Fg2

November 2000

Guide to Good Practice

INNOVATORS IN CLAY™
 Choice and quality
you can rely on -
service you can
build on

CHOICE and SERVICE - these are the two words which inspire us The Ibstock Brick Guide to Good Practice contains essential
at Ibstock Brick. information on all aspects of building with clay bricks. It clearly
describes how desired levels of brickwork integrity can be achieved
A choice built on our commitment to provide an evolving range
by explaining the technical properties of bricks. It also suggests how
of clay bricks to meet your every aesthetic, technical and
specific design features and detailing can be incorporated to protect
planning need.
brickwork from adverse weathering.
The Ibstock brick range contains a wide choice of facing bricks in a
For further technical advice and answers to individual design
breathtaking array of colours and textures. We also produce
requirements, one phone call will put you in touch with Ibstock's
imperial sized bricks to blend with older brickwork and Class A and
dedicated team of design advisors and technical specialists.
B engineering bricks to satisfy the most demanding structural
requirements. All bricks are manufactured under ISO 9001 Quality We have the widest choice of products, expert guidance and
Systems and to BS 3921:1985. committed service. At Ibstock, we strive to make your job easier
every step of the way, from answering your initial enquiry through
Our special shape brick service provides solutions to every design
to the completion of your project.
challenge. Standard shapes to BS 4729:1990 or individual
purpose-made shapes can be matched or contrasted with virtually
any brick in the Ibstock range.

At Ibstock we back choice with service. We are dedicated to helping

you make the right choice by providing the soundest design and
technical advice. The ultimate aim is to ensure that you design and
build quality brickwork which will stand the test of time.

2
Contents
Brick Selection ..........................4

Brick Types And Textures

Dimensional Variation
Definition of Sizes
Special Shape Bricks
Brickwork Dimensions
Compressive Strength
Water Absorption Insulation ................................26
Durability
Sound Insulation
Brickwork ................................11 Thermal Insulation

Mortars Good Site Practice.....................29

Mortar Performance
Brick Bonding Storage

Joint Profiles Mortar

Staining and Remedial Measures Mortar Plasticisers and Air Entrainers

Joints
Exposure ................................16 Appearance
Cavity Ties
Exposure of Brickwork
DPCs and Cavity Trays
Exposure to Wind-Driven Rain
Protection
Exposure within Brick Construction
Cavity Insulation
Water Penetration
Bricklaying in Winter
Design Detailing and Design Features
Damp Proof Courses Other Sources of Reference ........32

Movement ................................24 Design and Technical Services.....33

Products and Services................34

Movement of Brickwork
Ancillary Fixings Contact Numbers ......................36

3
 Brick Selection

Brick Types and Textures TEXTURES

The colour and texture of bricks is influenced both by firing and Extruded Perforated Wirecut Bricks

shaping and by the addition of minerals and pigments, but the

characteristics of the clay are crucial.

Ibstock's widely distributed manufacturing plants produce an

exceptional range of colours and textures from a variety of local
clays. The company has extensive natural resources including vast
reserves of Etruria Marl and Weald clays, as well as many other Smooth

excellent shales and fireclays.

Heavy investment in some of the most up-to-date computerised

plant and equipment in Europe means that manufacturing and firing Sandfaced
processes can be closely controlled, and automated brick handling
ensures rapid distribution to all parts of the country.

Ibstock bricks are manufactured to BS 3921:1985 - 'Specification

for Clay Bricks’. For a technical specification please refer to Dragfaced

Ibstock Brick ‘The Range’ or visit our website at www.ibstock.co.uk.

BRICK TYPES Rolled / Creased

Perforated
(Perforation patterns vary). Perforated bricks shall have holes not
exceeding 25% of the gross volume of the brick (BS 3921:1985)

Rusticated - should be laid with

texture pointing downwards

Frogged, Machine Moulded, Repressed and

Frogged Traditional Stock Bricks - are laid frog up

Frogged bricks shall have depressions in one or more bed surfaces

but their total volume shall not exceed 20% of the gross volume of
the brick (BS 3921:1985).

Sand Creased

Smooth Sanded

Some Stock Bricks may

be rotated to create a different
aesthetic appearance if preferred.

Engineering Handmade

These are not chosen for appearance, have no requirement for

colour and/or texture. They have a guaranteed minimum compressive Repressed

strength (Class A ≥ 70N/mm2, Class B ≥ 50N/mm2), and a

maximum water absorption (Class A ≤ 4.5%, Class B ≤ 7.0%).

Waterstruck - should be
laid with the lip at the bottom
4
 Brick Selection

DIMENSIONAL VARIATION SPECIAL SHAPE BRICKS

BS 3921 specifies brick size and tolerance (based on the
measurement of 24 bricks).
It is important to understand that bricks complying with the
standard have varying shape characteristics depending on the
method of manufacture. For example, the moulded process by
which some stock bricks are made results in a less uniformly
shaped product than that made by the wirecut or pressed process.
The designer must take account of this, particularly for situations
such as piers, columns and brickwork between windows where
close dimensional control may be required.
A comprehensive range of special shape bricks, manufactured to
BS 4729:1990, is readily available and these can be supplied to
complement or contrast with any colour or texture in the Ibstock
range. Non standard specials (in virtually any shape, size or finish)
are also available to individual specification.
They can be used to resolve bonding problems at changes of
angle, to enhance the appearance of window and door openings
or to create decorative features such as corbels. The Ibstock
Special Shaped Bricks literature illustrates our comprehensive
range of Specials.

Bricks should be selected from several packs on site, both to

minimise the possibility of variable joint dimensions and to achieve How to Specify Special Shape Bricks
appropriate colour mixing throughout the facing brickwork, as
Please provide us with the following:
described in Clauses 30.2 and 32.4 of BS 5628:Part 3:1985,
1. Product type.
also BS 8000:Part 3, clause 3.5.
2. Special brick type - code and full description.

3. Application - suitability of specials for exposure requirements.

DEFINITION OF SIZES
Co-ordinating Size - the size of a co-ordinating space allocated
to a brick, including allowances for joints and tolerances.
4. Quantity required.
5. Delivery - commencement and phasing - manufacturing
programme linked to construction programme.

Work Size - the size of a brick specified for its manufacture, to 6. Packaging requirements.

which its actual size should conform within specified 7. Orientation of special (e.g. for window opening, is

permissible deviations. application for cill, reveal or head?)

8. Consequent requirements for texture.

Sizes
9. Handing requirements - with respect to asymmetric shapes
Length mm Width mm Height mm
and directional texture (Note:- some handing convention
Co-ordinating size 225 112.5 75
to BS 4729 is opposite to what might be expected).
Work size 215 102.5 65
10. Special angle requirements.

11. Special requirements at returns.

Co-ordinating Sizes
12. Specify if solid bricks are required, and also if the bed

225 needs to be faced.

112.5
13. Non-standard faces or textures.
75 14. Position of perforations or other holes.
10 cross joint
15. Special requirements for tolerances.

16. Associated bricks required (e.g. plinth stretchers may

10 bed
joint also require plinth headers).

17. Position of code stamp. Additional points for

non-standard shapes

18. Description of application.

19. Availability of drawings of both proposed shapes and

their application in work.

102.5 20. Is design input and advice required?
215
65 21. Are cut and bonded shapes acceptable? If so this could

lead to quicker availability.

Work Sizes

5
Brick Selection

BRICKWORK DIMENSIONS All brickwork dimensions are then determined by one of

three conditions.
Brickwork dimensions should be used whenever possible at the
1. Brick + 2 Joints CO+
design stage, to minimise the need for cut bricks. Tables 1 and 2
eg: door and window openings
give dimensions for vertical and horizontal brickwork courses, based
2. Brick + 1 Joint CO
on the British Standard co-ordinating size of 225mm x 112.5mm x
Brick panel with opposite return ends
75mm, which includes 10mm joints, (this size being identified by
3. Brick only CO -
the term CO). Table 1 & 3 should be used for 73mm bricks.
Brick Piers or Panels between openings
Note:
In order to avoid cutting bricks, panels should therefore be either CO+, CO
or CO- as indicated in Figure 1.

Council Offices, Brighton, East Sussex

Roughdales Albany Cream

6
Brick Selection

TABLE 1 - HORIZONTAL BRICKWORK DIMENSIONS USING 215mm BRICKS AND 10mm MOTAR JOINTS
Number CO + CO CO - Number CO+ CO CO-
of Bricks Joint (Co-ordinating Size) Joint of Bricks Joint (Co-ordinating Size) Joint
/
1 2 122.5 112.5 102.5 25 5635 5625 5615
1 235 225 215 25 1/2 5747.5 5737.5 5727.5
1 1/2 347.5 337.5 327.5 26 5860 5850 5840
2 460 450 440 26 / 1 2 5972.5 5962.5 5952.5
2 1/2 572.5 562.5 552.5 27 6085 6075 6065
3 685 675 665 27 1/2 6197.5 6187.5 6177.5
3 1/2 797.5 787.5 777.5 28 6310 6300 6290
4 910 900 890 28 1/2 6422.5 6412.5 6402.5
4 1/2 1022.5 1012.5 1002.5 29 6535 6525 6515
5 1135 1125 1115 29 / 1 2 6647.5 6637.5 6627.5
5 1/2 1247.5 1237.5 1227.5 30 6760 6750 6740
6 1360 1350 1340 30 1/2 6872.5 6862.5 6852.5
6 1/2 1472.5 1462.5 1452.5 31 6985 6975 6965
7 1585 1575 1565 31 1/2 7097.5 7087.5 7077.5
7 1/2 1697.5 1687.5 1677.5 32 7210 7200 7190
8 1810 1800 1790 32 1/2 7322.5 7312.5 7302.5
8 1/2 1922.5 1912.5 1902.5 33 7435 7425 7415
9 2035 2025 2015 33 1/2 7547.5 7537.5 7527.5
9 1/2 2147.5 2137.5 2127.5 34 7660 7650 7640
10 2260 2250 2240 34 / 1 2 7772.5 7762.5 7752.5
10 1/2 2372.5 2362.5 2352.5 35 7885 7875 7865
11 2485 2475 2465 35 1/2 7997.5 7987.5 7977.5
11 1/2 2597.5 2587.5 2577.5 36 8110 8100 8090
consider movement joints for copings and cappings 36 1/2 8222.5 8212.5 8202.5
12 2710 2700 2690 37 8335 8325 8315
12 1/2 2822.5 2812.5 2802.5 37 / 1 2 8447.5 8437.5 8427.5
13 2935 2925 2915 38 8560 8550 8540
13 1/2 3047.5 3037.5 3027.5 38 1/2 8672.5 8662.5 8652.5
14 3160 3150 3140 39 8785 8775 8765
14 1/2 3272.5 3262.5 3252.5 39 1/2 8897.5 8887.5 8877.5
15 3385 3375 3365 40 9010 9000 8990
15 / 1 2 3497.5 3487.5 3477.5 40 1/2 9122.5 9112.5 9102.5
16 3610 3600 3590 41 9235 9225 9215
16 1/2 3722.5 3712.5 3702.5 41 1/2 9347.5 9337.5 9327.5
17 3835 3825 3815 42 9460 9450 9440
17 1/2 3947.5 3937.5 3927.5 42 / 1 2 9572.5 9562.5 9552.5
18 4060 4050 4040 43 9685 9675 9665
18 1/2 4172.5 4162.5 4152.5 43 1/2 9797.5 9787.5 9777.5
19 4285 4275 4265 44 9910 9900 9890
19 1/2 4397.5 4387.5 4377.5 44 1/2 10023 10012.5 10003
20 4510 4500 4490 consider movement joints at 10 - 12m max centres in half brick skins to cavity walls

20 1/2 4622.5 4612.5 4602.5 45 10135 10125 10115

21 4735 4725 4715 45 / 1 2 10248 10237.5 10228
21 1/2 4847.5 4837.5 4827.5 46 10360 10350 10340
22 4960 4950 4940 46 1/2 10473 10462.5 10453
22 1/2 5072.5 5062.5 5052.5 47 10585 10575 10565
consider movement joints at 5 - 6m max centres in parapet and freestanding 47 1/2 10698 10687.5 10678
walls, also where differing materials are used or different colour bricks 48 10810 10800 10790
23 5185 5175 5165 48 1/2 10923 10912.5 10903
23 1/2 5297.5 5287.5 5277.5 49 11035 11025 11015
24 5410 5400 5390 49 1/2 11148 11137.5 11128
24 1/2 5522.5 5512.5 5502.5 50 11260 11250 11240

7
 Brick Selection

TABLE 2 - VERTICAL BRICKWORK COURSES DIMENSIONS TABLE TABLE 3 - VERTICAL BRICKWORK COURSES DIMENSIONS TABLE
USING 65mm BRICKS AND 10mm MORTAR JOINTS USING 73mm BRICKS AND 10mm MORTAR JOINTS

Course Height Course Height Course Height Course Height Course Height Course Height
1 75 18 1350 35 2625 1 83 18 1494 35 2905
2 150 19 1425 36 2700 2 166 19 1577 36 2988
3 225 20 1500 37 2775 3 249 20 1660 37 3071
4 300 21 1575 38 2850 4 332 21 1743 38 3454
5 375 22 1650 39 2925 5 415 22 1826 39 3237
6 450 23 1725 40 3000 6 498 23 1909 40 3320
7 525 24 1800 41 3075 7 581 24 1992 41 3403
8 600 25 1875 42 3150 8 664 25 2075 42 3486
9 675 26 1950 43 3225 9 747 26 2158 43 3569
10 750 27 2025 44 3300 10 830 27 2241 44 3652
11 825 28 2100 45 3375 11 913 28 2324 45 3735
12 900 29 2175 46 3450 12 996 29 2407 46 3818
13 975 30 2250 47 3525 13 1079 30 2490 47 3901
14 1050 31 2325 48 3600 14 1162 31 2573 48 3984
15 1125 32 2400 49 3675 15 1245 32 2656 49 4067
16 200 33 2475 50 3750 16 1328 33 2739 50 4150
17 1275 34 2550 51 3825 17 1411 34 2822 51 4233

CO+
(elevation)

4 x CO +

CO + condition door or window opening

CO
(plan)

CO condition 4 x CO

CO-
(plan)

FIGURE 1
Design to Minimise Cutting CO - condition 4 x CO -

8
Brick Selection

COMPRESSIVE STRENGTH
Brick strength is related to the raw materials and to the forming
and firing processes used in manufacture. Bricks are available with
compressive strengths ranging from 5N/mm2 to greater than
70N/mm2. In designs where brick strength is an important factor
e.g. Ioadbearing masonry, it is recommended that designers check
the latest performance data. Buchanan Galleries, Glasgow
Throckley Oatmeal Textured & Nostell Harewood Russet Buff

WATER ABSORPTION
Soluble Salts
The masonry structural code, BS 5628:Part 1:1992, relates
categories of water absorption (expressed as a percentage increase Two categories of soluble salt content are defined:
in weight), to characteristic flexural strength. Categories are:- less
Low (L) The percentage by mass of soluble ions, measured as
than 7%, 7% to 12% and greater than 12%. Many dense wirecut
described in appendix B of BS 3921:1985 shall not exceed
bricks fall into the first category while moulded stock bricks are
the following:
generally in the latter.
Magnesium 0.030%
Potassium 0.030%
DURABILITY
Sodium 0.030%
BS 3921:1985 classifies durability by specific reference to frost
Sulfate 0.500%
resistance and to soluble salts content.
Normal (N)
Note: There is no direct relationship between water absorption and
Magnesium
frost resistance - many bricks with a high water absorption also
have excellent frost resistance.
Potassium
Sodium
} the sum of 0.25%

Sulfate 1.6%
Frost Resistance

Three categories of frost resistance are defined:

1. Frost Resistant (F) Bricks - durable in all building situations Durability Designations
including those where they are in a saturated condition and
Categories of frost resistance and soluble salt content are
subjected to repeated freezing and thawing. Examples where
combined in BS 3921:1985 to provide durability designations.
brickwork is likely to become saturated include below ground
(Shown in Table 4).
level dpc, parapets, copings, freestanding and retaining walls.

2. Moderately Frost Resistant (M) Bricks - durable except when

in a saturated condition and subjected to repeated freezing and
thawing. Generally this means that they can be used in normal
TABLE 4 - Durability Designations
walling situations between ground dpc level up to eaves (but Designation Frost Resistance Soluble Salts
Content
not in projecting detailing).
FL Frost Resistant (F) Low (L)
3. Not Frost Resistant (O) Bricks - not frost resistant. May only FN Frost Resistant (F) Normal (N)

be used internally. Protection from the weather must be ML Moderately Frost

Resistant (M) Low (L)
provided when stored on site and during construction.
MN Moderately Frost
Resistant (M) Normal (N)
OL Not Frost Resistant (O) Low (L)
ON Not Frost Resistant (O) Normal (N)

Note:
Guidance on the selection of bricks and mortars for use in a variety of
environments, particularly where brickwork might be subject to saturation and
liable to freezing and thawing, is given in BS 5628:Part 3 - Table 13. Some of
these situations are reproduced in Tables 5, 6, 7 and 8 of this publication.

9
Brick Selection

TABLE 5 - BRICKS FOR WORK BELOW OR WITHIN 150mm ABOVE GROUND LEVEL

Suitable qualities Suitable mortar

Brickwork near external ground level: of bricks designations

1
Low risk of saturation FL, FN (i) (ii) (iii)2
- well drained site

High risk of saturation FL, FN1 (i) (ii)

- poorly drained site without freezing

High risk of saturation, FL, FN1 (i) (ii)

- poorly drained site with freezing

Brickwork wholly below FL, FN1, ML, MN1 (i) (ii) (iii)
ground level3

Notes:
1. The use of sulfate resisting Portland cement is recommended.
2. Strict supervision of batching is particularly important to ensure that the requisite amount of cement is incorporated in designation (iii) mortars.
3. Where brickwork is (at least 150mm) below finished external ground level, most ML and MN clay bricks can be suitable, although the manufacturers’
recommendations should be sought.

TABLE 6 - BRICKS FOR EXTERNAL WALLS OF BUILDINGS

(excluding parapet walls, chimney stacks, cills, copings and cappings).

Suitable qualities Suitable mortar

of bricks designations

Low risk of saturation. Walling well protected by

roof overhangs, cills and cladding designed to shed FL, FN1, ML, MN1 (i) (ii) (iii)
water clear of brickwork.

High risk of saturation. Brickwork inadequately FL (i) (ii)

protected and saturated by water run-off FN1 (i) (ii)

Note:
1. The use of sulfate-resisting Portland cement is recommended with designation (ii) or (iii) mortar.

TABLE 7 - BRICKS FOR BOUNDARY WALLS OR PARAPETS

(excluding the coping or capping).

Suitable qualities Suitable mortar

of bricks designations

Effective coping used FL, FN1, ML, MN1 (i) (ii) (iii)

Flush capping used FL (j) (ii)

FN1 (i) (ii)

Note:
1. The use of sulfate-resisting Portland cement is recommended with designation (ii) mortar.

TABLE 8 - CILLS, CHIMNEYS, COPINGS AND CAPPINGS

Suitable qualities Suitable mortar

of bricks designations1

Standard format bricks and Standard3 or FL, FN2 (i)2

purpose-made special shapes

Notes:
1. Designation (i) mortar should be used for bedding associated DPCs in clay brickwork.
2. When used in chimney cappings, sulfate-resisting Portland cement is recommended.
3. To BS 4729.

10
Brickwork
MORTARS
Selection of the correct mortar mix depends on:
1. Brick characteristics.
2. Degree of exposure.
3. Application within the construction.
4. Season when bricklaying takes place.
Lime
Hydrated lime is manufactured to BS 890:1995 as a dry powder.
This greatly improves the subsequent workability and long term
performance of the mortar. It is recommended that ready mixed
lime:sand for mortar is used conforming to BS 4721:1986 when
tested by the methods given in BS 4551:1998. (Partially replaced
by BSEN 1015).
Sand
Well graded soft sand is recommended for brickwork mortar,
meeting the requirements of BS 1200:1996.
Cement
Only use cement conforming to BS 12. Specification for
Portland cement.
On Site Mixing
A recognised method of gauging is recommended to ensure that
the correct designation of mortar is achieved.
Ready to Use Mortar
It is recommended that the mortar suppliers' recommendations are
strictly followed when using ready to use (retarded) mortar.
Quantity Yield
One tonne of ready mixed lime:sand, when gauged with the
specified quantity of cement on-site, will generally be sufficient to
lay approximately 1000 bricks.
Coloured Mortars
A wide range of light-fast colours and shades is available and these
are supplied by leading manufacturers. Ibstock Brick’s Technical
Services can give advice on toning mortars to suit most products in
the Ibstock Brick range.
Adhesion
To achieve good adhesion a mortar must have good workability.
Mortar of poor workability will not perform adequately, and will
allow air to be trapped between the mortar and the brick, thus
preventing good bond formation. Bricks with rough bed faces
and medium suction rates will have high bond characteristics
because the mortar will key into the texture of the brick.
Conversely, bricks with low suction rates and a smooth texture
will have lower bond characteristics.
Highly porous bricks may rapidly absorb moisture during laying
(particularly in warm weather), causing the mortar to become
insufficiently plastic to allow repositioning of the bricks during
levelling. It is possible in such circumstances that no adhesion will
be obtained between bricks and mortar. Laying mortar beds in
shorter lengths to reduce drying will help. Wetting may assist
adhesion, but over wetting may lead to floating on the mortar
bed and to excessive efflorescence and staining.
Workability
Mortars containing only sand and cement tend to be coarse and
hard to work, often requiring more water than may be desirable for
strength considerations. The addition of lime increases workability,
reduces the water requirement and slightly increases strength.
Admixtures
Bonding agents, waterproofing admixtures and air entrained
mixtures can all be added to mortars. However, their use must be
strictly controlled and in accordance with the manufacturers’
instructions, particularly to avoid over mixing.
Permeability
Strong mortars will provide better resistance to water penetration,
but offer less resistance to differential movement. Rain penetration
can be greatly reduced by good design and proper selection of the
sand grading. Rich mortars (high cement content) will crack more
easily than weak mortars. Weak mortars are more tolerant to
movement but the voids between the sand grains will, however,
contain less cement, allowing water to penetrate more easily.
Uneven mixing of the mortar can result in a cement deficiency in
some areas, and rain penetration can occur under some conditions
of moderate exposure.
11
Brickwork

MORTAR PERFORMANCE
The air space within sand represents approximately one third of the Private House, Scunthorpe, Lincolnshire
Ashdown Village Mixture
volume. The strength and physical properties of mortar are altered
by the types of binder used to fill that air space.

For example, 3 parts sand to 1 part cement will result in the sand
voids (air spaces) being completely filled, producing a very strong
but brittle mortar.

Alternatively 3 parts sand to 1/2 part cement to 1/2 part lime

produces a well filled mortar, but with the extra adhesion and
flexibility given by the lime, balanced by the strength of the cement.
This is a 1:1:6 mix.

Altering these proportions to suit the strength requirement,

exposure level, workability or weather conditions can be of
considerable benefit to the durability of the final brickwork. (As
shown in Table 9).
Variations in the water suction rate of bricks can adversely affect
bricklaying. The wetness of the mortar mix can be increased or
reduced to maintain a consistent level of moisture whilst laying.
TABLE 9 - MORTAR MIXES FOR BRICKWORK
Only with high suction rate bricks in warm weather conditions
should docking (or wetting) of the bricks be considered. If it is
undertaken the bricks should not be soaked and only clean fresh
water should be used to avoid soluble salt contamination. A method
for testing the suction rate is laid down in BS 3921 Appendix H.
In the case of loadbearing brickwork, a test in accordance with
BS 5628:Part 1, can be specified to discover whether docking is
necessary or advisable.

Mortar Type of mortar2

designation

Cement:lime:sand3 Air-entrained mixes5

Masonry cement: Cement:sand with

sand3 plasticiser3
Proportions by volume4 Proportions by volume Proportions by volume

Increasing Increasing ability (i) 1 : 0 to 1/4 : 3

strength1 to accommodate (ii) 1 : 1/2 : 4 to 41/2 1 : 21/2 to 31/2 1 : 3 to 4
and movements due (iii) 1 : 1 : 5 to 6 1 : 4 to 5 1 : 5 to 6
improving to temperature (iv) 1 : 2 : 8 to 9 1 : 51/2 to 61/2 1 : 7 to 8
durability and moisture (v) 1 : 3 : 10 to 12 1 : 61/2 to 7 1:8
change

Increasing resistance to frost attack during construction

Improvement in adhesion and resistance to rain penetration

Notes:

1. Where mortar of a given compressive strength is required by the designer, 3. The range of sand contents is to allow for the effects of the differences in
the mix proportions should be determined from tests following the grading upon the properties of the mortar In general the lower proportion of
recommendations of appendix A of BS 5628:Part 1:1992. sand applies to grade C of BS 1200 whilst the higher proportion applies to

2. The different types of mortar that comprise any one designation are grade S of BS 1200.

approximately equivalent in compressive strength and do not generally differ
greatly in their other properties. Some general differences between types of
mortar are indicated by the arrows at the bottom of the table, but these
differences can be reduced (see 23.2. BS 5628:Part 3:1985)
4. The proportions are based on dry hydrated lime. The proportion of lime by
volume may be increased by up to 50% (V/V) in order to obtain workability.
5. At the discretion of the designer, air entraining admixtures may be added
to lime:sand mixes to improve their early frost resistance.
(Ready mixed lime: sand mixes may contain such admixtures).

12
Brickwork

BRICK BONDING Flemish Garden Wall Bond

The creative use of brick bonding, with or without contrasting or Like English Garden Wall bond, this was originally intended
complementary brick colours, can have a dramatic effect on the for use in solid walls which were required to be
appearance of a building. fair faced both sides.
The number of
In recent times stretcher bond has predominated, mainly because of
stretchers is increased
the speed with which it can be laid in cavity wall construction. There
and three stretchers
are, however, other traditional methods which can be used to enrich
are laid to one header
large areas of brickwork, although extra cutting is needed.
in each course.

English Bond

Alternative courses of headers and stretchers; one

Stretcher Bond
header placed centrally above each stretcher. This
is a very strong bond Originally used for single

when the wall is brick walls, now called

1/2 brick walls it became
1 brick thick (or
thicker). the obvious choice for
cavity walls as less
cutting was required.

Raking Bonds

Flemish Bond Herringbone and diagonal bonds can be effective

within an exposed framed construction, or
Alternate bricks are placed as header and stretcher in
contained within
every course. Each header is placed centrally
restraining
between the stretcher
brick courses.
immediately above
and below. This is not
as strong as the
English bond at
1 brick thick.
Quantities

One square metre of brickwork, a half brick thick, requires the

following number of bricks:
English Garden Wall Bond English bond ....................86 Flemish Garden Wall bond....67

An alternative version of English bond with header Flemish bond ..................77 Stretcher bond ....................60

courses being inserted at English Garden Wall bond..72

every fourth or sixth

Figures are assuming one header per brick. English and Flemish
course. This is a
bonds are attractive for dwarf and retaining walls where only one
correspondingly
good face is required. Stretcher bond is the most economical of all.
weaker bond.
To create a wall which is fair-faced on both sides, two stretcher walls
are built side by side with a continuous mortar joint between them,
the two walls being bonded together with ties (these are also
called collar jointed walls). Snap headers are a simple way of
adding variety.

13
Brickwork
JOINT PROFILES
The efficient shedding of water by mortar joints is essential for long
term performance. Masonry that remains saturated is more
susceptible to frost and sulfate attack. The choice of joint profile
should therefore be based first on performance criteria, with
aesthetic considerations being secondary. Tooling of the joints to
compact the mortar improves durability and rain-shedding qualities.
Curved Recessed (Bucket Handle)
This joint gives an improved appearance over a flush joint, with little
reduction in strength. Owing to the compressing of the joint and
the superior bond, it has good weather resistance, and is suitable
for all grades of exposure.
Flush
This gives maximum bearing area and is often favoured when
coarse textured bricks are used. With some brick types the finish
may appear a little irregular. Suitable for moderate and
sheltered exposures.
14
Quality of Workmanship
The quality of workmanship on site can have an overriding effect
on the weather resistance of the brickwork.
1. Bricks should be laid on a full bed of mortar.
2. All cross joints and collar joints should be fully filled.
3. Immediately after the brick is laid, excess mortar should be
struck off the external face of the work and off the internal
faces of the leaves of cavity walls.
4. Care should be taken to ensure that mortar is not scraped onto
the exposed face of the brick.
5. Unless otherwise specified, frogged bricks should be laid frog
up and the frogs should be filled with mortar completely.
Struck or Weathered (Weatherstruck)
This produces a contrasting effect of light and shade on the
brickwork. Such joints, when correctly formed, have excellent
strength and weather resistance and are suitable for all grades
of exposure.
Square Recessed (Raked)
This can produce interesting articulated joints, but weather
resistance and strength will be considerably less than with other
joints. Use only with frost resistant bricks in sheltered exposure
conditions. The recess should not exceed 3-4mm and is not
recommended with full fill cavity insulation.
Brickwork
STAINING AND REMEDIAL MEASURES
First of all it is important to identify the type of stain or deposit on
the brickwork. Secondly, of equal importance, is the need to
observe all necessary health and safety regulations with the use of
acids. Generally, efflorescence is soluble in water, stains are not.
White Efflorescence
As brickwork dries out some water soluble salts present in the
overall construction may form as a white deposit upon the surface.
Efflorescence can be unsightly but it is not harmful and will
ultimately disappear over a period of time by the natural action of
the wind and rain.
The risk of efflorescence can be reduced by the correct protection
of bricks and brickwork to avoid saturation.
Chemicals should not be used for the removal of white
efflorescence. It should be cleaned off using only a bristle brush
followed by a damp sponge if necessary. The deposit should be
collected and removed from site so that it does not enter the
brickwork elsewhere.
If efflorescence persists it is likely that a design fault or poor
workmanship is allowing excessive amounts of water to soak into
the brickwork.
Yellow or Green Efflorescence
These efflorescences or stains are commonly associated with new
brickwork in buff or cream coloured bricks and are due to the
presence of vanadium salts commonly found in the fire clays used in
the making of these bricks.
Like white efflorescence they should be allowed to weather away
naturally. Chemical washing with a proprietary brick cleaner is likely
to create a dark stain.
If this efflorescence is so pronounced as to require chemical
cleaning, it is recommended that a trial be carried out to a small
unobtrusive area of brickwork using a dilute solution of oxalic acid,
directly onto dry brickwork. This is followed by the application of
washing soda, which is left on the wall.
Iron Staining
Normally light to dark brown in colour it is generally most
pronounced on the mortar joints. This type of stain can be avoided
by good site protection to unfinished and "green" brickwork. It is
best left to weather away, but the mortar joint colour can be
restored by abrading with a round file.
Cement Staining
Remove large deposits with a wooden tool to prevent damage to
the brick face. The residue should be treated with a 10%
hydrochloric acid solution for darker bricks and a 5% solution for
lighter bricks. Pre-wet the brickwork prior to the use of acids.
Final rinse should be with a very low pressure washing. DO NOT
SATURATE THE BRICKWORK.
Lime Running (Leaching)
This is similar to white efflorescence but is hard not powdery. It is
caused when an excess of rainwater combines with fresh, uncured
mortar to release free limes present in the cement to form calcium
carbonate deposits on the surface of the brickwork. Removal of this
type of stain should be carried out at the earliest opportunity as
delay will result in carbonation which is difficult to remove.
To remove, wet the brickwork with clean tap water to
reduce suction.
DO NOT SATURATE THE BRICKWORK.
Brush on a 10% solution of hydrochloric acid. The brickwork should
then be thoroughly scrubbed to remove the staining, then washed
off with clean water. It may be necessary to repeat the cleaning
process more than once depending on severity.
Crazing
Crazing to the face of bricks will generally only affect very dense
wirecut products, for example, Smooth Blue. No specific time period
can be given as to when, or indeed if, this will occur.
Crazing is exaggerated in work by the deposit of impurities from
mortar and rain. Once the brickwork is cleaned down and the
impurities washed away, the evidence of the crazing is minimised.
Staining of Blue Bricks
Staining of blue bricks is commonly called "Peacocking". It appears
as an oil coloured type of stain on the face of the bricks and is a
natural characteristic of these products.
The most common stain to blue bricks which is similar in
appearance to "Peacocking" is associated with the saturation of
bricks and brickwork prior to and during construction which leads
to calcium deposits drying on the face of the bricks. Good site
protection to unused bricks and uncompleted brickwork is essential
to minimise, and in many cases, prevent this stain occuring.
15
Exposure

EXPOSURE OF BRICKWORK
A major factor influencing the performance of brickwork is the
degree to which it becomes saturated. Good design aims to
minimise water ingress, as excessive saturation can lead to frost or
sulfate attack and staining or corrosion of non-stainless steel wall
ties or reinforcement. Use of the appropriate DPC materials in the
correct positions will also significantly reduce saturation.
The exposure of the site and of different parts of the building will
have a bearing on the choice of both brick and mortar mix. The
degree of exposure of the site is classified either in terms of the
local spell indices, calculated using BS 8104:1992 or in terms of
the exposure categories given in BS 5628:Part 3:1985, BRE
Report Thermal Insulation - Avoiding Risks or NHBC Standards.

TABLE 10 - FACTORS AFFECTING RAIN PENETRATION OF CAVITY WALLS

Factor affecting Increasing probability of rain penetration in the direction of the arrow
rain penetration

Applied external finish Cladding Rendering Other (e.g. masonry paint, water repellent)

Mortar composition Cement:lime:sand Cement:sand plus plasticizer

Mortar joint finish and profile Bucket handle, weathered Flush Recessed, tooled Recessed, untooled

Air space (clear cavity) Over 50mm 50mm None

Insulation None Partial filling with Filled with type A Filled with type B
50mm air space insulant (50mm cavity) insulant (50mm cavity)

Note:
The table does not take into account the quality of workmanship or the architectural detailing.
A. Type A insulants, such as mineral fibre (see BS 6232) or polystyrene beads, should not be subjected to exposure conditions more severe than those
recommended for the equivalent unfilled wall.
B. Type B insulants, such as urea formaldehyde foam (see BS 5618) and granular plastic fills, are subject to various additional restrictions related to the
local exposure conditions and the type of construction.

Torquay Police Station, Devon

Swanage Handmade Torquay Blend

16
Exposure

EXPOSURE TO WIND-DRIVEN RAIN

TABLE 11 - EXPOSURE TO WIND-DRIVEN RAIN

• Inverness
Exposure Local spell index
Category calculated as described
Aberdeen • in BS8104:1992

L/m2 per spell

Severe More than 100

Dundee •
Perth •
Moderate / Severe 56.5 to 100

Moderate 33 to 56.5
• Glasgow • Edinburgh

Sheltered Less than 33

• Londonderry Newcastle •
• Carlisle

Belfast •
Middlesborough •
• Dungannon
Enniskillen
•

• York

• Hull

• Manchester

• Nottingham

• Stafford
Norwich •
• Shrewsbury
• Leicester • Peterborough
• Birmingham

• Northampton

Colchester •

Swansea
•

Cardiff • • Bristol
London •
Dover •

Southampton • Brighton
•

Exeter •

17
Exposure

EXPOSURE WITHIN BRICK CONSTRUCTION

flush eaves
parapet Severe

Moderate/Severe

Moderate
balcony

Sheltered

free standing

internal wall
(exposure-nil)

inspection chamber

overhanging
eaves

retaining wall

paving

The exposure category of tall buildings and those located on high The selection of brick and mortar for one part of the building may
ground should be classified one grade more severe than would determine the choice for the whole structure in order to achieve
appear to be required. Certain parts of buildings may also require a uniformity of appearance and performance.
more severe grading e.g. parapet walls, tops of walls unprotected
by roof overhangs, freestanding walls and areas of walls below DPC
adjacent to ground level.

18
Exposure

WATER PENETRATION
Some water will inevitably penetrate the outer leaf in long periods of Penetration of a leaf built from low absorption bricks will generally
wind-driven rain. The degree of penetration depends largely on the occur more quickly than through one built from high absorption
intensity and duration of wind and rain. bricks in the same exposure conditions. The latter delays
penetration but it will occur eventually if the rain continues long
During light wind-driven rain, damp patches usually appear first at
enough for the bricks to become saturated.
the joints on the cavity face. When the rain stops they dry out.
After longer or more intense periods of wind-driven rain, the entire
face may become wet and eventually water may run freely down the
inner face.

Resistance of Outer Leaf to Wind-driven Rain

Slight dampness Most of inner Water running freely

at perpends face damp, but down inner
no running face
water

Cavity tray Cavity tray

virtually dry damp

Sheltered Moderate Severe Standing water in

cavity tray (drains
from weepholes
when wind drops)

Potential Routes for Water Penetration

Open perpend
Water directed
Mortar into insulation
obstruction

Tie sloping
down to
inside leaf Tie sheds water
into cavity Ponding

Water splashes
off extruded Slabs overlapped
bed water directed in
Dispaced board
catches drips

Cavity bridged Water now

above DPC on inner
leaf

Unfilled Cavity Partially Filled Cavity Filled Cavity

19
Exposure

DESIGN DETAILING
Good design involves the durability of a building in addition to
place, purpose, form and function. It is therefore important to
design the individual elements of a building with an eye to the
prevention of future defects.

For sites of severe exposure special details may be necessary,

but in many other cases simply following established good
practice guidelines will help to minimise future problems.

Essentially the main factor to take into account in the UK

climate is water penetration from above and below. In addition
to the aspects previously indicated, other factors, such as
Overhanging
structural stability and lack of movement joint provision, may eaves to
increase
also have a bearing on the weather resistance capabilities of protection to
wall below
brickwork, e.g., moisture penetration through cracks.

Where architectural details which increase exposure are

considered essential to the design, it is necessary to ensure
that the bricks specified are of the appropriate
durability designation.
Insulation stopped
just short of cavity tray
DESIGN FEATURES
Certain design features will increase the vulnerability of
brickwork and the risk of it becoming saturated, with
Stop ends Cavity tray including
consequent risk of frost damage. In these cases more durable stop ends

bricks and mortar mixes are required, this choice may then
Drainage
have to be applied to the whole building. weephole
at not greater
than 1 metre
intervals,
Examples of features which will increase the local minimum
2 per opening
exposure are: Sealant

• Recessed windows with sloping masonry at the bottom.

• Flush cills.
• Little or no overhang at verges. Timber window frame
secured to brickwork
• Large expanses of glazing or impervious cladding above by non corroding
cramps
masonry (without provision for shedding run-off water).
• Areas of rendering adjoining brickwork and recessed from
it with no effective seal or other protection at the junction.
IC 1.1
• Vertical tile hanging with little or no projection cill brick
DPC below cill stepped
above brickwork. down across cavity.
Weepholes, minimum
• Parapet or other walls with a flush capping e.g. of brick. Stop end 2 per opening.

• Features which project from the main plane of the wall

without weathering or flashings.

Reference should be made to BS 5628 Parts 1 and 3 for

general information on the design of masonry. Eave/Window Section

20
 Exposure

Vertical DPC to
DAMP PROOF COURSES project 25mm into
cavity and be
returned into
brickwork rebate

Vertical DPC to
project 25mm into
cavity and be Sealant
returned into
frame rebate

Sealant, critical in
this construction

Sub-cill, to
project 50mm
from face of
wall

Vertical DPC Window with Cavity tray

rigidity supported
to be lapped in Rebated Jambs accross cavity
front of cill DPC

Window Opening Cill DPC

with Flush Jambs bedded in mortar

DPC DPC

Caplock Half
Round Coping

Bitumen polymer DPC

Cavity closer

Rising Damp Prevention

150mm
min

DPC rises
150mm min.
across cavity

Horizontal
DPC (projects a minimum
Damp of 25mm into cavity)
Prevention

Parapet Wall
21
Exposure

DAMP PROOF COURSES

Gable Abutments
to Cavity Walls

Stepped Cavity Tray

Note:
It is essential to provide a series of stepped cavity
trays at each bed course which follows the profile of
the roof. These are readily available from most DPC
specialist providers.

22
Exposure
On steep pitched
roofs it will be
necessary to
DAMP PROOF COURSES - CHIMNEYS install a second
tray at high level 6

Detail around
Flue liner flue liner

2 Fit the front apron 3

The top edge of the
apron fits under the
DPC tray. Fold down 4
1 the DPC tray
projection. Fit the
back gutter
sole plate 4

Build brickwork 1
to DPC level and
3
add roof level
DPC tray 2

6
Fit the side flashings 5
Fit the back gutter
6

Caplock
Overhanging
Coping

Horizontal DPC

Exclusion of Water

Good detailing contributes significantly in reducing the risk of water

Thickness of
penetration. Wetting can be reduced by ensuring that water is Mechanical
wall to be
protection to
related to
thrown clear of the wall by the use of adequate overhangs and DPM
height of
Vertical DPM
drips, and by providing drainage to take water away from the to prevent Minimum of 2
staining/ courses of DPC 1
masonry. Large areas of glazing can produce copious amounts of efforescence on or 2 bricks in
exposed face designation (i)
surface run-off, which can cause excessive wetting and the
possibility of water penetrating the masonry below.

With ‘N’ durability designation bricks, where walls are likely to

remain wet for long periods, consideration should be given to the
use of stronger mortar mixes or sulfate resisting cement.
Retaining Wall

23
Movement

MOVEMENT OF BRICKWORK
Movement of brickwork should be considered at the design stage.
The main sources of movement referenced here relate to moisture
and temperature. Other factors may relate to loading and creep,
and in certain situations, it may be necessary to consider the effects
allowance of typically 30% to allow for the compressibility of the
filler and the performance of appropriate sealants. Thus movement
joints at 10m centres will need to be approximately 13mm wide
and the distance between movement joints should ideally never

of chemical action, ground movement and settlement.
In general, reversible movements are caused by temperature
changes and these can be calculated by reference to the
coefficient of thermal expansion, as indicated in Appendix A4 of
BS 5628:Part 3 and the Ibstock Brick Design Guide on Movement.
However, irreversible expansion caused by adsorption of water
molecules by the fired clay brick can be larger and continue, albeit
at a reducing rate, for a period of years.
exceed 12m. Most constructions are set to a 5/6 metre grid
therefore for design purposes it is normally accepted that
movement joints should be considered at 10/12 metre centres.
Movement takes place around corners and not just in straight runs
of masonry. It is therefore important to include all continuous
masonry in the assessment.
Unrestrained or lightly restrained walls (such as parapets and small
freestanding walls) should be given double this amount of
movement provision. In these cases, the distance between
movement joints should be 5-6 metre centres, with coping and
cappings at half these distances.

As indicated in BS 5628:Part 3, present evidence suggests that

vertical movement of unrestrained walls is of the same order as
horizontal movement. This standard also refers to the use of flexible
cellular polyethylene or foam rubbers as suitable compressible
materials and the use of sealants such as low modulas silicone
which are suitable for sealing of movement joints. This standard also
advises on unsuitable materials, e.g. fibreboard. Further guidance
on the selection of sealants is given in BS 6213.
Church, Bridlington, Yorkshire
Roughdales Chester Red Blend
Clay and concrete units have different movement characteristics,
these differences being in both magnitude and direction. They
The movement properties of common building materials including should not be bonded together but separated by either a vertical
brickwork are set out in Table 12. or horizontal movement joint or by a slip plane.

The spacing and thickness of movement joints is related to the When brickwork is to be used to clad a reinforced concrete
detailed design, length and height of the brickwork, together with frame, the design should make particular allowance for
any requirements for structural restraint. differential movement.

An indication for normal storey height walls is that the joint width Detailed advice based on BS 5628:Part 3 is available from Ibstock
(in mm) should be at least equal to the joint spacing (in m) plus an Brick’s Technical Services Department.

TABLE 12 - MOISTURE MOVEMENT & THERMAL PROPERTIES OF COMMON BUILDING MATERIALS

Reversible moisture Irreversible moisture Coefficient of thermal

movement % movement% expansion per °C X 10-6
Timber ± (0.5 - 2.5)† 4 - 70†
Steel (depending on type) 10 - 18 (depending on type)
Concrete ± (0.02 - 0.10) (0.03 - 0.08) 7 - 14 (depending on type)
BRICK & BLOCK
Dense concrete aggregate concrete products ± (0.02 - 0.04) - (0.02 - 0.06) 6 - 12
Lightweight aggregate concrete (autoclaved) products ± (0.03 - 0.06) 8 - 12
Aerated (autoclaved) products ± (0.02 - 0.03) - (0.05 - 0.09) 8
Calcium silicate bricks ± (0.01 - 0.05) - (0.01 - 0.04) 8 - 14
Clay bricks ± (0.02) + (0.02 - 0.07) 5-8

Note:
+expansion -shrinkage †depending on direction measured

24
Movement

ANCILLARY FIXINGS

Reinforcement

Brickwork is strongest in compression. The forces set up by

reversible movement, irreversible movement or simply by changes
in section due to door or window openings, can induce tensile
forces, resulting in cracking. Such behaviour may be modified or
controlled by bed joint reinforcement which can accommodate the
tensile forces and help bond adjacent courses together in a
homogeneous mass.

Stitching rods may be inserted and grouted into the perforations

contained in some bricks to both locate and support the bricks over
door and window openings. The rods should be stainless steel and
used in accordance with the Structural Engineer's specification.

Mechanical Fixings

Innovative brickwork detailing, particularly corbelling that exceeds

the recommendations of BS 5628:Part 3, or where the bearing for Ikon Gallery, Birmingham, West Midlands
Leicester Red Stock
successive courses in 103mm brickwork is less than 70mm, may
require proprietary channels, cranked or special shape ties and Wall Ties
angle supports fixed back to a reinforced concrete or concrete cased
Cavity brickwork must incorporate wall ties (usually stainless steel)
steel structure. The use of an SBR (Styrene Butadiene Rubber)
embedded in the horizontal mortar joints to a minimum depth
additive may also be considered where bricks are to be bedded on
of 50mm. Tie length and type (refer to BS 5628:Part 3 Table 9B)
stainless steel angles.
depends upon the cavity width and requirements for strength,
Non-loadbearing arches, particularly those possessing a small rise flexibility and retention of insulation materials. Ties should
in relation to their span, may similarly require additional support be staggered and evenly distributed in accordance with
or restraint. BS 5628:Part 3 (Table 9A), typically at 900mm centres
horizontally and 450mm centres vertically. Additional ties should
also be provided within 225mm of movement joints or openings
at a maximum 300mm vertical centres.
Continuous runs of
brickwork in
buildings require
movement joints at
10 - 12m centres
Easily compressed filler

Movement joint
required where
return is less Outer face
than 1m

Unrestrained
walls: movement Sealant
joints at max.
At returns At junction of 5 - 6m centres
and change restrained and Filled and Sealed Joints
in height unrestrained walls
These are general guidelines only.
For specific advice contact the
Positioning of Movement Joints Ibstock Brick Design Advisory Service.

25
Insulation

SOUND INSULATION
The sound resistance of a solid masonry wall is related principally
to its weight (expressed as mass per unit area). For cavity walls,
sound insulation is additionally related to the width of the cavity
insulation and the rigidity and spacing of wall ties.
Part E of the Building Regulations requires the weight of a solid
masonry wall (including the plaster) to be at least 375kg/m2. For
a cavity wall, its weight (including plaster) must be at least
2
415kg/m . Specifications for common types of wall which meet
these requirements are given in Schedule 1 of Part E.
The minimum weight of brick to be used, depending on the
type of construction, is indicated in Table 13.
It must be remembered that the smallest crack which provides
an air passage will greatly reduce sound insulation.
Good workmanship is necessary to ensure that all perpend
joints are fully filled, that bricks are laid frog up and that
plastering is of a high standard.
Of equal importance during the design stage is the reduction of
flanking transmission and particular care is therefore necessary
where floors are continued through separating walls and in
detailing window and door openings.

TABLE 13 - DENSITY OF BRICKS REQUIRED

Wall Plaster finish

Material and Thickness Specified weight Number of Type Average density
dimensions (mm) at least (kg/m2) sides of brick to be
includes finish used (kgm3)

2 Lightweight 1610
Solid Wall 375
2 Gypsum 1610

Brick size (mm) 215mm

65 x 102.5 x 215

2 Lightweight 1970
Cavity Wall 415
2 Gypsum 1970

255mm

Note:
The average weight of the brick to be used depends on achieving at least the following values for mortar and plaster:
(a) mortar- 1800 kg/m3 in joints 10 mm thick (b) plaster - lightweight 10 kg/m2 gypsum 17 kg/m2.

Aldersley Leisure Village, Wolverhampton, West Midlands

Throckley Smooth Buff & Atlas Smooth Blue

26
Insulation

THERMAL INSULATION
Building Regulations currently require a U value of not more than Early consultation with the cavity-fill manufacturer is advisable,
2
0.45W/m deg K for external walls. This may shortly reduce to particularly in relation to exposure of the site. Standards of
0.35 or possibly 0.30 when using the elemental method of workmanship and site supervision are critical as there is no residual
determination. This can readily be achieved with the range of cavity to prevent rain penetrating across to the inner leaf.
insulants available. Examples of cavity construction with the
In partially filled cavity construction, a clear cavity of not less than
resultant U-values are shown in Table 14. The thermal conductivity
50mm must be maintained in order to avoid bridging and to
('k' value), for use in calculating the U-value of brickwork
prevent the penetration of wind-driven rain.
construction, is given in the technical information that appears on
Ibstock Brick’s Product Specification sheets that are available In order to accommodate the insulation and provide the required

on request.
Care is needed when considering a fully filled cavity since this can
increase the likelihood of moisture penetration. When selecting an
insulant for this application, reference should be made to the
relevant British Standards or Agrement Certificates.
residual cavity, longer wall ties may be required together with
special clips to fix the insulant securely to the inner leaf. Insertion of
an insulant within a cavity does not affect the durability of the
external brickwork, but to reduce the risk of rain penetration to the
internal skin, mortar joints should be completely filled, using only
curved recessed (bucket handle) or weatherstruck joints.

Wall ties to be
bedded level,
with drips
downward

Insulation cut
To minimise mortar
cleanly at extra
inside cavity:
wall ties
1. Build up one
course of bricks
to form trough.
Inner face of outer 2. Clean mortar
leaf to be struck from cavity.
clean before next
3. Place next
batt is placed
cavity batt.
Insulation 4. Build up
clipped to remaining
inner leaf brickwork.
Insulation cut
cleanly at extra
wall ties

Board to
collect
All edges, (to mortar
be cut where droppings
neccessary) to and protect
be cleanly cavity
butt jointed

Joints in
insulation to
be coursed
with inner and
outer skin

Preferred Method: Alternative Method:

Build outer leaf first to minimise Build inner leaf first.
the amount of mortar in cavity.
Partially Filled Cavity
Fully Filled Cavity

27
Insulation

THERMAL INSULATION

TABLE 14 EXAMPLES OF CAVITY BRICKWORK CONSTRUCTION WITH APPROPRIATE THERMAL INSULATION U-VALUES
U-value Outer Leaf Cavity Insulation Examples Inner Leaf - Type & Thermal Finish
(Brick Type & Density) Conductivity 'k' value)
0.27 Clay Facing Bricks 50mm Clear Cavity 100mm Lightweight block (0.11k) 50mm dry lining board on dabs (2.28R)
up to and including 2000kg/m3
0.28 Clay Facing Bricks 55mm EPS Board (0.026k) 100mm Lightweight block (0.11k) 13mm plasterboard on dabs
up to and including 2000kg/m3 in 100mm cavity
0.28 Clay Facing Bricks 50mm Clear Cavity 100mm Medium density 13mm plasterboard on dabs
up to and including 2000kg/m3 48mm Polyisocyanurate boards (0.019K) block (0.19k)
0.28 Clay Facing Bricks 60mm EPS (0.033K) 150mm Lightweight block (0.11k) 13mm plasterboard on dabs
up to and including 2000kg/m3 in 100mm cavity
0.30 Clay Facing Bricks 1400kg/m3 50mm Clear Cavity Handmade Facing (0.38k) Fair face
50mm Polyisocyanurate boards (0.019K)
0.30 Clay Facing Bricks 50mm Clear Cavity 100mm Medium density 50mm dry lining board on dabs (2.28R)
up to and including 2000kg/m3 block (0.19k)
0.30 Clay Facing Bricks Bubble insulation in 60mm Cavity 150mm Lightweight block (0.11k) 13mm plasterboard on dabs
up to and including 2000kg/m3 NHBC require 75mm
0.30 Stock Brick 1500kg/m3 50mm Injected foam (0.018k) Clay Common (0.50k) 13mm plasterboard on dabs
0.32 Clay Facing Bricks 60mm EPS board (0.033K) 100mm Lightweight block (0.11k) 13mm plasterboard on dabs
up to and including 2000kg/m3 in 100mm cavity
0.33 Clay Facing Bricks 50mm Epsx Board (0.032K) 100mm Lightweight block (0.11k) 13mm plasterboard on dabs
up to and including 2000kg/m3 in 100mm cavity
0.34 Clay Facing Bricks 1400kg/m3 50mm Clear Cavity Handmade Facing (0.38k) Fair face
50mm Insulation batts (0.024K)
0.34 Clay Facing Bricks Bubble insulation in 60mm Cavity 100mm Lightweight block (0.11k) 13mm plasterboard on dabs
up to and including 2000kg/m3 NHBC require 75mm
0.34 Clay Facing Bricks 50mm Clear Cavity 100mm Medium density block (0.19k) 13mm plasterboard on dabs
up to and including 2000kg/m3 38mm Polyisocyanurate boards (0.019K)
0.35 Clay Facing Bricks 50mm Clear Cavity 100mm Medium density block (0.17k) 40mm dry lining board on dabs (1.73R)
up to and including 2000kg/m3
0.38 Clay Facing Brick 1700kg/m3 75mm Mineral Wool batts (0.036k) 100mm Heavyweight Block (1.12k) 13mm plasterboard on dabs
0.40 Handmade Facing 1400kg/m3 50mm Clear Cavity Handmade Facing (0.38k) Fair face
30mm Phenolic foam boards (0.018k)
0.40 Stock Brick 1400kg/m3 50mm Clear Cavity 100mm Lightweight block (0.11k) 13mm plasterboard on dabs
50mm cellular glass (0.048k)
0.41 Clay Facing Brick 1700kg/m3 65mm Mineral Wool batts (0.036k) Clay Common (0.50k) 13mm plasterboard on dabs
0.42 Stock Brick 1500kg/m3 75mm fibre boards (0.040k) Clay Common (0.50k) 13mm plasterboard on dabs
0.43 Clay Facing brick 1600kg/m3 50mm Clear Cavity 190mm Lightweight Block (0.11k) 13mm plasterboard on dabs

The information in the above table is for guidance only and independent calculations should be made on individual constructions.
Increasing the thickness of materials will also help to reduce the U-value.
Methods of calculating U-values are under review and this may change the above results. ‘k’ values given are manufacturers figures.
Note:
The products mentioned above are used for examples only and no preference or recommendation is intended.
There is a large variety of suppliers of similar products.

English Martyrs Church, Biddulph, Stoke-on-Trent

Chesterton Red Smooth
Chesterton Etruria Mixture
Roughdales Albany Cream
Westbrick Staffordshire Blue Brindle Smooth

28
Good Site Practice

STORAGE
Bricks should be inspected on delivery. They should be unloaded
directly onto a dry level area or scaffold and protected from the
weather. It is important not to overload floor slabs or scaffolds with
large stacks of bricks.
Ready-mixed lime:sand for mortar should be stored in a clean area
on a hard, impervious surface, and protected from the weather.
Extreme variations of moisture content will affect gauging.
APPEARANCE
In order to achieve a uniform appearance throughout the building
and to avoid the possibility of patches or bands of differing shades,
bricks should be used from a minimum of 3 packs at the same time.
Placing of bricks from one pack in one part of the wall should be
avoided. Consideration should be given to constructing a 100 brick
site reference panel in accordance with BS 3921:1985:Appendix F.
Variations in the jointing profile due to poor workmanship or
uncontrolled mortar mixes will adversely affect appearance.

MORTAR
CAVITY TIES
The mortar should be correctly proportioned and thoroughly mixed.
All wall ties must be bedded to a minimum depth of 50mm, at
Nothing but clean water should be added later, and mortar should
right angles to the run of the wall and not pushed into the joint.
not be 'knocked up' after it has started to set.
They should slope down towards the outer leaf. The drip must
be located in the centre of the cavity and point downwards.
Consideration should be given to the use of stainless steel ties.

Park & Ride Scheme, Rowley Regis, West Midlands

Leicester Multi Red Stock, Roughdales Golden Brown Multi Rustic &
Westbrick Staffordshire Blue Brindle Smooth
Globe Theatre, London
Leicester Red Stock
West Hoathly Handmade Multi
MORTAR PLASTICISERS AND AIR ENTRAINERS Laybrook Bramber Multi
Laybrook Sevenoaks Yellow
Under certain circumstances an air entrainer can be used to reduce Aldridge Staffordshire Georgian

the water requirement of the mortar by up to 50%.

This considerably improves the productivity in winter - but the
additive must be included in the mortar at initial mixing stage to
ensure consistency and minimal strength loss. Ideally, air entraining
agents should only be used in ready to use mortar.

JOINTS
All joints between bricks should be fully filled. Deep furrows in bed
joints and 'tipped and tailed' perpends will let additional water pass
through the brickwork and are not recommended.

Unless otherwise instructed, mortar joints should be finished curved

recessed (bucket handle) or weatherstruck. Jointing as the work
proceeds is preferable.

29
Good Site Practice

DPCS AND CAVITY TRAYS

DPCs and cavity trays should be sandwiched in mortar. Joints to
DPCs and cavity trays should be lapped a minimum of 100mm and
sealed to prevent the downward movement of moisture. All cavity
trays and combined lintels must have stop ends. Drainage
weepholes shall be provided at not greater than 1 metre intervals
and a minimum of 2 weepholes over each opening.

PROTECTION
All walls must be covered when work stops, rain on new work
Private Housing, Camden, London
can cause: Funton Second Hard Stock

Colour change of mortar Lime stains

Saturation Efflorescence CAVITY INSULATION
Bricks left uncovered on scaffolds are particularly prone to Cavities are designed to prevent water penetration to the inner leaf.

saturation by rain and snow. All covers must be secured to prevent

Full Fill Cavities
them being dislodged by wind.
Complete filling of a normal 50-75mm wall cavity with insulant
Variation in the moisture content of mortars will frequently lead to
can considerably increase the risk of rain penetration, the type
colour changes; this is most marked in the case of darker coloured
of insulant and the exposure of the site should therefore be
mortars, and particularly where joints have been tooled.
assessed carefully. Consideration to increasing the cavity width
All newly erected brickwork, and brickwork under construction must may be appropriate in order to meet thermal and rain
be protected adequately from rain, snow and frost. In most cases resistance requirements.
this is achieved by covering the wall head with a water resistant
material, but problems can arise in some situations: e.g. in Partial Filled Cavities
brickwork facing to concrete construction, where rain may frequently
Maintain the specified cavity, placing insulation batts against the
run off the concrete in quantity and penetrate behind the facing
inner leaf and secure them with specially designed wall tie clips.
brickwork. In this situation a water resisting material is normally
fixed to the vertical surface of the concrete and draped over, and Where a clear airspace of a minimum of 50mm is maintained,

clear of, the brickwork, being lifted as work proceeds. partial fill insulation does not increase the risk of rain penetration.

Hessian is frequently used as an insulating layer in sunny weather, Where cavity fill insulation is used the DPC cavity tray must be

but it is useless if it becomes wet. Apart from the loss of its value provided with stop ends to prevent water running into the cavity

as insulation, hessian which is soaking wet will frequently cause and saturating the insulation. Achieving good workmanship

serious staining and efflorescence of the brickwork. It must, is essential.

therefore, be covered with plastic or other waterproof materials in

adverse conditions.

Every opportunity must be taken to allow the brickwork to dry out

when conditions permit. To encourage this, the cover should be
supported clear of the face(s) of the wall, either by laying it over a
wooden framework or over projecting bricks, so that ventilation can
take place beneath the cover.

Mortar splashing and staining of brickwork will also occur in wet

weather unless the inner scaffold board is turned back when work
is left.

30
Good Site Practice

BRICKLAYING IN WINTER
Bricklaying should be discontinued when the brickwork temperature
falls below 3°C, and when frost is imminent. Although some
guidance can be obtained from the air temperature, it is the
temperature of the brickwork that is important.

In the absence of a suitable thermometer, some indication of

whether or not the brickwork is below freezing point may be
obtained by applying a small quantity of water onto the bricks (e.g.
by paintbrush or similar). If the film of water freezes, then clearly
bricklaying should not commence.

Mortar Strength

Although the stronger, more dense mortars (designations (i) and

(ii)) are more resistant to freezing and are normally used in more
exposed building situations, less strong mortars (designation (iii))
are frequently used for the external walls of buildings in more
sheltered situations. A 1:1:6 cement:lime:sand mortar has adequate
long term durability provided that it is correctly gauged, but some
additional protection may be needed if it is to resist freezing at an
early age, when it is still ‘green’ and before adequate strength has
developed. The development of strength takes place more slowly at
low temperatures.

The use of accelerators such as 'anti-freeze' agents is

not recommended.

Adhesion

In its simplest terms, bond relies on the binder paste in the mortar
flowing into the pore structure of the brick. The mortar must,
however, retain sufficient water for its hydraulic properties to
develop and, hence for setting to occur.

In winter, because the brickwork dries more slowly, the mortar will
require less water. The mortar should, therefore be as stiff as
possible whilst retaining sufficient flexibility to allow alignment to
take place. Laid bricks should not be 'trued up' once initial stiffening
has taken place since this will permanently break the mortar bond.

Winter Protection

Stocks of all materials, particularly bricks, should be protected from

rain, snow and frost and from ground contamination, and splashing
by passing vehicles.

Private Housing, Chester, Cheshire

Westbrick Axminster Blend
Cattybrook Cheddar Red
Westbrick Staffordshire Slate Blue Smooth

31
Other Sources of Reference

The following sources of reference list the principal British Standards BS Specifications for Insulation Systems
for materials, design, workmanship and insulation systems, and
BS 3837: Expanded polystyrene boards
these should be consulted as appropriate. Reference should also be
Part 1 1996 Specification for boards
made, as necessary, to the relevant sections of The Building
manufactured from expandable beads
Regulations 1991, as amended.
BS 4841: Part 1 1993 Laminated board for
BS Specifications for Materials, Design general purposes
and Workmanship BS 5617: 1996 Specification for urea-formaldehyde (UF)
foam systems suitable for thermal insulation of
BS 743: 1970 Specification for materials for damp-
cavity walls with masonry or concrete inner
proof courses
and outer leaves
BS 1199/1200: 1996 Specifications for building sands from
BS 5618: 1996 Code of practice for thermal insulation
natural sources
of cavity walls (with masonry or concrete
BS 1243: 1978 Specification for metal ties for cavity
inner and outer leaves) by filling with
wall construction
urea-formaldehyde (UF) foam systems
BS 3921: 1985 Specification for clay bricks
BS 6676: Thermal insulation of cavity walls using
BS 4721: 1986 Specification for ready-mixed
man-made mineral fibre batts (slabs)
building mortars
Part 1 1994 Specification for man-made
BS 4729: 1990 Specification for shapes and sizes of
mineral fibre batts (slabs)
special bricks
Part 2 1994 Code of practice for installation
BS 5628: Code of Practice for use of masonry.
of batts (slabs) filling the cavity
Part 1 1992 Structural use of
BS 8208: Guide to.assessment of suitability of
unreinforced masonry.
external cavity walls for filling with thermal
Part 2 1995 Structural use of reinforced
insulants Part 1 1985 Existing traditional
and pre-stressed masonry.
cavity construction
Part 3 1985 Materials and components,
design and workmanship.
Also Useful
BS 6093: 1993 Design of Joints and Jointing in
BRE Thermal Insulation:Avoiding Risks
Building Construction
BDA Design Note Number 10: Designing for Movement in Brickwork
BS 6213: 1992 Guide to selection of
BDA Design Note Number 11: Improved Standards of Insulation
constructional sealants
BDA Building Note I :Brickwork Good Site Practice BDA Building
BS 6398: 1983 Specification for bitumen damp proof
Note 2:Cleaning of Brickwork
courses for masonry
BDA Guide to Successful Brickwork
BS 6515: 1996 Specification for polyethylene
damp-proof courses for masonry Guidance on the preparation of specifications can be obtained from
BS 8000: Workmanship on building sites. Part 3 1989 The National Building Specification and from NHBC Standards.
Code of Practice
BS 8104: 1992 Code of Practice for assessing exposure Ibstock Brick Design Guides
of walls to wind-driven rain Designing for Movement
BS 8215: 1991 Code of Practice for design and Freestanding Walls
installation of damp-proof courses in The Easy Arch
masonry construction Plinths
DD 140:part 2 Recommendations for Design of Wall Ties Corbelling
Copings & Cappings in Clay Brickwork and Cast Stone

32
Design and Technical Services

Specialist advice, precise information, speed of response... in a word

service. Our aim is a simple one: to ensure that our standards of Additional Notes
service are as exceptional as our range of products.
• Ibstock Brick’s Design and Technical Services
Departments can advise on the correct specification of
Design Service
mortar mixes and joint profiles.
The Ibstock Brick Design Advisory Service is Quality Assured to ISO
• Specifiers should consult manufacturers of DPC
9001. Our in-house Design Advisors can offer practical advice on
materials, sealants, fixings and reinforcement for advice
issues as wide ranging from movement control, support of corbels
on the use of these products.
and modelling features, water penetration to assistance with the
production of architectural detailing. • Intermediate DPCs must be used where cavity fill
insulation is specified in buildings exceeding two
Ibstock Brick’s Design Service is pleased to advise on the design
storeys. Some fills are not recommended in areas of
and use of both standard and purpose-made special shape bricks.
severe exposure.
By detailing and planning the use of special shape bricks at an early
• Wall ties must comply with BS 1243 and DD 140 and
stage, delivery schedules can be prepared appropriately, thus
should be installed fully bedded in accordance with
helping to ensure the availability of special shape bricks when
the manufacturer's recommendations, particularly
required on site. Additionally, early consultation at the design stage
where they are used to locate partial fill cavity
can serve to avoid potential detailing problems, resulting in more
insulation materials.
cost effective solutions.
• It is advisable to ensure that the width of the clear
Technical Service cavity is not less than 50mm.

To help cover the complete spectrum of technical queries,
Ibstock Brick's Technical Service offers a range of skills, including
technical and practical on-site advice regarding the properties and
performance of bricks and brickwork. Ibstock will be delighted to
arrange tailor-made technical training seminars, and to provide
up-to-the minute information on British Standards and
Codes of Practice.
• Specifiers are invited to discuss their particular
requirements with Ibstock Brick’s Design and Technical
Services Departments, who will advise on the
application or modification of any of the details
contained in this literature.

Although the information in this publication, and any other information provided by
Ibstock Brick is believed to be accurate, correct and complete, and not misleading,
no reliance should be placed upon its contents as being applicable to any particular
circumstances. Any advice, opinion, information or other contents are published only
on the footing that the company, its servants or agents or contributors to this
publication shall be under no liability whatsoever in respect of its contents or for any
loss howsoever caused.

33
Products and Services

RANGE BROCHURE
Being our most useful and
requested piece of literature, the
new range brochure has recently
been updated and improved.
Private Housing, Loxley, Warwickshire
The brochure contains over 350 Roughdales Chester Red Blend
bricks, illustrated in panels, along with
relevant technical data.

All bricks that are available in imperial sizes, are clearly marked with
PAVER RANGE
an symbol, for ease of reference. New products are also clearly
BROCHURE
marked, with a "new product" label next to each panel.
Ibstock Brick manufactures a range
On every page is a relevant project photograph. There is a healthy
of clay pavers and fittings in various
balance of commercial, public and private buildings, and many
colours to suit differing
projects show the use of good detailing, specials and
applications. This brochure
complementary colour combinations.
illustrates panels of these pavers
The back cover has contact information for each sales office, alongside photographs of the
illustrating their location, as well as factory locations on a map. pavers in work.

SPECIAL SHAPED BRICKS BROCHURE Towards the back of the brochure are clear laying instructions, to

Another key piece of Ibstock Brick literature is our Special Shaped help with your paving project.

Bricks brochure. This catalogue illustrates the range of popular,

HATHERNWARE BROCHURE
standard specials on offer from Ibstock and is arranged in an easy
to use format. Ibstock Hathernware has been
synonymous with high quality
The brochure is arranged in sections by shape, which are clearly terracotta and faience for over a
identified with colour coded strips. Each section century. The majority of work is
shows 3D drawings of the purpose-made, offering the designer
indivdual shapes, the brick almost unlimited design freedom.
shapes in work, associated
dimension table and relevant Bespoke architectural terracotta and

photography of the products in faience has contributed to the

built schemes. refurbishment of many famous buildings,

including the British Museum of Natural History.

All designed to give our customers A new brochure is available, which shows examples of what can
all the relevant information to be achieved by using terracotta and faience - to create
pursue their special shape enquiry. unique buildings.

If you wish to receive any of our brochures, call our

Literature Hotline on : 0870 903 4030

34
Products and Services

WEBSITE
The Ibstock Brick website provides an on-line up to date guide to
the multitude of products and services now available from Ibstock.
With its simple menu and easy navigation, you can gain fast
access to practical and technical details, news and new products,
SAMPLES SERVICE
a summary of our product range on the Brick Selector button,
Ibstock Brick's sample service is available for all our bricks
and numerous project case studies.
and pavers. We offer brick/paver panels and brick/paver boxes
In addition useful DXF files
for all products.
can be downloaded directly
Our latest innovation is the new to your CAD application to
Ibstock Brick Sample Card, which assist with the design of
is available for our best selling brickwork detailing.
products. These Sample Cards
are high quality photographs
CD ROM
of our products on durable
Our latest communication
card, for easier selection,
innovation is the Ibstock CD Rom (version 3). It contains a brick
storage and display.
selector, which allows the user to match their requirements along
To order samples, please contact with their technical properties and project photographs. A section
your local Representative or Sales Office, who will be pleased to on special shaped bricks includes a high
help. (Sales Office numbers are listed on the back of this guide). quality video on the production and
application of specials and further
QUALITY ASSURANCE
drawings on how and where to make the
Ibstock Brick is committed to the highest standards of quality. It best use of specials. It also contains
operates comprehensive quality management systems in compliance contact details, location maps and the
with BS EN ISO 9001:1994, maintains BSI Registered Firm status facility to order up to date literature.
and holds Kitemark licences.

DESIGN MAGAZINE
Ibstock Brick's Design magazine is a regular publication which is
dedicated to good architectural detailing. Featuring a summary of
the projects, photographs and architects' working drawings, the
magazine is free of charge. To receive
your regular copy contact the
Literature Hotline on
0870 903 4030.

Private Housing, Hale, Cheshire

Ashdown Cottage Mixture
Cattybrook Cheddar Red

35