MASONRY

Haydite Masonry Unit Productivity
Increase Productivity with Haydite Lightweight Masonry Units

Haydite concrete blocks are lightweightThe masonry process is perceived to be one of the most labor intensive aspects of construction today. Since masonry units (blocks) must be handled and placed one-by-one, increased mason productivity is the key to effective management of masonry construction.

In tests conducted both in the field and at the National Concrete Masonry Association Research and Development Laboratory, it has been dramatically shown that the size and weight of masonry units are primary factors influencing the speed at which blocks can be laid. The test results confirm that lightweight block made with expanded shale, clay or slate aggregate significantly increased mason productivity over heavyweight units, especially when 24" units were used.

These facts alone make lightweight block walls cost competitive with any other wall system. But considering the reduced structural loading, better fire rating, greater strength, and much better thermal insulating and sound absorbing properties, lightweight concrete blocks are more than cost competitive. They are cost effective.

Haydite productivity chartThe productivity gained with 8"x 8"x 16" (standard size) lightweight block is represented by the "Field Test" graph. Although productivity improvement varied from course to course, the graph shows there was a significant overall increase in productivity with the lightweight units. The Productivity Comparison Tables are based on laboratory data compiled during the construction of four wall sections.

The figures shown reflect averages for all six courses of each wall section. Table 1 (Size Factor) compares 24" masonry units to l6" units.The table shows that the use of 24" masonry units significantly increases mason productivity: 39% with heavyweight units; 43.6% with lightweight units. InTable 2 (Weight Factor) the gains in productivity attributed to lighter weight are shown.

Productivity Comparison Table Productivity increased 14.9% with 16" lightweight units, and 18.6 % with 24" lightweight units as compared to heavyweight units of the same sizes.

The test firmly establishes that masonry units of lighter weight and greater length dramatically increase mason productivity.

Table 3 (Size& Weight Factor) compares the use of heavyweight 16" units to lightweight 24" units over the same time period. The result is an amazing 64.9 % increase in productivity.

Although not specifically identified in the test, it is logical to believe that the use of lightweight units reduces the long term fatigue experienced by masons during the life of a job. This should result in even greater increases in productivity and improved mason morale.

 

In short, the use of expanded shale clay or slate lightweight masonry units is better business 100% of the time.


Haydite Masonry Unit Properties

Haydite aggregate is produced by expanding suitable shales in rotary kilns at a flame temperature of approximately 2200 degrees F. It is a hard, inert, vitreous material with innumerable isolated air cells. Mixed with Portland Cement and made into concrete masonry units, it produces the finest lightweight unit available. The Data Sheet below presents a summary of these properties.

Weight
The concrete in a Haydite masonry unit can be custom blended to achieve the desired density and can be less that 85 lbs. cf 3 when using only Haydite and cement. It is the unique combination of low weight and high strength of Haydite units which gives them their outstanding physical characteristics. The table shown below gives the approximate weights of 8" and 12" Haydite units at various concrete densities. The weight of a given nominal size unit will vary, as indicated in the table, depending upon the equivalent thickness, the degree of compaction, number of cores, etc.

Strength
Haydite masonry units surpass the requirements of A.S.T.M. Designation: C-90 "Load Bearing Concrete Masonry Units". Haydite units for engineered masonry construction can easily achieve the high net area strengths required.

Fire Resistance
The lightweight vitreous nature of Haydite aggregate imparts excellent fire resistive properties to Haydite masonry units. These units are rated for 2, 3 and 4 hour fire resistance periods . These ratings are based on factors such as face shell thickness, equivalent thickness, and cement-aggregate ratio.
The heat resisting properties of Haydite are being constantly demonstrated through the use of Haydite refractory concrete at service temperatures up to 2000oF. in blast furnace downcomers, coke oven floors, jet engines test cells, etc.
Texture
Haydite aggregate, due to its strength, grading and particle shape, is outstanding in its ability to produce block with pleasing, desirable, uniform textures. This pleasing architectural finish is highly desirable for many different types of construction.

Thermal Insulation
Haydite Lightweight Units can provide twice the insulative R-value of normal weight concrete units, while still providing a very high degree of thermal mass.

Properties
Lightweight
Medium
Normal
Aggregate
100% Haydite
Expanded Shale
ASTM C-331
Blend of
Lightweight
&
Normal weight
ASTM C-331 & ASTM C-33
Blend of
Lightweight
&
Normal weight
ASTM C-331 & ASTM C-33
Typically
Normal weight
ASTM C-33
Concrete
Oven Dry Density1
lbs./cf3
Less Than
85
Less Than
105
105 to 125
125 or more
8" Units
Block Weight 2
lbs. max
24.7
30.0
35.1
39
Fire Resistance  3
Hours
(UBC, BOCA, SBC)
2
2
1
1
Fire Resistance
Hours 4
(certain local codes)
2
1
1
1
R Value
(Perlite Fill)5
7.5
5.8
4.4
3.8
Sound Transmission
Class STC
46 6
46 7
48 7
49 7
12" Units
Block Weight 2
lbs. max
34.7
42.3
49.4
55
Fire Resistance 3
Hours
(UBC, BOCA, SBC)
4
4
3
3
Fire Resistance
Hours 4
(certain local codes)
4
3
3
3
R Value
(Perlite Fill)5
10.9
8.2
6.1
5.2
Sound Transmission
Class STC
50 6
49 7
51 7
52 7

1  ASTM C 90 - 93 STANDARD SPECIFICATION FOR LOAD BEARING CONCRETE MASONRY UNITS.
2   CALCULATED FOR 51% SOLID 8' UNITS, AND 47% SOLID 12"- UNITS, AT A MOISTURE CONTENT OF 40'/o OF MAXIMUM WATER ABSORPTION PERMITTED FOR TYPE I UNITS IN EACH WEIGHT CLASSIFICATION 
3  UNIFORM BUILDING CODE (1994), BUILDING OFFICIALS AND CODE ADMINISTRATORS (1994), STANDARD BUILDING CODE (1991)
4  ALTHOUGH BOCA AND UBC GUIDELINES ESTABLISH REQUIRED EQUIVALENT THICKNESS THROUGH VOLUMETRIC INTERPOLATION OF BLENDED AGGREGATES SOME STATES HAVE NOT ADOPTED THIS PRACTICE. PLEASE CHECK YOUR LOCAL BUILDING CODES.
5   INDIANA CONCRETE MASONRY ASSOCIATION, GUIDE FOR USE WITH ASHREA STANDARD 90.1-1989
6  EXPANDED SHALE CLAY AND SLATE INSTITUTE, LIGHTWEIGHT CONCRETE INFORMATION SHEET NO. 8
7  NATIONAL CONCRETE MASONRY ASSOCIATION, TEK 13-1

Copyright 2009 DiGeronimo Aggregates LLC, All Rights Reserved, 8900 Hemlock Road, Independence, Ohio 44131 (888) 593-0395

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