Basics Masonry Construction, 2006
Basics Masonry Construction, 2006
CONSTRUCTION
MASONRY
CONSTRUCTION
CONSTRUIRE EN BOIS
Nils Kummer
CONCEPTION
PRINCIPES DE REPRÉSENTATION GRAPHIQUE
CONSTRUCTION
EXERCICE DE LA PROFESSION
PHYSIQUE DU BÂTIMENT ET INSTALLATIONS
CONSTRUCTION
TECHNIQUES
MATÉRIAUX DE CONSTRUCTION
ARCHITECTURE DU PAYSAGE
URBANISME
THÉORIE
BASICS
www.birkhauser.com
Nils Kummer
Masonry
Construction
Nils
BertKummer
Bielefeld - Sebastian El Khouli
Entwurfsidee
Masonry
Construction
Birkhäuser
BIRKHÄUSER
Basel
BASEL
Contents
Foreword _7
Introduction _8
Masonry _8
The brick _9
Mortar for masonry _9
In conclusion _67
Appendix _68
Standards _68
Literature _69
Picture credits _69
The author _70
Foreword
“The brick is another master-teacher. How profound that little format
is, handy, how useful for every purpose. What logic its structure shows
in bond. How lively is that play of joints. And what richness even the sim-
plest area of wall possesses. But what discipline this material demands.”
What Ludwig Mies van der Rohe (1886–1969), one of the most influ-
ential artists of the 20th century and the last director of the Dessau
Bauhaus, is enthusiastically celebrating here is nothing other than one
of the lowest common denominators and at the same time essential basic
elements of any architecture: masonry. It appears in so many different
forms that it is scarcely possible to provide a complete survey. Whether
you look at ancient amphitheatres, Babylonian temples, modern muse-
ums or simple houses: without bare brick combined with simple mortar,
architecture as we know it today can scarcely be explained.
But the well-nigh infinite creative variety afforded by masonry con-
ceals strict rules that have to be obeyed if the desired overall impression
is to be guaranteed. The pathway from the brick to the wall, to the room
and finally to the whole building is neither short nor simple.
The “Basics” series of books aims to present information didactically
and in a form appropriate to practice. It will introduce students to the
various specialist fields of training in architecture. Content is developed
stage by stage, using readily understandable introductions and explana-
tions. The essential points of departure are built up systematically and
explored further in the individual volumes. The concept is not to provide
a comprehensive collection of expert knowledge, but to introduce the
subject, explain it, and provide the necessary expertise for skilled imple-
mentation.
The present volume aims to introduce students systematically to the
subject of masonry. Bricks and mortar, the elemental basic components,
are used to devise rules for building a wall. The emphasis is on the over-
all systems and material-dependent properties that are essential for
understanding a “wall”. The interplay of bricks, the forms of masonry
bonds, and the aesthetic of masonry walls with apertures, projections
and recesses are explained soundly and methodically – from brick to
wall – so that students can understand the essence of masonry and apply
their insights directly to their designs and projects.
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7 AM
Introduction
Masonry buildings cannot be reduced to any particular tradition,
fashion or style: timeless in their flexibility, fundamental to both classi-
cal and avant-garde architecture, open to stylistic trends throughout the
ages, capable of being both ordinary and experimental. The facades of
contemporary high-rise buildings and modern glass structures may man-
age without classical masonry as a basic architectural principle, but it is
difficult to find buildings without a masonry wall somewhere inside, thus
reconfirming the existential character of masonry.
The book will present the “Basics” of masonry, together with the
emands it makes. First of all we need to look at its basic components,
d
bricks and mortar. The rules for fitting these elements together to make
a wall form the theoretical and creative basis in the second chapter for
understanding the wall constructions explained in the third. Then, mov-
ing from plain brick construction to the completed wall, we arrive in the
fourth chapter at the question of which building materials are suitable for
the types of work described earlier, thus ending up with the brick again.
masonry
Masonry is not a building material like wood or steel, but a combina-
tion of two individual materials, bricks and mortar, handled according to
the rules of a craft. It is frequently classified as a composite material, and
thus more like reinforced concrete than concrete, for example, as the
quality of the end product depends on the quality of both the materials
and the execution.
There are different kinds of bricks and mortar for all these functions
and structures. It is therefore important to know the most important prop-
erties of the two materials as well as about construction, so that the ideal
combination can be achieved.
8 8:12 AM
e
fac
bed
e
fac
er
hea etch
der str
fac
e
the brick
Asked about bricks, most people would probably sketch a uniform
shape and size: the standard brick. Developed over millennia, bricks lend
their character to most masonry facades and are firmly linked with our
idea of masonry. But there are a whole variety of different shapes and
sizes: flat Roman bricks, large manufactured blocks or octagonal moulded
bricks. And the brick forms the basis for the whole set of craft rules of
erecting a masonry building, even today. These rules govern the size of
rooms and buildings, apertures and built-in features, and they structure
facades.
8:12
9 AM
10 8:12 AM
Rules of construction
As masonry is a craft, there are certain rules for achieving a high-
quality finish. The most important aims are:
These rules form a theoretical basis for the wall structures given in
the third chapter. They show the principles and methods for creating
masonry from its components, the preferred dimensions, and how to
form connections and apertures correctly for the material. The individ-
ual wall will be considered first.
The specified dimension is the basic theoretical measurement, the Specified dimension
grid or the module multiplied to put together the whole masonry con- and nominal dimension
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11
The specified dimension consists of the nominal dimension executed
and the corresponding joint, i.e.:
If you now imagine a masonry wall with window apertures and trans-
verse walls, you will very quickly realize that there are different dimen-
sions for the wall width, aperture and projections because of the mortar
joints.
External dimension The external dimension is the wall thickness. One joint must always
be subtracted from the specified dimension as there is always one joint
missing, regardless of the number of bricks.
specified
specified dimension
dimension
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The projection dimension measures the piece of wall between open- Projection dimension
ing and wall or wall projections. Here, the missing joint in the external di-
mension and the additional joint in the aperture dimensions balance each
other out.
joint joint
nominal nominal nominal nominal nominal
dimension dimension dimension dimension dimension
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13
aperture dimension
specified specified
dimension dimension
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unit dimensions and designations
These hitherto theoretical definitions have left open the question of
actual dimensions, which are independent of the brick and joint sizes
chosen. These sizes can vary, and have led to different standards in
different countries, according to local traditions.
Joint sizes can also vary, without changing the system. New manu-
facturing technology and the need to meet the greater-than-ever demands
on masonry for heat and sound insulation, and in terms of loadbearing
capacity, mean that masonry technique is no longer based on the centi-
metre joint. Modern manufactured blocks are finished to such low toler-
ances that joints need be only a few millimetres thick.
For example:
Traditional: German normal format brick 24 cm + 1 cm joint = 25 cm
Modern technique: Manufactured block 24.7 cm + 3 mm joint = 25 cm
◼ Tip: In Germany, these dimensions are fixed by the ◯ Note: Different countries have other standard
DIN 4172 standard dimension in the building industry, bricks, based on national traditions or different units
which has prescribed a basic module of 25 cm for shell (e.g. inches), e.g. 21.5 × 10.25 × 6.5 cm in England,
construction since the post-Second World War rebuild- 19 × 9 × 6.5 cm in Belgium, and 8 × 4 × 2.25 inches
ing, basing itself on traditional formats. The later DIN (20.3 × 10.2 × 5.7 cm) in the USA.
18000 modular standard for building, which promised
to be simpler to use with its decimetric basic module
of M – 10 cm, has not caught on in Germany.
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15
11 5 17 5
11 5 24
11 5 24
24
24
115
115
71
52
German normal German thin 2DF (1½ NF) 3DF (2¼ NF)
format (NF) format (DF)
24
24 5
30 36
24
30
24
24
115
24 24
115 1 115
115
115
1775 5 25
115
115
¾ brick ¼ brick
16 7:51 AM
2DF (1½ NF)
NF format DF format 3DF (2¼ NF)
Germany Germany Germany
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17
Cut units are specially designated in the top view on laying drawings:
the ¾ unit (17.75 cm) by a diagonal, the ½ unit (11.5 cm) by a cross, and
the ¼ unit (5.25 cm) by a point or a circle.
brick courses
The individual rows in a masonry structure are called courses.
A distinction is made according to the run of the bricks:
—— Stretcher course: bricks are laid parallel with the axis of the wall
—— Header course: bricks are laid transversely to the wall axis
—— Brick-on-edge course: bricks are laid transversely and standing
edgewise on their long sides
—— Soldier course: bricks stand edgewise on their narrow sides as an
upright header course
While the stretcher and header courses are combined with each other
in different ways as bonds, the edge and soldier courses with their larger
head joints offer greater bond strength between the bricks and better
pressure dispersal, as they do not break as easily as a horizontal brick.
They are therefore used for lintels, seatings and cornices.
masonry bonds
To produce high-quality masonry with a good loadbearing capacity
from bricks and mortar there are certain craft rules that must be followed
when laying bricks – the bond rules. These rules distinguish between four
so-called school bonds – those most commonly taught – according to
the sequence in which the brick courses are laid on one another, and the
way they are offset from each other.
Some of the bond rules are general, and give us the first two school
bonds.
Rules:
—— All the courses must be laid horizontally.
—— The brick height should not be greater than the brick width.
—— Only bricks of the same height should be used in a single course
(only at wall ends can there be exceptions in every second course).
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stretcher course
header course
brick-on-edge course
soldier course
The brick offset is crucial for the wall’s loadbearing capacity. The
greater the offset, i.e. the more shallow the racking back of the bricks,
the greater the resistance to longitudinal cracks. ◯
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19
wall ½ brick thick
½ brick offset
stretcher course
begins with
¾ bricks
special case
where wall begins repetition after four courses
20 7:51 AM
In stretcher bond, all courses in the masonry are made up of stretcher Stretcher bond
courses offset by the length of ½ brick. As this bond does not permit an
offset running transversely to the wall axis, it can only be used for wall
½ brick thick, e.g. for internal walls, facer skins and chimneys. A wider
wall can be built only with larger bricks. Stretcher bond offers good com-
pressive and tensile strength because of the large brick offset. It is also
possible to use an offset of ¹/³ or ¼ of a brick length, but this entails some
loss of loadbearing capacity.
In header bond, all the courses consist of header courses offset by Header bond
the length of ¼ brick. This bond can only be used for one-brick walls.
Because of the low overlap the bond has less loadbearing capacity and
inclines to diagonal cracks because of the steep racking. It is however
particularly suitable for narrow masonry radii.
Combining these bonds and following two more rules gives the last
two commonly taught bonds.
Rules:
—— Stretcher and header courses alternate.
—— One stretcher course begins with a ¾ brick (for thicker walls, with
correspondingly more ¾ bricks).
English bond consist of alternate courses of stretchers and headers. English bond
The offset is ¼ brick. This produces usefully shallow racking by ¼ and ¾
brick lengths in each case.
Like English bond, English cross bond begins with alternate stretcher English cross bond
and header courses. But the perpends of the stretcher courses are offset
against each other by ½ brick, so the joint pattern repeats only every four
courses. This bond has a more varied joint pattern, but it is also more
steeply racked and therefore more prone to diagonal cracks.
There are also some decorative bonds, but these are only of histori-
cal or regional significance. Examples are double Flemish bond, Yorkshire
bond and Flemish bond. > Fig. 15
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21
double Flemish bond
Yorkshire bond
Flemish bond
Regular constructions
Corners in walls For corners, niches, projections and columns, there are special
points of detail covered by the bond rules.
Rules:
—— The stretcher courses run through at corners, junctions and joints;
the header courses abut.
—— Parallel walls should have the same sequence of courses.
—— Only one perpend in each course should start from an inside
corner.
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English bond
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23
1½ bricks thick
1brick thick
1½ bricks thick 2 bricks thick ¼ brick rebate
Masonry columns Two points should be noted when constructing masonry columns:
◯ Note: Because of new brick formats and techniques ◯ Note: Chimneys are almost always built of special-
for constructing loadbearing walls, which are generally purpose bricks today, so the exposed masonry is simply
built using “random masonry bond” (not following the cladding. The masonry structure shown here merely il-
rules of bonding, but keeping to the standard minimum lustrates the possibilities and rules of bonded masonry.
dimensions for the offset), these school bonds are gen-
erally used only for exposed masonry (see Chapter
Masonry structures, External walls).
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wall junction wall junction
English cross bond English bond
1 brick thick 2 bricks thick/1 brick thick
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25
aperture dimension
aperture dimension
individual load
max.25
pressure force
60
˚
ceiling load
60
˚
support width
vertical load
loads above wall openings horizontal thrust in
(vault effect) masonry arches
Masonry apertures Apertures for windows, doors or passageways in the wall are subject
to craft rules and traditions, as well as the wall itself.
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The top of the door or window can also be built according to the rules.
As masonry cannot absorb bending forces, apertures cannot be topped
with bonded masonry without “support”, so beams, formerly made of
wood or stone, and now of concrete, can be placed over the aperture. The
beams dissipate the imposed load from the masonry above into the side
walls through the structural conditions in terms of bending, restricting the
possible size of the aperture according to the material used for the beam. ◯
Another aperture suitable for masonry is an arch with masonry above Masonry arches
it, which transforms all the imposed loads into pressure forces and trans-
fers them to their points of support. The difficulty of this construction
lies in the horizontal thrust that the loaded arch exerts on the masonry.
This thrust, which increases in shallower arches, must be absorbed either
by the wall or by additional piers.
If the radius is increased to the full width of the aperture and circles
are drawn around the two support points, a pointed arch is produced.
Both types of arch should consist of an uneven number of bricks, so that
a keystone, which starts the load distribution, can be placed at the apex
of the arch, rather than a perpend. The keystone should end in a bed joint
of the masonry, so that the filler courses above the apex of the arch do
not become too large. For window rebates, arches can be built in two
rows of bricks, displaced vertically.
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27
radiu
s=a
pert
ure w
idth
radius = aperture/2
th
ure wid
= apert
radius
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abutment
rise approx.
rise
2 cm
Joint configurationS
In addition to masonry bonds, the configuration of the mortar joints
can make a considerable contribution to the appearance of the masonry.
The colour or depth of the joints can emphasize them or make them
inconspicuous for design purposes. ●
For trowel-finished joints the mortar pushed out at the sides when a Flush pointing
brick is put in place is struck off and smoothed down a little later with a
piece of wood or a hose. The advantage of this method lies in the good
seal it creates for the joint and the need to apply the mortar to the whole
surface, which improves the loadbearing capacity of the masonry.
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Fig. 26: Joints
Subsequent pointing However, if the uniformity of the joints is important in terms of col-
our and design, it can be advantageous to point subsequently. Here, the
fresh mortar is scratched out with a wooden lath to a depth of about
20 mm and the opening cleaned; if absorbent bricks, which draw the
water out of the mortar, are being used, the opening must be moistened
before being closed again with the pointing mortar. Attention must be
paid to high-quality finish because of the two kinds of mortar; this will
● guarantee the loadbearing capacity and density of the construction.
Finishing rules
Masonry must be bonded, and also built horizontal, true and plumb.
The first course is crucial, as it compensates for uneven terrain. The rows
of bricks should then be laid from the corners. This can be done by hand
up to a weight of 25 kg per brick, above which auxiliary equipment is
needed. The mortar must be applied to the full area of the bed joints; for
small bricks with a trowel, for larger sizes with a mortar template, which
keeps the height of the joints consistent over the full length of the wall.
The perpends must also be closed to ensure that the masonry is rain- and
wind-proof, either by covering the full surface with mortar or by flushing
mortar pockets in the middle of the brick. To save time and expense,
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correct joint configuration incorrect joint configuration
rain
damp
penetration
masonry is sometimes built without using mortar for the perpends. But
here it is essential to meet all the demands of weather protection (by
using a layer of rendering or cladding) and sound insulation (good
sound-reducing bricks). Bricks using a tongue and groove system are
preferred for this.
If highly absorbent bricks are being used, care should be taken before
laying them to dampen the wall, as the bricks will draw too much water
out of the drying mortar. The bricks will then also absorb fewer salts from
the mortar that would later be visible on the surface of the brick as
“efflorescence”. At the same time, a completely soaked brick will prevent
proper binding with the mortar. Bricks and masonry should therefore
be protected against rain, as well as against unduly strong sunlight. In
frost, bricks can only be laid if precautions are taken, as mortar hardens
more slowly with falling temperatures, and stops hardening altogether
at –10 °C. Building materials should be covered as soon as the temper-
ature falls to 5 °C, and at temperatures under 0 °C bricks and mixing
water should be warmed. Frozen materials should not be used, and parts
of the wall that have already been damaged must be removed.
building in stone
Natural stone is the Ur-form of masonry. From the simple, mortar-
less piling up of unworked stones in various sizes (drystone walling) to
stones of equal sizes laid according to bonding rules (ashlar masonry),
there are various special types of natural stone masonry. However, nat-
ural stones are now used less for actual masonry than as curtain facade
material for walls, and therefore they will not be dealt with more fully
here. Exceptions are primarily found in monument protection and land-
scape architecture.
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31
new approaches
In addition to the traditional building method prescribed by the bond-
ing rules, new approaches have developed, based on new manufacturing
methods and building materials, intended above all to make masonry con-
struction cheaper and less time-consuming.
Moulded brick For moulded brick masonry, the dimension tolerance of the bricks
masonry has been minimized so that the joint height can be reduced to 1–3 mm
(thin bed). The mortar is applied with a roller, or the bricks are dipped
in the water. As the joint proportion is minimized and homogeneous
masonry produced, material and time are saved, and favourable statical
values achieved, > Chapter Masonry structures, Structural behaviour and there are
◯ fewer thermal bridges.
As the brick rows can only accommodate low tolerances, the first
layer should be laid with great care. Small offset blocks can be used for
this purpose. They are available in different heights and with good insu-
lation properties.
Dry masonry Dry masonry uses no mortar at all. For reasons of loadbearing
c apacity, however, such wall constructions are restricted to low storey
and building heights. The ceiling loads on the walls must be even, so that
this pressure can compensate for the lack of adhesion from the mortar.
Masonry kits To save the time needed for cutting large stones to size, masonry kits
offer the possibility of assembling whole sections of walls in the right di-
mensions in the factory, and delivering them to the site as individual parts
with a laying plan. This method is a reasonably priced alternative, par-
ticularly if there are many diagonals (gable walls) or apertures.
32 7:51 AM
This method takes prefabrication a little further at the factory stage: Prefabrication
manufacturers deliver whole storey-height walls, including apertures, to construction method
the site. The bricks have to be reinforced to stabilize the structure and
erection requires a crane or mobile crane. The expense is set off against
the consistent quality of the factory work (although the erector is of
course responsible for the wall connection points).
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33
34 7:51 AM
Masonry structures
The structures listed below refer to the wall in its built state. The con-
struction rules explained above apply in principle to all masonry struc-
tures, and deal merely with assembling bricks and mortar. There are var-
ious ways of finishing a construction, combinations with other building
materials and dependencies on other parts of a building. These relate to
the location where the building is to be used and the role of the wall
structures.
Masonry walls can be loaded vertically from ceilings and other parts
of the building, by self-weight and also by horizontal forces such as wind,
soil pressure and impact forces, or cantilever loads from projecting or
suspended elements.
Structural behaviour
The loadbearing capacity of masonry is determined by the bonding
of brick and mortar. The adhesion or friction between brick and mortar
affect how horizontal forces are absorbed and provide vertical load dis-
tribution over the full area; the joint compensates for brick tolerances.
Its ability to absorb compressive forces is far greater than its acceptance
of tensile or tensile bending forces, i.e. a precisely bedded brick can
transfer loads as compressive force but would break without this bed-
ding surface. The brick and its mortar joint are pressed together from
above in vertical loading. The brick conducts the compressive forces, and
the mortar, which is more easily deformed, tries to sag. These different
behaviours produce stress at the point of contact between bricks and
mortar, and then to compressive stress in the mortar and tensile stress
in the brick. At the same time, this lateral tensile stress in the brick
reduces its compressive strength. If the load becomes too great, verti-
cal cracks will appear in the brick and the mortar will collapse. Uneven
application of mortar increases tension peaks and the danger of collapse.
Greater join thicknesses and the use of lightweight mortar are also
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35
loads compressive force
self-weight
wind
brick failure
suction cantilever loads stone
tensile stress
wind
pressure mortar compressive stress mortar
deformation
tensions caused by
different deformations at
impact load
stone the contact point
Aerated bricks and cavities weaken the cross-section and thus load-
bearing capacity. Adhesion between bricks and mortar also allows force
to be absorbed horizontally.
external walls
External masonry walls are loadbearing walls, except for infill within
other loadbearing systems (frame construction, construction slabs etc.),
or free-standing walls. They also separate the inside of the building from
36 8:00 AM
the outside, and so must give protection against cold, rain, snow and
sound from the outside. At the same time, design questions play a part
in decisions about whether the masonry should be visible from the out-
side or not.
External walls with just one wall built in bond are called single-leaf Single-leaf masonry
masonry. This structure, simple to erect in terms of craftsmanship, has
to perform all the functions of an outside wall.
Single-leaf exposed masonry, a wall structure that is visible from both Single-leaf exposed
sides or at least from the outside, displays a disparity between thermal masonry
Their pores quickly become permeated with moisture, they are not
frost-resistant and thus not suitable for unprotected use. Conversely,
weather-resistant bricks with a high specific density offer little resistance
to heat penetration and would require uneconomic wall thicknesses. This
structure can therefore no longer be used in this way. ◯
For facing masonry, on the other hand, a wall several units thick be- Facing masonry
tween two different kinds of masonry is used inside the bond, so that the
bricks showing on the outside offer good protection against weather and
frost, and the inner series takes over the thermal insulation. Here the
whole cross-section including the facing can be added to the load disper-
sal; the brick with the lowest compressive strength provides the basis for
calculations. A joint between the two series of stones, offset course-wise,
2 cm thick and closed with seal mortar, offers protection for the inner set
of units. This is an elaborate structure, and the units in it must be well
◯ Note: The specific thermal conductivity (λ) indicates ◯ Note: The thermal transfer resistance (R) indicates
how much heat a structural element will transfer under a structural element’s insulation capacity, according to
fixed conditions. The smaller the value, the better the its thickness. It is calculated from the ratio of course
thermal insulation. thickness to specific heat conductivity. The transitions
at the extremities of the element are also calculated,
and the individual values added for multi-course ele-
ments.
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37
facing masonry with external/ with internal compound thermal with cladding
thermal insulation insulation
insulation
rendering
matched to each other, in order to avoid different settling rates and defor-
mations. Very precise planning is also needed, because unit formats often
differ. This structure is recommended only for visual or formal reasons,
or if a special brick is to be used or there is a request to manage without
expansion joints in the exposed masonry. > Chapter External walls
Single-leaf masonry Thus, for example, external rendering can be applied; this improves
with external thermal insulation as thermal insulation rendering. The visual effect of
rendering
bonded masonry is lost in single-leaf masonry with external rendering,
but large-format units can be used, built in random bond with a thin mor-
tar bed. They have better insulation properties, and are economical to
use. As the whole cross-section of the wall contributes to the thermal in-
sulation, weaknesses must be avoided to prevent thermal bridges. Spe-
cial constructions are needed, especially for lintels and ceiling supports.
Ceiling supports Ceilings must be connected with the enclosing walls by their sup-
ports on the wall via adhesions and friction. As a rule a bearing edge of
◯ 10–12 cm is needed.
38 8:00 AM
heat loss cracks where
through material changes
reinforced ceiling height not
concrete in the brick grid
ceiling
◯ Note: If there is not enough area to support the ceil- ● Example: Condensate: Warm air can hold more water
ing, steel tie bars must be fixed into the masonry. As vapour than cold air. If warm air meets cold air, mist
this exposes the masonry to horizontal tensile forces, or water vapour is formed. If warm air meets a cold ob
the wall areas must receive a corresponding imposed ject, excess water is released, forming a condensate.
load to counter the tensile forces. This means that ties For heated air in a room, if an outside wall is poorly
cannot be fixed in parapet areas. Gable walls can also insulated, or even not insulated at all, water will be
be attached to the roof structure with tie bars. deposited on the cold internal side or in the cooled
structural element. This then leads to structural dam-
age from frost or mould.
8:00 AM
39
For this reason, additional insulation must be provided at the outer
edge of the ceiling. It should be noted here that single-leaf rendered walls
may be subject to cracks on the outside because of different expansion
and deformation at the point where the different materials meet, so that
rain may penetrate the building. Fabric can be applied to bridge the point
of transition and secure the rendering, but the use of L-shells is also rec-
ommended. These are made of the same material as the wall, and some
already have insulation strips. They avoid the change of material while
◯ acting as a formwork element for the reinforced concrete.
Wall apertures These weaknesses also occur for wall apertures. As masonry cannot
accept tensile or bending loads, it is impossible to build across a wall
aperture without support. Additional beams are needed to resist the loads
and transfer them transversely into the adjacent parts of the wall. As
steel does not meet fire protection criteria, these beams are usually made
of reinforced concrete and, like the ceilings, must have additional ther-
mal insulation or be built using U-shells. These special parts can either
be made on the spot, e.g. at the same time as the concrete ceiling is cast,
or delivered to the site as prefabricated lintels, reinforced in the factory.
Tie beams/ U-shells can also be used to create peripheral tie beams and ring
ring beams beams. Other factors, such as wind forces, cause tensile forces in a build-
ing. These are transferred by the ceilings as sheets and cannot be
absorbed by the walls alone. Peripheral tie beams can be made in the
form of reinforced concrete beams or U-shells under the ceiling, or of
appropriately reinforced ceiling strips. They transfer forces for all exter-
nal and transverse walls. In the case of ceilings with no sheet action or
with sliding supports (e.g. under flat roofs) the peripheral tie beams
should run round the whole building as a continuous ring (ring beam).
40 8:00 AM
To improve the wall structure’s thermal insulation properties, insula- Single-leaf masonry
tion or thermal insulation rendering can be applied to its internal side. with internal insu-
lation
This construction is problematical in terms of building science, however,
as there is a danger that condensate will form on the inside of the cold
masonry and impregnate the construction with moisture, which may lead
to mould formation. For this reason, this method tends to be used for
refurbishment, when it is not permissible to alter listed facades.
To avoid these problems, the insulation is not fixed inside in a lami- Laminated thermal
nated thermal insulation system, but stuck onto the masonry and fixed insulation systems
(LHIS)
with ties. To protect the insulation from the weather, however, a special
layer of water- or moisture-resistant rendering is applied directly to the
insulating material. As the rendering needs a solid ground, and as no
holes or pressure points should be created by external factors, the insu-
lation must resist compression and provide sufficient general resistance.
LHIS is a common system for reasons of economy, above all when refur-
bishing existing buildings.
Basement walls are single-leaf in all structures. An approach using Basement walls
waterproof reinforced concrete (“White Tub”) is increasingly common,
but another wall structure may be preferable. Basement walls need to be
well reinforced against soil pressure, which affects the surface of the wall
vertically, and against load transfer. When fixing dimensions, wall height,
soil pressure and the superimposed load from the surface of the terrain
should be taken into account. The thermal insulation that is applied out-
side (perimeter insulation) also has to be able to stand up to the soil pres-
sure in working basement spaces with high thermal insulation demands,
and must therefore be compression resistant. It can be made of sheet
foamed glass, polystyrene particle foam or extruded polystyrene foam
sheets. Basement walls must also be sealed against moisture in the soil.
A concrete finish is preferred if there is heavy potential pressure from
water, but if the load is less and the water does not exert pressure, hori-
zontal and vertical sealing should be provided. The horizontal membrane
in the form of a sealing sheet should be applied to the full area of the con-
crete slab, and must join up with vertical sealing in the form of sheets or
bituminous coatings on the on the outside of the wall under the first row
8:00 AM
41
ditch refilling
cellar wall waterproofing with no pressure cellar wall waterproofing for accumulated
from water seepage water
Plinth zone The plinth zone is more heavily loaded than the masonry above it by
the adjacent soil and the effects of splash water. Hence, it should be
sealed against moisture by a vertical membrane to a height of 30 cm
above the top edge of the terrain. This ends with a horizontal damp course
the full width of the wall, which prevents moisture from rising further into
the masonry above it. This damp course should be protected by a row of
weatherproof bricks, by cladding, or by applying a special water-resis-
tant plinth rendering. The transition between the renderings can be car-
ried out through the structure or by using differences in smoothness.
Plaster bases, e.g. in expanded metal, help to avoid cracks at this point.
42 8:00 AM
damp course
rendering
plinth
>15
basement
The cavity is there to prevent water penetrating directly into the inner Double-leaf masonry
leaf and thus into the interior, and causing damage such as mould forma- with cavity
tion. If moisture has penetrated the outer leaf, it is removed via the cavity.
To this end, ventilation apertures should be placed in the plinth area and
at the top of the wall and wall apertures. These are usually open perpends
with a horizontal damp course. This is achieved by laying a sealant strip
or film as a “Z-barrier” across the full area of the bed joint below the open
settlement joints, and taking it to the inner leaf with an incline of 1–2 cm
and then 15 cm upwards.
8:00 AM
43
with cavity with core insulation with insulation and cavity
Full-fill This version increases the resistance to heat transfer, but not the
cavity walls thickness of the brick, and thus the thickness of the whole wall. The
insulation can be in the form of blankets or strips fastened to the inner
leaf, or loose granules or mixtures, which are shaken into the gap; care
must be taken to distribute them evenly. The disadvantage of this struc-
ture lies in the fact that water can get in behind the front leaf. It is diffi-
cult to remove, and reduces the thermal insulation properties of the struc-
ture, as damp building materials transfer heat better than dry ones. The
insulation material must therefore be permanently water-resistant, and
joints and connection points must prevent water from penetrating. Softer
mineral fibre strips should be packed tightly, and plastic foams given a
stepped rebate or tongue and groove. Any damage caused by fixing the
blankets or the outer leaf should be sealed. If insulation material is poured
or shaken in, care should be taken that no material can fall out of the
drainage apertures, e.g. by installing a rustproof perforated grille.
44 8:00 AM
damp course
open perpend
In all constructions, the inner leaf serves mainly to provide structural Inner leaf
stability and transfer load. It can be built with loadbearing bricks of a high
specific density; these have low resistance to heat transfer, but offer a
high level of sound insulation. Essentially, all standard bricks and mor-
tars approved by the building authorities can be used for the inner leaf.
> Chapter Building materials As the inner side usually has a layer of internal ren-
dering applied to it that covers the bricks, large blocks can be used, run-
ning counter to the bonding rules, as they are built in random bond and
with a thin mortar bed, but are very strong. Supporting concrete ceilings
is not a problem for insulated versions. Thermal insulation can be placed
continuously in front of the inner leaf. The full area of the ceiling can be
supported by it and thermal insulation can be additionally improved
where appropriate by placing an insulating strip in front of it.
The external leaf protects the rest of the masonry from external fac- External leaf
tors and the weather. For this reason, only materials should be used that
are appropriate for these conditions and are not sensitive to frost, mois-
ture and the effects of being on the outside. Such units are offered by
8:00 AM
45
Fig. 37: Ceiling support in double-leaf masonry
The outer leaf determines the appearance of the building and is ide-
ally built in the commonly taught bonds described above. But this leaf
can absorb only its own self-weight and has to be fixed to the inner leaf
by wire anchors to secure it against wind pressure or suction, and avoid
Tiping over, collapsing or bulging. The number of anchors needed and
their diameter depend on the distance between the leaves and the height
of the wall. Separate attention should be paid to open edges of apertures,
corners of the building or expansion joints, as well as rounded parts of
the structure. The appropriate measures must be taken to prevent mois-
ture from being transported from the outer to the inner leaf, such as fitting
plastic discs so that the water can drip off in the gap.
46 8:00 AM
drip disc
bracket
angle
The leaf must be secured against slipping away at the base. The first
run of anchors should therefore be placed as low as possible. The lower
sealing strip should extend to the front edge of the outer leaf.
The minimum thickness for the outer leaf is 9 cm. Anything thinner
is referred to as wall cladding. > Chapter External walls For reasons of space
8:00 AM
47
open
perpend
>30
>10
and thus of expense, the outer leaf is usually half a brick thick, so the vis-
ible bonds are not regular, as the most commonly taught bonds (except
the stretcher bond) cannot be built in this way.
Apertures For aesthetic reasons, the bond should generally run throughout the
area of the wall. Apertures, windows and doors and any projections there-
fore need special anchors to hold the units in position. Lintels are often
built in soldier bond, which is however not a regular construction, unlike
the arch constructions described above, and cannot carry any load. The
bricks should therefore be supported by brackets, which is cheap, but vis-
ible from the outside. Or there may be an invisible joint reinforcement to
hold the bricks in place. Brick manufacturers also offer U-shells, which
are reinforced and filled with concrete. These constructions transfer the
load into the wall areas adjacent at the sides. All metal parts should be
rustproof, ideally made of stainless steel, as galvanized items can be dam-
aged in transport or fitting, and flaws are hard to see or reach after fitting.
Joints The outer leaf deforms differently from the inner leaf as a result of
temperature and weather. Vertical and horizontal movement joints should
therefore be planned for the outer leaf to absorb this deformation.
As well as the material-dependent distances between the expansion
48 8:00 AM
built-in
angle visible
joints, > Tab. 1 the walls should be separated at the corners on the basis
of factors relating to the points of the compass. The west wall expands
most, and the north wall least. These joints can however be offset by half
the gap between the joints towards the middle, if this is architecturally
desirable. Cracks around window sills caused by different loading of sill
and the masonry around it can also be prevented by expansion joints on
both sides. Structural reinforcement in the upper sill area may replace
these joints. Horizontal joints should always be planned under the
underpinning.
Free-standing walls are very restricted in terms of height, as they are Non-loadbearing
supported only at the base point and have no stabilizing imposed load. external walls –
free-standing walls
The walls must therefore be thicker or stabilized by crosswalls or columns.
As they are outdoors and exposed to frost, they must use frost-resistant
materials and foundations and be protected against moisture. Horizon-
tal dampproof courses are needed above ground level, and the top of the
wall should be protected by blocks, metal sheeting or concrete coping
and damp courses.
8:00 AM
49
expansion north wall expansion
joint joint
elastic
sealant
west wall
foam toroid
east wall
expansion joint
expansion
joint south wall
movement joint corner arrangement
50 8:00 AM
block, edge course waterproof concrete metal coping
internal walls
Internal walls are not directly connected to the outdoors. They are
already protected from cold, rain and snow by the external walls, ceilings
and floors. Their main function is to separate internal areas, use zones
or sightlines. The separation may require greater sound insulation, e.g.
between dwellings, between bedrooms and living areas, between office
and production areas, or it may have a fire protection function.
Some inner walls also have to carry part of the load of the building,
or stiffen the building or individual sections of wall. They can thus be load-
bearing in direct connection with the adjacent structural elements, or
non-loadbearing, in which case all they have to do to avoid falling over is
transfer their self-weight and the horizontal loads on their area to other
structural elements. These different requirements are reflected in both
the dimensioning and the detail of the connection points. Specific den-
sity affects compressive strength and above all sound insulation, and
plays a key part in relation to internal walls. Here, units with a high mass
and specific density offer both great compressive strength and good
sound insulation.
Loadbearing internal walls stiffen the building and provide ceiling Loadbearing and
supports. To stiffen a wall, the connection with it should be tension- and stiffening internal
walls
compression-resistant; building materials with approximately the same
deformation behaviour should be chosen where possible for the sake of
stability. Connection is achieved by building both walls to the same height
in bond or by leaving gaps (socket connection) or protruding bricks
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51
with external with thermal insulation compound thermal
rendering rendering insulation system
light mineral rendering thermal insulation rendering compound thermal insulation
2 cm 0.31 W/mK 3 cm 0.07 W/mK system 6 cm 0.035 W/mK
transverse brick 30 cm 0.14 W/mK transverse brick 30 cm 0.14 W/mK transverse brick 30 cm 0.14 W/mK
internal rendering 1.5 cm 0.7 W/mK internal rendering 1.5 cm 0.7 W/mK internal rendering 1.5 cm 0.7 W/mK
52 8:00 AM
An efficient alternative is butt walling, which also requires tensile
bars or anchors; the joint is pointed subsequently. This connection can
be used only at internal corners, and has the advantage that when con-
necting with the external walls the thermal insulation of the external wall
is not compromised by the intrusion of interlocking bricks from the inter-
nal wall, which could be made of different materials.
Walls separating adjacent dwellings must always be twin-leaf struc- Party walls
tures for sound insulation purposes. The cavity width depends on the
mass of the partitioning leaves; a width of 5 cm is recommended. The
cavity should be filled with tightly packed mineral fibre blankets cover-
ing the full surface. Sound insulation is improved further by lagging in
two layers with offset seams. Rigid foam sheets are inadmissible. Care
should always be taken that no mortar drops into the joint. When build-
ing or attaching ceilings, the insulation should always be continued above
the edge of the wall or ceiling.
Non-loadbearing internal walls may not be used for either stiffening Non-loadbearing
or load transfer, and must not be subjected to wind loads. They carry all internal walls
their self-weight and light bracket loads (e.g. shelves, pictures etc.), and
must transfer impact loads to adjacent structural elements. Wall lengths
have been calculated according to height, the way in which the wall is
attached to adjacent structural elements (two-sided to four-sided mount-
ing), and possible imposed loads from ceiling deformations. They are
presented in a table that may be used without acknowledgement. ●
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53
anchor anchor
mortar
rigid wall connection with rigid wall connection with rigid wall connection with flat steel
groove (plan view) flat steel anchor (plan view) anchor (section)
joint sealant
insulation
sliding wall connections sliding ceiling connection sliding ceiling connection with
(plan view) wall supported on three sides
with free upper edge
54 8:00 AM
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55
Building materials
Earlier chapters describe masonry units in general terms and distin-
guish them only in terms of dimensions, geometry or the place where
they are to be used. The question now arises of which material is suit-
able for a particular construction and the functions it has to perform. Var-
ious kinds of brick and mortar are listed and distinguished below.
Masonry standards: The harmonized European product number series EN 771 (Specifica-
harmonized European tion for masonry units) is valid in the EU states. The series consists of:
product standard
56 7:59 AM
● Important: In Germany, the so-called user standards are used to translate the CE classi
fication values to make them compatible with national standards. These provide precise
values or admissible fields for the declared specifications (DIN V 20000-401 to DIN V
20000-404). Since the European standards do not address some requirements that have
already been introduced, which are therefore not covered by the usage standards, so-called
residual standards were added for the sake of completeness:
These also regulate all previously valid product properties, characteristics and differentia-
tions and lay down precise values and specifications in table form, e.g. for compressive
strength and specific density classes, and for unit perforations.
7:59 AM
57
Fig. 46: Clay masonry units
Tab. 2: Bricks
58 7:59 AM
HD bricks with a gross dry density of >1000 kg/m3 are suitable for
both protected and unprotected masonry. This includes resistant units
for the outer leaf and heavy sound-insulating units for the internal walls.
7:59 AM
59
Fig. 47: Calcium silicate units
Calcium silicate units Calcium silicate units have been made only since they were patented
in 1880. Unlike bricks, they are not fired. Instead, a mixture of sand, water
and lime is hardened under high pressure.
60 7:59 AM
Fig. 48: Porous concrete units
This type was also developed in the late 19th century. For the man- Aerated concrete
ufacture of aerated concrete units, a mixture of quartz sand, lime and units
cement is poured moulds with water and provided with steel mesh rein-
forcement according to purpose. Powdered aluminium is used as an
expanding agent, increasing the proportion of pores to 90% of the mate-
rial’s volume through the release of hydrogen. The unmoulded material
is cut and hardened under pressure.
Material: Lime, quartz sand, cement, water, expanding agent to form pores (aluminium)
Aggregates:
Manufacture: Mixed, moulded and hardened under pressure
Dimensions: In mm (e.g. 240 × 300 × 238)
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61
Fig. 49: Concrete and lightweight concrete units
Aerated concrete slabs and prefabricated slabs are used only for
non-loadbearing walls with different loadbearing systems, and for sound
insulation walls.
62 7:59 AM
strength class (average value)
30
25
20
strength class
15
10
hollow lightweight
HD solid brick
LD hollow brick
aerated concrete
prefabricated block
solid lightweight
concrete brick
concrete block
Fig. 50: Comparative strength classes
Concrete and lightweight concrete units are cast in moulds and Concrete and light-
stored until they reach their ultimate strength. The difference between weight concrete units
the two lies in the nature of the aggregates. Only lightweight aggregates
with a porous microstructure (primarily natural pumice or expanded clay)
may be used for lightweight concrete.
7:59 AM
63
specific density (average value)
2.5
2
specific density
1.5
0.5
0
ck
ck
ck
ck
ck
k
loc
ric
ric
ric
ric
blo
blo
blo
bri
bri
db
eb
eb
gb
eb
lid
ted
e
ret
ret
rin
oli
llo
ret
ret
llo
so
ica
ee
nc
nc
ho
nc
ho
nc
HD
te
gin
co
co
r
co
co
LD
ica
arb
d
an
en
li d
ht
ht
w
sil
ref
eig
llo
so
d
eig
lid
um
ate
ep
ho
htw
so
htw
lci
for
ret
HD
lig
ca
lig
er
nc
lid
p
w
co
llo
te
so
ed
ica
ho
rat
sil
ae
um
lci
ca
64 7:59 AM
Tab. 6: Mortar types
● Important: Site-mixed mortar is not covered by ● Important: Similarly to bricks, the national stan-
uropean standards. National user or working stan
E dards DIN V 20000-412 (user standard) and DIN 18580
dards must be consulted here. (residual standard) apply additionally in Germany. But
essentially the specifications of DIN 1053-1 still apply.
7:59 AM
65
1–3 mm. Here the dry density may not be less than 1500 kg/m3 and the
maximum aggregate particle size is 2 mm. All mortar types are allocated
to the mortar groups M1–M30 according to their compressive strength;
the compressive strength value is given in N/mm2. If a mortar complies
● with DIN EN 998-2 it is marked with the CE sign.
66 7:59 AM
In conclusion
The information contained in this book can give only a rough guide
to the many possibilities offered by masonry construction. For this rea-
son, it does not generally cover the regulations laid down in the differ-
ent national standards, which sometimes differ. These will have to be
addressed separately, using the list of standards in the Appendix. But the
knowledge presented does provide the necessary basis for understand-
ing the essential rules of the craft and the areas in which masonry is used,
and makes it possible for the reader to continue independently.
All in all, these “Basics” make it possible to explore the diverse world
of masonry construction and approach it correctly.
8:01 AM
67
Appendix
standards
Masonry units:
EN 771-1 (consult national Specifications for bricks – Part 1: Clay masonry units
versions)
EN 771-2 (consult national Specifications for bricks – Part 2: Calcium silicate masonry units
versions)
EN 771-3 (consult national Specifications for bricks – Part 3: Aggregate concrete masonry
versions) units (dense and lightweight aggregates)
EN 771-4 (consult national Specifications for bricks – Part 4: Autoclaved aerated concrete
versions) masonry units
EN 771-5 (consult national Specifications for bricks – Part 5: Manufactured stone masonry
versions) units
EN 771-6 (consult national Specifications for bricks – Part 6: Natural stone masonry units
versions)
Masonry mortar:
EN 998-2 (consult national Specifications for mortar in masonry structures –
versions) Part 2: Masonry mortar
68 8:01 AM
Literature
Kenneth Burke: Perspectives by Incongruity, Indiana University Press,
Bloomington 1964
Francis D. K. Ching: Building Construction Illustrated, 5th edition,
John Wiley & Sons, 2014
Construction Products Directive: Directive of the Council of
21 December 1988 (89/106/EEC)
Andrea Deplazes (ed.): Constructing Architecture, Birkhäuser, Basel
2013
Jacques Heyman: The Stone Skeleton: Stuctural Engineering of Masonry
Architecture, Cambridge University Press, Cambridge 1995
Theodor Hugues, Klaus Greilich, Christine Peter: Detail Practice:
Building with Large Clay Blocks and Panels, Birkhäuser, Basel 2005
Ernst Neufert, Peter Neufert: Architects’ Data, 4th edition,
John Wiley & Sons, 2012
Andrea Palladio: I Quattro Libri dell’ Architettura, English translation by
Robert Tavernor, MIT Press, Cambridge, Massachusetts 1997
Günter Pfeifer, Rolf Ramcke, Joachim Achtziger, Konrad Zilch: Masonry
Construction Manual, Birkhäuser, Basel 2001
Andrew Watts: Modern Construction Roofs, Springer, Wien New York
2006
picture credits
Illustration page 10: Bert Bielefeld, Nils Kummer
Illustration page 34: Bert Bielefeld, Nils Kummer
Illustration page 55: Gesellschaft Weltkulturgut Hansestadt Lübeck,
Willy-Brandt-Allee 19, 23554 Lübeck
Figures 1–51: Nils Kummer
Figure 26: supported by: Bert Bielefeld and Kalksandstein-Info GmbH
(see Figure 47)
Figures 39, 41: supported by: Deutsche Kahneisen GmbH,
Nobelstrasse 51–55, 12057 Berlin, www.jordahl.de
Figures 44, 46: supported by: Wienerberger Ziegelindustrie GmbH,
Oldenburger Allee 36, 30659 Hanover, www.wienerberger.de
Figure 47: supported by: Kalksandstein-Info GmbH, Entenfangweg 15,
30419 Hanover, www.kalksandstein.de
Figure 48: supported by: Bundesverband Porenbetonindustrie e.V.,
Dostojewskistrasse10, 65187 Wiesbaden, www.bv-porenbeton.de
Figure 49: supported by: Meier Betonwerk GmbH, Industriestrasse 3,
09236 Claussnitz/OT Diethensdorf, www.meier-mauersteine.de
8:04 AM
69
THE AUTHOR
Nils Kummer, architect, has worked for various clients and employ-
ers in the public and private sectors since graduating from TU Dortmund.
He has managed national and international projects and his writings and
drawings have been published by various publishers.
70 8:11 AM
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Series editor: Bert Bielefeld This work is subject to copyright. All rights are
Concept: Bert Bielefeld, Annette Gref reserved, whether the whole or part of the
Translation from German into English: material is concerned, specifically the rights of
Michael Robinson translation, reprinting, re-use of illustrations,
English copy editing: Monica Buckland recitation, broadcasting, reproduction on
Layout print edition: Andreas Hidber microfilms or in other ways, and storage in
EPUB production: Kösel Media, Krugzell databases. For any kind of use, permission
of the copyright owner must be obtained.
Quotation page 7: Detail Review of Architecture,
10/2005, Munich, page 1066 This publication is also available as a softcover
(ISBN 978-3-7643-7645-1) and in a German
Library of Congress Cataloging-in-Publication language edition (ISBN PDF 978-3-0356-1251-6;
data ISBN EPUB 978-3-0356-1146-5).
A CIP catalog record for this book has been
applied for at the Library of Congress. © 2015 Birkhäuser Verlag GmbH, Basel
P.O. Box 44, 4009 Basel, Switzerland
Bibliographic information published by the Part of Walter de Gruyter GmbH, Berlin/Boston
erman National Library
G
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cation in the Deutsche Nationalbibliografie; ISBN 978-3-0356-1217-2 EPUB
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