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Clayblock® products are produced by the world’smarket leader in clay technology and have beenused successfully in Europe for over 30 years.
Clayblock® products comply with BritishStandard BS EN 771-1:2003, CE marked, LABCRegistered Details-Registration No. RD1820312,and can be used in masonry designed inaccordance with Euro code 6 (UK).
Use of the Clayblock® system is supported by atechnical report and design guidance publicationby Lucideon Limited.
Why choose clay?
Used for thousands of years in constructionworld-wide, clay remains the most sustainablesolution for modern buildings. It’s naturalproperties means that it provides a complete,long term sustainability, not only offeringincreasingly sophisticated low-carbon productmanufacture, but giving a building life over 150years with little or no maintenance.
Strong and durable, yet lighter and easier to work with than many of the alternatives, clay also builds-in sound and temperature-controlbenefits wherever it’s used—creating the idealinternal living environment.
From sustainability credentials and build qualityto the ease of use on-site, clay is a materialequipped to meet every demand of modernconstruction.
SucceSSful & SuStainable
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The heart of the system-and the secret of it’s speed and efficiency—is the precision-engineered clayblock. A unique interlocking design rules out the need for mortar in the vertical joints and consistentmanufacturing quality allows for true 1mm bed joints. Used successfully for decades across Europe,and now well-established as a building solution for Ireland and UK working conditions, Clayblock®products can be used in load-bearing and non-load-bearing applications and are ideal for:
With it’s lean laying process and rapid daily output, the Clayblock® system brings cost and timesavingbenefits throughout the build while it’s thermal and acoustic efficiencies bring further advantages fordecades to follow—the design life for a Clayblock® wall is over 150 years.
It’s extremely fast, virtually dry, safe and simple touse, immensely strong, efficient for stock-holding
and storage and environmentally friendly.
about the clayblock SyStem
Single leaf (monolithic) internal & external walls
Partition walls and separating walls
Inner leaf of brick-faced cavity walls
Inner and outer leaves of rendered cavity walls
Infill panels within framed structures
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dryer
In comparison to traditional block work,Clayblock® construction uses around 95% lesswater. In a typical 212m² building, concreteblocks will require 1060 litres of watercompared to just 72 litres for the Clayblock®system
The system takes less time to achieve awatertight shell thus accellerating the project shedule
faster
With no mortar needed in vertical joints and a minimal 1mm bed joint, the Clayblock®system rises rapidly. An average of 30-40m²per man per day is easily achievable, muchfaster than traditional masonry
The Clayblock® system is capable of beingbuilt to storey height in one day
Floors can be placed without the need fornormal backing up so the external envelopecan be completed more quickly
While surpassing masonry structures for fireresistance, longevity and sustainability,Clayblock® construction can even be fasterthan timber frame construction—with theadded benefit of allowing parallel working forinternal and external trades earlier in theprogramme
Our thin bed mortar can be used from 0degrees celsius and above, meaning thatprojects can gain days/weeks extra in workingtime during winter which would otherwise belost with traditional masonry
clayblock in depth
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To get the best use from the Clayblock® system, it’s important first to understand the tools andmaterials that define the process:
clayblock in uSe
Thin Bed Mortar is a mix of fine-ground sand,cement and other ingredients specific toClayblock® construction.
Mixed locally to laying, it allows for thin joints which will achieve full strength in just24 hours
Unlike traditional mortar, which is oftenlimited to use only when the temperatureexceeds 3°C, our mortar can be used from0°C, allowing block layers to minimiseweather related delays
Each 15kg pack requires just 3.6 litres of waterand will lay 1 No. pack of blocks when appliedwith the correct rolling tools
A Roller to apply the thin bed mortar allows forthe swift and simple creation of true 1mm bedjoints.
parge coat
A high performance parge coat is analternative to a wet plaster parge coat toprovide an airtight barrier prior to theapplication of plasterboard on dabs or otherinternal finishes
Our parge coat product is a high performancemodern parge coat that has been specificallydesigned and tested for fast application ontothe Clayblock® walling systems. It has beenengineered to increase airtightness and tooptimise the sound and thermal performanceof the system.
Our parge coat can be easily applied by brushor roller ensuring fast, de-skilled application
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note 1: The maximum depth of the recess orchase should include the depth of any holereached when forming the recess or chase.
note 2: Vertical chases which do not extendmore than one third of the storey height abovefloor level may have a depth up to 80mm and awidth up to 120mm, if the thickness of the wall is225mm or more.
note 3: The horizontal distance betweenadjacent chases or between a chase and a recessor an opening should not be less than 225mm.
note 4: The horizontal distance between anytwo adjacent recesses, whether they occur on thesame side or on opposite sides of the wall, orbetween a recess and an opening, should not beless than twice the width of the wider of the tworecesses.
note 5: The cumulative width of vertical chasesand recesses should not exceed 0.13 times thelength of the wall.
note 6: When installing gas pipework intochases cut into the Clayblock® wall the pipeworkshould be secured using proprietary side fixedclips into the face of the block and not into theinner face of the chase. As with all masonry types,the sealing of the chase should be in line withGas Safe regulations. If in doubt, the advice of aHeating Engineer should be sought.
If chases are too deep or back-to-back the structural integrity of the wall will have been altered andtherefore will be subject to a structural engineers survey and report. The person chasing for electricalwork may not be the same person who hangs a picture or cuts a retrospective window, therefore, allchases should be sensibly placed allowing everyone the opportunity of working out where servicesare in relation to lights, switches, sockets and appliance points.
Contractors must follow guidelines to make the installation of electrical cables as safe as possible.Ideally works pertaining to chasing and making good should be completed prior to applying a pargecoat. Should chasing and making good be undertaken after a parge coat is applied then an additionalparge coat must be applied over the chased area.
chases
Installing chases for the purposes of runningservices is best achieved by using a proprietarytool designed specifically for the purpose e.g. a wall chaser with two parallel diamond tippedcutting wheels. A bolster chisel can then be usedto remove the cut section. The chase should thenbe sealed for air tightness using a parge coatapplication.
clayblock in uSe
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clayblock in uSe
Safer
Clayblock® products are generally lighter thanconcrete (optimum weight under 11kg)allowing workers to maintain steadyproduction rates without the risk of repetitivestrain injuries
Precision engineering means no sharpcorners, reducing the risk of cuts and grazes
Thin bed mortar is applied with a roller,reducing dermatological risk
The thin bed joint mix is mixed locally to theworkplace, which means a reduction inforklift movements, less plant/pedestriancontact and no need for noisy cement mixers
more efficient
Thermally efficient in helping to regulatevariations in temperature and humidity; air-tightness is maximised with a parge coator wet plaster
Acoustically efficient
Fire resistance is outstanding – Clayblock®achieves a Class A1 rating for a 100mm wall
Breathable – assists in regulating seasonalhumidity
No moisture shrinkage – no disruption tofinishes, fewer movement joints (1:20 linearmetres) and reduced risk of cracking due toshrinkage
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clayblock in uSe
the method
1. Lay the first course on a traditional sand-cementmortar bed
2. Ensure the first blocks are level, horizontal in bothdirections and vertically plumb. This is the most crucialstage of the process, as it determines the levelness ofeach of the subsequent build storeys, and the speedand accuracy of the construction as a whole
4. Apply the mortar (mixed close to the build) to theblocks with a roller
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3. Mix thin bed mortar according to guidelinequantities – don’t mix more than you need
clayblock in uSe
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5. Repeat until a precision wall is complete – up tofour times faster than traditional methods
6. Wall ties are easily installed (see other products)
8. Block-cutting is straightforward
7. If insulation is preferred than it can be applied simply
lintels
A range of system-compliant lintels from allleading manufacturers are widely available.
fixings
Many off-the-shelf fixings are suitable for usewith Clayblock® products covering the completerange of light to heavy requirements.
Wall ties
Because of the thin joints created with Clayblock®standard ties are not suitable. However, a range ofpurpose made, system-compliant stainless steelties are widely available.
A wide variety of fixtures and accessories are available for use with Clayblock® products somespecifically created to work with the system (in conjunction with industry-leading partners) and othersavailable as standard items.
fixtureS and acceSSorieS
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understanding exactly how clayblock works in practice is absolutelyvital to getting the maximum benefit from the system, which is whyclayblock® and our supplier will do everything we can to ensure weprovide the site training and support contractors need. our expertlyrun courses are designed to suit tradesmen, designers, productionpersonnel and management.
clayblock training and Support
If you are interested or just need moreinformation about our training, please contact us:
Email: [email protected]: www.clayblock.ie
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the clayblock core range
12
dim
enSi
on
SW
x l
x h
(mm
)
Qu
an
tity
Sq m
Qu
an
tity
/pk
no/
Sq m
Wei
gh
tea
ch kg
Wei
gh
t/pa
ck kg
con
du
ctiV
ity
dry
blo
ckla
mbd
a W
/mk
aco
uSt
icre
SiSt
an
cerw
(db)
com
preS
SiV
eSt
ren
gth
n/S
q.m
m
pro
du
ctio
nra
teSq
m/m
an/h
r
clay
blo
ck10
010
0x30
0x22
415
160/
10.6
6.4
1032
0.31
4010
8 to
10
clay
blo
ck14
014
0x30
0x22
415
120/
8.0
7.9
955
0.28
4110
5 to
8
clay
blo
ck19
019
0x30
0x22
415
80/5
.310
.787
00.
0044
103
to 6
clay
blo
ck36
5
t10
365x
248x
249
1660
/3.7
14.7
990
0.10
>40
102
to 5
clay
blo
ck36
5
t836
5x24
8x24
916
60/3
.713
.583
00.
08>4
010
2 to
5
clay
blo
ck42
5
t842
5x24
8x24
916
48/4
15.7
770
0.08
>40
––
other productS
toolS & acceSSorieS
13
RECIPROCATING ALLIGATOR SAW
THIN BED ROLLER
SPIRIT LEVEL
PADDLE DRILL
TAPE MEASURE
STANDARD PPE
Clayblock products can be laid using a widerange of standard construction and masonrytools and equipment. however there are anumber of specialised tools availble to assistwith speed and efficiency of laying.
Please contact us for specific requirements
monolithic u-block
Optional SizesInsulated or not
inSulated clay lintelS
Optional SizesInsulated or not150mm bearing
tieS for internal WallJunctionS
Also cavity wall tiesBrick and stone tiesProfile less than 1mm
abutment tie forperimeter Wall
No cross bond requiredAlso joist hangersProfile less than 1mm
dryfix SyStem
Alternative to mixedmortarFast and effective
fixingS
Most standard fixings are suitable
call to discuss your specific requirements
technical
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Please note: Sizes of vertical chases and recesses in masonry, allowed without calculation
chases and recesses formed afterconstruction of masonry
chases and recesses formed duringconstruction of masonry
thickness of wallmm
max depth mm
max width mm
maximum wallleaf thickness
remaining mm
max width mm
85-115 30 100 70 300
116-175 30 125 90 300
176-225 30 150 140 300
226-300 30 175 175 300
>300 30 200 215 300
SuStainable
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clayblock products have...
Up to 30% MARSS materials from alternative,recycled and secondary sources
Low embodied energy
An end of life function as a useful crushedhard-core – 150+ years
95% less water use in construction
Minimal waste during use
Clay is a natural material equipped to meet every demand of modern construction. Used forthousands of years in construction worldwide, clay remains the most sustainable solution for modernbuildings. Its natural properties means that it provides a complete, long term sustainability, not onlyoffering increasingly sophisticated low-carbon product manufacture, but giving a building life of over150 years with little or no maintenance.
Create an optimum living environment, ask for comfort without complication, simplify construction,reduce trades and increase workflow.
While matching masonry structures for fire-resistance, longevity and sustainability, Clayblockconstruction can even be faster than timber frame construction – with the added benefit of allowingparallel working for internal and external trades earlier in the programme
THERMAL WALL SOLUTIONS
Email: [email protected] Web: www.clayblock.ie
robert JohnstonTechnical Director
Phone: 087 451 3278Email: [email protected]
Szilárd czakóSales Director
Phone: 087 774 5465Email: [email protected]
diSclaimerClayblock Limited as well as its directors, employees, agents and representatives disclaim any responsibility, express or implied, for the accuracy or completeness of the informationcontained in this brochure or its suitability for a certain purpose. This brochure does not constitute a complete description of all articles distributed by Clayblock Limited and cannot containall relevant information for their use. All products, components, methods etc. described herein are subject to continuous technical development and may therefore be modified by ClayblockLimited without further notice. Such modification may cause the information herein to become partially or entirely inapplicable. This brochure cannot and does not substitute the client’sown necessary assessment and evaluation of the items described herein as well as the involvement of professional advice as to planning and construction. This also applies to technicalnorms applicable to a certain project, which should be reviewed by qualified consulting engineers and/or architects. If and to the extent the brochure contains statements in relation to thirdparty products, such statements are based on Clayblock Limited and its suppliers own experience made under certain circumstances. Such statements may prove correct or incorrect underdifferent circumstances. Clayblock Limited shall not be liable for the correctness and completeness of the information, conclusions and predictions contained in such statements. Any liabilityof Clayblock Limited in connection with the products and methods described in this brochure is valid only if and to the extent agreed upon in writing between Clayblock Limited and theclient, e.g. in the form of a definitive written purchase agreement. If the client chooses to use or process articles or components displayed herein in a way differing from the methodsrecommended herein, the client in such circumstances has to obtain Clayblock Limited written approval in order to preserve liability claims, if any.
