Commercial and Industrial Bricklaying

Module 6: Commercial and Industrial Bricklaying 

This module covers large-scale construction techniques, focusing on high-rise brickwork, cladding systems, and fire safety for commercial and industrial projects.

6.1 High-Rise Brickwork and Scaffolding Coordination

Key Challenges in High-Rise Brickwork

• Wind Load Resistance: Tall structures require reinforced cavity walls with vertical bed joint reinforcement (BJAR).

• Differential Movement: Steel frames and brickwork expand at different rates → slip joints and flexible ties prevent cracking.

• Mortar Selection: High-strength M12 mortar for lower floors; lime-enhanced mixes for upper floors to accommodate movement.

Scaffolding Best Practices

• System Scaffolding: Modular frames (e.g., Cuplok, Kwikstage) for stability at height.

• Loading Bays: Dedicated areas for material hoists to prevent scaffold overloading.

• Tied Scaffolds: Anchored to the building every 4m vertically, 6m horizontally (per BS EN 12811).

• Daily Inspections: Check guardrails, toe boards, and base plates before work begins.

Safety Tip: Use debris netting to prevent falling bricks/mortar.

6.2 Cladding Systems and Fixings

Brick Cladding Types

1. Traditional Brick Veneer:

• Non-load-bearing outer leaf with cavity ties (3-4 per m²).

• Requires stainless steel lintels and cavity trays for drainage.

2. Prefabricated Brick Panels:

• Offsite-manufactured panels craned into place → faster installation.

• Fixings: Embedded M16 threaded rods or brackets tied to the structural frame.

3. Rainscreen Brick Cladding:

• Ventilated cavity (50-75mm) behind brick slips for moisture control.

• Support Systems:

• Vertical Rails (aluminium/SS) with brick slip carriers.

• Adjustable Brackets for thermal expansion.

Critical Fixings & Tolerances

• Wall Ties: Stainless steel (Grade 304/316) with drip grooves to prevent water tracking.

• Expansion Joints: Every 12m horizontally to prevent thermal cracking.

• Fire Barriers: Mineral wool cavity barriers at floor edges to comply with Building Regs Part B.

Common Mistake: Incorrect tie spacing causes cladding bowing under wind loads.

6.3 Fireproofing Techniques for Commercial Buildings

Fire-Resistant Brickwork Strategies

1. Compartmentation Walls:

• 2-hour fire-rated brick walls (215mm thick with firestop mortar).

• Fireproofing Joints: Intumescent sealants around service penetrations.

2. Fireproof Cladding Systems:

• Brick Slips on Fire-Rated Boards:

• Calcium silicate boards (e.g., Promat) behind brick slips.

• Achieves REI 120+ (fire resistance for 120+ mins).

3. Structural Fire Protection:

• Encasement: Brickwork around steel columns (min. 100mm cover).

• Fireproof Mortar: Vermiculite-enhanced mixes for spray-applied protection.

Testing & Compliance

• BS 476-22: Fire resistance tests for walls.

• Euroclass A1: Non-combustible materials for high-rises (post-Grenfell regulations).

Case Study:

• A 30-storey London office used prefabricated brick panels with intumescent barriers, reducing on-site labour by 40%.

Why These Skills Matter

• Safety: Grenfell Tower Inquiry led to stricter cladding fire regulations.

• Efficiency: Prefabrication cuts high-rise construction time by 30%.

• Career Growth: Specialist brickwork contractors charge £50-£80/hr for commercial projects.

Practical Task:

• Draft a scaffolding and bricklaying plan for a 10-storey brick-clad office.