January 2020

BRICKWORK
AND MODERN
METHODS OF
CONSTRUCTION

Brick Development Association www.brick.org.uk

BRICKWORK & MMC 2

Contents Page

INTRODUCTION 03
MMC DEFINITIONS 04
HISTORY OF BRICKWORK MMC 05
SLIP PANEL SYSTEMS
- INDIVIDUAL SLIPS 06
- PANEL SYSTEMS 07
- RAIL AND TILE 08

PRECAST CONCRETE 09

PRE FABRICATED COMPONENTS 10

ROBOTICS 11

DESIGN & SPECIFICATION 12

REFERENCES AND FURTHER READING 15

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INTRODUCTION
In construction there is a continuous desire to build projects to a higher quality, on a
shorter timescale and at a reduced cost. The government's Construction Sector Deal
challenges the industry to reduce construction cost by 1/3 and construction time by 1/2,
whilst improving quality.
One of the key drivers identified to
achieve these targets is the development
and expansion of Modern Methods of
Construction. Brick manufacturers have
been at the forefront of developing MMC
systems for several years.
Clay brick has undergone a dramatic
transformation during the 20th century.
From solid wall construction to the
modern cavity wall, with improved levels of
insulation and reduced water penetration.
CAUTION REQUIRED
The sector needs to be mindful that during
the push for quicker and cheaper we don't
compromise the quality of what is built, as
has happened with previous attempts to
develop MMC. One of the principal benefits
of hand laid clay brick is that it has a very
long history of quality performance with a
large and proven supply chain.
Assessing when it is appropriate to
use a MMC system, to gain maximum Traditional solid wall construction
benefits, has historically been a complex
issue. Research from Richard Willetts at
the Facade Engineering department of
the University of Bath has made some
substantial recent progress.

Modern cavity wall construction Traditional brick detailing

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MMC DEFINITIONS
Historically the term Modern Methods of Construction has been used as quite a loose
term to describe all different types of construction system, construction components and
construction processes. MMC is not as well understood as the traditional construction
trades.
The Government's Joint Industry Working Group on MMC have produced a definition
framework to enable MMC within homebuilding to be better understood, with regularised
terminology. The definition framework spans all types of pre-manufacturing, site based
materials and process innovation.

MMC definition framework produced by MHCLG Joint Industry Working Group.

BRICKWORK MMC OPTIONS

MMC is probably most widely understood as fabricating building components, in factories
away from the site, but it can also cover a number of other systems and processes. The
term 'pre-manufacturing' includes processes completed away from the final installed
position, including in remote factories, near site or on-site 'pop up' factories. Brickwork
solutions fall into a number of categories including:
Category 1 - pre-manufactured 3D primary structure with brick slips.
Category 2 - whole wall build up & brick faced pre-cast concrete sandwich panels.
Category 3 - pre-manufactured lintels & arches.
Category 5 - pre-manufactured chimneys, balconies, decorative panels & soffit systems.
Category 6 - site applied brick slip systems, panel systems & precast concrete panels.
Category 7 - brick laying robots

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HISTORY OF BRICKWORK MMC

Brick making was introduced to the UK by
the Romans and their process for making
and laying bricks would be recognisable to
a modern day audience. One of the great
selling points for brickwork is the long
established reputation for durability and
robustness.
Throughout the history of the brick there
have been examples of the 'traditional'
brick unit being developed for specific
purposes.
MATHEMATICAL TILES
The 18th and 19th century saw the use
of mathematical tiles around Kent and
East Sussex. These are essentially an
overlapping brick slip system which would
have been fixed to a timber frame and
grouted to resemble brickwork.
These systems can be seen as a precursor
to modern day slip systems and share
much of the same design reasoning. Timber framed property clad in mathematical tiles

Glazed finish on mathematical tiles

Stretcher and header units Overlapping fixings onto timber frame

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BRICK SLIPS - INDIVIDUAL SLIPS

INDIVIDUAL SLIP SYSTEMS
Individual brick slip systems can cover a wide range of different uses, depending on the
required performance.
In the most simple scenario, brick slips can be used internally as a decorative finish. In this
scenario the wall build up and adhesive will be similar to the application of tiles. To ensure that
the slips replicate the effect of traditional brickwork it is important to follow the normal setting
out, for bonding and coursing.
Slips are placed individually, which has
the benefit of being able to accommodate
construction tolerances but requires some
skilled application.
Individual slip systems are also available
for locations with increased performance
requirements, including externally, where
they are often used as an over-cladding.
These systems will often include a backing
board or track, which will improve adhesion
and aid setting out.
Systems incorporating insulation can be
used for new build applications, or for
over-cladding existing buildings to improve Individual slips with track and insulation system
thermal performance. The insulation is
often supplied as part of a panel, pre-
bonded to a track sheet to provide a grid
for fixing the individual slips. Alternatively
the slips may be bonded directly to the
insulation.

Mesh backing board to improve adhesion Brick slips used internally

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BRICK SLIPS - PANEL SYSTEMS

PANEL SYSTEMS
Panel systems are brick slips bonded to a rigid backer board or panel. Panel based systems
are normally pre-manufactured and supplied with the brick slip already attached (sometimes
pre-pointed). The main benefits are that brick bonding is completed under controlled factory
conditions and speed of install is increased on site.
The specification of boards/backers used can vary significantly in terms of weather tightness,
moisture absorption and fire performance, the panel shapes can be standard or bespoke and
of varying aspect ratio and size; their design influences the handleability and installation on
site. How panels are joined and aligned is also critical to the eventual finish, so construction
tolerances must be co-ordinated.

Panel system on 3D primary structure

Typical brick slip panel system Panel system corner profile

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BRICK SLIPS - RAIL AND TILE SYSTEMS

RAIL AND TILE SYSTEMS
This is a group of systems where metal rails are fixed back to a supporting frame on site,
and brick components are clipped or slotted into the rail. This can produce a mechanically
retained slip, with no reliance on adhesive, which makes them non-combustible and therefore
suitable for use on high-rise projects. The potential for performance variation is in the material
the rail is made from, including any coatings applied, the design of the rail and the brick.
The decreased weight of construction and reduced wall thickness, when compared to hand
laid brickwork, means that the benefits are enhanced as the number of storeys increases.
These systems are typically used for high rise construction and specific details, such as
balconies or dormers.

Window reveal detail

Curved profile Rail system to achieve mechanical fixing

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PRECAST CONCRETE
PRECAST CONCRETE
These panels are generally not considered
to be a rainscreen system. Whole wall
build-ups, including cavity and insulation
are possible, which can dramatically speed
up construction and benefit sites that
suffer from challenging logistics. Although
they create their own issues of increased
design coordination and less flexibility for
changes.
Precast systems can also be used to create
details that would not be possible with
hand laid construction, which has opened
up a new language for brick architecture.

Precast panels with engineering bricks Precast panels to create details unachievable in hand laid construction

Panels can be fixed to a variety of frame types

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PREFABRICATED COMPONENTS
STRUCTURAL COMPONENTS
The most widely used structural components are lintels and arches. Sometimes these
will be a single material but more usually they will be a composite of steel or concrete and
brick slips. A more recent development is prefabricated brickwork wall panels. These are
factory formed brick and mortar walls that can be craned and transported as a unit and
then positioned on site, eliminating the need for bricklayers on site.
The use of structural components can reduce the complexity of construction required on
site and the amount of formwork and falsework required for construction.

Brickwork soffit system

NON-STRUCTURAL COMPONENTS
Non-structural components tend to be used
to reduce the complexity of construction
required on site, but don't form part of the
primary building structure.
The use of these components essentially
shifts the construction time required on site Pre-manufactured chimney

to an off-site manufacturing location. Early

engagement with a manufacturer is essential
to ensure that construction time and quality
improvements are realised.
Some of the most well known examples are
pre-manufactured chimneys, which can be
lightweight and allow quicker installation. The
labour time for complex decorative panels
can also be shifted off site if it is beneficial
for the construction sequence.
Some non-structural components, such as
soffit systems, enable new types of design
solution. Single skin prefabricated brickwork

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ROBOTIC CONSTRUCTION
CURRENT SOLUTIONS
Bricklaying robots have been developed
which can replicate some of the more
repetitive elements of bricklaying. SAM 100
is one of the most well developed solutions
available and consists of automated arm
on a track, which places the brick with
mortar already applied.

Sam 100 Bricklaying robot in action

ALTERNATIVE APPROACHES IN DEVELOPMENT

The currently available solutions have limitations to their widespread use due to the high
capital costs and required enabling works. An alternative 'relative robotics' approach
uses a smaller scale robot, which can move over the brickwork and build as 'swarms'.
Both approaches require digital modelling of the project which can enable other benefits,
such as reducing waste and optimising deliveries.

Developed prototype ready for site trials Prototype for relative robotics

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DESIGN AND SPECIFICATION

MMC SUITABILITY
Once the decision has been made to proceed with a brickwork design solution, the
evaluation to determine whether a hand laid or MMC option is appropriate can begin. It
is important that the evaluation is holistic and project specific including; cost, speed of
construction and quality.
It is impossible to have a 'one size fits all' approach to projects and the most efficient
solution may be a combination of hand laid and MMC.
INSTALLATION AND PROJECT LOGISTICS
One of the key principles of brickwork MMC
is to increase the construction speed on site,
by reducing complexity or transferring the
process to an offsite location.
This is a potential benefit for projects with a
time critical construction programme, such
as schools.
Holistic evaluation is required however, as interdependent factors such as delivery, storage,
distribution, crane availability and the possibility to work on multiple construction activities
concurrently will also impact the critical path and overall project performance.
Hand laid construction utilises the well-established supply chain of bricklayers, and whilst
most MMC solutions can reduce the required installer skill, other MMC solutions require
alternative specialist skill sets. The availability of appropriately skilled labour should be
carefully considered.
LEAD-IN TIMES
Traditional hand laid construction typically has short lead-in times and ready availability
compared to other facade systems. The installation time for MMC systems will often be
quicker than hand laid construction however. The different lead-in time will vary the point at
which capital outlay is required. Finally, the lead time will also impact when the design needs
to be frozen.
For MMC solutions to be beneficial, the holistic time and cost benefits need to be greater
than those achieved by hand laid construction.

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DESIGN AND SPECIFICATION

PROJECT SCALE
Larger and more repetitive projects will typically maximise the benefits of using MMC. This is
because the accumulated benefit of each element can be such that they outweigh the extra
coordination required to move the fabrication/construction off-site.

COMPLEXITY OF DETAILING
The complexity and the repetition of the
brickwork detailing can influence whether
MMC will be beneficial. Individual slip and
panel systems will achieve the greatest time
savings when the detailing is simple and
repetitive.
Conversely if the detailing is complex and
repetitive then precast or pre-manufactured
components may result in a time saving over
hand laid construction.
WEIGHT OF CONSTRUCTION
In particular areas, such as gable ends
and balconies, reducing the weight of the
construction can allow the primary structure
to be reduced because less weight needs to
be supported.
For these areas, individual slip systems
and panel systems can reduce the weight
whilst blending in with hand laid panels of
brickwork.

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DESIGN AND SPECIFICATION

THERMAL PERFORMANCE
For refurbishment and over-cladding of
existing structures MMC slip systems can
offer an effective solution.
Historic buildings have little or no
insulation, so the use of a slip system
incorporating external insulation can be a
way of improving the facade performance,
whilst retaining the attractive appearance
of brickwork.
COMPLIANCE AND LIFESPAN
There are a number of different
manufacturers producing MMC systems.
It is important to ensure that the specified
system is appropriate to the risk class of
the project.
Third party assessment, such as BBA
certification or BSI kite mark can be a
useful indication. A positive factor for hand
laid brickwork is the long life expectancy
and minimal maintenance. Some MMC
solutions will not match this long-term
performance so care should be taken
during specification to ensure that design
life of the system is appropriate.
BRICK RETENTION
Generally this is not a risk for certified
MMC systems. However for individual
components and composite systems, it
should be confirmed that they are suitable
for use in the designed location.
Good installation controls are required
to ensure that systems are installed as
tested. Poor workmanship or installation
in unfavourable weather conditions can
affect the performance and appearance.
FIRE AND COMBUSTIBILITY
Brickwork MMC systems will need to comply with the ban on combustible materials
above the regulated height threshold and not contribute to the spread of flame below
this height.
All systems and components must be evaluated by a suitability competent person who
understands the wider fire life safety design and construction strategy.

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REFERENCES AND FURTHER READING

Characterising the Performance of Thin Brick Facade Systems to enable more Informed Design Choices for Specifiers. Richard
Willetts, 2018/19. MSc Architectural Engineering: Façade Engineering. The University of Bath, Department of Architecture and
Civil Engineering.

EN 771-1, Specification for masonry units Part 1: Clay masonry units

BS EN 845-1, Specification for ancillary components for masonry – Part 1: Ties, tension straps, hangers and brackets

BS EN 845-2, Specification for ancillary components for masonry – Part 2: Lintels

BS EN 845-3, Specification for ancillary components for masonry – Part 3: Bed joint reinforcement of steel meshwork

BS EN 998-2, Specification for mortar for masonry – Part 2: Masonry mortar

BS EN 1990, Eurocode – Basis of structural design

BS EN 1996-1-1, Eurocode 6 – Design of masonry structures – Part 1-1: General rules for reinforced and unreinforced masonry
structures

BS EN 1996-1-2, Eurocode 6. Design of masonry structures. General rules. Structural fire design

BS EN 1996-2, Eurocode 6 – Design of masonry structures – Part 2: Design considerations, selection of materials and execution
of masonry

BS EN 1996-3, Eurocode 6. Design of masonry structures. Simplified calculation methods for unreinforced masonry structures

PD 6697, Recommendations for the design of masonry structures to BS EN 1996-1-1 and BS EN 1996-2

BS 8000-3, Workmanship on building sites – Part 3: Code of practice for masonry

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