Quality masonry

Masonry Construction, May, 2005 by Ron Willis

All masonry contractors strive to perform "quality" work; however, we don't live in a perfect world. If we did, the design would be flawless, labor would make no mistakes, working conditions would be ideal, and the material would be perfect in size dimensions, texture, and strength.

Consequently, the word, "quality" is a relative term. What is good quality work to some contractors, architects, or owners may be unacceptable to others in the same profession.

Standard determines quality

Bricklayers are human and make mistakes and create imperfections. The masonry trade is an art that takes a knowledge of many variables--wet or dry climate, cold or hot weather, and hard or soft material--beyond the basic workmanship skills to produce a quality product. Any tradesman can lay up good material in ideal conditions, but it takes a real craftsman to build something well with a slightly inferior material, in not so ideal working situations.

The contractor's goal is to do the very best possible with what he has to work with. That goal is not always acceptable to the architect or owner. Sometimes masonry contractors let architects and general contractors intimidate them about imperfections in the material.

However, remember that you have rights too. In the first place, you didn't choose the material, they did. Secondly, there are standards for determining what is acceptable quality and what is not.

ASTM standards cover almost any type of material or situation. ASTM has developed the accepted standard for any number of trades.

Stand your ground

My company used the following response when we were questioned about chips and color variations in the CMU. It helps to have letters like this one on file when needed.

"We would like to emphasize that we don't take lightly the charge that our work is unacceptable. It is extremely important to us, and we have built our business on the principle of always doing 'top quality work.'

"We would like you to consider the information contained in ASTM Standard Specification for Loadbearing Concrete Masonry Units. This specification is considered the standard for the industry relating to allowable tolerances. There are no chips in our work that would not be tolerated with these standards. The relative section of the standard (ASTM 1999, Section 4, Volume 04.05, C 90, p.76) is quoted below for your edification."

7. Finish and Appearance

7.1 All units shall be sound and free of cracks or other defects that would interfere with the proper placement of the unit or would significantly impair the strength or permanence of the construction. Minor cracks incidental to the usual method of manufacture or minor chipping resulting from customary methods of handling in shipment and delivery are not grounds for rejection.

7.2 Where units are to be used in exposed wall construction, the face or faces that are to be exposed shall not show chips or cracks, not otherwise permitted, or other imperfections when viewed from a distance of not less than 20ft (6.1 m) under diffused lighting.

7.2.1 Five percent of a shipment containing chips not larger than 1 in. (25.4 mm) in any dimension, or cracks not wider than 0.02 in. (0.5 mm) and not longer than 25% of the nominal height of the unit is permitted.

7.3 The color and texture of units shall be specified by the purchaser. The finished surfaces that will be exposed in place shall conform to an approved sample consisting of not less than four units, representing the range of texture and color permitted.

"Comparing your concerns to the reality of the job shows that we are in compliance with the industry-accepted standard.

"The standard states that the wall should be 'viewed from a distance of not less than 20 ft (6.1 m) under diffused lighting.' This condition was not met in your evaluation.

"Five percent of a shipment containing chips not larger than 1 in. (25.4 mm) in any dimension, or cracks not wider than 0.02 in. (0.5 mm) and not longer than 25% of the nominal height of the unit is permitted." A 1-inch chip is pretty large. We would never install a unit with a chip that big in it.

"The color and texture of units shall be specified by the purchaser. The finished surfaces that will be exposed in place shall conform to an approved sample consisting of not less than four units, representing the range of texture and color permitted." It looks like the four unit range was not adhered to.

"We think that we have more than complied with the accepted standards of this industry. Therefore, we ask you to reconsider your judgment and scrutiny of our work and material in view of the standard referenced herein."

The next time the owner, architect, or general contractor corners you and starts complaining about the material or workmanship, realize that there isn't any such thing as a perfect unit. And, sometimes what you have is the best that you can get.

Obviously there are ways to lay up border-line-tolerant material that can improve it's looks. It's always good to use those practices to keep from having problems that can be avoided.