

230mm

SS

S

S


15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

01 2 3 4 5 6 7 12111098

HE

IG

HT

B

ET

WE

EN

S

UP

PO

RT

S

(m

)


110mm90mm

150mm

230mm

FS

S

S


15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

01 2 3 4 5 6 7 12111098

HE

IG

HT

B

ET

WE

EN

S

UP

PO

RT

S

(m

)


110mm90mm

150mm230mm

SS

F

S


15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

01 2 3 4 5 6 7 12111098

HE

IG

HT

B

ET

WE

EN

S

UP

PO

RT

S

(m

)


110mm90mm

150mm230mm

FS

F

S


ADV03766

1.218




15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

01 2 3 4 5 6 7 12111098

HE

IG

HT

B

ET

WE

EN

S

UP

PO

RT

S

(m

)


110mm90mm

150mm

230mm

SS

S

S


15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

01 2 3 4 5 6 7 12111098

HE

IG

HT

B

ET

WE

EN

S

UP

PO

RT

S

(m

)


110mm90mm

150mm

230mm

FS

S

S


15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

01 2 3 4 5 6 7 12111098

HE

IG

HT

B

ET

WE

EN

S

UP

PO

RT

S

(m

)


110mm90mm

150mm230mm

SS

F

S


15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

01 2 3 4 5 6 7 12111098

HE

IG

HT

B

ET

WE

EN

S

UP

PO

RT

S

(m

)


110mm90mm

150mm230mm

FS

F

S


ADV03767

1.219




15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

01 2 3 4 5 6 7 12111098

HE

IG

HT

B

ET

WE

EN

S

UP

PO

RT

S

(m

)


110mm90mm

150mm

230mm

SS

S

S


15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

01 2 3 4 5 6 7 12111098

HE

IG

HT

B

ET

WE

EN

S

UP

PO

RT

S

(m

)


110mm90mm

150mm

230mm

FS

S

S


15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

01 2 3 4 5 6 7 12111098

HE

IG

HT

B

ET

WE

EN

S

UP

PO

RT

S

(m

)


110mm90mm

150mm230mm

SS

F

S


15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

01 2 3 4 5 6 7 12111098

HE

IG

HT

B

ET

WE

EN

S

UP

PO

RT

S

(m

)


110mm90mm

150mm230mm

FS

F

S


ADV03768

1.220




15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

01 2 3 4 5 6 7 12111098

HE

IG

HT

B

ET

WE

EN

S

UP

PO

RT

S

(m

)


110mm90mm

150mm

230mm

SS

S

S


15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

01 2 3 4 5 6 7 12111098

HE

IG

HT

B

ET

WE

EN

S

UP

PO

RT

S

(m

)


110mm90mm

150mm

230mm

FS

S

S


15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

01 2 3 4 5 6 7 12111098

HE

IG

HT

B

ET

WE

EN

S

UP

PO

RT

S

(m

)


110mm90mm

150mm230mm

SS

F

S


15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

01 2 3 4 5 6 7 12111098

HE

IG

HT

B

ET

WE

EN

S

UP

PO

RT

S

(m

)


110mm90mm

150mm230mm

FS

F

S


Structural Adequacy for Panels with Unsupported Ends

This figure shows the situation where there is support top and bottom but none on the sides. This applies

where there are control joints, large openings, long walls, etc. To use this graph select the desired FRL in

minutes and the height of the wall. The line above the intersection shows the brick thickness required.

Maximum Wall Heights for Structural Adequacy for any Wall Length



ADV03769

7

6

5

4

3

2

1

060 90 120 240180

MA

XI

MU

M

WA

LL

H

EI

GH

T

(m

)

F R L F O R S T R U C T U R A L A D E Q U A C Y ( m i n u t e s )

110mm90mm

150mm

230mm

FF

S

S

Top and bottom supported, ends not supported.

Masonry Design for Integrity FRL

It is impractical to provide test results for all possible wall designs, and therefore ‘Integrity’ must be proved in

some other way. The most practical way to prove ‘Integrity’ is to prove ‘Structural Adequacy’ and ‘Insulation’

equal to or better than the ‘Integrity’ requirement. Logically, if the wall is designed to minimise ‘bowing’ it will

not crack and therefore resist the passage of flame and gas for the specified time.

This method is also the best way to prove ‘Integrity’ even when a wall may not be required to comply with a

‘StructuralAdequacy’FRLvalue,suchasisthecasewithnon-loadbearingwalls.Eg.IftheBCArequiresanFRL

of-/90/90,thewallhasnoactual‘StructuralAdequacy’requirement,buttoproveIntegrityof90minutes,the

wall must be structurally adequate for at least 90 minutes. ■

Masonry Design for Insulation FRL

Insulation is the one FRL component that a brick manufacturer does control. It is governed by the ‘type of

material’ and ‘material thickness’.

‘Material thickness’ (t) is defined in AS3700, Clause 6.5.2 as the overall thickness for bricks with cores not more

than 30% of the brick’s overall volume.

For cavity walls, t = the sum of material thicknesses in both leaves.

Effect of Recesses for Services on FRLs

Recesses that are less than half of the masonry thickness and are less than 10,000 mm2 (0.01 m2) for both sides

within any 5 m2 of the wall area do not have an effect on fire ratings.

If these limits are exceeded, the masonry design thickness must be reduced by the depth of the recess. ■



ADV03770

Wallthickness(mm)

90

110

140 or 150 160 (150 plus 10 mm

230 180 220

render on both sides) (90/90 cavity) (110/110 cavity)

Insulationperiod(minutes) 60 90 120 180 240 240 240

Table 5. Insulation periods for standard bricks (minutes)

Note: Wall thickness excludes render on side of wall exposed to fire. ■

Effect of Chases on Fire Rated Masonry

Structural Adequacy FRL

To assess the effect of chases on Structural Adequacy FRLs, the direction in which the wall spans must be taken

into account.

• Wallsspanningverticallymaybechasedverticallytofullheightbuthorizontalchasesarelimitedinlength

to 4 times the wall’s thickness.

• Wallsspanningverticallyandhorizontallymaybechasedeitherhorizontallyuptohalfthewall’slengthor

vertically up to half the wall’s height.

If these limits are exceeded, the masonry design thickness must be reduced by the depth of the chase or, in the

case of vertical chases, designed as 2 walls with unsupported ends at the chase. Horizontal chases in all walls

should be kept to a bare minimum.

Note:Chasesaffectthesoundreductioncapacityofwalls.See‘AcousticDesign’page1.225ofthismanual.

Integrity and Insulation FRLs

AS3700 limits the maximum depth of chase to 30 mm and the maximum area of chase to 1,000 mm2. The

maximum total area of chases on both sides of any 5 m2 of wall is limited to 100,000 mm2 (0.1 m2). If these limits

are exceeded, the masonry design thickness must be reduced by the depth of the chase. ■



ADV03771

Options for Increasing FRLs

Structural Adequacy FRLs can be increased by adding wall stiffeners, by increasing the overall thickness, by

adding reinforcement or by protecting the wall, e.g. with Boral Plasterboard’s ‘FireStop’ board, fixed to furring

channels (on both sides of the wall if a fire rating is required from both sides). Note: Be careful of the effect of

plasterboardonsoundreductioninpartywalls.See‘AcousticDesign’page1.225ofthismanual.

Integrity FRLs are increased by increasing the other two FRL values to the required Integrity FRL.

Insulation FRLs can be increased by adding another leaf of masonry, by rendering both sides of the wall if the

firecancomefromeitherside.Note:OnlyONEthicknessofrenderisaddedtothematerialthicknessandthat

must be on the ‘cold’ side because the render on the exposed face will drop off early in a fire. ■



ADV03772

ACOUSTIC DESIGn

Acoustic Performance Rating

The BCA requirements are met by:

1. TestingasampleofconstructedwallstoverifythattheymeettheWeightedStandardisedLevelDifference

(Dnt,w–explainedfurtherin“AcousticPerformanceOn-Site’onpage1.231ofthismanual)requirements;

or

2. Constructing walls using the same materials and techniques as walls that have been constructed and tested

in a laboratory and shown to meet the Weighted Sound Reduction Index (Rw)requirements;or,

3. Constructing walls using the materials and techniques in the ‘Acceptable Construction Practice’ section of

theBCA;and,

4. Where impact sound reduction is required, it is to be achieved by discontinuous construction, except for

Class9cbuildingswherethereisatest;and,

5. Exceptwheretherequirementsareverifiedbyon-sitetesting,chasingofservicesintomasonrywallsisnot

allowed and electrical outlets on either side of the wall must be offset by no less than 100 mm.

The BCA acoustic performance requirements in Class 1, 2, 3 and 9c buildings are shown below in the tables.

Table 6. BCA Volume 2 Requirements for walls separating (Class 1) sole occupancy units

Wall separating Wall Rating

Soleoccupancyunit-allareasexceptthose below

Soleoccupancyunit-allareasexceptthose below

Rw+Ctr ≥50

Soleoccupancyunit-bathroom,sanitary compartment, laundry or kitchen

Soleoccupancyunit-habitableroomexcept a kitchen

Rw+Ctr ≥50 and

discontinuous construction

Northern Territory and Queensland have different requirements for acoustic performance of walls separating

Class1buildings.Thedifferencesare; inthetableabove, inRow1thewallratingrequiredisRw ≥45 and in

bottom row the rating required is Rw ≥50 with impact sound resistance, which may be determined by a tapping

testcomparingtoadeemed-to-satisfywall.t



ADV1225

ADV1226

1.226



Acoustic Performance Rating (continued)

Table 7. BCA Volume 1 Requirements for walls separating sole occupancy units from other parts of the building in Class 2 & 3 Buildings.

Wall separating Wall RatingSoleoccupancyunit-allareasexceptthose below

Soleoccupancyunit-allareasexceptthose below Rw+Ctr ≥50

Soleoccupancyunit-bathroom,sanitarycompartment, laundry or kitchen

Soleoccupancyunit-habitableroomexcept a kitchen

Rw+Ctr ≥50and

discontinuous construction

Soleoccupancyunit-allareas Plant room or lift shaftRw ≥50

anddiscontinuous construction

Soleoccupancyunit-allareas Stairway, public corridor, public lobby or areas of different classification Rw ≥50

Northern Territory and Queensland have different requirements for Class 2 and 3 buildings. The requirements

simply stated are that all separating walls shown in Table 7 have a rating of Rw ≥45, except those in row 2

where the walls must have a rating of Rw ≥50 and discontinuous construction or test to be no less resistant to

impactnoisethanadeemed-to-satisfywall(byatappingtest).

Table 8. BCA Volume 1 Requirements for walls separating sole occupancy units and other parts of the building in Class 9c Buildings (aged care facilities).

Wall separating Wall Rating

Soleoccupancyunit-allareas Soleoccupancyunit-allareasexceptthose below Rw ≥45

Soleoccupancyunit-allareas Laundry, kitchen

Rw ≥45and

discontinuous constructionor

No less resistant to impact noise than adeemed-to-satisfywall

Soleoccupancyunit-allareasBathroom, sanitary compartment (but not an associated ensuite), plant room, utilities room

Rw ≥45

Table 9. BCA Service separation* in Class 1, 2, 3 & 9c buildings.

Building service Adjacent room Barrier rating

A duct, soil, waste, water supply or stormwater pipe that serves or passes through more than one unit.

Sole occupancy unit habitable room other than a kitchen. Rw+Ctr ≥40

Sole occupancy unit kitchen or non habitable room Rw+Ctr ≥25

*InClass1buildingstherequirementsapplytothoseservicesthatpassthroughmorethanoneDwelling.InClass2,3&9crequirements apply to all stormwater pipes and other services that pass through more than one sole occupancy unit.

NorthernTerritoryandQueenslandhavedifferentrequirementsforseparationofservicesinthetableabove;the

requirements are respectively Rw ≥45 and Rw ≥30, which for masonry construction are roughly equivalent to the

figures in the table.

Weighted Sound Reduction Index (Rw)

Rwisasingle-numberratingofthesoundreductionthroughawallorotherbuildingelement.Sincethesound

reduction may be different at different frequencies, test measurements are subjected to a standard procedure

that yields a single number that is about equal to the average sound reduction in the middle of the human

hearing range. Two spectral corrections can be applied to Rw: “C” and “Ctr”. C compensates for medium to high

frequency noise and Ctr compensates for low frequency noise. “C” and “Ctr” are both negative numbers. ■

Impact Sound Resistance

The BCA Amendment 14 says there is no appropriate test for impact sound reduction in walls. However, in the

case of Class 9c buildings the BCA allows impact sound reduction to be demonstrated by showing a wall

performsnoworsethanadeemed-to-satisfywall.Toachieveimpactsoundresistance,theBCArequireswalls

consist of two leaves with at least a 20 mm cavity between them and if ties are needed in masonry walls they

mustbeoftheresilienttype.Exceptfortheresilienttiesinmasonrywallstherearetobenomechanicallinkages

between the walls, except at the periphery (i.e. through walls, floors and ceilings). ■

BCA Deemed-to-Satisfy Walls

BCAVolume1Amendment14SpecificationF5.2Table2givesdeemed-to-satisfywallsforsoundinsulationfor

walls separating sole occupancy units.

BCA Volume 2 Amendment 14 Table 3.8.6.2 gives deemed-to-satisfy walls for sound insulation for walls

separating two or more Class 1 Buildings. These walls are the same as those in Volume 1 except only walls

achieving Rw+Ctr ≥50 are allowed.

Deemed-to-satisfyclaybrickwallsaredetailedonthefollowingpages.t



ADV03775

ADV03776

1.228



Two leaves of 110 mm clay brick masonry with:

(a) Acavitynotlessthan50mmbetweenleaves;and

(b) 50 mm thick glass wool insulation with a density of 11 kg/m3 or 50 mm thick polyester insulation with a density of 20 kg/m3 in the cavity.

Construction Rating

Table 10. BCA Volume 1 Amendment 14 Deemed-to-Satisfy Brick Walls

BCA Deemed-to-Satisfy Walls (continued)

Rw+Ctr≥50

Two leaves of 110 mm clay brick masonry with:

(a) Acavitynotlessthan50mmbetweenleaves; and

(b) 13 mm cement render on each outside face.

Rw+Ctr≥50

Single leaf of 110 mm clay brick masonry with:

(a) A row of 70 mm x 35 mm timber studs or 64 mm steel studs at600mmcentres,spaced20mmfromthemasonrywall;and

(b) 50 mm thick mineral insulation or glass wool insulation with a density of 11 kg/m3positionedbetweenstuds;and,

(c) one layer of 13 mm plasterboard fixed to outside face of studs and outside face of masonry.

Rw+Ctr≥50

Single leaf of 90 mm clay brick masonry with:

(a) A row of 70 mm x 35 mm timber studs or 64 mm steels studs at 600 mm centres, spaced 20 mm from each face of the masonrywall;and

(b) 50 mm thick mineral insulation or glass wool insulation with a density of 11 kg/m3positionedbetweenstudsineachrow;and

(c) one layer of 13 mm plasterboard fixed to studs on each outside face.

Rw+Ctr≥50

ADV03777

1.229



Single leaf of 150 mm brick masonry with 13 mm cement render on each face.

Construction Rating

Table 10. BCA Volume 1 Amendment 14 Deemed-to-Satisfy Brick Walls (continued)

BCA Deemed-to-Satisfy Walls (continued)

Rw≥50


Rw≥50


Rw≥45

Solid v. Cavity Walls

Acoustic performance with single leaf masonry follows the ‘Mass Law’. The acoustic performance of these walls

depends on their mass. More mass gives better performance, however, the relationship is logarithmic: If a 110

mm wall gives Rw = 45, a 230 mm wall of the same brick may give Rw = 57.

Cavity walls behave differently because sound waves can resonate in cavities. The narrower the cavity becomes,

the more resonance occurs. Insulation in the cavity helps absorb resonating sound and narrow cavities should

have bond breaker board, to prevent mortar from providing a bridge for sound to travel between the leaves. ■

Brick Walls with Render

Render on one side of a brick wall adds 2 or 3 to the wall’s Rw but adding render to the second side only adds

1 to the wall’s Rw. The render appears to fill defects in the wall surface reducing the sound transmission, but

thisisaone-offbenefit.■

Brick Walls with Plasterboard

Cornice cement daubs, used to fix plasterboard directly to brick walls, create a small cavity in which resonance

occurs. Brick walls with daub fixed plasterboard on both sides stop less noise than the same walls, bare.

Adding extra daubs (halving spacing) gives lower performances, presumably due to extra ‘bridges’ through the

daubs.

Plasterboard on furring channel is marginally better than daub fixed. A bigger cavity between the wall and the

plasterboard makes it harder for resonating energy to build up pressure on the board. When standard furring

channel clips are used, this system transfers vibrations to the plasterboard via the channels and clips. Boral

Impact Clips (BICs) have a rubber shank on their masonry anchor that isolates the vibrations from the masonry.

The use of BIC mounts can add 3 or 4 dB to the wall’s Rw. Polyester and glass wool in the cavity helps prevent

resonanceandfurtherdecreasesthesoundtransmission.Densergradesofplasterboardandadditional layers

of plasterboard (fixed with grab screws and leaving no cavities) also decrease sound transmission. ■



ADV03778

Points to Consider When Designing Walls for Acoustic Performance

The BCA specifies minimum levels for sound isolation but experience shows that achieving the minimum

standards is not always sufficient to satisfy occupants. In view of this it is recommended that architects,

developers, builders, etc., consider a higher level of sound insulation, commensurate with the expectations of

theenduser.Enduserexpectationsarefrequentlyrelatedtothecostofoccupyingtheunit.

Wall design is a balance between acoustical performance, thickness, weight and cost. Frequently it is not

possible to optimise one factor without seriously compromising the others. ■

Acoustic Performance On-Site

The Rw ratings on walling systems are obtained from tests carried out in accredited laboratories, under

controlledconditions.Whenidenticalpartitionsinbuildingsaretestedin-situ,itisoftenfoundthattheactual

resultobtained,calledtheWeightedStandardisedLevelDifference(Dnt,w), is lower than the laboratory Rw. This

reduction in performance can be due to rooms being too small, varying size of the element being tested, flanking

paths (noise passing through other parts of the building) or background noise. The allowance in the BCA for a

difference of 5 between the laboratory test and the field test is not to allow for poor construction practice. To

repeat the performance in the field, attention to detail in the design and construction of the partition and its

adjoiningfloor/ceilingandassociatedstructureisofprimeimportance.Eventhemostbasicelements,ifignored,

can seriously downgrade the sound insulation performance.

The most common field faults include bricklayers not completely filling all mortar joints, poor sealing between

walls and other building elements, electrical power outlets being placed back to back, chasing masonry and

concrete walls, leaving gaps in insulation, screwing into insulation and winding it around the screw when

attaching sheet materials, not staggering joints in sheet materials and poor sealing of penetrations.

Boral Bricks cannot guarantee that field performance ratings will match laboratory performance. However, with

careful attention during construction of the wall, correct installation to specification and proper caulking/

sealing, the assembly should produce a field performance close to and comparable with tested values. The

following items can also affect the acoustic performance on site. ■



ADV03779

Perimeter Acoustical Sealing

As the Rw of a wall increases, the control of flanking paths becomes more critical. Consequently, the perimeter

sealing requirements for a low sound rating wall, such as Rw = 45, are much less than for a high sound rating

wall, such as Rw = 60. Note: it is neither necessary, nor is it cost effective, to provide very high perimeter

acoustic sealing for a low Rw wall.

Effectivesealantshavethefollowingproperties:

• Goodflexibility,(elasticset);

• Lowhardness;

• Excellentadhesion,usuallytoconcrete,timber,plasterandgalvanisedsteel;

• Minimalshrinkage(lessthan5%);

• Moderatedensity(greaterthan800kg/m3);andare,

• Fireratedwhererequired(AllwallsrequiredbytheBCAtobesoundratedalsohavefireratings).

All of the above properties must be maintained over the useful life of the building, that is, greater than 20

years.

Note:Use of expanding foam sealants is not acceptable.

Refer to the manufacturer to ensure the particular type or grade of sealant is suitable for the purpose. ■

Doors

Hollow,coredandevensoliddoorsgenerallyprovideunsatisfactorysoundinsulation.Doorscanprovidedirect

air leaks between rooms lowering the overall Rw of the wall in which they are inserted. Where sound insulation

is important, specialised heavyweight doors or, preferably, two doors separated by an absorbent lined airspace

or lobby should be used. ■



ADV03780

Lightweight Panels Above Doors

Panels are often incorporated for aesthetic reasons, however, they should not be used unless they have an Rw

equal to or better than the wall’s requirement. ■

Air Paths Through Gaps, Cracks or Holes

Seal all gaps, cracks or openings, however small, with an acoustic sealant. Holes readily conduct airborne

sounds and can considerably reduce the Rw of a wall. ■

Appliances

Noise producing fixtures or appliances such as water closets, cisterns, water storage tanks, sluices, dishwashers,

washing machines and pumps should be isolated from the structure with resilient mountings and flexible service

leads and connections. ■

Electrical Outlets & Service Pipes

Penetrations of all sorts should be avoided but if unavoidable, seal around them effectively. If possible introduce

a discontinuity in pipe work between fittings, such as a flexible connection within or on the line of a partition.

Use acoustically rated boxes for all general power outlets, light switches, telephone connections, television

outlets, etc. Seal the sides of electrical boxes and the perimeter of all penetrations with acoustic sealant. Offset

all power outlets on either side of a wall by at least 100 mm. ■



ADV03781

1.3 Brick Masonry Construction

The following information relates to the construction of brick walls to meet AS3700, the design and aesthetic

requirements.

Mortar

AS3700: 2001, Table 10.1 gives the options for mortar mixes classified as M1 to M4. M1 mortars are for

restoration applications. M2 mortars are for use in interior walls above dampcourse or in exterior walls above

dampcourse if more than one km from a body of salt water and 10 km from a surf coast and the wall has protection

from water ingress above. M3 and M4 mortars are those most commonly used in construction. Table 11 gives the

proportions of themost commonly usedmortars. Other deemed-to-satisfy compositions are given in AS3700.

Special mortars that are tested and shown to meet requirements are allowed with verification on site.

Note: Proportionsarebyvolumeandshouldbemeasuredwithabucketorgaugebox,NOTASHOVEL.

Table 11. Typical Mortar Mixes


Section 1.3. Brick Masonry Construction 1.301

ADV03783

Refertopage1.104fordescriptionofDurabilityClass.*Methylcellulosetype,notairentrainerssuchasdetergent.

Where masonry strength is crucial, trial walls should be constructed with the bricks and mortar to be used on

the job, then tested before construction commences. Masonry bond strength is related to the suction of the

bricks, the particle size distribution of the sand, cement content, additive contents, etc. For many jobs these

panels can also be used as physical samples of the required quality of the bricklaying and cleaning.

Note:AS 3700 allows the use of:

• CementscomplyingwithAS3972orAS1316

• LimecomplyingwithAS1672.1

• Sandthatisfreeofanydeleteriousmaterials

• Waterthatisfreefromdeleteriousmaterialsand

• Admixtures including plasticisers, air entraining agents and set retarders complying with AS1478.1,

cellulose-typewater thickeners, colouringpigments complyingwithBSEN12878andbondingpolymers.

t

Mortar Durability

Mix proportions by volume Type Class Portland or Hydrated Water Blended Cement Lime Sand Thickener*

M1 PRO 0 1 3 No

M2 PRO 1 2 9 No

M3 GP 1 1 6 No

M3 GP 1 0 5 Yes

M4 EXP 1 1⁄2 41⁄2 No

M4 EXP 1 0 4 Yes

Mortar (continued)

No other material may be used until tests on masonry constructed with the mortar, made with the material or

admixture shows the masonry complies with the standard’s requirements for compressive strength, flexural

strength and durability.

Deleteriousmaterialsarethosereducingthestrengthordurabilityofthemasonryandincludinganythingthat

attacksthebuilt-incomponents.Thismeanstheuseoffireclay,detergent,sugar,softdrink,etc.,arebanned.

Most of these materials severely reduce mortar strength and durability. Water thickener must be used only

according to the manufacturer’s directions because overuse severely reduces mortar strength.

Mortar Estimator

Table 12. Estimated Material Requirements to Lay 1,000 Standard Bricks



ADV03784

Mix Composition 40 kg bags 25 kg bags Cubic metres Tonnes of (C:L:S) of cement of lime of sand damp sand

M3 1 : 1 : 6 4 2.4 0.64 1.2

M3 1 : 0 : 5 4 0 0.64 1.2

M4 1 : 0 : 4 6.5 0 0.64 1.2

M4 1 : 1⁄2 : 41⁄2 5.3 1.6 0.64 1.2

This table assumes partial filling of cores and typical site wastage.

Only make sufficient mortar for immediate use. If mortar starts to set, it may be re-tempered once only.

Where bricklaying is interrupted, the mortar should be covered to prevent evaporation and mixed with the trowel

before continuing. t

Mortar (continued)

Mortar Colour

The mortar colour can dramatically affect the overall look. The colour of mortar is influenced by the colour of the

cement and the aggregates (sand). Many pigments are also available ranging in colour through red, yellow,

brown, green, blue and black (mainly oxides but carbon black can be used to give black mortar). The cheapest

way of colouring mortar is to use coloured sand. White and yellow sands are commonly available but red and

brown sands are also available. Sands are normally natural materials which vary considerably even in the one

deposit. To ensure colour consistency, sufficient sand from the one batch should be set aside for the whole job.

Where colour is crucial to the look of the masonry, before accepting the sand, a trial wall should be built (4 bricks

x 10 courses). After the mortar dries assess the colour. Where oxides or carbon black are used as colours never

use more than 10% by weight of the cement content.

Colours are additive in their effect and it is possible to get different shades and tones of mortar using different

combinations of cement, sands and oxides.

Table 13: Typical Coloured Mortar Components

Note: The colour of mortar can be severely degraded by incorrect or poor brick cleaning. ■



ADV03785

MortarColour Cement Sand Oxide

Red Grey WhiteorYelloworRed Red

Yellow Off-whiteorGrey Yellow Yellow&Brown

Cream Off-white Yellow None

Tan Grey WhiteorYellow Brown

Black Grey Yellow Black

Joint Types

The type of joint can dramatically affect the overall look of brick masonry. Joints can be used to create a casual,

rusticorformallooktobrickwork.Therearemanydifferentjoints;themostcommononesusedinAustraliaare

shown below.

Terminology and joint preference differs in different countries and within Australia. Where there is any

confusion, always use a drawing or physical sample to avoid misunderstandings.

Shallow ironed joints are recommended in areas requiring exposure grade bricks and mortar. Tooling the joint to

produce ironed and struck joints is equivalent to steel trowelling concrete and produces a dense smooth surface

which sheds water and dirt better than other types of joint. Ironed and struck joints should always be used for

bricks with straight sharp edges such as Smooth Face and Velour bricks.

Raked joints may be used with any type of brick but they tend to retain dirt and may lead to streaks down the

masonry in dirty environments. Raking must not come closer than 5 mm to any core. This usually limits raking to

less than 10 mm, however it is best to check the bricks that are being used before raking. AS3700 specifies that

joints in walls in marine, severe marine or aggressive environments or on aggressive soils must be tooled to a

dense smooth surface. This precludes raking and in practice ironed joints are the only ones that consistently

meet the requirement.

Flush joints may be used with any type of brick. However, flush joints are particularly effective with rumbled

bricks as flush joints make the joints look to be of variable thickness that gives a pleasing rustic look. ■



ADV03786

Flush Joint Raked Joint Ironed Joint Weathered JointStruck Joint

Joint Sizes

Mortar bed joints are required to be less than 10 mm unless the design specifies another thickness. A different

thickness may only be specified after the designer considers the effect on compressive and flexural strength of

themasonry.Duringconstructionmortarbedjointsareallowedtodeviateby±3mm.Becauseofpoorpractice

or lack of proper direction some slabs and footings are finished at the wrong height. Mortar joints up to 50 mm

thick have been used to get the correct coursing, however, this is not allowed under AS3700.

Perpends are to have a minimum design thickness of 5 mm. In structural brickwork perpends may be up to 10

mmthickerthanthespecifiedthicknessbutnothinner.Infacebrickworkperpendsmaydeviateby±5mmfrom

the average width but in any one wall the maximum difference allowable between any two perpends is 8 mm.

The preceding tolerances do not apply in the case of thin bed mortars and perpend tolerances do not apply where

perpends are not filled with mortar. ■

Weepholes

Weepholes are to allow moisture that collects in the cavity to escape. Weepholes should be spaced at less than

1200 mm centres wherever flashing is built into the masonry to shed water from the cavity. Weepholes are

usually empty perpends (10 mm wide) but proprietary products are available to prevent the entry of insects. In

high wind areas it has been known for water to be blown up the cavity onto the inner wall and as this is very

undesirable, more, narrower weepholes are usually built into the wall. It is essential that weepholes remain

open and render and other applied coatings, where used, must be raked out of the joint. ■



ADV03787

Brick Estimator

Brickwork is based on the 600 mm unit, (seven courses high and two and a half bricks long). This unit fits in with

doors, windows and other building materials. The number of bricks required for a wall can be determined from

theBrickCoursingHeightandBrickGaugetablesonpages1.310-1.312ofthismanual.Selecttheheightofthe

wall and from the following page for the brick height chosen determine the number of courses. From the next

page for 230 mm long bricks or the one after for 290 mm bricks, determine the number of bricks for the length

of your wall. A half brick should be calculated as 1 whole brick, due to site wastage. Multiply the number of

bricks by the number of courses to give the number of bricks for the wall. Saw cutting bricks may mean getting

two halves from a brick but this is not usual practice because of the cost of cutting. ■



ADV03788

Brick bonds and other decorative effects

A bond is the pattern in which bricks are laid. The most common bond is Stretcher Bond which consists of

courses of full bricks where every course is offset half a brick from the course below. When following the mortar

joint, stretcher bond has the longest vertical pathway and therefore the best bend strength.

Stretcher bond is used in walls one brick wide. Where walls are two or more bricks wide then stretcher bond

needs ties to hold the leaves together to give it a monolithic action. To avoid the use of ties traditional practice

has been to lay some of the bricks sideways. This has usually been either full courses of headers with full

coursesof stretcher (English)or coursesofalternatingheaderandstretcher (Flemish).Avariationof Flemish

BondisGardenWallBondwherecoursesaremadeofaheaderandthreestretchersalternating.

Cornertreatmentcanbedifferentinthesebonds.Englishcornersendinfullstretchersorfullheaders,andany

partbrickrequiredtomakeupthecourseissetinsidethecorner.Dutchcornersendinthepartbricks.

Variations on these bonds are common in particular a header course every three or six courses with stretcher

courses between.

Although these bonds have traditionally been developed for thick walls, they can be used in single leaf walls as

adecorativeeffectusingcutbricksfortheheaders.Suchwallsareusuallynon-loadbearing.Cuttingcostsare

high but not excessive as the headers have the cut side turned in and the bricks can be bolstered.

Otherdecorativebondsmaybeused innon-loadbearingapplications,particularly in the formofpanels.The

limitations are strengths lower than Stretcher Bond and the cost of cutting and slower brick laying. The

decorative effect of bonds is highlighted by using a mortar in a contrasting colour to the brick.

Other bonds include:

• StackBond–Brickslaidhorizontallyinverticalcolumnssoallverticaljointsalign.

• SoldierStackBond–Brickslaidverticallyinverticalcolumnssoallverticaljointsalign.

• 1/3Bond–Everycourseisoffsetby1/3ofabrick.

• Zigzag Bond, Vertical Zigzag Bond, 45˚ Stretcher Bond, Chevron Bond, BasketWeave Bond, 45˚ Basket

Weave Bond and virtually any pattern that tessellates. t



ADV03789

Brick bonds and other decorative effects (continued)

Other decorative effects are available such as:

• Layingbandsofbricksofthesamecolourwithdifferenttexturesegsmoothfacedandrockfaced;

• Layingbandsofbrickswithdifferent(contrastingorcomplimentary)colours;

• Corbelling(brickssetoutfromthewall);

• Racking(brickssetbackintothewall);

• Quoining(cornerbricksindifferentcoloursorsetoutfromthewall);

• Soldiersaboveopeningsorasasinglecourse;

• Copingsonpiersandparapetwalls;

• Sillsindifferentcoloursortextures,usingsillbricks,etc.;or,

In the late 1800’s bricks of contrasting colours were laid in patterns such as diamonds or crosses. A more subtle

effect can be made by laying bricks with different textures or corbelling the bricks in these patterns.

Combinationsoftheaboveeffectscanbeused.Eg.AnAmericanArchitectspecifiedacorbelledcoursewiththe

course below to be laid in the darkest bricks selected from the packs delivered. The darker band accentuated

the shadowing effect from the corbelled course. t



ADV03790

ADV03791


Section 1.3. Brick Masonry Construction 1.309Brick bonds and other decorative effects (continued)

Stack Bond Soldier Course (With Stretcher Bond)

Stretcher Bond Common Bond (Full Headers every 6th Course)

Flemish Bond Common Bond (Flemish every 6th Course)

English Cross or Dutch Bond Garden Wall Bond

ADV03792

1.310


Section 1.3. Brick Masonry Construction

76mm 119mm 162mm 50mm 90mm

3000

2700

2400

2100

1800

1500

1200

900

600

300

3000mm

2700mm

2400mm

2100mm

1800mm

1500mm

1200mm

900mm

600mm

300mm

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

50

49

48

47

46

45

44

43

42

41

40

39

38

37

36

35

34

33

32

31

30

29

28

27

26

25

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

36

35

34

33

32

31

30

29

28

27

26

25

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

30

29

28

27

26

25

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

Brick Coursing Height

Brick Gauge

230 mm Long Bricks

ADV03793



1 230 250

11⁄2 350 370

2 470 490

21⁄2 590 610

3 710 730

31⁄2 830 850

4 950 970

41⁄2 1070 1090

5 1190 1210

51⁄2 1310 1330

6 1430 1450

61⁄2 1550 1570

7 1670 1690

71⁄2 1790 1810

8 1910 1930

81⁄2 2030 2050

9 2150 2170

91⁄2 2270 2290

10 2390 2410

101⁄2 2510 2530

11 2630 2650

111⁄2 2750 2770

12 2870 2890

121⁄2 2990 3010

13 3110 3130

26 6230 6250

261⁄2 6350 6370

27 6470 6490

271⁄2 6590 6610

28 6710 6730

281⁄2 6830 6850

29 6950 6970

291⁄2 7070 7090

30 7190 7210

301⁄2 7310 7330

31 7430 7450

311⁄2 7550 7570

32 7670 7690

321⁄2 7790 7810

33 7910 7930

331⁄2 8030 8050

34 8150 8170

341⁄2 8270 8290

35 8390 8410

351⁄2 8510 8530

36 8630 8650

361⁄2 8750 8770

37 8870 8890

371⁄2 8990 9010

38 9110 9130

381⁄2 9230

39 9350

391⁄2 9470

40 9590

401⁄2 9710

41 9830

411⁄2 9950

42 10070

421⁄2 10190

43 10310

431⁄2 10430

44 10550

441⁄2 10670

45 10790

451⁄2 10910

46 11030

461⁄2 11150

47 11270

471⁄2 11390

48 11510

481⁄2 11630

49 11750

491⁄2 11870

50 11990

100 23990

No. of Length Opening Bricks (mm) (mm)



No. of Length Bricks (mm)

131⁄2 3230 3250

14 3350 3370

141⁄2 3470 3490

15 3590 3610

151⁄2 3710 3730

16 3830 3850

161⁄2 3950 3970

17 4070 4090

171⁄2 4190 4210

18 4310 4330

181⁄2 4430 4450

19 4550 4570

191⁄2 4670 4690

20 4790 4810

201⁄2 4910 4930

21 5030 5050

211⁄2 5150 5170

22 5270 5290

221⁄2 5390 5410

23 5510 5530

231⁄2 5630 5650

24 5750 5770

241⁄2 5870 5890

25 5990 6010

251⁄2 6110 6130

ADV03794

1.312


Section 1.3. Brick Masonry Construction

1 290 310

11⁄3 390 410

12⁄3 490 510

2 590 610

21⁄3 690 710

22⁄3 790 810

3 890 910

31⁄3 990 1010

32⁄3 1090 1110

4 1190 1210

41⁄3 1290 1310

42⁄3 1390 1410

5 1490 1510

51⁄3 1590 1610

52⁄3 1690 1710

6 1790 1810

61⁄3 1890 1910

62⁄3 1990 2010

7 2090 2110

71⁄3 2190 2210

72⁄3 2290 2310

8 2390 2410

81⁄3 2490 2510

82⁄3 2590 2610

9 2690 2710

91⁄3 2790 2810

92⁄3 2890 2910

10 2990 3010

101⁄3 3090 3110

102⁄3 3190 3210

11 3290 3310

111⁄3 3390 3410

112⁄3 3490 3510

12 3590 3610

121⁄3 3690 3710

122⁄3 3790 3810

13 3890 3910

131⁄3 3990 4010

261⁄3 7890

262⁄3 7990

27 8090

271⁄3 8190

272⁄3 8290

28 8390

281⁄3 8490

282⁄3 8590

29 8690

291⁄3 8790

292⁄3 8890

30 8990

301⁄3 9090

302⁄3 9190

31 9290

311⁄3 9390

312⁄3 9490

32 9590

321⁄3 9690

322⁄3 9790

33 9890

331⁄3 9990

332⁄3 10090

34 10190

341⁄3 10290

342⁄3 10390

35 10490

351⁄3 10590

352⁄3 10690

36 10790

361⁄3 10890

362⁄3 10990

37 11090

371⁄3 11190

372⁄3 11290

38 11390

381⁄3 11490

382⁄3 11590

39 11690

391⁄3 11790

392⁄3 11890

40 11990

401⁄3 12090

402⁄3 12190

41 12290

411⁄3 12390

412⁄3 12490

42 12590

421⁄3 12690

422⁄3 12790

43 12890

431⁄3 12990

432⁄3 13090

44 13190

441⁄3 13290

442⁄3 13390

45 13490

451⁄3 13590

452⁄3 13690

46 13790

461⁄3 13890

462⁄3 13990

47 14090

471⁄3 14190

472⁄3 14290

48 14390

481⁄3 14490

482⁄3 14590

49 14690

491⁄3 14790

492⁄3 14890

50 14990

100 29990





132⁄3 4090 4110

14 4190 4210

141⁄3 4290 4310

142⁄3 4390 4410

15 4490 4510

151⁄3 4590 4610

152⁄3 4690 4710

16 4790 4810

161⁄3 4890 4910

162⁄3 4990 5010

17 5090 5110

171⁄3 5190 5210

172⁄3 5290 5310

18 5390 5410

181⁄3 5490 5510

182⁄3 5590 5610

19 5690 5710

191⁄3 5790 5810

192⁄3 5890 5910

20 5990 6010

201⁄3 6090 6110

202⁄3 6190 6210

21 6290 6310

211⁄3 6390 6410

212⁄3 6490 6510

22 6590 6610

221⁄3 6690 6710

222⁄3 6790 6810

23 6890 6910

231⁄3 6990 7010

232⁄3 7090 7110

24 7190 7210

241⁄3 7290 7310

242⁄3 7390 7410

25 7490 7510

251⁄3 7590 7610

252⁄3 7690 7710

26 7790 7810

Brick Gauge

290 mm Long Bricks

Blending

Raw materials for brick making are from natural sources and these vary in colour within any one deposit. Brick

makers blend materials to moderate the colour variation but it still occurs. Colour variation may be caused by

different conditions across the kiln. No matter how well made, bricks delivered to site will have some degree of

colour variation.

Poorly blended bricks may show unwanted patches, streaks and bands of colour in the finished masonry.

To avoid this:

• Allbricksrequiredfortheproject,orasmanypacksaswillfit,shouldbedeliveredatonetimeandstored

onsite;and,

• Bricksshouldbedrawn fromat least fourpackssimultaneously,workingdown from thecornersofeach

pack. ■

Brick Storage

Bricks stored on site should be covered and kept off the ground. Bricks may absorb ground water containing salts

or coloured minerals creating subsequent problems with staining. Bricks when laid saturated usually produce

excessive efflorescence as the masonry dries. Saturated bricks may also adversely affect the mortar bond

strength.

Moving bricks around the site may cause chipping and excessive movement of packs should be avoided. ■



ADV03795

Laying Practices

The following practices are recommended:

• Mortar,extrudedfromtappingthebrickdowntothestringline,shouldbecutoffwithanupwardstrokeof

the trowel. In this manner, a clean cut is made, without smearing the face of the brick.

• Jointsshouldbetooledprogressivelyasthebricksarelaid,whenthemortarisfirmtothumbpressure.High

suction bricks require joints to be tooled more frequently than low suction bricks. Tooling too late produces

a ‘burned’ joint, where the surface may not be smooth and dense.

• Afterallowingthemortartoundergoinitialset,withinaday,drybrushmortarsmears,toremoveanydags,

and then wet brush any remaining mortar stains. Mortar that is allowed to set on the masonry face may

requirehigh-pressurewaterjetcleaningormorecostly,riskymethodsofcleaning.

• Cavities should be kept as clear as possible from mortar droppings. Flushing out the cavity removes

inadvertently dropped mortar and ensures ties are clean and flashing and damp proof courses are not

bridged. It is poor practice and usually ineffective to flush large quantities of dropped mortar from cavities.

Usual practice is for the bricklayer to leave out one or more bricks at the base of the wall above a flashing

or the damp proof course for the washings to come out. Washings can cause serious staining where they

run down over lower brickwork and should be rinsed off thoroughly each day.

• Scaffoldingshouldbekeptatleast150mmfromthefaceofthebrickworktopreventabuildupofmortar

droppings against the masonry.

• When bricklaying is interrupted by rain or rain is expected overnight, masonry should be protected by

covering it. Saturated masonry will produce excessive efflorescence and may lead to staining with some

bricks.

• Facebricksaresuppliedwithonefaceandoneheadersuitableforexposing(i.e.tobeseenafterlaying).

Face bricks with unwanted marks, chips or cracks on a header should be laid with that header inside a

mortared joint. Face bricks with unwanted marks, chips or cracks on the face should be set aside by the

bricklayer (or labourer) for use as commons. Boral will not be responsible for replacing bricks with unwanted

marks, chips or cracks that have been laid. ■



ADV03796

Control Joints

Control joints must not be bridged by mortar or render. After laying the bricks or rendering, the joint must be

cleaned. Lumps of mortar or render can transfer forces across the closing joint and will cause the bricks to crack

(or spall). Control joints are usually constructed with a highly compressible material (in the form of a sheet or

rod) inserted to keep dirt and moisture from penetrating to the cavity. For aesthetic reasons a compressible

caulking material, matched to the mortar colour, is usually applied on the outside. As the joint closes,

compressible caulking compounds may be extruded from the joint but incompressible ones may damage the

bricks. If extruded caulking compound is considered unsightly, it can be cut out and replaced or the compound

can be recessed during construction. Care must be taken when choosing a caulking compound to ensure it is a

highly compressible type that will survive for the design life of the building and not discolour significantly. There

are numerous suitable materials available and manufacturer’s recommendations should be sought.

Where a control joint has flexible masonry ties built in, a piece of the compressible material must be removed

to accommodate the tie. ■

Damp Courses and Flashing

Membranetypedampproofcourses(DPC)mustbelaidacrossthefullwidthofthewallorleafandmustproject

throughthemortaroneithersideandbecompletelyvisibleafterlayingandcleaningiscomplete.RecessingDPC

belowtheedgeofthebrickworksothatthemortarbridgestheDPCinvalidatesitsuseandisthereforeentirely

unacceptable. Bridged DPCmay lead to rising damp, salt attack and or accelerated corrosion of the built-in

components that may lead to structural failure. Recessing flashing below the mortar although common is not

good practice as it allows the water that should be shed to soak into the wall below the flashing.

DPCandflashingatthebaseofawallmaybecombined.Lengthsshouldbeaslongaspossiblebutwherenot

continuous, two adjacent pieces should overlap by at least 150 mm and if possible be sealed together. If a

termiteshieldisusedinthesamejointastheDPC,theDPCmaterialmustbecompatiblewiththetermiteshield

orcorrosionmaydestroytheDPC.

GeneralpracticehasbeentorecommendthatflashingsandDPCsbesandwichedbetweenthemortar.Thereis

someevidencethatthecommonpracticeoflayingflashingsandDPCdirectlyonthelowercourseofbricksand

placing the mortar on top may be superior in some instances. ■



ADV03797

Cleaning of Clay Masonry

The Basics of Brick Cleaning

The cleaner the bricklayer leaves the wall, the easier will be the cleaning task. The majority of the mortar

residues and smears should be cleaned before they set hard. However, in most cases some additional cleaning

will be required to completely remove the mortar residue.

Cleaning techniquesmay involvehigh-pressurewater jetequipmentorhandmethods.Whatever technique is

used, the following requirements must be observed to ensure additional staining problems are avoided.

Test Areas

Testing in one or more small areas is the safest way to determine the correct technique and chemical solution

to remove mortar residues. This must occur well before final cleaning, as it will usually not be possible to assess

the effectiveness of the test clean until the masonry dries.

Clean Soluble Salt Deposits First

Efflorescence, a white ‘fluffy’ deposit, cannot be removed by water or acid. Dry brushing to remove the

efflorescence before washing is recommended. If efflorescence is wetted, the salts go into solution and are

drawnbackintothebrickworkandwillreappearasthemasonrydries.Efflorescencewilleventuallydisappear

through natural weathering.

Vanadium salts produce a green or yellow efflorescence or stain (mainly seen on cream and light coloured clay

bricks). Hydrochloric acid will make these stains much worse and may make them impossible to clean. Mild

vanadium stains may be treated with sodium hypochlorite (household bleach). Spray or brush on dry brickwork

and leave until the stain disappears, then rinse off. Proprietary mould cleaners containing sodium hypochlorite

and sodium hydroxide can be used as above and have been found very effective. Proprietary brick cleaners may

also be effective and should be used only according to the manufacturer’s instructions. Proprietary cleaners

usually contain acids that must be neutralised after use with a solution of 15 grams of washing soda

per litre of water.

More than one chemical application may be required and the walls should be rinsed thoroughly after each

treatment. t



ADV03798

Cleaning of Clay Masonry (continued)

High Pressure Cleaning

High-pressurewaterwashingisnowcommonforcleaningbrickwork.Ifusedthepressuremustbekeptbelow

1000 psi (7000 kPa), the nozzle must be kept 500 mm from the brick face and the nozzle must be a wide fan jet

type with an angle of 15 degrees.

The following practices must be observed:

• Cleaningshouldnotstartuntilthemortarhashardened.

• Hardlumpsorpersistentsmearsshouldberemovedbyhand.

• Maskadjacentmaterials.

• Donotapplytheacidwiththehigh-pressuresprayer.Usealow-pressuresprayorbroomiton.

• Cleanfromtoptobottominsmallsections.

• Workintheshade,aheadofthesun,ifpossible.

• DONOTUSEEXCESSIVEPRESSUREORGETTOOCLOSE,asthiswilldamagethefaceofthebrickandthe

mortar joint. Mortar joints that are no longer smooth with sharp edges is a clear sign of excessive pressure.

Excessivepressureisusedtomakecleaningfaster;itdoesnotdoabetterjobofcleaning.t



ADV03799


Saturate the Wall Surface

Failure to completely saturate the surface of the wall is in itself a major cause of cleaning stains. Cleaning

solutions containing dissolved mortar particles and acids will be drawn into a dry masonry wall, causing

staining. Furthermore, saturating the surface of the wall keeps the acid solution on the face of the masonry

where the mortar smears are present. It is not true that face saturation weakens the acid and slows the

cleaning.

Water should be trained on the wall until the brick suction is exhausted. The area to be cleaned must be

saturated as well as all brickwork areas below. If the wall appears to be drying on the surface, reapply water

until ready to apply the cleaning solution.

Recommended acid strengths are based on application to a surface saturated wall.

Note: This point must be strictly adhered to for bricks manufactured in Queensland. Their raw materials contain

large amounts of iron oxide and failure to saturate the surface of the wall allows acid solutions to react

with the iron oxide and create severe iron oxide staining. Failure to saturate the surface of the bricks

manufactured in other parts of Australia can also lead to the acid reacting with iron oxide but to a much

lesser degree. This form of staining is known as acid burn and is particularly visible on light coloured

bricks. Acid absorption into bricks can also lead to vanadium and manganese staining. t



ADV03800


Acids – The Basics

Thetraditionalmasonry-cleaningchemicalishydrochloricacid,(alsoknownasmuriaticacidorspiritsofsalts).

Its main function is to dissolve the cement in the mortar mix. It has few other uses and in many stain situations

should not be used.

Hydrochloric acid is a corrosive S6 poison and care must be taken when using it. If acid is splashed onto the skin

it should be immediately swabbed with clean water, or more effectively, with a solution of bicarbonate of soda

in water, which will neutralise the acid.

The recommended acid strength for light coloured clay bricks is 1 part acid to 20 parts water and for other bricks

is1partacidto10partswater.Acidtakestimetodissolvethecementandshouldbeleftonfor4-6minutes(or

longer if needed) before washing off. After washing a solution of 15 g per litre of washing soda or 24 g per litre

of sodium bicarbonate should be sprayed on to neutralise any remaining acid. Excess hydrochloric acidwill

eventually evaporate from the brickwork, however, it is likely to cause staining of the bricks and damage to

built-in components. Other acids such as sulfuric acid or nitric acid will not evaporate and are not used in

brick cleaning.

Note: The recommended strength must be strictly adhered to. Bricks manufactured in Queensland may contain

large amounts of iron oxide and the use of acid solutions stronger than 1 part acid to 20 parts water can

dissolve these particles and create iron oxide staining. For light coloured bricks manufactured elsewhere

the use of solutions stronger than 1 part acid to 20 parts water can lead to acid burn.

Proprietary masonry cleaning solutions containing a mixture of acids are available. If used, the manufacturer’s

recommendationsmustbestrictlyadheredto.Excessiveandincorrectuseofsomeproprietarycleaningsolutions

has in the past, produced very bad staining. t



ADV03801


Safety Precautions

Allmasonry-cleaningacidsaredangerous.Acidsthatdonotdissolvecementasquicklyashydrochloricacidare

not necessarily safer and can be very much more dangerous to human health. To avoid personal injury:

• Weargoggles,glovesandprotectiveclothing.

• Alwayspouracidsintowater–thisavoidssplashesofhighlyconcentratedacidontotheoperator.

• Ifsplashedontothebody,washwithcleanwaterandifpossible,neutralisewithamixtureofbicarbonate

of soda and water.

• Themanufacturer’s instructionsandsafetyprecautionsmustbestrictlyadheredto ifproprietarycleaning

products are used. ■



ADV03802

Clay Brick Property Tables1.4


1.401

ADV03803

Section 1.4 Clay Brick Property Tables

Escu

ra® S

moo

th F

ace

Bro

wn

Choc

Tan

Cinn

amon

Crea

mFl

ame

Red

Hem

pJu

teN

evad

a Cr

eam

Wor

k si

ze (m

m)

230x

110x

7623

0x11

0x76

230x

110x

7623

0x11

0x76

230x

110x

7623

0x11

0x76

230x

110x

7623

0x11

0x76

Dimensionalcategory

DW1

DW1

DW1

DW1

DW1

DW1

DW1

DW1

Perfo

ratio

n (%

)<3

0<3

0<3

0<3

0<3

0<3

0<3

0<3

0Av

e un

it w

eigh

t (kg

)2.

92.

92.

92.

92.

93

32.

9Ap

prox

num

ber p

er m

249

4949

4949

4949

49W

all s

urfa

ce d

ensi

ty (k

g/m

2 )19

019

019

019

019

019

019

019

0Ch

arac

teris

tic u

ncon

fined

com

pres

sive

stre

ngth

of t

he u

nit (

f’uc)

MPa

>22

>15

>15

>22

>15

>22

>15

>15

Stre

ngth

sof

mas

onry

(MPa

)–

Char

acte

ristic

com

pres

sive

stre

ngth

(f’ m)M

3*mortar(GP)

>6.6

>5.4

>5.4

>6.6

>5.4

>6.6

>5.4

>5.4

– Ch

arac

teris

tic c

ompr

essi

ve s

treng

th (f

’ m)M

4*mortar(EXP)

>7.0

>5.8

>5.8

>7.0

>5.8

>7.0

>5.8

>5.8

Co-efficientofgrowth‘em’(mm/m/15yrs)

<1.1

<1.1

<1.1

<1.1

<1.1

<1.1

<1.1

<1.1

Salt

atta

ck re

sist

ance

cat

egor

yEXP

EXP

GPGP

EXP

GPGP

GPLi

abili

ty to

effl

ores

ceN

il to

slig

htN

il to

slig

htN

il to

slig

htN

il to

slig

htN

il to

slig

htN

il to

slig

htN

il to

slig

htN

il to

slig

htLi

me

pitti

ngN

il to

slig

htN

ilN

ilN

il to

slig

htN

ilN

il N

ilN

ilFi

re ra

ting

(FRL

) min

utes

– In

sula

tion

unre

nder

ed90

9090

9090

9090

90N

o pe

r pac

k40

034

034

040

034

040

034

034

0Pa

ck w

eigh

t (kg

)12

0092

592

512

0092

512

0010

2092

5Pa

ck d

imen

sion

s (m

m)

1150

x920

x775

1150

x770

x684

1150

x770

x684

1150

x920

x775

1150

x770

x684

1150

x920

x775

1150

x770

x684

1150

x770

x684

Escu

ra® S

moo

th F

ace

Mel

bour

ne

Red

Pear

l Gre

yRe

dSa

lmon

Pin

kTa

upe

Terr

acot

taVi

ctor

ian

Pink

Wor

k si

ze (m

m)

230x

110x

7623

0x11

0x76

230x

110x

7623

0x11

0x76

230x

110x

7623

0x11

0x76

230x

110x

76Dimensionalcategory

DW1

DW1

DW1

DW1

DW1

DW1

DW1

Perfo

ratio

n (%

)<3

0<3

0<3

0<3

0<3

0<3

0<3

0Av

e un

it w

eigh

t (kg

)3.

42.

92.

92.

93

2.9

3.4

Appr

ox n

umbe

r per

m2

4949

4949

4949

49W

all s

urfa

ce d

ensi

ty (k

g/m

2 )21

019

019

019

019

019

021

0Ch

arac

teris

tic u

ncon

fined

com

pres

sive

stre

ngth

of t

he u

nit (

f’uc)

MPa

>22

>15

>22

>15

>22

>22

>22

Stre

ngth

sof

mas

onry

(MPa

)–

Char

acte

ristic

com

pres

sive

stre

ngth

(f’ m)M

3*mortar(GP)

>8.5

>5.4

>6.6

>5.4

>6.6

>6.6

>8.5

– Ch

arac

teris

tic c

ompr

essi

ve s

treng

th (f

’ m)M

4*mortar(EXP)

>9.0

>5.8

>7.0

>5.8

>7.0

>7.0

>9.0


<1.4

<1.1

<1.1

<1.1

<1.1

<1.1

<1.4

Salt

atta

ck re

sist

ance

cat

egor

yEXP

GPEXP

GPGP

GPEXP

Liab

ility

to e

fflor

esce

Nil

to s

light

Nil

to s

light

Nil

to s

light

Nil

to s

light

Nil

to s

light

Nil

to s

light

Nil

to s

light

Lim

e pi

tting

Nil

Nil

Nil

to s

light

Nil

Nil

to s

light

Nil

to s

light

Nil

Fire

ratin

g (F

RL) m

inut

es –

Insu

latio

n un

rend

ered

9090

9090

9090

90N

o pe

r pac

k27

234

040

034

040

040

027

2Pa

ck w

eigh

t (kg

)95

092

512

0092

512

0012

0095

0Pa

ck d

imen

sion

s (m

m)

865x

710x

935

1150

x770

x684

1150

x920

x775

1150

x770

x684

1150

x920

x775

1150

x920

x775

865x

710x

935

All t

estin

g is

car

ried

out i

n ac

cord

ance

with

Aus

tralia

n St

anda

rds

AS/N

ZS44

56 te

st m

etho

ds w

here

app

licab

le. T

estin

g is

car

ried

out i

n N

ATA

regi

ster

ed la

bora

torie

s.Durabilityclassificationbasedonproductknowledgeunderlocalclimateconditions.

This

tech

nica

l inf

orm

atio

n re

pres

ents

ave

rage

pro

perti

es o

btai

ned

from

pro

duct

ion

lots

and

sho

uld

not b

e us

ed fo

r spe

cific

atio

n pu

rpos

es.

For m

ore

deta

iled

spec

ifica

tion

cont

act B

oral

Bric

ks. U

nit w

eigh

t quo

ted

is a

n ap

prox

imat

e w

eigh

t and

can

var

y. Th

is in

form

atio

n is

sub

ject

to c

hang

e w

ithou

t not

ice.


1.402

ADV03804


Escu

ra® –

Sm

ooth

Fac

e Sl

imlin

eB

row

nCr

eam

Red

Wor

k si

ze (m

m)

230x

110x

5023

0x11

0x50

230x

110x


DW1

DW1

DW1

Perfo

ratio

n (%

)30

3030

Ave

unit

wei

ght (

kg)

22

2Ap

prox

num

ber p

er m

270

7070

Wal

l sur

face

den

sity

(kg/

m2 )

200

200

200

Char

acte

ristic

unc

onfin

ed c

ompr

essi

ve s

treng

th o

f the

uni

t (f’u

c) M

Pa>2

2>2

2>2

2St

reng

ths

ofm

ason

ry(M

Pa)

– Ch

arac

teris

tic c

ompr

essi

ve s

treng

th (f

’ m)M

3*mortar(GP)

>6.6

>6.6

>6.6

– Ch

arac

teris

tic c

ompr

essi

ve s

treng

th (f

’ m)M

4*mortar(EXP)

>7.0

>7.0

>7.0


<1.1

<1.1

<1.1

Salt

atta

ck re

sist

ance

cat

egor

yEXP

GPEXP

Liab

ility

to e

fflor

esce

Nil

to s

light

Nil

to s

light

Nil

to s

light

Lim

e pi

tting

Nil

to s

light

Nil

to s

light

Nil

to s

light

Fire

ratin

g (F

RL) m

inut

es –

Insu

latio

n un

rend

ered

9090

90N

o pe

r pac

k51

051

051

0Pa

ck w

eigh

t (kg

)11

0011

0011

00Pa

ck d

imen

sion

s (m

m)

1150

x920

x690

1150

x920

x690

1150

x920

x690

Escu

ra® –

Vel

our

Bro

wn

Crea

mFl

ame

Red

Nev

ada

Crea

mPe

arl G

rey

Red

Salm

on P

ink

Taup

eTe

rrac

otta

Wor

k si

ze (m

m)

230x

110x

7623

0x11

0x76

230x

110x

7623

0x11

0x76

230x

110x

7623

0x11

0x76

230x

110x

7623

0x11

0x76

230x

110x


DW1

DW1

DW1

DW1

DW1

DW1

DW1

DW1

DW1

Perfo

ratio

n (%

)<3

0<3

0<3

0<3

0<3

0<3

0<3

0<3

0<3

0Av

e un

it w

eigh

t (kg

)2.

92.

92.

92.

92.

92.

92.

92.

92.

9Ap

prox

num

ber p

er m

249

4949

4949

4949

4949

Wal

l sur

face

den

sity

(kg/

m2 )

190

190

190

190

190

190

190

190

190

Char

acte

ristic

unc

onfin

ed c

ompr

essi

ve s

treng

th o

f the

uni

t (f’u

c) M

Pa>2

2>2

2>1

5>1

5>1

5>2

2>1

5>2

2>2

2St

reng

ths

ofm

ason

ry(M

Pa)

– Ch

arac

teris

tic c

ompr

essi

ve s

treng

th (f

’ m)M

3*mortar(GP)

>6.6

>6.6

>5.4

>5.4

>5.4

>6.6

>5.4

>6.6

>6.6

– Ch

arac

teris

tic c

ompr

essi

ve s

treng

th (f

’ m)M

4*mortar(EXP)

>7.0

>7.0

>5.8

>5.8

>5.8

>7.0

>5.8

>7.0

>7.0


<1.1

<1.1

<1.1

<1.1

<1.1

<1.1

<1.1

<1.1

<1.1

Salt

atta

ck re

sist

ance

cat

egor

yGP

GPGP

GPGP

GPGP

GPGP

Liab

ility

to e

fflor

esce

Nil

to s

light

Nil

to s

light

Nil

to s

light

Nil

to s

light

Nil

to s

light

Nil

to s

light

Nil

to s

light

Nil

to s

light

Nil

to s

light

Lim

e pi

tting

Nil

to s

light

Nil

to s

light

Nil

Nil

Nil

Nil

to s

light

Nil

Nil

to s

light

Nil

to s

light

Fire

ratin

g (F

RL) m

inut

es –

Insu

latio

n un

rend

ered

9090

9090

9090

9090

90N

o pe

r pac

k40

040

034

034

034

040

034

040

040

0Pa

ck w

eigh

t (kg

)12

0012

0092

592

592

512

0092

512

0012

00Pa

ck d

imen

sion

s (m

m)

1150

x920

x775

1150

x920

x775

1150

x770

x684

1150

x770

x684

1150

x770

x684

1150

x920

x775

1150

x770

x684

1150

x920

x775

1150

x920

x775

All t

estin

g is

car

ried

out i

n ac

cord

ance

with

Aus

tralia

n St

anda

rds

AS/N

ZS44

56 te

st m

etho

ds w

here

app

licab

le. T

estin

g is

car

ried

out i

n N

ATA

regi

ster

ed la

bora

torie


This

tech

nica

l inf

orm

atio

n re

pres

ents

ave

rage

pro

perti

es o

btai

ned

from

pro

duct

ion

lots

and

sho

uld

not b

e us

ed fo

r spe

cific

atio

n pu

rpos

es.

For m

ore

deta

iled

spec

ifica

tion

cont

act B

oral

Bric

ks. U

nit w

eigh

t quo

ted

is a

n ap

prox

imat

e w

eigh

t and

can

var

y. Th

is in

form

atio

n is

sub

ject

to c

hang

e w

ithou

t not

ice.


1.403

ADV03805


Escu

ra® –

Pre

ssed

Crea

mRe

d

Wor

k si

ze (m

m)

230x

110x

7623

0x11

0x76

Dimensionalcategory

DW1

DW1

Perfo

ratio

n (%

)Fr

ogFr

ogAv

e un

it w

eigh

t (kg

)4.

14.

1Ap

prox

num

ber p

er m

249

49W

all s

urfa

ce d

ensi

ty (k

g/m

2 )24

024

0Ch

arac

teris

tic u

ncon

fined

com

pres

sive

stre

ngth

of t

he u

nit (

f’uc)

MPa

>22

>22

Stre

ngth

s of

mas

onry

(MPa

)–

Char

acte

ristic

com

pres

sive

stre

ngth

(f’ m)M

3*mortar(GP)

>6.6

>6.6

– Ch

arac

teris

tic c

ompr

essi

ve s

treng

th (f

’ m)M

4*mortar(EXP)

>7.0

>7.0


<1.4

<1.4

Salt

atta

ck re

sist

ance

cat

egor

yEXP

EXP

Liab

ility

to e

fflor

esce

Nil

to s

light

Nil

to s

light

Lim

e pi

tting

Nil

Nil

Fire

ratin

g (F

RL) m

inut

es –

Insu

latio

n un

rend

ered

9090

No

per p

ack

272

272

Pack

wei

ght (

kg)

1200

1200

Pack

dim

ensi

ons

(mm

)89

0x72

5x94

089

0x72

5x94

0

Escu

ra® –

Dry

Pre

ssed

Bla

ck

Bea

uty

Red

Rum

Silv

er

Shad

owTi

nto

Crea

mW

ork

size

(mm

)23

0x11

0x76

230x

110x

7623

0x11

0x76

230x

110x


DW1

DW1

DW1

DW1

Perfo

ratio

n (%

)Fr

ogFr

ogFr

ogFr

ogAv

e un

it w

eigh

t (kg

)4.

04.

04.

04.

0Ap

prox

num

ber p

er m

249

4949

49W

all s

urfa

ce d

ensi

ty (k

g/m

2 )24

024

024

024

0Ch

arac

teris

tic u

ncon

fined

com

pres

sive

stre

ngth

of t

he u

nit (

f’uc)

MPa

>15

>15

>15

>15

Stre

ngth

sof

mas

onry

(MPa

)–

Char

acte

ristic

com

pres

sive

stre

ngth

(f’ m)M

3*mortar(GP)

5.2

5.2

5.2

5.2

– Ch

arac

teris

tic c

ompr

essi

ve s

treng

th (f

’ m)M

4*mortar(EXP)

5.6

5.6

5.6

5.6


<0.7

<0.7

<0.7

<0.7

Salt

atta

ck re

sist

ance

cat

egor

yEXP

GPEXP

EXP

Liab

ility

to e

fflor

esce

Nil

to s

light

Nil

to s

light

Nil

to s

light

Nil

to s

light

Lim

e pi

tting

Nil

Nil

Nil

Nil

Fire

ratin

g (F

RL) m

inut

es –

Insu

latio

n un

rend

ered

9090

9090

No

per p

ack

500

500

500

500

Pack

wei

ght (

kg)

1850

1850

1850

1850

Pack

dim

ensi

ons

(mm

)11

50x9

00x1

000

1150

x900

x100

011

50x9

00x1

000

1150

x900

x100

0

All t

estin

g is

car

ried

out i

n ac

cord

ance

with

Aus

tralia

n St

anda

rds

AS/N

ZS44

56 te

st m

etho

ds w

here

app

licab

le. T

estin

g is

car

ried

out i

n N

ATA

regi

ster

ed la

bora

torie


This

tech

nica

l inf

orm

atio

n re

pres

ents

ave

rage

pro

perti

es o

btai

ned

from

pro

duct

ion

lots

and

sho

uld

not b

e us

ed fo

r spe

cific

atio

n pu

rpos

es.

For m

ore

deta

iled

spec

ifica

tion

cont

act B

oral

Bric

ks. U

nit w

eigh

t quo

ted

is a

n ap

prox

imat

e w

eigh

t and

can

var

y. Th

is in

form

atio

n is

sub

ject

to c

hang

e w

ithou

t not

ice.

TypicaldataforallotherBoralfacebrickscanbefound

usingtheReferenceGuidesonthefollowingpages.Look

upyourrequiredproductbyBrickName(page1.404)or

RangeName(page1.405),andmatchthecodetothe

correspondingPropertyTableLegendonpage1.406.

FortypicaldatarelatingtoBoralclaypavers,referto

Section2.4–PaverPropertyTables–page2.401.


1.404

ADV03806

Rang

e N

ame

Bric

k N

ame

Code

NUV

OA

dobe

KHO

RIZO

N N

SWAl

abas

ter

JN

UVO

Allo

yK

OASI

SAl

pine

KHO

RIZO

N V

ICAm

ber B

laze

CEL

AN N

SWAm

ber B

laze

CEL

ANAm

ber B

laze

50m

mE

HORI

ZON

NSW

Amet

hyst

JHO

RIZO

N N

SWAn

tique

Cre

amJ

HORI

ZON

NSW

Antiq

ue G

rey

JHO

RIZO

N N

SWAn

tique

Nat

ural

JHO

RIZO

N N

SWAn

tique

Pin

kJ

HORI

ZON

VIC

Argy

leC

HORI

ZON

NSW

Arnh

em S

ands

MOA

SIS

Asco

tK

NUV

OBa

mbo

oK

OASI

SBa

ntry

Cov

eJ

OASI

SBe

ach

KOA

SIS

Beac

h Do

uble

Hei

ght

LHO

RIZO

N V

ICBe

aum

onde

CW

OODS

TOCK

Bent

ley

KW

OODS

TOCK

Bent

ley

Doub

le H

eigh

tL

HORI

ZON

VIC

Berw

ick

Rust

icC

OASI

SBi

anca

KOA

SIS

Bisq

ueK

OASI

SBi

sque

Dou

ble

Heig

htL

HORI

ZON

NSW

Blac

khea

thH

NUV

OBl

ue R

ioK

NUV

OBo

ulde

rG

HORI

ZON

VIC

Brow

n Te

rrai

nA

HORI

ZON

VIC

Brus

hwoo

dC

OASI

SCa

meo

JW

OODS

TOCK

Casc

ade

MN

UVO

Ches

tnut

KN

UVO

Chin

oG

OASI

SCl

assi

c Li

mes

tone

Hue

JEL

ANCl

evel

and

CEL

ANCl

evel

and

50m

mE

NUV

OCo

coG

Rang

e N

ame

Bric

k N

ame

Code

WOO

DSTO

CKCo

loni

alG

HORI

ZON

VIC

Colo

ny R

ose

GOA

SIS

Cora

l Mis

tJ

HORI

ZON

NSW

Cora

l San

dsM

OASI

SCo

rals

tone

KW

OODS

TOCK

Coun

try R

ose

MRE

VIVE

Crea

m R

ockf

ace

GRE

VIVE

Crea

m T

extu

reG

WOO

DSTO

CKCr

estw

ood

MHO

RIZO

N N

SWDe

lta S

ands

MOA

SIS

Dese

rt Sa

geJ

NUV

ODo

min

oD

WOO

DSTO

CKDr

ysda

leM

ELAN

Duch

ess

CW

OODS

TOCK

Dusk

MHO

RIZO

N V

ICEl

dora

doG

HORI

ZON

VIC

Embe

r Glo

wC

NUV

OEs

pres

soD

NUV

OEu

caly

ptK

WOO

DSTO

CKEu

reka

GEL

ANFl

oren

tine

Lim

esto

neN

WOO

DSTO

CKFr

esco

MHO

RIZO

N Q

LDGi

rraw

een

KHO

RIZO

N N

SWGr

aphi

teJ

ELAN

Grey

Nua

nce

CEL

ANGr

ey N

uanc

e 50

mm

EHO

RIZO

N V

ICGy

psy

Rose

COA

SIS

Haze

JOA

SIS

Hend

raK

WOO

DSTO

CKH

erita

ge

GW

OODS

TOCK

Hillv

iew

MHO

RIZO

N V

ICHi

stor

ic R

edG

WOO

DSTO

CKHo

neyc

ombe

MHO

RIZO

N V

ICIro

nbar

kA

NUV

OIv

ory

KHO

RIZO

N N

SWJa

rosi

teJ

HORI

ZON

VIC

Jarr

ahA

HORI

ZON

VIC

Kim

berle

yC

WOO

DSTO

CKKi

ngsl

eyK

Rang

e N

ame

Bric

k N

ame

Code

WOO

DSTO

CKKi

ngsl

ey D

oubl

e He

ight

LHO

RIZO

N V

ICKu

rraj

ong

AEL

ANLa

Mes

aC

ELAN

La M

esa

50m

mE

ELAN

Laba

ssa

CEL

ANLa

bass

a 50

mm

EHO

RIZO

N V

ICLa

chla

nA

WOO

DSTO

CKLa

trobe

KW

OODS

TOCK

Latro

be D

oubl

e He

ight

LHO

RIZO

N N

SWLe

ura

IW

OODS

TOCK

Lexi

ngto

nK

WOO

DSTO

CKLe

xing

ton

Doub

le H

eigh

tL

OASI

SLi

mes

tone

Hue

JHO

RIZO

N N

SWLi

ndem

anJ

OASI

SLi

nden

MHO

RIZO

N Q

LDLo

ngre

ach

KN

UVO

Man

grov

eG

HORI

ZON

NSW

Meg

alon

gH

NUV

OM

erlo

tD

NUV

OM

ist

GHO

RIZO

N V

ICM

ocha

AEL

ANM

ocha

50m

mE

NUV

OM

oss

GW

OODS

TOCK

Mow

bray

KW

OODS

TOCK

Mow

bray

Dou

ble

Heig

htL

HORI

ZON

NSW

Mur

ray

Rive

rH

OASI

SN

elso

n Co

veJ

HORI

ZON

VIC

Old

Woo

dvill

eC

ELAN

Opa

l Blu

shN

OASI

SOp

al C

ove

JHO

RIZO

N V

ICOr

ient

AN

UVO

Pana

ma

KHO

RIZO

N N

SWPe

wte

r San

dsM

WOO

DSTO

CKPo

rt Ph

illip

GW

OODS

TOCK

Potte

rs G

old

KW

OODS

TOCK

Potte

rs G

old

Doub

le H

eigh

tL

ELAN

Rahe

enC

ELAN

Ratta

nC

HORI

ZON

NSW

Red

Cove

H

Rang

e N

ame

Bric

k N

ame

Code

REVI

VERe

d Te

xtur

e –

No

Arris

MRE

VIVE

Red

Text

ure

– Sm

ooth

Arr

isM

ELAN

Ripp

onle

aC

OASI

SRi

verc

lay

KW

OODS

TOCK

Rose

KOA

SIS

Rose

Cov

eJ

WOO

DSTO

CKRo

se D

oubl

e He

ight

LEL

ANRo

uge

AHO

RIZO

N N

SWRu

belli

teJ

OASI

SSa

ble

JHO

RIZO

N V

ICSa

ndal

woo

dB

WOO

DSTO

CKSa

ndhu

rst

MW

OODS

TOCK

Sand

ston

e Go

ldK

WOO

DSTO

CKSa

ndst

one

Gold

Dou

ble

Heig

htL

HORI

ZON

NSW

Sand

y Ba

yH

HORI

ZON

VIC

Sand

y Be

ach

CW

OODS

TOCK

Settl

erG

HORI

ZON

VIC

Sien

naC

OASI

SSi

rius

Cove

JN

UVO

Slat

eK

NUV

OSo

ft Su

ede

GOA

SIS

Sorr

ell

KHO

RIZO

N Q

LDSt

Geo

rge

KOA

SIS

Ston

ewas

hK

OASI

SSt

onew

ash

Doub

le H

eigh

tL

NUV

OSt

orm

GHO

RIZO

N V

ICSu

nbur

stG

WOO

DSTO

CKSy

dney

Tow

nG

HORI

ZON

VIC

Tana

mi

COA

SIS

Tund

raJ

NUV

OVa

nilla

GN

UVO

Vict

oria

n Bl

ueD

NUV

OVi

ctor

ian

Blue

50m

mF

HORI

ZON

QLD

Win

dora

hK

HORI

ZON

VIC

Win

dsor

CW

OODS

TOCK

Win

ter G

old

KW

OODS

TOCK

Win

ter G

old

Doub

le H

eigh

tL


LEG

END

– L

iste

d A

lpha

betic

ally

by

Bri

ck N

ame

Chris

Rectangle


1.405

ADV03807


Rang

e N

ame

Bric

k N

ame

Code

ELAN

Ambe

r Bla

ze (N

SW)

CEL

ANAm

ber B

laze

50m

mE

ELAN

Clev

elan

dC

ELAN

Clev

elan

d 50

mm

EEL

ANDu

ches

sC

ELAN

Flore

ntin

e Lim

esto

neN

ELAN

Grey

Nua

nce

CEL

ANGr

ey N

uanc

e 50

mm

EEL

ANLa

Mes

aC

ELAN

La M

esa

50m

mE

ELAN

Laba

ssa

CEL

ANLa

bass

a 50

mm

EEL

AN

Moc

ha 5

0mm

EEL

AN

Opal

Blu

shN

ELAN

Rahe

enC

ELAN

Ratta

nC

ELAN

Ripp

onle

aC

ELAN

Roug

eA

HORI

ZON

NSW

Alab

aste

rJ

HORI

ZON

NSW

Amet

hyst

JHO

RIZO

N N

SWAn

tique

Cre

amJ

HORI

ZON

NSW

Antiq

ue G

rey

JHO

RIZO

N N

SWAn

tique

Nat

ural

JHO

RIZO

N N

SWAn

tique

Pin

kJ

HORI

ZON

NSW

Arnh

em S

ands

MHO

RIZO

N N

SWBl

ackh

eath

HHO

RIZO

N N

SWCo

ral S

ands

MHO

RIZO

N N

SWDe

lta S

ands

MHO

RIZO

N N

SWGr

aphi

teJ

HORI

ZON

NSW

Jaro

site

JHO

RIZO

N N

SWLe

ura

IHO

RIZO

N N

SWLin

dem

anJ

HORI

ZON

NSW

Meg

alon

gH

HORI

ZON

NSW

Mur

ray R

iver

HHO

RIZO

N N

SWPe

wte

r San

dsM

HORI

ZON

NSW

Red

Cove

HHO

RIZO

N N

SWRu

belli

teJ

HORI

ZON

NSW

Sand

y Bay

H

Rang

e N

ame

Bric

k N

ame

Code

HORI

ZON

QLD

Girra

wee

nK

HORI

ZON

QLD

Long

reac

hK

HORI

ZON

QLD

St G

eorg

eK

HORI

ZON

QLD

Win

dora

hK

HORI

ZON

VIC

Ambe

r Bla

zeC

HORI

ZON

VIC

Argy

leC

HORI

ZON

VIC

Beau

mon

deC

HORI

ZON

VIC

Berw

ick R

ustic

CHO

RIZO

N V

ICBr

own

Terra

inA

HORI

ZON

VIC

Brus

hwoo

dC

HORI

ZON

VIC

Colo

ny R

ose

GHO

RIZO

N V

ICEl

dora

doG

HORI

ZON

VIC

Embe

r Glo

wC

HORI

ZON

VIC

Gyps

y Ros

eC

HORI

ZON

VIC

Hist

oric

Red

GHO

RIZO

N V

ICIro

nbar

kA

HORI

ZON

VIC

Jarra

hA

HORI

ZON

VIC

Kim

berle

yC

HORI

ZON

VIC

Kurra

jong

AHO

RIZO

N V

ICLa

chla

nA

HORI

ZON

VIC

Moc

haA

HORI

ZON

VIC

Old

Woo

dvill

eC

HORI

ZON

VIC

Orie

ntA

HORI

ZON

VIC

Sand

alw

ood

BHO

RIZO

N V

ICSa

ndy B

each

CHO

RIZO

N V

ICSi

enna

CHO

RIZO

N V

ICSu

nbur

stG

HORI

ZON

VIC

Tana

mi

CHO

RIZO

N V

ICW

inds

orC

NU

VOAd

obe

KN

UVO

Allo

yK

NUV

OBa

mbo

oK

NUV

OBl

ue R

ioK

NUV

OBo

ulde

rG

NUV

OCh

estn

utK

NUV

OCh

ino

GN

UVO

Coco

GN

UVO

Dom

ino

DN

UVO

Espr

esso

D

Rang

e N

ame

Bric

k N

ame

Code

NUV

OEu

calyp

tK

NUV

OIvo

ryK

NUV

OM

angr

ove

GN

UVO

Mer

lot

DN

UVO

Mist

GN

UVO

Mos

sG

NU

VOPa

nam

aK

NUV

OSl

ate

KN

UVO

Soft

Sued

eG

NUV

OSt

orm

GN

UVO

Vani

llaG

NUV

OVi

ctor

ian

Blue

DN

UVO

Vict

oria

n Bl

ue 5

0mm

F

OASI

SAl

pine

KOA

SIS

Asco

tK

OASI

SBa

ntry

Cov

eJ

OASI

SBe

ach

KOA

SIS

Beac

h Do

uble

Hei

ght

LOA

SIS

Bian

caK

OASI

SBi

sque

KOA

SIS

Bisq

ue D

oubl

e He

ight

LOA

SIS

Cam

eoJ

OASI

SCl

assic

Lim

esto

ne H

ueJ

OASI

SCo

ral M

istJ

OASI

SCo

ralst

one

KOA

SIS

Dese

rt Sa

geJ

OASI

SHa

zeJ

OASI

SHe

ndra

KOA

SIS

Limes

tone

Hue

JOA

SIS

Linde

nM

OASI

SN

elso

n Co

veJ

OASI

SOp

al C

ove

JOA

SIS

Rive

rcla

yK

OASI

SRo

se C

ove

JOA

SIS

Sabl

eJ

OASI

SSi

rius C

ove

JOA

SIS

Sorre

llK

OASI

SSt

onew

ash

KOA

SIS

Ston

ewas

h Do

uble

Hei

ght

LOA

SIS

Tund

raJ

Rang

e N

ame

Bric

k N

ame

Code

REVI

VECr

eam

Roc

kfac

eG

REVI

VECr

eam

Text

ure

GRE

VIVE

Red

Text

ure

– N

o Ar

risM

REVI

VERe

d Te

xtur

e –

Smoo

th A

rris

M

WOO

DSTO

CKBe

ntle

yK

WOO

DSTO

CKBe

ntle

y Dou

ble

Heig

htL

WOO

DSTO

CKCa

scad

eM

WOO

DSTO

CKCo

loni

alG

WOO

DSTO

CKCo

untry

Ros

eM

WOO

DSTO

CKCr

estw

ood

MW

OODS

TOCK

Drys

dale

MW

OODS

TOCK

Dusk

MW

OODS

TOCK

Eure

kaG

WOO

DSTO

CKFr

esco

MW

OODS

TOCK

Herit

age

GW

OODS

TOCK

Hillv

iew

MW

OODS

TOCK

Hone

ycom

beM

WOO

DSTO

CKKi

ngsle

yK

WOO

DSTO

CKKi

ngsle

y Dou

ble

Heig

htL

WOO

DSTO

CKLa

trobe

KW

OODS

TOCK

Latro

be D

oubl

e He

ight

LW

OODS

TOCK

Lexin

gton

KW

OODS

TOCK

Lexin

gton

Dou

ble

Heig

htL

WOO

DSTO

CKM

owbr

ayK

WOO

DSTO

CKM

owbr

ay D

oubl

e He

ight

LW

OODS

TOCK

Port

Phill

ipG

WOO

DSTO

CKPo

tters

Gol

dK

WOO

DSTO

CKPo

tters

Gol

d Do

uble

Hei

ght

LW

OODS

TOCK

Rose

KW

OODS

TOCK

Rose

Dou

ble

Heig

htL

WOO

DSTO

CKSa

ndhu

rst

MW

OODS

TOCK

Sand

ston

e Go

ldK

WOO

DSTO

CKSa

ndst

one

Gold

Dou

ble

Heig

htL

WOO

DSTO

CKSe

ttler

GW

OODS

TOCK

Sydn

ey To

wn

GW

OODS

TOCK

Win

ter G

old

KW

OODS

TOCK

Win

ter G

old

Doub

le H

eigh

tL

LEG

END

– L

iste

d A

lpha

betic

ally

by

Rang

e N

ame

Chris

Rectangle


1.406

ADV03808


Lege

ndFo

r the

pro

duct

& ra

nge

nam

e re

latin

g to

the

refe

renc

e co

des

show

n be

low

refe

r to

the

follo

win

g al

phab

etic

al le

gend

AB

CD

EF

GW

ork

size

(mm

)23

0x11

0x76

230x

110x

7623

0x11

0x76

230x

110x

7623

0x11

0x50

230x

110x

5023

0x11

0x76

Dimensionalcategory

DW1

DW1

DW1

DW1

DW1

DW1

DW1

Perfo

ratio

n (%

)<3

0<3

0<3

0<3

0<3

0<3

0<3

0Av

e un

it w

eigh

t (kg

)3.

23.

13.

33.

22.

32.

22.

9Ap

prox

num

ber p

er m

249

4949

4970

7049

Bric

kwor

k lo

ad/m

2 (kg/

m2 )

205

200

210

210

210

200

190

Char

acte

ristic

unc

onfin

ed c

ompr

essi

ve s

treng

th o

f the

uni

t (f’u

c) M

Pa>2

2>2

2>2

2>2

2>2

2>2

3>1

5St

reng

ths

of m

ason

ry (M

Pa)

– C

hara

cter

istic

com

pres

sive

stre

ngth

(f’ m)M

3*mortar(GP)

>6.6

>6.6

>8.5

>6.6

>5.1

>6.6

>5.4

– C

hara

cter

istic

com

pres

sive

stre

ngth

(f’ m)M

4*mortar(EXP)

>7.0

>7.0

>9.0

>7.0

>5.4

>7.0

>5.8


<1.4

<1.4

<1.4

<1.4

<1.4

<1.4

<1.1

Salt

atta

ck re

sist

ance

cat

egor

yEXP

GPEXP

EXP

EXP

EXP

GPLi

abili

ty to

effl

ores

ceN

ilN

ilN

il to

slig

htN

il to

slig

htN

il to

slig

htN

il to

slig

htN

il to

slig

htLi

me

pitti

ngN

ilN

ilN

ilN

ilN

ilN

ilN

ilFirerating(FRL)minutes-InsulationUnrendered

9090

9090

9090

90N

o pe

r pac

k46

046

027

227

242

442

434

0Pa

ck w

eigh

t (kg

)15

1814

7295

095

010

0092

592

5Pa

ck d

imen

sion

s (m

m)

1150

x 9

12 x

880

1150

x 9

12 x

880

865x

710x

935

865x

710x

935

865x

730x

935

865x

710x

935

1150

x770

x684

HI

JK

LM

NW

ork

size

(mm

)23

0x11

0x76

230x

110x

7623

0x11

0x76

230x

110x

7623

0x11

0x16

223

0x11

0x76

290x

90x1


DW1

DW1

DW1

DW1

DW1

DW1

DW1

Perfo

ratio

n (%

)<3

0<3

0<3

0<3

0<3

0<3

0<3

0Av

e un

it w

eigh

t (kg

)2.

92.

92.

92.

95.

83.

05.

4Ap

prox

num

ber p

er m

249

4949

4924

.549

19.5

Bric

kwor

k lo

ad/m

2 (kg/

m2 )

190

190

190

185

190

190

160

Char

acte

ristic

unc

onfin

ed c

ompr

essi

ve s

treng

th o

f the

uni

t (f’u

c) M

Pa>2

2>2

2>2

2>1

0>1

0>1

8>1

0St

reng

ths

of m

ason

ry(M

Pa)

– C

hara

cter

istic

com

pres

sive

stre

ngth

(f’ m)M

3*mortar(GP)

>6.6

>6.6

>6.6

>4.4

>5.5

>5.9

>5.4

– C

hara

cter

istic

com

pres

sive

stre

ngth

(f’ m)M

4*mortar(EXP)

>7.0

>7.0

>7.0

>4.7

>5.9

>6.4

>5.8


<1.1

<1.1

<1.1

<1.0

<1.0

<1.0

<0.8

Salt

atta

ck re

sist

ance

cat

egor

yGP

EXP

GPEXP

EXP

EXP

GPLi

abili

ty to

effl

ores

ceN

il to

slig

htN

il to

slig

htN

il to

slig

htN

il to

slig

htN

il to

slig

htN

il to

slig

htSl

ight

Lim

e pi

tting

Nil

to s

light

Nil

to s

light

Nil

to m

oder

ate

Nil

to m

oder

ate

Nil

to m

oder

ate

Nil

to s

light

Nil

Firerating(FRL)minutes-InsulationUnrendered

9090

9090

9090

60N

o pe

r pac

k40

040

028

838

017

240

013

2Pa

ck w

eigh

t (kg

)12

0012

0083

610

8010

5012

0071

3Pa

ck d

imen

sion

s (m

m)

1150

x920

x775

1150

x770

x685

920x

920x

880

1000

x860

x930

1000

x820

x930

1150

x912

x770

980x

770x

870

All t

estin

g is

car

ried

out i

n ac

cord

ance

with

Aus

tralia

n St

anda

rds

AS/N

ZS44

56 te

st m

etho

ds w

here

app

licab

le. T

estin

g is

car

ried

out i

n N

ATA

regi

ster

ed la

bora

torie


This

tech

nica

l inf

orm

atio

n re

pres

ents

ave

rage

pro

perti

es o

btai

ned

from

pro

duct

ion

lots

and

sho

uld

not b

e us

ed fo

r spe

cific

atio

n pu

rpos

es.

For m

ore

deta

iled

spec

ifica

tion

cont

act B

oral

Bric

ks. U

nit w

eigh

t quo

ted

is a

n ap

prox

imat

e w

eigh

t and

can

var

y. Th

is in

form

atio

n is

sub

ject

to c

hang

e w

ithou

t not

ice.


1.407

ADV03809


Boral Bricks Blends Brand Blend Name Blend Mix Ratio

Horizon Brighton Sands 1CoralSands/1DeltaSands 50% / 50%Horizon Capes Lagoon 2Sandy Bay/1Murray River 66% / 33%Horizon Carrington 2Pink/1Cream/1Natural 50% / 25% / 25%Horizon Castlemaine 1Pink/1Cream/1Natural/1Grey 25% / 25% 25% / 25%Horizon Chalcedony 2Rubellite/1Jarosite/1Graphite 50% / 25% / 25%Horizon Copeland 2Cream/1Grey 66% / 33%Horizon EchoPoint 1Sandy Bay/1Red Cove/1Murray River 33% / 33% / 33%Horizon Galena 2Jarosite/1Graphite 66% / 33%Horizon GeorgesBasin 1Sandy Bay/1Red Cove 50% / 50%Horizon Hawkesbury 1Pink/1Cream 50% / 50%Horizon Hunter 2Pink/1Cream/1Grey 50% / 25% / 25%Horizon Manning 3Pink/1Natural 75% / 25%Horizon Outback 5Windorah/1StGeorge 83% / 17%Horizon Patterson 3Cream/1Natural 75% / 25%Horizon Reef 1CoralSands/1PewterSands/1Delta 33% / 33% / 33%Oasis Barclay 1Sorrell/1Alpine/1Riverclay 33% / 33% / 33%Oasis Bendemeer 1Linden/1Albion 50% / 50%Oasis Grange 1Hendra/1Ascot 50% / 50%Oasis Raffia 5Sorrell/1Alpine 85% / 15%Oasis Sandstone Blush 5Cameo/2Limestone Hue 70% / 30%Oasis Tambo 5Alpine/1Sorrell 85% / 15%Woodstock Apsley 1Sandhurst/1Drysdale/1Hillview/1Crestwood 25% / 25% 25% / 25%Woodstock BakehouseGold 1Lexington/1PottersGold/1SandstoneGold 33% / 33% / 33%Woodstock Barweave 1Lexington /2 Mowbray 33% / 66%Woodstock Boyd 1Country Rose/1Cascade 50% / 50%Woodstock Brunswick 5Mowbray/1Kingsley 85% / 15%Woodstock Carbrook 4Bentley/1Kingsley 80% / 20%Woodstock Clarence 1Honeycombe/1Dusk 50% / 50%Woodstock Daintree 1Sandhurst/1Crestwood 50% / 50%Woodstock DiggersGold 1PottersGold/1SandstoneGold/1WinterGold 33% / 33% / 33%Woodstock Dustwood 5Lexington/1PottersGold 85% / 15%Woodstock Glenayr 1Sandhurst/1Drysdale 50% / 50%Woodstock Hastings 1Honeycombe/1Dusk/1Cascade 33% / 33% / 33%Woodstock Highland 5SandstoneGold/1WinterGold 85% / 15%Woodstock HomesteadGold 1PottersGold/1SandstoneGold 50% / 50%Woodstock Macleay 1Honeycombe/1Cascade 50% / 50%Woodstock Mt Cotton 2Bentley/2Mowbray/1Kingsley 40% / 40% / 20%Woodstock Rywood 5WinterGold/1SandstoneGold 85% / 15%Woodstock Stockmans 1Sandhurst/1Crestwood/2Hillview 25% / 25% / 50%Woodstock Wickham 1Bentley/1Mowbray 50% / 50%Woodstock Wilson 1Dusk/1CountryRose/1Cascade 33% / 33% / 33%Woodstock Woodland 1Sandhurst/1Drysdale/1Crestwood 33% / 33% / 33%

2. Pavers

2 Pavers

Paver Properties2.1

Section 2.1 relates to the properties of pavers made to meet the requirements of Australian Standard AS4455 Part

2 Pavers and Flags. This information is provided as a guide only to the properties of interest to a pavement designer

or layer and does not constitute a recommendation for any type of pavement or any technique for paving. Typical

properties for individual pavers can be found on the data sheets.

Paver Dimensions

Pavers can be made in any shape that tessellates but for manufacturing reasons they are usually restricted to

rectangles or squares. Rectangular pavers are usually made so that two laid together with a 2-5 mm gap in

between, form a square. AS4455.2 differentiates between pavers and flags in that a paver has a plan area less

than 0.08 m2 (i.e. less than 280 mm x 280 mm square). Pavers being smaller than flags allow changing of levels more

easily. Pavers are also easier to cut than flags to fit complex geometries such as tight re-entrant angles or curves.

Pavers can be any size; however, the common work size has plan dimensions of 230 mm long x 115 wide. This size

was chosen for the practical reason that pavers tend to be made in the same plants as bricks and the manufacturing

machinery is designed for this size. Commonly pavers are made in 40 mm, 50 mm and 65 mm heights and because

flexible pavements rely on pavers interlocking and sharing forces, a minimum thickness is required for different

applications. Manufacturers specify the work size of the pavers they sell.

Clay paver sizes vary when they are fired but over and undersized units average each other out when blended

properly during laying. Paver dimensions are measured by dry stacking 20 units, measuring the total length and

comparing that measurement to twenty times the work size.

Pavers are classified according to how much they deviate from twenty times the work size.

• DimensionalCategory,DPA1means, for typicalpavers, theheightandwidthwilldifferby lessthan50mm

from twenty times the work size and the length will differ less than 60 mm.

• DimensionalCategory,DPA2means,fortypicalpavers,theheightandwidthwilldifferby lessthan40mm

from twenty times the work size and the length will differ less than 50 mm.

• DimensionalCategory,DP0meanstherearenorequirements.Thisisusuallyreservedfornon-standardpavers

that have been rumbled or otherwise distorted in manufacture for aesthetic reasons.

DPOpaversarereservedforresidentialpathways.DPA1andDPA2paversarespecifiedinapplicationsrequiring

tighter tolerances to share loads more effectively. This is specifically those areas where there is a higher volume of

traffic or heavier loads. ■


Section 2.1 Paver Properties 2.101

ADV2101



ADV2102

Paving Strength

Minimum Breaking Load

The most important strength for pavers is their resistance to breaking under a bending load. This is because pavers

are mainly supported from below and they are loaded from above. Bend strength is measured according to

AS4456.5, where a load is applied across the middle of a paver, supported across its width 25 mm in from both

ends. The test imitates the extreme case of the possible field loading, where there is no support from the sides and

the bedding course has failed.

Pavers in any one batch have a range of strengths that would usually follow a normal distribution. Normal practice

has been to use the Minimum Breaking Load in pavement design. This is the lowest breaking load found when

measuring 10 samples.

Compressive Strength of Pavers

Paver compressive strength is measured by individually crushing 10 pavers in the same way it is for bricks. This

gives the compressive strength of each paver and the mean compressive strength of the lot. A factor can be applied

to eliminate the test constraints to give the unconfined compressive strength of each paver, which by further

mathematical treatment can give the Characteristic Unconfined Compressive Strength. While the compressive

strength is critical in masonry design, it is almost never relevant in pavement design. ■



ADV2103

Durability

Salt attack is the most common durability problem. Salt can be absorbed into pavers in the form of a solution. As

the water evaporates, the salt is drawn towards the outside face. The evaporating water leaves the solution super-

saturated so salt crystals begin to form. The salt crystals grow in the pores just below the surface and depending

on the texture of the paver, the amount of salt, the rate of drying and the temperature, the salt may fill the pores,

exerting very high pressures on the matrix. The energy in the constrained salt crystal is large, and when a sufficient

number of constrained salt crystals of large enough size are present, the energy is converted to new surface energy

and movement, i.e. it ‘pops’ a piece of the outer surface off, and salt attack has begun.

Pavers are assessed according to AS/NZS4456.10 Resistance to Salt Attack and classed into grades. In summary

the grades of paver can be used as follows:

• GeneralPurposeGrade(GP)

Suitable for use in all pavements not requiring Exposure Grade pavers.

• ExposureGrade(EXP)

Suitable for use: around salt water pools; within 100 metres of a non-surf coast; within 1 kilometre of a surf coast;

and in contact with aggressive soils or environments. Exposure grade pavers can also be used in GP applications.

Boral provides pavers in both EXP and GP grades.

Freeze-thaw is an uncommon durability problem in Australia, affecting only alpine areas. As water freezes it

expands and if sufficient pressure is generated, pieces break off. Freeze-thaw resistance is determined according

to an ASTM test, which is done mainly on pavers exported to Northern Asia. Although failure is due to a constrained

particle in both cases, the mechanism is different and pavers that pass the salt attack test do not necessarily pass

the freeze thaw test and vice versa. Should freeze-thaw resistant pavers be needed, contact your Boral sales

representative so they can nominate those available. ■

Slip Resistance

The slip resistance of a pavement is obviously important. AS/NZS 4586:1999 Appendix A. Slip Resistance

Classification of New Pedestrian Surface Materials: Wet Pendulum Test Method is used to determine paver slip/

skid resistance. The test simulates a rubber soled shoe on a wet pavement. A classification of ‘W’ (low contribution

of the paver to the risk of slipping when wet) is the minimum requirement for pavers, the only other acceptable

classification is ‘V’ (very low contribution of the paver to the risk of slipping when wet). ■



ADV2104

Abrasion Resistance

The abrasion resistance gives an indication of the paver’s ability to withstand wear. AS/NZS 4456.9:1997

DeterminingAbrasionResistance isusedfortestingtheabrasionresistanceofclaypavers.Thetestconsistsof

fixing pavers over holes in the side of a rotating box filled with ball bearings. The test was designed to simulate the

action of high-heeled (stiletto) shoes on pavers, which is known to be highly aggressive because of the high point

loads. Abrasion resistance is only required for public area pavements and the Mean Abrasion Resistance required

depends on the volume of traffic. ■

Moisture Expansion

Clay products expand over time as they absorb water into their structure. The expansion is not uniform and one

quarter of the expansion occurs in the first six months, one half in the first two years and three-quarters in the first

5 years. The Characteristic Expansion is estimated from an accelerated test and expressed as a coefficient of

expansion (em). For Boral pavers the characteristic expansion is usually between 0.8 and 1.2 mm/m. Moisture

expansion is taken up in the gaps between pavers in flexible pavements however, in rigid pavements (including

copers around pools) stresses are usually relieved by creep in the adhesive and it is essential the correct adhesive

is used. Reducing the residual moisture expansion by storing the pavers in ambient or moist atmosphere is known

as ‘grassing’ the pavers. For pavers with a high moisture expansion this should be considered if using the pavers for

rigid pavements where there are opposite movements in concrete shrinkage and paver expansion. ■

Efflorescence

Pavers may contain soluble salts that come to the surface when the paver dries. The source of the soluble salts is

the raw materials used in the production process.

Paver efflorescence is usually white but there is a special form of efflorescence (known as vanadium staining) that

is coloured yellow, green or reddish-brown and is therefore particularly visible on light coloured pavers.

Boral pavers have little to no efflorescence and paver efflorescence should not be confused with the efflorescence

that is seen on pavements in some areas after laying. This form of efflorescence mainly comes from the subgrade

or the base course materials used in the construction process. Frequently efflorescence comes from poorly graded

bedding sand not acting as a capillary break, allowing salt laden water to be drawn up from below. ■



ADV2105

Pitting due to Lime

If paver making raw materials contain particles of calcium carbonate, these will be converted into quicklime in the

kiln. Water subsequently combines with the quicklime to form hydrated lime and in the process it expands. If lime

particles are sufficiently large and sufficiently near the surface they ‘pop’ off a piece of the paver, leaving a

generally circular pit with a white spot in the bottom.

Boral pavers rarely show lime pitting. ■

Cold Water Absorption

While pavers absorb water and the joints in segmental pavements allow some water to pass through the pavement,

these surfaces are usually classed as ‘impermeable’ in landscape design. Some special pavers are made to allow

water to drain through but such permeable pavers are uncommon in Australia. Most permeable pavements are

designed to allow water to penetrate through the gaps between pavers not through the paver.

The amount of water that a paver can absorb is measured by the 24 hour cold-water absorption (CWA) test. The

results of water absorption tests are of use to the paver manufacturer for quality assurance but are rarely of any

value to anyone else. With proper drainage of the base course and attention to levels, pavers should not look

continually wet in a pavement, regardless of the CWA. Sealing pavers with silicones, siliconates, urethanes,

polyesters or acrylics may lower the CWA or seal the surface giving a lower test result. Sealing can be done at the

manufacturing stage but the benefit to the user is hard to quantify. Sealing can give a false result in a salt attack or

freeze thaw test and is specifically banned by some test methods. Sealing after the pavers are laid is generally not

advised as only the top surface is sealed and water rising from below will generally bring up salts, to be deposited

under the coating. If this happens it cannot be rectified in most cases. Where it is expected that grease and oil may

be dropped on paving then sealing will make it easier to keep the pavement clean. Remember, no coating lasts for

ever and some coatings darken over time. ■

2.2 Pavement Design


2.201

ADV2201

Section 2.2 Pavement Design

This section contains recommendations for typical pavement systems. Local experience may support departures

from these recommendations where satisfactory in-situ performance has been demonstrated over a period of time.

The recommendations are not applicable for pavements on poorly drained sites and sites classified as highly

reactive clay sites, extremely reactive clay sites or problem sites according to AS2870.1; engineering design is

required for such sites. While rigid pavements are described below and some minor recommendations are made,

both rigid pavements and water permeable pavements are beyond the scope of this manual.

Pavement Types

Pavers are used to make segmental pavements. Segmental pavements are divided into two major sub-groups,

flexible and rigid. A rigid pavement relies on having a rigid layer (usually a concrete slab) to distribute the imposed

loads to the subgrade, a flexible pavement does not. Pavements can be further sub-divided on their use.

1. Pedestrian traffic only

2. Pedestrian traffic and light vehicles (axle loads less than 3 tonnes)

3. Pedestrian traffic and commercial vehicles (axle loads greater than 3 tonnes)

4. Primarily vehicular traffic

Flexible Pavements are constructed in layers; subgrade, base course, bedding course and surface course. In

situations where heavy vehicular traffic is expected or the subgrade is of marginal strength, an additional layer, the

sub-base,maybeinsertedbetweenthesubgradeandthebasecourse.Onrareoccasions,wherethesubgradeis

strong rock and it is sufficiently level, the bedding course may be laid directly on the subgrade.

Rigid Pavements are also constructed in layers; subgrade, rigid base course, bedding course and a surface course.

The bedding course is omitted in some situations where the pavers are adhered directly to the rigid course. Rigid

pavements become more common as loads increase and are usually not constructed to carry only pedestrian traffic.

In some parts of Australia a significant proportion of domestic driveways are rigid segmental pavements and this

trend is growing elsewhere. The decision to use a flexible or rigid pavement depends on specific site conditions and

a comparative cost analysis. Boral does not recommend rigid pavements over flexible pavements or one system of

rigid paving over another. Rigid pavements will not be discussed in detail in this manual. t


2.202

ADV2202


Pavement Types (continued)

• The‘Pedestriantrafficonly’categoryistypicallyresidentialpathsandhardlandscapedareas,pathsinpublic

gardens and parks, pedestrian areas around buildings such as offices, schools, etc. and pedestrian areas

around entertainment or sporting facilities. These pavements are usually closed to all vehicles.

• The ‘Pedestrian traffic and occasional light vehicles’ category is typically residential driveways and areas

around buildings, used occasionally by light vans and utilities for deliveries or for access for maintenance work.

Heavier vehicles such as those picking up full rubbish skips or delivering concrete, bricks, etc are likely to cause

some damage.

• The‘Pedestriantrafficandcommercialvehicles’categoryistypicallypublicmalls,crossovers,drivewaysthat

carry occasional commercial vehicles and lightly trafficked streets. Commercial vehicles are classified as those

having a gross weight equal to or greater than 3 tonnes.

• The‘Primarilyvehiculartraffic’categoryisroads.Fewsegmentallypavedroadsarenowconstructedhowever;

this form of construction was widespread in the past as can be seen with many surviving examples of cobbled

streets. Detailed engineering design is required for roads, due to the high superimposed loads and the

consequence of failure. Construction of segmentally paved roads is generally the same as for asphalt roads up

to the bedding course. The bedding course and surface course construction is then generally the same as for

other pavements but 65 mm or thicker pavers are used and a herringbone laying pattern is mandatory. ■


2.203

ADV2203


Description of Layers and Basic Engineering Design Requirements

Figure 1. Typical elements of flexible pavements

Clay paversSurface course

Bedding course

Base course

Subgrade

Jointing sand

ConcreteEdge Strip

Subgrade

The subgrade is the natural ground or constructed soil which supports the loads transmitted by the overlying

pavement layers. The natural ground may be rock or soil that is sufficiently strong for the purpose. Where the

natural soil is not strong enough to bear the loads, the natural soil or imported fill may be compacted to produce the

desired strength. Compaction is the most cost effective measure for increasing the strength of soil.

Soil strength is assessed using the Californian Bearing Ratio (CBR) test (AS 1289.6.1. Parts 1, 2 or 3). The CBR test

measures the shear strength of the soil and the result is expressed as a percentage of the shear strength of a

sample composed of Californian marble (or limestone) chips. The most common CBR test is the remoulded

laboratory test where the sample may be tested immediately after compaction or it may be soaked to fill all pores

with water before testing. Soaking represents the worst case in the field i.e. a saturated subgrade. The decision to

use a soaked or un-soaked CBR in the design should reflect the expected in-service conditions.

For pavements carrying only pedestrian and occasional light vehicular traffic it is usual practice to estimate the CBR

from soil classification data or local knowledge. Measuring the CBR is usually restricted to situations where the

potential savings from using lower grade materials or thinner layers outweighs the cost of the test.

If the materials in the subgrade have a soaked CBR value less than 5% and are to carry vehicular traffic, stabilisation

with cement, lime, ground granulated blast-furnace slag or the use of geotextiles or lean mix concrete should be

considered.

The top of the finished subgrade is calculated from the top of the pavement (minus the thickness of the pavers,

bedding course and base course). The level of the top of the pavement is governed by aesthetics and practical

matters such as positioning of damp-proof courses and physical termite barriers in adjacent masonry, step heights,

and whether the pavement is to be flush with, above or below the surrounding landscape, etc. ■


2.204

ADV2204


Base Course

The base course is a constructed layer which transfers the loads from the surface course to the subgrade. The

thickness of the base course varies depending on the subgrade classification and the intended use. For pavements

carrying loads in excess of domestic driveways, the base course should be designed on sound engineering

principles. The thickness of the base course increases for lower CBR subgrades but thinner base courses may be

used where the base course materials are stabilised or where a geotextile is used appropriately.

The base course in a flexible pavement is made from granular material compacted in layers. Particularly for large

projects, where traffic volumes and loads are expected to be high, field density testing should be used to verify that

the required soil density has been achieved.

The material used in the base course should conform to local requirements for base course materials for asphalt

roads. Base course materials are natural or manufactured granular material which interlocks on compaction, usually

being a nominal 20 mm aggregate with less than 6% clay. The top surface of the base course should be close-knit

to prevent bedding course materials falling down leaving cavities under the pavers, but where such material is not

available or where subgrade movement is likely a geotextile should be used.

Table 1. Typical Grading for Base Course MaterialsSieve Size Percent Passing

26.5 mm 10019.0 mm 95-10013.2 mm 78-929.5 mm 63-83

4.75 mm 44-642.36 mm 30-50425 µm 14-2275 µm 4-12

Stabilisation of base course materials is recommended in areas of very high rainfall, as stabilised materials are less

susceptible to the effects of saturation.

When resurfacing existing pavements, if the pavement is stable, then no further preparation is required as the

existing pavement can usually be regarded as a suitable subgrade and base course.

In rigid pavements the base course is usually a nominal 20 MPa reinforced concrete slab designed to AS 3600

Concrete Structures requirements. ■


2.205

ADV2205


Bedding Course

The bedding course passes the loads from the pavers to the base course. It also acts as a capillary break to prevent

(possibly salt laden) moisture being drawn up to the pavers and in the laying process allows pavers to settle more

or less so that pavers of slightly different heights finish with the top surfaces aligned. Bedding course material

should be well-graded, coarse, sharp sand (typical of a concrete sand) with less than 3% clay. Bricklaying sands,

loams and fatty sands do not consolidate as do sharp sands and because of their fines content, do not provide a

capillary break and so should not be used. Manufactured sands with excessive fines, (eg crusher dust or quarry

fines), should not be used as they do not provide a capillary break and this results in efflorescence caused by saline

ground waters.

Table 2. Typical Grading for Bedding Course MaterialsSieve Size Percent Passing

9.5 mm 1004.75 mm 90-1002.36 mm 75-1001.18 mm 55-90600 µm 35-59300 µm 8-30

150 µm s 0-1075 µm 0-5

The bedding course should be screeded to a nominal 25-30 mm thickness and the base course should be finished

accurately enough not to need to vary this thickness. However in the event of poor workmanship, the bedding

course may be varied but it must never be less than 20 mm thick and should not be more than 40 mm thick. It is

most important that the bedding course is of uniform thickness.

Geotextiles may be laid on top of the base course under the bedding sand. They act as a separation layer and are

particularly effective in preventing the loss of bedding sand due to cracking in the base course caused by movement

in subgrades. Should there be a loss of bedding sand, the pavers may subside and possibly chip or break. Geotextiles

may also be effective as a drainage layer.

Stabilisation of bedding course materials should be considered where the pavement is constructed on a steep

slope. Stabilisation reduces the likelihood of bedding course material being flushed out leaving cavities under the

pavement. In most other instances stabilisation of the base course is not recommended as it increases the cost for

no commensurate benefit and in some instances leads to increased efflorescence on the laid pavement. ■


2.206

ADV2206


Surface Course

The surface course comprises pavers. Paver thickness should be specified for all pavements. Paver durability grade

should be specified only where salt attack or freeze/thaw is an issue. Paver bend strength should be specified for

pavements carrying vehicles. Paver abrasion resistance should be specified for pavers in public area pavements (i.e.

those with high levels of pedestrian traffic). Paver slip resistance should be specified for pavers in public areas.

Table 3. Recommended Specifications for Clay Pavers

ApplicationMinimum thickness

(mm)

Minimum characteristic

breaking load (kN)

Dimensionaldeviation

Slip resistance classification

Mean abrasion resistance (cm2)

Residential (domestic) pavementsPedestrian traffic only 40 2 DP0 W N/ADriveway,lightvehiclesonly 40 3 DPA1 W N/ADriveway,includingcommercialvehicles 60 5 DPA1 W N/A

Public area pavementsPedestrian traffic only 40 2 DPA1 W Low volume: 7

Medium volume: 5.5High volume: 3.5

(See Note 1)

Pedestrian traffic and light vehicles (axle loads < 3 tonnes) 50 3 DPA2 W

Pedestrian traffic and commercial vehicles (axle loads > 3 tonnes) 60 5 DPA2 W

Roads

General vehicular traffic on minor or local roads 60 6 DPA2 W

N/A(See Note 2)

Note 1: Typical low volume pedestrian traffic is up to the level found in schools and public areas of residential

complexes. Typical medium volume pedestrian traffic is found in suburban shopping precincts or sports venues.

Typical high volume pedestrian traffic is found in inner city and major suburban malls and transport hubs (often over

30 000 passes per day).

Note 2: Minor and local roads are those carrying up to 1000 vehicles per day (i.e. excludes collector roads). ■


2.207

ADV2207


Edge Restraints

Edge restraints are existing structures or constructed features, which are sometimes seen as decorative features

but in reality are of great structural importance. Edge restraints as the name suggests constrain lateral movement

of pavers at the edge of the pavement. This combined with sand in the joints is critical in producing rotational and

horizontal interlock. Failure of the edge restraint will lead to failure of the pavement. As the design load and traffic

volume increase the edge restraint should be upgraded. For pavements carrying pedestrian traffic only, pavers on

edge, timber on edge or mortar haunching of the edges is usually sufficient. For a driveway carrying commercial

vehicles a reinforced concrete strip (beam or slab) forms a suitable edge restraint. (Such strips may be hidden by the

edge pavers being bonded to it or it may be left visible as part of the pavement’s aesthetic). Concrete restraints

should meet AS3600 requirements and should be constructed from ready mixed concrete with a minimum strength

of 20 MPa. ■

Figure 2. Typical edge restraint systems

Paveronedge(ortreatedtimber)setinmortarorconcrete.

Hardwoodonedgesupportedbyhardwoodstakes

Mortarhaunch


2.208

ADV2208


Figure 2. Typical edge restraint systems (continued)

Preformedconcrete

Concretepouredonsite(drivewaysmainly).

Concretepouredonsite(drivewaysmainly)

Figure 3. Using an existing structure as an edge restraint


Bedding course

Base course

Subgrade

Jointing sand

Damp Proof Course

150mm

Mortar Bed

Theedgepaverissetonamortarbed(shownasgrey).


2.209

ADV2209


Drainage

The most common reason for the failure of pavements is inadequate sub-surface drainage. So where it is necessary,

during construction install sufficient stormwater and sub-soil drainage to prevent the accumulation of water in any

area excavated for the pavement. All trenches should be backfilled to ensure they perform similarly to the

undisturbed ground around them. However, even where this is done effectively, after completion of the paving,

water pooling on the surface may penetrate through the pavement and cause softening of the subgrade. Although

pavers do not allow large amounts of water to drain through them the joints do allow water to penetrate,

particularly in the early life of the pavement.

Water infiltration due to poor drainage may also cause the growth of moss, mould, fungus and lichen which looks

unsightly and may be slippery. Pavement design should ensure that surface water is directed to collection points

where it can be discharged safely.

Figure 4. Typical drainage systems in flexible pavement


Bedding course

Base course

Subgrade

PVC Pipe

Figure 4 shows a typical drainage arrangement in a sloping flexible pavement at a concrete, edge restraint or

transverse beam. A slotted PVC pipe with a filter sock, drains water from the base course to the side and out of the

pavement. A smaller PVC pipe with a filter cap drains water from the bedding course out of the pavement. ■


2.210

ADV2210


Paver Laying Patterns

Various paving patterns can be formed and some of these are illustrated on the next page. For pavements carrying

vehicles herringbone pattern (either 90˚ or 45˚) should be specified. For pavements carrying pedestrians only, the

choice of pattern is a matter of personal preference. It must be remembered that some patterns require significantly

more cutting than others and this may affect the cost of laying. For example, tracery pattern is developed from a

unit consisting of four whole pavers and a half a paver whereas running pattern only has part pavers at each end of

the pavement.

When specifying the pattern it is best to remember the function, setting and size of the pavement. Pavements laid

on a granular bedding course, carrying vehicular traffic must use a herringbone pattern. Herringbone patterns have

contiguous pavers over the shortest distance of any pattern (i.e. no straight joint extends for more than 1½ pavers)

and therefore resist shunting best. Simple patterns should always be used in small spaces while large spaces can

use patterns with large repeat distances to advantage.

A major advantage of pavers over flags is that pavers can be formed into more complex patterns. By using different

laying patterns and colours, many effects can be created. As with a carpet the effect can be a solid uniform colour,

a mottle producing an overall colour impression, random coloured highlights, a polychrome patchwork, geometric

patterns, etc. Some designers have used pavers to create pictures on a grand scale. Effects may also be much more

subtle such as using regular arrays of similar coloured pavers to produce textural effects. t


2.211

ADV2211


Paver Laying Patterns (continued)

45°Herringbone 90°Herringbone ZigZag

Basketweave2x2 Basketweave2x1 45°Basketweave (¾BasketweaveorBasketweavevariant)

Stack Stretcherorrunning Off-setstretcherorrunning

45°Stack Mixedstackandrunning Tracery

Off-setstack


2.212

ADV2212


Joints Between Pavers

Pavers laid on bedding sand should have gaps of 2-3 mm left between them for the jointing sand. To be effective,

gaps should never be less than 1 mm nor more than 5 mm. After laying the pavers jointing sand is spread over and

broomed into the gaps. A plate vibrator is then passed over the surface, levelling the pavers and vibrating sand

down into the gaps while settling and compressing the pavers into the bedding sand. At the same time some of the

bedding sand is forced up into the joints.

Sand filled joints are essential as the sand interlocks the pavers so that imposed forces are shared between

adjacent pavers. Interlock is of three types; vertical, horizontal and rotational.

• Vertical interlockensuresapaverdoesnotslidedown relative to itsneighboursbysharing loadsbetween

neighbouring pavers.

• Rotationalinterlockensuresthatapaverloadedatonesidedoesnotrotate.Paversneedspacetorotatesoedge

restraints and proper filling of the joints prevent movement that would otherwise allow pavers to rotate. The sand

moves the point at which the pavers would rotate (i.e. the hinge) to the top of the joint and prevents the top edges

of adjacent pavers coming into contact. Pavers contacting their neighbours are very likely to chip when loaded.

• Horizontalinterlockisprovidedbythelayingpattern.Wheeledtrafficpushesthepaversandwherestraight

lines occur in the laying pattern the pavers can move past each other (this is called shunting). Where the

pavement carries wheeled traffic a herringbone pattern (either 45˚ or 90˚) is recommended. There seems to be

no difference in the performance of the different styles of herringbone or in orientation relative to the traffic.

For pavements only carrying pedestrian traffic, horizontal interlock is required to a much lower degree and a

wide range of decorative laying patterns may be used. Gaps between pavers that are too narrow (<1 mm) do

not allow sufficient sand for effective interlock.

Jointing sands should be rounded, free flowing sand, typically dune sand.

Table 4. Typical Grading for Jointing SandsSieve Size Percent Passing2.36 mm 1001.18 mm 75-95600 µm 50-80300 µm 20-45150 µm 5-1575 µm 0-5

Typical gradings for jointing sands overlap typical gradings for bedding sands and so one sand may be suitable for

both requirements. Bedding and jointing sands are frequently whatever is readily available in the local area and

may not meet the typical gradings above. Proprietary jointing sands containing various additives are available, but

their cost usually limits them to specialised uses. ■


2.213

ADV2213


Tolerance on Course Levels

Subgrade should be finished to +0, -25 mm of the design level.

Where the pavers are laid on bedding sand the base course (and where used the sub-base) should be finished to

+0, -25 mm except where it abuts existing structures where +0, -10 mm is appropriate and in any 3 metre length the

surface should not be higher or lower than 10 mm from the average (taking into account any falls).

Bedding courses should be finished to the thickness required to bring the surface course to the design level, taking

into account the thickness of the surface course and compaction as the pavers are vibrated to settle them into the

bedding course. This will depend on the bedding course materials and its moisture content. Where local experience

is not available the required thickness should be established by trial.

Surface courses should be finished to ±6 mm of the design level, except where it abuts a kerb or drainage

channel where it should be finished to +6, -0 mm. In all cases there should be less than 3 mm difference between

adjoining pavers. ■

Crossfalls

A 1:60 crossfall is normally satisfactory for drainage. Crossfalls should not be less than 1% (1:100) unless specific

measures have been taken to ensure water does not build up on the pavement e.g. covering it with a roof. The

general rule is that the broader the paved area the greater the crossfall. Crossfalls are sometimes restricted by the

site’s landform and some pooling of water in heavy rain may be acceptable. ■


2.214

ADV2214


Steep Gradients

Even on the best constructed pavements, water running over or dripping or splashing onto steeply sloping

pavements may wash out the jointing sand, particularly early in the life of the pavement. Localised rutting (usually

from inadequate subgrade or base course preparation), loss of bedding sand (usually from poor sub-surface

drainage), and localised movement (usually at or near poor edge restraints) can also lead to loss of the jointing sand.

For pavements carrying wheeled traffic (such as driveways) this is a particular problem as it may result in the

pavers chipping or shunting (moving laterally). To avoid shunting and chipping pavers, maintaining the jointing sand

and using a restraint system are essential. Rigid pavement with the pavers adhered directly to a concrete slab and

the joints filled with mortar or grout has been used successfully as an alternative.

Maintaining the jointing sand is as simple as sweeping more sand over when needed. Proprietary jointing sands are

available containing cement, mineral and polymeric binders. The additives bond the sand together and this has

been shown to be beneficial on steeply sloping pavements because the sand does not wash out as easily, but

beware of potential staining problems. Use only as directed by the manufacturer and construct a small trial area to

test if there are any problems in use.

The principle of restraint systems is to subdivide the pavement into (typically 5 metre) sections restrained at the

periphery. Because the section length is short the potential for movement is reduced. A typical restraint system

uses a plain concrete transverse beam. Concrete beams should be designed to AS3600 requirements and be

constructed from ready mixed concrete with a minimum strength of 20 MPa.

Figure 5. Typical plain concrete transverse beam for a steep single residence driveway


Bedding course

Base course

Subgrade

PVC Pipe

The depth of the concrete beam depends on the soil type. Typically for a single residence driveway on clay, the

beam is 250 – 300 mm deep. The pavers are adhered to the beam typically with a 1:4 cement to sand mortar with

additives to enhance bonding or the pavers are pressed into wet low slump concrete. An exposed plain or exposed

aggregate concrete beam can be used instead of having pavers bonded to it. ■

2.3 Pavement Construction


2.301

ADV2301

Section 2.3 Pavement Construction

Each job is different and the descriptions below may or may not be suitable in any particular instance. The steps in

the construction of the pavement may vary in their order. For example, edge restraints for a heavy duty driveway

will usually be constructed between the preparation of the subgrade and the base course but may be constructed

between the preparation of the base course and the bedding course. However, for light duty driveways edge

restraints may be put in after preparation of the base course and for domestic pathways professional paviours

almost always put in edge restraints after laying the surface course. For an amateur it is best to construct the edge

restraints early.

Paver Estimator

Pavers can be different sizes and shapes and pavements can be any size and shape. The more complex the

pavement’s shape usually the more cutting and therefore the more pavers required. For regular pavements,

determine the number of pavers for the length of the pavement and the number of rows for the width of the

pavement. Half pavers should be calculated as a whole paver, due to site wastage. Multiply the number of pavers

by the number of rows to give the number of pavers for the pavement. Saw cutting pavers is usual practice but that

does not mean two pieces will be obtained from any paver. For complex pavements, draw the pavement accurately

to scale on squared paper and work out the approximate area and multiply this area by the factor in the relevant

paver property table. Always allow some excess pavers for site wastage. ■

Subgrade Preparation

The subgrade should be prepared to the design profile. The prepared area should be wider than the pavement,

extending beyond the rear edge of the edge restraints or up to existing structures. Unsuitable material including the

topsoil, roots and other organic matter should be removed from the subgrade. Proof rolling may be used to identify

areasofunstablesubgrade,whichshouldberemovedorcompactedtoachievethedesiredstrength.Observinga

loaded truck slowly crossing the area will generally show areas of unstable subgrade. The subgrade should be

excavated, compacted, trimmed or built up with compacted base course material as necessary to within +0mm, -25

mm of the design level.

The most common reason for the failure of pavements is inadequate subsurface drainage and so, where necessary,

install sufficient stormwater and subsoil drainage to prevent the accumulation of water in any area excavated for

the pavement. Water accumulating in this location could reduce the stability of the whole structure or bring

efflorescing salts to the pavement surface and detract from appearance or durability. All trenches should be

backfilled to ensure they perform similarly to the undisturbed ground around them. ■


2.302

ADV2302


Base course Preparation for Flexible Pavements

The base course is made from granular material (usually called road base) compacted in layers. The thickness of the

layers and the number of passes of the compactor should be matched to the capability of the compaction device.

For large machinery it is usual to compact in 150 mm layers but for a vibrating plate compactor layers less than 100

mm are usual. The number of passes of the compactor varies but for a vibrating plate compactor three passes is

usually satisfactory for domestic pavements carrying only pedestrian traffic. In typical domestic pavements 100

mm of compacted base course is usually sufficient.

The base course should be screeded and compacted to the design profile (+0, -25 mm except where it abuts existing

structures where +0, -10 mm is appropriate). The top surface should be closed after compaction but if holes are

apparent because of the nature of the material used, fines can be screeded on and compacted into the surface to

fill any voids.

Where stabilised base course is required, in most circumstances it is best to purchase it ready mixed, just before

use. Cement stabilised materials may set if not used within a few hours and if a delay is expected slower setting

materials and retarders are available. Mixing on site should only be done in a concrete mixer as it is difficult to get

an even distribution of the binder by hand mixing. ■

Edge Restraints for Flexible Pavements

All edges of all pavements must be restrained to prevent lateral movement of the pavers and consequent loss of

interlock. The size and strength of the restraints must be adequate to support the intended loads. The shape and

style of the restraints must prevent the escape of bedding course material from beneath the pavers and must be

aesthetically pleasing.

Edge restraints should be formed before compacting adjacent pavement layers. However, adjacent layers may first

be compacted then some compacted material may be carefully cut and removed for the haunch1 if the haunch

material is initially fluid e.g. concrete or mortar. Concrete and mortar haunching, and concrete beams and slabs

should be mature before vibration and compaction of the surface course is undertaken.

As a minimum, haunching must continue down to the underside of the bedding course. As haunching is usually a

barrier to water movement, drainage should be provided through the haunching to prevent the build up of water in

the bedding course. ■

1A‘haunch’isthatpartofanarchbetweenthecrownandthespringingline,ineffect,ahalfanarch.Becauseofitsshape,inpaving‘haunch’hascometomeanthematerialsupportingthesideofthepavement.‘Haunching’isanalternateformof‘haunch’.


2.303

ADV2303


Bedding Course for Flexible Pavements

Bedding course material should be well-graded, coarse, sharp sand (typical of a concrete sand). Bricklaying sands,

loams and fatty sands do not consolidate as do sharp sands and because of their fines content do not provide a

capillary break and thus should not be used. Manufactured sands with excessive fines, (crusher dust), should not be

used as they do not provide a capillary break and this results in efflorescence on the pavers.

The moisture content of the bedding course should be uniform, so stockpiled material should be covered before

use.

Waterproof membranes beneath the bedding course are not advised except where the paving is completely under

cover. A waterproof membrane will prevent salt laden water being drawn up to the surface limiting efflorescence

but it is unnecessary with a properly chosen base course material. The reason for not using a waterproof membrane

is that it traps water causing the base course to become saturated and this can lead to pumping, the loss of fines

and the eventual breakdown of the pavement. Where the surface of the base course is not densely compacted or

where movement may occur in the sub-grade opening up cracks in the base course (i.e. where bedding sand may be

lost), the use of geotextiles is usually beneficial. Geotextiles are tough, polymeric felts with holes small enough to

preventthesandpenetrating.Otherclothsaregenerallynotsuitable.

Cement-stabilised bedding sands are not recommended where well-graded bedding sand is available. If poor

quality bedding sands must be used very lean cement stabilisation may be appropriate. Adding two to four per cent

cement (by volume) to the bedding sand is usually satisfactory. Where the slope of a pavement exceeds 1:15 cement

stabilising the bedding sand is practical and should prevent water scouring out the sand. For driveways with a

sloping pavement having a length greater than 5 metres, a transverse concrete beam running between edge

restraints should also be used. A capping course of pavers is bonded onto the top surface of the beam and the

pavers, up slope from the beam, are then laid on cement-stabilised sand. (See Section 2.214 for more information

on flexibly paved sloping driveways.)

The bedding course should be screeded to 25 -30 mm thick. The base course should be finished accurately enough

to not need to vary this thickness, however, the bedding course may not be less than 20 mm thick and not more than

40 mm thick. t


2.304

ADV2304


Bedding Course for Flexible Pavements (continued)

Either of the following installation procedures is acceptable:

• Spread thematerial loose and screed to the final level plus an amount to accommodate the reduction in

thickness that will occur when the pavers are vibrated; or,

• Spreadthemateriallooseandscreedtothefinallevel.Vibrateandcompactthissandusingthesamevibrating

plate compactor as that used for vibrating the pavers. Finally spread and screed a thin layer to form a loose

surface onto which the pavers can be laid.

In either method the sand should be disturbed as little as possible before laying the pavers. Any disturbance may

lead to final surface undulations. Gaps between edge restraints or at the intersection with other pavements should

be sealed to avoid loss of bedding sand.

Screeding is usually done by placing rails (sometimes called trammels) made of pieces of timber or pipe at the right

level and dragging a piece of straight timber or aluminium over them levelling the sand. After removing the rails

there is a depression in the sand and that is usually filled by the paviour trowelling on some sand as the pavers are

laid. Where the edge restraints are in place and sufficiently close together, a screed can be made from a piece of

timber notched to fit within the restraints or a piece cut to fit between the restraints then a second, longer piece of

wood is nailed to the top of the first piece of timber. The timber is drawn along the restraints levelling the sand

between them.

Figure 6. Screeding bedding sand

Edge restraint set toconcrete level

Screed Bed

Trammel

Where the slope of the pavement changes direction, screed to an apex or ‘v’ then flatten the apex with a trowel or

fill and smooth the depression so the directional change is over as many pavers as possible and the height

difference between neighbouring pavers is minimised. ■


2.305

ADV2305


Paver Storage

Pavers stored on site should be covered and kept off the ground. Saturated pavers may adversely affect the bond

strength in rigid pavements or where pavers are adhered to cross beams.

Store pavers away from where saw cutting of bricks and pavers is being conducted, and away from cement and

other materials which may stain them.

Moving pavers around the site may cause chipping, so excessive movement of packs should be avoided. ■

Blending

Some colour variation is inevitable in clay pavers. Colour variation when poorly handled may lead to unwanted

patches, streaks and bands of colour in the finished pavement. The raw materials for paver making are natural clays

and shales and these vary in colour within any one deposit. Paver makers blend materials to moderate the colour

variation and tightly control the conditions in the kiln but no matter how well made, pavers delivered to site will

have some degree of colour variation.

To minimise colour variation and the visible effects of it, the following is recommended:

• Allpaversoftheonecolourrequiredtocompleteapavementshouldbeorderedattheonetime;

• Allpaversrequiredfortheproject,butinanycaseasmanypacksaswillfit,shouldbedeliveredatonetime

and stored on site;

• Paversshouldbedrawnfromasmanypacksaspossible,simultaneously,workingdownfromthecornersof

each pack; and,

• Edgepaversofthesamecolourasthebulkofthepavementshouldbeselectedatthesametimeasthosein

the adjacent pavement. Those requiring cutting should then be marked up, cut and positioned. Selecting all

edge pavers separately for cutting may produce an undesirable effect.

Paversaresuppliedwithonefacesuitableforexposing(i.e.tobeseenafterlaying).Onsomepaversbothfacesare

suitable for exposing but they may look different. The paviour should ensure where two sides are different the

pavers are laid to produce the aesthetic required. Two faced pavers that have unwanted marks, chips or cracks on

one face should be turned over, exposing the good face in the pavement. Single sided pavers that have unwanted

marks, chips or cracks on the face or any paver with significant edge damage should be set aside by the paviour (or

labourer) for cutting pieces. Boral will not be responsible for replacing pavers with unwanted marks, chips or cracks

that have been laid. ■


2.306

ADV2306


Laying Practices

Pavers being a regular form are usually laid in regular patterns containing straight lines. These lines are critical to

the look of the pavement and are marked out with stringlines which are used to set out the pavers. Judging the

line(s) to use requires an assessment of the pattern and the site. Where there is a strong central line in the

pavement this is usually critical and a stringline would be placed on that line and set out would be from that line.

Pavements abutting existing structures usually follow their lines and gauging should be done from them. Edges or

ends of pavers are usually aligned with the stringline but in the case of 45˚ herringbone corners are aligned to it.

While experienced paviours gauge by eye it is usual practice to place stringlines at regular intervals (10 rows in

pavements on sand bedding courses) to check the pattern is regular. If the line of the pavers has deviated from the

stringline it is usually necessary to remove a few rows of pavers and relay them making adjustments to the joint

widthtoreturntothecorrectalignment.Dependingonthemagnitudeofthemisalignment,realigningmayneedthe

removal and relaying of three or four rows.

Pavers are usually laid from one side or from the centreline. 90˚ herringbone is usually laid from a corner or

sometimes from the centre of one side advancing out in the shape of a triangle. Whole pavers are laid first followed

by part pavers.

Pavers on Sand Bedding Courses

Pavers must be laid so that there is a joint of 2 to 5 mm between them. Pavers should never be butted up against each

other. Where joints are too narrow insufficient sand will fill them and it is likely the pavers will contact each other

which will lead to chipping of corners and edges and may lead to rutting, shunting and the failure of the pavement.

Laying is usually forward from the laid pavers and not from the sand in front. Where laying from the front must be

done the bedding sand should be compacted and only a thin screed layer left loose on top and where possible

boards should be used to minimise the disturbance and prevent the need to re-screed the sand. Pavers should be

placed in the correct position without regard to their neighbours, leaving gaps where a full paver will not fit. Small

amounts of sand may be trowelled on to adjust the level if needed. This is particularly the case where two or more

different types of paver are used in the one pavement.

Pavers with Mortared Joints

Mortared joints in pavements are usually 10 mm and laying is from the side or front of the pavers. Good brick laying

techniques should be used including laying to stringlines or using levels to ensure pavers are to the required level. It

is usually easier to lay part pavers at the same time as laying whole pavers. Careful mortar preparation, clean

working and fully bedding and filling all joints are important. t


2.307

ADV2307


Laying Practices (continued)

Laying Part Pavers

Whole (and damaged or part) pavers are held over the holes left after laying the whole pavers and the piece

required to fill that hole is marked directly on the paver. Where this is not possible carefully measure the piece

requiredandtransferthemeasurementstoapaver.Note:Donotforgetthegapforthejointingsand.Paversshould

always be cut using a masonry saw as this is the only way to get an accurate cut. For small jobs done by non-

professional paviours, because of the cost of hiring a masonry saw, masonry wheels or blades on angle grinders

and bolsters are frequently used but the accuracy of the cut suffers. It must be remembered that many pavers are

very dense and may break into many pieces if hit with a bolster. It is always better to have two larger cut pavers

than one whole paver and one small piece. Cut pavers should always be greater than one third of the area of the

paver when cut across the paver or greater than one quarter of the area of the paver when cut diagonally.

For cutting dense hard materials, masonry saw blades without teeth are preferred. For cutting softer materials

toothedmasonrysawbladesarepreferred.Obviouslyaprofessionalpaviourwill require twoblades if they lay

concrete and clay pavers. Toothed blades used to cut hard pavers usually wear faster than smooth blades.

Laying Pavers on Curves and Around Obstacles

The smaller rectangular or square objects are the tighter the curve they can follow. If you do not mind the look of ‘v’

shaped joints, with no gap at the base and a 20 mm gap at the top, standard pavers can form a circle 3.5 metres in

diameter. Few people want such wide ‘v’ shaped joints (which also have to be mortar filled because sand will wash

out) and so it is common practice to cut pavers to suit the curve.

Figure 7: Curve formed without cutting pavers Curves formed by cutting one or two sides of the pavers.

To minimise cutting some paviours cut only one side of the paver or cut every second paver. If only one side of each

paver is cut, the joints do not point to a common centre so the curve has a skewed appearance. Curves formed of

alternating uncut and double-cut pavers also have an unusual appearance. It is a matter for each individual to

decide if they find the aesthetic acceptable, particularly around tight curves such as manhole covers or trees. t


2.308

ADV2308



Figure 8. Manhole cover detail

Figure 8 shows a soldier course of double-cut, tapered pavers in a circle around a manhole cover, set in a 45°

herringbone pavement. Note the small pieces of paver needed to maintain the pattern and fit the circular inclusion.

It is almost impossible to eliminate these smaller pieces but judicious use of half pavers will allow an increase in

the size of the smaller cuts giving the pavement greater stability in this area.

Corners in Header Courses

A soldier course or a single or double stretcher course is often used around paving as a border. For corners that are

not right angles a properly cut mitre is essential to avoid an overhang. At right angled corners in a soldier course a

mitred joint is recommended. t

Figure 9. Non-right angle corners

Unmitred 45° angle Mitred 45° angle

Figure 10. Right angle corners in double stretcher course


2.309

ADV2309



Figure 11. Corners in soldier course

Figure 12. Treatment of right angled service covers

In Figure 12, note on the left hand cover the use of two larger cut pavers in the top, bottom and left hand sides to

replace the one thin sliver in the soldier course as shown on the right hand side. Around both edge courses in the

body of the paving, note the use of half pavers (dark brown) to avoid the use of a small triangular piece at the edge

of the soldier or stretcher course. Small pieces of paver as shown on the right hand side of the right hand cover

should be avoided. This half paver technique should also be used adjacent to borders around any 45° pattern. t


2.310

ADV2310



Figure 13. Treatment of recessed covers

For recessed covers, pavers should be cut and fitted to maintain the pattern. Small pieces inside the recess are not

a problem as they are restrained by the edge and the pieces are normally glued to the cover. To maintain the pattern

outside the cover it can be necessary to use small pieces of paver. It is usual to remove the bedding sand under

these pieces and replace it with mortar for stability.

Warnings:

1. Cutting pavers produces a very fine dust (becoming a mud when using a proper water cooled masonry saw).

Pavers contain crystalline silica and dust from dry cutting is hazardous to your health if breathed in.

2. The residue from cutting forms a hard, solid mud which in sufficient quantities will block drains. It is advisable

to have a container under the drain on a brick saw bench to act as a sediment trap. The sediment should be

removed periodically throughout the cutting and disposed of properly. Allowing this sediment to flow into

drains or water courses attracts a fine in most jurisdictions.

3. The residue from cutting and the spray from the saw can get into the pores of bricks, pavers and other

materials leaving a permanent stain. This should be prevented by careful placement of the saw but should this

happen the only technique known to have been successful in removing the stain from bricks and pavers is to

rub the stain with a firm cloth with a paste of sand blasting grit (glass fragments). This is very time-consuming,

physically hard work and not guaranteed to work. It may harm the bricks or pavers and should always be tried

on a small inconspicuous area first to test the effect. ■


2.311

ADV2311


Sand Filled Joints

Joint-filling sand should be spread over the surface of the pavers and swept into the joints. Sand should be dry to

flowintoandfilljointseffectively.Dampsandshouldnotbeusedasthejointswillnotbefilledeffectively.Sands

containing clay should not be used as they are likely to stain the surface of the pavers.

Commercially prepared stabilised, jointing sands are available and although more costly than bulk sand may be

better in some instances. The manufacturer’s advice should be sought on the proper use of these sands as improper

use may lead to staining of the pavers. ■

Mortar Filled Joints

Mortared joints are now rare in large pavements, however where mortared joints are used they should be finished

as an ‘ironed’ joint. Mortar smears on such pavements will usually require cleaning and the same precautions and

techniques as used to clean bricks apply. Mortar composition must be carefully controlled to achieve good bonding

and prevent excessive shrinkage. ■

Compaction

Compaction is necessary for all pavements laid on sand base courses and should follow laying and joint filling as

soon as possible but should not occur closer than one metre to the unrestrained working edge of the pavement

under construction. No area of paving should be left uncompacted at the completion of the day’s work, apart from

the edge strip of the laying face.

Compaction should be carried out using a vibrating plate compactor with a plan area of not less than 0.25 m2 or a

rubber-rolled mechanical vibrator. Vibrating plate compactors should be fitted with a glider attachment but where

not available the plate may be wrapped in carpet or a carpet square or a sheet of plywood can be laid over the

pavers to protect them from damage during compaction.

The area to be compacted should be swept clean of joint filling sand and then receive at least two passes of the

vibrating plate compactor. The joints should then be topped up by sweeping joint filling sand over the area prior to a

final compaction consisting of at least two more passes of the vibrating plate compactor. Compaction should

continue until the tops of all pavers are in the same plane. No paver should be more than 3 mm out of plane with its

neighbours.

The jointing sand will continue to settle over the ensuing weeks, and should be topped-up by brooming sand over

empty joints until they are filled. Vibration for this topping up is not required. ■


2.312

ADV2312


Trafficking After Construction

Flexible pavements may be trafficked immediately after construction depending on the nature and age of the edge

restraints. Where edge restraints are constructed with cement, traffic should be restricted until they gain

sufficient strength. ■

Cleaning

In most cases cleaning pavements after construction is as simple as picking up and sweeping off the sand, paver

pieces etc. In some instances there is mortar to clean up. Cleaning mortar off pavers is best done when fresh as it

is easier and less likely to create problems.

Hosing, vacuuming or blowing of any pavement with sand filled joints is not recommended for the first three months

of its life. Hand brooming is recommended in this time. If jointing sand is removed broom more on to top up the

joints. High pressure water or steam cleaning is not recommended for householders and should only be done by

trained professionals. High pressure water is the basis of a cutting technique, used for cutting stone, glass,

concrete, tiles, pavers, and some metals. Incorrect use of high pressure will damage the face of the pavers. Small,

cheap, high pressure cleaners, capable of exceeding 15 MPa (2200 PSI), are now commonly available and incorrectly

used they will damage pavements.

Clay pavers do not change colour in service. Changes in colour are usually related to the build-up of dirt, coloured

materials on the surface (red wine, tannins, grease, food, tyre marks, etc.), growths (lichen, moss and algae), salts

(efflorescence) or physical damage. Colour change in one area and not another is usually an indicator of the source

of the problem.

All pavements are subject to spillages and soiling and a build-up of dirt and grime. Frequent sweeping and washing

reduces the effect of dirt and grime and maintains the attractiveness of a pavement. Washing with detergents and

liquid household bleach (sodium hypochlorite) will not damage the pavers but remember incorrect use of these

chemicals has severe environmental consequences and in some areas there are penalties for putting them into the

stormwater system.

Where grease or oil (including greasy food) will be spilled on the pavement, such as around barbecues, outside

take-away food shops, around public eating places, driveways, etc., using dark coloured pavers makes the problem

less noticeable. Sealers can be used to prevent or minimise absorption into the pavers and make removal by

washing with detergent easier. Prevention is the only 100% cure but it should be remembered that weathering and

bacterial action will eventually remove the residue once the cause is removed. t


2.313

ADV2313


Cleaning (continued)

Efflorescence

This is a powdery deposit of salts (usually white or yellow), often found on the surface of clay pavers after rain. The

source of this stain could be the pavers but almost always it comes from the soil under the pavement, or from

cement (if the soil was stabilised), or both. Dry brushing to remove the efflorescence before washing is

recommended. If efflorescence is wetted, the salts go into solution and are drawn back into the pavers and will

reappear as the pavement dries. Efflorescence will eventually disappear through natural weathering.

White scum

Donotconfusewhitescumwithefflorescence.Whitescumisathinwhitefilmonthesurfaceofpavers.Thisfilmis

invisible when the pavers are wet but shows up as the surface begins to dry. Scum often appears after an

attempted removal of mortar stains or after the sanding of the joints with sand that has a high clay content.

White scum is particularly difficult to remove. Water, detergents or hydrochloric acid often do not have any effect

on it. However scrubbing with a proprietary brick cleaner will often improve the appearance of pavements affected

by this stain.

Dirt and grime

Frequent sweeping and hosing will usually ensure a clean pavement. It this is not enough, washing with a detergent

or a proprietary cleaner may be required.

Vanadium stains

Vanadium salts produce a green or yellow efflorescence which is mainly seen on cream and light coloured clay

pavers. Hydrochloric acid will make these stains much worse and may make them impossible to clean. Vanadium

stains will disappear in time but in most cases they are easy to clean. Mild vanadium stains may be treated with

sodium hypochlorite (household bleach). Spray or brush it on the dry pavers and leave until the stain disappears,

then rinse off. Proprietary mould cleaners containing sodium hypochlorite and sodium hydroxide can be used as

above and have been found very effective. Proprietary brick cleaners may also be effective and should only be used

according to the manufacturer’s instructions. t


2.314

ADV2314



Fresh mortar stains

Whilethemortarissoft,lightlycoveritwithdampcleansand.Dunesandisbestbutitisveryimportantthatthe

sand has no clay in it. Sweep the sand towards the edge of the pavement. Repeat if needed. Follow this with a light

covering of dry clean sand and sweep towards the edge. Any sticky wet mortar residues that escaped the wet

sanding will be removed by the dry sand. The next day after the pavement has dried, some mortar residue may still

be visible as a faint white film. Smooth pavers may be carefully wiped with a cloth to take off most of the remaining

film but the film will generally weather away if left untouched. Some efflorescence will appear as the pavement

dries but it is not damaging to the pavers. Follow the instructions above to deal with the efflorescence.

Oil and bitumen

These stains usually need two treatments with a commercial emulsifying agent. First, mix the emulsifier with

kerosene to remove the stain. Then clean the kerosene off with the emulsifier mixed only with water. When dealing

with petroleum, asphalt and bituminous emulsion, scrape off the excess material and scrub the surface with

scouring powder and water. Chilling the surface with ice or solid carbon dioxide can cause brittleness in the asphalt

and assist removal.

For petrol or lubricating oil stains, free oil must be mopped up immediately with an absorbent material such as

paper towelling. Wiping should be avoided as it spreads the stain and tends to force the oil into the pavement.

Hardened oil must be scraped off. The area affected should then be covered with a dry absorbent material such as

diatomaceous earth, fine white clay, kaolin or whiting and the procedure repeated until there is no further

improvement. Subsequently use detergent to clean up, and rinse well with clean water.

Food stains and tyre marks

Scrub with a full-strength commercial detergent and rinse well. t


2.315

ADV2315



Hardened mortar stains

In mortar the cement binds the sand particles to each other and to other surfaces. Cleaning starts with breaking

down these bonds and in general this requires the use of hydrochloric acid.

Recommended acid strengths are based on application to a surface saturated paver. The recommended acid

strength for light coloured clay pavers is 1 part acid to 20 parts water and for other pavers is 1 part acid to 10 parts

water. Stronger acid solutions do not work more effectively and will cause staining.

Hydrochloric acid is a corrosive S6 poison and care must be taken when using it. To avoid personal injury:

• Weargoggles,glovesandprotectiveclothing.

• Alwayspouracidsintowater–thisavoidssplashesofhighlyconcentratedacidontotheoperator.

• Ifsplashedontothebody,washwithcleanwaterandifpossible,neutralisewithamixtureofbicarbonateof

soda and water.

Before attempting to clean off mortar, make sure any efflorescence and particularly any vanadium stains are

removed, then using a piece of wood or paver, knock off any mortar lumps.

The next step is to fully saturate the pavers with water. This does not dilute the acid, rather it keeps it on the

surface where the mortar is. Failure to completely saturate the surface of the pavers allows cleaning solutions,

containing dissolved mortar and acids, to be drawn into the pavers, causing staining.

Note: Saturating pavers and using the correct strength of hydrochloric acid solution must be strictly adhered to for

pavers manufactured in Queensland. Their raw materials contain large amounts of iron oxide and failure to saturate

the surface or using strong acid solutions allows acid to react with the iron oxide and create severe iron oxide

staining. Failure to do this with pavers manufactured in other parts of Australia may lead to the acid reacting with

iron oxide but to a much lesser degree. This form of staining is known as acid burn and is particularly visible on light

coloured pavers. Acid absorption into bricks can also lead to vanadium and manganese staining.

Next apply the acid solution with a stiff bristled (not wire) brush and scrub vigorously. Acid takes time to dissolve

the cement and scrubbing may take 4-6 minutes (or longer). Work at an area no larger than one square metre at a

time and as soon as the pavers are clean wash down thoroughly. After washing, a solution of 15 g per litre of

washing soda or 24 g per litre of sodium bicarbonate should be sprayed on to neutralise any remaining acid.

(Continue spraying until no bubbling occurs). Excess hydrochloric acid will eventually evaporate; however, it is likely

tocausestaining.Otheracidssuchassulfuricacidornitricacidwillnotevaporateandarenotusedincleaning.

High-pressure water jet cleaning is not recommended for pavements with sanded joints as it will remove the sand.

If a high-pressure water jet cleaner is used on pavers, with mortared or grouted joints, be careful not to damage the

pavers. Keep the pressure below 1200 psi (8000 kPa), use a wide fan jet nozzle, keeping it at least 500 mm from the

surface and work at an angle not vertically. t


2.316

ADV2316



Fungi, moulds, moss and lichens

These are common, particularly in shady or damp parts of the pavement. They sometimes appear as localised dark

stains or patches of green, giving a dirty and unsightly appearance.

Alternatively these growths may add to the appearance of the pavement. They will not damage the pavement but

may cause it to become slippery. To remove these growths, vigorously brush the effected area when it is dry. High-

pressure water may also be used following the precautions above. Although the problem may appear to be gone,

the cause is still present and it is recommended that a poison be applied. Copper sulphate solution or sodium

hypochlorite (liquid household bleach) generally work well if used as directed on the container. Proprietary

herbicides and fungicides are available from plant nurseries, however, some of these may discolour the pavement.

Check their effect on a small part of the pavement before proceeding to clean the whole area. Follow the

manufacturer’s directions and avoid nearby garden plants or lawn, especially on the lower side of the paved area

being treated.

Chewing gum

In large areas, wire brushes free from rust should remove the majority of chewing gum. This may require several

attempts and the wire may leave traces of steel on the paver which in time will rust leaving a stain. Careful

application of high-pressure water jets can also be successful. For smaller areas freeze each piece of chewing gum

with a carbon dioxide aerosol or dry ice. The chewing gum can then be chipped off with a scraper. ■

Clay Paver Property Tables2.4


2.401

ADV03810

Section 2.4 Clay Paver Property Tables

Clay

Pav

er R

ange

PAVE

SCA

PE®

SUM

MER

SET®

Aut

umn

Crea

mB

irch

Coffe

eM

oroc

coM

erin

oRu

mba

Tan

Gar

net

Ony

xO

pal

Zirc

on

Wor

k si

ze (m

m)

228x

113x

4022

8x11

3x40

228x

113x

4022

8x11

3x40

228x

113x

4022

8x11

3x40

228x

113x

4022

8x11

3x40

228x

113x

4022

8x11

3x40

228x

113x


DPA1

DPA1

DPA1

DPA1

DPA1

DPA1

DPA1

DPA1

DPA1

DPA1

DPA1

Ave

unit

wei

ght (

kg)

2.0

2.0

2.0

2.0

2.0

2.0

2.0

2.0

2.0

2.0

2.0

Appr

ox n

umbe

r per

m2

3838

3838

3838

3838

3838

38Co

-effi

cien

t of g

row

th ‘e

m’ (

mm

/m/1

5yrs

)<0

.9<0

.9<0

.9<0

.9<0

.9<0

.9<0

.9<0

.9<0

.9<0

.9<0

.9M

inim

um b

reak

ing

load

(kN

)>3

.5>4

.5>5

.0>5

.5>4

.5>5

.5>5

.0>6

.5>5

.0>4

.0>3

.5M

ean

Abra

sion

Inde

x (c

m3 )

<4.5

<4.5

<4.5

<4.5

<4.5

<4.5

<4.5

<7.0

<6.0

<8.0

<6.0

Slip

resi

stan

ce c

lass

ifica

tion

WW

WW

WW

WW

WW

WSa

lt at

tack

resi

stan

ce c

ateg

ory

GPGP

GPGP

GPGP

GPGP

GPGP

GPSa

lt sa

feN

oN

oN

oN

oN

oN

oN

oN

oN

oN

oN

oLi

abili

ty to

effl

ores

ceN

il to

slig

htN

il to

slig

htN

il to

slig

htN

il to

slig

htN

il to

slig

htN

il to

slig

htN

il to

slig

htN

il to

slig

htN

il to

slig

htN

il to

slig

htN

il to

slig

htLi

me

pitti

ngN

ilN

ilN

ilN

ilN

ilN

ilN

ilN

ilN

ilN

ilN

ilN

o pe

r pac

k55

055

055

055

055

055

055

055

055

055

055

0Pa

ck w

eigh

t (kg

)11

0011

0011

0011

0011

0011

0011

0011

0011

0011

0011

00Pa

ck d

imen

sion

s (m

m)

1150

x680

x790

1150

x680

x790

1150

x680

x790

1150

x680

x790

1150

x680

x790

1150

x680

x790

1150

x680

x790

1150

x680

x790

1150

x680

x790

1150

x680

x790

1150

x680

x790

Clay

Pav

er R

ange

BRI

NG

ELLY

Alm

ond

Ash

Crea

mRe

dRe

sort

Cre

amRe

sort

Iron

-st

one

Reso

rt T

er-

raco

ttaTa

n B

lend

Terr

acot

ta

Wor

k si

ze (m

m)

230x

114x

5023

0x11

4x50

230x

114x

5023

0x11

4x50

230x

113x

5023

0x11

3x50

230x

113x

5023

0x11

4x50

230x

114x


DPA2

DPA2

DPA2

DPA2

DPA2

DPA2

DPA2

DPA2

DPA2

Ave

unit

wei

ght (

kg)

2.8

2.8

2.8

2.8

2.8

2.8

2.8

2.8

2.8

Appr

ox n

umbe

r per

m2

3737

3737

3737

3737

37Co

-effi

cien

t of g

row

th ‘e

m’ (

mm

/m/1

5yrs

)<1

.0<1

.0<1

.0<1

.0<1

.0<1

.0<1

.0<1

.0<1

.0M

inim

um b

reak

ing

load

(kN

)>1

0>1

0>6

.5>1

0>6

.5>7

.5>7

.0>7

.0>9

.0M

ean

Abra

sion

Inde

x (c

m3 )

<2.0

<2.0

<2.5

<2.0

<2.0

<2.0

<2.0

<2.5

<2.0

Slip

resi

stan

ce c

lass

ifica

tion

VV

VV

VV

VV

VSa

lt at

tack

resi

stan

ce c

ateg

ory

GPGP

GPGP

GPGP

GPGP

GPSa

lt sa

feN

oN

oN

oN

oN

oN

oN

oN

oN

oLi

abili

ty to

effl

ores

ceSl

ight

Slig

htSl

ight

Slig

htN

il to

slig

htN

il to

slig

htN

il to

slig

htSl

ight

Slig

htLi

me

pitti

ngN

ilN

ilN

ilN

ilN

ilN

ilN

ilN

ilN

ilN

o pe

r pac

k

510

510

510

510

510

510

510

510

510

Pack

wei

ght (

kg)

1428

1428

1428

1428

1428

1428

1428

1428

1428

Pack

dim

ensi

ons

(mm

) 11

50x9

05x6

0011

50x9

05x6

0011

50x9

05x6

0011

50x9

05x6

0011

50x9

05x6

0011

50x9

05x6

0011

50x9

05x6

0011

50x9

05x6

0011

50x9

05x6

00

All t

estin

g is

car

ried

out i

n ac

cord

ance

with

Aus

tralia

n St

anda

rds

AS/N

ZS44

56 &

458

6, A

STM

C67

test

met

hods

whe

re a

pplic

able

. Tes

ting

is c

arrie

d ou

t in

NAT

A re

gist

ered

labo

rato

ries.

Durabilityclassificationbasedonproductknowledgeunderlocalclimateconditions.

This

tech

nica

l inf

orm

atio

n re

pres

ents

ave

rage

pro

perti

es o

btai

ned

from

pro

duct

ion

lots

and

sho

uld

not b

e us

ed fo

r spe

cific

atio

n pu

rpos

es.

For m

ore

deta

iled

spec

ifica

tion

cont

act B

oral

Bric

ks. U

nit w

eigh

t quo

ted

is a

n ap

prox

imat

e w

eigh

t and

can

var

y. Th

is in

form

atio

n is

sub

ject

to c

hang

e w

ithou

t not

ice.

Face Brick Range3

3. Face Brick R

ang

e

Engineered Utility Brick Range

4. En

gin

eered U

tility B

rick Ran

ge

4

Standard Commercial Common NSW

TYPICAL PROPERTIES BADGERYS CREEK BRINGELLY KEMPSEY

Dimensions – Work Size (LxWxH – mm) 230x110x76Dimensional Category DW1Average Unit Weight (kg) 3.0Approximate number per m2 49Lime Pitting Nil to SlightNo. per pack # 320 400Pack Weight (kg) # 928 1200Pack Dimensions (LxWxH – mm) # 920x920x880 1150x770x912Wall Surface Density (kg/m2) 182Characteristic Unconfined Compressive Strength (f’uc MPa) >22 >18Coefficient of Expansion (mm/m/15 years) <1.1 <0.9Salt Attack Resistance Category GPLiability to Effloresce Nil to slightWeighted Sound Reduction Index – Rw (C,Ctr)Unrendered 46 (-2, -5)Rendered (one side) 48 (-2, -5)Rendered (both sides) 50 (-2, -5)Fire Resistance Level Insulation (minutes)Unrendered 90Rendered (both sides) 120Unrendered (Structural Adequacy/Integrity/Insulation)^ 90/90/90

# Pack size of 320 cannot be handled by a forklift with tines, however will be placed on pallets on request.

^ Assumes FRL for fully supported single skin wall up to 3.0m height.

All testing is carried out in accordance with Australian Standards AS/NZS4456 test methods where applicable. Testing is carried out in NATA registered laboratories

Durability classification based on product knowledge under local climate conditions.

This technical information represents average properties obtained from production lots and should not be used for specification purposes. For more detailed specification contact Boral Bricks. Unit weight quoted is an approximate weight and can vary. This information is subject to change without notice.


Section 4. Product Data Sheet



Standard Commercial CommonFIRE RESISTANCE & SOUND TRANSMISSION FOR TYPICAL WALL APPLICATIONS


The Building Code (BCA) Section C defines the type and class of buildings and designates three fire resistance levels. These levels are structural adequacy, integrity and insulation, and are written in the form 60/60/60. Information on how to calculate these is provided in the Clay Brick and Paver Institute (CBPI) publication, “Manual 5: Fire Resistance Levels for Clay Brick Walls” available at www.thinkbrick.com.au The figures below provide typical wall examples.


The Rw has two reduction figures to account for high range noise (C) and low range noise (Ctr). The reduction figures are added to the Rw and are written Rw (C,Ctr).

Note: S = Supported. Indicating moment is passed to a transverse structure such as a concrete slab, braced roofing trusses, a perpendicular wall, etc.

Boral Clay Bricks and PaversPhone 13 30 35Fax 1300 363 035Email [email protected]

All masonry walls should be designed by a qualified structural engineer. Variation in colour, texture and size is a natural characteristic of clay products. © Copyright Boral Bricks Pty Ltd – all rights reserved 2008. Boral Bricks Pty Ltd ABN 66 082 448 342.

S

S

S

S

110mm

S

S

S

S

110mm110mm

FRL for Insulation 90 minutes

FRL for wall height up to 3.0 metres 90/90/90


FRL for Integrity is the lower of the FRLs for Insulation or Structural Adequacy

For both leaves equally loaded (±10%)FRL for Structural Adequacy – wall height up to 3.3 metres 240 minutes – wall height up to 4.1 metres 90 minutes

For both leaves unequally loaded (i.e. >10% variance)FRL for Structural Adequacy – wall height up to 2.5 metres 240 minutes – wall height up to 3.0 metres 90 minutes

Sound reduction of a wall consisting of two leaves 110mm brick with a 50mm cavity– Rendered both sides Rw + Ctr ≥ 50 & impact attenuation – Unrendered with 50mm glass wool insulation with a density of 11 kg/m3 Rw + Ctr ≥ 50 & impact attenuation– Unrendered with 50mm polyester insulation with a density of 20 kg/m3 Rw + Ctr ≥ 50 & impact attenuation

ADV03813NSW

Jumbo Common NSW

TYPICAL PROPERTIES BADGERYS CREEK BRINGELLY

Dimensions – Work Size (LxWxH – mm) 230x110x119Dimensional Category DW2Average Unit Weight (kg) 4.3 4.5Approximate number per m2 32.5Lime Pitting Nil to SlightNo. per pack 192 245Pack Weight (kg) 864 1152Pack Dimensions (LxWxH – mm) 920x920x880 1150x770x833Wall Surface Density (kg/m2) 180Characteristic Unconfined Compressive Strength (f’uc MPa) >22Coefficient of Expansion (mm/m/15 years) <1.1Salt Attack Resistance Category GPLiability to Effloresce Nil to slightWeighted Sound Reduction Index – Rw (C,Ctr)Unrendered 46 (-2, -5)Rendered (one side) 48 (-2, -5)Rendered (both sides) 50 (-2, -5)Fire Resistance Level Insulation (minutes)Unrendered 90Rendered (both sides) 120Unrendered (Structural Adequacy/Integrity/Insulation)^ 90/90/90









Jumbo CommonFIRE RESISTANCE & SOUND TRANSMISSION FOR TYPICAL WALL APPLICATIONS








S

S

S

S

110mm

S

S

S

S

110mm

110mm








ADV03815NSW

Double Height CommonNSW

TYPICAL PROPERTIES BADGERYS CREEK BRINGELLY KEMPSEY

Dimensions – Work Size (LxWxH – mm) 230x110x162Dimensional Category DW1Average Unit Weight (kg) 5.7 6.0Approximate number per m2 24.5Lime Pitting Nil to SlightNo. per pack 160 172 200Pack Weight (kg) 992 1100 1200Pack Dimensions (LxWxH – mm) 920x920x880 935x830x995 1150x972x770Wall Surface Density (kg/m2) 180Characteristic Unconfined Compressive Strength (f’uc MPa) >22 >18Coefficient of Expansion (mm/m/15 years) <1.1 <0.9Salt Attack Resistance Category GPLiability to Effloresce Nil to slightWeighted Sound Reduction Index – Rw (C,Ctr)Unrendered 46 (-2, -5)Rendered (one side) 48 (-2, -5)Rendered (both sides) 50 (-2, -5)Fire Resistance Level Insulation (minutes)Unrendered 90Rendered (both sides) 120Unrendered (Structural Adequacy/Integrity/Insulation)^ 90/90/90


This technical information is subject to change without notice.








Double Height CommonFIRE RESISTANCE & SOUND TRANSMISSION FOR TYPICAL WALL APPLICATIONS








S

S

S

S

110mm

S

S

S

S

110mm

110mm








ADV03817NSW



Scratch Face CommonNSW

TYPICAL PROPERTIESDimensions – Work Size (LxWxH – mm) 230x110x76Dimensional Category DW1Average Unit Weight (kg) 2.9Approximate number per m2 49Lime Pitting Nil to SlightNo. per pack 320Pack Weight (kg) 928Pack Dimensions (LxWxH – mm) 920x920x880Wall Surface Density (kg/m2) 180Characteristic Unconfined Compressive Strength (f’uc MPa) >22Coefficient of Expansion (mm/m/15 years) <1.1Salt Attack Resistance Category GPLiability to Effloresce Nil to slightWeighted Sound Reduction Index – Rw (C,Ctr)Unrendered 46 (-2, -5)Rendered (one side) 48 (-2, -5)Rendered (both sides) 50 (-2, -5)Fire Resistance Level Insulation (minutes)Unrendered 90Rendered (both sides) 120Unrendered (Structural Adequacy/Integrity/Insulation)^ 90/90/90









ADV05177NSW

Scratch Face CommonFIRE RESISTANCE & SOUND TRANSMISSION FOR TYPICAL WALL APPLICATIONS






S

S

S

S

110mm

S

S

S

S

110mm110mm







Sound reduction of a wall consisting of two leaves 110mm brick with a 50mm cavity– Rendered both sides Rw + Ctr ≥ 50 & impact attenuation – Unrendered with 50mm

glass wool insulation with a density of 11 kg/m3 Rw + Ctr ≥ 50 & impact attenuation

– Unrendered with 50mm polyester insulation with a density of 20 kg/m3 Rw + Ctr ≥ 50 & impact attenuation

PartyWall BrickNSW

TYPICAL PROPERTIES PW76 PW119

Dimensions – Work Size (LxWxH – mm) 230x150x76 230x150x119Dimensional Category DW2Average Unit Weight (kg) 4.0 6.0Approximate number per m2 49 32.5Lime Pitting Nil to SlightNo. per pack 280 180Pack Weight (kg) 1120 1080Pack Dimensions (LxWxH – mm) 1450x1080x810 1150x750x952Wall Surface Density (kg/m2) 240Characteristic Unconfined Compressive Strength (f’uc MPa) >22Coefficient of Expansion (mm/m/15 years) <1.1Salt Attack Resistance Category GPLiability to Effloresce Nil to slightWeighted Sound Reduction Index – Rw (C,Ctr)Unrendered 49 (-2, -5)Rendered (one side) 52 (-2, -5)Rendered (both sides) 55 (-2, -5)Fire Resistance Level Insulation (minutes)Unrendered 120Rendered (both sides) 180Unrendered (Structural Adequacy/Integrity/Insulation)^ 120/120/120







ADV03819



PartyWall BrickFIRE RESISTANCE & SOUND TRANSMISSION FOR TYPICAL WALL APPLICATIONS






PartyWall PW76

PartyWall PW119



S

S

S

S

150mm

S

S

S

S

150mm





Special Paint Grade BrickNSW

TYPICAL PROPERTIES BRINGELLY KEMPSEY

Dimensions – Work Size (LxWxH – mm) 230x110x76Dimensional Category DW2Average Unit Weight (kg) 3Approximate number per m2 49Lime Pitting Nil to SlightNo. per pack 400Pack Weight (kg) 1240Pack Dimensions (LxWxH – mm) 1150x770x912Wall Surface Density (kg/m2) 180Characteristic Unconfined Compressive Strength (f’uc MPa) >22 >18Coefficient of Expansion (mm/m/15 years) <1.1 <0.9Salt Attack Resistance Category GPLiability to Effloresce Nil to slightWeighted Sound Reduction Index – Rw (C,Ctr)Unrendered 46 (-2, -5)Rendered (one side) 48 (-2, -5)Rendered (both sides) 49 (-2, -5)Fire Resistance Level Insulation (minutes)Unrendered 90Rendered (both sides) 120Unrendered (Structural Adequacy/Integrity/Insulation)^ 90/90/90









Special Paint Grade BrickFIRE RESISTANCE & SOUND TRANSMISSION FOR TYPICAL WALL APPLICATIONS








S

S

S

S

110mm

S

S

S

S

110mm110mm








ADV03821NSW

Coastal Common NSW

TYPICAL PROPERTIES BRINGELLY KEMPSEY

Dimensions – Work Size (LxWxH – mm) 230x110x76Dimensional Category DW1Average Unit Weight (kg) 2.9Approximate number per m2 49Lime Pitting Nil to SlightNo. per pack 400Pack Weight (kg) 1200Pack Dimensions (LxWxH – mm) 1150x912x770Wall Surface Density (kg/m2) 180Characteristic Unconfined Compressive Strength (f’uc MPa) >22 >18Coefficient of Expansion (mm/m/15 years) <1.1 <0.9Salt Attack Resistance Category EXPLiability to Effloresce Nil to slightWeighted Sound Reduction Index – Rw (C,Ctr)Unrendered 46 (-2, -5)Rendered (one side) 48 (-2, -5)Rendered (both sides) 49 (-2, -5)Fire Resistance Level Insulation (minutes)Unrendered 90Rendered (both sides) 120Unrendered (Structural Adequacy/Integrity/Insulation)^ 90/90/90









Coastal CommonFIRE RESISTANCE & SOUND TRANSMISSION FOR TYPICAL WALL APPLICATIONS








S

S

S

S

110mm

S

S

S

S

110mm110mm








ADV03823NSW

Coastal Jumbo CommonNSW

TYPICAL PROPERTIESDimensions – Work Size (LxWxH – mm) 230x110x119Dimensional Category DW1Average Unit Weight (kg) 4.5Approximate number per m2 32.5Lime Pitting Nil to SlightNo. per pack 235Pack Weight (kg) 1100Pack Dimensions (LxWxH – mm) 1150x833x770Wall Surface Density (kg/m2) 180Characteristic Unconfined Compressive Strength (f’uc MPa) >18Coefficient of Expansion (mm/m/15 years) <0.9Salt Attack Resistance Category EXPLiability to Effloresce Nil to slightWeighted Sound Reduction Index – Rw (C,Ctr)Unrendered 46 (-2, -5)Rendered (one side) 48 (-2, -5)Rendered (both sides) 49 (-2, -5)Fire Resistance Level Insulation (minutes)Unrendered 90Rendered (both sides) 120Unrendered (Structural Adequacy/Integrity/Insulation)^ 90/90/90









Coastal Jumbo CommonFIRE RESISTANCE & SOUND TRANSMISSION FOR TYPICAL WALL APPLICATIONS








S

S

S

S

110mm

S

S

S

S

110mm

110mm








ADV03825NSW

Coastal Double Height CommonNSW

TYPICAL PROPERTIESDimensions – Work Size (LxWxH – mm) 230x110x162Dimensional Category DW1Average Unit Weight (kg) 6.0Approximate number per m2 24.5Lime Pitting Nil to SlightNo. per pack 172Pack Weight (kg) 1200Pack Dimensions (LxWxH – mm) 1150x972x770Wall Surface Density (kg/m2) 180Characteristic Unconfined Compressive Strength (f’uc MPa) >18Coefficient of Expansion (mm/m/15 years) <0.9Salt Attack Resistance Category EXPLiability to Effloresce Nil to slightWeighted Sound Reduction Index – Rw (C,Ctr)Unrendered 46 (-2, -5)Rendered (one side) 48 (-2, -5)Rendered (both sides) 49 (-2, -5)Fire Resistance Level Insulation (minutes)Unrendered 90Rendered (both sides) 120Unrendered (Structural Adequacy/Integrity/Insulation)^ 90/90/90









Coastal Double Height CommonFIRE RESISTANCE & SOUND TRANSMISSION FOR TYPICAL WALL APPLICATIONS








S

S

S

S

110mm

S

S

S

S

110mm

110mm








ADV03827NSW

Standard Commercial Common VIC

TYPICAL PROPERTIES ALbuRY SCORESbY ThOmASTOwn

Dimensions – Work Size (LxWxH – mm) 230x110x76Dimensional Category DW1Average Unit Weight (kg) 2.9 3.2 3.3Approximate number per m2 49Lime Pitting Nil to Slight NilNo. per pack # 340 460 272Wall Surface Density (kg/m2) 190 205 210Characteristic Unconfined Compressive Strength (f’uc MPa) >15 >22Coefficient of Expansion (mm/m/15 years) <1.1 <1.4Salt Attack Resistance Category GP EXP EXPLiability to Effloresce Nil to slight Nil Nil to slightweighted Sound Reduction Index – Rw (C,Ctr)Unrendered 46 (-2, -5)Rendered (one side) 48 (-2, -5)Rendered (both sides) 50 (-2, -5)Fire Resistance Level Insulation (minutes)Unrendered 90Rendered (both sides) 120Unrendered (Structural Adequacy/Integrity/Insulation)^ 90/90/90









Standard Commercial CommonFIRE RESISTAnCE & SOunD TRAnSmISSIOn FOR TYPICAL wALL APPLICATIOnS



weighted Sound Reduction Index (Rw)


note: S = Supported. Indicating moment is passed to a transverse structure such as a concrete slab, braced roofing trusses, a perpendicular wall, etc.



S

S

S

S

110mm

S

S

S

S

110mm110mm








ADV03812VIC

Jumbo Common VIC

TYPICAL PROPERTIES ALbuRY SCORESbY

Dimensions – Work Size (LxWxH – mm) 230x110x119Dimensional Category DW2Average Unit Weight (kg) 4.5Approximate number per m2 32.5Lime Pitting Nil to SlightNo. per pack 230 305Wall Surface Density (kg/m2) 180Characteristic Unconfined Compressive Strength (f’uc MPa) >22Coefficient of Expansion (mm/m/15 years) <1.1Salt Attack Resistance Category GPLiability to Effloresce Nil to slightweighted Sound Reduction Index – Rw (C,Ctr)Unrendered 46 (-2, -5)Rendered (one side) 48 (-2, -5)Rendered (both sides) 50 (-2, -5)Fire Resistance Level Insulation (minutes)Unrendered 90Rendered (both sides) 120Unrendered (Structural Adequacy/Integrity/Insulation)^ 90/90/90









Jumbo CommonFIRE RESISTAnCE & SOunD TRAnSmISSIOn FOR TYPICAL wALL APPLICATIOnS



weighted Sound Reduction Index (Rw)


note: S = Supported. Indicating moment is passed to a transverse structure such as a concrete slab, braced roofing trusses, a perpendicular wall, etc.



S

S

S

S

110mm

S

S

S

S

110mm

110mm








ADV03814VIC

Purpose Made CommonQLD

TYPICAL PROPERTIESDimensions – Work Size (LxWxH – mm) 230x110x76Dimensional Category DW1Average Unit Weight (kg) 2.8Approximate number per m2 49Lime Pitting Nil to SlightNo. per pack 380Pack Weight (kg) 1100Pack Dimensions (LxWxH – mm) 930x840x1000Wall Surface Density (kg/m2) 180Characteristic Unconfined Compressive Strength (f'uc MPa) >10Coefficient of Expansion (mm/m/15 years) <1.1Salt Attack Resistance Category GPLiability to Effloresce Nil to slightWeighted Sound Reduction Index – Rw (C,Ctr)Unrendered 46 (-2, -5)Rendered (one side) 48 (-2, -5)Rendered (both sides) 49 (-2, -5)Fire Resistance Level Insulation (minutes)Unrendered 90Rendered (both sides) 120Unrendered (Structural Adequacy/Integrity/Insulation)^ 90/90/90


All testing is carried out in accordance with Australian Standards AS/NZS4456 test methods where applicable. Testing is carried out in NATA registered laboratories.







Purpose Made CommonFIRE RESISTANCE & SOUND TRANSMISSION FOR TYPICAL WALL APPLICATIONSFire Resistance Levels (FRL)







S

S

S

S

110mm

S

S

S

S

110mm110mm








ADV03813QLD

Double Height CommonQLD

TYPICAL PROPERTIESDimensions – Work Size (LxWxH – mm) 230x110x162Dimensional Category DW1Average Unit Weight (kg) 5.8Approximate number per m2 24.5Lime Pitting Nil to SlightNo. per pack 172Pack Weight (kg) 1050Pack Dimensions (LxWxH – mm) 930x820x1000Wall Surface Density (kg/m2) 180Characteristic Unconfined Compressive Strength (f'uc MPa) >10Coefficient of Expansion (mm/m/15 years) <1.1Salt Attack Resistance Category GPLiability to Effloresce Nil to slightWeighted Sound Reduction Index – Rw (C,Ctr)Unrendered 46 (-2, -5)Rendered (one side) 48 (-2, -5)Rendered (both sides) 49 (-2, -5)Fire Resistance Level Insulation (minutes)Unrendered 90Rendered (both sides) 120Unrendered (Structural Adequacy/Integrity/Insulation)^ 90/90/90


All testing is carried out in accordance with Australian Standards AS/NZS4456 test methods where applicable. Testing is carried out in NATA registered laboratories.







Double Height CommonFIRE RESISTANCE & SOUND TRANSMISSION FOR TYPICAL WALL APPLICATIONSFire Resistance Levels (FRL)







S

S

S

S

110mm

S

S

S

S

110mm

110mm








ADV03827QLD

Paver Range5

5. Paver R

ang

e

6. Pro

jects in V

iew

Projects in View6

ADV05003 10/08

PIV, Boral’s publication profiling a range of architecturally-inspired projects featuring

Boral’s bricks, blocks, pavers and retaining walls, is full of the latest public and

private sector commercial projects, designs, and ideas. PIV also features industry

news, events and more, to keep you constantly up to date.

Subscription to PIV is FREE. Subscribe on-line, and you will ensure that PIV is

emailed directly to you. There are benefits to subscribing – you not only have the

latest information delivered direct to your desktop, but as a PIV subscriber, you will

also have access to additional ‘un-published’ photography and direct links to

product information.

Visit www.boral.com.au/piv to subscribe and access previous editions.

Subscribe by registering online at:

www.boral.com.au/piv

Projects In View

If you have a project that you would like us to consider for inclusion in PIV please call your Boral Clay Bricks & Pavers sales representative, or phone our contact centre on

13 30 35

Civic qualities at the forefront

of Police Station design

High quality housing that’s affordable, too

Wall design delivers

benefits galore

PIV12: PROJECTS IN VIEW

A walk on the style side

Welcome to the twelvth

edition of PIV featuring

Boral Clay Bricks and Masonry.

Centre attracts more than admiration

01 Wally’s Walkway, Macquarie University, North Ryde NSW

02 Vermont Sports Pavilion Extension, Vermont VIC

03 Warehouse Distribution Centre, Minto NSW

04 Police Station, Cranbourne VIC

05 Apartment Complex, Pyrmont NSW

06 Cardinia Life, Pakenham VIC

07 Springvale Police Station, Springvale VIC

08 Nelsons Grove Retirement Village, Pemulwuy NSW

Contents

Issue 12 November 07

PIVPROJECTS IN VIEW

Centre attracts more than admiration

Wally’s Walkway, Macquarie University, North Ryde NSW

Vermont Sports Pavilion Extension, Vermont VIC

Warehouse Distribution Centre, Minto NSW

Carpark honours local heritage

A Renaissance in retirement living

Wall-to-wall opportunities at Interchange Park

PIV13:PROJECTS IN VIEW

A shining star in Jamisontown

Welcome to the thirteenth



Green estate chooses choc tan bricks

01 Carlisle Homes Display Village, Tarneit, VIC

02 Bingara Gorge Sales & Information Centre, Wilton, NSW

03 Renaissance Victoria Point Retirement Village, Moreton Bay, QLD

04 Concord Hospital Mental Health Precinct, Concord, NSW

05 Shaula Apartments, Jamisontown, NSW

06 Esplanade Carpark, Port Willunga, SA

07 Interchange Park, Eastern Creek, NSW

08 Harmony Village Retirement Complex, Shepparton, VIC

Contents

Issue 13 March 08

A Renaissance in retirement living

Wall-to-wall opportunities at Interchange Park


Welcome to the thirteenth



Green estate chooses choc tan bricks

Bingara Gorge Sales & Information Centre, Wilton, NSW

Renaissance Victoria Point Retirement Village, Moreton Bay, QLD

Concord Hospital Mental Health Precinct, Concord, NSW

05 Shaula Apartments, Jamisontown, NSW

06 Esplanade Carpark, Port Willunga, SA

07 Interchange Park, Eastern Creek, NSW

08 Harmony Village Retirement Complex, Shepparton, VIC

A honey of a project

Rousing interest in Rouse Hill

Combining kids with culture


Bricks and Masonry team up at Oakleigh Centre

Welcome to the fourteenth edition of PIV featuring Boral Clay Bricks and Masonry.

Discovering Masonry

01 Altona Performing Arts Centre & Primary School

02 Beekeepers Inn03 Oakleigh Centre for Intellectually Disabled Citizens

04 Rouse Hill Town Centre 05 Discovery House06 Logistics Building, Caulfield Medical Centre

07 Boral Timber Woodhead Project, Pernod Ricard Head Office

08 Lightening the load on energy and water at Kempsey

09 Harrison School

Contents

Issue 14 July 08

7. Referen

ce Material

Reference Material7

Bricks

Free face samples Professionally present your project concept to your client with actual clay brick and paver colour and texture samples. This special service enables you to select and receive facing samples by express courier to your door.

ADV05001 10/08

Contact the Boral CHIPexpress® service

Phone 13 30 35 Fax 1300 36 30 35 Using fax order forms provided Email [email protected] Web www.boral.com.au/bricks

115mm x 76mm x 10mm

115mm x 114mm x 10mmPavers

Bricks

230mm x 76mm x 10mm

230mm x 114mm x 40mm/50mm (full size)Pavers

76mm

10mm

114mm115mm115mm

Bricks Pavers

10mm

40mm/ 50mm

76mm

10mm

114mm

230mm230mm

Bricks Pavers

NSW and Queensland chip sizes

Victoria chip sizes

Free Clay Brick and Paver Samples

Project

Company

Address

Email

Phone

Fax

Special delivery instructions

1.

2.

3.

4.

5.

ADV05002 08/04

Fax this form to Boral Bricks CHIPexpress®

1300 36 30 35

CHIPexpress® samples can also be ordered by calling

13 30 35

or emailing your request to

[email protected]

Detached home Villa / townhouses

1.

2.

3.

4.

5.

Please send more order forms

High rise med. density

Commercial (provide description below)

Fax Order FormClay Bricks & Pavers

Clay brick and paver samples required

Name

Brochures required

technical manual bricks

Documents