Bricks & Pavers Technical Manual - Boral

Bricks & Pavers Technical Manual 

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ADV05000 08/04


Contents 1 of 2 

1.0 Bricks 

1.1 Brick Properties 

1.101 Brick Dimensions 

1.102 Brick Strength 

1.103 Water Absorption 

1.104 Durability 

1.2 Brick Masonry Design 

1.201 Robustness 

1.205 Masonry Strength 

1.206 Durability of Masonry 

1.208 Brick Ties 

1.209 Movement in Masonry Walls 

1.211 Thermal Properties 

1.213 Masonry Design for Fire Resistance 

1.214 Masonry Design for Structural Adequacy 

FRL 

1.222 Masonry Design for Integrity FRL 

1.222 Masonry Design for Insulation FRL 

1.222 Effect of Recesses for Services on FRL’s 

1.223 Effect of Chases on Fire Rated Masonry 

1.224 Options for Increasing FRL’s 

1.225 Acoustic Performance Rating 

1.3 Brick Masonry Construction 

1.301 Mortar 

1.304 Joint Types 

1.305 Joint Sizes 

1.305 Weepholes 

1.306 Brick Estimator 

1.307 Brick Bonds 

1.310 Brick Coursing Height 

1.4 Property Tables 

1.105 Moisture Expansion 

1.105 Efflorescence 

1.105 Pitting due to Lime 

1.227 Weighted Sound Reduction Index (Rw) 

1.227 Impact Sound Resistance 

1.227 BCA Deemed to Satisfy Walls 

1.230 Solid v Cavity Walls 

1.230 Brick Walls with Render 

1.230 Brick Walls with Plasterboard 

1.231 Points to Consider When Designing 

Walls for Acoustic Performance 

1.231 Acoustic Performance On-Site 

1.232 Perimeter Acoustical Sealing 

1.232 Doors 

1.233 Lightweight Panels Above Doors 

1.233 Air Paths Through Gaps, Cracks or Holes 

1.233 Appliances 

1.233 Electrical Outlets & Service Pipes 

1.311 Brick Gauge 

1.313 Blending 

1.313 Brick Storage 

1.314 Laying Practices 

1.315 Control Joints 

1.315 Damp Courses and Flashing 

1.316 Cleaning of Clay Masonry 

ADV05004 (1/2) 10/08


Contents 2 of 2 

2.0 Pavers 

3.0 Face Brick Range 

2.1 Paver Properties 

2.101 Paver Dimensions 

2.102 Paving Strength 

2.103 Durability 

2.103 Slip Resistance 

2.104 Abrasion Resistance 

2.2 Pavement Design 

2.201 Pavement Types 

2.203 Description of Layers & Basic 

Engineering Design Requirements 

2.203 Subgrade 

2.204 Base Course 

2.205 Bedding Course 

2.206 Surface Course 

2.3 Pavement Construction 

2.301 Paver Estimator 

2.301 Subgrade Preparation 

2.302 Base course Preparation for Flexible 

Pavements 

2.302 Edge Restraints for Flexible Pavements 

2.303 Bedding Course for Flexible Pavements 

2.305 Paver Storage 

2.4 Property Tables 

4.0 Engineered Utility Brick Range 

5.0 Paver Range 

6.0 Projects In View 

7.0 Reference Material 

Product Data Sheets 

2.104 Moisture Expansion 

2.104 Efflorescence 

2.105 Pitting due to Lime 

2.105 Cold Water Absorption 

2.207 Edge Restraints 

2.209 Drainage 

2.210 Paver Laying Patterns 

2.212 Joints Between Pavers 

2.213 Tolerance on Course Levels 

2.213 Crossfalls 

2.214 Steep Gradients 

2.305 Blending 

2.306 Laying Practices 

2.311 Sand Filled Joints 

2.311 Mortar Filled Joints 

2.311 Compaction 

2.312 Trafficking After Construction 

2.312 Cleaning 

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ADV05004 (2/2) 10/08

1 Bricks 

1. Bricks

1.1 Brick Properties


Section 1.1 Brick Properties 1.101 

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

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

designer or builder. 

Brick Dimensions 

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

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

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

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

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

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

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

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

properties. 

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

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

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

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

• For standard bricks, Dimensional Category DW1 means the height and width will differ by less than plus or 

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

• For standard bricks, Dimensional Category DW2 means the height and width will differ by less than plus or 

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

• Dimensional Category, DW0 means there are no requirements. This is usually reserved for non-standard 

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

for aesthetic reasons. ■ 

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Brick Strength 

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

Characteristic Unconfined Compressive Strength (f’uc) 

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

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

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

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

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

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

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

Unconfined Compressive Strength 

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

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

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

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

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

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

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

Unconfined Compressive Strength. 

Compressive Strength of Bricks 

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

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

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

Strength. ■ 

ADV03744



Water Absorption 

Cold Water Absorption 

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

relationship between water absorption and the water-tightness of walls. The results of water absorption tests 

are used by the brick manufacturer for quality assurance. 

Initial Rate of Absorption 

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

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

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

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

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

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

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

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

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

rate. In either case there will be poor bond. 

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

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

critical. ■ 

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Durability 

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

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

water leaves the solution super-saturated so salt crystals begin to form. The salt crystals grow in the pores just 

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

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

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

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

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

• Protected Grade (PRO) 

Suitable for use in elements above the damp-proof course in non-marine exterior environments. Elements 

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

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

• General Purpose Grade (GP) 

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

aggressive soils and environments (see AS3700 Appendix E). General purpose grade bricks can also be used 

in PRO applications. 

• Exposure Grade (EXP) 

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

surf coast or up to 100 metres from a non-surf coast or in contact with aggressive soils and environments. 

The distances are specified from mean high water mark. Exposure grade bricks can also be used in PRO and 

GP applications. 

Boral bricks are classified as either EXP or GP. ■ 

ADV03746



Moisture Expansion 

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

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

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

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

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

Efflorescence 

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

is the raw materials used in the brick production process. 

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

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

construction process (eg. Mortar). 

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

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

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

Boral bricks have a nil to slight efflorescence. ■ 

Pitting due to Lime 

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

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

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

a generally circular pit. 

Boral Bricks rarely show lime pitting. ■ 

ADV03747

1.2 Brick Masonry Design


Section 1.2. Brick Masonry Design 1.201 

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

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

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

engineer. 

Robustness 

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

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

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

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

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

Table 1. Maximum Height of Isolated Piers 

Pier Thickness (mm) Maximum Height (m) 

230 x 230 3.105 

350 x 350 4.725 

Table 2. Maximum Height of Walls with Free Ends 

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

Maximum Wall Length (m) 

Maximum Wall Height (m) 

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

90 0.54 2.43 3.24 

110 0.66 2.97 3.96 

150 0.90 4.05 5.40 

230 1.38 6.21 8.28 

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

90 1.08 3.24 

110 1.32 3.96 

150 1.80 5.40 

230 2.76 8.28 

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

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

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

Where wall lengths exceed those in Table 3 above, AS 3700 Equation 4.6.2 (4) must be used to determine the maximum 

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

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

ADV03749



Robustness (continued) 

How to Use the Boral Robustness Graphs 

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

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

Laterally supported one end 

and top laterally supported 

by other than concrete slab 

8 

7 

6 

5 

4 

3 

2 

1 

0 

1 2 3 4 5 6 7 8 

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

R 

S 

R 

F 

230mm 

150mm 

110x110mm 

90x90mm 

110mm 

90mm 

1. Select the graph for the chosen wall restraint 

(support) criteria. In this example there is support 

on one side and the top is supported by other 

than a concrete slab. Typically this would be a 

wall supporting roof frames, joined into another 

wall at one end and with a door at the other 

end. 

2. Plot the intersection of the design Wall Height 

and the Wall Length on the graph. (For this 

example 3 m height x 5 m length). 

3. The lines ABOVE the intersection point indicate 

wall thickness that are acceptable. In this 

example, the intersection point is just below the 

line for 110 mm bricks. Therefore a single leaf of 

110 mm bricks would be suitable and the most 

economical. 

ADV03750



Robustness Limits 



Laterally supported both ends 


by a concrete slab 

8 

7 

6 

5 

4 

3 

2 

1 

0 

1 2 3 4 5 6 7 8 


Laterally supported 

both ends and 

top unsupported 

8 

7 

6 

5 

4 

3 

2 

1 

0 

1 2 3 4 5 6 7 8 


R 

R 

R 

R 

F 

R 

R 

150mm 

110x110mm 

90x90mm 

110mm 

R 

90mm 

150mm 

110x110mm 

90x90mm 

110mm 

90mm 



Laterally supported both ends 


by other than concrete slab 

8 

7 

6 

5 

4 

3 

2 

1 

0 

1 2 3 4 5 6 7 8 



one end and 


8 

7 

6 

5 

4 

3 

2 

1 

0 

R 

S 

R 

R 

150mm 

110x110mm 

90x90mm 

110mm 

90mm 

230mm 

150mm 

110x110mm 

90x90mm 

110mm 

90mm 

1 2 3 4 5 6 7 8 


R 

F 

R 

F 

ADV03751


Section 1.2. Brick Masonry Design 

Robustness Limits 




by other than a concrete slab 

8 

7 

6 

5 

4 

3 

2 

1 

0 

1 2 3 4 5 6 7 8 


R 

S 

R 

F 

230mm 

150mm 

110x110mm 

90x90mm 

110mm 

90mm 




by a concrete slab 

8 

7 

6 

5 

4 

3 

2 

1 

0 

1 2 3 4 5 6 7 8 


R 

1.204 

R 

R 

F 

150mm 

110x110mm 

90x90mm 

110mm 

90mm 

ADV03752



Masonry Strength 

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

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

Characteristic Compressive Strength of Masonry – f’m 

f’m = km kh √f‘uc 

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

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

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

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

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

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

Characteristic Flexural Tensile Strength of Masonry – f’mt 

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

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

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

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

meets the stated values. 

Characteristic Shear Strength of Masonry – f‘ms 

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

course, it is taken to be zero unless testing shows another value. Elsewhere, mortar joints have f’ms values of 

between 0.15 and 0.35 MPa. ■ 

ADV03753



Durability of Masonry 

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

undue maintenance. That is, all masonry materials, including bricks, mortar and all built-in components, must be 

sufficiently durable for the exposure classification of the site (see AS3700 Appendix E). Masonry designed to 

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

defines the durability requirements for bricks, built-in components and mortar in different environments. 

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

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

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

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

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

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

Boral bricks graded ‘General Purpose’ (GP) are suitable for use in all walls, excluding external walls in severe 

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

Boral bricks graded ‘Exposure Grade’ (EXP) are suitable for use in all walls including external walls exposed to 

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

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

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

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

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

responsibility to specify the appropriate durability grade of bricks, mortar and built-in components and it is the 

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

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

of each site. t 

ADV03754



Durability of Masonry (continued) 

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

resistance category. 

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

AS3700 Table 10.1. 

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

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

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

incorporate a drip groove to prevent the run-off from the slab running down the brickwork. A damp proof course 

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

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

over time. 

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

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

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

ADV03755



Brick Ties 

In brick veneer construction, ties are used to pass all the lateral out-of-plane loads and forces (such as from 

wind) to the structural backing. In cavity brick construction ties either pass the lateral out-of-plane loads and 

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

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

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

veneer construction and Clause 12.3.3.2 for cavity brick construction. 

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

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

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

requiring exposure grade materials or very long life. Galvanised steel ties are those most commonly used. 

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

were deficient. Problems found included: 

• galvanised ties rusted through; 

• ties only built into one leaf during construction; 

• loose ties; 

• absent ties; and, 

• incorrect duty ties used. 

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

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

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

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

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

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

difference is trivial. ■ 

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Movement in Masonry Walls 

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

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

the same. 

Expansion Joints 

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

designed to suit the magnitude of the movement. 

Clay products expand permanently over time. This is the opposite of cement-based products, which permanently 

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

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

as the concrete frame shrinks. 

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

0.008 mm/m/°C is usually recommended. Expansion and contraction from wetting and drying of clay bricks is 

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

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

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

constructed, should be 20-25 mm. However, in most buildings articulation joints are used and these are closer 

than required for expansion making separate expansion joints unnecessary. 

Articulation Joints 

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

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

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

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

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

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

ADV03757



Movement in Masonry Walls (continued) 

Control Joints (General) 

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

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

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

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

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

External control joints should be finished with a soft flexible sealant to prevent moisture penetration. 

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

veneer. In internal masonry, control gaps are not usually required, except at re-entrant angles in long walls. 

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

component may be ignored in calculations. Internal control joints can usually be located at a full-height opening 

such as a door or window. 

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

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

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

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

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

to the overall design of the structure. In 

portal frame construction, the control 

joint is positioned at a column so that 

both ends can be tied to the column’s 

flanges. 

The principles of control joint 

construction are illustrated in the 

adjacent figure. ■ 

Articulation joints with 

compressible backing 

and mastic sealant 

Dividing wall with 

articulation joint and 

M F A's at intersection 

with cavity wall 

Brick ties on each side 

of articulation joint 

Articulation 

joint 

ADV03758


Section 1.2. Brick Masonry Design 1.211a 

Thermal Properties 

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

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

purposes and have now added requirements for energy efficiency performance of buildings. ‘Energy efficiency’ 

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

performance is the only aspect impacting on brick masonry construction. 

Australia is divided into 8 climatic zones. (Eastern Sydney and Perth are in Zone 5, Adelaide, Melbourne and 

Western Sydney are in Zone 6, Brisbane is in Zone 2 and Canberra is in Zone 7). The zones and Local Government 

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

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

boundaries between zones are those between council areas. 

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

1. Each sole occupancy unit of a Class 2 building or Class 4 part of a building must achieve not less than 3 stars 

and the average for all of the sole occupancies in the building must be at least 3.5 stars for Zones 1-3 and 

4 stars for Zones 4-8. Energy efficiency of buildings expressed as a ‘Star Rating’ is determined using thermal 

calculation software that complies with the ABCB Protocol for House Energy Rating Software. 

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

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

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

than or equal to that calculated for a reference building. 

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

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

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

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

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

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

for House Energy Rating Software. 

While the BCA sets these minimum requirements, State Governments may adopt these minimums or may opt for 

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

the State adopts. t 

ADV1211A



Thermal Properties (continued) 

Variations to the BCA Requirements in brief are: 

1.211b 

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

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

In the Northern Territory the BCA 2008, Volume 1 Energy Efficiency provisions do not apply. 

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

or a solar water heater system. 

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

occupancies in the building must be at least 5 stars. 

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

In NSW the Energy Efficiency provisions of the BCA do not apply to Class 1 and 2 buildings, Class 4 parts of 

buildings and certain Class 10 buildings. Developments (including additions and alterations) in these classes are 

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

sustainability rating software, which initially incorporated energy and water efficiency. It is a web-based system 

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

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

reductions are on a base developed by the NSW Department of Planning before the scheme came into effect 

and they vary from place to place. The thermal comfort aspects of BASIX can be satisfied by following either the 

‘simplified’, ‘DIY’ or ‘assessor’ routes. The ‘simplified’ is rigid and very conservative. The ‘DIY’ is conservative 

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

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

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

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

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

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

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

space is usually the most cost-effective measure to increase comfort. There is no exact relationship between 

the walls’ performance and the energy ratings. The deemed to satisfy requirements in the BCA or BASIX are 

conservative because they consider the walls in isolation. Designs using only deemed to satisfy solutions will 

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

assessor can provide cheaper building solutions, more than off-setting the cost of their services. t 

ADV1211B




1.212a 

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

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

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

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

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

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

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

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

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

temperature difference across the wall) which is not the case because of the day-night temperature cycle. Cavity 

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

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

Decoding the BCA Deemed to Satisfy provisions 

Volumes 1&2: 

• ‘Achieve a surface density of not less than 220 kg per square meter’ 

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

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

horizontal bond beam. 

• ‘Incorporate a cavity of 20 to 35 mm’ 

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

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

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

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

prevention of moisture penetration must be maintained. 

• ‘Masonry that has a thermal conductivity of less than 0.8’ 

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

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

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

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

ADV1212A


Section 1.2. Brick Masonry Design 1.212b 


• Volume 2: Tables J1.5a and J1.5b R-value requirements 

R-values depend on the total wall construction and are determined by adding the R-values for the individual 

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

Outdoor air film, indoor air film, cavities & plasterboard have the values shown in the tables. The R-values for 

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

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

and using the numbers given the R-value can be extrapolated for any brick. Brick weights may change over time 

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

latest weight of any particular brick. 

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

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

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

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

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

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

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

Different R-values are required of different walls in different situations and it is recommended that you consult 

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

appropriate R-values for the calculations. ■ 

ADV1212B



Masonry Design for Fire Resistance 

Fire Resistance Levels (FRL) 

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

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

Volume 2. 

There are three figures in the Fire Resistance Level. 

Eg: FRL 120/60/90 means that the wall must achieve Structural Adequacy for 120 minutes / Integrity for 60 minutes / 

Insulation for 90 minutes. 

Structural Adequacy 

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

length or restraints so therefore do not control Structural Adequacy. 

Integrity 

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

and they must maintain insulation. Extensive fire testing of masonry has shown integrity to be closely related to 

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

Adequacy or the Insulation periods. 

Insulation 

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

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

ADV03761



Masonry Design for Structural Adequacy FRL 

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

earthquake loads. 

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

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

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

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

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

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

recalculated for an increased thickness and/or extra restraints. 

There are 3 formulae for calculating Srf. 

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

vertical edge). 

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

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

fits all’ method of calculating the wall thickness. 

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

at least one end is supported. 

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

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

like portal frame factories. 

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

is no load on either leaf) the thickness is equal to two-thirds of the sum of the thicknesses of both leaves and 

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

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

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

fire resistant material. t 

ADV03762



Masonry Design for Structural Adequacy FRL (continued) 

Refer to the Structural Adequacy Graphs on the following pages for maximum height and length values for walls 

of different thicknesses and restraint conditions. 

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

Adequacy requirements. 

How to Use the Boral Structural Adequacy FRL Graphs 

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


on all sides 

15 

14 

13 

12 

11 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

0 

1 2 3 4 5 6 7 8 9 10 11 12 

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

S 

S 

S 

S 

230mm 

150mm 

110mm 

90mm 

1. Select the graph with Structural Adequacy for 

the required minutes. (240 minutes for this 

example). 

2. Select the graph for the chosen wall restraint 

(support) criteria. (Support on both vertical 

edges, top and bottom for this example). 

3. Plot the intersection of the design Wall Height 

and the Wall Length on the graph. (For this 

example 3 m height x 5 m length). 

4. The line ABOVE the intersection indicates the 

minimum brick thickness required for the wall. 

In this example, 150 mm bricks would be 

suitable and the most economical. 

ADV03763



Structural Adequacy for 60 Minutes FRL 




on all sides 

15 

14 

13 

12 

11 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

0 

15 

14 

13 

12 

11 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

0 

1 2 3 4 5 6 7 8 9 10 11 12 



on three sides, 


1 2 3 4 5 6 7 8 9 10 11 12 


S 

S 

S 

S 

F 

S 

S 

230mm 

150mm 

110mm 

90mm 

S 

230mm 

150mm 

110mm 

90mm 





one end unsupported 

15 

14 

13 

12 

11 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

0 

15 

14 

13 

12 

11 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

0 

1.216 

1 2 3 4 5 6 7 8 9 10 11 12 



one end and bottom, 

one end and top unsupported 

S 

S 

S 

F 

230mm 

150mm 

110mm 

90mm 

230mm 

150mm 

110mm 

90mm 

1 2 3 4 5 6 7 8 9 10 11 12 


S 

F 

S 

F 

ADV03764







on all sides 

15 

14 

13 

12 

11 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

0 

15 

14 

13 

12 

11 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

0 

1 2 3 4 5 6 7 8 9 10 11 12 





S 

S 

S 

S 

230mm 

150mm 

110mm 

90mm 

230mm 

150mm 

110mm 

90mm 

1 2 3 4 5 6 7 8 9 10 11 12 


S 

F 

S 

S 






15 

14 

13 

12 

11 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

0 

15 

14 

13 

12 

11 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

0 

1.217 

1 2 3 4 5 6 7 8 9 10 11 12 





S 

S 

S 

F 

230mm 

150mm 

110mm 

90mm 

230mm 

150mm 

110mm 

90mm 

1 2 3 4 5 6 7 8 9 10 11 12 


S 

F 

S 

F 

ADV03765







on all sides 

15 

14 

13 

12 

11 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

0 

15 

14 

13 

12 

11 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

0 

1 2 3 4 5 6 7 8 9 10 11 12 





S 

S 

S 

S 

230mm 

150mm 

110mm 

90mm 

230mm 

150mm 

110mm 

90mm 

1 2 3 4 5 6 7 8 9 10 11 12 


S 

F 

S 

S 






15 

14 

13 

12 

11 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

0 

15 

14 

13 

12 

11 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

0 

1.218 

1 2 3 4 5 6 7 8 9 10 11 12 





S 

S 

S 

F 

230mm 

150mm 

110mm 

90mm 

230mm 

150mm 

110mm 

90mm 

1 2 3 4 5 6 7 8 9 10 11 12 


S 

F 

S 

F 

ADV03766







on all sides 

15 

14 

13 

12 

11 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

0 

15 

14 

13 

12 

11 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

0 

1 2 3 4 5 6 7 8 9 10 11 12 





S 

S 

S 

S 

230mm 

150mm 

110mm 

90mm 

230mm 

150mm 

110mm 

90mm 

1 2 3 4 5 6 7 8 9 10 11 12 


S 

F 

S 

S 






15 

14 

13 

12 

11 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

0 

15 

14 

13 

12 

11 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

0 

1.219 

1 2 3 4 5 6 7 8 9 10 11 12 





S 

S 

S 

F 

230mm 

150mm 

110mm 

90mm 

230mm 

150mm 

110mm 

90mm 

1 2 3 4 5 6 7 8 9 10 11 12 


S 

F 

S 

F 

ADV03767







on all sides 

15 

14 

13 

12 

11 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

0 

15 

14 

13 

12 

11 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

0 

1 2 3 4 5 6 7 8 9 10 11 12 





S 

S 

S 

S 

230mm 

150mm 

110mm 

90mm 

230mm 

150mm 

110mm 

90mm 

1 2 3 4 5 6 7 8 9 10 11 12 


S 

F 

S 

S 






15 

14 

13 

12 

11 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

0 

15 

14 

13 

12 

11 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

0 

1.220 

1 2 3 4 5 6 7 8 9 10 11 12 





S 

S 

S 

F 

230mm 

150mm 

110mm 

90mm 

230mm 

150mm 

110mm 

90mm 

1 2 3 4 5 6 7 8 9 10 11 12 


S 

F 

S 

F 

ADV03768



Structural Adequacy for Panels with Unsupported Ends 

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

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

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

Maximum Wall Heights for Structural Adequacy for any Wall Length 

M A X I M U M W A L L H E I G H T ( m ) 

Top and bottom supported, 

ends not supported. 

7 

6 

5 

4 

3 

2 

1 

0 

60 90 120 180 240 

F R L F O R S T R U C T U R A L A D E Q U A C Y 

( m i n u t e s ) 

F 

S 

S 

F 

230mm 

150mm 

110mm 

90mm 

ADV03769



Masonry Design for Integrity FRL 

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

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

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

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

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

‘Structural Adequacy’ FRL value, such as is the case with non-load bearing walls. Eg. If the BCA requires an FRL 

of -/90/90, the wall has no actual ‘Structural Adequacy’ requirement, but to prove Integrity of 90 minutes, the 

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

Masonry Design for Insulation FRL 

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

material’ and ‘material thickness’. 

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

than 30% of the brick’s overall volume. 

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

Table 5. Insulation periods for standard bricks (minutes) 

Wall thickness (mm) 

90 

110 

140 or 150 160 (150 plus 10 mm 180 220 

230 

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

Insulation period (minutes) 60 90 120 180 240 240 240 

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

Effect of Recesses for Services on FRLs 

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

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

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

ADV03770



Effect of Chases on Fire Rated Masonry 

Structural Adequacy FRL 

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

into account. 

• Walls spanning vertically may be chased vertically to full height but horizontal chases are limited in length 

to 4 times the wall’s thickness. 

• Walls spanning vertically and horizontally may be chased either horizontally up to half the wall’s length or 

vertically up to half the wall’s height. 

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

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

should be kept to a bare minimum. 

Note: Chases affect the sound reduction capacity of walls. See ‘Acoustic Design’ page 1.225 of this manual. 

Integrity and Insulation FRLs 

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

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

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

ADV03771



Options for Increasing FRLs 

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

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

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

plasterboard on sound reduction in party walls. See ‘Acoustic Design’ page 1.225 of this manual. 

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

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

fire can come from either side. Note: Only ONE thickness of render is added to the material thickness and that 

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

ADV03772



ACOUSTIC DESIGn 

Acoustic Performance Rating 

The BCA requirements are met by: 

1. Testing a sample of constructed walls to verify that they meet the Weighted Standardised Level Difference 

(Dnt,w – explained further in “Acoustic Performance On-Site’ on page 1.231 of this manual) requirements; 

or 

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

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

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

the BCA; and, 

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

Class 9c buildings where there is a test; and, 

5. Except where the requirements are verified by on-site testing, chasing of services into masonry walls is not 

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

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

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

Sole occupancy unit- all areas except 

those below 

Sole occupancy unit- bathroom, 

sanitary compartment, laundry or 

kitchen 

Wall separating Wall Rating 


those below 

Sole occupancy unit- habitable room 

except a kitchen 

Rw+Ctr ≥50 

Rw+Ctr ≥50 

and 

discontinuous construction 

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

Class 1 buildings. The differences are; in the table above, in Row 1 the wall rating required is Rw ≥45 and in 

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

test comparing to a deemed-to-satisfy wall. t 

ADV1225



Acoustic Performance Rating (continued) 

1.226 

Table 7. BCA Volume 1 Requirements for walls separating sole occupancy units from other parts of the 

building in Class 2 & 3 Buildings. 


those below 

Sole occupancy unit- bathroom, sanitary 

compartment, laundry or kitchen 



those below 

Sole occupancy unit- habitable room 

except a kitchen 

Sole occupancy unit- all areas Plant room or lift shaft 

Sole occupancy unit- all areas 

Stairway, public corridor, public lobby or 

areas of different classification 

Rw+Ctr ≥50 

Rw+Ctr ≥50 

and 


Rw ≥50 

and 


Rw ≥50 

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

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

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

impact noise than a deemed-to-satisfy wall (by a tapping test). 

Table 8. BCA Volume 1 Requirements for walls separating sole occupancy units and other parts of the 

building in Class 9c Buildings (aged care facilities). 




those below 

Rw ≥45 

Rw ≥45 

and 

Sole occupancy unit- all areas Laundry, kitchen 

Bathroom, sanitary compartment (but 


or 

No less resistant to impact noise than 

a deemed-to-satisfy wall 


not an associated ensuite), plant room, 

utilities room 

Rw ≥45 

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

Building service Adjacent room Barrier rating 

A duct, soil, waste, water supply or 

stormwater pipe that serves or passes 

through more than one unit. 

Sole occupancy unit habitable room 

other than a kitchen. 

Sole occupancy unit kitchen or non 

habitable room 

Rw+Ctr ≥40 

Rw+Ctr ≥25 

*In Class 1 buildings the requirements apply to those services that pass through more than one Dwelling. In Class 2, 3 & 9c 

requirements apply to all stormwater pipes and other services that pass through more than one sole occupancy unit. 

Northern Territory and Queensland have different requirements for separation of services in the table above; the 

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

figures in the table. 

ADV1226



Weighted Sound Reduction Index (Rw) 

Rw is a single-number rating of the sound reduction through a wall or other building element. Since the sound 

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

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

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

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

Impact Sound Resistance 

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

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

performs no worse than a deemed-to-satisfy wall. To achieve impact sound resistance, the BCA requires walls 

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

must be of the resilient type. Except for the resilient ties in masonry walls there are to be no mechanical linkages 

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

BCA Deemed-to-Satisfy Walls 

BCA Volume 1 Amendment 14 Specification F5.2 Table 2 gives deemed-to-satisfy walls for sound insulation for 

walls separating sole occupancy units. 

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

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

achieving Rw+Ctr ≥50 are allowed. 

Deemed-to-satisfy clay brick walls are detailed on the following pages. t 

ADV03775



BCA Deemed-to-Satisfy Walls (continued) 

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

Two leaves of 110 mm clay brick masonry with: 

(a) A cavity not less than 50 mm between leaves; and 

(b) 50 mm thick glass wool insulation with a density of 11 

kg/m3 or 50 mm thick polyester insulation with a density 

of 20 kg/m3 in the cavity. 

1.228 

Construction Rating 

Two leaves of 110 mm clay brick masonry with: 

(a) A cavity not less than 50 mm between leaves; 

and 

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

Single leaf of 110 mm clay brick masonry with: 

(a) A row of 70 mm x 35 mm timber studs or 64 mm steel studs 

at 600 mm centres, spaced 20 mm from the masonry wall; 

and 

(b) 50 mm thick mineral insulation or glass wool insulation with 

a density of 11 kg/m 3 positioned between studs; and, 

(c) one layer of 13 mm plasterboard fixed to outside face of 

studs and outside face of masonry. 

Single leaf of 90 mm clay brick masonry with: 

(a) A row of 70 mm x 35 mm timber studs or 64 mm steels studs 

at 600 mm centres, spaced 20 mm from each face of the 

masonry wall; and 

(b) 50 mm thick mineral insulation or glass wool insulation with 

a density of 11 kg/m 3 positioned between studs in each row; 

and 

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

outside face. 

Rw+Ctr≥50 

Rw+Ctr≥50 

Rw+Ctr≥50 

Rw+Ctr≥50 

ADV03776



BCA Deemed-to-Satisfy Walls (continued) 

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

Single leaf of 150 mm brick masonry with 

13 mm cement render on each face. 

1.229 

Construction Rating 





Rw≥50 

Rw≥50 

Rw≥45 

ADV03777



Solid v. Cavity Walls 

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

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

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

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

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

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

Brick Walls with Render 

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

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

this is a one-off benefit. ■ 

Brick Walls with Plasterboard 

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

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

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

daubs. 

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

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

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

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

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

resonance and further decreases the sound transmission. Denser grades of plasterboard and additional layers 

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

ADV03778



Points to Consider When Designing Walls 

for Acoustic Performance 

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

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

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

the end user. End user expectations are frequently related to the cost of occupying the unit. 

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

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

Acoustic Performance On-Site 

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

controlled conditions. When identical partitions in buildings are tested in-situ, it is often found that the actual 

result obtained, called the Weighted Standardised Level Difference (Dnt,w), is lower than the laboratory Rw. This 

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

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

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

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

adjoining floor/ceiling and associated structure is of prime importance. Even the most basic elements, if ignored, 

can seriously downgrade the sound insulation performance. 

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

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

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

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

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

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

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

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

ADV03779



Perimeter Acoustical Sealing 

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

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

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

acoustic sealing for a low Rw wall. 

Effective sealants have the following properties: 

• Good flexibility, (elastic set); 

• Low hardness; 

• Excellent adhesion, usually to concrete, timber, plaster and galvanised steel; 

• Minimal shrinkage (less than 5%); 

• Moderate density (greater than 800 kg/m 3 ); and are, 

• Fire rated where required (All walls required by the BCA to be sound rated also have fire ratings). 

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

years. 

Note: Use of expanding foam sealants is not acceptable. 

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

Doors 

Hollow, cored and even solid doors generally provide unsatisfactory sound insulation. Doors can provide direct 

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

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

or lobby should be used. ■ 

ADV03780



Lightweight Panels Above Doors 

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

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

Air Paths Through Gaps, Cracks or Holes 

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

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

Appliances 

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

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

leads and connections. ■ 

Electrical Outlets & Service Pipes 

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

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

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

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

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

ADV03781

1.3 Brick Masonry Construction


Section 1.3. Brick Masonry Construction 1.301 

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

requirements. 

Mortar 

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

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

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

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

proportions of the most commonly used mortars. Other deemed-to-satisfy compositions are given in AS3700. 

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

Note: Proportions are by volume and should be measured with a bucket or gauge box, NOT A SHOVEL. 

Table 11. Typical Mortar Mixes 

Mix proportions by volume 

Mortar Durability 

Type Class 

Portland or Hydrated Water 

Blended Cement Lime Sand Thickener* 

M1 PRO 0 1 3 No 

M2 PRO 1 2 9 No 

M3 GP 1 1 6 No 

M3 GP 1 0 5 Yes 

M4 EXP 1 1 ⁄2 4 1 ⁄2 No 

M4 EXP 1 0 4 Yes 

Refer to page 1.104 for description of Durability Class. *Methylcellulose type, not air entrainers such as detergent. 

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

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

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

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

Note: AS 3700 allows the use of: 

• Cements complying with AS 3972 or AS 1316 

• Lime complying with AS 1672.1 

• Sand that is free of any deleterious materials 

• Water that is free from deleterious materials and 

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

cellulose-type water thickeners, colouring pigments complying with BS EN 12878 and bonding polymers. 

t 

ADV03783



Mortar (continued) 

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

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

strength and durability. 

Deleterious materials are those reducing the strength or durability of the masonry and including anything that 

attacks the built-in components. This means the use of fire clay, detergent, sugar, soft drink, etc., are banned. 

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

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

Mortar Estimator 

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

Mix Composition 40 kg bags 25 kg bags Cubic metres Tonnes of 

(C:L:S) of cement of lime of sand damp sand 

M3 1 : 1 : 6 4 2.4 0.64 1.2 

M3 1 : 0 : 5 4 0 0.64 1.2 

M4 1 : 0 : 4 6.5 0 0.64 1.2 

M4 1 : 1 ⁄2 : 4 1 ⁄2 5.3 1.6 0.64 1.2 

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

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

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

before continuing. t 

ADV03784



Mortar (continued) 

Mortar Colour 

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

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

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

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

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

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

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

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

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

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

combinations of cement, sands and oxides. 

Table 13: Typical Coloured Mortar Components 

Mortar Colour Cement Sand Oxide 

Red Grey White or Yellow or Red Red 

Yellow Off-white or Grey Yellow Yellow & Brown 

Cream Off-white Yellow None 

Tan Grey White or Yellow Brown 

Black Grey Yellow Black 

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

ADV03785



Joint Types 

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

rustic or formal look to brickwork. There are many different joints; the most common ones used in Australia are 

shown below. 

Flush Joint Raked Joint Ironed Joint Struck Joint 

Weathered Joint 

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

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

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

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

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

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

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

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

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

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

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

meet the requirement. 

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

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

ADV03786



Joint Sizes 

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

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

the masonry. During construction mortar bed joints are allowed to deviate by ± 3mm. Because of poor practice 

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

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

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

mm thicker than the specified thickness but no thinner. In face brickwork perpends may deviate by ± 5 mm from 

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

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

perpends are not filled with mortar. ■ 

Weepholes 

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

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

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

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

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

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

ADV03787



Brick Estimator 

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

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

the Brick Coursing Height and Brick Gauge tables on pages 1.310-1.312 of this manual. Select the height of the 

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

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

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

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

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

ADV03788



Brick bonds and other decorative effects 

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

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

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

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

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

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

courses of stretcher (English) or courses of alternating header and stretcher (Flemish). A variation of Flemish 

Bond is Garden Wall Bond where courses are made of a header and three stretchers alternating. 

Corner treatment can be different in these bonds. English corners end in full stretchers or full headers, and any 

part brick required to make up the course is set inside the corner. Dutch corners end in the part bricks. 

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

courses between. 

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

a decorative effect using cut bricks for the headers. Such walls are usually non-load bearing. Cutting costs are 

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

Other decorative bonds may be used in non-load bearing applications, particularly in the form of panels. The 

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

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

Other bonds include: 

• Stack Bond – Bricks laid horizontally in vertical columns so all vertical joints align. 

• Soldier Stack Bond – Bricks laid vertically in vertical columns so all vertical joints align. 

• 1/3 Bond – Every course is offset by 1/3 of a brick. 

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

Weave Bond and virtually any pattern that tessellates. t 

ADV03789



Brick bonds and other decorative effects (continued) 

Other decorative effects are available such as: 

• Laying bands of bricks of the same colour with different textures eg smooth faced and rock faced; 

• Laying bands of bricks with different (contrasting or complimentary) colours; 

• Corbelling (bricks set out from the wall); 

• Racking (bricks set back into the wall); 

• Quoining (corner bricks in different colours or set out from the wall); 

• Soldiers above openings or as a single course; 

• Copings on piers and parapet walls; 

• Sills in different colours or textures, using sill bricks, etc.; or, 

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

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

Combinations of the above effects can be used. Eg. An American Architect specified a corbelled course with the 

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

the shadowing effect from the corbelled course. t 

ADV03790



Brick bonds and other decorative effects (continued) 

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

Flemish Bond Common Bond (Flemish every 6th Course) 

English Cross or Dutch Bond Garden Wall Bond 

Stack Bond Soldier Course (With Stretcher Bond) 

ADV03791

ADV03792 

1.310 


Section 1.3. Brick Masonry Construction 

76mm 119mm 162mm 50mm 90mm 

3000 

2700 

2400 

2100 

1800 

1500 

1200 

900 

600 

300 

3000mm 

2700mm 

2400mm 

2100mm 

1800mm 

1500mm 

1200mm 

900mm 

600mm 

300mm 

24 

23 

22 

21 

20 

19 

18 

17 

16 

15 

14 

13 

12 

11 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

18 

17 

16 

15 

14 

13 

12 

11 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

50 

49 

48 

47 

46 

45 

44 

43 

42 

41 

40 

39 

38 

37 

36 

35 

34 

33 

32 

31 

30 

29 

28 

27 

26 

25 

24 

23 

22 

21 

20 

19 

18 

17 

16 

15 

14 

13 

12 

11 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

36 

35 

34 

33 

32 

31 

30 

29 

28 

27 

26 

25 

24 

23 

22 

21 

20 

19 

18 

17 

16 

15 

14 

13 

12 

11 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

30 

29 

28 

27 

26 

25 

24 

23 

22 

21 

20 

19 

18 

17 

16 

15 

14 

13 

12 

11 

10 

9 

8 

7 

6 

5 

4 

3 

2 

1 

Brick Coursing Height



Brick Gauge 

230 mm Long Bricks 

No. of Length Opening 

Bricks (mm) (mm) 

1 230 250 

1 1 ⁄2 350 370 

2 470 490 

2 1 ⁄2 590 610 

3 710 730 

3 1 ⁄2 830 850 

4 950 970 

4 1 ⁄2 1070 1090 

5 1190 1210 

5 1 ⁄2 1310 1330 

6 1430 1450 

6 1 ⁄2 1550 1570 

7 1670 1690 

7 1 ⁄2 1790 1810 

8 1910 1930 

8 1 ⁄2 2030 2050 

9 2150 2170 

9 1 ⁄2 2270 2290 

10 2390 2410 

10 1 ⁄2 2510 2530 

11 2630 2650 

11 1 ⁄2 2750 2770 

12 2870 2890 

12 1 ⁄2 2990 3010 

13 3110 3130 



13 1 ⁄2 3230 3250 

14 3350 3370 

14 1 ⁄2 3470 3490 

15 3590 3610 

15 1 ⁄2 3710 3730 

16 3830 3850 

16 1 ⁄2 3950 3970 

17 4070 4090 

17 1 ⁄2 4190 4210 

18 4310 4330 

18 1 ⁄2 4430 4450 

19 4550 4570 

19 1 ⁄2 4670 4690 

20 4790 4810 

20 1 ⁄2 4910 4930 

21 5030 5050 

21 1 ⁄2 5150 5170 

22 5270 5290 

22 1 ⁄2 5390 5410 

23 5510 5530 

23 1 ⁄2 5630 5650 

24 5750 5770 

24 1 ⁄2 5870 5890 

25 5990 6010 

25 1 ⁄2 6110 6130 



26 6230 6250 

26 1 ⁄2 6350 6370 

27 6470 6490 

27 1 ⁄2 6590 6610 

28 6710 6730 

28 1 ⁄2 6830 6850 

29 6950 6970 

29 1 ⁄2 7070 7090 

30 7190 7210 

30 1 ⁄2 7310 7330 

31 7430 7450 

31 1 ⁄2 7550 7570 

32 7670 7690 

32 1 ⁄2 7790 7810 

33 7910 7930 

33 1 ⁄2 8030 8050 

34 8150 8170 

34 1 ⁄2 8270 8290 

35 8390 8410 

35 1 ⁄2 8510 8530 

36 8630 8650 

36 1 ⁄2 8750 8770 

37 8870 8890 

37 1 ⁄2 8990 9010 

38 9110 9130 

No. of Length 

Bricks (mm) 

38 1 ⁄2 9230 

39 9350 

39 1 ⁄2 9470 

40 9590 

40 1 ⁄2 9710 

41 9830 

41 1 ⁄2 9950 

42 10070 

42 1 ⁄2 10190 

43 10310 

43 1 ⁄2 10430 

44 10550 

44 1 ⁄2 10670 

45 10790 

45 1 ⁄2 10910 

46 11030 

46 1 ⁄2 11150 

47 11270 

47 1 ⁄2 11390 

48 11510 

48 1 ⁄2 11630 

49 11750 

49 1 ⁄2 11870 

50 11990 

100 23990 

ADV03793


Section 1.3. Brick Masonry Construction 

Brick Gauge 

290 mm Long Bricks 



1 290 310 

1 1 ⁄3 390 410 

1 2 ⁄3 490 510 

2 590 610 

2 1 ⁄3 690 710 

2 2 ⁄3 790 810 

3 890 910 

3 1 ⁄3 990 1010 

3 2 ⁄3 1090 1110 

4 1190 1210 

4 1 ⁄3 1290 1310 

4 2 ⁄3 1390 1410 

5 1490 1510 

5 1 ⁄3 1590 1610 

5 2 ⁄3 1690 1710 

6 1790 1810 

6 1 ⁄3 1890 1910 

6 2 ⁄3 1990 2010 

7 2090 2110 

7 1 ⁄3 2190 2210 

7 2 ⁄3 2290 2310 

8 2390 2410 

8 1 ⁄3 2490 2510 

8 2 ⁄3 2590 2610 

9 2690 2710 

9 1 ⁄3 2790 2810 

9 2 ⁄3 2890 2910 

10 2990 3010 

10 1 ⁄3 3090 3110 

10 2 ⁄3 3190 3210 

11 3290 3310 

11 1 ⁄3 3390 3410 

11 2 ⁄3 3490 3510 

12 3590 3610 

12 1 ⁄3 3690 3710 

12 2 ⁄3 3790 3810 

13 3890 3910 

13 1 ⁄3 3990 4010 



13 2 ⁄3 4090 4110 

14 4190 4210 

14 1 ⁄3 4290 4310 

14 2 ⁄3 4390 4410 

15 4490 4510 

15 1 ⁄3 4590 4610 

15 2 ⁄3 4690 4710 

16 4790 4810 

16 1 ⁄3 4890 4910 

16 2 ⁄3 4990 5010 

17 5090 5110 

17 1 ⁄3 5190 5210 

17 2 ⁄3 5290 5310 

18 5390 5410 

18 1 ⁄3 5490 5510 

18 2 ⁄3 5590 5610 

19 5690 5710 

19 1 ⁄3 5790 5810 

19 2 ⁄3 5890 5910 

20 5990 6010 

20 1 ⁄3 6090 6110 

20 2 ⁄3 6190 6210 

21 6290 6310 

21 1 ⁄3 6390 6410 

21 2 ⁄3 6490 6510 

22 6590 6610 

22 1 ⁄3 6690 6710 

22 2 ⁄3 6790 6810 

23 6890 6910 

23 1 ⁄3 6990 7010 

23 2 ⁄3 7090 7110 

24 7190 7210 

24 1 ⁄3 7290 7310 

24 2 ⁄3 7390 7410 

25 7490 7510 

25 1 ⁄3 7590 7610 

25 2 ⁄3 7690 7710 

26 7790 7810 

No. of Length 


26 1 ⁄3 7890 

26 2 ⁄3 7990 

27 8090 

27 1 ⁄3 8190 

27 2 ⁄3 8290 

28 8390 

28 1 ⁄3 8490 

28 2 ⁄3 8590 

29 8690 

29 1 ⁄3 8790 

29 2 ⁄3 8890 

30 8990 

30 1 ⁄3 9090 

30 2 ⁄3 9190 

31 9290 

31 1 ⁄3 9390 

31 2 ⁄3 9490 

32 9590 

32 1 ⁄3 9690 

32 2 ⁄3 9790 

33 9890 

33 1 ⁄3 9990 

33 2 ⁄3 10090 

34 10190 

34 1 ⁄3 10290 

34 2 ⁄3 10390 

35 10490 

35 1 ⁄3 10590 

35 2 ⁄3 10690 

36 10790 

36 1 ⁄3 10890 

36 2 ⁄3 10990 

37 11090 

37 1 ⁄3 11190 

37 2 ⁄3 11290 

38 11390 

38 1 ⁄3 11490 

38 2 ⁄3 11590 

No. of Length 


39 11690 

39 1 ⁄3 11790 

39 2 ⁄3 11890 

40 11990 

40 1 ⁄3 12090 

40 2 ⁄3 12190 

41 12290 

41 1 ⁄3 12390 

41 2 ⁄3 12490 

42 12590 

42 1 ⁄3 12690 

42 2 ⁄3 12790 

43 12890 

43 1 ⁄3 12990 

43 2 ⁄3 13090 

44 13190 

44 1 ⁄3 13290 

44 2 ⁄3 13390 

45 13490 

45 1 ⁄3 13590 

45 2 ⁄3 13690 

46 13790 

46 1 ⁄3 13890 

46 2 ⁄3 13990 

47 14090 

47 1 ⁄3 14190 

47 2 ⁄3 14290 

48 14390 

48 1 ⁄3 14490 

48 2 ⁄3 14590 

49 14690 

49 1 ⁄3 14790 

49 2 ⁄3 14890 

50 14990 

100 29990 

1.312 

ADV03794



Blending 

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

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

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

colour variation. 

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

To avoid this: 

• All bricks required for the project, or as many packs as will fit, should be delivered at one time and stored 

on site; and, 

• Bricks should be drawn from at least four packs simultaneously, working down from the corners of each 

pack. ■ 

Brick Storage 

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

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

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

strength. 

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

ADV03795



Laying Practices 

The following practices are recommended: 

• Mortar, extruded from tapping the brick down to the string line, should be cut off with an upward stroke of 

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

• Joints should be tooled progressively as the bricks are laid, when the mortar is firm to thumb pressure. High 

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

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

• After allowing the mortar to undergo initial set, within a day, dry brush mortar smears, to remove any dags, 

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

require high-pressure water jet cleaning or more costly, risky methods of cleaning. 

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

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

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

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

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

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

• Scaffolding should be kept at least 150 mm from the face of the brickwork to prevent a build up of mortar 

droppings against the masonry. 

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

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

bricks. 

• Face bricks are supplied with one face and one header suitable for exposing (i.e. to be seen after laying). 

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

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

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

marks, chips or cracks that have been laid. ■ 

ADV03796



Control Joints 

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

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

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

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

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

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

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

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

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

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

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

to accommodate the tie. ■ 

Damp Courses and Flashing 

Membrane type damp proof courses (DPC) must be laid across the full width of the wall or leaf and must project 

through the mortar on either side and be completely visible after laying and cleaning is complete. Recessing DPC 

below the edge of the brickwork so that the mortar bridges the DPC invalidates its use and is therefore entirely 

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

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

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

DPC and flashing at the base of a wall may be combined. Lengths should be as long as possible but where not 

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

termite shield is used in the same joint as the DPC, the DPC material must be compatible with the termite shield 

or corrosion may destroy the DPC. 

General practice has been to recommend that flashings and DPCs be sandwiched between the mortar. There is 

some evidence that the common practice of laying flashings and DPC directly on the lower course of bricks and 

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

ADV03797



Cleaning of Clay Masonry 

The Basics of Brick Cleaning 

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

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

will be required to completely remove the mortar residue. 

Cleaning techniques may involve high-pressure water jet equipment or hand methods. Whatever technique is 

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

Test Areas 

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

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

the effectiveness of the test clean until the masonry dries. 

Clean Soluble Salt Deposits First 

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

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

drawn back into the brickwork and will reappear as the masonry dries. Efflorescence will eventually disappear 

through natural weathering. 

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

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

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

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

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

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

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

per litre of water. 

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

treatment. t 

ADV03798



Cleaning of Clay Masonry (continued) 

High Pressure Cleaning 

High-pressure water washing is now common for cleaning brickwork. If used the pressure must be kept below 

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

type with an angle of 15 degrees. 

The following practices must be observed: 

• Cleaning should not start until the mortar has hardened. 

• Hard lumps or persistent smears should be removed by hand. 

• Mask adjacent materials. 

• Do not apply the acid with the high-pressure sprayer. Use a low-pressure spray or broom it on. 

• Clean from top to bottom in small sections. 

• Work in the shade, ahead of the sun, if possible. 

• DO NOT USE EXCESSIVE PRESSURE OR GET TOO CLOSE, as this will damage the face of the brick and the 

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

Excessive pressure is used to make cleaning faster; it does not do a better job of cleaning. t 

ADV03799




Saturate the Wall Surface 

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

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

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

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

cleaning. 

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

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

until ready to apply the cleaning solution. 

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

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

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

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

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

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

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

ADV03800




Acids – The Basics 

The traditional masonry-cleaning chemical is hydrochloric acid, (also known as muriatic acid or spirits of salts). 

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

should not be used. 

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

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

in water, which will neutralise the acid. 

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

is 1 part acid to 10 parts water. Acid takes time to dissolve the cement and should be left on for 4-6 minutes (or 

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

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

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

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

brick cleaning. 

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

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

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

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

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

recommendations must be strictly adhered to. Excessive and incorrect use of some proprietary cleaning solutions 

has in the past, produced very bad staining. t 

ADV03801




Safety Precautions 

All masonry-cleaning acids are dangerous. Acids that do not dissolve cement as quickly as hydrochloric acid are 

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

• Wear goggles, gloves and protective clothing. 

• Always pour acids into water – this avoids splashes of highly concentrated acid onto the operator. 

• If splashed onto the body, wash with clean water and if possible, neutralise with a mixture of bicarbonate 

of soda and water. 

• The manufacturer’s instructions and safety precautions must be strictly adhered to if proprietary cleaning 

products are used. ■ 

ADV03802

1.4 

Clay Brick Property Tables


Section 1.4 Clay Brick Property Tables 

Escura ® Smooth Face Brown Choc Tan Cinnamon Cream Flame Red Hemp Jute 

Nevada 

Cream 

Work size (mm) 230x110x76 230x110x76 230x110x76 230x110x76 230x110x76 230x110x76 230x110x76 230x110x76 

Dimensional category DW1 DW1 DW1 DW1 DW1 DW1 DW1 DW1 

Perforation (%) 15 

Strengths of masonry (MPa) 

– Characteristic compressive strength (f’m) M3* mortar (GP) >6.6 >5.4 >5.4 >6.6 >5.4 >6.6 >5.4 >5.4 

– Characteristic compressive strength (f’m) M4* mortar (EXP) >7.0 >5.8 >5.8 >7.0 >5.8 >7.0 >5.8 >5.8 

Co-efficient of growth ‘em’ (mm/m/15yrs) 9.0 >5.8 >7.0 >5.8 >7.0 >7.0 >9.0 

Co-efficient of growth ‘em’ (mm/m/15yrs)



Escura ® – Smooth Face Slimline Brown Cream Red 

Work size (mm) 230x110x50 230x110x50 230x110x50 

Dimensional category DW1 DW1 DW1 

Perforation (%) 30 30 30 

Ave unit weight (kg) 2 2 2 

Approx number per m2 70 70 70 

Wall surface density (kg/m2 ) 200 200 200 

Characteristic unconfined compressive strength of the unit (f’uc) MPa >22 >22 >22 


– Characteristic compressive strength (f’m) M3* mortar (GP) >6.6 >6.6 >6.6 

– Characteristic compressive strength (f’m) M4* mortar (EXP) >7.0 >7.0 >7.0 

Co-efficient of growth ‘em’ (mm/m/15yrs) 5.4 >5.4 >5.4 >6.6 >5.4 >6.6 >6.6 

– Characteristic compressive strength (f’m) M4* mortar (EXP) >7.0 >7.0 >5.8 >5.8 >5.8 >7.0 >5.8 >7.0 >7.0 




Typical data for all other Boral face bricks can be found 

using the Reference Guides on the following pages. Look 

up your required product by Brick Name (page 1.404) or 

Range Name (page 1.405), and match the code to the 

corresponding Property Table Legend on page 1.406. 

For typical data relating to Boral clay pavers, refer to 

Section 2.4 – Paver Property Tables – page 2.401. 

Escura ® – Pressed Cream Red 

Work size (mm) 230x110x76 230x110x76 

Dimensional category DW1 DW1 

Perforation (%) Frog Frog 

Ave unit weight (kg) 4.1 4.1 

Approx number per m2 49 49 

Wall surface density (kg/m2 ) 240 240 

Characteristic unconfined compressive strength of the unit (f’uc) MPa >22 >22 


– Characteristic compressive strength (f’m) M3* mortar (GP) >6.6 >6.6 

– Characteristic compressive strength (f’m) M4* mortar (EXP) >7.0 >7.0 

Co-efficient of growth ‘em’ (mm/m/15yrs) 15 >15 >15 


– Characteristic compressive strength (f’m) M3* mortar (GP) 5.2 5.2 5.2 5.2 

– Characteristic compressive strength (f’m) M4* mortar (EXP) 5.6 5.6 5.6 5.6 




LEGEND – Listed Alphabetically by Brick Name 

1.404 

Range Name Brick Name Code 

REVIVE Red Texture – No Arris M 

REVIVE Red Texture – Smooth Arris M 

ELAN Ripponlea C 

OASIS Riverclay K 

WOODSTOCK Rose K 

OASIS Rose Cove J 

WOODSTOCK Rose Double Height L 

ELAN Rouge A 

HORIZON NSW Rubellite J 

OASIS Sable J 

HORIZON VIC Sandalwood B 

WOODSTOCK Sandhurst M 

WOODSTOCK Sandstone Gold K 

WOODSTOCK Sandstone Gold Double Height L 

HORIZON NSW Sandy Bay H 

HORIZON VIC Sandy Beach C 

WOODSTOCK Settler G 

HORIZON VIC Sienna C 

OASIS Sirius Cove J 

NUVO Slate K 

NUVO Soft Suede G 

OASIS Sorrell K 

HORIZON QLD St George K 

OASIS Stonewash K 

OASIS Stonewash Double Height L 

NUVO Storm G 

HORIZON VIC Sunburst G 

WOODSTOCK Sydney Town G 

HORIZON VIC Tanami C 

OASIS Tundra J 

NUVO Vanilla G 

NUVO Victorian Blue D 

NUVO Victorian Blue 50mm F 

HORIZON QLD Windorah K 

HORIZON VIC Windsor C 

WOODSTOCK Winter Gold K 

WOODSTOCK Winter Gold Double Height L 


WOODSTOCK Kingsley Double Height L 

HORIZON VIC Kurrajong A 

ELAN La Mesa C 

ELAN La Mesa 50mm E 

ELAN Labassa C 

ELAN Labassa 50mm E 

HORIZON VIC Lachlan A 

WOODSTOCK Latrobe K 

WOODSTOCK Latrobe Double Height L 

HORIZON NSW Leura I 

WOODSTOCK Lexington K 

WOODSTOCK Lexington Double Height L 

OASIS Limestone Hue J 

HORIZON NSW Lindeman J 

OASIS Linden M 

HORIZON QLD Longreach K 

NUVO Mangrove G 

HORIZON NSW Megalong H 

NUVO Merlot D 

NUVO Mist G 

HORIZON VIC Mocha A 

ELAN Mocha 50mm E 

NUVO Moss G 

WOODSTOCK Mowbray K 

WOODSTOCK Mowbray Double Height L 

HORIZON NSW Murray River H 

OASIS Nelson Cove J 

HORIZON VIC Old Woodville C 

ELAN Opal Blush N 

OASIS Opal Cove J 

HORIZON VIC Orient A 

NUVO Panama K 

HORIZON NSW Pewter Sands M 

WOODSTOCK Port Phillip G 

WOODSTOCK Potters Gold K 

WOODSTOCK Potters Gold Double Height L 

ELAN Raheen C 

ELAN Rattan C 

HORIZON NSW Red Cove H 


WOODSTOCK Colonial G 

HORIZON VIC Colony Rose G 

OASIS Coral Mist J 

HORIZON NSW Coral Sands M 

OASIS Coralstone K 

WOODSTOCK Country Rose M 

REVIVE Cream Rockface G 

REVIVE Cream Texture G 

WOODSTOCK Crestwood M 

HORIZON NSW Delta Sands M 

OASIS Desert Sage J 

NUVO Domino D 

WOODSTOCK Drysdale M 

ELAN Duchess C 

WOODSTOCK Dusk M 

HORIZON VIC Eldorado G 

HORIZON VIC Ember Glow C 

NUVO Espresso D 

NUVO Eucalypt K 

WOODSTOCK Eureka G 

ELAN Florentine Limestone N 

WOODSTOCK Fresco M 

HORIZON QLD Girraween K 

HORIZON NSW Graphite J 

ELAN Grey Nuance C 

ELAN Grey Nuance 50mm E 

HORIZON VIC Gypsy Rose C 

OASIS Haze J 

OASIS Hendra K 

WOODSTOCK Heritage G 

WOODSTOCK Hillview M 

HORIZON VIC Historic Red G 

WOODSTOCK Honeycombe M 

HORIZON VIC Ironbark A 

NUVO Ivory K 

HORIZON NSW Jarosite J 

HORIZON VIC Jarrah A 

HORIZON VIC Kimberley C 

WOODSTOCK Kingsley K 


NUVO Adobe K 

HORIZON NSW Alabaster J 

NUVO Alloy K 

OASIS Alpine K 

HORIZON VIC Amber Blaze C 

ELAN NSW Amber Blaze C 

ELAN Amber Blaze 50mm E 

HORIZON NSW Amethyst J 

HORIZON NSW Antique Cream J 

HORIZON NSW Antique Grey J 

HORIZON NSW Antique Natural J 

HORIZON NSW Antique Pink J 

HORIZON VIC Argyle C 

HORIZON NSW Arnhem Sands M 

OASIS Ascot K 

NUVO Bamboo K 

OASIS Bantry Cove J 

OASIS Beach K 

OASIS Beach Double Height L 

HORIZON VIC Beaumonde C 

WOODSTOCK Bentley K 

WOODSTOCK Bentley Double Height L 

HORIZON VIC Berwick Rustic C 

OASIS Bianca K 

OASIS Bisque K 

OASIS Bisque Double Height L 

HORIZON NSW Blackheath H 

NUVO Blue Rio K 

NUVO Boulder G 

HORIZON VIC Brown Terrain A 

HORIZON VIC Brushwood C 

OASIS Cameo J 

WOODSTOCK Cascade M 

NUVO Chestnut K 

NUVO Chino G 

OASIS Classic Limestone Hue J 

ELAN Cleveland C 

ELAN Cleveland 50mm E 

NUVO Coco G 

ADV03806



LEGEND – Listed Alphabetically by Range Name 


REVIVE Cream Rockface G 

REVIVE Cream Texture G 

REVIVE Red Texture – No Arris M 

REVIVE Red Texture – Smooth Arris M 


HORIZON QLD Girraween K 

HORIZON QLD Longreach K 

HORIZON QLD St George K 

HORIZON QLD Windorah K 

WOODSTOCK Bentley K 

WOODSTOCK Bentley Double Height L 

WOODSTOCK Cascade M 

WOODSTOCK Colonial G 

WOODSTOCK Country Rose M 

WOODSTOCK Crestwood M 

WOODSTOCK Drysdale M 

WOODSTOCK Dusk M 

WOODSTOCK Eureka G 

WOODSTOCK Fresco M 

WOODSTOCK Heritage G 

WOODSTOCK Hillview M 

WOODSTOCK Honeycombe M 

WOODSTOCK Kingsley K 

WOODSTOCK Kingsley Double Height L 

WOODSTOCK Latrobe K 

WOODSTOCK Latrobe Double Height L 

WOODSTOCK Lexington K 

WOODSTOCK Lexington Double Height L 

WOODSTOCK Mowbray K 

WOODSTOCK Mowbray Double Height L 

WOODSTOCK Port Phillip G 

WOODSTOCK Potters Gold K 

WOODSTOCK Potters Gold Double Height L 

WOODSTOCK Rose K 

WOODSTOCK Rose Double Height L 

WOODSTOCK Sandhurst M 

WOODSTOCK Sandstone Gold K 

WOODSTOCK Sandstone Gold Double Height L 

WOODSTOCK Settler G 

WOODSTOCK Sydney Town G 

WOODSTOCK Winter Gold K 

WOODSTOCK Winter Gold Double Height L 


NUVO Eucalypt K 

NUVO Ivory K 

NUVO Mangrove G 

NUVO Merlot D 

NUVO Mist G 

NUVO Moss G 

NUVO Panama K 

NUVO Slate K 

NUVO Soft Suede G 

NUVO Storm G 

NUVO Vanilla G 

NUVO Victorian Blue D 

NUVO Victorian Blue 50mm F 

HORIZON VIC Amber Blaze C 

HORIZON VIC Argyle C 

HORIZON VIC Beaumonde C 

HORIZON VIC Berwick Rustic C 

HORIZON VIC Brown Terrain A 

HORIZON VIC Brushwood C 

HORIZON VIC Colony Rose G 

HORIZON VIC Eldorado G 

HORIZON VIC Ember Glow C 

HORIZON VIC Gypsy Rose C 

HORIZON VIC Historic Red G 

HORIZON VIC Ironbark A 

HORIZON VIC Jarrah A 

HORIZON VIC Kimberley C 

HORIZON VIC Kurrajong A 

HORIZON VIC Lachlan A 

HORIZON VIC Mocha A 

HORIZON VIC Old Woodville C 

HORIZON VIC Orient A 

HORIZON VIC Sandalwood B 

HORIZON VIC Sandy Beach C 

HORIZON VIC Sienna C 

HORIZON VIC Sunburst G 

HORIZON VIC Tanami C 

HORIZON VIC Windsor C 


ELAN Amber Blaze (NSW) C 

ELAN Amber Blaze 50mm E 

ELAN Cleveland C 

ELAN Cleveland 50mm E 

ELAN Duchess C 

ELAN Florentine Limestone N 

ELAN Grey Nuance C 

ELAN Grey Nuance 50mm E 

ELAN La Mesa C 

ELAN La Mesa 50mm E 

ELAN Labassa C 

ELAN Labassa 50mm E 

ELAN Mocha 50mm E 

ELAN Opal Blush N 

ELAN Raheen C 

ELAN Rattan C 

ELAN Ripponlea C 

ELAN Rouge A 

1.405 

OASIS Alpine K 

OASIS Ascot K 

OASIS Bantry Cove J 

OASIS Beach K 

OASIS Beach Double Height L 

OASIS Bianca K 

OASIS Bisque K 

OASIS Bisque Double Height L 

OASIS Cameo J 

OASIS Classic Limestone Hue J 

OASIS Coral Mist J 

OASIS Coralstone K 

OASIS Desert Sage J 

OASIS Haze J 

OASIS Hendra K 

OASIS Limestone Hue J 

OASIS Linden M 

OASIS Nelson Cove J 

OASIS Opal Cove J 

OASIS Riverclay K 

OASIS Rose Cove J 

OASIS Sable J 

OASIS Sirius Cove J 

OASIS Sorrell K 

OASIS Stonewash K 

OASIS Stonewash Double Height L 

OASIS Tundra J 

NUVO Adobe K 

NUVO Alloy K 

NUVO Bamboo K 

NUVO Blue Rio K 

NUVO Boulder G 

NUVO Chestnut K 

NUVO Chino G 

NUVO Coco G 

NUVO Domino D 

NUVO Espresso D 

HORIZON NSW Alabaster J 

HORIZON NSW Amethyst J 

HORIZON NSW Antique Cream J 

HORIZON NSW Antique Grey J 

HORIZON NSW Antique Natural J 

HORIZON NSW Antique Pink J 

HORIZON NSW Arnhem Sands M 

HORIZON NSW Blackheath H 

HORIZON NSW Coral Sands M 

HORIZON NSW Delta Sands M 

HORIZON NSW Graphite J 

HORIZON NSW Jarosite J 

HORIZON NSW Leura I 

HORIZON NSW Lindeman J 

HORIZON NSW Megalong H 

HORIZON NSW Murray River H 

HORIZON NSW Pewter Sands M 

HORIZON NSW Red Cove H 

HORIZON NSW Rubellite J 

HORIZON NSW Sandy Bay H 

ADV03807



For the product & range name relating to the reference codes shown below refer to the following alphabetical legend 

Legend 

A B C D E F G 

Work size (mm) 230x110x76 230x110x76 230x110x76 230x110x76 230x110x50 230x110x50 230x110x76 

Dimensional category DW1 DW1 DW1 DW1 DW1 DW1 DW1 

Perforation (%) 15 


– Characteristic compressive strength (f’m) M3* mortar (GP) >6.6 >6.6 >8.5 >6.6 >5.1 >6.6 >5.4 

– Characteristic compressive strength (f’m) M4* mortar (EXP) >7.0 >7.0 >9.0 >7.0 >5.4 >7.0 >5.8 

Co-efficient of growth ‘em’ (mm/m/15yrs) 5.4 

– Characteristic compressive strength (f’m) M4* mortar (EXP) >7.0 >7.0 >7.0 >4.7 >5.9 >6.4 >5.8 




1.407 

Boral Bricks Blends 

Brand Blend Name Blend Mix Ratio 

Horizon Brighton Sands 1Coral Sands/1Delta Sands 50% / 50% 

Horizon Capes Lagoon 2Sandy Bay/1Murray River 66% / 33% 

Horizon Carrington 2Pink/1Cream/1Natural 50% / 25% / 25% 

Horizon Castlemaine 1Pink/1Cream/1Natural/1Grey 25% / 25% 25% / 25% 

Horizon Chalcedony 2Rubellite/1Jarosite/1Graphite 50% / 25% / 25% 

Horizon Copeland 2Cream/1Grey 66% / 33% 

Horizon Echo Point 1Sandy Bay/1Red Cove/1Murray River 33% / 33% / 33% 

Horizon Galena 2Jarosite/1Graphite 66% / 33% 

Horizon Georges Basin 1Sandy Bay/1Red Cove 50% / 50% 

Horizon Hawkesbury 1Pink/1Cream 50% / 50% 

Horizon Hunter 2Pink/1Cream/1Grey 50% / 25% / 25% 

Horizon Manning 3Pink/1Natural 75% / 25% 

Horizon Outback 5Windorah/1St George 83% / 17% 

Horizon Patterson 3Cream/1Natural 75% / 25% 

Horizon Reef 1Coral Sands/1Pewter Sands/1Delta 33% / 33% / 33% 

Oasis Barclay 1Sorrell/1Alpine/1Riverclay 33% / 33% / 33% 

Oasis Bendemeer 1Linden/1Albion 50% / 50% 

Oasis Grange 1Hendra/1Ascot 50% / 50% 

Oasis Raffia 5Sorrell/1Alpine 85% / 15% 

Oasis Sandstone Blush 5Cameo/2Limestone Hue 70% / 30% 

Oasis Tambo 5Alpine/1Sorrell 85% / 15% 

Woodstock Apsley 1Sandhurst/1Drysdale/1Hillview/1Crestwood 25% / 25% 25% / 25% 

Woodstock Bakehouse Gold 1Lexington /1Potters Gold/1Sandstone Gold 33% / 33% / 33% 

Woodstock Barweave 1Lexington /2 Mowbray 33% / 66% 

Woodstock Boyd 1Country Rose/1Cascade 50% / 50% 

Woodstock Brunswick 5Mowbray/1Kingsley 85% / 15% 

Woodstock Carbrook 4Bentley/1Kingsley 80% / 20% 

Woodstock Clarence 1Honeycombe/1Dusk 50% / 50% 

Woodstock Daintree 1Sandhurst/1Crestwood 50% / 50% 

Woodstock Diggers Gold 1Potters Gold/1Sandstone Gold/1Winter Gold 33% / 33% / 33% 

Woodstock Dustwood 5Lexington/1Potters Gold 85% / 15% 

Woodstock Glenayr 1Sandhurst/1Drysdale 50% / 50% 

Woodstock Hastings 1Honeycombe/1Dusk/1Cascade 33% / 33% / 33% 

Woodstock Highland 5Sandstone Gold/1Winter Gold 85% / 15% 

Woodstock Homestead Gold 1Potters Gold/1Sandstone Gold 50% / 50% 

Woodstock Macleay 1Honeycombe/1Cascade 50% / 50% 

Woodstock Mt Cotton 2Bentley/2Mowbray/1Kingsley 40% / 40% / 20% 

Woodstock Rywood 5Winter Gold/1Sandstone Gold 85% / 15% 

Woodstock Stockmans 1Sandhurst/1Crestwood/2Hillview 25% / 25% / 50% 

Woodstock Wickham 1Bentley/1Mowbray 50% / 50% 

Woodstock Wilson 1Dusk/1Country Rose/1Cascade 33% / 33% / 33% 

Woodstock Woodland 1Sandhurst/1Drysdale/1Crestwood 33% / 33% / 33% 

ADV03809

2 Pavers 

2. Pavers

2.1 

Paver Properties


Section 2.1 Paver Properties 2.101 

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

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

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

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

Paver Dimensions 

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

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

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

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

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

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

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

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

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

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

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

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

comparing that measurement to twenty times the work size. 

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

• Dimensional Category, DPA1 means, for typical pavers, the height and width will differ by less than 50 mm 

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

• Dimensional Category, DPA2 means, for typical pavers, the height and width will differ by less than 40 mm 

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

• Dimensional Category, DP0 means there are no requirements. This is usually reserved for non-standard pavers 

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

DPO pavers are reserved for residential pathways. DPA1 and DPA2 pavers are specified in applications requiring 

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

traffic or heavier loads. ■ 

ADV2101



Paving Strength 

Minimum Breaking Load 

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

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

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

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

the bedding course has failed. 

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

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

measuring 10 samples. 

Compressive Strength of Pavers 

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

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

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

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

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

ADV2102



Durability 

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

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

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

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

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

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

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

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

the grades of paver can be used as follows: 

• General Purpose Grade (GP) 

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

• Exposure Grade (EXP) 

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

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

Boral provides pavers in both EXP and GP grades. 

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

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

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

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

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

representative so they can nominate those available. ■ 

Slip Resistance 

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

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

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

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

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

ADV2103



Abrasion Resistance 

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

Determining Abrasion Resistance is used for testing the abrasion resistance of clay pavers. The test consists of 

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

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

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

depends on the volume of traffic. ■ 

Moisture Expansion 

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

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

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

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

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

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

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

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

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

Efflorescence 

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

the raw materials used in the production process. 

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

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

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

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

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

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

ADV2104



Pitting due to Lime 

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

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

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

generally circular pit with a white spot in the bottom. 

Boral pavers rarely show lime pitting. ■ 

Cold Water Absorption 

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

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

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

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

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

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

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

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

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

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

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

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

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

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

ever and some coatings darken over time. ■ 

ADV2105

2.2 Pavement Design


Section 2.2 Pavement Design 

2.201 

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

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

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

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

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

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

Pavement Types 

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

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

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

1. Pedestrian traffic only 

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

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

4. Primarily vehicular traffic 

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

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

sub-base, may be inserted between the subgrade and the base course. On rare occasions, where the subgrade is 

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

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

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

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

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

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

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

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

ADV2201



Pavement Types (continued) 

2.202 

• The ‘Pedestrian traffic only’ category is typically residential paths and hard landscaped areas, paths in public 

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

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

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

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

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

some damage. 

• The ‘Pedestrian traffic and commercial vehicles’ category is typically public malls, crossovers, driveways that 

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

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

• The ‘Primarily vehicular traffic’ category is roads. Few segmentally paved roads are now constructed however; 

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

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

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

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

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

ADV2202



2.203 

Description of Layers and Basic Engineering Design 

Requirements 

Figure 1. Typical elements of flexible pavements 

Concrete 

Edge Strip 

Subgrade 

Jointing sand 

Clay pavers 

Surface course 

Bedding course 

Base course 

Subgrade 

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

considered. 

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

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

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

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

ADV2203



Base Course 

2.204 

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

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

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

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

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

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

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

the required soil density has been achieved. 

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

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

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

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

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

Table 1. Typical Grading for Base Course Materials 

Sieve Size Percent Passing 

26.5 mm 100 

19.0 mm 95-100 

13.2 mm 78-92 

9.5 mm 63-83 

4.75 mm 44-64 

2.36 mm 30-50 

425 µm 14-22 

75 µm 4-12 

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

susceptible to the effects of saturation. 

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

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

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

Concrete Structures requirements. ■ 

ADV2204



Bedding Course 

2.205 

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

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

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

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

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

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

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

ground waters. 

Table 2. Typical Grading for Bedding Course Materials 

Sieve Size Percent Passing 

9.5 mm 100 

4.75 mm 90-100 

2.36 mm 75-100 

1.18 mm 55-90 

600 µm 35-59 

300 µm 8-30 

150 µm s 0-10 

75 µm 0-5 

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

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

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

most important that the bedding course is of uniform thickness. 

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

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

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

may also be effective as a drainage layer. 

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

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

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

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

ADV2205



Surface Course 

2.206 

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

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

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

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

Table 3. Recommended Specifications for Clay Pavers 

Application 

Minimum 

thickness 

(mm) 

Minimum 

characteristic 

breaking load (kN) 

Dimensional 

deviation 

Slip resistance 

classification 

Mean abrasion 

resistance (cm 2 ) 

Residential (domestic) pavements 

Pedestrian traffic only 40 2 DP0 W N/A 

Driveway, light vehicles only 40 3 DPA1 W N/A 

Driveway, including commercial 

vehicles 

Public area pavements 

60 5 DPA1 W N/A 

Pedestrian traffic only 40 2 DPA1 W Low volume: 7 

Pedestrian traffic and light vehicles 

(axle loads < 3 tonnes) 

Pedestrian traffic and commercial 

vehicles (axle loads > 3 tonnes) 

Roads 

50 

60 

3 

5 

DPA2 

DPA2 

W 

W 

Medium volume: 5.5 

High volume: 3.5 

(See Note 1) 

General vehicular traffic on minor 

or local roads 

60 6 DPA2 W 

N/A 

(See Note 2) 

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

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

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

30 000 passes per day). 

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

ADV2206



Edge Restraints 

2.207 

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

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

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

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

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

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

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

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

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

of 20 MPa. ■ 

Figure 2. Typical edge restraint systems 

Paver on edge (or treated timber) set in mortar or concrete. 

Hardwood on edge supported by hardwood stakes 

Mortar haunch 

ADV2207



Figure 2. Typical edge restraint systems (continued) 

Preformed concrete 

Concrete poured on site (driveways mainly). 

Concrete poured on site (driveways mainly) 

Figure 3. Using an existing structure as an edge restraint 

150mm 

Damp Proof Course 

Mortar Bed 

The edge paver is set on a mortar bed (shown as grey). 

2.208 

Jointing sand 

Clay pavers 



Base course 

Subgrade 

ADV2208



Drainage 

2.209 

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

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

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

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

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

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

particularly in the early life of the pavement. 

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

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

where it can be discharged safely. 

Figure 4. Typical drainage systems in flexible pavement 

PVC Pipe 

Clay pavers 



Base course 

Subgrade 

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

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

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

ADV2209



Paver Laying Patterns 

2.210 

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

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

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

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

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

the pavement. 

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

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

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

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

use patterns with large repeat distances to advantage. 

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

laying patterns and colours, many effects can be created. As with a carpet the effect can be a solid uniform colour, 

a mottle producing an overall colour impression, random coloured highlights, a polychrome patchwork, geometric 

patterns, etc. Some designers have used pavers to create pictures on a grand scale. Effects may also be much more 

subtle such as using regular arrays of similar coloured pavers to produce textural effects. t 

ADV2210



Paver Laying Patterns (continued) 

45° Herringbone 90° Herringbone Zig Zag 

Basket weave 2 x 2 Basket weave 2 x 1 45° Basket weave 

(¾ Basket weave or Basket weave variant) 

Stack Stretcher or running Off-set stretcher or running 

45° Stack Mixed stack and running Tracery 

Off-set stack 

2.211 

ADV2211



Joints Between Pavers 

2.212 

Pavers laid on bedding sand should have gaps of 2-3 mm left between them for the jointing sand. To be effective, 

gaps should never be less than 1 mm nor more than 5 mm. After laying the pavers jointing sand is spread over and 

broomed into the gaps. A plate vibrator is then passed over the surface, levelling the pavers and vibrating sand 

down into the gaps while settling and compressing the pavers into the bedding sand. At the same time some of the 

bedding sand is forced up into the joints. 

Sand filled joints are essential as the sand interlocks the pavers so that imposed forces are shared between 

adjacent pavers. Interlock is of three types; vertical, horizontal and rotational. 

• Vertical interlock ensures a paver does not slide down relative to its neighbours by sharing loads between 

neighbouring pavers. 

• Rotational interlock ensures that a paver loaded at one side does not rotate. Pavers need space to rotate so edge 

restraints and proper filling of the joints prevent movement that would otherwise allow pavers to rotate. The sand 

moves the point at which the pavers would rotate (i.e. the hinge) to the top of the joint and prevents the top edges 

of adjacent pavers coming into contact. Pavers contacting their neighbours are very likely to chip when loaded. 

• Horizontal interlock is provided by the laying pattern. Wheeled traffic pushes the pavers and where straight 

lines occur in the laying pattern the pavers can move past each other (this is called shunting). Where the 

pavement carries wheeled traffic a herringbone pattern (either 45˚ or 90˚) is recommended. There seems to be 

no difference in the performance of the different styles of herringbone or in orientation relative to the traffic. 

For pavements only carrying pedestrian traffic, horizontal interlock is required to a much lower degree and a 

wide range of decorative laying patterns may be used. Gaps between pavers that are too narrow (



Tolerance on Course Levels 

Subgrade should be finished to +0, -25 mm of the design level. 

2.213 

Where the pavers are laid on bedding sand the base course (and where used the sub-base) should be finished to 

+0, -25 mm except where it abuts existing structures where +0, -10 mm is appropriate and in any 3 metre length the 

surface should not be higher or lower than 10 mm from the average (taking into account any falls). 

Bedding courses should be finished to the thickness required to bring the surface course to the design level, taking 

into account the thickness of the surface course and compaction as the pavers are vibrated to settle them into the 

bedding course. This will depend on the bedding course materials and its moisture content. Where local experience 

is not available the required thickness should be established by trial. 

Surface courses should be finished to ±6 mm of the design level, except where it abuts a kerb or drainage 

channel where it should be finished to +6, -0 mm. In all cases there should be less than 3 mm difference between 

adjoining pavers. ■ 

Crossfalls 

A 1:60 crossfall is normally satisfactory for drainage. Crossfalls should not be less than 1% (1:100) unless specific 

measures have been taken to ensure water does not build up on the pavement e.g. covering it with a roof. The 

general rule is that the broader the paved area the greater the crossfall. Crossfalls are sometimes restricted by the 

site’s landform and some pooling of water in heavy rain may be acceptable. ■ 

ADV2213



Steep Gradients 

2.214 

Even on the best constructed pavements, water running over or dripping or splashing onto steeply sloping 

pavements may wash out the jointing sand, particularly early in the life of the pavement. Localised rutting (usually 

from inadequate subgrade or base course preparation), loss of bedding sand (usually from poor sub-surface 

drainage), and localised movement (usually at or near poor edge restraints) can also lead to loss of the jointing sand. 

For pavements carrying wheeled traffic (such as driveways) this is a particular problem as it may result in the 

pavers chipping or shunting (moving laterally). To avoid shunting and chipping pavers, maintaining the jointing sand 

and using a restraint system are essential. Rigid pavement with the pavers adhered directly to a concrete slab and 

the joints filled with mortar or grout has been used successfully as an alternative. 

Maintaining the jointing sand is as simple as sweeping more sand over when needed. Proprietary jointing sands are 

available containing cement, mineral and polymeric binders. The additives bond the sand together and this has 

been shown to be beneficial on steeply sloping pavements because the sand does not wash out as easily, but 

beware of potential staining problems. Use only as directed by the manufacturer and construct a small trial area to 

test if there are any problems in use. 

The principle of restraint systems is to subdivide the pavement into (typically 5 metre) sections restrained at the 

periphery. Because the section length is short the potential for movement is reduced. A typical restraint system 

uses a plain concrete transverse beam. Concrete beams should be designed to AS3600 requirements and be 

constructed from ready mixed concrete with a minimum strength of 20 MPa. 

Figure 5. Typical plain concrete transverse beam for a steep single residence driveway 

PVC Pipe 

Clay pavers 



Base course 

Subgrade 

The depth of the concrete beam depends on the soil type. Typically for a single residence driveway on clay, the 

beam is 250 – 300 mm deep. The pavers are adhered to the beam typically with a 1:4 cement to sand mortar with 

additives to enhance bonding or the pavers are pressed into wet low slump concrete. An exposed plain or exposed 

aggregate concrete beam can be used instead of having pavers bonded to it. ■ 

ADV2214

2.3 Pavement Construction


Section 2.3 Pavement Construction 

2.301 

Each job is different and the descriptions below may or may not be suitable in any particular instance. The steps in 

the construction of the pavement may vary in their order. For example, edge restraints for a heavy duty driveway 

will usually be constructed between the preparation of the subgrade and the base course but may be constructed 

between the preparation of the base course and the bedding course. However, for light duty driveways edge 

restraints may be put in after preparation of the base course and for domestic pathways professional paviours 

almost always put in edge restraints after laying the surface course. For an amateur it is best to construct the edge 

restraints early. 

Paver Estimator 

Pavers can be different sizes and shapes and pavements can be any size and shape. The more complex the 

pavement’s shape usually the more cutting and therefore the more pavers required. For regular pavements, 

determine the number of pavers for the length of the pavement and the number of rows for the width of the 

pavement. Half pavers should be calculated as a whole paver, due to site wastage. Multiply the number of pavers 

by the number of rows to give the number of pavers for the pavement. Saw cutting pavers is usual practice but that 

does not mean two pieces will be obtained from any paver. For complex pavements, draw the pavement accurately 

to scale on squared paper and work out the approximate area and multiply this area by the factor in the relevant 

paver property table. Always allow some excess pavers for site wastage. ■ 

Subgrade Preparation 

The subgrade should be prepared to the design profile. The prepared area should be wider than the pavement, 

extending beyond the rear edge of the edge restraints or up to existing structures. Unsuitable material including the 

topsoil, roots and other organic matter should be removed from the subgrade. Proof rolling may be used to identify 

areas of unstable subgrade, which should be removed or compacted to achieve the desired strength. Observing a 

loaded truck slowly crossing the area will generally show areas of unstable subgrade. The subgrade should be 

excavated, compacted, trimmed or built up with compacted base course material as necessary to within +0mm, -25 

mm of the design level. 

The most common reason for the failure of pavements is inadequate subsurface drainage and so, where necessary, 

install sufficient stormwater and subsoil drainage to prevent the accumulation of water in any area excavated for 

the pavement. Water accumulating in this location could reduce the stability of the whole structure or bring 

efflorescing salts to the pavement surface and detract from appearance or durability. All trenches should be 

backfilled to ensure they perform similarly to the undisturbed ground around them. ■ 

ADV2301



Base course Preparation for Flexible Pavements 

2.302 

The base course is made from granular material (usually called road base) compacted in layers. The thickness of the 

layers and the number of passes of the compactor should be matched to the capability of the compaction device. 

For large machinery it is usual to compact in 150 mm layers but for a vibrating plate compactor layers less than 100 

mm are usual. The number of passes of the compactor varies but for a vibrating plate compactor three passes is 

usually satisfactory for domestic pavements carrying only pedestrian traffic. In typical domestic pavements 100 

mm of compacted base course is usually sufficient. 

The base course should be screeded and compacted to the design profile (+0, -25 mm except where it abuts existing 

structures where +0, -10 mm is appropriate). The top surface should be closed after compaction but if holes are 

apparent because of the nature of the material used, fines can be screeded on and compacted into the surface to 

fill any voids. 

Where stabilised base course is required, in most circumstances it is best to purchase it ready mixed, just before 

use. Cement stabilised materials may set if not used within a few hours and if a delay is expected slower setting 

materials and retarders are available. Mixing on site should only be done in a concrete mixer as it is difficult to get 

an even distribution of the binder by hand mixing. ■ 

Edge Restraints for Flexible Pavements 

All edges of all pavements must be restrained to prevent lateral movement of the pavers and consequent loss of 

interlock. The size and strength of the restraints must be adequate to support the intended loads. The shape and 

style of the restraints must prevent the escape of bedding course material from beneath the pavers and must be 

aesthetically pleasing. 

Edge restraints should be formed before compacting adjacent pavement layers. However, adjacent layers may first 

be compacted then some compacted material may be carefully cut and removed for the haunch1 if the haunch 

material is initially fluid e.g. concrete or mortar. Concrete and mortar haunching, and concrete beams and slabs 

should be mature before vibration and compaction of the surface course is undertaken. 

As a minimum, haunching must continue down to the underside of the bedding course. As haunching is usually a 

barrier to water movement, drainage should be provided through the haunching to prevent the build up of water in 

the bedding course. ■ 

1 A ‘haunch’ is that part of an arch between the crown and the springing line, in effect, a half an arch. Because of 

its shape, in paving ‘haunch’ has come to mean the material supporting the side of the pavement. ‘Haunching’ is 

an alternate form of ‘haunch’. 

ADV2302



Bedding Course for Flexible Pavements 

2.303 

Bedding course material should be well-graded, coarse, sharp sand (typical of a concrete sand). Bricklaying sands, 

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

capillary break and thus should not be used. Manufactured sands with excessive fines, (crusher dust), should not be 

used as they do not provide a capillary break and this results in efflorescence on the pavers. 

The moisture content of the bedding course should be uniform, so stockpiled material should be covered before 

use. 

Waterproof membranes beneath the bedding course are not advised except where the paving is completely under 

cover. A waterproof membrane will prevent salt laden water being drawn up to the surface limiting efflorescence 

but it is unnecessary with a properly chosen base course material. The reason for not using a waterproof membrane 

is that it traps water causing the base course to become saturated and this can lead to pumping, the loss of fines 

and the eventual breakdown of the pavement. Where the surface of the base course is not densely compacted or 

where movement may occur in the sub-grade opening up cracks in the base course (i.e. where bedding sand may be 

lost), the use of geotextiles is usually beneficial. Geotextiles are tough, polymeric felts with holes small enough to 

prevent the sand penetrating. Other cloths are generally not suitable. 

Cement-stabilised bedding sands are not recommended where well-graded bedding sand is available. If poor 

quality bedding sands must be used very lean cement stabilisation may be appropriate. Adding two to four per cent 

cement (by volume) to the bedding sand is usually satisfactory. Where the slope of a pavement exceeds 1:15 cement 

stabilising the bedding sand is practical and should prevent water scouring out the sand. For driveways with a 

sloping pavement having a length greater than 5 metres, a transverse concrete beam running between edge 

restraints should also be used. A capping course of pavers is bonded onto the top surface of the beam and the 

pavers, up slope from the beam, are then laid on cement-stabilised sand. (See Section 2.214 for more information 

on flexibly paved sloping driveways.) 

The bedding course should be screeded to 25 -30 mm thick. The base course should be finished accurately enough 

to not need to vary this thickness, however, the bedding course may not be less than 20 mm thick and not more than 

40 mm thick. t 

ADV2303



Bedding Course for Flexible Pavements (continued) 

Either of the following installation procedures is acceptable: 

2.304 

• Spread the material loose and screed to the final level plus an amount to accommodate the reduction in 

thickness that will occur when the pavers are vibrated; or, 

• Spread the material loose and screed to the final level. Vibrate and compact this sand using the same vibrating 

plate compactor as that used for vibrating the pavers. Finally spread and screed a thin layer to form a loose 

surface onto which the pavers can be laid. 

In either method the sand should be disturbed as little as possible before laying the pavers. Any disturbance may 

lead to final surface undulations. Gaps between edge restraints or at the intersection with other pavements should 

be sealed to avoid loss of bedding sand. 

Screeding is usually done by placing rails (sometimes called trammels) made of pieces of timber or pipe at the right 

level and dragging a piece of straight timber or aluminium over them levelling the sand. After removing the rails 

there is a depression in the sand and that is usually filled by the paviour trowelling on some sand as the pavers are 

laid. Where the edge restraints are in place and sufficiently close together, a screed can be made from a piece of 

timber notched to fit within the restraints or a piece cut to fit between the restraints then a second, longer piece of 

wood is nailed to the top of the first piece of timber. The timber is drawn along the restraints levelling the sand 

between them. 

Figure 6. Screeding bedding sand 

Screed Bed 

Trammel 

Edge restraint set to 

concrete level 

Where the slope of the pavement changes direction, screed to an apex or ‘v’ then flatten the apex with a trowel or 

fill and smooth the depression so the directional change is over as many pavers as possible and the height 

difference between neighbouring pavers is minimised. ■ 

ADV2304



Paver Storage 

2.305 

Pavers stored on site should be covered and kept off the ground. Saturated pavers may adversely affect the bond 

strength in rigid pavements or where pavers are adhered to cross beams. 

Store pavers away from where saw cutting of bricks and pavers is being conducted, and away from cement and 

other materials which may stain them. 

Moving pavers around the site may cause chipping, so excessive movement of packs should be avoided. ■ 

Blending 

Some colour variation is inevitable in clay pavers. Colour variation when poorly handled may lead to unwanted 

patches, streaks and bands of colour in the finished pavement. The raw materials for paver making are natural clays 

and shales and these vary in colour within any one deposit. Paver makers blend materials to moderate the colour 

variation and tightly control the conditions in the kiln but no matter how well made, pavers delivered to site will 

have some degree of colour variation. 

To minimise colour variation and the visible effects of it, the following is recommended: 

• All pavers of the one colour required to complete a pavement should be ordered at the one time; 

• All pavers required for the project, but in any case as many packs as will fit, should be delivered at one time 

and stored on site; 

• Pavers should be drawn from as many packs as possible, simultaneously, working down from the corners of 

each pack; and, 

• Edge pavers of the same colour as the bulk of the pavement should be selected at the same time as those in 

the adjacent pavement. Those requiring cutting should then be marked up, cut and positioned. Selecting all 

edge pavers separately for cutting may produce an undesirable effect. 

Pavers are supplied with one face suitable for exposing (i.e. to be seen after laying). On some pavers both faces are 

suitable for exposing but they may look different. The paviour should ensure where two sides are different the 

pavers are laid to produce the aesthetic required. Two faced pavers that have unwanted marks, chips or cracks on 

one face should be turned over, exposing the good face in the pavement. Single sided pavers that have unwanted 

marks, chips or cracks on the face or any paver with significant edge damage should be set aside by the paviour (or 

labourer) for cutting pieces. Boral will not be responsible for replacing pavers with unwanted marks, chips or cracks 

that have been laid. ■ 

ADV2305



Laying Practices 

2.306 

Pavers being a regular form are usually laid in regular patterns containing straight lines. These lines are critical to 

the look of the pavement and are marked out with stringlines which are used to set out the pavers. Judging the 

line(s) to use requires an assessment of the pattern and the site. Where there is a strong central line in the 

pavement this is usually critical and a stringline would be placed on that line and set out would be from that line. 

Pavements abutting existing structures usually follow their lines and gauging should be done from them. Edges or 

ends of pavers are usually aligned with the stringline but in the case of 45˚ herringbone corners are aligned to it. 

While experienced paviours gauge by eye it is usual practice to place stringlines at regular intervals (10 rows in 

pavements on sand bedding courses) to check the pattern is regular. If the line of the pavers has deviated from the 

stringline it is usually necessary to remove a few rows of pavers and relay them making adjustments to the joint 

width to return to the correct alignment. Depending on the magnitude of the misalignment, realigning may need the 

removal and relaying of three or four rows. 

Pavers are usually laid from one side or from the centreline. 90˚ herringbone is usually laid from a corner or 

sometimes from the centre of one side advancing out in the shape of a triangle. Whole pavers are laid first followed 

by part pavers. 

Pavers on Sand Bedding Courses 

Pavers must be laid so that there is a joint of 2 to 5 mm between them. Pavers should never be butted up against each 

other. Where joints are too narrow insufficient sand will fill them and it is likely the pavers will contact each other 

which will lead to chipping of corners and edges and may lead to rutting, shunting and the failure of the pavement. 

Laying is usually forward from the laid pavers and not from the sand in front. Where laying from the front must be 

done the bedding sand should be compacted and only a thin screed layer left loose on top and where possible 

boards should be used to minimise the disturbance and prevent the need to re-screed the sand. Pavers should be 

placed in the correct position without regard to their neighbours, leaving gaps where a full paver will not fit. Small 

amounts of sand may be trowelled on to adjust the level if needed. This is particularly the case where two or more 

different types of paver are used in the one pavement. 

Pavers with Mortared Joints 

Mortared joints in pavements are usually 10 mm and laying is from the side or front of the pavers. Good brick laying 

techniques should be used including laying to stringlines or using levels to ensure pavers are to the required level. It 

is usually easier to lay part pavers at the same time as laying whole pavers. Careful mortar preparation, clean 

working and fully bedding and filling all joints are important. t 

ADV2306



Laying Practices (continued) 

Laying Part Pavers 

2.307 

Whole (and damaged or part) pavers are held over the holes left after laying the whole pavers and the piece 

required to fill that hole is marked directly on the paver. Where this is not possible carefully measure the piece 

required and transfer the measurements to a paver. Note: Do not forget the gap for the jointing sand. Pavers should 

always be cut using a masonry saw as this is the only way to get an accurate cut. For small jobs done by nonprofessional 

paviours, because of the cost of hiring a masonry saw, masonry wheels or blades on angle grinders 

and bolsters are frequently used but the accuracy of the cut suffers. It must be remembered that many pavers are 

very dense and may break into many pieces if hit with a bolster. It is always better to have two larger cut pavers 

than one whole paver and one small piece. Cut pavers should always be greater than one third of the area of the 

paver when cut across the paver or greater than one quarter of the area of the paver when cut diagonally. 

For cutting dense hard materials, masonry saw blades without teeth are preferred. For cutting softer materials 

toothed masonry saw blades are preferred. Obviously a professional paviour will require two blades if they lay 

concrete and clay pavers. Toothed blades used to cut hard pavers usually wear faster than smooth blades. 

Laying Pavers on Curves and Around Obstacles 

The smaller rectangular or square objects are the tighter the curve they can follow. If you do not mind the look of ‘v’ 

shaped joints, with no gap at the base and a 20 mm gap at the top, standard pavers can form a circle 3.5 metres in 

diameter. Few people want such wide ‘v’ shaped joints (which also have to be mortar filled because sand will wash 

out) and so it is common practice to cut pavers to suit the curve. 

Figure 7: 

Curve formed without cutting pavers Curves formed by cutting one or two sides of the pavers. 

To minimise cutting some paviours cut only one side of the paver or cut every second paver. If only one side of each 

paver is cut, the joints do not point to a common centre so the curve has a skewed appearance. Curves formed of 

alternating uncut and double-cut pavers also have an unusual appearance. It is a matter for each individual to 

decide if they find the aesthetic acceptable, particularly around tight curves such as manhole covers or trees. t 

ADV2307




Figure 8. Manhole cover detail 

2.308 

Figure 8 shows a soldier course of double-cut, tapered pavers in a circle around a manhole cover, set in a 45° 

herringbone pavement. Note the small pieces of paver needed to maintain the pattern and fit the circular inclusion. 

It is almost impossible to eliminate these smaller pieces but judicious use of half pavers will allow an increase in 

the size of the smaller cuts giving the pavement greater stability in this area. 

Corners in Header Courses 

A soldier course or a single or double stretcher course is often used around paving as a border. For corners that are 

not right angles a properly cut mitre is essential to avoid an overhang. At right angled corners in a soldier course a 

mitred joint is recommended. t 

Figure 9. Non-right angle corners 

Unmitred 45° angle Mitred 45° angle 

Figure 10. Right angle corners in double stretcher course 

ADV2308




Figure 11. Corners in soldier course 

Figure 12. Treatment of right angled service covers 

2.309 

In Figure 12, note on the left hand cover the use of two larger cut pavers in the top, bottom and left hand sides to 

replace the one thin sliver in the soldier course as shown on the right hand side. Around both edge courses in the 

body of the paving, note the use of half pavers (dark brown) to avoid the use of a small triangular piece at the edge 

of the soldier or stretcher course. Small pieces of paver as shown on the right hand side of the right hand cover 

should be avoided. This half paver technique should also be used adjacent to borders around any 45° pattern. t 

ADV2309




Figure 13. Treatment of recessed covers 

2.310 

For recessed covers, pavers should be cut and fitted to maintain the pattern. Small pieces inside the recess are not 

a problem as they are restrained by the edge and the pieces are normally glued to the cover. To maintain the pattern 

outside the cover it can be necessary to use small pieces of paver. It is usual to remove the bedding sand under 

these pieces and replace it with mortar for stability. 

Warnings: 

1. Cutting pavers produces a very fine dust (becoming a mud when using a proper water cooled masonry saw). 

Pavers contain crystalline silica and dust from dry cutting is hazardous to your health if breathed in. 

2. The residue from cutting forms a hard, solid mud which in sufficient quantities will block drains. It is advisable 

to have a container under the drain on a brick saw bench to act as a sediment trap. The sediment should be 

removed periodically throughout the cutting and disposed of properly. Allowing this sediment to flow into 

drains or water courses attracts a fine in most jurisdictions. 

3. The residue from cutting and the spray from the saw can get into the pores of bricks, pavers and other 

materials leaving a permanent stain. This should be prevented by careful placement of the saw but should this 

happen the only technique known to have been successful in removing the stain from bricks and pavers is to 

rub the stain with a firm cloth with a paste of sand blasting grit (glass fragments). This is very time-consuming, 

physically hard work and not guaranteed to work. It may harm the bricks or pavers and should always be tried 

on a small inconspicuous area first to test the effect. ■ 

ADV2310



Sand Filled Joints 

2.311 

Joint-filling sand should be spread over the surface of the pavers and swept into the joints. Sand should be dry to 

flow into and fill joints effectively. Damp sand should not be used as the joints will not be filled effectively. Sands 

containing clay should not be used as they are likely to stain the surface of the pavers. 

Commercially prepared stabilised, jointing sands are available and although more costly than bulk sand may be 

better in some instances. The manufacturer’s advice should be sought on the proper use of these sands as improper 

use may lead to staining of the pavers. ■ 

Mortar Filled Joints 

Mortared joints are now rare in large pavements, however where mortared joints are used they should be finished 

as an ‘ironed’ joint. Mortar smears on such pavements will usually require cleaning and the same precautions and 

techniques as used to clean bricks apply. Mortar composition must be carefully controlled to achieve good bonding 

and prevent excessive shrinkage. ■ 

Compaction 

Compaction is necessary for all pavements laid on sand base courses and should follow laying and joint filling as 

soon as possible but should not occur closer than one metre to the unrestrained working edge of the pavement 

under construction. No area of paving should be left uncompacted at the completion of the day’s work, apart from 

the edge strip of the laying face. 

Compaction should be carried out using a vibrating plate compactor with a plan area of not less than 0.25 m2 or a 

rubber-rolled mechanical vibrator. Vibrating plate compactors should be fitted with a glider attachment but where 

not available the plate may be wrapped in carpet or a carpet square or a sheet of plywood can be laid over the 

pavers to protect them from damage during compaction. 

The area to be compacted should be swept clean of joint filling sand and then receive at least two passes of the 

vibrating plate compactor. The joints should then be topped up by sweeping joint filling sand over the area prior to a 

final compaction consisting of at least two more passes of the vibrating plate compactor. Compaction should 

continue until the tops of all pavers are in the same plane. No paver should be more than 3 mm out of plane with its 

neighbours. 

The jointing sand will continue to settle over the ensuing weeks, and should be topped-up by brooming sand over 

empty joints until they are filled. Vibration for this topping up is not required. ■ 

ADV2311



Trafficking After Construction 

2.312 

Flexible pavements may be trafficked immediately after construction depending on the nature and age of the edge 

restraints. Where edge restraints are constructed with cement, traffic should be restricted until they gain 

sufficient strength. ■ 

Cleaning 

In most cases cleaning pavements after construction is as simple as picking up and sweeping off the sand, paver 

pieces etc. In some instances there is mortar to clean up. Cleaning mortar off pavers is best done when fresh as it 

is easier and less likely to create problems. 

Hosing, vacuuming or blowing of any pavement with sand filled joints is not recommended for the first three months 

of its life. Hand brooming is recommended in this time. If jointing sand is removed broom more on to top up the 

joints. High pressure water or steam cleaning is not recommended for householders and should only be done by 

trained professionals. High pressure water is the basis of a cutting technique, used for cutting stone, glass, 

concrete, tiles, pavers, and some metals. Incorrect use of high pressure will damage the face of the pavers. Small, 

cheap, high pressure cleaners, capable of exceeding 15 MPa (2200 PSI), are now commonly available and incorrectly 

used they will damage pavements. 

Clay pavers do not change colour in service. Changes in colour are usually related to the build-up of dirt, coloured 

materials on the surface (red wine, tannins, grease, food, tyre marks, etc.), growths (lichen, moss and algae), salts 

(efflorescence) or physical damage. Colour change in one area and not another is usually an indicator of the source 

of the problem. 

All pavements are subject to spillages and soiling and a build-up of dirt and grime. Frequent sweeping and washing 

reduces the effect of dirt and grime and maintains the attractiveness of a pavement. Washing with detergents and 

liquid household bleach (sodium hypochlorite) will not damage the pavers but remember incorrect use of these 

chemicals has severe environmental consequences and in some areas there are penalties for putting them into the 

stormwater system. 

Where grease or oil (including greasy food) will be spilled on the pavement, such as around barbecues, outside 

take-away food shops, around public eating places, driveways, etc., using dark coloured pavers makes the problem 

less noticeable. Sealers can be used to prevent or minimise absorption into the pavers and make removal by 

washing with detergent easier. Prevention is the only 100% cure but it should be remembered that weathering and 

bacterial action will eventually remove the residue once the cause is removed. t 

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Cleaning (continued) 

Efflorescence 

2.313 

This is a powdery deposit of salts (usually white or yellow), often found on the surface of clay pavers after rain. The 

source of this stain could be the pavers but almost always it comes from the soil under the pavement, or from 

cement (if the soil was stabilised), or both. Dry brushing to remove the efflorescence before washing is 

recommended. If efflorescence is wetted, the salts go into solution and are drawn back into the pavers and will 

reappear as the pavement dries. Efflorescence will eventually disappear through natural weathering. 

White scum 

Do not confuse white scum with efflorescence. White scum is a thin white film on the surface of pavers. This film is 

invisible when the pavers are wet but shows up as the surface begins to dry. Scum often appears after an 

attempted removal of mortar stains or after the sanding of the joints with sand that has a high clay content. 

White scum is particularly difficult to remove. Water, detergents or hydrochloric acid often do not have any effect 

on it. However scrubbing with a proprietary brick cleaner will often improve the appearance of pavements affected 

by this stain. 

Dirt and grime 

Frequent sweeping and hosing will usually ensure a clean pavement. It this is not enough, washing with a detergent 

or a proprietary cleaner may be required. 

Vanadium stains 

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

pavers. Hydrochloric acid will make these stains much worse and may make them impossible to clean. Vanadium 

stains will disappear in time but in most cases they are easy to clean. Mild vanadium stains may be treated with 

sodium hypochlorite (household bleach). Spray or brush it on the dry pavers and leave until the stain disappears, 

then rinse off. Proprietary mould cleaners containing sodium hypochlorite and sodium hydroxide can be used as 

above and have been found very effective. Proprietary brick cleaners may also be effective and should only be used 

according to the manufacturer’s instructions. t 

ADV2313




Fresh mortar stains 

2.314 

While the mortar is soft, lightly cover it with damp clean sand. Dune sand is best but it is very important that the 

sand has no clay in it. Sweep the sand towards the edge of the pavement. Repeat if needed. Follow this with a light 

covering of dry clean sand and sweep towards the edge. Any sticky wet mortar residues that escaped the wet 

sanding will be removed by the dry sand. The next day after the pavement has dried, some mortar residue may still 

be visible as a faint white film. Smooth pavers may be carefully wiped with a cloth to take off most of the remaining 

film but the film will generally weather away if left untouched. Some efflorescence will appear as the pavement 

dries but it is not damaging to the pavers. Follow the instructions above to deal with the efflorescence. 

Oil and bitumen 

These stains usually need two treatments with a commercial emulsifying agent. First, mix the emulsifier with 

kerosene to remove the stain. Then clean the kerosene off with the emulsifier mixed only with water. When dealing 

with petroleum, asphalt and bituminous emulsion, scrape off the excess material and scrub the surface with 

scouring powder and water. Chilling the surface with ice or solid carbon dioxide can cause brittleness in the asphalt 

and assist removal. 

For petrol or lubricating oil stains, free oil must be mopped up immediately with an absorbent material such as 

paper towelling. Wiping should be avoided as it spreads the stain and tends to force the oil into the pavement. 

Hardened oil must be scraped off. The area affected should then be covered with a dry absorbent material such as 

diatomaceous earth, fine white clay, kaolin or whiting and the procedure repeated until there is no further 

improvement. Subsequently use detergent to clean up, and rinse well with clean water. 

Food stains and tyre marks 

Scrub with a full-strength commercial detergent and rinse well. t 

ADV2314




Hardened mortar stains 

2.315 

In mortar the cement binds the sand particles to each other and to other surfaces. Cleaning starts with breaking 

down these bonds and in general this requires the use of hydrochloric acid. 

Recommended acid strengths are based on application to a surface saturated paver. The recommended acid 

strength for light coloured clay pavers is 1 part acid to 20 parts water and for other pavers is 1 part acid to 10 parts 

water. Stronger acid solutions do not work more effectively and will cause staining. 

Hydrochloric acid is a corrosive S6 poison and care must be taken when using it. To avoid personal injury: 

• Wear goggles, gloves and protective clothing. 

• Always pour acids into water – this avoids splashes of highly concentrated acid onto the operator. 

• If splashed onto the body, wash with clean water and if possible, neutralise with a mixture of bicarbonate of 

soda and water. 

Before attempting to clean off mortar, make sure any efflorescence and particularly any vanadium stains are 

removed, then using a piece of wood or paver, knock off any mortar lumps. 

The next step is to fully saturate the pavers with water. This does not dilute the acid, rather it keeps it on the 

surface where the mortar is. Failure to completely saturate the surface of the pavers allows cleaning solutions, 

containing dissolved mortar and acids, to be drawn into the pavers, causing staining. 

Note: Saturating pavers and using the correct strength of hydrochloric acid solution must be strictly adhered to for 

pavers manufactured in Queensland. Their raw materials contain large amounts of iron oxide and failure to saturate 

the surface or using strong acid solutions allows acid to react with the iron oxide and create severe iron oxide 

staining. Failure to do this with pavers manufactured in other parts of Australia may lead to the acid reacting with 

iron oxide but to a much lesser degree. This form of staining is known as acid burn and is particularly visible on light 

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

Next apply the acid solution with a stiff bristled (not wire) brush and scrub vigorously. Acid takes time to dissolve 

the cement and scrubbing may take 4-6 minutes (or longer). Work at an area no larger than one square metre at a 

time and as soon as the pavers are clean wash down thoroughly. After washing, a solution of 15 g per litre of 

washing soda or 24 g per litre of sodium bicarbonate should be sprayed on to neutralise any remaining acid. 

(Continue spraying until no bubbling occurs). Excess hydrochloric acid will eventually evaporate; however, it is likely 

to cause staining. Other acids such as sulfuric acid or nitric acid will not evaporate and are not used in cleaning. 

High-pressure water jet cleaning is not recommended for pavements with sanded joints as it will remove the sand. 

If a high-pressure water jet cleaner is used on pavers, with mortared or grouted joints, be careful not to damage the 

pavers. Keep the pressure below 1200 psi (8000 kPa), use a wide fan jet nozzle, keeping it at least 500 mm from the 

surface and work at an angle not vertically. t 

ADV2315




Fungi, moulds, moss and lichens 

2.316 

These are common, particularly in shady or damp parts of the pavement. They sometimes appear as localised dark 

stains or patches of green, giving a dirty and unsightly appearance. 

Alternatively these growths may add to the appearance of the pavement. They will not damage the pavement but 

may cause it to become slippery. To remove these growths, vigorously brush the effected area when it is dry. Highpressure 

water may also be used following the precautions above. Although the problem may appear to be gone, 

the cause is still present and it is recommended that a poison be applied. Copper sulphate solution or sodium 

hypochlorite (liquid household bleach) generally work well if used as directed on the container. Proprietary 

herbicides and fungicides are available from plant nurseries, however, some of these may discolour the pavement. 

Check their effect on a small part of the pavement before proceeding to clean the whole area. Follow the 

manufacturer’s directions and avoid nearby garden plants or lawn, especially on the lower side of the paved area 

being treated. 

Chewing gum 

In large areas, wire brushes free from rust should remove the majority of chewing gum. This may require several 

attempts and the wire may leave traces of steel on the paver which in time will rust leaving a stain. Careful 

application of high-pressure water jets can also be successful. For smaller areas freeze each piece of chewing gum 

with a carbon dioxide aerosol or dry ice. The chewing gum can then be chipped off with a scraper. ■ 

ADV2316

2.4 

Clay Paver Property Tables


Section 2.4 Clay Paver Property Tables 

PAVESCAPE ® SUMMERSET ® 

Autumn 

Cream 

Birch Coffee Morocco Merino Rumba Tan Garnet Onyx Opal Zircon 

Work size (mm) 228x113x40 228x113x40 228x113x40 228x113x40 228x113x40 228x113x40 228x113x40 228x113x40 228x113x40 228x113x40 228x113x40 

Dimensional category DPA1 DPA1 DPA1 DPA1 DPA1 DPA1 DPA1 DPA1 DPA1 DPA1 DPA1 

Ave unit weight (kg) 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 

Approx number per m2 38 38 38 38 38 38 38 38 38 38 38 

Co-efficient of growth ‘em’ (mm/m/15yrs) 3.5 

Mean Abrasion Index (cm3 )

3 

Face Brick Range 

3. Face Brick Range

4 

Engineered Utility Brick Range 

4. Engineered Utility 

Brick Range


Section 4. Product Data Sheet 

Standard 

Commercial 

Common 

NSW 

TYPICAL PROPERTIES BADGERYS CREEK BRINGELLY KEMPSEY 

Dimensions – Work Size (LxWxH – mm) 230x110x76 

Dimensional Category DW1 

Average Unit Weight (kg) 3.0 

Approximate number per m2 49 

Lime Pitting Nil to Slight 

No. per pack # 320 400 

Pack Weight (kg) # 928 1200 

Pack Dimensions (LxWxH – mm) # 920x920x880 1150x770x912 

Wall Surface Density (kg/m2 ) 182 

Characteristic Unconfined Compressive Strength (f’uc MPa) >22 >18 

Coefficient of Expansion (mm/m/15 years)



Standard Commercial Common 

FIRE RESISTANCE & SOUND TRANSMISSION FOR TYPICAL WALL APPLICATIONS 


The Building Code (BCA) Section C defines the type and class of buildings and designates three fire resistance levels. 

These levels are structural adequacy, integrity and insulation, and are written in the form 60/60/60. Information on how to 

calculate these is provided in the Clay Brick and Paver Institute (CBPI) publication, “Manual 5: Fire Resistance Levels for 

Clay Brick Walls” available at www.thinkbrick.com.au The figures below provide typical wall examples. 


The Rw has two reduction figures to account for high range noise (C) and low range noise (Ctr). 

The reduction figures are added to the Rw and are written Rw (C,Ctr). 

Note: S = Supported. Indicating moment is passed to a transverse structure such as a concrete slab, 

braced roofing trusses, a perpendicular wall, etc. 

S 

S 

S 

S 

S 

S 

All masonry walls should be designed by a qualified structural engineer. Variation in colour, texture and size is a natural characteristic of clay products. 

© Copyright Boral Bricks Pty Ltd – all rights reserved 2008. Boral Bricks Pty Ltd ABN 66 082 448 342. 

Boral Clay Bricks and Pavers 

Phone 13 30 35 

Fax 1300 363 035 

Email bricks@boral.com.au 

www.boral.com.au 

S 

110mm 

110mm 

110mm 

S 

FRL for Insulation 90 minutes 

FRL for wall height up to 3.0 metres 90/90/90 


FRL for Integrity is the lower of the FRLs 

for Insulation or Structural Adequacy 

For both leaves equally loaded (±10%) 

FRL for Structural Adequacy 

– wall height up to 3.3 metres 240 minutes 


For both leaves unequally loaded (i.e. >10% variance) 




Sound reduction of a wall consisting of 

two leaves 110mm brick with a 50mm cavity 

– Rendered both sides Rw + Ctr ≥ 50 & impact attenuation 

– Unrendered with 50mm 

glass wool insulation with 

a density of 11 kg/m3 Rw + Ctr ≥ 50 & impact attenuation 


polyester insulation with 


ADV03813NSW



Jumbo 

Common 

NSW 

TYPICAL PROPERTIES BADGERYS CREEK BRINGELLY 



Average Unit Weight (kg) 4.3 4.5 

Approximate number per m2 32.5 


No. per pack 192 245 

Pack Weight (kg) 864 1152 

Pack Dimensions (LxWxH – mm) 920x920x880 1150x770x833 


Characteristic Unconfined Compressive Strength (f’uc MPa) >22 




Jumbo Common 












S 

S 

S 

S 

S 

S 




Phone 13 30 35 

Fax 1300 363 035 



S 

110mm 

110mm 

S 

110mm 























ADV03815NSW



Double 

Height 

Common 

NSW 

TYPICAL PROPERTIES BADGERYS CREEK BRINGELLY KEMPSEY 






No. per pack 160 172 200 

Pack Weight (kg) 992 1100 1200 

Pack Dimensions (LxWxH – mm) 920x920x880 935x830x995 1150x972x770 






Double Height Common 












S 

S 

S 

S 

S 

S 




Phone 13 30 35 

Fax 1300 363 035 



S 

110mm 

110mm 

S 

110mm 























ADV03817NSW



Scratch Face 

Common 

NSW 

TYPICAL PROPERTIES 






No. per pack 320 

Pack Weight (kg) 928 

Pack Dimensions (LxWxH – mm) 920x920x880 






Scratch Face Common 












S 

S 

S 

S 

S 

S 




Phone 13 30 35 

Fax 1300 363 035 



S 

110mm 

110mm 

110mm 

S 























ADV05177NSW



PartyWall 

Brick 

NSW 

TYPICAL PROPERTIES PW76 PW119 

Dimensions – Work Size (LxWxH – mm) 230x150x76 230x150x119 



Approximate number per m2 49 32.5 



Pack Weight (kg) 1120 1080 

Pack Dimensions (LxWxH – mm) 1450x1080x810 1150x750x952 






PartyWall Brick 












PartyWall PW76 

S 

PartyWall PW119 

S 

S 

S 

S 

S 




Phone 13 30 35 

Fax 1300 363 035 



S 

S 

150mm 

150mm 





ADV03819



Special 

Paint Grade 

Brick 

NSW 

TYPICAL PROPERTIES BRINGELLY KEMPSEY 



Average Unit Weight (kg) 3 











Special Paint Grade Brick 












S 

S 

S 

S 

S 

S 




Phone 13 30 35 

Fax 1300 363 035 



S 

110mm 

110mm 

110mm 

S 























ADV03821NSW



Coastal 

Common 

NSW 

TYPICAL PROPERTIES BRINGELLY KEMPSEY 














Coastal Common 












S 

S 

S 

S 

S 

S 




Phone 13 30 35 

Fax 1300 363 035 



S 

110mm 

110mm 

110mm 

S 























ADV03823NSW



Coastal 

Jumbo 

Common 

NSW 















Coastal Jumbo Common 












S 

S 

S 

S 

S 

S 




Phone 13 30 35 

Fax 1300 363 035 



S 

110mm 

110mm 

S 

110mm 























ADV03825NSW



Coastal 

Double Height 

Common 

NSW 















Coastal Double Height Common 












S 

S 

S 

S 

S 

S 




Phone 13 30 35 

Fax 1300 363 035 



S 

110mm 

110mm 

S 

110mm 























ADV03827NSW



Standard 

Commercial 

Common 

VIC 

TYPICAL PROPERTIES ALbuRY SCORESbY ThOmASTOwn 



Average Unit Weight (kg) 2.9 3.2 3.3 


Lime Pitting Nil to Slight Nil 

No. per pack # 340 460 272 

Wall Surface Density (kg/m2 ) 190 205 210 





Standard Commercial Common 

FIRE RESISTAnCE & SOunD TRAnSmISSIOn FOR TYPICAL wALL APPLICATIOnS 






weighted Sound Reduction Index (Rw) 



note: S = Supported. Indicating moment is passed to a transverse structure such as a concrete slab, 


S 

S 

S 

S 

S 

S 




Phone 13 30 35 

Fax 1300 363 035 



S 

110mm 

110mm 

110mm 

S 























ADV03812VIC



Jumbo 

Common 

VIC 

TYPICAL PROPERTIES ALbuRY SCORESbY 












Jumbo Common 

FIRE RESISTAnCE & SOunD TRAnSmISSIOn FOR TYPICAL wALL APPLICATIOnS 






weighted Sound Reduction Index (Rw) 



note: S = Supported. Indicating moment is passed to a transverse structure such as a concrete slab, 


S 

S 

S 

S 

S 

S 




Phone 13 30 35 

Fax 1300 363 035 



S 

110mm 

110mm 

S 

110mm 























ADV03814VIC



Purpose 

Made 

Common 

QLD 











Characteristic Unconfined Compressive Strength (f'uc MPa) >10 




Purpose Made Common 












S 

S 

S 

S 

S 

S 




Phone 13 30 35 

Fax 1300 363 035 



S 

110mm 

110mm 

110mm 

S 























ADV03813QLD



Double Height 

Common 

QLD 











Characteristic Unconfined Compressive Strength (f'uc MPa) >10 




Double Height Common 












S 

S 

S 

S 

S 

S 




Phone 13 30 35 

Fax 1300 363 035 



S 

110mm 

110mm 

S 

110mm 























ADV03827QLD

5 

Paver Range 

5. Paver Range

6 

Projects in View 

6. Projects in View

Projects In View 

PIV, Boral’s publication profiling a range of architecturally-inspired projects featuring 

Boral’s bricks, blocks, pavers and retaining walls, is full of the latest public and 

private sector commercial projects, designs, and ideas. PIV also features industry 

news, events and more, to keep you constantly up to date. 

Subscription to PIV is FREE. Subscribe on-line, and you will ensure that PIV is 

emailed directly to you. There are benefits to subscribing – you not only have the 

latest information delivered direct to your desktop, but as a PIV subscriber, you will 

also have access to additional ‘un-published’ photography and direct links to 

product information. 

Visit www.boral.com.au/piv to subscribe and access previous editions. 

Subscribe by registering online at: 

www.boral.com.au/piv 

If you have a project that you would 

like us to consider for inclusion in PIV 

please call your Boral Clay Bricks & 

Pavers sales representative, or phone 

our contact centre on 

13 30 35 

Issue 12 November 07 

A walk on the style side 

Civic qualities at the forefront 

of Police Station design 

PIV PIV 

12: PROJECTS IN VIEW 

Centre Centre attracts attracts more more than than admiration admiration 

Contents 

01 Wally’s Walkway, Macquarie University, North Ryde NSW 

02 Vermont Sports Pavilion Extension, Vermont VIC 

03 Warehouse Distribution Centre, Minto NSW 

04 Police Station, Cranbourne VIC 

PROJECTS IN VIEW 

Wally’s Walkway, Macquarie University, North Ryde NSW 

Vermont Sports Pavilion Extension, Vermont VIC 

Warehouse Distribution Centre, Minto NSW 

Issue 13 March 08 

Wall design delivers 

benefits galore 

A shining star in Jamisontown 

High quality housing that’s affordable, too 

Carpark honours local heritage A Renaissance Renaissance in retirement retirement living living 

Contents 

Green Green estate estate chooses chooses choc choc tan tan bricks bricks 

Welcome to the twelvth 

edition of PIV featuring 

Boral Clay Bricks and Masonry. 

05 Apartment Complex, Pyrmont NSW 

06 Cardinia Life, Pakenham VIC 

07 Springvale Police Station, Springvale VIC 

08 Nelsons Grove Retirement Village, Pemulwuy NSW 

01 Carlisle Homes Display Village, Tarneit, VIC 

02 Bingara Gorge Sales & Information Centre, Wilton, NSW 

03 Renaissance Victoria Point Retirement Village, Moreton Bay, QLD 

04 Concord Hospital Mental Health Precinct, Concord, NSW 

Bingara Gorge Sales & Information Centre, Wilton, NSW 

Renaissance Victoria Point Retirement Village, Moreton Bay, QLD 

Concord Hospital Mental Health Precinct, Concord, NSW 

PIV PIV 

13: 13: 

PROJECTS PROJECTS IN IN VIEW VIEW 

Contents 

Issue 14 July 08 

Wall-to-wall 

Wall-to-wall 

opportunities opportunities at 

Interchange Interchange Park Park 

Bricks and Masonry team up at Oakleigh Centre 

A honey of a project Rousing interest in Rouse Hill 

Discovering Masonry 

05 05 Shaula Shaula Apartments, Apartments, Jamisontown, Jamisontown, NSW NSW 

06 06 Esplanade Esplanade Carpark, Carpark, Port Port Willunga, Willunga, SA SA 

07 07 Interchange Interchange Park, Park, Eastern Eastern Creek, Creek, NSW NSW 

08 08 Harmony Harmony Village Village Retirement Retirement Complex, Complex, Shepparton, Shepparton, VIC VIC 

Welcome Welcome to to the the thirteenth thirteenth 

edition edition of PIV PIV featuring featuring 

Boral Boral Clay Clay Bricks Bricks and and Masonry. Masonry. 

01 Altona Performing Arts Centre & Primary School 

04 Rouse Hill Town Centre 

02 Beekeepers Inn 

05 Discovery House 

03 Oakleigh Centre for Intellectually Disabled Citizens 

06 Logistics Building, Caulfield Medical Centre 

PIV 

14: PROJECTS IN VIEW 

Combining kids 

with culture 

Welcome to the fourteenth 

edition of PIV featuring 

Boral Clay Bricks and Masonry. 

07 Boral Timber Woodhead Project, Pernod Ricard Head Office 

08 Lightening the load on energy and water at Kempsey 

09 Harrison School 

ADV05003 10/08

7 

Reference Material 

7. Reference Material

Free Clay Brick and Paver Samples 

Free face samples 

Professionally present your project concept to your client with actual clay 

brick and paver colour and texture samples. This special service enables 

you to select and receive facing samples by express courier to your door. 

NSW and Queensland chip sizes 

Bricks 

Pavers 

Bricks 

115mm x 76mm x 10mm 

115mm x 114mm x 10mm 

Victoria chip sizes 

Pavers 

230mm x 76mm x 10mm 

230mm x 114mm x 40mm/50mm (full size) 

Contact the Boral CHIPexpress ® service 

Phone 13 30 35 

Fax 1300 36 30 35 Using fax order forms provided 


Web www.boral.com.au/bricks 

10mm 

10mm 

230mm 

115mm 

76mm 

115mm 

Bricks Pavers 

76mm 

230mm 

Bricks Pavers 

114mm 

114mm 

10mm 

40mm/ 50mm 

ADV05001 10/08

Clay Bricks & Pavers 

Name 

Project 

Company 

Address 

Phone 

Fax 

Email 

Detached home Villa/townhouses 

Commercial (provide description below) 

Special delivery instructions 

Clay brick and paver samples required 

Brochures required 

1. 

2. 

3. 

4. 

5. 

1. 

2. 

3. 

4. 

5. 

Fax Order Form 

High rise med. density 

Fax this form to 

Boral Bricks CHIPexpress ® 

1300 36 30 35 

CHIPexpress ® samples can 

also be ordered by calling 

13 30 35 

or emailing your request to 

bricks@boral.com.au 

Please send more order forms 

ADV05002 08/04

Bricks & Pavers Technical Manual - Boral

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