Bor11999 QLD Manual Bk12

BORAL MASONRY
Build something great™
Masonry Design Guide

STRUCTURAL, FIRE AND ACOUSTICS QUEENSLAND BOOK 1
www.boral.com.au/masonry Updated February 2008

Queensland Book 1 A
PAGE
PAGE
A Introduction
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2 Products @ a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4
Fast Find Product and Application Guide . . . . . . . . . . . . . . . A3 About This Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6
B Structural Design
Introduction to the Structural Design of Masonry . . . . . . . . B2 Movement (Control Joints) . . . . . . . . . . . . . . . . . . . . . . . . . . B6
Robustness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2 Energy Efficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7
Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5 Reinforced Masonry Lintels . . . . . . . . . . . . . . . . . . . . . . . . B10
Bending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5 Design of Core Filled and Steel Reinforced

Masonry Retaining Walls . . . . . . . . . . . . . . . . . . . . . . . . . . B11
Shear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6
Structural Design Guidelines for
Durability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6 Core Filled and Steel Reinforced
Masonry Retaining Walls . . . . . . . . . . . . . . . . . . . . . . . . . . B13
C Fire Design
Masonry Design for Fire Resistance (FRL) . . . . . . . . . . . . . . C2 Effect of Chases on Fire Rated Masonry . . . . . . . . . . . . . . . C4
Masonry Design for Structural Adequacy FRL . . . . . . . . . . . C2 How to Select Boral Masonry Units for
Fire Rated Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C5
Masonry Design for Integrity FRL . . . . . . . . . . . . . . . . . . . . . C3
Structural Adequacy Selection Graphs and Tables . . . . . . . . C8
Masonry Design for Insulation FRL. . . . . . . . . . . . . . . . . . . . C4
Index to Structural Adequacy Selection Graphs . . . . . . . . . . C8
D Acoustic Design
Acoustic Performance Ratings (STC and Rw) . . . . . . . . . . . . D2 Guidelines for Optimum Performance . . . . . . . . . . . . . . . . . D4
Designing Masonry Walls for Acoustic Performance On-site . . . . . . . . . . . . . . . . . . . . . . . D5

Acoustic Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3
Home Cinema Rooms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6
E Fire and Acoustic Systems

Finding Acoustic Systems and
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . E2
FireLight (FL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E4
Standard Grey Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E6
Concrete-Basalt Bricks (B): Rippa and Speed-E Brick . . . . . . E8
The information presented herein is supplied in good faith and to the best of our knowledge was accurate at the time of preparation. No responsibility can be accepted by
Boral or its staff for any errors or omissions. Users are advised to make their own determination as to the suitability of this information in relation to their particular purpose
and specific circumstances. Since the information contained in this document may be applied under conditions beyond our control, no responsibility can be accepted by us
for any loss or damage caused by any person acting or refraining from action as a result of this information.
A2 February 2008 | BORAL MASONRY DESIGN GUIDE

Queensland Book 1 A
The quickest way to find a Boral Masonry Structural, Fire or Acoustic Wall Solution.
Simply follow the FAST FIND GUIDE on the right hand side of the table.
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NLB = Non-loadbearing
LB = Loadbearing
NLB LB NLB LB NLB LB NLB LB NLB LB a Boral
FireLight (FL) – – – – E4 – E4 – – –
Solution
1 Select your application
criteria from the top of
Standard Grey Block – – E6 E6 E6 E6 E6 E6 – – the table
2 Go straight to the
Core Filled Block E6 E6 E6 E6 E6 E6 E6 E6 E6 E6 section letter and page
number indicated at the
intersection of product
Designer Block – – – – – – – – rows and application
columns (e.g. Section E,
Page E6 in this example)
Concrete-Basalt Brick (B) Please refer to MDG Book 2,
– – E8 E8 E8 E8 E8 E8 – – Boral Masonry Block and Brick Guide
(Rippa and Speed-E Brick)
For technical support and sales office details please refer to the outside back cover
BORAL MASONRY DESIGN GUIDE | February 2008 A3

Qu
Q ensslland BBook
Queensland
uueeeen oook 1 A
Boral Engineered Blocks

for Structural, Fire and Acoustic Wall Systems
• Standard Grey Blocks

Made as hollow, reduced core and solid units
for 60, 90 and 120-minute Insulation FRLs. Used
for loadbearing and non-loadbearing masonry.
140 and 190mm thick units can be partially
reinforced for walls of portal frame buildings
and houses in cyclonic areas.

Queensland
Q
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Queeeens
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and BBoo
Bookk 1 A
Boral Engineered Bricks

for Structural, Fire and Acoustic Wall Systems
• Core Fill Block rendered walls (mass law). Acoustic performance with
Made with recessed webs to accommodate horizontal plasterboard is better than clay because resonances
steel. Used for cantilever-design retaining walls, are dampened by its higher porosity.
basement walls and for large, loadbearing walls
• FireLight Bricks (FL)
requiring 120 or 240-minute Insulation FRLs.
FireLight is a lightweight material that has been
• Concrete-Basalt Bricks (B): developed and tested for high fire and acoustic ratings.
Speed-E Brick and Rippa Block It is ideal for plasterboard-lined and non-loadbearing
Concrete-Basalt is a denseweight, load-bearing walls in high-rise home units and wherever weight
material. The 45% basalt content of these bricks allows minimisation is critical. Acoustic tests have proven
the use of the higher Slenderness ratios in AS3700, the requirements of BCA:2007 can be met with
Table 6.1. Its Insulation FRLs are slightly higher than plasterboard-lined walls that are thinner than some
clay units. The material is slightly more dense than “deemed-to-satisfy” options.
clay so acoustic performance is slightly higher for
BORAL MASONRY DESIGN GUIDE | February 2008 A5

Queensland Book 1 A
Boral Masonry This guide has been prepared as a comprehensive Boral

Commercial Construction Solutions Product Reference Guide. It does not attempt to cover all
the requirements of the Codes and Standards which apply
Boral Masonry Queensland offers a comprehensive range of
to masonry construction for structural, fire or acoustic
proven products and systems including Masonry Blocks,
applications. All structural, fire and acoustic detailing
Masonry Bricks, Fire and Acoustic Wall Systems, Segmental
should be checked and approved by appropriately qualified
Block Retaining Walls and Segmental Paving Products.
engineers before construction. Boral reserves the right to
What’s in this Guide change the contents of this guide without notice.
The Boral Masonry Structural, Fire and Acoustic guide Please note that this guide is based on products available at
(this book), provides a summary of important design the time of publication from the Boral Masonry Queensland
information for structural, fire and acoustic masonry sales region. Different products and specifications may
applications and an extensive range of fire and/or acoustic apply to Boral products sourced from other regions.
systems to cater for many design scenarios.
Additional Assistance and Information
Section B — Structural Design • Contact Details: Please refer to the outside back cover of
Section B discusses design issues relevant to the selection this publication for Boral Masonry contact details.
of Boral Masonry products for structural adequacy, based on
• Colour and Texture Variation: The supply of raw
appropriate wall design criteria.
materials can vary over time. In addition, variation can
Section C — Fire Design occur between product types and production batches. Also
please recognise the printed colours in this brochure are
Section C discusses the relevant design processes for
only a guide. Please, always ask to see a sample of your
the selection of Boral Masonry Products for fire rated
colour/texture choice before specifying or ordering.
applications. This section includes a step-by-step selection
guide and a series of selection graphs which can greatly • Terms and Conditions of Sale: For a full set of Terms
speed up the preliminary selection and comparison of and Conditions of Sale please contact your nearest Boral
suitable designs and products. Masonry sales office.
Section D — Acoustic Design

Section D provides a brief overview of acoustic rating methods,
relevant considerations for acoustic design and guidelines
for good acoustic design and detailing methods.
Section E — Fire and Acoustic Systems

Section E of this guide provides an extensive range of fire
and acoustic wall system solutions supported by test results
and acoustic performance estimates.

BORAL MASONRY

B STRUCTURAL DESIGN
1 B
Queensland Book 1 B
Legend to Symbols used in Robustness Calculations:

Introduction to the Structural
H = the clear height of a member between horizontal
Design of Masonry lateral supports, in metres;
The following design information is based on Australian = for a member without top horizontal support, the
Standard AS3700:2001 Masonry structures’. Reference to overall height from the bottom lateral support, in
‘Clauses’ and ‘Formulae’ are those used in AS3700. This metres
information is provided as a guide only to the processes
involved in designing masonry. All masonry should be tr = the minimum thickness of the member, in
designed by a suitably qualified structural engineer. metres
= in cavity-wall construction, the minimum thickness

Robustness of the thicker leaf
AS3700, Clause 4.6.1 requires walls to have an adequate or two thirds the sum or thicknesses of the two
degree of ‘Robustness’. Robustness is a minimum design leaves, whichever is greater, in metres
requirement, and may be overridden by Fire, Wind, Snow, or in diaphragm wall construction, the overall
Earthquake, Live and Dead Load requirements. thickness of the wall, in metres
In robustness calculations, there are height, length, and kt = a thickness coefficient, values as given in AS3700
panel action formulae. By reworking the standard formulae Table 7.2 (see the end of this section)
provided and inserting known data, it is possible to
determine whether a chosen design and Boral masonry Cv,Ch = robustness coefficient, values as given in AS3700
product will provide adequate robustness. Should the initial Table 4.2 (see end of this section) for edge restraints
product/design chosen not provide a suitable solution, then a at top, bottom and vertical sides (either separately
thicker Boral masonry product more suited to the application or in combination)
should be evaluated, or alternatively, add extra restraints Lr = the clear length of the wall between vertical
or reinforcement. lateral supports, in metres; or
The following section is laid out with AS3700 formulae and = for a wall without a vertical support at one end or
explanation in the left hand column, while worked examples at a control joint or for walls containing openings,
can be found in the adjacent right hand column. the length to that unsupported end or control joint
or edge of opening, in metres.
B2 February 2008 | BORAL MASONRY DESIGN GUIDE

Queensland Book 1 B
Formulae and Explanation Worked Examples
Isolated Piers Aim: To determine the Maximum Wall

Formula 4.6.2 (1) is used for isolated piers. Masonry Height of an Isolated Pier
with a length less than one fifth of its height and ‘free’ Example 1: Minimum wall thickness tr = 230mm
ends, is considered to be an ‘isolated pier’. A single leaf structure, unreinforced, then
Formula (1) is: H Cv = 13.5
Cv
tr H 0.23 x 13.5
H 3.105m (maximum wall height)
By re-working formula (1), the maximum height for an
isolated pier can be determined: Example 2: Minimum wall thickness, tr = 140mm
H tr x Cv A single leaf structure, reinforced, then
Cv = 30
Where Cv is obtained from AS3700 Table 4.2 (Refer to
Page B5). H 0.14 x 30
H 4.200m (maximum wall height)
Wall with Free Ends Aim: To determine the Maximum Height

Formula 4.6.2 (2) is used for walls spanning vertically of a Wall with Free Ends
(i.e. wall with free ends). Criteria: Minimum wall thickness, tr = 110mm
kt = 1 (wall without piers)
Formula (2) is: H
Cv Example 1: If wall is freestanding, then Cv=6
kt x tr
(must be checked by an engineer for
By re-working formula (2), the maximum wall height wind loads etc.)
is: H 1.0 x 0.11 x 6
H 0.660m
H kt x tr x Cv.
Example 2: If wall is laterally restrained along its top,
Where kt is obtained from AS3700 Table 7.2 (Refer to then Cv=27
Page B5) H 1.0 x 0.11 x 27
or H 2.970m
Example 3: If wall is laterally restrained along its top

By re-working formula (2), the minimum wall thickness
and supports a slab, then Cv=36
is:
H 1.0 x 0.11 x 36
H H 3.960m
kt x tr
Cv
BORAL MASONRY DESIGN GUIDE | February 2008 B3

Queensland Book 1 B
Wall with Restraint at End or Ends Aim: To determine the Maximum Length
Formula 4.6.2 (3) is for walls spanning horizontally [i.e. of a Wall with Restraint at End or
restrained end(s)]. Walls that have one or both ends Ends
laterally restrained and Criteria: Wall thickness tr = 110mm
L
Ch Example 1: If wall is restrained along one end, then
tr
Ch = 12
i.e. L tr x Ch L 0.11 x 12
L 1.320m
Where Ch is obtained from AS3700 Table 4.2. (Refer to
Example 2: If wall is restrained along both ends, then
Page B5)
Ch = 36
H L 0.11 x 36
= no limit
tr L 3.960m
NOTE: If the wall exceeds the permitted length, then a
NOTE: This means that although the wall height is not thicker wall is required or formula 4.6.2 (4) governs and
limited by its thickness, the wall length is limited. Stair H will be limited. (See below).
wells and chimneys work to this formula.
Wall with Restraint at Top and End or Ends Aim: To determine the Maximum Height of
Formula 4.6.2 (4) is for walls spanning vertically and a Wall with Restraint at Top and End
horizontally (i.e. with restraint along the top and one or or Ends
two ends) and length L tr x Ch. Criteria: Wall thickness tr = 110mm
Where Ch is obtained from AS3700 Table 4.2. (Refer to Wall length = 2m
Page B5) Example 1: If wall supports a slab, then Cv = 36, and
Formula (4) is: H Ch if restrained along one end, then Ch = 12
Cv +
tr Lr — Chtr
By reworking formula (4), the maximum wall height is:

H ( 36 + 2 — 1212x 0.11 ) 0.11
H ( C + L C— C t ) t
v
r
h
hr
r H 5.9m
NOTE: Control joints, and openings greater than one fifth

of wall height are treated as free ends unless specific
measures are taken to provide adequate lateral support.

Queensland Book 1 B
Table B1 (Extract from AS3700 : Table 4.2)

Strength
Cv
Top and bottom edge Compressive strength is resistance to load, measured by the
restraints to wall panels Vertically Vertically reinforced
unreinforced or prestressed amount of pressure to crush a masonry unit. The pressure,
Free 12 with usually measured in megapascals (MPa), is the force in
reinforcement kilonewtons (kN) x 1000, divided by the loaded area in
6 continuous into
SUPPORT
square mm.
support. Otherwise
6.
Unconfined compressive strength is compressive strength,
Load other than
concrete slab or no load multiplied by an aspect ratio, Ka (see AS4456.4, Table 1). The
Lateral 27 36 unit height divided by its thickness is used to determine
Support
the aspect ratio.
SUPPORT
Concrete Slab A solid brick will give a lower compressive strength if

Lateral
crushed on its end rather than on its flat, as normally laid.
Support 36 48
In theory, the aspect ratio will convert both tests to the same
SUPPORT unconfined compressive strength.
ISOLATED PIERS The strength of hollow blocks is calculated by dividing the
Lateral force by the face shells only. A 90mm hollow and 90mm
Support 13.5 30 solid block are both 10MPa, but since the area of the face
SUPPORT shells on the hollow block is about half the area of the solid
block, the hollow will only carry half the load of the solid.
Ch
Edge restraints on Characteristic Unconfined Compressive Strength of
vertical sides of Horizontally
Horizontally
wall panels unreinforced
reinforced or masonry UNITS is ƒ ’ uc.
prestressed
24 with ƒ ’ uc is the average of crushing forces divided by loaded
SUPPORT
reinforcement areas, multiplied by the aspect ratio, minus the standard

12 continuous past
deviation x 1.65.
support.
Otherwise 16
Characteristic Compressive Strength of a masonry
WALL is ƒ ’ m.
SUPPORT
SUPPORT
36 48 ƒ’m is the square root of ƒ’uc, multiplied by Km (a mortar

strength factor), multiplied by Kh (a factor for the amount of
mortar joints) as per AS3700, 3.3.2.
Table B2 (Extract from AS3700 : Table 7.2) The Km factor is 1.4 for M3 mortar on solid and cored units
Thickness Coefficient (kt) for Walls Stiffened by Monolithically and is 1.6 for the face shells of hollow units. For the richer
Engaged Piers
M4 mortar it is 1.5 (Table 3.1).
Pier Spacing/Pier Width Thickness Coefficient (kt)
(Refer to Note 1) Pier Thickness Ratio (twp/t) The Kh factor is 1 for 76mm high units with 10mm mortar
1 2 3 beds and is 1.3 for 190mm units with 10mm mortar beds.
6 1.0 1.4 2.0
8 1.0 1.3 1.7 In other words, a wall of 190mm high units is 30% stronger
10 1.0 1.2 1.4 than a wall of 76mm high units of the same ƒ’uc.
15 1.0 1.1 1.2
20 or more 1.0 1.0 1.0
NOTES: 1. Pier spacing is taken as the distance between centrelines of piers. Bending
2. Linear interpolation may be used.
Characteristic Flexural Tensile Strength is ƒ’mt.
twp t
Masonry is good in compression but poor in tension. Mortar
Wall Leaf joint strength is generally zero or 0.2MPa for loads from wind,
Pier Width earthquake etc. Higher bending forces may require masonry
Pier Spacing to be partially reinforced.

Queensland Book 1 B
environment ideal for bacteria, which feeds lichens and

Shear
algae which can eventually be detrimental.
Characteristic Shear Strength is ƒ’ms.
AS/NZS4456.10 gives methods of testing and definitions for
At damp course, it is zero unless tested. Elsewhere, mortar
durability (salt tests). An alternative to testing is a history of
joints have ƒ’ms values of between 0.15 and 0.35MPa.
survival in a marine environment. Concrete masonry has been
As with tension, high shear loads may require partially used for Surf Club construction around Australia for decades.
reinforced masonry.
Movement
Durability In general, concrete units contract as they cure while clay
Masonry designed for ‘Durability’ is deemed to satisfy when units will expand. They both expand as they take up water
it meets the requirements of AS3700 Section 5, which and contract as they dry. They both expand as they get hot
details what areas require Exposure, General Purpose and and contract as they cool.
Protected grades. Assessment of these grades is defined in
AS/NZS4456.10 Resistance to Salt Attack. Curing Movement in Concrete Units
AS/NZS4456.12 gives methods for determining coefficients
AS3700 defines the usage of each of these grades as: of curing contraction and coefficients of drying contraction
Protected Grade (PRO) for concrete units.
Elements above the damp-proof course in non-marine exterior Drying Contraction
environments. Elements above the damp-proof course in other The drying contraction test on masonry units is an indication
exterior environments, with a waterproof coating, properly of their maximum amount of movement from totally saturated
flashed junctions with other building elements and a top to ambient dry. A typical result is 0.5mm/m but can be as high
covering (roof or coping) protecting the masonry. as 1mm/m for lightweight units that are more absorptive. For
General Purpose Grade (GP) example, a drying contraction of 0.5mm/m, in an 8m panel
Suitable for use in an external wall excluding severe marine of masonry, has the potential to shrink 4mm from saturated
environment. condition to dry.
Exposure Grade (EXP) External Control Joints

Suitable for use in external walls exposed to severe marine AS3700, Clause 4.8 requires control joint spacing to limit
environments, i.e. up to 1km from a surf coast or up to 100m panel movement to:
from a non surf coast. The distances are specified from mean
• 10mm maximum for opening of control joints,
high water mark.
• 15mm maximum for closing of control joints, and
Mortar mix requirements for durability are detailed in
AS3700 Table 10.1. Mortar joints must be ironed. • 5mm minimum when closed.
Salt attack is the most common durability problem. The salt The Australian Masonry Manual recommends control joints
in salt water is in solution. It can be absorbed into masonry at 8m centres for concrete units, 6m centres for lightweight
or at least, its mortar joints. When the water evaporates, it (<1600kg/m3) units and at potential points of cracking such
migrates towards the outside face taking the salt with it until as at openings and at steps in the masonry.
the amount of water left is saturated. It can no longer hold all
The Concrete Masonry Association of Australia Design
the salt in solution and salt crystals begin to form.
Manual permits 16m spacing for bond beams and for panels
The salt crystals then take up space, sometimes more than the with horizontal and vertical reinforcement.
texture of the masonry will allow. The crystal then ‘pops’ a piece
Spacing should be measured around corners, not from
of the outer surface off to make room and salt attack begins.
corners. Ideally, the control joint is located near the corner,
Walls below damp course also require greater durability. concealed behind a down pipe.
Even if they are well away from the coast, they may be
External control joints should be finished with a flexible
subjected to acidic or alkaline soils. In any case, moisture
sealant.
in the ground is absorbed into the masonry, creating an

Queensland Book 1 B
Control joints create a ‘free end’ in terms of ‘robustness’ R-value of Insulation to be Added to Wall Types
and FRLs for structural adequacy, so their positioning is for Required Total R-value
critical to the overall design of the structure.
Class 2, 3, 4 and 9c Class 5 to 9b
In portal frame construction, the control joint is positioned at Wall
Type Zones 1, 2, 3 and 5 Zones 1, 2, 3 and 5
a column so that both ends can be tied to the column flanges.
A 1.0 1.4
The mason and renderer must keep the control joint clean,
B 0.7 1.1
otherwise, bridging mortar or render will induce cracks from C 0.9 1.3
those points as the masonry moves. If ties are used over
control joints, they must be sleeved to allow movement. Masonry R-values without air films added (BCA:2007, Vol
1, Specification J1.5, Figure 2, Notes) are:
Adding extra cement to mortar or render causes more
shrinkage. Lightweight units are only 5MPa, so are susceptible 90mm hollow (10.01) = 0.09
to cracking if laid in rich mortar or rendered with a cement- 110mm bricks = 0.12
rich mix. 140mm hollow (15.01) = 0.15
190mm hollow (20.01) = 0.20
Internal Control Joints
The Australian Masonry Manual specifies the spacing 10mm render adds 0.02
of internal control joints for concrete units at 12m A wall mass 220kg/m2 is defined in BCA Volume 2 as:
maximum.
Two leaves of 90mm concrete masonry or...
140mm concrete blocks with a reinforced bond beam

Energy Efficiency for Class 2 and reinforced cores at 1m maximum spacing and 10mm
to 9 Buildings - Queensland plasterboard or render or...
The Building Code of Australia (BCA) 2007, Volume 1, Clause 190mm concrete blocks with a bond beam and reinforced
J1.5 requires the walls of Class 2, 3, 4 and 9c buildings cores at 1.8m maximum spacing.
in Queensland to have a “Total R-Value” of 1.4 or...
a w a l l m a s s 2 2 0 k g / m 2 in Climate Zone 5 Shading, from a balcony, eaves or similar:
(Great Dividing Range, west of Brisbane), or... Each storey needs to have a minimum horizontal projection
“Shading” in Climate Zones 1, 2 and 3 (the rest of from the outside face equal to 0.27 times the wall
Queensland). height measured from floor level to the underside of the
Walls of Class 5 and 6 buildings and Class 7 to 9b buildings projection.
with conditioned spaces require a “Total R-Value” of 1.8 or... The “Total R-value”, the 220kg/m2 and Shading options do
a wall mass 220kg/m2 and various other conditions not apply to south-facing walls (south-south-east to south-south-
described in Table J1.5b. west) of Class 2, 3 and 4 buildings south of latitude 20°.
Where 220kg/m2 and “thermal conductivity of less than Alternative verification for Class 2 and 4 buildings can
0.8” is mentioned in Table J1.5b, it can be taken as 2 leaves be achieved through a minimum 3 star assessment for each
of 10.01 masonry [see BCA:2007, Vol 1, Specification J1.2, sole-occupancy unit and an average of 3.5 stars in Zone 1,
Table 2a, Item 3 (e)(iii)]. 2 or 3, and 4 stars in Zone 5, using calculations defined in
“Total R-Value” means the sum of thermal resistances Clause JV1. For Class 3 and 5 to 9 buildings, verification
(m2.K/W) of wall components including air spaces and can be achieved by calculating energy consumption to meet
associated surface resistances. values as per Clause JV2 or by comparison with a reference
building as per Clause JV3.
Specification J1.5 “Wall Construction”, gives R-values for
wall types (A) (B) and (C) without insulation. Details are
on the following page.

Queensland Book 1 B
R-Values for Typical Wall Construction
External wall construction description Item Item Description R-Value
(A) Masonry veneer — 25mm to 50mm cavity space, 10mm

internal plaster on 90mm stud frame
1.
2.
Outdoor air film (7m/s)
Masonry 90mm thick denseweight block
0.03
0.09
1
3. Cavity air space (115 to 140mm, made up of

90mm stud + 25mm to 50mm air space non-reflective) 0.17
2
4. Plasterboard, gypsum (10mm, 880kg/m ) 3
0.06
3 5. Indoor air film (still air) 0.12

Total R-Value 0.47
4
(B) Cavity masonry — 20mm to 50mm cavity space, 10mm

internal plaster on battens or furring channels
1.
2.
Masonry 90mm denseweight block
0.03
0.09
1
3. Brick cavity air space (20mm to 50mm, non-reflective) 0.17
2 4. Masonry 90mm denseweight block 0.09
5. Cavity air space (20mm to 35mm, non-reflective) 0.17
3
0.06
4 7. Indoor air film (still air) 0.12
Total R-Value 0.73
5
Denseweight hollow concrete block with internal plaster

(C) on battens or furring channels
1.
2.
Denseweight 140mm hollow concrete block
0.03
0.15
1 3. Cavity air space (20mm to 35mm non-reflective) 0.17
0.06
2
5. Indoor air film (still air) 0.12
Total R-Value 0.53
3
Concrete masonry R-values without air films added (BCA:2007,

Specification J1.5, Figure 2, Notes) are:
90mm hollow (10.01) = 0.09
110mm bricks = 0.12
140mm hollow (15.01) = 0.15
190mm hollow (20.01) = 0.20
10mm render adds 0.02

Queensland Book 1 B
Wall mass 220kg/m2 is defined (in BCA, Volume 2,

Energy Efficiency Queensland
Explanation of Fig. 3.12.1.3) as:
Houses
Two leaves of 90mm concrete masonry or...
In the Building Code of Australia (BCA) 2007, Volume 2, Part
3.12, Queensland has retained the BCA:2005 requirements 140mm concrete block with a bond beam and reinforced
which, for walls are: cores at 1m maximum spacing and 10mm plasterboard or
render or...
“Total R-Values” or...
190mm concrete block with a bond beam and reinforced
in Zone 5 (Great Dividing Range, west of Brisbane), cores at 1.8m maximum spacing.
a Mass 220kg/m2 (details below) or...
Shading (Zone 1, 2 and 3 only): The eaves, balcony,
in Zones 1, 2 and 3 (the rest of Qld), Shading of walls. carport or similar is required to project 0.25 times the
South-facing walls (between south-east and south-west) dimension measured from floor level to the underside of
below Latitude 20° are not required to satisfy the Total R- the projection.
value or Shading option.
2 Storey Dwellings:
“Total R-Value” means the sum of thermal resistances
(m2.K/W) of wall components including air spaces and Shading is not required for the lower storey walls where
associated surface resistances. they are 15.01 or 20.01 masonry.
Single-Leaf Walls: If both storeys have walls of lightweight construction,

they must both satisfy the Total R-Value or the Shading
For Zones 1, 2 and 3, the required Total R-Value is 1. requirement.
Single-leaf walls are deemed to be satisfied by 15.01 or
20.01 masonry with plasterboard on battens and insulation
having an R-value 0.5 between battens.
In Zone 5, the wall above, with bond beam and some core-
filling achieves the 220kg/m2 requirement (see below).
Without the 220kg/m2 wall mass, insulation with an R-value
0.9 is required to reach a Total R-Value of 1.4.
Where insulation is on the external face of the masonry,

behind cladding, and the internal face is rendered or lined
with daub-fixed plasterboard, the R-value of the insulation
is 0.52 in Zones 1, 2 and 3 and R 0.92 for Zone 5.
For 2 storey dwellings in Zone 1, 2 and 3, insulation is not

required for the lower storey walls where they are 15.01
or 20.01 masonry.
Block Veneer Walls:
The R-values of 90mm block veneer and cavity block walls

without insulation added are on Page B8 (from BCA:2007,
Volume 1, Specification J1.5). Block veneer in Zone 1, 2
and 3, requires insulation with an R-value 0.53 to reach
the Total R-value of 1. In Zone 5 it is R 0.93 for the Total
R-value of 1.4.
Cavity Walls in Zone 1, 2 and 3 require insulation with

an R-value 0.27 to reach the Total R-value of 1. In Zone
5, 90mm cavity walls satisfy the wall mass 220kg/m2
requirement.

Queensland Book 1 B
Reinforced Masonry Lintels

Moment and Shear Capacities for Series 150 Blocks (140mm leaf)
NOTES
Vertical Vertical
Vc = Shear capacity (kN)
Bars Vc Mc Bars Vc Mc
Mc = Moment capacity (kNm)
N12 5.1 2.6 N12 12.5 9.3
N16 6.3 2.6 N16 13.7 16.0 Mortar type, M3
Block characteristic compressive strength,
ƒ’ uc = 15MPa
Horizontal Grout compressive strength,
ƒ’ c = 20MPa
Bars Vc Mc
N12 5.1 2.0
Cut on-site Cement content min. (Grout) = 300kg/m3
N16 6.3 2.9
100
Horizontal
300
15.12 Bars Vc Mc
N12 10.2 4.0
70 N16 12.6 4.7
15.12
70
Moment and Shear Capacities for Series 200 Blocks (190mm leaf)
Vertical Vertical
N12 7.9 3.6 N12 6.4 2.9
N16 10.2 3.6 N16 7.6 3.6
N20 13.1 3.6 N20 9.1 3.6
Horizontal Horizontal
100 100 N12 6.4 2.9
N12 8.2 4.0
N16 9.3 6.9 N16 7.6 5.0
N20 10.6 9.9 N20 9.1 6.5
20.12 20.12
129 (N12 bars)
127 (N16 bars) 95
125 (N20 bars)
Vertical Vertical
N12 17.9 18.0 N12 16.4 9.5
N16 20.2 30.2 N16 17.6 16.6
N20 23.1 32.2 N20 19.0 24.4
20.20 or 20.20 or
20.01 cut 20.01 cut
on-site on-site
Horizontal Horizontal
300 300
N12 16.4 8.0 N12 12.9 5.7
N16 18.6 13.4 N16 15.2 9.5
N20 21.3 17.2 N20 18.1 9.9
20.12 20.12
129 (Y12 bars)
127 (Y16 bars) 95
125 (Y20 bars)

Queensland Book 1 B
Design of Core Filled and Boundary
Steel Reinforced Masonry

Retaining Walls
Introduction
Backfill
The information presented here is supplied in good faith
and to the best of our knowledge was accurate at the time of
preparation. However, from time to time, additional or modified
data may be released by the CMAA. Any such information will
supersede the information presented in this guide.
This section provides specifications, design tables and typical

details for a range of reinforced concrete masonry retaining walls
Ground level
and their associated reinforced concrete bases. It is intended
Base Type 1
as a general guide for suitably qualified and experienced
professional engineers, who for any particular proposed Foundation
retaining wall, must accept the responsibility for carrying

out a comprehensive site investigation, determining the soil Fig B1 — Typical Wall Layout for Base Type 1
characteristics and other design parameters of the particular
site, and for designing and detailing the structures. Boundary
It is important for the professional engineer to determine

the strength and stability of the foundation material and the
drainage system required to ensure there will not be a build
up of hydrostatic pressure behind the wall. Backfill
All designs are based on:
• Reinforced Concrete Masonry Structures — AS3700 :

2001 SA Masonry Code.
• Reinforced Concrete Base — AS3600 :

1988 Concrete Structures.
• Reinforcement — AS1302 :
Ground level
1982 Steel Reinforcing Bars for Concrete.
Base Type 2
• Concrete Blocks — AS4455 :
1997 Concrete Masonry Units. Foundation
Wall Types Fig B2 — Typical Wall Layout for Base Type 2

Design tables in this section are given for walls up to 3.4
metres high and for two base types:
Construction Recommendations
Loading Conditions
These tables cover:
General
Recommendations specifically applicable to reinforced
• Sloping backfill (up to 1 in 4) without any surcharge
masonry retaining walls include:
or
• The provision of clean-out openings in the bottom course
• Level backfill with a 5kPa surcharge to permit removal of mortar droppings and other debris
and to allow vertical reinforcement to be positioned and
Since typical cases only are presented, these tables may not tied. These openings should be closed (generally done with
provide an ideal solution for a particular application. formwork) before grouting.

Queensland Book 1 B
• The use of H blocks above the first course. These blocks Impermeable
layer sloping
are easier to fill with grout which provides the required to drain
continuous protection to the reinforcement. If rebated flush- Drain
ended blocks are used in lieu of H blocks, they should be
laid with alternate courses inverted to provide grout cover
to horizontal reinforcement, which should be supported
20mm clear of the webs of flush-ended blocks.
• The forming of weepholes by leaving out mortar in the Backfill
vertical joints at the required locations. Where H blocks are

used, and weepholes are required, they may be provided by
placing 25mm diameter PVC pipes through the vertical joint
at the required locations. Alternatively, flush-ended blocks
may be placed on either side of the required weephole
location so a mortar-free joint may be formed.
• The accurate positioning of reinforcement to give a minimum

of 55mm of cover to the face of the bar and its secure tying Fig B3 — Sealing Backfill Surface
before placing concrete or grout.
at the base of the wall. The outlets of the pipe must be
• The removal of mortar dags protruding into cores before beyond the ends of the wall unless the pipe is connected
grouting. to a proper stormwater drainage system.
• The use, whenever available, of ready-mixed grout to workability For higher walls, or in cases where excessive groundwater
specifications given in AS3700 should be used. Site-mixed exists, it may be necessary to provide another agricultural
grout, if used, should be mixed thoroughly in a tilting-drum pipe drain at mid-height of the wall.
mixer to the same specification as ready-mixed grout.
• The filling of all cores with grout, whether reinforced Vertical layer of
granular material
or not. This is essential to bond and protect horizontal
reinforcement, to provide a full barrier against water
penetration and to give maximum weight for stability.
• The thorough compaction of the grout so voids are To prevent clay or

silt infiltrating the
not left. Compaction may be achieved with a high- drainage system a
geofabric material
frequency pencil vibrator, used carefully. (The main Continuous may be wrapped
agricultural pipe around the gravel
vertical reinforcing bars should not be used to compact drain surrounded and/or the pipe
by free-draining
the grout). Control joints should be built into the masonry gravel or crushed
stone
at all points of potential cracking.
Backfill Drainage
It is essential that steps be taken to prevent the backfill behind
the wall from becoming saturated. These steps should include:
Fig B4 — Continuous Drainage Within the Backfill
Sealing Backfill Surface Walls with Base Type 1
To prevent saturation of backfill by surface run-off, the
surface of the backfill should be sealed by covering it with Care must be taken to ensure that clay and silt do not
a compacted layer of low permeability material. The surface infiltrate the drainage material or agricultural pipe. The use
should be sloped towards an open drain. of a geofabric envelope around the gravel and/or a geofabric
Continuous Drainage Within the Backfill sock over the pipe will assist.
This can be achieved by placing free-draining gravel or crushed
stone to a width of approximately 300mm immediately
behind the wall with a continuous agricultural pipe located

Queensland Book 1 B
Backfill Free draining

granular material
Locate the
continuous drain
at the bottom of Free-draining
the base gravel or stone
Weepholes
between
blocks
Drain

Walls with Base Type 2
Walls with Base Type 1
Water Penetration
If it is considered necessary to reduce the passage of
moisture through the wall, for aesthetic or other reasons
such as aggressive groundwater, the earth face of the wall
Extra should be treated with an appropriate sealer such as water-
agricultural
pipe drain resistant render or water-resistant paint, or by tanking with
bituminous materials.
Structural Design Guidelines

Acceptable Soil Combinations
• For retaining walls founded on sand (Type A soil), the
retained material must be similar and with a friction angle
of 38° or greater, eg Type A soil — clean sand or gravel.
• For retaining walls founded on other soils, the retained

Fig B6 — Continuous Drainage for High Walls
and/or Excessive Groundwater material must be a free draining material with a friction
angle of 27° or greater, eg Type A soil — clean sand or gravel,
Weepholes
Type B soil — coarse grained with silt or some clay.
Weepholes should be provided above the finished ground
level. A drain should be provided in front of the wall to
prevent saturation of the ground.
55mm cover to
The horizontal spacing of the weepholes depends on the wall reinforcement
provisions made for directing water towards the holes. The
simplest, but most effective, method is to place one or two
buckets of free-draining gravel or crushed stone around the
Clean-out
intake end of each hole. In this case, the horizontal spacing course
30mm
should not exceed 1.5 metres. If the layers of draining
material are continuous for the full length of the wall,
weephole spacing may be increased to an extent depending
50mm cover to all
on the quantity of water expected. base reinforcement
Note: For walls higher than 2200mm, a second row of

weepholes may be required. However, staining of the wall
could result. Fig B8 — Typical Set-out Detail

Queensland Book 1 B
Sloping backfill
Optional or surcharge
capping
Longitudinal
reinforcement: N12 in
Sloping alternate courses
190 backfill or commencing from top
surcharge course. Omit on top of
Optional clean-out block
capping
Height
of
190mm Vertical reinforcement:
Longitudinal reinforcement: N12 @400 cts
N12 in alternate courses Longitudinal blocks
commencing from top course. reinforcement: 190
Omit on top of clean-out block N12 in
alternate
courses
Sloping commencing
140 backfill or from top 450
surcharge course. Omit H = 2200 min
on top of to 3400 lap
clean-out
block
N12 @400
Optional cts K Bars
capping
H = 1400
to 2000
H = 800 290
to 1200 N12 @400
cts
Height of
290mm
blocks V Bars
600 V Bars
450 V Bars min
min lap
X Bars X Bars X Bars
lap
200 250 300

350 400
550
N12 @400 N16 @400

180 N16 @400
230
B
B 330
B
Fig B9 — Construction Guidelines for Reinforced and Core Filled Retaining Walls with Base Type 1
Table B3 — Design Guidelines for Reinforced and Core Filled Retaining Walls with Base Type 1
Wall Height Reinforcement Base Dimensions

Total
Height Height of Blockwork X-Bars Width, B (mm)
(mm) 150 200 300 and with following backfill conditions
H Series Series Series V-Bars K-Bars Level Max 1 in 4 Slope
800 800 — — N12 at 400 — 800 1000
1000 1000 — — N12 at 400 — 1000 1200
1200 1200 — — N12 at 400 — 1100 1500
1400 — 1400 — N12 at 400 — 1300 1700
1600 — 1600 — N16 at 400 — 1400 2000
1800 — 1800 — N16 at 400 — 1600 2200
2000 — 2000 — N16 at 200 — 1700 2500
2200 — 1400 800 N16 at 400 N16 at 400 1900 2800
2400 — 1600 800 N16 at 400 N16 at 400 2000 3100
2600 — 1600 1000 N20 at 400 N20 at 400 2200 3300
2800 — 1800 1000 N20 at 400 N20 at 400 2400 3600
3000 — 2000 1000 N16 at 200 N16 at 200 2600 3900
3200 — 2000 1200 N20 at 200 N16 at 200 2800 4200
3400 — 2000 1400 N20 at 200 N16 at 200 2900 4500

Queensland Book 1 B
Surcharge or
sloping backfill
(1 in 4 max.)
Optional
capping
Surcharge or
sloping backfill N16 in top course only
(1 in 4 max.) 190
Height of
Optional 190mm
capping blocks N12@400 cts
Longitudinal
reinforcement Longitudinal reinforcement:
N12@400cts. N16 in top N12@400
commencing from course only
top course. Omit on
top of clean-out 190
Surcharge or
sloping backfill course
Longitudinal 600
(1 in 4 max.) 140 min.
reinforcement
N12@400 cts. H = 2200 lap
Optional Omit on top of to 3400
capping clean-out course
Longitudinal reinforcement
2 x N12@400cts. Omit on
N12@400 cts top of clean-out course
H = 1400
to 2000 290
H = 800 N12@400 cts
K Bars
to 1200 Height of
V Bars V Bars 290mm
blocks V Bars
600
450 min.
min. lap
lap SL72 Fabric SL72 Fabric SL72 Fabric
250 250 300

D D D
N16@400 N16@400
N16@400
N12@400
N12@400
W W W
B B B
Fig B10 — Construction Guidelines for Reinforced and Core Filled Walls with Base Type 2
Table B4 — Design Guidelines for Reinforced and Core Filled Walls with Base Type 2
Wall Height Reinforcement Base Dimensions

Max. 1 in 4
Total Level Backfill Sloping Backfill
Height Height of Blockwork Heel Width Base Width Heel Depth Base Width Heel Depth
(mm) 150 200 300 (mm) (mm) (mm) (mm) (mm)
H Series Series Series V-Bars K-Bars W B D B D
800 800 — — N12 at 400 — 450 600 500 800 500
1000 1000 — — N12 at 400 — 450 800 500 1000 500
1200 1200 — — N12 at 400 — 450 1000 500 1200 600
1400 — 1400 — N16 at 400 — 450 1200 500 1400 600
1600 — 1600 N16 at 400 — 450 1400 600 1600 700
1800 — 1800 N16 at 400 — 450 1600 700 1800 800
2000 — 2000 N16 at 200 600 1800 700 2000 800
2200 — 1400 800 N16 at 400 N16 at 400 600 2000 800 2200 900
2400 — 1600 800 N16 at 400 N16 at 400 600 2200 900 2400 1000
2600 — 1600 1000 N20 at 400 N20 at 400 900 2400 900 2600 1000
2800 — 1800 1000 N20 at 400 N20 at 400 900 2600 900 2800 1100
3000 — 2000 1000 N16 at 200 N16 at 200 900 2800 1000 3000 1200
3200 — 2000 1200 N20 at 200 N16 at 200 900 3000 1100 3200 1300
3400 — 2000 1400 N20 at 200 N16 at 200 900 3200 1200 3400 1500

Queensland Book 1 B
190
Floor slab reinforcement Starter bar to match

N12 at 200 cts wall reinforcement
above
One-course bond
beam with N12 bar
20.20 knock-out block

saw-cut at floor soffit level
Series 200
blocks
Horizontal Note:
2700 max. reinforcement, Wall blocks and
N12 at 400 cts reinforcement as
for 'Typical Details'
Tanking to back face of wall

e.g. Bituminous coating
Vertical
reinforcement:
N16 @400 cts, False wall
central
Floor slab
reinforcement Drained cavity
200 200
55mm N12 @400 cts N16 @400 cts or

cover N12 at 200 cts Ag. drain Ag. drain
1000
Fig B11 — Typical Details — Fig B12 — Alternative Details —

Fully Propped Wall Fully Propped Wall

Queensland Book 1 B
290
190
140
190
Timber floor
Timber floor
One-course
bond beam using
20.20 knock-out block
with 1xN12 bar
Pole plate fixed

65mm cover to to bond beam
back face
Vertical reinforcement
N16 at 400 cts, central
2700 max.
Natural
soil
Note:
Series 200 Reinforcement as
blocks for ‘Typical Details’
Horizontal reinforcement, Tanking to

N12 at 400 cts back face 290
of wall
Series 300 65mm cover

1200 blocks to back face
False wall
Clean-out
course Natural
soil
Floor slab Drained cavity
reinforcement
300
300
N12 at 400 cts N16 at 200 cts

1500
or N20 at 400 cts Ag. drain
55mm cover Ag. drain
Fig B13 — Typical Details — Fig B14 — Alternative Details —

Unpropped or Partially Propped Wall Unpropped or Partially Propped Wall
NOTE: Backfill must be completed prior to construction of timber floor.

Q
Que
uee
een
ensslandd BBoo
Queensland
lan Book
ook
ok 1 B
Note:
Retaining wall shall be propped prior to
190 backfilling and remain in place for a
minimum of 7 days after placing floor slab
Floor slab reinforcement

to suit site conditions
450
lap Vapour barrier and
sand bedding under slab
Knock-out block
saw-cut at floor
soffit level N12 at same spacing as
vertical reinforcement
N12 at same spacing as vertical

reinforcement (spacing 'S')
lapped 450 in wall and floor
Horizontal
reinforcement,
N12 at 400 cts
Free-draining gravel
Vertical
reinforcement: 'H' (2200 max.)
N12 at spacing 'S',
centrally placed
Natural soil
Ag. drain 65mØ
fall at 1:100 to
Use H blocks for outlet
sub-floor wall
section
Bars
450 lap
Clean-out course
Note:
Starter bars, Footing size and
N12 @ spacing 'S', 450 min. 600 min.
reinforcement to suit
centrally placed site conditions
Fig B15 — Typical Details — Subfloor Retaining Walls
Vertical Reinforcement Spacing

Height H(mm) Spacing S(mm)
d 1500 600
! 1500 d2200 400

BORAL MASONRY

C FIRE DESIGN
1 C
Queensland Book 1 C
Masonry Design for Masonry Design for

Fire Resistance Structural Adequacy FRL
Fire Resistance Levels (FRL) Legend for the following formulae
FRL come from the Building Code of Australia’s (BCA) tables Srf = the slenderness ratio in design for fire resistance
for Type A, B or C construction. The Type of construction for structural adequacy. See table C2 on page C7 for
depends on the Class of building and the number of stories maximum Srf.
or floors.
avf = 0.75 if the member is laterally supported along its top
There are 3 figures in the Fire Resistance Level. edge.
eg: FRL 60/120/120 meaning Structural Adequacy for 60 = 2.0 if the member is not laterally supported along its
minutes / Integrity for 120 minutes / Insulation for 120 top edge.
minutes.
H = the clear height of a member between horizontal
Structural Adequacy lateral supports; or
This governs the wall height, length, thickness and restraints. = for a member without top horizontal support, the
Masonry unit suppliers do not control the wall height, length overall height from the bottom lateral support.
or restraints, therefore do not control Structural Adequacy.
However, information that is useful in the design of masonry t = the overall thickness of the member cross-section
walls is the maximum Slenderness ratio (Srf). Boral Masonry perpendicular to the principal axis under consideration;
provides Srf information for all of its masonry units, and its for members of cavity wall construction, the wall
use is discussed in more detail later. thickness assessed is in accordance with Clause
6.3.2.1(a) and (b).
Integrity
ah = 1.0 if the member is laterally supported along both
This is the resistance to the passage of flame or gas. To
its vertical edges.
provide ‘integrity’, masonry walls must be structurally
adequate because cracks that form when it bows can allow = 2.5 if the member is laterally supported along one
flame through the wall. Since the masonry unit supplier vertical edge.
does not control Structural Adequacy, they cannot control
L = The clear length of a wall between vertical lateral
‘integrity’ either.
supports; or
Insulation = for a wall without vertical support at one end or at
This is resistance to the passage of heat. Insulation is a control joint or for walls containing openings, the
governed by the type and thickness of the material used to length to that unsupported end or control joint or
produce the masonry unit. This is controlled by the masonry edge of opening.
unit manufacturer. In relation to FRL, masonry must always
provide ‘Insulation’ to an equal or better level than is required NOTE: A control joint in a wall, or an edge to an opening
for ‘Integrity’. in a wall, shall be regarded as an unsupported edge to the
wall unless specific measures are taken to provide adequate
lateral support at the edge.
Structural Adequacy may be overridden 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 masonry panel size, depending on its
restraints and thickness.
C2 February 2008 | BORAL MASONRY DESIGN GUIDE

Queensland Book 1 C
The Slenderness ratio (Srf) of the proposed wall is calculated NOTE:* Refer to the Structural Adequacy Selection Graphs
as per Clause 6.3.2.2. If this value is less than the maximum on pages C9 to C15 for maximum height values.
Srf in Table 6.1 [or the Srf calculated from Fire Tests and
For cavity walls, two thirds of the total thickness can be
Clause 6.3.3(b)(ii)], then the wall complies. If the Srf of
used for t, provided that BOTH leaves are restrained in the
the wall is greater than the maximum permissible, it
same positions (eg: external leaf stops at slab also). If the
is recalculated for an increased thickness and/or extra
external leaf is a veneer to the slab edge, the internal leaf
restraints.
must provide the Structural Adequacy FRL on its own.
There are 4 formulae for calculating Srf: 6.3.2.2 (1) and (2)
For reinforced masonry, the Srf of 36, from Table 6.1 may be
are the HEIGHT formulae.
used. Reinforcement can be horizontal, as bond beams when
FORMULA 1 and 2 is: avf H spanning between columns. Reinforcement can be vertical,
Srf =
t as filled cores when spanning between slabs. In either case,
reinforcement can be spaced up to 2m apart, depending on
6.3.2.2 (3) is the PANEL ACTION formula. span. This reinforcement stiffens the masonry and resists
bowing. Reinforced walls with Srf < 36 have a 240 minute
FORMULA 3 is: 0.7 avf H ah L
Srf =
t ¥ FRL for Structural Adequacy.
All calculations should be checked by an engineer. Other

6.3.2.2 (4) is the LENGTH formula. loads may supersede Structural Adequacy requirements.
FORMULA 4 is: S = a L
rf h
t Masonry Design for
The actual Srf is the lesser of the resulting figures.
Integrity FRL
(The resistance to the passage of flame or gas).
Formula (1) and (2) always govern where there is no end
restraint, and often govern where walls are long, relative to It is impractical to provide test results for all possible
their height. Projects with multiple wall lengths (eg: home masonry wall designs, and therefore ‘Integrity’ must be
units) can use this formula as a ‘one size fits all’ method of proved in some other way. With masonry wall design, the
calculating the masonry thickness. most practical way to prove ‘Integrity’ is to prove ‘Structural
Adequacy’ and ‘Insulation’ equal to or better than the
Formula (3) allows a wall to exceed the height given by
‘Integrity’ requirement. (Logically, if the wall is designed to
formula (1) and (2) provided at least one end is restrained
minimise ‘bowing’ it will not crack and therefore resist the
as well as the top.
passage of flame and gas for the specified time).
Formula (4) governs the wall length, often where there is no
This method is also the best way to prove ‘integrity’
top restraint (eg: portal frame factories) and where walls are
even when a wall may not be required to comply with a
short, relative to their height (eg: a lift well or vent shaft).
‘structural adequacy’ FRL value, such as is the case with
From a suppliers perspective, it is helpful to be able to non loadbearing walls. eg: if the BCA requires an FRL
calculate the maximum height* for a given thickness of -/90/90, the wall has no actual ‘structural adequacy’
(masonry unit), requirement, but to prove integrity of 90 minutes, the wall
Srf x t must be structurally adequate for 90 minutes.
eg: H =
Avf
and calculate the thickness from a given wall size.

Avf x H
t =
Srf
where ‘t’ is the OVERALL thickness, whether the units are

solid or hollow.
BORAL MASONRY DESIGN GUIDE | February 2008 C3

Queensland Book 1 C
Masonry Design for Effect of Chases on Fire Rated

Insulation FRL Masonry
Insulation is the one FRL component that a masonry unit Structural Adequacy FRL
manufacturer does control. It is governed by the ‘type of To assess the effect of chases on Structural Adequacy FRLs,
material’ and the ‘material thickness’. the direction in which the wall spans must be taken into
account.
‘Material thickness’ is defined in AS3700, Clause 6.5.2
as the overall thickness for solid and grouted units and Walls spanning vertically may be chased vertically. The
units with cores not more than 30% of the unit’s overall horizontal chase is limited to 4 times the wall thickness.
volume.
Walls spanning vertically and horizontally may be chased
For hollow units (cores > 30%), the material thickness is the horizontally up to half the wall length. Horizontal chases
net volume divided by the face area. should be kept to a bare minimum. Walls spanning vertically
and horizontally may be chased vertically up to half the
For cavity walls, t = the sum of material thicknesses in
wall height.
both leaves. (not two thirds as for the Structural Adequacy
FRL). If these limits are exceeded, the masonry design thickness
must be reduced by the depth of the recess or, in the case
Options for Increasing FRLs
of vertical chases, designed as 2 walls with unsupported
The Structural Adequacy FRL can be increased by adding ends at the chase.
wall stiffeners, by increasing the overall thickness, by
adding reinforcement or by protecting the wall with Boral Integrity and Insulation FRLs
Plasterboard ‘FireStop’ board, fixed to furring channels (on Maximum depth of recess is 30mm. Maximum area is
both sides of the wall if a fire rating is required from both 1,000mm2. Total maximum area on both sides of any 5m2
sides). of wall is 100,000mm2
Integrity FRLs are increased by increasing the other two If these limits are exceeded, the masonry design thickness
FRL values to the required Integrity FRL. must be reduced by the depth of the recess.
Insulation FRLs can be increased by core filling, by adding Recesses for Services
another leaf of masonry, by rendering both sides of the
Recesses that are less than half of the masonry thickness
wall if the fire can come from either side. NOTE: Only ONE
and are less than 10,000mm2 for both sides within any 5m2
thickness of render is added to the material thickness and
of the masonry, do not have an effect on fire ratings.
that must be on the ‘cold’ side because the render on the
exposed face will drop off early in a fire). If these limits are exceeded, the masonry design thickness
must be reduced by the depth of the recess.
Boral ‘FireStop’ plasterboard on furring channels can
increase the Insulation FRL from either side. Unlike render,
the Boral FireStop and furring system does not drop off the
hot side so quickly due to the board’s fire resistance, the
mechanical fixing of the board to furring and the furring
to the wall.

Queensland Book 1 C
How to Select Boral Masonry Units for Fire Rated Walls

All design information, table data and graphs in this guide Tables and graphs assume all walls are built on concrete
are derived from formulae in AS3700 : 2001 Masonry slabs or broad footings and have adequate restraints. Piers,
Structures, Part 6.3 for Structural Adequacy Fire Resistance cavity walls, freestanding walls, earthquake, wind and other
Levels (FRL) and Part 4.6 for Robustness. loads are not addressed in this guide. All fire rated walls
should be designed by a suitably qualified engineer.
Step 1 Example
Determine required wall FRL from the Building Code
of Australia (BCA).
eg: 120/60/60
The Building Code of Australia (BCA), Section C defines
Insulation
the CLASS and TYPE of building and designates the
Integrity
required Fire Resistant Level (FRL) in terms of three
Structural Adequacy
criteria. See adjacent example.
NOTE: For masonry wall design, the FRL for any given eg. If the BCA required FRL is: —/120/60
wall must comply with:
Then the chosen wall design must have an
Structural Adequacy Integrity Insulation actual FRL of: 120/120/120 or better.
Refer to the section ‘Design for Integrity’ on page C3 for

additional explanation.
Worked Example
• A 4.6m high, 6m long fire wall in 3 storey offices. BCA
specifies Class 5, Type b Construction.
• BCA Specification C1.1, Table 4 specifies an FRL

120/120/120.
• For this example, the wall is laterally restrained along

the top and both ends and is non-loadbearing.

Queensland Book 1 C
Step 2 Worked Example

Select an appropriate Boral Masonry Unit based on From Table C1, the following units all achieve 120 minutes
the FRL ‘Insulation Requirement’. FRL for ‘Insulation’:—
The third figure in an FRL rating is the ‘Insulation’.
• 15.709 FL and Rippa FL.
Table C1 provides the ‘Insulation’ values for the various
• 15.48 Grout-filled (however the use of Firelight
Boral units.
(FL) may be more cost effective if the wall is non-
Check the ‘Materials Attributes’ (see notes below the table) loadbearing).
to ensure the selection is fit for its purpose.
Table C1 — FRL Insulation Values for Boral Masonry Units (Queensland)

Fire INSULATION FRL (minutes)
Test 30 60 90 120 180 240 Material Styly Nos.
Yes FireLight (FL) Rippa FL
Yes FireLight (FL) 15.709 FL
d.t.s. Basalt (B) Speed-E Brick and Rippa Block
d.t.s. Grey and Designer Block 15.01
d.t.s. Grey and Designer Block 10.01; 10.31; 20.01 (NQLD)
d.t.s. { Grey and Designer Block 20.01 (SQLD)
d.t.s. - Grey and Designer Block 12.709
d.t.s. Grey and Designer Block 15.709
d.t.s. Grouted 140mm 15.42; 15.48
d.t.s. Grouted 190mm 20.42; 20.48
d.t.s. Cavity wall 15.01 + 10.01
d.t.s. Cavity wall 10.01 + 10.31
d.t.s. ‘deemed-to-satisfy’
Indicates extra insulation with 10mm render on both faces
{ Note that 20.01 blocks sold in North Queensland are rated at 60 minutes for insulation.
Material Attributes (Queensland) Designer Block ƒ’uc=10MPa

FireLight (FL) ƒ’uc=3MPa Blocks provide a 60 or 90 minute Insulation FRL. Suitable
FireLight is a lightweight material that has been developed for LOADBEARING applications.
and tested for high fire and acoustic ratings. It is ideal for Standard Grey Block ƒ’uc=15MPa
plasterboard-lined non-loadbearing walls in high-rise home units Made as hollow, reduced core and solid units for 60, 90 and
and wherever weight minimisation is critical. Acoustic tests 120-minute Insulation FRLs. Used for loadbearing and non-
have proven the requirements of BCA:2005 can be met with loadbearing masonry, 140 and 190mm thick units can be
plasterboard-lined walls that are thinner than some “deemed- partially reinforced for walls of portal frame buildings and
to-satisfy” options. houses in cyclonic areas.
Concrete-Basalt Brick (B) ƒ’uc=10MPa Core Fill Block ƒ’uc=15MPa
(Speed-E and Rippa)
Made with recessed webs to accommodate horizontal steel.
Concrete-Basalt is a denseweight, load-bearing material. Used for cantilever-design retaining walls, basement walls
The 45% basalt content of these bricks allows the use and for large, loadbearing walls requiring 120 or 240-minute
of the higher Slenderness ratios AS3700, Table 6.1. Its Insulation FRLs.
Insulation FRLs are slightly higher than clay units. The
material is slightly more dense than clay so acoustic
performance is slightly higher for rendered walls
(mass law). Acoustic performance with plasterboard
is better than clay because resonances are dampened by its
higher porosity.

Queensland Book 1 C
Step 3 Worked Example

Check the ‘Structural Adequacy’ of the selected The calculated Srf value for your wall design MUST NOT
units. EXCEED the value from the accompanying table.
The Slenderness ratio (Srf) of a fire rated wall is calculated See following page for an explanation on using the Boral
as per AS3700 : 2001, Clause 6.3.2.2, and must not exceed Srf graphs to assist preliminary selection.
the Srf values given in AS3700 or calculated from Fire
eg. FireLight — required to provide Structural Adequacy
Tests.
for 120 minutes has an Srf = 24.9.
Table C2 provides the maximum Srf values for Boral
Also refer to the previous explanation and AS3700 for Srf
masonry units.
calculation methods.
In this example, the Srf for a 140mm thick wall, 4.6m high,
with lateral restraint along the top is 24.7 as per AS3700,
Formula 6.3.2.2 (2) See page C3.
This is less than the maximum Srf for FireLight at a

120 minute Structural Adequacy FRL, therefore passes.
Reinforced masonry also passes, however unless the wall
is loadbearing, FireLight will be more economical.
Table C2 — Maximum Srf Values for Boral Masonry Units

Maximum Srf Values
Fire FRL (minutes) for Structural Adequacy
Test 30 60 90 120 180 240 Material Condition of use
Yes 29 29 26.9 24.9 22.2 20.3 FireLight (FL) Non loadbearing ONLY
d.t.s. 25 22.5 21 20 18 17 Concrete-Basalt (B) Any
d.t.s. 19.5 18 17 16 15.5 15 Standard dense concrete Any
d.t.s. 36 36 36 36 36 36 Reinforced masonry Any
d.t.s. ‘deemed-to-satisfy’, as per AS3700:2001, Table 6.1.

Queensland Book 1 C
Boral Structural Adequacy Selection Graphs and Tables

To assist with the preliminary selection of Boral masonry IMPORTANT
units for fire rated walls, a graphical selection method based The following selection graphs are based on Specific
on Srf values has been developed. Products manufactured at Queensland Boral Plants.
Should these units be sourced from other plants, the
The following pages provide graphs and tables for a selection
specification should be checked with the respective
of Boral masonry units where at least one end of the wall
supply plant.
has lateral restraint.
Additional tables are provided for walls with no end restraint

and for reinforced/grout filled masonry, following these
graphs.
How to Use the Boral Structural Adequacy FRL Graphs
FireLight Block — (FL) Worked Example
1. Select the appropriate masonry unit material.
SUPPORT
2. Select the appropriate page with Structural
Structural Adequacy
SUPPORT
SUPPORT
Adequacy for the required minutes. (120

120 minutes FRL
Laterally supported minutes for this example).
both ends and top SUPPORT
9
Leaf 3. Select the appropriate graph for the chosen wall
Thickness
8
restraint (support) criteria. (Support on both
sides, top and bottom for this example).
7
190mm
4. Plot the intersection of the Wall Height and the
6
Height of wall between supports (m)
Wall Length on the graph. (For this example

5 4.6m height x 6m length).
140mm
4
110mm 5. The result MUST FALL BELOW the coloured line
3
100mm indicated for the chosen masonry unit thickness.
90mm
In this example, the result is above the line for
2 110mm units but below the line for 140mm
1 units. Therefore 140mm units would be suitable.
(110mm units would not be suitable for this
0
0 1 2 3 4 5 6 7 8 9
example).
Length of wall between supports (m)
Index to Structural Adequacy FRL Graphs and Tables

Product Group FRL Minutes (Structural Adequacy) Page
FireLight Block (FL) 60 C9
Concrete-Basalt Bricks 60 C12
Concrete-Basalt Bricks 90 C13
Standard Grey 60 C14
Standard Grey 90 C15
Designer Block 60 C14
Designer Block 90 C15
Walls Restrained at Top (Unrestrained Ends) 60 — 240 C16
Reinforced and Grout-Filled Masonry Walls 60 — 240 C16

Queensland Book 1 C
Boral FireLight™ Bricks and Blocks (FL) — Srf = 29

Structural Adequacy for 60 minutes Fire Resistant Level (FRL)
SUPPORT
Structural Adequacy Structural Adequacy
SUPPORT
SUPPORT
SUPPORT
SUPPORT
60 minutes FRL 60 minutes FRL
Laterally supported Laterally supported
both ends and top SUPPORT both ends, top free SUPPORT
9 9
Leaf Leaf
Thickness Thickness
8 190mm 8
7 7
6 6

5 140mm 5
4 4
110mm
190mm
100mm
3 90mm 3
2 2 140mm
110mm
100mm
1 1 90mm
0 0
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
Length of wall between supports (m) Length of wall between supports (m)
SUPPORT
SUPPORT
SUPPORT

one end and top SUPPORT one end top free SUPPORT
9 9
Leaf Leaf
Thickness Thickness
8 8
7 7
6 6
190mm
5 5
4 140mm 4
110mm 3
3
100mm
90mm
2 2
190mm
140mm
1 1 110mm
90/100mm
0 0
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9

Queensland Book 1 C
Boral FireLight™ Bricks and Blocks (FL) — Srf = 26.9

SUPPORT
Structural Adequacy SUPPORT Structural Adequacy
SUPPORT
SUPPORT
SUPPORT
9 9
Leaf Leaf
Thickness Thickness
8 190mm 8
7 7
6 6

5 140mm 5
4 4
110mm
100mm
3 90mm 3 190mm
2 2 140mm
110mm
100mm
1 1 90mm
0 0
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
SUPPORT
SUPPORT
SUPPORT

one end and top SUPPORT one end, top free SUPPORT
9 9
Leaf Leaf
Thickness Thickness
8 8
7 7
6 6
190mm
5 5
4 140mm 4
110mm 3
3 100mm
90mm
2 2
190mm
140mm
1 1 110mm
90/100mm
0 0
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9

Queensland Book 1 C
Boral FireLight™ Bricks and Blocks (FL) — Srf = 24.9

SUPPORT
SUPPORT
SUPPORT
SUPPORT
SUPPORT
9 9
Leaf Leaf
Thickness Thickness
8 8
7 7
190mm
6 6

5 5
140mm
4 4
110mm
100mm
3 90mm 3
190mm
2 2 140mm
110mm
100mm
1 1 90mm
0 0
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
SUPPORT
SUPPORT
SUPPORT

one end and top SUPPORT one end top free SUPPORT
9 9
Leaf Leaf
Thickness Thickness
8 8
7 7
6 6
190mm
5 5
4 140mm 4
110mm 3
3 100mm
90mm
2 2
190mm
140mm
1 1 110mm
90/100mm
0 0
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9

Queensland Book 1 C
Concrete-Basalt (B): Rippa and Speed-E Brick — Srf = 22.5

SUPPORT
Structural Adequacy SUPPORT Structural Adequacy
SUPPORT
SUPPORT
SUPPORT
9 9
Leaf Leaf
Thickness Thickness
8 8
7 7
6 6

5 5
140mm 4
4
110mm
3 3
90mm
2 2
140mm
110mm
1 1 90mm
0 0
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
SUPPORT
SUPPORT
SUPPORT

9 9
Leaf Leaf
Thickness Thickness
8 8
7 7
6 6
5 5
4 140mm 4
3 110mm 3
90mm
2 2
140mm
1 1 110mm
90mm
0 0
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9

Queensland Book 1 C
Concrete-Basalt (B): Rippa and Speed-E Brick — Srf = 21.0

SUPPORT
SUPPORT
SUPPORT
SUPPORT
SUPPORT
9 9
Leaf Leaf
Thickness Thickness
8 8
7 7
6 6

5 5
4 140mm 4
3 110mm 3
90mm
2 2
140mm
1 110mm
1 90mm
0 0
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
SUPPORT
SUPPORT
SUPPORT

9 9
Leaf Leaf
Thickness Thickness
8 8
7 7
6 6
5 5
4 140mm 4
3 110mm 3
90mm
2 2
140mm
1 1 110mm
90mm
0 0
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9

Queensland Book 1 C
Standard Grey and Designer Block™ — Srf = 18.0

SUPPORT
SUPPORT
SUPPORT
SUPPORT
SUPPORT
9 9
Leaf Leaf
Thickness Thickness
8 8
7 7
6 6

5 5
190mm
4 4
140mm
3 3
110mm
90mm 2
2 190mm
140mm
1 1 110mm
90mm
0 0
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
SUPPORT
SUPPORT
SUPPORT

9 9
Leaf Leaf
Thickness Thickness
8 8
7 7
6 6
5 5
190mm
4 4
140mm
3 3
110mm
90mm 2
2
190mm
140mm
1 1 110mm
90mm
0 0
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9

Queensland Book 1 C
Standard Grey and Designer Block™ — Srf = 17.0

SUPPORT
SUPPORT
SUPPORT
SUPPORT
SUPPORT
9 9
Leaf Leaf
Thickness Thickness
8 8
7 7
6 6

5 5
190mm
4 4
3 140mm 3
110mm
2 90mm 2
190mm
140mm
1 1 110mm
90mm
0 0
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
SUPPORT
SUPPORT
SUPPORT

9 9
Leaf Leaf
Thickness Thickness
8 8
7 7
6 6
5 5
190mm
4 4
3 140mm 3
110mm
2 90mm 2
190mm
140mm
1 1 110mm
90mm
0 0
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9

Queensland Book 1 C
Walls Restrained at Top (Unrestrained Ends) SUPPORT
Walls without restraint to the ends, but with lateral restraint along their top have
maximum heights irrespective of their length as detailed in the following table. (Most
doorways and windows create free ends). SUPPORT
Material Thickness Maximum Wall Height (metres)
Structural Adequacy (FRL minutes)
60 90 120 180 240
90mm 2.430 2.430 2.430 2.430 2.430
100mm 2.700 2.700 2.700 2.700 2.700

FireLight (FL) 110mm 2.970 2.970 2.970 2.970 2.970
140mm 3.780 3.780 3.780 3.780 3.780
190mm 5.130 5.130 5.130 5.130 5.130

Concrete-Basalt 110mm 2.970 2.970 2.933 2.640 2.493
90mm 2.160 2.040 1.920 1.860 1.800
110mm 2.640 2.493 2.347 2.273 2.200

Standard Grey and Designer Block
140mm 3.360 3.173 2.987 2.893 2.800
190mm 4.560 4.307 4.053 3.927 3.800
140mm 5.040 5.040 5.040 5.040 5.040

Reinforced and Grout Filled*
190mm 6.840 6.840 6.840 6.840 6.840
*Governed by Robustness. Can be higher if supporting a slab. These heights can be exceeded when one or both ends are restrained as well as the top.
Reinforced Masonry Walls

Reinforced cores spanning vertically, Reinforced bond beams spanning horizontally,
ie. restraint top and bottom ie. restraint bottom and both ends
60 – 240 minutes FRL 60 – 240 minutes FRL
Lateral support along top
SUPPORT Lateral support at both ends
SUPPORT
SUPPORT
Single Steel reinforced Single Steel reinforced and

and fully grouted cores Core fill fully grouted bond beams
spacing Bond beam spacing
Slab or broad footing SUPPORT Slab or broad footing SUPPORT

Maximum Leaf Maximum Leaf
Wall Height Core Fill Thickness Wall Length Bond Beam Thickness
(metres) Steel Spacing (metres) (mm) (metres) Steel Spacing (metres) (mm)
4.000 N12 Every 10th core — (2m) 140 4.000 N12 Every 10th course — (2m) 140
6.840 N16 Every 8th core — (1.6m) 190 6.840 N16 Every 8th course — (1.6m) 190
Maximum vertical load on wall = 11.25 H kN/m where H is in metres.

BORAL MASONRY

D ACOUSTIC DESIGN
1 D
Queensland Book 1 D
Acoustic Performance Ratings Masonry with Plasterboard Systems

Daub-fixed Plasterboard
STC and Rw. The cornice cement daubs, used to fix plasterboard to
STC (Sound Transmission Class) and Rw (Weighted Sound masonry, create a small cavity in which resonances can
Reduction Index) are similar in that they are a single number occur. The more dense, smooth and impervious the masonry
evaluation of STL (Sound Transmission Loss) measurements is the more it will ‘bounce’ or resonate the sound, allowing
over 16 frequencies. the plasterboard to re-radiate the sound.
The use of STC was changed to Rw in BCA Amendment 6,
Tests on linings with extra daubs (spacing was halved)
issued in January 2000.
gave lower performances, presumably due to extra ‘bridges’
The lowest frequency measured in Rw is 100Hz. (STC through the daubs.
started at 125Hz).
Concrete masonry has a coarser texture and is more porous
The highest frequency measured in Rw is 3150Hz. (STC than clay.
finished at 4000 Hz).
The noise energy that gets through the wall and ‘bounces’
AS1276 gives a set contour that is positioned over the STL off the plasterboard is re-absorbed into the concrete, where
results so that the total of points above the results and below it dissipates, as a tiny amount of heat.
the contour (deficiencies) does not exceed 32.
Lightweight concrete masonry performs relatively poorly
Rw is then read off where the contour crosses the 500Hz when bare. When lined, it gives a vast improvement.
line. The maximum 8dB deficiency, which pulled the STC Higher density concrete units improve the Rw of the bare
contour down, is not used for Rw. wall, but when plasterboard is daub fixed, the amount
Instead, there are two numbers after Rw, eg: Rw45 (-1; -5). of improvement decreases as the concrete units begin to
The first figure in the brackets is an indication of deterioration behave similarly to clay.
due to high frequency noise (eg. a blender). The second figure
Masonry with Plasterboard on Furring
indicates deterioration due to low frequency noise (eg. low
speed trucks, bass guitar, or home cinema speakers). Channels
Furring channels are rollformed galvanised metal battens to
Impact Sound Resistance which plasterboard can be fixed, using self tapping screws.
From May 2004, the BCA requires impact rated walls to be Popular products include Rondo rollformed steel furring
of ‘discontinuous construction’. Although Queensland has channel (N°129 which is 28mm deep) or (N°308 which is
not adopted the new acoustic requirements, they are often 16mm deep).
specified for quality home units.
Furring channels increase the gap between masonry and
An impact rating is required for walls where a wet area plasterboard, making it harder for resonating energy to build
(including a kitchen) is opposite a habitable room in an up pressure on the board.
adjoining apartment.
Plumbing and electrical services can be fitted into this gap,
Masonry with Render avoiding the need to “chase” recesses into the masonry.
Acoustic performance with single leaf rendered masonry A further increase of 3 or 4dB can be achieved with Tontine
follows the ‘Mass Law’. The acoustic performance of these TSB3 polyester (or equivalent) insulation in the cavity
walls depends on their mass. More mass gives better between the plasterboard and masonry.
performance. The relationship is logarithmic: If a 110mm
wall gives Rw45, a 230mm wall of the same brick may give Another increase of 3 to 5dB can be achieved with a second
Rw57, and a 450mm wall may give Rw63. layer of plasterboard, fixed with grab screws to the first
layer, (and no gaps).
Cavity walls behave differently. Sound waves can resonate
in cavities. The narrower the cavity becomes, the more Boral Plasterboard now make ‘SoundStop’, a higher density
resonance occurs. Insulation in the cavity helps absorb board.
resonating sound. Narrow cavities should have bond breaker
board to prevent mortar from providing a bridge for sound to
travel between leaves.
D2 February 2008 | BORAL MASONRY DESIGN GUIDE

Queensland Book 1 D
Masonry with Plasterboard on Stud How loud is noise?

Framing
In this system, vibrations are isolated by the gap between
the masonry and the stud frame.
Plasterboard is screw fixed to the outside of a stud wall,

which is positioned 20mm from one face of the masonry.
An extra 6dB can be gained by placing Tontine TSB5

insulation between the studs. The other side of the masonry
can be lined with daub fixed plasterboard or rendered.
13mm render can add an extra 1dB more than daub fixed
board.
This system complies with the BCA requirement of

‘discontinuous construction’ for impact rated walls.
Designing Masonry Walls for

Acoustic Performance
Building acoustics is the science of controlling noise in
buildings, including the minimisation of noise transmission
from one space to another and the control of noise levels and
characteristics within a space. The term ‘building acoustics’ Sound Insulation
embraces sound insulation and sound absorption. The two Any wall system that separates one dwelling from another,
functions are quite distinct and should not be confused. or that separates one room from another, should be selected
to provide a sufficient level of insulation against noise.
Noise has been defined as sound which is undesired by
the recipient, but it is very subjective and it depends on There are two types of noise transfer through partitions,
the reactions of the individual. However, when a noise is airborne transfer, and structure-borne transfer. Both may
troublesome it can reduce comfort and efficiency and, if need to be considered in order to achieve the desired
a person is subjected to it for long enough periods, it can result.
result in physical discomfort or mental distress.
Noise sources, such as voices, televisions and musical
In the domestic situation, a noisy neighbour can be one of instruments, generate noise in the air in one room, and this
the main problems experienced in attached dwellings. The noise passes through the partition and into the room on the
best defence against noise must be to ensure that proper other side. This is known as airborne noise.
precautions are taken at the design stage and during
As we know, some partitions are better than others at
construction of a building. This means that the correct
isolating airborne noise. In order to simply compare the
acoustic climate must be provided in each space and that
isolating performance of partitions Rw rating was developed.
noise transmission levels are compatible with the usage.
A partition with a high Rw rating isolates sound better than a
Remedial measures, after occupation, can be expensive and
partition with a low Rw rating. If we compare two partitions,
inconvenient. Ideally, the sound insulation requirements
and one has an Rw which is 10 rating points higher, then
for a building should take into account both internal and
the noise passing through the wall with the higher Rw will
external sound transmission.
be about half the loudness when compared with the noise
passing through the wall with the lower Rw.
The Rw ratings are obtained from tests carried out in certified

laboratories, under controlled conditions. When identical
partitions are part of buildings and tested in-situ, it is often
found that the actual Rw rating obtained, usually called the
BORAL MASONRY DESIGN GUIDE | February 2008 D3

Queensland Book 1 D
Weighted Standardised Level Difference (Dnt,w), is lower the material, and determined by calculation from the
than the laboratory Rw. This reduction in performance average amount of sound energy absorbed over a range of
can be due to flanking paths (that is to say that noise also frequencies between 250Hz and 2000Hz.
passes through other parts of the building) or may be due
Boral Acousticell blocks have extremely high absorption
to poor detailing such as incorrect installation of pipes,
rates (90%) at low frequency. Refer to Acousticell product
power points etc.
page in this guide and the Boral Masonry Block Guide.
Structure-borne Noise and Weighted The porous surface and lightweight aggregates in lightweight
Normalised Impact Sound Pressure Level masonry give it high sound absorption values (> 50%) across
(L’n,w) all frequencies. Refer to the ‘Lightweight’ product page in
When a building element is directly, or indirectly, impacted the Fire Rated Walls section of this guide.
or vibrated then some of the energy passes through the
Sound Isolation Criteria
partition and is re-radiated as noise to the room on the other
side. This is called structure-borne noise or impact noise. From May 2004, the Building Code of Australia (BCA)
specifications for minimum levels of sound isolation have
For walls, the most common sources of structure-borne noise are: been increased. Although the new levels have not been
• Cupboard doors, fixed to party walls, being closed adopted by Queensland at the time of printing, they are
often specified for quality home units. These increased
• Kitchen appliances being used on benches touching walls specifications are:
• Plumbing fittings, particularly taps, being connected to walls • Unit to corridor or stairs Rw 50
• Light switches being turned on and off, and • Unit to unit Rw + Ctr 50
• Dishwashers, washing machines, clothes dryers etc. • Where a wet area of one unit adjoins a habitable room
touching walls in another unit, the wall construction must ‘be of a
Walls satisfy ‘impact’ or structure-borne noise isolation either by discontinuous type.’
conforming to the ‘deemed to satisfy’ provisions of the Building
Code of Australia ‘Impact Sound’ or ‘Test of Equivalence’, using Guidelines for Optimum
a single number description for impact insulation or the Opinion Performance
of a suitably qualified acoustic engineer.
To achieve the optimum performance for a wall system, the
The generally accepted test for impact is Weighted exact construction as specified including perimeter sealing must
Normalised Impact Sound Pressure Level or L’n,w. In this be adopted.
method of interpreting impact sound resistance, lower
Any variations from the systems detailed in this guide should
values represent better impact insulation.
be approved by the project acoustic consultant as it can
Another single number description used for impact is the increase or decrease the acoustical isolation of wall systems.
Impact Insulation Class or IIC. When used for walls it may be
called WIIC for laboratory testing or WFIIC for field testing. Installation
Unfortunately, as there are different test methods used to Unless careful attention to installation detail is followed,
obtain the impact rating for walls, results cannot always be significant reductions in sound isolation can occur,
directly compared. particularly with high performance walls. The following
need to be taken into account.
The larger the value of the WIIC the better the impact insulation.
Perimeter Acoustical Sealing
Noise Reduction Coefficient (NRC)
It should be noted that as the sound isolation performance
Designers of theatres, music rooms and power transformer
of a partition increases, then the control of flanking paths
enclosures etc may often choose materials which have an
becomes more critical. Consequently, the perimeter sealing
efficient sound absorption value and incorporate them
requirements for a low sound rating wall, such as Rw30,
within the building design. The level of sound absorption for
are much less than for a high sound rating wall, such
material is stated as the NRC (Noise Reduction Coefficient).
as Rw60. However, it is neither necessary, nor is it cost
This value is derived as a result of acoustic testing on
effective, to provide very high perimeter acoustic sealing

Queensland Book 1 D
for a low rating Rw wall. The perimeter isolation for each IMPORTANT: The use of expanding foam sealants is not
leaf must be commensurate with the acoustic isolation of acceptable.
the leaf. It cannot be over emphasised, however, that for high
Reference should be made to the manufacturer to ensure
performance walls, the sealing of each leaf must be virtually
the particular type or grade of sealant is suitable for the
airtight.
purpose.
For a sealant to be effective at controlling noise passing
through gaps, it must have the following properties. Noise Flanking
It is beyond the scope of this manual to provide full details
• Good flexibility, elastic set
for control of all flanking paths. However, flanking can
• Low hardness significantly reduce the perceived isolation of a wall system
• Excellent adhesion, usually to concrete, timber, plaster and should therefore be given careful consideration.
and galvanised steel
Typical flanking paths are shown in the Fig D1.
• Minimal shrinkage (less than 5%)
• Moderate density (greater than 800kg/m3), and
• Fire rated where required (All walls required by the BCA Acoustic Performance On-Site
to be sound rated also have fire ratings)
Laboratory Test results are achieved under ideal controlled
All of the above properties must be maintained over the conditions, and estimates are calculated from known
useful life of the building, that is, greater than 20 years. performance, experience and computer simulation programs.
To repeat the performance in the field, attention to detail in
Examples of a suitable sealant include:
the design and construction of the partition and its adjoining
• Bostik Findley — Fireban One floor/ ceiling and associated structure is of prime importance.
• Boral Plasterboard Fyreflex Even the most basic principles, if ignored, can seriously
• Boral Plasterboard WR Sealant downgrade the sound insulation performance of a building
element.
• Tremco synthetic rubber acoustical sealant
• Some silicone sealants and
• Some acrylic latex sealants
Through ventilation Through windows, doors,

and service ducts gaps and air leaks
Through
ceilings and the
above ceiling
cavity
Through
perimeter joints
between the wall
and floor, or the
wall and ceiling
(or underside of
the floor slab) or
wall junctions
Through back to
back cupboards
Through light
switches, or GPO's,
located in the wall,
poor sealing at
penetrations
Through floors
and the below
floor crawl
space
Through shared building elements such as floor boards, floor

joists, continuous plasterboard walls, continuous plasterboard
ceilings, and even continuous concrete walls and floors
Fig D1 — Flanking Paths
BORAL MASONRY DESIGN GUIDE | February 2008 D5

Queensland Book 1 D
Boral Masonry cannot guarantee that field performance ratings Appliances

will match laboratory or estimated opinions. However, with In cases where sound insulation is important, noise
careful attention during erection of the wall, correct installation producing fixtures or appliances such as water closets,
to specification and proper caulking/sealing, the assembly cisterns, water storage tanks, sluices, dishwashers, washing
should produce a field performance close to and comparable machines and pumps should be repositioned or isolated from
with tested or estimated values. Apart from installation the structure with resilient mountings and flexible service
procedures, workmanship and caulking, the following items leads and connections.
can also affect the acoustic performance on site.
Where fittings are duplicated on opposite sides of partitions,
Doors they should be offset.
Hollow, cored and even solid doors generally provide
unsatisfactory sound insulation between rooms. Doors can
Electrical Outlets and Service Pipes
also provide direct air leaks between rooms thus having a Electrical outlets, switch boxes and similar penetrations
bad effect on the overall sound insulation of the partition should not be placed back to back. If power outlets are
in which they are inserted. The higher the insulation of the installed back-to-back, they will create a flanking path or
partition, the worse is the effect of doors. sound leak. Seal backs and sides of boxes and the perimeter
of all penetrations with acoustic sealant.
Where sound insulation is important, specialised
heavyweight doors or, preferably, two doors separated by Penetrations should be avoided where sound insulation is
an absorbent lined airspace or lobby should be used. important. This includes recessed fittings or ducts such as
skirting heating, electrical or telephone wiring trunking, light
Lightweight Panels Above Doors fittings, inter-communication systems and alarms, medical
These are often incorporated for aesthetic reasons, however, and laboratory gas outlets. Plumbing connections between
the performance of a partition with good sound insulation fittings or appliances on opposite sides of a partition offer a
can be considerably degraded by lightweight panels. path for transmission of sound and should be sealed. If possible
introduce discontinuity in the pipework between fittings, such
Air Paths Through Gaps, Cracks or Holes as a flexible connection within or on the line of a partition.
Gaps, cracks or openings, however small, readily conduct
airborne sounds and can considerably reduce the sound
insulation of a construction.
Home Cinema Rooms
Boral Masonry and Plasterboard divisions have a number
of high performance wall systems which have been
Noise paths specifically developed for home cinema applications.
through vents
or lightweight Please contact Boral Masonry for additional assistance and
decorative panels
information on the available solutions, or visit the website: www.boral.
com.au/cinemazone for solutions using Boral masonry products.
Noise paths
through lightweight
panel doors
Noise paths
through vents
Noise paths
through gaps
Fig D2 — Flanking Paths
Fig D3 — Acoustic Performance Overview

BORAL MASONRY

E FIRE AND ACOUSTIC SYSTEMS
1 E
Fire and Acoustic Systems
PAGE
BOOK 1 E2
Boral Fire and Acoustic Masonry Wall Systems

This section of the Boral Masonry Design Guide contains The following illustration details typical page layouts and
detailed information on the fire and acoustic performance the type and location of information you may need to
of Boral masonry products, and provides System Solutions complete your product selection and wall design.
for fire and acoustic wall designs.
Finding Acoustic Systems and

Technical Specifications
Product
Name Product Introduction
and Application Product Specific
Information Acoustic Test Results
Product Icons with
and Wall Lining System
dimensions for
Information
products available
in your region/state Product Identification
Fire and Acoustic Systems Fire and Acoustic Systems
PAGE
BOOK
PAGE
BOOK
1 E4 1 E5
FireLight Brick (FL) Acoustic Systems - 110mm Rippa FireLight Block

INTRODUCTION ACOUSTIC DESIGN ACOUSTIC
110mm
Boral FireLight bricks are manufactured CONSIDERATIONS RATING
WALL LINING RIPPA FIRELIGHT WALL LINING
76
from a low-density material which The first 2 tests on the following Rw (c, ctr)
BLOCK (FL)
page E5 comply with the BCA:2005 Boral Test Nº
230 provides high fire rated performance
110
and minimum weight for non- requirements for unit-to-corridor or
• 1 x 13mm Boral Plasterboard screw fixed
loadbearing applications. stair walls which is Rw50 in Part F5 50 • 1 x 13mm Boral Plasterboard daub fixed • 28mm furring channels at 600mm centres
120.715 FL (-2, -8)
and at the time of printing, is Rw45 in at 500mm centres. • Standard Clips
Opinion • Tontine TSB3 insulation in cavity.
Boral FireLight is ideal for concrete the BCA Queensland Appendix. 169mm
framed office buildings and high-rise
The 1st diagram, giving Rw50 is an • 1 x 13mm Boral Plasterboard screw fixed
home units. 52
162
FireLight is manufactured in 110 and
opinion based on the 2nd test and
similar tests where impact clips and
(-2, -8)
02154-T013
• 1 x 13mm Boral Plasterboard daub fixed
at 500mm centres.
• 28mm furring channels at 600mm centres
• Boral Impact Clips^ Wall Cross
• Tontine TSB3 insulation in cavity.
110
390
140mm thicknesses and in a range of standard clips were compared on the
same wall. The standard clips are much
181mm

section Icon
size formats to suit fire and/or acoustic
12.162.01 FL wall construction in brick and block
more economical than impact clips. 59
(-2, -7)
02154-T014
at 500mm centres.
over 16mm
• 28mm furring channels at 600mm centres
• Boral Impact Clips^
and Overall
coursing. The 3rd test complies with BCA, Part
Please refer to the appropriate

F5 requirements of Rw + ctr > 50, for
197mm • Tontine TSB3 insulation in cavity.
System
unit-to-unit walls between wet areas 57
product pages in Book 2 for additional
information regarding past sizes etc.
or dry-to-dry (no impact required). (-2, -7)
02154-T009
at 500mm centres.
• 1 x 13mm Boral Plasterboard
• 51mm studs 10mm* clear of masonry
Thickness
This system, with the impact clip,
190 200mm
also complies with the current BCA
Availability 390
FIRE DESIGN CONSIDERATIONS
FireLight is a fire tested lightweight
Queensland Appendix requirement for 56 • 1 x 10mm Boral Plasterboard daub fixed
wet-to-dry walls. (-1, -6) • 51mm studs 10mm* clear of masonry
information 140
15.709 FL
(made to order)
concrete block which is unique to
Boral, and provides excellent fire The 4th and 5th tests comply with
02154-T010
at 500mm centres.
194mm
for your rating characteristics. Please refer to

the fire performance characteristics in
BCA, Part F5 requirements of Rw + ctr
> 50, for unit-to-unit walls requiring
* 20mm clearspace required for impact rating outside Queensland
^ Impact rated in Queensland (2007)

region/state the specification table. an impact rating (a wall separating
a wet area of one unit from a dry Impact rated in NSW, Vic, SA and Qld
area in another unit). This system
easily complies with the current BCA
Queensland Appendix requirement for
Availability all unit-to-unit walls (Rw 45 and 50).
• Lead time 0-2 weeks.
Specifications
Maximum Slenderness Ratio (Srf) Rw (Estimate or *Tested) Rw+Ctr
Unit Nº Nº Insulation (minutes) With Lining System
Product ƒ ’ uc Wt per per FRL (minutes) { | } ~ for
Code TxLxH (mm) MPa kg m2 Pallet 60 90 120 180 240 IMPACT
120.715 FL 110x230x76 3 2.6 48.5 400 29.0 26.9 24.9 22.2 20.3 47 52 58 56 62 50
120
12.162.01 FL 110x390x162 3 7.1 14.6 150 29.0 26.9 24.9 22.2 20.3 47 52 58 56 62 50
120
15.709 FL 140x190x390 3 11.6 12.5 150 29.0 26.9 24.9 22.2 20.3 47 52 58 56 62 50
180
{ | } ~ Refer to Lining Systems on Page E3.

Impact = Complies with BCA requirement for Impact Sound Resistance.
Acoustic Acoustic Test Lining, Framing and

Performance Result (Rw) and Insulation Description for
Fire Performance Impact Isolation each side of the wall
Data Data
Information (IIC)
Product
Specifications
PAGE
BOOK
1 E3
When information is provided in the table, it is tabulated,
Acoustic Systems Data
under the System Headings of , , , ,  and .
Acoustic performance information for six of the most popular
The following Table details the wall lining and insulation
wall lining systems may be provided within the Product
information for these six systems, and provides thickness
Specification Tables on the following product pages.
information to assist wall thickness calculation.
Alternatively, you may be referred to more detailed test
Acoustic performance estimates have been calculated by
information and alternative lining systems.
Wilkinson Murray (Acoustic Consultants).
LINING BORAL MASONRY

SYSTEM WALL LINING BRICK OR BLOCK WALL LINING
Refer to
As per product pages
product pages
 • 13mm Render Masonry

Thickness
+26mm
• 13mm Render
 • 1 x 13mm Boral Plasterboard daub fixed Masonry

Thickness
+32mm

• 28mm furring channel at 600mm centres
 • 1 x 13mm Boral Plasterboard daub fixed Masonry
Thickness
+59mm
•
•
Standard Clips at 1200mm centres
Tontine TSB3 insulation in cavity

Masonry or 1 x 6mm Villaboard™ screw fixed over
Thickness

+84mm
• 1 x 13mm Boral Plasterboard daub fixed or • 28mm furring channel at 600mm centres
+77mm
• Boral Impact Clips at 1200mm centres
• Tontine TSB3 insulation in cavity
• 1 x 13mm Boral Plasterboard screw fixed • 1 x 13mm Boral Plasterboard screw fixed
• 28mm furring channel at 600mm centres • 28mm furring channel at 600mm centres
 •
•
Standard Clips at 1200mm centres
Masonry
Thickness
+98mm
•
•
Boral Impact Clips at 1200mm centres
• 1 x 13mm Boral Plasterboard screw fixed • 1 x 13mm Boral Plasterboard screw fixed

• 28mm furring channel at 600mm centres • 64mm steel studs at 600mm centres
• Standard Clips at 1200mm centres Masonry • 20mm gap required for impact rating
Thickness
• Tontine TSB2 insulation in cavity +140mm
• Tontine TSB5 insulation in cavity
Acousti
c Estim
ate s with
these L Ratio (Srf) Rw (Estimate or *Tested) Rw+Ctr
ining System utes) With Lining System
s
) { | } ~ for
PAGE
BOOK
1 E4
FireLight Brick (FL)

80 240 IMPACT
INTRODUCTION ACOUSTIC DESIGN
230
76
Boral FireLight bricks are manufactured
from a low-density material which
provides high fire rated performance
CONSIDERATIONS
The first 2 tests on the following
page E5 comply with the BCA:2005
2.2 20.3 47 52 58 56 62 50
110
120.715 FL
and minimum weight for non-
loadbearing applications.
Boral FireLight is ideal for concrete

requirements for unit-to-corridor or
stair walls which is Rw50 in Part F5
and at the time of printing, is Rw45 in
the BCA Queensland Appendix.
Read off
home units.
The 1st diagram, giving Rw50 is an
opinion based on the 2nd test and Acoustic
2.2 20.3 47 52 58 56 62 50
162
FireLight is manufactured in 110 and similar tests where impact clips and
110
12.162.01 FL
390
140mm thicknesses and in a range of
size formats to suit fire and/or acoustic
wall construction in brick and block
standard clips were compared on the
same wall. The standard clips are much
more economical than impact clips. Performance

product pages in Book 2 for additional
unit-to-unit walls between wet areas
or dry-to-dry (no impact required).
(Rw) from
information regarding past sizes etc.
intersection
This system, with the impact clip,
190
140
390
also complies with the current BCA
wet-to-dry walls.
2.2 20.3 47 52 58 56 62 50
15.709 FL
(made to order) Boral, and provides excellent fire
rating characteristics. Please refer to
the fire performance characteristics in
The 4th and 5th tests comply with
BCA, Part F5 requirements of Rw + ctr
> 50, for unit-to-unit walls requiring
of product
row and
the specification table. an impact rating (a wall separating
a wet area of one unit from a dry
Availability
all unit-to-unit walls (Rw 45 and 50).
lining system
Specifications
Unit Nº Nº
Insulation (minutes) With Lining System
column
Product ƒ’ uc Wt per per FRL (minutes) { | } ~ for
Code TxLxH (mm) MPa kg m2 Pallet 60 90 120 180 240 IMPACT
120.715 FL 110x230x76 3 2.6 48.5 400 29.0 26.9 24.9 22.2 20.3 47 52 58 56 62 50
120
12.162.01 FL 110x390x162 3 7.1 14.6 150 29.0 26.9 24.9 22.2 20.3 47 52 58 56 62 50
120
15.709 FL 140x190x390 3 11.6 12.5 150 29.0 26.9 24.9 22.2 20.3 47 52 58 56 62 50
180
{ | } ~ Refer to Lining Systems on Page E3.

Impact = Complies with BCA requirement for Impact Sound Resistance.
PAGE
BOOK 1 E4
FireLight Brick (FL)

INTRODUCTION ACOUSTIC DESIGN
Boral FireLight bricks are manufactured CONSIDERATIONS
76
from a low-density material which The first 2 tests on the following
230 provides high fire rated performance page E5 comply with the BCA:2005
110
and minimum weight for non- requirements for unit-to-corridor or
loadbearing applications. stair walls which is Rw50 in Part F5
120.715 FL
and at the time of printing, is Rw45 in
Boral FireLight is ideal for concrete the BCA Queensland Appendix.
The 1st diagram, giving Rw50 is an
home units.
opinion based on the 2nd test and
162
FireLight is manufactured in 110 and similar tests where impact clips and
140mm thicknesses and in a range of standard clips were compared on the
390
110 size formats to suit fire and/or acoustic same wall. The standard clips are much
more economical than impact clips.
12.162.01 FL wall construction in brick and block
unit-to-unit walls between wet areas
product pages in Book 2 for additional or dry-to-dry (no impact required).
information regarding past sizes etc. This system, with the impact clip,
190
FIRE DESIGN CONSIDERATIONS also complies with the current BCA
390
140 wet-to-dry walls.
15.709 FL
(made to order) Boral, and provides excellent fire The 4th and 5th tests comply with
rating characteristics. Please refer to BCA, Part F5 requirements of Rw + ctr
the fire performance characteristics in > 50, for unit-to-unit walls requiring
the specification table. an impact rating (a wall separating
a wet area of one unit from a dry
Availability all unit-to-unit walls (Rw 45 and 50).
Specifications
Unit Nº Nº Insulation (minutes) With Lining System
Product ƒ ’ uc Wt per per FRL (minutes)      for 
Code TxLxH (mm) MPa kg m2 Pallet 60 90 120 180 240 IMPACT 
120.715 FL 110x230x76 3 2.6 48.5 400 29.0 26.9 24.9 22.2 20.3 47 52 58 56 62 50
120
12.162.01 FL110x390x162 3 7.1 14.6 150 29.0 26.9 24.9 22.2 20.3 47 52 58 56 62 50
120
15.709 FL 140x190x390 3 11.6 12.5 150 29.0 26.9 24.9 22.2 20.3 47 52 58 56 62 50
180
      Refer to Lining Systems on Page E3.

Impact = Complies with BCA requirement for Impact Sound Resistance.
PAGE
BOOK
1 E5
Acoustic Systems - 110mm Rippa FireLight Block

ACOUSTIC
110mm
RATING
WALL LINING RIPPA FIRELIGHT WALL LINING
Rw (c, ctr)
BLOCK (FL)
Boral Test Nº

50 • 1 x 13mm Boral Plasterboard daub fixed • 28mm furring channels at 600mm centres
(-2, -8) at 500mm centres. • Standard Clips
Opinion • Tontine TSB3 insulation in cavity.
169mm

52 • 1 x 13mm Boral Plasterboard daub fixed • 28mm furring channels at 600mm centres
(-2, -8) at 500mm centres. • Boral Impact Clips^
02154-T013 • Tontine TSB3 insulation in cavity.
181mm

59 • 1 x 13mm Boral Plasterboard daub fixed
over 16mm
(-2, -7) • 28mm furring channels at 600mm centres
at 500mm centres.
02154-T014 • Boral Impact Clips^

(-2, -7) • 51mm studs 10mm* clear of masonry
at 500mm centres.
02154-T009 • Tontine TSB5 insulation in cavity∞.
200mm

(-1, -6) • 51mm studs 10mm* clear of masonry
at 500mm centres.
02154-T010 • Tontine TSB5 insulation in cavity∞.
194mm
* 20mm clearspace required for impact rating outside Queensland
^ Impact rated in Queensland (2007)
∞ Impact rated in NSW, Vic, SA and Qld

PAGE
BOOK 1 E6
Grey Block Standard and Core Fill

INTRODUCTION performance, and known acoustic ACOUSTIC DESIGN
Boral Grey blocks have been an integral performance values which will satisfy CONSIDERATIONS
part of Australia’s construction industry many common BCA requirements. Standard Grey being of a relatively
for more than 3 decades, and continue dense material provides inherent
Standard Grey blocks are manufactured
to provide cost effective, practical sound resistance. This performance
in 90, 110, 140, 190, and 290mm
and engineered solutions for the full may be sufficient for many applications
thicknesses to suit most wall
spectrum of construction applications. without enhancement. Where higher
construction applications.
performance is required, the addition
All ‘Standard Grey Block’ and ‘Core Fill
FIRE DESIGN CONSIDERATIONS of render is effective while board-lining
Block’ products are manufactured to AS/
The fire resistance performance of systems using furring systems and Boral
NZS4455 ‘Masonry units and segmental
Boral concrete blocks is determined Impact Clips or plasterboard on light-
pavers 1997’ using modern high pressure
as per AS3700 : 2001 Section 6. weight studs and polyester insulation
moulding techniques and controlled
These products can provide adequate materials can provide high acoustic
dense-weight concrete materials.
fire performance for many common insulation. Please refer to acoustic test/
All Standard Grey blocks have inherent fire rated wall applications. Please estimate data for appropriate systems.
fire and acoustic performance properties also refer to fire performance graphs
FRACTIONAL SIZE BLOCKS
which automatically allocates them and design information in Sections
Boral Masonry Queensland manufactures
‘deemed-to-satisfy’ values for fire A and B of this guide for additional
an extensive range of special purpose blocks
selection information.
Availability
and fractional size blocks to complement
• Please refer to the Boral Masonry Blocks and Bricks Guide (MDG Book 2) for detailed availability information on these products. the products detailed on this page.
Specifications
Unit Insulation (minutes) With Lining System
Product ƒ ’ uc Mass FRL (minutes)       for 
Code Type MPa kg 60 90 120 180 240 Impact 
10.01 Hollow 15 11.1 18.0 17.0 16.0 15.5 15.0 46 46 50 57 55 60
10.31 Solid 15 14.5 18.0 17.0 16.0 15.5 15.0 47 47 51 58 56 61
60 
12.709 Hollow 15 13.3 18.0 17.0 16.0 15.5 15.0 46 46 50 57 55 60
90 
15.01 Hollow 15 13.0 18.0 17.0 16.0 15.5 15.0 47 47 51 58 56 61
(no grout fill) 60
15.709 Reduced Core 15 17.8 18.0 17.0 16.0 15.5 15.0 50 48* 54 61* 61* 64 51
120 
20.01^ Hollow 15 16.0 18.0 17.0 16.0 15.5 15.0 48 48 52 59 57 62 50
90^
15.48 Reinforced 15 12.5 36.0 36.0 36.0 36.0 36.0 53 51 56 63 61 66 52
and Grout Filled 120 
20.48 Reinforced 15 14.0 36.0 36.0 36.0 36.0 36.0 56 55 60 67 65 69 54
and Grout Filled 240 Rw + Ctr = 50
30.48 Reinforced 15 18.1 36.0 36.0 36.0 36.0 36.0 59 59 64 71 69 72 56

and Grout Filled 240
      Refer to Lining Systems on Page E3. Impact = Complies with BCA requirement for Impact Sound Resistance nationally,
 and  comply in Queensland.  Additional Insulation with  Lining System (10mm render both sides).
^ Note that 20.01 block sold in Northern Queensland are rated at 60 minutes for insulation and achieve 90 minutes with render on both faces.
PAGE
BOOK
1 E7
Acoustic Systems - 140mm Grey Block Reduced Core

ACOUSTIC
140mm
RATING
WALL LINING GREY BLOCK WALL LINING
Rw (c, ctr)
REDUCED CORE
Boral Test Nº
48
(-2, -7) • Bare wall. • Bare wall, 140mm thick, reduced cores.
271
140mm
49 • 1 x 10mm Boral Plasterboard on cornice

(-2, -6) • Bare wall.
cement daub fixed at 500mm centres.
274
153mm
48 • 1 x 10mm Boral Plasterboard on cornice • 1 x 10mm Boral Plasterboard on cornice

(-1, -7) cement daub fixed at 500mm centres. cement daubs fixed at 500mm centres.
272
166mm
• 1 x 10mm Boral Plasterboard screw
fixed at 500mm centres
50 • 1 x 10mm Boral Plasterboard on cornice
• 28mm furring channels
(opinion) cement daub fixed at 500mm centres.
• Beta-Fix Clips with 42mm clear of
Masonry.
205mm
• 1 x 10mm Boral Plasterboard screw
56 fixed at 500mm centres
• 1 x 10mm Boral Plasterboard on cornice • 28mm furring channels
(-3, -9) cement daub fixed at 500mm centres.
275 • Boral Impact Clips*
• 1 x 10mm Boral Plasterboard screw • 1 x 10mm Boral Plasterboard screw

61 fixed at 500mm centres
(-5, -12) fixed at 500mm centres
• 28mm furring channel • 28mm furring channels
Bassett • Boral Impact Clips*
4998-01 • Standard Clips
• Tontine TSB3 insulation in cavity. 232mm • Tontine TSB3 insulation in cavity.
* Impact rated in Queensland (2007)
See Lining System  for NSW

PAGE
BOOK 1 E8
Grey Block Standard and Core Fill

Series 100 Series 120
Full Height Full Height Solid Full Height
190 190 190
390 390 390

90 90 110
10.01 10.31 12.709

Full Full Solid Full
Series 150
Full Height Core Fill Block
190 190 190
390 390 390

140 140 140
15.01 15.48 15.709

Full ‘H’ Block Reduced Core
Series 200
Full Height Core Fill Block
190 190
390 390
190 190
20.01 20.48
Full ‘H’ Block
Series 300
Core Fill Block
190
290 390
30.48
‘H’ Block
PAGE
BOOK
1 E9
Concrete-Basalt (B): Rippa and Speed-E Brick

INTRODUCTION Please refer to the fire performance The 2nd diagram, giving Rw50,
Boral Masonry Queensland Concrete- characteristics in the specifications table. complies with the Queensland
Basalt (B): Rippa and Speed-E Bricks have Appendix minimum requirement for
ACOUSTIC DESIGN
an ƒ’uc of 15MPa, making them excellent inter-tenancy walls that separate a
CONSIDERATIONS
for loadbearing or non-loadbearing wet area from a habitable room. The
The mass of the Concrete-Basalt
applications. They provide good fire requirement is much higher in the
material is 7% heavier than Clay
performance and acoustic performance BCA, Part F5 which applies outside
therefore walls from Concrete-Basalt
characteristics where minimising weight Queensland and the impact rating is
products perform slightly better.
is not a primary consideration. to be “of discontinuous construction”
Its texture is coarser and its porosity is such as an independent stud or cavity
Concrete-Basalt Bricks are a
higher than Clay, so it performs better wall without ties.
popular choice for walls in domestic
with plasterboard, particularly when
applications and high-rise units The 3rd test shows a 3dB improvement
daub-fixed.
where they are commonly used with over the 2nd test though the addition
a rendered finish. They are also Please refer to acoustic test/estimate data of insulation between the furring
commonly used for loadbearing walls in this guide for appropriate systems. channels. This is worth the small extra
in 3-storey unit construction with cost as it can compensate for noise
CONCRETE BASALT (B):
plasterboard or render finish. leaks through power points etc.
RIPPA BRICK
BORAL CONCRETE-BASALT The first test on the following page The 4th test complies with the more
BRICKS E10 complies with the BCA:2005 stringent BCA, Part F5 requirements
The Boral Speed-E Brick is 230mm long Queensland Appendix requirements of Rw + ctr ≥ 50, for unit-to-unit walls
by 162mm high, equal to 2 courses of for unit-to-corridor, unit-to-stair walls between wet areas or between dry areas
standard brick with mortar, making and inter-tenancy walls that separate (no impact required). This system,
them a highly efficient and cost- two wet areas or two dry areas. This with the impact clip, also complies
effective construction component. is Rw45 at the time of printing, but is with the current BCA Queensland
much higher in the BCA, Part F5 which Appendix requirement for wet-to-dry
applies outside Queensland. walls. Outside Queensland, the impact
These products are manufactured from
clips and furring channels would be
Concrete-Basalt which provides good
replaced with an independent stud
fire performance characteristics in
system or a cavity wall without ties.
loadbearing conditions.
Availability
• No minimum order quantities apply.
Specifications
Unit Nº Insulation (minutes) With Lining System
Product ƒ ’ uc mass per FRL (minutes)       for 
Code TxLxH (mm) MPa kg m2 60 90 120 180 240   
Impact
120.715 B 110x230x76 10 4.0 48.5 22.5 21.0 20.0 18.0 17.0 48 46 51 56 55 62 50
Standard Solid 90 
120.796 B 110x230x162 10 7.1 24.3 22.5 21.0 20.0 18.0 17.0 46 46 51 55 54 61
Speed-E Cored 90 
120.162.01 B 110x390x162 10 10.4 14.6 22.5 21.0 20.0 18.0 17.0 45 45* 51 55* 54 61
Rippa Block 90 
      Refer to Lining Systems on Page E3. Impact = Complies with BCA requirement for Impact Sound Resistance.
 Additional Insulation with  Lining System (10mm render both sides).
PAGE
BOOK 1 E10
Concrete-Basalt (B): Rippa and Speed-E Brick
162
76 162
230 230 390

110 110 110
Brick 120.796 12.162.01

(1 in every 7 bricks supplied is Speed-E Brick (B) Cored Rippa Brick
solid for corner applications)
Acoustic Systems - Rippa and Speed-E Brick

ACOUSTIC
RATING RIPPA and
WALL LINING WALL LINING
Rw (c, ctr) SPEED-E BRICK
Boral Test Nº
45
(-2, -5) • 1 x 10mm Boral Plasterboard daub fixed. • 1 x 10mm Boral Plasterboard daub fixed.
RMIT 01-070
136mm
50 • 1 x 10mm Boral Plasterboard screw fixed

(-2, -7) • 1 x 10mm Boral Plasterboard daub fixed. • 28mm furring channels
RMIT 01-066 • Boral Impact Clips*.
175mm

53 • 28mm furring channel
(-2, -6) • 1 x 10mm Boral Plasterboard daub fixed.
• Boral Impact Clips*
RMIT 01-062
• 60mm insulation in cavity.
175mm

55
• 1 x 10mm Boral Plasterboard daub fixed. • 28mm furring channels
(-1, -5)
• Boral Impact Clips*
RMIT 01-065
• 60mm insulation in cavity.
185mm
45 • 1 x 13mm Render (deemed to comply: • 1 x 13mm Render (deemed to comply:

(per BCA) BCA, Specification F5.2.2). BCA, Specification F5.2.2).
D.T.S.
136mm
* Impact rated in Queensland (2007)
See Lining System  for NSW

PAGE
BOOK
1 E11
NOTES
Customer support
Queensland
1. Stock colours Colours other than stock colours are made ‘to’ order.
Not all colours displayed in this brochure are available in all states.
(Contact your nearest Boral Masonry office for your area’s stock colours.)
A surcharge applies to orders less than the set minimum quantity.
2. Brochure colours The printed colours in this Masonry Design Guide are
only a guide. Please ask to see a sample of your colour/texture before
specifying or ordering.
3. Colour and texture variation The supply of raw materials can vary
over time. In addition, variation can occur between product types and
production batches.
4. We reserve the right to change the details in this publication without

notice.
5. For a full set of Terms and Conditions of Sale please contact your
nearest Boral Masonry sales office.
© Boral Masonry - all rights reserved 2007.
Orders, product samples and sales enquiries Other regional sales offices
QLD NQ VIC ACT

62 Industrial Ave, Cairns Level 1 16 Whyalla Street,
Wacol, 8 Palmer Street, 17-47 Turner Street, Fyshwick,
QLD 4076 Portsmith, Port Melbourne, ACT 2609
Tel (07) 3271 9292 QLD 4870 VIC 3207 Tel (02) 6239 1029
Fax (07) 3271 1581 Tel (07) 4035 1888 Tel (03) 9681 9722 Fax (02) 6280 6262
Fax (07) 4035 1208 Fax (03) 9681 9766 SA
Townsville NSW
Main North Road,
360 Bayswater Road,
Clunies Ross Street, Pooraka,
Garbutt,
Prospect, SA 5095
QLD 4814
NSW 2148 Tel (08) 8262 3529
Tel (07) 4725 6285
Tel (02) 9840 2333 Fax (08) 8260 3011
Fax (07) 4725 6043
Fax (02) 9840 2344
Mackay
David Muir Street,
Slade Point,
QLD 4740
Tel (07) 4955 1155
Fax (07) 4955 4130
eBC 03218 Feb08
For technical assistance:

Revised 150208
Call Specifier Line on 1300 360 255

Visit www.boral.com.au/mdg

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BORAL MASONRY

Build something great™

Masonry Design Guide

www.boral.com.au/masonry Updated February 2008

Fast Find Product and Application Guide . . . . . . . . . . . . . . . A3 About This Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6

Robustness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2 Energy Efficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7

Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5 Reinforced Masonry Lintels . . . . . . . . . . . . . . . . . . . . . . . . B10

Bending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5 Design of Core Filled and Steel Reinforced

Designing Masonry Walls for Acoustic Performance On-site . . . . . . . . . . . . . . . . . . . . . . . D5

E Fire and Acoustic Systems

Standard Grey Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E6

Concrete-Basalt Bricks (B): Rippa and Speed-E Brick . . . . . . E8

A2 February 2008 | BORAL MASONRY DESIGN GUIDE

BORAL MASONRY DESIGN GUIDE | February 2008 A3

Boral Engineered Blocks

• Standard Grey Blocks

A4 February 2008 | BORAL MASONRY DESIGN GUIDE

Boral Engineered Bricks

BORAL MASONRY DESIGN GUIDE | February 2008 A5

Boral Masonry This guide has been prepared as a comprehensive Boral

Section D — Acoustic Design

Section E — Fire and Acoustic Systems

A6 February 2008 | BORAL MASONRY DESIGN GUIDE

Masonry Design Guide

Legend to Symbols used in Robustness Calculations:

= in cavity-wall construction, the minimum thickness

B2 February 2008 | BORAL MASONRY DESIGN GUIDE

Formulae and Explanation Worked Examples

Isolated Piers Aim: To determine the Maximum Wall

Formulae and Explanation Worked Examples

Wall with Free Ends Aim: To determine the Maximum Height

Example 3: If wall is laterally restrained along its top

BORAL MASONRY DESIGN GUIDE | February 2008 B3

Formulae and Explanation Worked Examples

Formulae and Explanation Worked Examples

By reworking formula (4), the maximum wall height is:

NOTE: Control joints, and openings greater than one fifth

B4 February 2008 | BORAL MASONRY DESIGN GUIDE

Table B1 (Extract from AS3700 : Table 4.2)

Concrete Slab A solid brick will give a lower compressive strength if

reinforcement areas, multiplied by the aspect ratio, minus the standard

36 48 ƒ’m is the square root of ƒ’uc, multiplied by Km (a mortar

BORAL MASONRY DESIGN GUIDE | February 2008 B5

environment ideal for bacteria, which feeds lichens and

Exposure Grade (EXP) External Control Joints

B6 February 2008 | BORAL MASONRY DESIGN GUIDE

140mm concrete blocks with a reinforced bond beam

BORAL MASONRY DESIGN GUIDE | February 2008 B7

R-Values for Typical Wall Construction

External wall construction description Item Item Description R-Value

(A) Masonry veneer — 25mm to 50mm cavity space, 10mm

3. Cavity air space (115 to 140mm, made up of

3 5. Indoor air film (still air) 0.12

(B) Cavity masonry — 20mm to 50mm cavity space, 10mm

Denseweight hollow concrete block with internal plaster

Concrete masonry R-values without air films added (BCA:2007,

B8 February 2008 | BORAL MASONRY DESIGN GUIDE

Wall mass  220kg/m2 is defined (in BCA, Volume 2,

Single-Leaf Walls: If both storeys have walls of lightweight construction,

Where insulation is on the external face of the masonry,

For 2 storey dwellings in Zone 1, 2 and 3, insulation is not

Block Veneer Walls:

The R-values of 90mm block veneer and cavity block walls

Wall mass 220kg/m2 is defined (in BCA, Volume 2,