BRICKLAYERS MAnuAL“When all else fails read the instructions”

1St EDItIOn 2008

SECtIOn C

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SECtIOn C - BRICKLAYER

C1 Building walls with ecobrick C1.1 General Notes

Construction of brick walls in both residential and commercial buildings are covered by the relevant sections in the Building Code of Australia, AS3700-2001 Masonry Structures (and all amendments and supplements since 2001), AS1684-2006 the Residential Timber framed Construction Standard and AS1170.2-2002 Minimum Design Loads on Structures [known as the SAA Loading Code] plus any other relevant codes and standards.

This information is provided on the basis that the wall is being built by a person trained and skilled in the art of bricklaying and conversant with the requirements of the relevant building codes and practices outlined above.

The intention of these notes is to provide helpful information and to highlight variations to standard bricklaying practice.

C1.2 Wall Types

Cavity Walls

ecobrick can be used for cavity wall construction. The cavity walls can be made up from the following combinations - Clay - ecobrick; ecobrick - ecobrick or ecobrick - framed.

ecobrick can be used externally but will require surface protection with either render or appropriate paint finishes.

Single leaf walls

Single leaf walls comprise internal walls for residential building and as partition walls for commercial/industrial buildings. Construction techniques are similar for both types of wall systems though structural and support systems may vary depending on application.

C1.3 Wall Loads

ecobrick is a load bearing wall when specific height and load considerations are met. [Refer AS1684 and AS1170 for specific construction details).

Generally ecobrick is a brick product appropriate for the loads associated with single level construction. ecobrick cannot withstand the high compressive loads associated with multilevel load bearing construction.

Walls to be built in high wind load areas must conform to the relevant designs codes of those locations.

See Carpentry Section for specific roof attachment details.

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C2 Practical Issues

C2.1 Transport and Storage

Being a cement based product the exposed surface ecobricks can and will be affected by long term exposure to moisture/water. ecobricks are generally delivered to site covered in plastic is it is recommended to keep them covered until just prior to use.

C2.2 Cement or Mortar

Builders Choice Thin Bed mortar to a finished mortar joint of 3mm thick is one recommended method to bond ecobricks together.

The Thin Bed mortar powder is mixed with water to a form a loose paste, which can then be applied with a standard bricklayers trowel or a specialised notched trowel.

As the mortar open time is short, it is preferable to lay only one or two ecobricks at one time rather than trying to lay a line of bricks. We recommend that you clean up with water before the mortar has dried, otherwise it may have to be removed by mechanical means. [Available from ecobrick]

Builders Choice AAC Cement is specialised cement that is another method to bond ecobricks together. AAC Cement is mixed with sand and lime to form thick mortar. The mortar is applied with a standard bricklayer’s trowel to a joint of 10mm.

The ratio for this mortar is 6 parts bricklayers sand, 1 part AAC Cement and 1/3 Lime and is used in the same way a standard bricklaying mortar is used. We recommend that you clean up with water while the mortar is still moist, otherwise it may have to be removed by mechanical means. [Available from ecobrick and BGC builders supplies]

C2.3 Wet ecobrick

Observation is the best way to gauge the level of moisture in an ecobrick. A dry ecobrick is a light grey/pink in colour and has a “bright” appearance and feels quite light when picked up.

A wet ecobrick has a dark dull grey appearance and feels quite heavy when picked up. Do not plaster a wet ecobrick but allow sufficient time for the bricks to dry out before plastering. [Drying time will depend on ambient temperature conditions and could be up to 7 days]

The bricks will not deteriorate but applying cement based mortars and renders to wet bricks will cause drummy plaster or plaster to fall off a wall once the bricks dry out.

C2.4 Cutting

ecobrick is a light-weight concrete product and can be safely cut with a standard timber or metal saw, or with hand tools like brick bolsters and chisels.

For large numbers of bricks, we recommend that you use a tungsten tipped saw. Alternatively, if you wish to use a brick cutting machine or angle grinder, you may do so as long as the grinder has suitable dust collection equipment connected.

A hand chisel is suitable when chasing out a wall, although power tools can also be used so long as there is a dust collecting device attached.

C2.5 Dust Exposure

As ecobricks are a cement based product, unprotected long-term exposure to the cement dust is not advisable. When using power cutting tools, please remember that it is a health requirement to use dust extraction equipment connected to the cutting tool.

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Wall 1

Masonry external leaf with ecobrick internal leaf.

Wall 2

ecobrick external wall with ecobrick internal leaf.

2. External render

C3 Cavity Wall Systems TYPICAL CROSS SECTION OF A DOUBLE BRICK CAVITY WALL

Information

InstructionGeneral cross section [not to scale]

Drawings are for illustrative purposes only

1. Damp proof course

7. Top plates

5. Windows & Doors

6. Lintels

Waterproof membrane and white ant protection

4. Wall ties

3. Internal finish3. Internal finish

Weep hole

Weep hole

Tile roof Metal roof InsulationInsulation

Weep hole

Single GlazingSingle Glazing

Weep hole

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C3.1 Damp Proof Course

The intention of a damp course is to prevent the movement of moisture up into the wall structure. The damp course is an integral part of any external wall system irrespective of wall material.

The damp course can be either mechanical or more commonly a cement based compound.

Mortar Types

Two methods of assembling ecobrick are available.

Builders Choice Thin Bed Mortar - mixed with water to a paste will provide a 3mm mortar joint.

Builders Choice AAC cement mixed with sand and a small portion of lime will provide a 10mm mortar joint. The ratio is 6 x sand to 1 of AAC cement to 1⁄3 lime.

Builders Choice Thin Bed Mortar is the mortar system required to achieve a four (4) hour fire rating for an ecobrick wall.

Mortar for non ecobrick walls, to other masonry manufacturers specifications.

C3.2 External finishes

1. ecobrick walls will require the application of a render or paint finish to protect the surface. See Plasterer Section for more detailed recommendations.

2. Clay masonry walls will not generally require any surface treatments.

Note: The external render on an ecobrick wall must finish at or above the damp proof course.

C3.3 Internal Finishes

ecobrick can be finished with a plaster and set finish or a plasterboard system. See Plasterer Section for more detailed information.

C3.4 Wall ties

Cavity walls

Clay/ecobrick wall combination used with Builders Choice AAC cement can be tied together using standard wall ties used in accordance with AS3700. The recommended spacing of ties is at 600mm centre’s for normal walls and at 300mm vertical centres around openings and no further away that 120mm from openings.

ecobrick/ecobrick walls assembled with Builders Choice Thin Bed Mortar should use spiked ties that are hammered into the each leaf of the wall. Spacing of the ties as per AS3700 indicated above.

Internal Walls

Intersecting walls should be butt jointed using flat strap connectors placed at every joint. The strap should be embedded at a minimum distance of 90mm.

Tying into other construction materials.

ecobrick can be tied into existing masonry, steel or concrete members by securely attaching a steel strap to the existing material and then ensuring this strap extends into the ecobrick mortar joint to a minimum depth of 100mm.

C3.5 Windows and doors

Installation of window and doors follow standard practice as outlined in the Australian Window Associations handbook . ‘An industry guide to the correct installation of windows and doors.’ [Copyright 2006 - Australian Window Association]

Copies available AWA or to HIA members on HIA website.

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C3.6 Lintels

Steel lintels are recommended for all openings.

C3.7 Fixing top plate and stick roof or trusses

See Carpenters Section for detailed information.

C3.8 Movement joints, joining walls & lintels

Movement joints are required in ecobrick walls to allow for expansion and contraction of the building materials through normal thermal and structural movements in buildings.

• Thenominallengthofacontinuouswallbeforeaexpansionjointisrequiredis6metres.

• Shouldthewallbecontinuousandhavecornersthenthereshouldbeanexpansionjointwithin3metres of the corner.

• Expansionjointsshouldincludeanexpandingconnectortotiethewallstogetherandthegapfilledwith polyurethane backing rods and mastic.

• Openingsincludedinwallsshouldhavesteellintelsfittedtosupportthebrickwork.Thelintelshouldextend at minimum of 300mm onto the supporting brickwork.

• Supportingalintelonthe90mmwidthofwallispermittedonlyifnoadditionalunsupportedloadsareapplied above the lintel and the load is spread. [Point loads are not recommended]

• Expansionjointsarerequiredinexternalrenderedwallsandaweatherresistantmasticistobeusedto ensure a waterproof joint.

• ecobrickwallsbondedtoecobrickwallsatjunctionswiththeappropriateconnectorsunlessitisamovement joint.

• Bondingecobricktodissimilarwallmaterialsaseparationofthematerialsisessentialthroughtheuseof appropriate connectors with the resultant gap filled with polyurethane backing rods and finished with a mastic.

C3 Cavity Wall Systems [Cont.]

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C3.9 Structural Loads - Cavity Walls

There are any number of variables with cavity walls ranging from a suitable foundation and footings to the number and size of openings in a cavity wall.

This document is not able to deal with all these variables.

C3.10 Recommendations

Our recommendation is that any cavity wall with or without a structural load should to be designed by an appropriately qualified structural engineer to suit the service conditions of the project.

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C3 Cavity Wall Systems [Cont.] TYPICAL CROSS SECTION OF A VENEER CONSTRUCTION

1. Damp proof course

7. Top plates

5. Windows & Doors

6. Lintels

Waterproof membrane and termite protection

Single Glazing

4. Wall ties

3. Internal finish3. Internal finish

Wall 3

An ecobrick external leaf with framed internal leaf.

[The typical brick veneer wall]

Wall 4

A framed external wall with ecobrick as the internal wall.

[A reverse veneer wall]

Bulk insulation

Single Glazing

Bulk insulation

2. External render

Weep hole

Weep hole

General cross section [not to scale]

Drawings are for illustrative purposes only

Tile roof Metal roof

Information

Instruction

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C3.11 Damp Proof Course - Cement Mortar

The intention of a damp course is to prevent the movement of moisture up into the wall. The damp course is an integral part of any external wall system irrespective of wall material.

The damp course can be either mechanical or more commonly a cement based compound.

Mortar Types

Two methods of assembling ecobrick are available.

Builders Choice Thin Bed Mortar - mixed with water to a paste will provide a 3mm mortar joint.

Builders Choice AAC cement mixed with sand and a small portion of lime will provide a 10mm mortar joint. The ratio is 6 x sand to 1 of AAC cement to 1⁄3 lime.

Builders Choice Thin Bed Mortar is the mortar system required to achieve a four (4) hour fire rating for an ecobrick wall.

Mortar for non ecobrick walls to other masonry manufacturers specifications.

C3.12 External finishes

Masonry walls will not generally not require any surface treatments.

ecobrick walls will require the application of a render or paint finish to protect the surface. See the Plasterer Section for more detailed recommendations.

Note: The external render on an ecobrick wall must finish at or above the damp proof course.

ecobrick can be finished with a plaster and set finish or a hardwall system. See Plasterers section for more detailed information.

C3.13 Internal finishes

ecobrick can be finished with a plaster and set finish or a hardwall system. See the Plasterer Section for more detailed information.

C3.14 Wall ties

Cavity walls

A veneer/ecobrick wall combination can be tied together using standard wall ties used in accordance with AS3700. The recommended spacing of ties is at 600mm centres for normal walls and at 300mm vertical centres around openings and no further away that120mm from openings.

Reverse veneer walls should use spiked ties that are nailed to the frame and hammered into the ecobricks. Spacing of the ties as per AS3700 shown above.

The wall ties will vary according to the type of mortar used to assemble the ecobrick wall.

C3.15 Internal Walls

Intersecting walls should be butt jointed using flat strap connectors placed at every joint. The strap should be embedded at a minimum distance of 90mm.

C3.16 Tying into other construction materials

ecobrick can be tied into existing masonry, steel or concrete members by securely attaching a steel strap to the existing material and then ensuring this strap extends into the ecobrick mortar joint to a minimum depth of 100mm.

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C3.17 Windows and doors

Installation of window and doors follow standard practice as outlined in the Australian Window Associations handbook . ‘An industry standard to the correct installation of windows and doors.’ [Copyright 2006 Australian Window Association]

C3.18 Lintels

Steel lintels are recommended for all openings .

C3.19 Fixing top plate and stick roof or trusses

See the Carpenter Section for detailed information.

C3.20 Construction Joints and Horizontal Slip Joints

Movement joints are required in ecobrick walls to allow for expansion and contraction of the building materials through normal thermal and structural movements in buildings.

• Thenominallengthofacontinuouswallbeforeaexpansionjointisnecessaryis6metres.

• Shouldthewallbecontinuousandhavecornersthenthereshouldbeanexpansionjointwithin3metres of the corner.

• Expansionjointsshouldincludeandexpandingconnectortotiethewallstogetherandthegapfilled with polyurethane backing rods and mastic.

• Expansionjointsarerequiredinexternalrenderedwallsandaweatherresistantmasticistobeused to ensure a waterproof joint.

• Openingsincludedinecobrickwallsshouldhavesteellintelsfittedtosupportthebrickwork.Thelintel should extend at minimum of 300mm onto the supporting brickwork.

• Supportingalintelonthe90mmwidthofwallsispermittedonlyifnoadditionalunsupportedloadsare applied above the lintel and load is spread. [Point loads are not recommended]

• ecobrickwallsbondedtoecobrickwallsatjunctionswiththeappropriateconnectorsunlessitisamovement joint.

• Bondingecobricktodissimilarwallmaterialsaseparationofthematerialsisessentialthroughtheuseof appropriate connectors with the resultant gap filled with polyurethane backing rods and finished with a mastic.

C4 Single Wall Systems

C4.1 General Notes

Single width ecobrick walls are common in residential buildings to reduce noise transmission and improve thermal efficiency.

The commercial application of ecobrick single walls are for partition walls, screen walls and to act as fire screens due to the four (4) hour fire rating.

Long lengths of single leaf walls will require expansions joint and in heights over 2.00 metres will require lateral support.

C4.2 Building a single leaf wall

The following charts have been prepared from AS3700 ‘Masonry Structures Code” and indicate the height to length ratios under the specified conditions.

C3 Cavity Wall Systems [Cont.]

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The following ratios are based on the assumption that

• ThewallistointernalonlyandthedataappliestowallsinawindclassificationareofN2(40m/s).

• Thewallisinasinglestorybuildingwiththetopofthewalllaterallyrestrainedbytheroofandwithout any openings.

• Thedataisbasedonnothavinganyintermediatesupportforthefullheightofthewall.

• ExternalwallsinhighwindloadareasmustconformtotheSAALoadingCodeforthegeographicarea.

• Thisinformationcannotbeusedforfirewallsaseachfirewallisspecifiedforaveryspecificapplication.

Table 1 is suitable to be used where there are no immediate supports for the wall for its entire height.

Table 2 is to be used in situations where a ceiling frame is securely fastened to the wall at between 2.4m and 2.8m above the base of the wall.

Table 1

Maximum HeightMaximum

length between intersecting walls

4.5m 8.5m

5.0m 8.5m

5.5m 8.5m

6.0m 8.5m

6.5m 8.0m

7.0m 7.0m

Table 2

Maximum HeightMaximum

length between intersecting walls

4.5m 7.5m

5.0m 6.5m

5.5m 6.0m

6.0m 5.5m

6.5m 5.5m

7.0m 5.0m

C4.3 Single Wall Support Systems

Single leaf ecobrick walls can used for internal partitions in commercial or industrial buildings.

C4.4 Starting the wall

These walls should always be started used a cement based mortar. The use of a cement based mortar istheensurethefirstcourseislaidlevel.Ecobrickshaveaconsistentshapeandsizewhichmeansallother course will remain level. In the case of excessive undulations a “C” channel fixed to the floor may offer an alternative level base for the first course.

C4.5 Supporting long lengths of wall

Walls can be supported by the placement of piers or columns at the nominated intervals.

Another method is to use lightweight “C” section and “H” section channels supported at both ends of the “C” or “H” section channel.

NOTE Using lightweight channels is conditional on the channels being secured to a wall or if used centre wall, being secured top and bottom.

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C5 Low Wall Systems - Garden ecobricks can be used as a garden wall if the following general conditions are followed. A garden wall

would be used as a surround for a garden bed and should not exceed 800mm in height or 200mm in length (unsupported).

• Thefoundation(earth)iscompactedtoformastableandsolidbaseforthewall.

• Asolidfootingshouldbeincludedforagardenwallsgreaterthan400mminheight.ecobricklaidon the flat can be used as that footing and should extend past the proposed wall thickness by a minimum of 200mm on either side of the wall.

• An800mmhighwallshouldnotbefreestandingovertwo(2)metresinlength. Eitherintersectingwallsorpiersshouldbeusedtoensurestability.

• Toenhancethelifeofthewallandaestheticsitissuggestedthatarenderorpaintfinishbeappliedto the completed wall.

Note: The above description is a general description of the requirements for a low garden wall and should this description not be appropriate your circumstances we suggest you seek professional help.

C6 Low Retaining Walls - general description ecobrick is a light weight material but it can be used for retaining loose materials, like builders sand, to a

height no greater than 800mm. The lightness of ecobrick itself can be partially compensated by the use of additional bricks to make the wall thicker.

Ecobrickretainingwallsarenotsuitableforheavysoils(clay),gravel,rocksormaterialsthathaveahighdegree of slump.

Note: The minimum brick dimensions for a low retaining wall are the 600mm long x 200mm high and 200mm thick.

See Diagram 1.

The following information is a general guide only and should be used in conjunction with engineering advice for your particular location.

• Thefoundation(earth)iscompactedtoformastableandsolidbaseforthewall.

• Asolidfootingshouldbeincludedforallwalls.ecobricklaidontheflatcanbeusedasthatfootingand should extend at least 500mm past the base on the wall on either side of the wall to help resist the possibility of tipping over.

• Asageneralrulegoingonebrickupmeansgoingonebrickoutstartingatthebaseofthewall.e.g. each brick is 200mm square so by going up four bricks high means the base layer is four bricks wide minimum. See Diagram 2.

• Retainingwallsshouldbeconstructedsothatthebricksareinterlockingtoimprovethewallstrength. A four brick wall does not mean the four bricks are laid side by side but some are laid at right angles to each other to help lock the wall together. See Diagram 3

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Diagram 1 Minimum brick size 600mm x 200mm x 200mm

Diagram 2 Standard detail for generic low ecobrick retaining wall.

Diagram 3 Interlocking wall.

Maximum and only allowable height will be 800 mm (4 bricks) bricks to be adhered with Builders Choice AAC cement. The general rule is that going up one brick means going out one brick.

So a wall made from four bricks 200mm high should be at minimum dimension of 800mm at the base layer.

Plan view - base layer (first layer on top of footings). Plan view - second layer on top of base layer.

Note: It is recommended that prior to building a retaining wall advice is sought from your local council and a structural engineer about soil conditions and the most appropriate construction method for your particular locality and material to be retained.

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C7 Fire Rating

C7.1 General

The ecobrick material has been tested by the CSIRO and been proven to withstand naked flame for four hours.

C7.2 Construction

An ecobrick fire rated wall is constructed using normal wall construction techniques.

The fire rating quoted in the CSIRO certificate 603 is based on using a thin bed mortar system to adhere the bricks together.

The primary consideration is to ensures all mortar joints are filled to ensure no air movement is possible to prevent the movement of smoke or fire though these spaces.

C7.3 Protecting other Materials

Steel columns and steel work should be literally encased with the ecobricks to protect the surface for the fire. The ecobrick will be connected to the steel using flexible connecting straps to ensure movement stress is not transferred. Any movement joints required to allow for expansion and contraction should be sealed with a fire proof mastic.

Clay or concrete walls are treated in the same way as steel and the use of flexible connecting straps is recommended. Any movement joints required to allow for expansion and contraction should be sealed with a fire proof mastic.

C7.4 Wall penetrations

Wall penetrations for supply of services will require appropriate fire rated products and must be used and the manufacturers instructions.

Penetrations for the windows and doors must use fire rated products and be installed to the manufacturers instructions.

C7.5 Expansion joints & dissimilar materials

To ensure dissimilar materials can expand and contract to accommodate the movement we recommend the use of a polyurethane mastic system. The Sika Firerate PU product has an equivalen 4 hour fire rating to the ecobricks. [Other mastics may be suitable so we suggest consulting the manufacturers specifications to ensure the mastic is approprate for AAC bricks prior to use.]

MoredetailedinformationisavailableintheecobrickTechnicalDataFile-FireRatedwallsE1.

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C8 Acoustic Walls

C8.1 General requirements

The construction of an ecobrick to be used as an acoustic wall requires normal construction methods.

To achieve highest acoustic values all of the joints must be filled with mortar including any connecting walls.

The ecobrick acoustic testing was conducted using a cement based mortar.

C8.1 Wall penetrations

Wall penetrations for supply of essential services will require an appropriately rated acoustic fitting be used in accordance with the manufacturers instructions.

Penetrations for the windows and doors must use appropriately rated acoustic products and be installed to the manufacturers instructions. (Technical information and advice is available for the Australian Window Association)

MoredetailedinformationisavailableintheecobrickTechnicalDataFile-AcousticWallsE2.

Warranty

Advanced Concrete Technologies warrants its products to be free from defects caused by faulty manufacture or materials. If any of its products are so defective the Company will at its option, repair or replace them, supply equivalent replacement products or reimburse the purchase price.

The warranty shall not apply to any loss or consequential loss suffered through or resulting from defects caused by faulty manufacture or materials.

Fittings or accessories supplied by third parties is beyond the control of Advanced Concrete Technologies and such is not warranted by Advanced Concrete Technologies.

© Copyright 2008 Advanced Concrete Technologies

ecobrick™ is a trademark of Advanced Concrete Technologies, its subsidiaries and affiliates.# Some images are used for illustration purposes only.

Advanced Concrete Technologies ABN: 62 005 736 005

Cnr Cook and Bannister Roads Canning Vale I WA I 6155

PO Box 1408 I Canning Vale I WA I 6155

t 08 9334 4750 f 08 9334 4751 e info@ecobrick.com.au w ecobrick.com.au SB

0800

939E

COBR

ICKL

AYER

General disclaimerThe information presented in this manual is general by nature and no liability is accepted by Advanced Concrete Technologies in its use. Advanced Concrete Technologies recommends that the advice of a registered builder or structural engineer be sought for any major building works prior to commencement of the works.