Don’t Let Weather Destroy Your Investment: The Essential Guide to Proper Masonry Material Storage

Whether you’re a seasoned contractor or a homeowner embarking on a DIY masonry project, protecting your valuable materials from weather and moisture damage is crucial for both your budget and project success. Uncontrolled moisture may reduce the structural soundness of buildings through freeze-thaw cycles, spalling and efflorescence in masonry, making proper storage techniques essential from the moment materials arrive on-site.

Understanding the Threats to Your Masonry Materials

Efflorescence, a white deposit of surface salt on the exterior of a building, can occur on masonry, which can also be damaged during freeze/thaw cycles as moisture within the masonry expands and contracts. These issues don’t just affect installed masonry – they can damage materials during storage as well. If water enters a concrete wall or foundation, it can cause the surface to expand outwards or flake off, a process knowing as spalling. This effect will eventually cause the structure to crumble, which can become a safety hazard if not resolved in time. Water infiltration can also cause a freeze-thaw reaction in colder climates, which forces the masonry to expand.

The financial impact of poor storage practices extends beyond material replacement costs. Without moisture control, a building can sustain significant damage that requires lots of time and money to fix, and this principle applies equally to materials awaiting installation.

Essential Storage Techniques for Different Masonry Materials

Concrete Blocks and CMUs

When storing concrete blocks on site, they should be kept on a flat, stable, and well-drained surface, preferably on pallets, to prevent them from absorbing ground moisture and to allow for easy access. They should also be covered to protect them from rain, which can affect their moisture content and workability with mortar. This protection is vital because water wicking into the cracks and pores of porous building materials, such as masonry blocks, concrete, or wood can compromise their structural integrity before installation even begins.

Brick Storage Best Practices

For brick storage, OSHA regulations provide important guidance. Brick stacks shall not be more than 7 feet in height. When a loose brick stack reaches a height of 4 feet, it shall be tapered back 2 inches in every foot of height above the 4-foot level. Additionally, bricks or blocks, which are on a pallet, are interlocked, banded, shrink-wrapped, or similarly bound for shipment offer better protection during storage.

Natural Stone Protection

Natural stone materials require special consideration due to their varying porosity levels. Stone masonry is the most durable, strong and weather resistant, thanks to the natural durability of the material, but proper storage still ensures optimal performance and prevents unnecessary weathering before installation.

Creating the Ideal Storage Environment

The foundation of proper masonry storage begins with site preparation. Slope the ground away from the foundations of all houses – this same principle applies to storage areas. Ensure your storage site has proper drainage to prevent water pooling around materials.

For covered storage, consider the lessons from building envelope design. To protect against rain penetration, you should also create a drainage plane within the wall system. Similarly, your storage area should incorporate drainage planes that direct water away from stored materials.

Moisture Control Strategies

Install a protective membrane, such as rubberized roofing or ice-dam protection materials, between the foundation and the sill plate to serve as a capillary break and reduce wicking of water up from the masonry foundation wall. Damp-proof all below-grade portions of the foundation wall and footing to prevent the wall from absorbing ground moisture by capillary action. These same principles can be adapted for material storage by using vapor barriers beneath stored materials and ensuring proper air circulation.

Temperature control is equally important. Insulation can regulate the temperature of a building’s walls, which keep interior surfaces above the dew point. The dew point is the temperature at which water vapor in the air begins to condense and form dew. If you know this number, you can prevent condensation from occurring.

Long-term Storage Solutions

For extended storage periods, consider implementing a comprehensive moisture management system. The ideal setup consists of a multi-part defense system, which includes surface protection, internal protection, drainage and drying. The kind of masonry you use will determine how you can employ this strategy to waterproof your building project.

Weatherproofing wood and masonry will not only prevent it from moisture damage, but it also protects it from UV rays, humidity, frost and insect damage. While you wouldn’t typically weatherproof stored materials, understanding these threats helps inform proper covering and protection strategies.

Working with Professional Suppliers

When sourcing materials, partnering with an experienced masonry supply company can make a significant difference in material quality and storage guidance. Jos.M.Troffa Materials Corporation is a premier landscape and masonry supply company. Located in the town of Setauket, we have been expertly servicing both commercial and residential customers throughout Long Island since 1972. We have a huge inventory of stone and masonry products and materials available for homeowners, builders, contractors, landscapers, designers, and developers. We offer the highest quality products to enhance any masonry job – from backyard projects to brand new home and business construction.

Established suppliers like Jos M. Troffa understand the importance of proper material handling from quarry to job site. The staff at Jos M Troffa is committed to providing their clients with the very best services possible. From help selecting products to the delivery of supplies, their crew will work with you every step of the way to ensure that all of your needs are met. The friendly and knowledgeable sales associates at Jos M Troffa go above and beyond to ensure that you have the best experience and get the highest quality products possible.

Protecting Your Investment

Proper masonry material storage isn’t just about preventing immediate damage – it’s about preserving the long-term performance of your construction investment. Even with proper detailing and maintenance, it is anticipated that some moisture will be absorbed by the masonry during rain events. This moisture can be stored within the masonry and later released through evaporation during dry weather without degrading the integrity of the wall. However, excessive moisture exposure during storage can overwhelm this natural capacity.

Remember that it’s impossible to control all moisture entering a building, but there are many tactics to manage the moisture so that damp materials dry out quickly and water can exit quickly. Architects and installers must take a holistic look at the building envelope, including sheathing, weather resistant barriers (WRBs), drainage planes, and attachment systems that will help keep moisture out of the assembly. These same holistic principles apply to material storage.

By implementing proper storage techniques, working with experienced suppliers, and understanding the science behind moisture control, you can protect your masonry materials investment and ensure your project’s long-term success. Whether you’re storing materials for a small patio project or a large commercial development, these principles will help safeguard your investment against weather and moisture damage.