MATERIALS FOR ARCHITECTS AND BUILDERS This page intentionally left blank MATERIALS FOR ARCHITECTS AND BUILDERS Fourth edition ARTHUR LYONS MA(Cantab) MSc(Warwick) PhD(Leicester) DipArchCons(Leicester) Hon LRSA FHEA Former Head of Quality, Principal Lecturer and Teacher Fellow, School of Architecture, Faculty of Art and Design, De Montfort University, Leicester, UK Amsterdam r Boston r Heidelberg r London r New York r Oxford r Paris r San diego r San francisco r Singapore r Sydney r Tokyo Butterworth-Heinemann is an imprint of Elsevier Butterworth-Heinemann is an imprint of Elsevier The Boulevard, Langford Lane, Kidlington, Oxford, OX5 1GB 30 Corporate Drive, Suite 400, Burlington, MA 01803, USA First edition 1997 Second edition 2003 Third edition 2007 Reprinted 2007, 2008 Copyright © 2010, Arthur Lyons. Published by Elsevier Ltd. All rights reserved The right of Arthur Lyons to be identified as the author of this work has been asserted in accordance with the Copyright, Designs and Patents Act 1988 Permission to reproduce extracts from BN EN 771 Part 1: 2003 (Figs 2 and 3) and BS 6915: 2001 (Fig. 19) is granted by BSI. British Standards can be obtained in PDF or hard copy formats from the BSI online shop: www.bsigroup.com/Shop or by contacting BSI Customer Services for hardcopies only: Tel: +44 (0) 20 8996 9001, Email: [email protected] No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means electronic, mechanical, photocopying, recording or otherwise without the prior written permission of the publisher Permissions may be sought directly from Elsevier’s Science & Technology Rights Department in Oxford, UK: phone (+44) (0) 1865 843830; fax (+44) (0) 1865 853333; email: [email protected]. Alternatively you can submit your request online by visiting the Elsevier web site at http://elsevier.com/locate/permissions, and selecting Obtaining permission to use Elsevier material Notice No responsibility is assumed by the publisher for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions or ideas contained in the material herein. Because of advances in building construction, advice must be obtained from the materials suppliers and appropriate statutory bodies. British Library Cataloguing in Publication Data Library of Congress Cataloging-in-Publication Data A catalog record for this book is available from the Library of Congress ISBN: 978-1-85617-519-7 For information on all Butterworth-Heinemann publications visit our website at www.elsevierdirect.com Printed and bound in Hong Kong, China 101112131410987654321 CONTENTS About the author vii Recycling timber 154 Preface to fourth edition viii References 155 Acknowledgements ix Information sources x 5 Ferrous and non-ferrous metals 164 Abbreviations xi Introduction 164 Ferrous metals 164 1 Bricks and brickwork 1 Ferrous alloys 180 Introduction 1 Coated steels 182 Clay bricks 1 Aluminium 185 Unfired clay bricks 17 Copper 190 Reclaimed clay bricks 17 Lead 197 Brickwork 18 Zinc 200 Calcium silicate bricks 29 Titanium 205 Concrete bricks 33 Process of metallic corrosion 206 References 35 References 208 2 Blocks and blockwork 37 6 Bitumen and flat roofing materials 216 Introduction 37 Introduction 216 Concrete blocks 37 Cold-deck, warm-deck and inverted roofs 216 Clay blocks 43 Reinforced bitumen membranes 217 Gypsum blocks 44 Mastic asphalt 221 Blockwork 46 Single-ply roofing systems 223 Beam and block flooring 50 Liquid coatings 225 Landscape blockwork 52 Green roofs 226 References 52 References 227 3 Lime, cement and concrete 55 7 Glass 231 Introduction 55 Introduction 231 Lime 55 Manufacture 232 Cement 58 Non-sheet products 234 Concrete 70 Sheet products 236 Reinforced concrete 84 Intelligent glass facades 255 Visual concrete 89 Glass supporting systems 255 Concrete components 97 Glazing checklist 261 References 98 References 261 4 Timber and timber products 105 8 Ceramic materials 266 Introduction 105 Introduction 266 Timber 106 Ceramic products 268 Timber products 136 References 275 vi CONTENTS 9 Stone and cast stone 278 Sealants 359 Introduction 278 Gaskets 364 Types of stone 278 Adhesives 366 Stonework 289 References 369 Deterioration of stone 294 Maintenance of stonework 295 15 Paints, wood stains, varnishes Cast stone 296 and colour 373 References 297 Introduction 373 Colour 373 10 Plastics 301 Paints 379 Introduction 301 Special paints 380 Polymerisation 301 Natural wood finishes 382 Polymer types 303 References 383 Additives 304 Degradation of plastics 304 16 Energy-saving materials and Properties of plastics 304 components 385 Plastics forming processes 306 Introduction 385 Plastics in construction 307 Photovoltaics 385 Recycling of plastics 316 Solar collectors 388 References 317 Solar air heating systems 389 Light pipes 389 11 Glass-fibre reinforced plastics, Heat pump systems 390 cement and gypsum 323 Groundwater cooling systems 391 Wind catchers 391 Introduction 323 Wind turbine systems 391 Glass fibres 323 Water management systems 392 Glass-fibre reinforced plastics 323 Phase change systems 393 Glass-fibre reinforced cement 327 References 393 Glass-fibre reinforced gypsum 329 References 331 17 Recycled and ecological materials 396 Introduction 396 12 Plaster and board materials 333 Straw bales 396 Introduction 333 Cardboard 397 Gypsum plaster 333 Rammed-earth and cob construction 397 Lime plaster 339 Earth-sheltered buildings 399 Calcium silicate boards 339 Clay products 400 References 339 Recycled tyres 400 Papercrete 401 13 Insulation materials 342 Sandbags 402 Introduction 342 References 402 Thermal and sound insulation materials 342 Inorganic insulation materials 343 18 Sustainability 404 Organic insulation materials 347 Introduction 404 Aluminium foil 352 Zero carbon targets 404 Chlorofluorocarbons in foamed plastics 353 Specification of materials 408 References 353 Recycling and deconstruction 409 References 409 14 Sealants, gaskets and adhesives 359 Introduction 359 Index 413 ABOUT THE AUTHOR Dr Arthur Lyons, author of texts on building materi- honoured with life membership of the Leicestershire als, was formerly head of quality, principal lecturer and and Rutland Society of Architects and he is a Fel- teacher fellow for building materials at the Leicester low of the Higher Education Academy. He retains his School of Architecture, Faculty of Art and Design, De active interest in architecture through liaison with the Montfort University, Leicester, UK. He was educated local society of architects and the Leicester School at Trinity Hall Cambridge, Warwick and Leicester Uni- of Architecture of De Montfort University. In addi- versities in the fields of natural sciences and polymer tion to this text, Arthur Lyons has written chapters science, and has a postgraduate diploma in archi- in Metric Handbook—Planning and Design Data,3rd tectural building conservation. He was a lecturer in edition, 2008, Architectural Press; ICE Manual of building materials within schools of architecture and Construction Materials, 2009, Institution of Civil Engi- surveying for 35 years. In recognition of his ser- neers and Construction Materials Reference Book, 2010, vices to architects and architecture, Arthur Lyons was Butterworth-Heinemann. PREFACE TO FOURTH EDITION Materials for Architects and Builders is written as an materials no longer in use are generally disregarded, introductory text to inform students at undergradu- except where increased concern for environmental ate degree and national diploma level of the relevant issues has created renewed interest. The use of chem- visual and physical properties of the widest range of ical terminology is kept to the minimum required to building materials. The fourth edition has been sig- understand each subject area, and is only significantly nificantly enhanced by the addition of more colour used within the context of the structure of plastics. images, illustrating the materials and, in many cases, Tabulated data is restricted to an informative level their use in buildings of architectural merit. The text appropriate to student use. An extensive bibliography embraces the broad environmental issues with sections and listed sources of technical information are pro- on energy saving and recycled materials. An additional vided at the end of each chapter to facilitate direct chapter on sustainability reflects the current debate on reference where necessary. climate change and governmental action to reduce car- The text is well illustrated with over 270 line draw- bon emissions and ameliorate global warming. There ings and colour photographs, showing the production, are eighteen chapters covering the wide range of mate- appearance and appropriate use of materials, but it rials under standard headings. Each chapter describes is not intended to describe construction details as the manufacture, salient properties and typical uses of these are illustrated in the standard texts on build- the various materials, with the aim of ensuring their ing construction. Environmental concerns including appropriate application within awareness of their eco- energy-conscious design and the effects of fire are logical impact. automatically considered as part of the broader under- European Standards are taking over from the pre- standing of the various materials. vious British Standards, and for most key materials, The text is essential reading for honours and foun- the European Norms have