Design Manual 3 The Full Brick Manual · as cavity brick, solid brick or double brick construction....

Design Manual 3

The Full Brick ManualC B P I

Acrobat Edition

Design Manual 3

The Full Brick Manual

First published September 1996ISBN 0 947160 01 9

Text by Tom McNeilly and MikeScully based on an original text byMax Granger.Illustrations by Max Granger.Special thanks to members of theCBPI Technical Committee for theirinput and assistance.Editing and project managementby Woodridge Media Pty Ltd.Art and design by Partners in Design Pty Ltd.

For many years clay bricks have been central to our defini-tion of housing. Today more and more Australians are re-discovering full brick construction.

The external walls of a full brick house are built with twoleaves of clay brick masonry separated by a narrow cavity. This method of construction is also known as cavity brick, solid brick or double brick.

Single thickness brick walls may be used between roomseliminating any requirement for steel or timber wall frames.Some or all of the inner walls of a full brick house may beleft as face (or exposed) brick or finished with render, plasterboard, timber or paint.

Full brick houses are:• Cooler in summer and warmer in winter.

• Quiet.

• Low maintenance.

• Affordable.This manual sets out design and construction details fordetached full brick housing and uses ample illustrations toshow that building in full brick is as simple and economicalas the familiar brick veneer.

This publication, its contents and format are copyright of the Clay Brick and Paver Institute(CBPI). This Acrobat edition may be stored and reproduced for individual reference and studywithout alteration or amendment. Local or state regulations may require variation from thepractices and recommendations contained in this publication.Whilst the contents are believed to be accurate and complete, the information given isintended for general guidance and does not replace the services of professional adviserson specific projects. CBPI cannot accept any liability whatsoever in respect to thispublication. Copyright © Clay Brick and Paver Institute 1996. ACN 003 873 309.

Clay Brick and Paver InstitutePO Box 6567, Baulkham Hills BC, NSW 2153, AustraliaTel (02) 9629 4922Fax (02) 9629 [email protected]

mailto:[email protected]

http://www.claybrick.com.au

http://www.woodridgemedia.com

http://www.pid.com.au

1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3WHAT ARE THE ADVANTAGES OF FULL BRICK CONSTRUCTION? . . . . . . . . . . . . . . . . . . . . . . . . . 4REGULATORY REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Bricks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Mortar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Damp-proof courses & flashings . . . . . . . . . . . . . . . . . . . . . . . . . . 5Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Wall ties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Flexible anchors or connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Lintels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

PLANNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Passive solar design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Dimensioning drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

DESIGN & CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Footings & slabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Brick piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Termite control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Fire resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Brick walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Sub-floor clay brick masonry . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10DPCs and cavity flashings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Walling above the DPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

•Bonding•Window and external door frames•Wall ties

Walls subject to high winds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Lintels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Articulation joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Control gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

•Steel door frames

•Timber door frames

•Articulation joints at standard-height doors

•External doors in cavity wallsBrick cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Internal wall finishes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

•Renders

•Sheeting

•PaintsSkirtings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Wall/ceiling junction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

SCHEDULING TRADES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

C O N T E N T S

CBPI Manual 3 : Full Brick Manual, published September 1996

2

FIGURES

1. Full brick walling on slab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32. Slab on ground for class A & S sites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73. Footing slab for class A & S sites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74. Slab on ground on class M & H sites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75. Strip footings with infill slab floors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86. Strip footings for class A & S sites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87. Strip footings on class M site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88. Isolated brick pier with concrete footing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99. Isolated brick pier with brick footing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 910.Cavity walls on strip footing with framed flooring & sub-floor vent . . 1011.Slab edge rebates for cavity walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1012.DPC and cavity flashings for full brick walls . . . . . . . . . . . . . . . . . . . . . . . 1013.DPCs for full brick walls on strip footings . . . . . . . . . . . . . . . . . . . . . . . . . 1114.External doors showing lintel & flashing details & fixing of frames . 1215.Lintel and flashing details and fixing of window frames . . . . . . . . . . . . 1216.Wall tie positioning and spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1217.Reinforced hollow clay units in high wind areas . . . . . . . . . . . . . . . . . . . 1318.Roof tie down for high wind areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1319.Tie down to clay brick masonry for tile or sheet roof in

wind classification areas W28 and W33 . . . . . . . . . . . . . . . . . . . . . . . . . . 1320.Typical articulation joint locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1521.Control and articulation joint detailing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1522.Masonry flexible anchor in articulation joints and control gaps . . . . . 1523. Internal doors showing switch wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1624.Steel door frames in cavity walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1725.Typical wall/ceiling junction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2026.Typical plumbing arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

TABLES1. Lintels for 110 & 90 mm single-storey clay brick masonry (mm) . . . . . 52. Optimum door width for standard-height doors . . . . . . . . . . . . . . . . . . . 163. Typical trades schedule for full brick house construction . . . . . . . . . . 23


3

For many years Australia has had a love affair with clay brick. For most of us the ubiquitous brick veneer hasdefined the great Australian dream of home ownership. Today there is a new player in the market with fullbrick construction taking the high ground in quality residential construction.

What is full brick? The external walls of a full brick house are built with two leaves of clay brick masonry separatedby a cavity. All or most of the internal dividing walls are built in single-leaf clay brick masonry. This is also knownas cavity brick, solid brick or double brick construction. Figure 1 shows a typical section of full brick walling.Full brick is much more than a revival of an ‘old’ form of construction. The internal walls of a full brick house maybe displayed as face brick or given a conventional finish. Modern construction materials and techniques have alsobeen adopted.The purpose of this technical manual is to assist designers, builders, specifiers and others involved in housingconstruction and to demonstrate that building in full brick is as simple and economical as the familiar brick veneer.

INTRODUCTION

Figure 1. Full brick walling on slab

“... building in full brick is as simple andeconomical as the familiar brick veneer.”


4

WHAT ARE THE ADVANTAGES OF FULL BRICK CONSTRUCTION?

REGUL ATORY REQUIREMENTS

• Full brick houses are cooler in summer and warmer in winter. The highmass of a full brick house absorbs the worst of the Australian summer andretains winter warmth. In conjunction with passive solar design principles,full brick construction ensures a comfortable, energy-efficient house.• Full brick houses are quiet. The two leaves of dense clay bricks on the out-side of a full brick house reduce noise entry. Single leaf internal clay brickmasonry reduces noise transfer between rooms.• Full brick houses are low maintenance. Bricks are extremely durable,immune to vermin and termite attack and do not require any finish to maintaintheir appearance or performance. Depending on the design, the full brickhouse may not require skirtings or architraves, reducing the amount of timberneeding repainting.• Full brick houses are affordable. As well as being more economical torun and maintain, the full brick house should cost little, if any, more to buildthan a conventional brick veneer. Full brick houses also command a premiumwhen it comes time to sell.

All buildings are required to comply with the Building Code of Australia (BCA),which in turn requires clay brick masonry to comply with AS 3700-1988,The SAA Masonry Code.At the time of writing this manual the Australian Building Control Board waspreparing the ABCB Housing Code (a simplified version of the BCA, specificto house construction) and Standards Australia was preparing a code formasonry housing. As far as possible these preliminary documents havebeen considered in the preparation of this manual.


5

Wall tiesWall ties are required to complywith AS 2699-1984, Wall ties formasonry construction, but a newStandard, AS/NZS 2699.1,Connectors and accessories formasonry construction Part 1: Wallties is in preparation. Wall ties forfull brick construction differ fromthose used in brick veneer but arereadily available.

Flexible anchors or connectorsThese are used to connect claybrick masonry across articulationjoints or control gaps. Anchors orconnectors are currently required tocomply with AS 2975-1987,Accessories for masonry construction, but AS/NZS 2699.2,Part 2, Anchors and accessories isin preparation.

LintelsLintels are usually standard or proprietary steel sections. They may also be reinforced clay brickmasonry, prefabricated or constructed on site.The following lintel span table issuitable for walls carrying a roofload provided there are not widely-spaced rafters or trusses locatednear the mid span of wide openings.If they occur, the given span shouldbe reduced by 15 per cent.Engineering advice is needed forlintels in walls carrying floor loadsor otherwise outside the limits ofthis table. Manufacturers also provide load/span tables for proprietary lintels.

M A T E R I A L S

Span Standard steel Minimum endsections support

Up to 1200 75 x 10 flat 100

1200 to 2100 100 x 100 x 6 angle 120

2100 to 3600 150 x 100 x 8 angle 150

Note: Unequal angle lintels should have their long leg vertical.

BRICKSClay bricks are required to complywith AS 1225-1984, Clay BuildingBricks. This is expected to besuperseded in mid-1996 by a newstandard covering all masonrymaterials. The requirements forbricks for full brick construction areidentical to those for brick veneer.Brick selection is a matter of personalchoice but light-coloured units witha smooth or slightly-textured facewill often be preferred for internal faceclay brick masonry.Like all manufactured products, claybricks vary slightly in size even withinthe same batch. However in themajority of cases the standard brickgauge tables can be applied. Thebricklayer will need to adjust thegauge if these tables are used forbricks of smaller or larger averagesize (work size). The alternative ofadjusting mortar joint thickness willoften be visually unsatisfactory.

MORTARThe requirements for mortar aregiven in AS 3700 and are identicalfor full brick and brick veneer construction. In both cases accuratemortar batching is important.

MATERIALS FOR FULL BRICK CONSTRUCTION

� Bricks: identical to those used in brick veneer.

� Mortar: identical to that used in brick veneer.

� DPCs and flashings: identical to those used in brick veneer.

� Wall ties: full brick wall ties are readily available.

� Flexible anchors or connectors: identical to those used in brick veneer.

� Lintels: identical to those used in brick veneer, but needed also onthe inner leaf.

� Vents: identical to those used in brick veneer.

C H E C K L I S T�Table 1. Lintels for 110 & 90 mm single-storey clay brick masonry (mm)

ACCESSORIESOne of the great qualities of fullbrick houses is their endurance.Clay brick masonry can last a thousand years and then some, so it is natural that the accessoriesbuilt into it must be selected for fitness of purpose and durability.

Damp-proof courses and flashingsCurrently AS 3700 requires materialsfor DPCs and flashings to complywith AS 2904-1986, Damp-proofcourses and flashings. A new standard with the same title wasissued as AS/NZS 2904:1995 andthis was used in preparing thismanual.The most commonly used DPCmaterials are bitumen- or polyethylene-coated aluminium orheavily-embossed polyethylene.Uncoated lead or copper are alsoapproved. Polyethylene is preferredin corrosive or saline environments.

VentsThe vents for full brick constructionare identical to those used in brickveneer.


6

P L A N N I N G

PASSIVE SOLAR DESIGNThis term is widely used but little understood. The basis of passive solar design is heavyweight constructionthat has the ability to store heat and moderate internaltemperatures.A full brick house with internal (partition) brick wallsprovides this mass, particularly when combined witha concrete slab floor. Studies have shown that the temperature range in a full brick house is close to thepreferred human comfort zone in both the coolest andhottest months. The other principles of good solardesign, such as providing large areas of appropriatelyshaded north-facing glass, particularly apply.This design technique works equally well in the temperatezones of Australia that includes Adelaide, Brisbane,Hobart, Melbourne, Perth and Sydney, and the cooltemperate zones that take in Canberra, Snowy Mountains,NSW Central Tablelands and Victoria’s High Country.Some designers favour the use of a relatively light-weight and light-coloured brick in the outer leaf (formaximum insulation and heat reflection) and a dark,heavyweight brick in the inner leaf (for maximum soundand heat absorption and heat storage). This is feasiblebut not necessarily practical. However it does reinforcethe point that different types and colours of brick canbe used inside and out.

DIMENSIONING DRAWINGSPlan the house so that dimensions are exact brick orbrick-and-a-half lengths. Where interior walls are to beface brick, dimension wall lengths from corners toopenings in brick unit sizes. This is critical becausethese walls will be regularly seen at close quarters. In the same way, vertical dimensions to window sills,heads and wall heights should be taken from the brickheight gauge.A further advantage of full brick construction is that allwalls are constructed by the one trade thereby reducingthe possibility of dimensional errors and set-out difficulties.

“... the temperature range in afull brick house is close to the

preferred human comfort zone”

“Dimension wall lengths fromcorners to openings in

brick unit sizes”

PLANNING THE FULL BRICK HOUSE

� The high mass of full brick houses is ideal for passive solar design.

� The passive solar benefits of full brick apply in most areas of Australia

� Different bricks can be selected for the internal and external clay brick masonry.

� Dimension in brick and brick-and-a-half lengths.

� Fewer trades equals fewer errors.

C H E C K L I S T�


7

FOOTINGS & SLABSFootings for brick walls must bedesigned in accordance with AS2870-1996 Residential slabs andfootings. Slabs for full brick are little more complicated than thosefor brick veneer. The principles forfooting and slab design for full brickon sloping sites are identical tothose for brick veneer.Local experience on known stablesites (around Perth, for example)may permit thinner slabs and lessreinforcing than shown here. In otherplaces, a variation of the slab-on-ground known as a waffle-raft maybe used.In areas with very reactive, deep-seated soil movements (such asAdelaide) local experience indicatesthat stiffer slab footings than thoseshown here are required. In suchcases AS 2870 gives guidance underthe additional site classifications ofM-D and H-D. It is also recommendedthat an experienced local engineerdesign the slab or check the proposed design when building on such sites.Sizes and reinforcing for strip footings, slabs-on-ground and footingslabs for full brick construction areshown in figures 2 to 4 and 5 to 7.

D E S I G N A N D C O N S T R U C T I O N

400

100 thick

External doubleleaf brick wall

Non-loadbearing internalbrick wall (up to 3 m high)

Reinforcing fabricF72 for slabs less than 18 m longF82 for longer slabs

Loadbearingbrick wall (supportingupper floor orover 3 m high)

Class A 3-8TMClass S 3-11TM

150 thick

500

300

Figure 2. Slab-on-ground for class A & S sites

Local experience on known stable sites (around Perth, for example)may permit thinner slabs and less reinforcing than shown here.

Figure 3. Footing slab for

class A & S sites

Figure 4.Slab-on-ground onclass M & H sites

400

200

300

100

400

Concrete-to-concrete contact150 mm minimum.

R10 fitments at600 centres

Layers of compacted fill as required

Internal brick walls on footing slab same asfor internal brick walls on slab-on-ground.

Class A 4-8TM

Class A 300

Class S400

Class S 4-11TM

Class A 3-8TMClass S 3-11TM

Reinforcing fabric: F72 for slabs less than18 m long, F82 for longer slabs.In WA F53 for slabs less than 12 m long,F63 for slabs up to 18 m long, and F62 for slabs longer than 18 m

300 300

100

Slab fabric

Loadbearing wall

1000 maximum

Beam

dep

th

Beam spacing

Site class Beam Beam Slab Bottom & wall type depth spacing fabric reinforcement

Class M articulated 500 mm 4 m F82 3-12TM

Class M non-articulated 800 mm 4 m F92 3-Y16

Class H articulated 800 mm 4 m F102 4-Y16

DPC

DPC

DPC


8

Figure 5. Strip footings with

infill slab floors

DPC

DPCInfill slab

Turn membrane up walls to form abond break when slab is placed. Trim membrane after slab is finished.

Weephole

Mortar cavity fill

Compacted fill Underlay membrane

Figure 6. Strip footings for class A & S sites

Not less than 75

400 300

DPC DPC

Class A 4-8TM

Class A300

Class A3-8TM

Class A300

Class S4-11TM

Class S3-11TM

Class S400 ifarticulated500 if not

Class S400 ifarticulated500 if not

External doubleleaf brick wall

Infill slab 100 mm thickF62 (F92 forbrittle floorcoverings)

Internal single leafbrick wall (loadbearingor non-loadbearing)

Compacted fill

Figure 7. Strip footings for articulated full

brick construction on class M site400

DPC

4-12TM

4-12TM

Pad footing minimumsize 400x 400x200 deep

Ant capping is only required in termite-prone areas

Internal brick walls, loadbearingand non-loadbearing

4-12TM

4-12TM

600

if ar

ticul

ated

, 900

if n

ot

650

500

400

“Local experience onknown stable sites may

permit thinner slabs and less reinforcing”

DPCDPC


9

BRICK PIERSPier construction for full brick issimilar to that in brick veneer and isillustrated in figures 8 and 9.

TERMITE CONTROLIn termite risk areas the BCA requiresattack to be controlled in accordancewith AS 3660.1-1995 Protection ofbuildings from subterranean termitesPart 1: New buildings. That standardrequires any structural material vulnerable to termite attack to beprotected. Therefore in a full brickhouse with a concrete floor and atimber framed roof, that frame mustbe protected, but no protection isneeded for the walls or floors.Under AS 3660.1 termite protectionfor full brick is identical to that forbrick veneer even though the materialrequiring protection is at least 2400mm above the termite barrier. Thissuggests that full brick houses areover-protected by the standard andare therefore super-safe from termite attack.

FIRE RESISTANCEAny external wall closer to a boundary than 900 mm is requiredto have an FRL of not less than60/60/60 when tested from the outside. The material with that resistance must extend to theunderside of a non-combustibleroof. Full brick construction easilysatisfies this requirement.A garage needs a similar FRL60/60/60 separation from the residence to which it is attached.This means that a full brick housewith a garage separated from it bya single leaf of clay brick masonrysatisfies the BCA requirements forfire resistance.For more information on this topicrefer to Design Manual 5, FireResistance Levels for Clay BrickWalls, published by the Clay Brickand Paver Institute.

FOOTINGS, SLABS, PIERS, TERMITE CONTROL AND FRLS

� Footing and slab design for full brick is very similar to that for brick veneer.

� Brick piers are virtually identical for full brick and brick veneer.

� Termite control measures are identical for full brick and brick veneer.

� Full brick construction easily satisfies regulation fire resistance requirements.


Figure 8. Isolated brick pierwith concrete footing

No tie-downor anchor boltrequired forfull masonrywall house

DPC above finished ground

Pad minimum thickness 200 mm

Ant capping only required in termite-prone areas

Figure 9. Isolated brick pierwith brick footing

250

Min

imum

hei

ght 1

500

(14

stan

dard

cou

rses

)

470

DPCbuilt intopier justabovegroundlevel (mortaraboveandbelowDPC)


10

BRICK WALLSSub-floor clay brick masonryThe construction of sub-floor claybrick masonry (figures 7, 8 and 10)is substantially similar to that in brickveneer. Masonry units used belowthe DPC shall be at least GeneralPurpose class but must be Exposureclass in a known aggressive environment. The provision of ventsunder suspended floors is shown in figure 10. It is also important toprovide for good air circulation byleaving openings in internal basewalls, large enough to also allowaccess to internal sub-floor spaces.

DPCs and cavity flashingsThe various forms of DPCs andcavity flashings are illustrated in figures 11, 12 and 13. These membranes should project beyondthe wall face during constructionbut may be cut off flush after themortar has set.

Figure 10. Cavity walls on strip footing with framed flooring and sub-floor vent

Vent

DPC

DPC

Omit brick at internal leafopposite vent positions

Ant capping is only required in termite-prone areas

Figure 12. DPC and cavity flashingsfor full brick walls

Figure 11. Slab edge rebates forcavity walls showing

DPCs and cavity flashings

MINIMUM EDGE STEP

ONE BRICK EDGE STEP

THREE BRICK EDGE STEP

First bedjoint &flashing15 mm

75 min.

150

90

200 minimum

150 minimum

150

min

imum

260

25 mm minimum step down

First bedjoint 4 mm

Flashing must finish flushwith outer face of clay brickmasonry so it is visible forthe full length of the wall

Mortar fill in cavitybelow flashing

Allow differential movementby placing 2 m lengths of DPCat each end of brick walls over10 m long built on slabs

Internal corner flashing foldedand lapped around corner

External corner flashingcut and folded at cornerwith separate lappingpiece inserted

Flashing turned 30 mm into innerleaf of clay brick masonry. Placeflashing material on dry bed jointsand put mortar bed on top.

Weep hole


11

Walling above the DPCThe bricklaying process for full brick varies little from that used inbrick veneer. Flush mortar joints are usually preferred internally foraesthetic reasons and becausethey eliminate dust-collectingledges and harsh shadow lines.Where render or sheeting finishesare to be applied, internal clay brickmasonry is sometimes laid withoutfilling the perpend joints. This iscommon practice in WesternAustralia.To reduce efflorescence and stainingit is good practice to cover the topof incomplete clay brick masonryduring breaks in construction untilthe roof is in place.Bonding of clay brick masonryabove the DPC is the straightforwardprocess of building everything inbond, including all intersectingwalls. Building up to toothings doesnot provide adequate bond strength.Where it is not possible to buildconnecting walls in bond by rakingback they must be tied with theequivalent of a light-duty tie in everysecond course.

Figure 13. DPCs for full brick walls on strip footings

DPC must finish flush withthe outer face of masonryon both sides

Build DPC into all piers onecourse above finished groundlevel. Sandwich DPC betweenmortar above and below in piers.

Lay DPC in walls with dry jointbeneath and mortar above only

Window and external door framescan be fixed after the masonry isconstructed but are usually built inas bricklaying proceeds with tiesand flashings as illustrated in figures14 and 15. Temporary protection offrames against damage or scratchingof finishes may be needed.Wall ties must be included at thecentres illustrated in figure 16 toprovide stability to the outer leaf.Particular attention must be given to the building in of extra ties atunbonded cross-wall intersectionsand at discontinuities such as window jambs and articulationjoints or control gaps.

“Flush mortar joints are usually preferred internally for aesthetic reasons”


12

Figure 14. External doors showing

lintel and flashing detailsand fixing of frames

Gal. steelflat lintel

Gal. steelangle lintel

Gal. steelflat lintels

Terrazzothreshold

Infill slabor frameddoor

TIMBER DOOR FRAME

Plugandscrewor nail

Headflashingswheneaves do not protectdoorhead

Boxed eave

Paver

Mastic bead

Change slab edgeat external doors

ALUMINIUM-FRAME SLIDING DOOR

Built-inlug ondoorframe

STEEL DOOR FRAME

Built-ingal. wireclip

Steeldoorframesupportsclay brickmasonry

Clay pavers mortared to slab as step

Figure 15. Lintel and flashing details

and fixing of window frames

Figure 16. Cavity wall tie positioning

and spacing

Gal. steelangle lintel Built-in

lintel

Splayed cutbrick sillwith 10 mmprojectionat low edge

Full-widthsill flashingfor exposedconditions/high rainfall

Re-barsbuilt intobed jointfrom lintel

Sill brickprojecting10 mmbeyondface ofclay brickmasonry

Headflashingrequiredwhenthere is no eave protection

Timbersill

Tile sillBrick-on-edge

sill

Built-inlug onwindowframe

Boxed eave

Splayedcut bricksill

Alternative sill flashing position

Recommendedsill flashingposition

Flashing 100 min.

Flashing 100 min.

Flashing 100 min.

Medium-duty wall ties at 600 mm centres (maximum) in body of wall. Ties at 300 mm average (400 mm maximum) centres at top edge around openings, at control gaps and at lateral supports

Control gap

Window opening

Lateral support (internal wall)Typical tie positions •


13

Walls subject to high windsIn those areas with design windspeeds of 28 m/s and above it is necessary to provide anchorage forthe roof. Details are provided in figures 17, 18 and 19.Where the design wind speed isabove 41 m/s it may be necessaryto reinforce the clay brick masonry.This is commonly done with externalwalls made from hollow units. (See figure 17.)

LintelsIt is common practice to leave agap in the mortar of about 10 mmat both ends of a steel lintel to allowit to expand without cracking theclay brick masonry. Reinforced claybrick masonry lintels can be used.

Figure 17. Reinforced hollow clay

units in high wind areas

Size and spacing of

vertical reinforcing

to engineer’s

detail

Starter bar

SINGLE-LEAF WALL of 140-150 mm thickclay masonry

Bond beam

Flashing

No edge stepor DPC forsingle-leafmasonry on slab

Bon

d be

am re

info

rcem

ent

to e

ngin

eer’s

det

ail

CAVITY WALL with inner leaf of reinforced140-150 mm thick hollow clay masonry

Figure 18. Roof tie down forhigh wind areas

Figure 19. Tie down to clay brick

masonry for tile or sheetroof in wind classification

areas W28 and W33

75 min.

See

engi

neer

’s d

etai

l for

req

uire

d tie

dow

n si

ze a

nd s

paci

ng

25 degree pitch

15 degree pitch

Soffitlined eave

25x1 mm(min.)gal. steelstrap at1800centres

10 mmrod builtin 50 mmboth sides

900

min

imum

(10

cour

ses

+ to

p pl

ate)

Three 30x2.8 mm nails

Three 30x2.8 mm nails

600 wide boxed eave

900

min

imum

(10

cour

ses

+ to

p pl

ate)

25x1 mm (minimum) gal.steel strap at 1800 centresbuilt in 50 mm minimum


14

Articulation jointsArticulation joints are vertical gapsin brick walls, or between clay brickmasonry and windows or doors, thatallow for minor footing movementswithout causing distress or significant wall cracking.Articulation joints provide the flexibilityneeded when building on reactiveclay soils. Articulation is not requiredfor clay brick masonry on stable sites.The basic design and constructionof articulation joints in the outer leafof a full brick house is similar to thatin a brick veneer. The principles areillustrated in figure 20.Where it is not possible to provideties to the other leaf on either sideof an articulation joint, it is necessaryto provide a structural connectionacross the joint. This is made withmasonry flexible anchors (MFAs)mortared into bed joints of claybrick masonry. See figure 21.Where MFAs are used in walls over3 m high or exposed to high winds,they must be built into the clay brickmasonry at half-height then at everyseventh course (600 mm) above.See figure 22. Articulation joints can usually be placed so that theyfunction also as control gaps.

BRICKLAYING BELOW AND ABOVE DPC

� Sub-floor clay brick masonry is very similar for full brick & brick veneer.

� DPC and cavity flashings follow the same principles as brick veneerconstruction.

� Bricklaying above the DPC varies little from brick veneer.

� Flush joints are preferred for internal face clay brick masonry.

� Bond or tie intersecting walls.

� Window and external door frames are usually built in during bricklaying and may need temporary protection.

� Tie across cavities with extra ties at openings, joints or gaps and atcross walls providing lateral support.

� Roof anchorage is necessary in high wind areas. Reinforcement isrequired above 41 m/s.

� Steel or reinforced brick lintels may be used.


Control gapsControl gaps are also called expansion gaps or joints and theirpurpose is to control differential andthermal movement of materials.They are essential in long runs ofclay brick masonry.The design and construction ofcontrol gaps in the external leaf of afull brick house is identical to that ina brick veneer. Except at re-entrantangles in long walls, control gapsare not usually required in internalclay brick masonry. Where an internalgap is required it can usually belocated at a full-height openingsuch as a door or window.

“Control gaps are not usually required in internal clay brick masonry”


15

Figure 20. Typical articulation joint locations

Alternative window lintel of timber or sheetedframe sufficient to carry top plate and roof loads.This acts as an articulation joint between the linteland clay brick masonry.

Lintel carrying clay brickmasonry with offsetarticulation joints atends of lintel

Articulation joint at full-height doors or windows.Note there is no articulation joint in clay brickmasonry below small window.

Full-height door openingacts as articulation joint

Articulation joint at (or within 600 mm of)internal corners

Alternative positions forarticulation joint 1-11/2 Hfrom external corners

Articulation joint atstandard-height door

Articulation jointsbelow the window

11 /2 H H H

Figure 21. Control and articulation

joint detailingFigure 22. Masonry flexible anchor in articulation joints and control gaps

Articulationjoints withcompressiblebacking andmasticsealant

Dividing wallwith articula-tion joint andMFAs atintersectionwith cavitywall

Brick ties inevery fourthcourse oneach side ofarticulationjoint

Articulation joint

Compressible foambacking strip builtinto dry verticaljoint. Cut foamaround MFA.

MFA set in bedjoint mortar

Mastic sealant

“Articulation is not required for clay brick masonry on stable sites”


16

DoorsFull height doors have many advantages in full brick construction:

• They are simple, neat and economical to build.

• They act as articulation joints.

• They allow for simple reticulationof electrical switch cabling.

The door itself can be full height oralternatively of normal height andhave a fixed panel of matchingthickness over it or the frame canbe made with a transom and fixedglass above the door leaf.With full height doors there is noneed to match opening widths tobrick sizes, but if they are to be ofnormal height with brickwork aboveit is important that both heights andwidths be compatible with brick sizes.Standard door height is 2040 mmso 24 courses of traditional bricksor 21 courses of modular bricksgive the required door openingheight while allowing for the framethickness.Door widths that match brick openings are given in table 2 and theconcepts are illustrated in figure 23.

Figure 23. Internal doors showing switch wiring

Articulation joint if required

Light switch cable

Light switch cable

Conduit and/or cablefor light switch

STANDARD-HEIGHT (2040)DOOR IN STEEL DOOR FRAME

FULL-HEIGHT DOORIN TIMBER JAMBS

24 courseheight

“With full height doors there is no need tomatch opening widths to brick sizes ...”

Brick length Frame type Door width Brick width Brick width(mm) (mm) opening (mm) opening (bricks)

Steel 720 730 3

Steel 820 850 31/2

Timber 770 850 31/2

Timber 870 970 4

Steel 770 810 22/3

Steel 870 910 3

Timber 720 810 22/3

Timber 820 910 2

Standard (230)

Modular (290)

Table 2.Optimum door width for standard-height doors


17

Steel door frames have been popular in commercial buildingsand home units and are increasinglyused in houses. They are readilyavailable with hinges fitted and canbe prepainted to match powder-coated aluminium window frames.Steel frames form a guide for brick-layers to build to and they increasethe sense of a strong, solid building.They do not require architraves,saving finishing time and cost.Basic steel frame sizes allow buildinginto 110 mm or 90 mm thick claybrick masonry with head heights tomatch 24 courses of standard bricksor 21 courses of modular bricks.Full-height steel frames are alsoavailable to order.Timber door frames are best withfull-height, floor-to-ceiling doors.When full-height timber frames areused it is best to finish the ceilingflush through the door openingwithout a frame at the top of thedoor. This way the timber doorjambs are simply two straight lengthsfixed to the clay brick masonry. The architraves covering the gapbetween frame and bricks are fourstraight pieces from floor to ceiling,eliminating mitre cuts in frames orarchitraves.Timber frames for standard 2040 mmhigh doors are widely available andrequire a flat steel arch bar to supportthe clay brick masonry above.

“Steel door frames ... do not require architraves, saving finishing time and cost”

ARTICULATION JOINTS, CONTROL GAPS, INTERNAL DOORS

� Articulation joints will usually be required on reactive sites.

� Articulation joints can also act as control gaps.

� Control gaps may be required in long runs of external clay brickmasonry but rarely in internal clay masonry

� Full height door openings have many advantages.

� Standard door sizes suit brick dimensions.

� Door openings can act as articulation joints.

� Steel door frames are inexpensive and solid.

� Timber door frames are best if full height.


Figure 24. Steel door frames

in cavity walls

Alternative steel door frames for cavity wall

Gal. wire clips built into bed joints

Articulation joints at standard-height doors When there is apotential for footing movement,stresses in the wall are concentratedat door heads and may causecracking at corners. An articulationjoint above selected internal doorswill help to solve this problem.The articulation joint should runfrom the door head to the ceilingand be a half-brick length awayfrom the side of the door frame.This gives a seat for the arch bar orclay brick masonry spanning theopening. See figure 23.External doors in cavity wallsSteel door frames in a cavity wallare illustrated in figure 24.


18

Brick cleaningThe cleaning of external clay brickmasonry in a full brick house isidentical to that of a brick veneer.Internal face clay brick masonry maybe acid cleaned. Neutralise afteracid cleaning and provide adequateventilation to ensure thorough dryingotherwise acid vapour may corrodeunprotected metallic and other susceptible objects. Follow localhealth and safety regulations.Prewetting the clay brick masonry isrecommended but do not saturatethe bricks — a light spray just aheadof the work in progress should besufficient.If internal walls are to be painted,mortar dags should be removed andthe walls hosed down with plainwater and allowed to dry prior topainting. The advice of the paintsupplier should be sought if wallshave been washed with a chemicalrather than water.

“Neutralise (internal face clay brick masonry)after acid cleaning and provide

adequate ventilation”


19

Internal wall finishesClay brick external walls do notrequire any finish to preserve theirfunction or appearance.In full brick construction all or someof the internal walls may be displayedas face brick. Clay bricks are naturallydurable and attractive and do notrequire the initial and ongoing costof additional treatment. Face brickis also economical as skirtings (andin many instances architraves) arenot required, reducing the amountof timber to be purchased, fitted,finished and maintained.Where other than internal face brickis desired a number of finishes areavailable: renders, board sheetingand paints. These can be appliedto full or dado height to selectedareas (for example specific walls or rooms) during construction or at a later stage, for instance duringrenovations.Where render, sheeting or wallpaperis used, service conduits or pipesmay be chased into walls. (Somestates permit electrical cable to beburied in the render.)Renders include:

• Float and set

• Exposed aggregate render

• Stucco/rustic

• Bagging

• Lime washThese are applied to the completedclay brick masonry by separatetrades (except bagging that is usuallydone by the bricklayer). Render fin-ishes are generally more expensiveand, except for exposed aggregaterenders and lime wash, also requirepainting. Bagging mortar may becoloured to eliminate painting.These finishes require more buildingtime as they must dry thoroughlyprior to any final paint application.Render finishes usually eliminatethe brick outline, the exceptionsbeing lime wash and, in somecases, bagging.

Sheeting requires fixing by trades-persons. There are four basicsheeting methods:

• Plasterboard is fixed by proprietaryadhesives directly to the clay brickmasonry. Alternatively it can befixed onto plasterboard packingpieces, battens or furring channels.Plasterboard requires painting.

• Fibre-cement board must be fixed to battens and also requirespainting.

• Timber, either sheeting or board,can be fixed to battens to full ordado height and can be painted or stained.

• Wallpaper may be hung on backing paper glued directly tothe clay brick masonry providingflush mortar joints have been used.

Paints Brick walls can be paintedwith any one of the many paintsavailable for masonry walls. Theseinclude standard acrylic or oil-basedpaints or thick (filler) paints designedto smooth uneven surfaces. Almostall paints require a sealer coat.

• Standard paints are suitable forclay brick masonry laid to facestandard.

• Standard paints may also be usedon non-face clay brick masonrywith filled, flush mortar joints.‘Sponged’ or ‘rubbed’ joints arealso suitable.

• Thicker paints are more suitablefor clay brick masonry that hasnot been laid to face standard.

• The paint manufacturer’s instructions must be followed.


20

SkirtingsSkirtings are not required on facebrick walls or walls that have beenbagged or lime washed. Otherwisesecure skirtings with wall plugs.

Wall/ceiling junctionA typical wall/ceiling junction using a standard cornice is shown in figure 25.

BRICK CLEANING AND INTERNAL FINISHES

� Neutralise after acid cleaning internal clay brick masonry and provide good ventilation

� No special finish is required for external clay brick walls.

� Some or all internal full brick walls may be displayed as face or finished.

� Finishes include render, sheeting, paint or wallpaper.


Figure 25. Typical wall/ceiling junction


21

Figure 26. Typical plumbing arrangements

CONCEAL PIPES BEHIND BATH AND VANITY

Tap holes in top

CONCEAL PIPES UNDER CUPBOARDS

150 mm

PROVIDE SPACE BEHIND CUPBOARDS

ServicesPlumbingDesigning and installing plumbingin a full brick house requires moreconsideration than in a framedstructure and minor changes in pro-cedure. Here are some guidelines:

• Position baths, sinks, basins andshowers on external walls so thatpipe runs to the outside are shortand can, where practicable, berun directly through the wall.

• Reduce chasing by hiding pipesbehind or under sinks, baths,vanities and basins.

• Choose baths, basins and sinksthat allow taps to be mounted onthe fitting rather than on the wall.

• Provide maintenance access tojunctions, traps and connectionpoints.

• Where chasing is necessary usea twin-blade masonry saw andrender or tile the area. Avoidinhaling dust containing silica.

Some typical plumbing options areillustrated in figure 26.


22

ElectricalAs with plumbing, electrical wiringrequires more consideration in a fullbrick design. With a little planning itis possible to wire a full brick housewithout chasing. Practices varyfrom state to state but here aresome guidelines:

• Position as many GPOs as possible on external walls.

• Where possible position GPOs inadjacent rooms back-to-back.

• Use full-height door frames toroute cables from the ceilingspace to the switch location.(See figures 23 and 24.)

• Use architrave-mounted switcheswhere possible. Alternatively usesurface-mounted switches locatedwithin 150 mm of the door frame.(See figures 23 and 24.)

• Route cable (through surface-mounted conduit if required byregulations) in cupboards andwardrobes.

• Have the bricklayer place flatplastic conduit in the bed jointsfrom door openings to the GPOor switch location.

• Flat conduit can also be used ina rendered wall although somestates still permit the cable to beburied in the render thickness.

• Conduit can sometimes be routedthrough the cavities in bricks orblocks.

Some of the electrical installationmust be carried out during bricklay-ing and the electrician may alsoneed to coordinate some aspectswith the bricklayer.

“With a little planning it is possible to wire a full brick house without chasing”

PLUMBING AND ELECTRICAL SERVICES

� Plumbing design and installation requires more consideration andminor changes in procedure.

� Reduce chasing by hiding pipes behind cabinets etc.

� When chasing, avoid inhaling dust containing silica.

� Choose fittings that allow taps to be mounted on them.

� Position GPOs on external walls or back-to-back where possible.

� Route switch cables through full height door frames.

� Route cable in cupboards and wardrobes or bury in render using flatconduit if required.

� Coordination between bricklayer and electrician is usually required.



23

The scheduling of trades for fullbrick construction will be differentfrom that for brick veneer. A typicalschedule is shown in table 3.

S C H E D U L I N G T R A D E S

Week 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Clear blockSet outCut & fillFormworkDrain rough-inTermite/level up piersReinforcementConcrete slabDrainsBricklayingRoof framingFascia, gutter, valleysRoofingChasingEavesElectrical rough-inPlumbingRenderingBrick cleaningPlasteringKitchenCeramic tilingJoineryPaintingElectrical fit-outPlumbing fit-outClean up

Note: This schedule is indicative only. Shading shows the period during which the activity is carried out.

MAY BE CARRIED OUT AT ANYTIME DURING THIS PERIOD

Table 3. Typical trades schedule for full brick house construction

MAY BE CARRIED OUT AT ANY TIME DURING THIS PERIOD


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