Brick cladding

The Novabrik brick cladding system

Novabrik, an innovative rain-screen, brick cladding system, which can replace conventional brickwork in many building applications, has recently been launched. It is an entirely dry form of construction requiring no mortar or conventional bricklaying skills to install.

Novabrik comprises brick-sized slips which lock together to form a weather-proof outer skin for timber-framed, steel-framed or concrete panel structures. The system is equally suited to use with conventional block-work walls or insulated concrete formwork (ICF) systems. Its interlocking construction works in a similar manner to tiling, with units overlapping to prevent water from penetrating the wall. The mortar-less construction creates a breathable skin that promotes free flow of air into the cavity, thus removing any moisture coming in from the outside.

Manufacturing Process

Manufacture takes place in a closed factory environment to ensure consistency of production throughout the year. Semi-dry concrete is delivered to a Besser semi-dry block plant through an automatic batching system which uses Hydronix microwave technology to ensure that the moisture content is consistent. C-grade, granular pigment, supplied by Lanxess (formerly Bayer), is added to the mix using a Kimido automatic pigment dosing system. A water repellent is also added to control efflorescence and reduce water absorption of the concrete. Water absorption of less than 6% is achieved which gives excellent product durability and resistance to freeze/thaw action. An admixture is also added to give a high early strength and improved compaction of the concrete.

Depending on the final colour of the product – Novabrik is available in eight colours ranging from Basalt, a dark charcoal, through to Classico, a white shade – concrete is produced using either grey or white cement. White cement is incorporated when lighter shades are required, otherwise grey is used. The semi-dry concrete mix is vibrated in steel production moulds to achieve a high-density concrete of 2275kg/m³ and a minimum compressive strength of 25MPa. Each cycle produces 32 Novabrik. The product is made as 16 pairs which are mechanically split after curing. After each production cycle, the units are transferred to steel pallets and placed in a racking system and carried automatically to a curing chamber which is maintained at a constant temperature of 35°C and a minimum humidity of 80%.

After 48 hours in the curing chamber the units have gained sufficient strength for splitting. An in-line splitter system, designed by Besser, is used to automatically split the Novabrik and marshal them ready for cubing. The 32 units are kept in their matching pairs to prevent movement and consequent face abrasion during transit. The Novabrik units are cubed and palletised with horizontal straps applied to each row and the finished cube covered by stretch film. The wrapping film completely envelopes the product as well as the pallet so that the product is fully weather-protected.

Installation on site .

Units are laid dry in conventional brick-bond onto a purpose made UPVC starter-track, with every fourth course mechanically fixed to vertical battens using proprietary fixings. Cutting is readily achieved with either wet or dry bench-sawing the preferred method, so on-site waste is kept to a minimum. Only a small number of ‘specials’ are needed to accommodate internal and external returns, angles etc. These are made on the same production equipment and are produced in multiples to ensure colour consistency. This approach means that take-off is very straightforward, specialist installation skills are not required and bought in trades are minimised.