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case-study
precast brick manufacturing process
off-site construction
TM
precast brick
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precast brick panels Precast concrete with bonded brickwork is often used to create complex wall cladding features such as arches, lintels and deep brickwork soffits. These products allow for creative designs and building features to be built in brickwork which otherwise would have been impossible in these parts of the building.
the process
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01
Positively keyed brick slips and returns (soffits/corners).
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03 02
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Construction of wooden mould to match the approved design drawings.
Keyed brick slips placed into the mould to match the approved design drawing bond pattern.
05
04
Joint thickness in-between the positively keyed slips is created using polystyrene strips at the approved dimension to ensure alignment and consistency.
Once the slips have been placed and joints have been formed, the unit is then cross referenced against the approved drawings for accuracy and tolerances. taylormaxwell.co.uk/facades
06
Sand is then placed over the polystyrene joints to assist in creating a seal to stop the concrete permeating through to the decorative face.
07 The edges of the moulded unit are then covered with a layer of silicon to further seal the concrete from permeating the decorative face .
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08 Placement of steel reinforcement and certified lifting eyes into the mould on top of the positively keyed slips as per the structural engineer’s specification. The addition of this reinforcement allows the precast unit to become a structural unit within the buildings fabric.
09 The final pieces of the mould are then added to create the final details of the unit, matching the approved drawings and ready to be cast.
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Self-compacting concrete is mixed and poured into the rear of the mould and then levelled off at the top to create the rear of the precast unit.
10
11 The unit is then stripped from the mould.
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12
The unit is cast and cured to achieve a minimum compressive strength of C40.
The unit is moved using the certified lifting eyes and straps and placed on a pallet with the decorative face up.
13 taylormaxwell.co.uk/facades
14
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The polystyrene strips and silicon edge seal are removed from the unit to reveal the joints.
15 The units are transported outside and any excess sand is removed using compressed air.
16 The complete precast units are then placed outside ready for packaging with open joints ready for site pointing by others.
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17
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Each unit is numbered and referenced to the approved drawings which have unique window and floor references to be interpreted on site.
delivery
The units are then loaded for dispatch.
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feeling inspired? contact your nearest facades solutions provider Taylor Maxwell Glasgow 3000 Academy Park, Gower Street, Glasgow, G51 1PR Taylor Maxwell Edinburgh 1a Clerk Street, Loanhead, Edinburgh, EH20 9DP Taylor Maxwell Leeds Unit 1 Bramley Grange, Skeltons Lane, Leeds LS14 3DW Taylor Maxwell Manchester Carlton House, 18 Albert Square, Manchester, M2 5PE Taylor Maxwell Nottingham Units 7 & 8, Castlebridge Office Village, Kirtley Drive, Castle Marina, Nottingham NG7 1LD Taylor Maxwell Birmingham 6080 Knights Court, Solihull Parkway, Birmingham Business Park, B37 7WY Taylor Maxwell Cardiff 13 Cathedral Road, Cardiff, CF11 9HA Taylor Maxwell Bristol Taylor Maxwell House, The Promenade, Clifton, Bristol, BS8 3NW Taylor Maxwell Barnet Cosmo House, 53 Wood Street, Barnet, EN5 4BS Taylor Maxwell Witham The Matchyns, Rivenhall End, Witham, CM8 3HA Taylor Maxwell Leatherhead Ashcombe House, 5 The Crescent, Leatherhead, Surrey KT22 8DY Taylor Maxwell Winchester Winchester House, Basingstoke Road, Kings Worthy, Winchester, SO23 7QF Vobster Cast Stone Co. Ltd. Newbury Works, Coleford, Radstock, BA3 5RX
Head Office Taylor Maxwell House The Promenade Clifton Bristol BS8 3NW
T: 0203 794 9377 E: info@taylor.maxwell.co.uk taylormaxwell.co.uk/facades