Delivering solutions that work for Architectural masonry

Brikmat Case Study: Sir Robert McAlpine: Northumbria University Development

Sir Robert MaCalpine, one of the UK's leading building and civil engineering contractors with a reputation for quality, recently completed a £50 million construction project delivering a new education complex for Northumbria University.

Located on a brownfield site to the east of Newcastle City Centre, this is a flagship environmental development demonstrating world-class design in the North East. The finished 24,000-sq. m scheme comprises of two distinctive five-storey buildings clad in glass and metal to give the impression of rippled, pleated and folded fabric skin: a worthy residence for the University's business, law and design faculties when it opens in September 2007.

Construction of the building required delivery of a number of complex environmental strategies that provided enhanced ventilation controlled solar gain and improved thermal efficiencies. However, as well as enhancing building performance these strategies also give the building its distinctive aesthetic appearance, and help to define the different functions taking place within the complex. The design school is accommodated in one building, whilst the law and business faculties share the second - each of these buildings looks out onto a shared courtyard. An eye-catching feature wall then runs around the external boundary of the development unifying the whole complex and creating a dramatic public face.

Bringing together cutting-edge mix of architecture and technology, the contractors were required to work through a number of complexities when it came to delivering this scheme. However, it was the architect's specification of dense heavy block for the exterior wall that served to present McAlpine Site Manager Jim Walker and his brickies with something of a challenge.

The Challenge

The block specified by the architects for the exterior wall was a heavy dense granite imported from China. This presented a two-fold problem: firstly - the sheer weight and physical size of the granite would compress the mortar joints in the block work and extrude mortar from the lower courses. Whilst this could result in a loss of gauge between the blocks, this also presented a risk to the aesthetic appearance of the feature block work. Secondly, even if the mortar did remain consistent, the non-porous composition of the blocks would prevent adequate absorption of moisture from the mortar. Blocks would literally 'slide' around on top of one another, forcing thebrickworkers to wait for the mortar to set between laying courses. This minimised the number of courses that could be built in any one day, presenting serious repercussions in terms of meeting the construction programme.

The Solution

Having worked for Sir Robert McAlpine for 31 years, experience taught Site Manager Jim Walker that in this instance the job required an effective tool that could help stabilise the block work to pevent dipping and floating, assure consistency of gauge, and prevent mortar courses from being compressed under the heavy stone.

Developed, tested and proven by building professionals, Brikmat was the ideal solution. A BBA approved masonry support system, Brikmat is placed in the horizontal bed joints to increase the stability of physically demanding masonry. Brikmat resists the stresses that are inherent in loaded masonry panels eliminating the risk of bed joint compression and mortar bleding. In the instance of the Northumbria University development, Brikmat provided a positive contact between the courses and allowed the mortar to set between the blocks while the bricklayers continued to build.

Jim Walker, Sir Robert McAlpine Site Manager, said:

"By preventing the blocks from dipping during construction, Brikmat allowed my team to build five successive courses in a single shift without the fear of the mortar joints at a lower level being pressed out under the weight of the stone. This dramatically improved productivity on site, reducing the installation time by approximately 30 per cent, which itself contributes to helping make significant cost savings as it reduced the amount of labour needed on the job. Brikmat also acts as a depth gauge which itself helps save on mortar and minimises waste."  

He continues:

"This is a product for even the most experience bricklayer. Whilst it was at first regarded with suspicion by our brickies on site, once they saw it being demonstrated the benefits spoke for themselves. Not only could they see how it would enable them to work faster and more accurately, it also promoted good workmanship that ultimately enhanced the overall quality and appearance of the finished blockwork. Using Brikmat was a resounding success for us - both as far as my brickies were concerned and, more importantly, the client, who has gone on to comment on the quality of the work. Brikmat is certainly a product I would use again on site, and I have already recommended it to colleagues working on another McAlpines scheme in Newcastle."