When all else fails read the instructions

1st EDITION 2008

Section C

BRICKLAYERS Manual

Section C - BRICKLAYER
C1

Building walls with ecobrick

C1.1

General Notes

Construction of brick walls in both residential and commercial buildings are covered by the relevant
sections in the Building Code of Australia, AS3700-2001 Masonry Structures (and all amendments and
supplements since 2001), AS1684-2006 the Residential Timber framed Construction Standard and
AS1170.2-2002 Minimum Design Loads on Structures [known as the SAA Loading Code] plus any
other relevant codes and standards.

This information is provided on the basis that the wall is being built by a person trained and skilled in
the art of bricklaying and conversant with the requirements of the relevant building codes and practices
outlined above.

The intention of these notes is to provide helpful information and to highlight variations to standard
bricklaying practice.

C1.2

Wall Types

Cavity Walls

ecobrick can be used for cavity wall construction. The cavity walls can be made up from the following
combinations - Clay - ecobrick; ecobrick - ecobrick or ecobrick - framed.

ecobrick can be used externally but will require surface protection with either render or appropriate paint
finishes.

Single leaf walls

Single leaf walls comprise internal walls for residential building and as partition walls for commercial/
industrial buildings. Construction techniques are similar for both types of wall systems though structural
and support systems may vary depending on application.

C1.3

Wall Loads

ecobrick is a load bearing wall when specific height and load considerations are met. [Refer AS1684 and
AS1170 for specific construction details).

Generally ecobrick is a brick product appropriate for the loads associated with single level construction.
ecobrick cannot withstand the high compressive loads associated with multilevel load bearing
construction.

Walls to be built in high wind load areas must conform to the relevant designs codes of those
locations.

See Carpentry Section for specific roof attachment details.

C2

Practical Issues

C2.1

Transport and Storage

Being a cement based product the exposed surface ecobricks can and will be affected by long
term exposure to moisture/water. ecobricks are generally delivered to site covered in plastic is it is
recommended to keep them covered until just prior to use.

C2.2

Cement or Mortar

Builders Choice Thin Bed mortar to a finished mortar joint of 3mm thick is one recommended
method to bond ecobricks together.

The Thin Bed mortar powder is mixed with water to a form a loose paste, which can then be applied
with a standard bricklayers trowel or a specialised notched trowel.

As the mortar open time is short, it is preferable to lay only one or two ecobricks at one time rather than
trying to lay a line of bricks. We recommend that you clean up with water before the mortar has dried,
otherwise it may have to be removed by mechanical means. [Available from ecobrick]

Builders Choice AAC Cement is specialised cement that is another method to bond ecobricks
together. AAC Cement is mixed with sand and lime to form thick mortar. The mortar is applied with a
standard bricklayers trowel to a joint of 10mm.

The ratio for this mortar is 6 parts bricklayers sand, 1 part AAC Cement and 1/3 Lime and is used in the
same way a standard bricklaying mortar is used. We recommend that you clean up with water while the
mortar is still moist, otherwise it may have to be removed by mechanical means. [Available from ecobrick
and BGC builders supplies]

C2.3

Wet ecobrick

Observation is the best way to gauge the level of moisture in an ecobrick. A dry ecobrick is a light grey/
pink in colour and has a bright appearance and feels quite light when picked up.

A wet ecobrick has a dark dull grey appearance and feels quite heavy when picked up. Do not plaster a
wet ecobrick but allow sufficient time for the bricks to dry out before plastering. [Drying time will depend
on ambient temperature conditions and could be up to 7 days]

The bricks will not deteriorate but applying cement based mortars and renders to wet bricks will cause
drummy plaster or plaster to fall off a wall once the bricks dry out.

C2.4

Cutting

ecobrick is a light-weight concrete product and can be safely cut with a standard timber or metal saw,
or with hand tools like brick bolsters and chisels.

For large numbers of bricks, we recommend that you use a tungsten tipped saw. Alternatively, if you
wish to use a brick cutting machine or angle grinder, you may do so as long as the grinder has suitable
dust collection equipment connected.

A hand chisel is suitable when chasing out a wall, although power tools can also be used so long as
there is a dust collecting device attached.

C2.5

Dust Exposure

As ecobricks are a cement based product, unprotected long-term exposure to the cement dust is not
advisable. When using power cutting tools, please remember that it is a health requirement to use dust
extraction equipment connected to the cutting tool.

C3

Cavity Wall Systems

TYPICAL CROSS SECTION OF A DOUBLE BRICK CAVITY WALL

Wall 1

Wall 2

Masonry external leaf with

ecobrick internal leaf.

ecobrick external wall with

ecobrick internal leaf.

Tile roof

Insulation

Metal roof

Insulation

7. Top plates

6. Lintels
Weep hole

Weep hole
5. Windows & Doors
Single Glazing

Single Glazing

2. External render
3. Internal finish

3. Internal finish

4. Wall ties
Weep hole

Weep hole
1. Damp proof course

Waterproof membrane and white ant protection

Information
Instruction

General cross section [not to scale]

Drawings are for illustrative purposes only

C3.1

Damp Proof Course

The intention of a damp course is to prevent the movement of moisture up into the wall structure. The
damp course is an integral part of any external wall system irrespective of wall material.

The damp course can be either mechanical or more commonly a cement based compound.

Mortar Types

Two methods of assembling ecobrick are available.

Builders Choice Thin Bed Mortar - mixed with water to a paste will provide a 3mm mortar joint.

Builders Choice AAC cement mixed with sand and a small portion of lime will provide a 10mm mortar
joint. The ratio is 6 x sand to 1 of AAC cement to 13 lime.

Builders Choice Thin Bed Mortar is the mortar system required to achieve a four (4) hour fire rating for an
ecobrick wall.

Mortar for non ecobrick walls, to other masonry manufacturers specifications.

C3.2

External finishes
1.

ecobrick walls will require the application of a render or paint finish to protect the surface.
See Plasterer Section for more detailed recommendations.

2.

Clay masonry walls will not generally require any surface treatments.

Note: The external render on an ecobrick wall must finish at or above the damp proof course.

C3.3

Internal Finishes

ecobrick can be finished with a plaster and set finish or a plasterboard system. See Plasterer Section for
more detailed information.

C3.4

Wall ties

Cavity walls

Clay/ecobrick wall combination used with Builders Choice AAC cement can be tied together using
standard wall ties used in accordance with AS3700. The recommended spacing of ties is at 600mm
centres for normal walls and at 300mm vertical centres around openings and no further away that
120mm from openings.

ecobrick/ecobrick walls assembled with Builders Choice Thin Bed Mortar should use spiked ties that
are hammered into the each leaf of the wall. Spacing of the ties as per AS3700 indicated above.

Internal Walls

Intersecting walls should be butt jointed using flat strap connectors placed at every joint. The strap
should be embedded at a minimum distance of 90mm.

Tying into other construction materials.

ecobrick can be tied into existing masonry, steel or concrete members by securely attaching a steel
strap to the existing material and then ensuring this strap extends into the ecobrick mortar joint to a
minimum depth of 100mm.

C3.5

Windows and doors

Installation of window and doors follow standard practice as outlined in the Australian Window
Associations handbook . An industry guide to the correct installation of windows and doors. [Copyright
2006 - Australian Window Association]

Copies available AWA or to HIA members on HIA website.

C3

Cavity Wall Systems [Cont.]

C3.6

Lintels

Steel lintels are recommended for all openings.

C3.7

Fixing top plate and stick roof or trusses

See Carpenters Section for detailed information.

C3.8

Movement joints, joining walls & lintels

Movement joints are required in ecobrick walls to allow for expansion and contraction of the building
materials through normal thermal and structural movements in buildings.
The nominal length of a continuous wall before a expansion joint is required is 6 metres.
Should the wall be continuous and have corners then there should be an expansion joint within 3
metres of the corner.
Expansion joints should include an expanding connector to tie the walls together and the gap filled
with polyurethane backing rods and mastic.
Openings included in walls should have steel lintels fitted to support the brickwork. The lintel should
extend at minimum of 300mm onto the supporting brickwork.
Supporting a lintel on the 90mm width of wall is permitted only if no additional unsupported loads are
applied above the lintel and the load is spread. [Point loads are not recommended]
Expansion joints are required in external rendered walls and a weather resistant mastic is to be used
to ensure a waterproof joint.
ecobrick walls bonded to ecobrick walls at junctions with the appropriate connectors unless it is a
movement joint.
Bonding ecobrick to dissimilar wall materials a separation of the materials is essential through the use
of appropriate connectors with the resultant gap filled with polyurethane backing rods and finished
with a mastic.

C3.9

Structural Loads - Cavity Walls

There are any number of variables with cavity walls ranging from a suitable foundation and footings to
the number and size of openings in a cavity wall.

This document is not able to deal with all these variables.

C3.10

Recommendations

Our recommendation is that any cavity wall with or without a structural load should to be designed by
an appropriately qualified structural engineer to suit the service conditions of the project.

C3

Cavity Wall Systems [Cont.]

TYPICAL CROSS SECTION OF A VENEER CONSTRUCTION

Wall 3

Wall 4

An ecobrick external leaf with framed internal leaf.

A framed external wall with ecobrick as the

internal wall.

[The typical brick veneer wall]

[A reverse veneer wall]

Tile roof

Metal roof
7. Top plates

Bulk insulation
Weep hole

Single Glazing

6. Lintels
Single Glazing

2. External render

3. Internal finish
5. Windows & Doors
Bulk insulation

Weep hole

4. Wall ties
1. Damp proof course

Waterproof membrane and termite protection

Information
Instruction

General cross section [not to scale]

Drawings are for illustrative purposes only

3. Internal finish

C3.11

Damp Proof Course - Cement Mortar

The intention of a damp course is to prevent the movement of moisture up into the wall. The damp
course is an integral part of any external wall system irrespective of wall material.

The damp course can be either mechanical or more commonly a cement based compound.

Mortar Types

Two methods of assembling ecobrick are available.

Builders Choice Thin Bed Mortar - mixed with water to a paste will provide a 3mm mortar joint.

Builders Choice AAC cement mixed with sand and a small portion of lime will provide a 10mm mortar
joint. The ratio is 6 x sand to 1 of AAC cement to 13 lime.

Builders Choice Thin Bed Mortar is the mortar system required to achieve a four (4) hour fire rating for
an ecobrick wall.

Mortar for non ecobrick walls to other masonry manufacturers specifications.

C3.12

External finishes

Masonry walls will not generally not require any surface treatments.

ecobrick walls will require the application of a render or paint finish to protect the surface. See the
Plasterer Section for more detailed recommendations.

Note: The external render on an ecobrick wall must finish at or above the damp proof course.

ecobrick can be finished with a plaster and set finish or a hardwall system. See Plasterers section for
more detailed information.

C3.13

Internal finishes

ecobrick can be finished with a plaster and set finish or a hardwall system. See the Plasterer Section for
more detailed information.

C3.14

Wall ties

Cavity walls

A veneer/ecobrick wall combination can be tied together using standard wall ties used in accordance
with AS3700. The recommended spacing of ties is at 600mm centres for normal walls and at 300mm
vertical centres around openings and no further away that120mm from openings.

Reverse veneer walls should use spiked ties that are nailed to the frame and hammered into the ecobricks.
Spacing of the ties as per AS3700 shown above.

The wall ties will vary according to the type of mortar used to assemble the ecobrick wall.

C3.15

Internal Walls

Intersecting walls should be butt jointed using flat strap connectors placed at every joint. The strap
should be embedded at a minimum distance of 90mm.

C3.16

Tying into other construction materials

ecobrick can be tied into existing masonry, steel or concrete members by securely attaching a steel strap to
the existing material and then ensuring this strap extends into the ecobrick mortar joint to a minimum depth
of 100mm.

C3

Cavity Wall Systems [Cont.]

C3.17

Windows and doors

Installation of window and doors follow standard practice as outlined in the Australian Window
Associations handbook . An industry standard to the correct installation of windows and doors.
[Copyright 2006 Australian Window Association]

C3.18

Lintels

Steel lintels are recommended for all openings .

C3.19

Fixing top plate and stick roof or trusses

See the Carpenter Section for detailed information.

C3.20

Construction Joints and Horizontal Slip Joints

Movement joints are required in ecobrick walls to allow for expansion and contraction of the building
materials through normal thermal and structural movements in buildings.
The nominal length of a continuous wall before a expansion joint is necessary is 6 metres.
Should the wall be continuous and have corners then there should be an expansion joint within 3
metres of the corner.
Expansion joints should include and expanding connector to tie the walls together and the gap
filled with polyurethane backing rods and mastic.
Expansion joints are required in external rendered walls and a weather resistant mastic is to be
used to ensure a waterproof joint.
Openings included in ecobrick walls should have steel lintels fitted to support the brickwork. The
lintel should extend at minimum of 300mm onto the supporting brickwork.
Supporting a lintel on the 90mm width of walls is permitted only if no additional unsupported loads
are applied above the lintel and load is spread. [Point loads are not recommended]
ecobrick walls bonded to ecobrick walls at junctions with the appropriate connectors unless it is a
movement joint.
Bonding ecobrick to dissimilar wall materials a separation of the materials is essential through the use
of appropriate connectors with the resultant gap filled with polyurethane backing rods and finished
with a mastic.

C4

Single Wall Systems

C4.1

General Notes

Single width ecobrick walls are common in residential buildings to reduce noise transmission and
improve thermal efficiency.

The commercial application of ecobrick single walls are for partition walls, screen walls and to act as fire
screens due to the four (4) hour fire rating.

Long lengths of single leaf walls will require expansions joint and in heights over 2.00 metres will require
lateral support.

C4.2

Building a single leaf wall

The following charts have been prepared from AS3700 Masonry Structures Code and indicate the
height to length ratios under the specified conditions.

10

The following ratios are based on the assumption that

The wall is to internal only and the data applies to walls in a wind classification are of N2 (40m/s).
The wall is in a single story building with the top of the wall laterally restrained by the roof and
without any openings.
The data is based on not having any intermediate support for the full height of the wall.
External walls in high wind load areas must conform to the SAA Loading Code for the geographic
area.
This information cannot be used for fire walls as each fire wall is specified for a very specific
application.
Table 1 is suitable to be used where there are no immediate supports for the wall for its entire height.
Table 2 is to be used in situations where a ceiling frame is securely fastened to the wall at between 2.4m and
2.8m above the base of the wall.
Table 1

Table 2

Maximum Height

Maximum
length between
intersecting walls

Maximum Height

Maximum
length between
intersecting walls

4.5m

8.5m

4.5m

7.5m

5.0m

8.5m

5.0m

6.5m

5.5m

8.5m

5.5m

6.0m

6.0m

8.5m

6.0m

5.5m

6.5m

8.0m

6.5m

5.5m

7.0m

7.0m

5.0m

7.0m

C4.3

Single Wall Support Systems

Single leaf ecobrick walls can used for internal partitions in commercial or industrial buildings.

C4.4

Starting the wall

These walls should always be started used a cement based mortar. The use of a cement based mortar
is the ensure the first course is laid level. Ecobricks have a consistent shape and size which means all
other course will remain level. In the case of excessive undulations a C channel fixed to the floor may
offer an alternative level base for the first course.

C4.5

Supporting long lengths of wall

Walls can be supported by the placement of piers or columns at the nominated intervals.

Another method is to use lightweight C section and H section channels supported at both ends of
the C or H section channel.

NOTE

Using lightweight channels is conditional on the channels being secured to a wall or if used centre wall,
being secured top and bottom.

11

C5

Low Wall Systems - Garden

ecobricks can be used as a garden wall if the following general conditions are followed. A garden wall
would be used as a surround for a garden bed and should not exceed 800mm in height or 200mm in
length (unsupported).
The foundation (earth) is compacted to form a stable and solid base for the wall.
A solid footing should be included for a garden walls greater than 400mm in height. ecobrick laid
on the flat can be used as that footing and should extend past the proposed wall thickness by a
minimum of 200mm on either side of the wall.
An 800mm high wall should not be free standing over two (2) metres in length.
Either intersecting walls or piers should be used to ensure stability.
To enhance the life of the wall and aesthetics it is suggested that a render or paint finish be applied
to the completed wall.
Note: The above description is a general description of the requirements for a low garden wall and
should this description not be appropriate your circumstances we suggest you seek professional help.

C6

Low Retaining Walls - general description

ecobrick is a light weight material but it can be used for retaining loose materials, like builders sand, to a
height no greater than 800mm. The lightness of ecobrick itself can be partially compensated by the use of
additional bricks to make the wall thicker.

Ecobrick retaining walls are not suitable for heavy soils (clay), gravel, rocks or materials that have a high
degree of slump.

Note: The minimum brick dimensions for a low retaining wall are the 600mm long x 200mm high and
200mm thick.

See Diagram 1.

The following information is a general guide only and should be used in conjunction with engineering
advice for your particular location.
The foundation (earth) is compacted to form a stable and solid base for the wall.
A solid footing should be included for all walls. ecobrick laid on the flat can be used as that footing
and should extend at least 500mm past the base on the wall on either side of the wall to help resist
the possibility of tipping over.
As a general rule going one brick up means going one brick out starting at the base of the wall.
e.g. each brick is 200mm square so by going up four bricks high means the base layer is four
bricks wide minimum. See Diagram 2.
Retaining walls should be constructed so that the bricks are interlocking to improve the wall
strength. A four brick wall does not mean the four bricks are laid side by side but some are laid at
right angles to each other to help lock the wall together. See Diagram 3

12

Diagram 1
Minimum brick size 600mm x 200mm x 200mm

Diagram 2
Standard detail for generic low ecobrick retaining wall.

Maximum and only allowable height will be 800 mm (4 bricks) bricks to be adhered with Builders Choice AAC
cement. The general rule is that going up one brick means going out one brick.
So a wall made from four bricks 200mm high should be at minimum dimension of 800mm at the base layer.

Diagram 3
Interlocking wall.

Plan view - base layer (first layer on top of footings).

Plan view - second layer on top of base layer.

Note: It is recommended that prior to building a retaining wall advice is sought from your local council and a structural engineer
about soil conditions and the most appropriate construction method for your particular locality and material to be retained.

13

C7

Fire Rating

C7.1

General

The ecobrick material has been tested by the CSIRO and been proven to withstand naked flame for
four hours.

C7.2

Construction

An ecobrick fire rated wall is constructed using normal wall construction techniques.

The fire rating quoted in the CSIRO certificate 603 is based on using a thin bed mortar system to adhere
the bricks together.

The primary consideration is to ensures all mortar joints are filled to ensure no air movement is possible
to prevent the movement of smoke or fire though these spaces.

C7.3

Protecting other Materials

Steel columns and steel work should be literally encased with the ecobricks to protect the surface for
the fire. The ecobrick will be connected to the steel using flexible connecting straps to ensure movement
stress is not transferred. Any movement joints required to allow for expansion and contraction should be
sealed with a fire proof mastic.

Clay or concrete walls are treated in the same way as steel and the use of flexible connecting straps is
recommended. Any movement joints required to allow for expansion and contraction should be sealed
with a fire proof mastic.

C7.4

Wall penetrations

Wall penetrations for supply of services will require appropriate fire rated products and must be used
and the manufacturers instructions.

Penetrations for the windows and doors must use fire rated products and be installed to the manufacturers
instructions.

C7.5

Expansion joints & dissimilar materials

To ensure dissimilar materials can expand and contract to accommodate the movement we recommend
the use of a polyurethane mastic system. The Sika Firerate PU product has an equivalen 4 hour fire
rating to the ecobricks. [Other mastics may be suitable so we suggest consulting the manufacturers
specifications to ensure the mastic is approprate for AAC bricks prior to use.]

More detailed information is available in the ecobrick Technical Data File - Fire Rated walls E1.

14

C8

Acoustic Walls

C8.1

General requirements

The construction of an ecobrick to be used as an acoustic wall requires normal construction methods.

To achieve highest acoustic values all of the joints must be filled with mortar including any connecting walls.

The ecobrick acoustic testing was conducted using a cement based mortar.

C8.1

Wall penetrations

Wall penetrations for supply of essential services will require an appropriately rated acoustic fitting be
used in accordance with the manufacturers instructions.

Penetrations for the windows and doors must use appropriately rated acoustic products and be
installed to the manufacturers instructions. (Technical information and advice is available for the
Australian Window Association)

More detailed information is available in the ecobrick Technical Data File - Acoustic Walls E2.

15

General disclaimer
The information presented in this manual is general by nature and no liability is accepted by Advanced Concrete Technologies in its use. Advanced Concrete Technologies
recommends that the advice of a registered builder or structural engineer be sought for any major building works prior to commencement of the works.

Warranty
Advanced Concrete Technologies warrants its products to be free from defects caused by faulty manufacture or materials. If any of its products are so
defective the Company will at its option, repair or replace them, supply equivalent replacement products or reimburse the purchase price.
The warranty shall not apply to any loss or consequential loss suffered through or resulting from defects caused by faulty manufacture or materials.
Fittings or accessories supplied by third parties is beyond the control of Advanced Concrete Technologies and such is not warranted by Advanced
Concrete Technologies.
ecobrick is a trademark of Advanced Concrete Technologies, its subsidiaries and affiliates.
#

Some images are used for illustration purposes only.

Advanced Concrete Technologies

ABN: 62 005 736 005

Cnr Cook and Bannister Roads

Canning Vale I WA I 6155
PO Box 1408 I Canning Vale I WA I 6155
t 08 9334 4750
e info@ecobrick.com.au

f 08 9334 4751
w ecobrick.com.au

SB0800939ECOBRICKLAYER

Copyright 2008 Advanced Concrete Technologies