This interactive publication is created to showcase the growing collection of brick and tile patterns that are possible with Mbrick Versa Liners
Embedded Thin Brick in Precast Construction Mike Denson
Embedded Thin Brick in Precast Construction Mike Denson
Marketing Sales - Why Embedded Thin Brick Layout / Take-off Ideas
Versaliner Creation Versaliner Options Liner Installation Process Other Versaliner Uses
Market Segments for Thin-Brick
•Retail-Big Box, Malls, multi-tenant •Education-all levels •Institutional-correctional, facilities, Military •Stadiums/Entertainment •Medical & Office •Parking Decks •Multi-Family Housing •Religion/Faith
why thin brick?
Embedded thin brick takes precast from this…
copyright
To this…
Embedded thin brick takes brick-clad construction sites from this…
copyright
To this…
copyright
Why embedded thin brick?
•A stronger brick wall •More usable space / same footprint •Less costly, less site disturbance •Faster enclosure time •Less natural resources (mfg/trans) •Numerous design options •Attractive Façade •Low to zero maintenance
why thin brick?
A Stronger Brick Wall
•Brick and Concrete - a monolithic structure •5,000 PSI Strength – vs. 800 PSI mortar •No maintenance, no degradation
More Useable Space
Insulated wall panel w/ embedded thin brick – 10”
Insulated conventional Wall w/ laid-up face brick – 16” width
A 10” wall on a building with a footprint of 300’ x 150’ realizes approx. 450 more useable SF per floor than a conventional 16” wall system. For commercial buildings with a lease rate of $21 per square foot, that is an additional $9,000 per floor!
Embedded thin brick lowers costs •Applied by low-cost labor, vs. mason rates •Install rate for thin brick: 150 SF/man hr (vs….)
•Reduced weather delays •Lower SF materials costs
Less Natural Resources
Thin brick requires less natural resources
Face brick = 62.19 cubic inches of material
About 1/6th
Thin brick = 10.72 cubic inches of material
thin brick saves resources
Reduced Carbon Footprint
•1/6 th the raw materials to excavate and transport •1/6 th the gas to fire materials
Reduced Carbon Footprint
•1/6 th the energy to ship to job site
Environmental Comparison Study
Project - Cancer Genetic Research Center University of Florida, Gainesville, Florida
environment compare 1
Environmental Comparison Study thin brick vs. full bed brick
Assumptions
Full bed brick (2 1/4” x 7 5/8” x 3 5/8”)
Thin brick modular size (2 1/4” x 7 5/8” x 5/8”)
• Shipping distance- raw materials 12 miles • Shipping distance- finished product 980 miles • Similar usage at job site (pieces used efficiently for both) • Fuel mileage for all trucking 8 miles per gallon • All trucking capacities 45,000 lbs.
environment compare 2
Environmental Comparison Study thin brick vs. full bed brick
Material and fuel savings using thin brick.
288 tons 1,440 tons Thin brick (actual)
Full bed brick (estimated)
Raw materials mined
Shipping raw material 13 loads (39 gal. Fuel)
64 loads (192 gal. Fuel)
Firing
710 mmbtu (natural gas) 3,500 mmbtu (natural gas)
Shipping bricks
12 loads one way (1,470 gal. of fuel)
57 loads one way (6,985 gal. Of fuel)
environment compare 3
Environmental Comparison Study thin brick vs. full bed brick
Material and fuel savings using thin brick. Raw materials saved 1,152 tons Diesel fuel saved 5,518 gal. Natural gas saved 2,790 mmbtu
environment compare 3 environment compare 4 45 FEWER TRUCKS ON THE ROAD! HEAT 14 HOMES FOR 1 YEAR!
Environmental Comparison Study- thin brick vs. full bed brick
The material saved from face brick could produce an additional 400,000 sq. ft. or 2.7 million pieces of thin brick
Embedded Thin brick ---
Impressive Design Options
Example of arch details .
Embedded Thin brick ---
Impressive Design Options
Example of
radius panel.
Embedded Thin brick ---
Impressive Design Options
Example of returns, also form liner cast together w/ brick
Embedded Thin brick ---
Impressive Design Options
Example of no brick corners .
Embedded Thin brick ---
Impressive Design Options
Concave joint, acid washed
Raked joint, acid washed
Concave joint, smooth
Does Size Matter….with embedding Thin Brick?
Embedded Thin brick ---
Example of recessed coursing
Impressive Design Options
Example: Recessed Coursing
Embedded Thin brick ---
Impressive Design Options Example: Recessed Coursing
Embedded Thin brick ---
Impressive Design Options
Example of protruded columns
Embedded Thin brick ---
Impressive Design Options
Example of embedded and panelized thin brick used together
Embedded Thin brick ---
Impressive Design Options
Example of interior use of embedded thin brick
Embedded Thin brick ---
Impressive Design Options
Recessed coursing, full corners, & mitered corners
Embedded Thin brick ---
Impressive Design Options
Calvert Street Parking Garage with intricate design elements, precast, historical matching.
Embedded Thin brick ---
What’s Next?? Emerging Market With Continued Growth & Demand ---------------------------------------------------- • New Tile-Ceramic-Clay products • Sustainable improvements • High Performance Systems • Thermomass • Release Agents • Non VOC, water based • Adhesives • Non VOC, water based • Sustainability within the industry-Precast Plants • Value-Based products and processes • Design limitations will be lifted!
Take Off Ideas
Full Face Brick 2 ¼” x 7 5/8” x 3 5/8” Basic Brick Sizes & Shapes
Take Off Ideas
Thin Brick Flat 2 ¼” x 7 5/8” - 5/8” thick Basic Brick Sizes & Shapes
Take Off Ideas
Thin Brick Corner 2 ¼” x 7 5/8” x 3 5/8” – 5/8” thick Basic Brick Sizes & Shapes
Take Off Ideas
Thin Brick Edge Cap 2 ¼” x 7 5/8” x 3 5/8” – 5/8” thick Basic Brick Sizes & Shapes
Take Off Ideas
Thin Brick Half 2 ¼” x 7 5/8” - 5/8” thick Basic Brick Sizes & Shapes
Take Off Ideas
Thin Brick Half 2 ¼” x 7 5/8” - 5/8” thick Basic Brick Sizes & Shapes
Take Off Ideas
• 8” Module (12” w/Uitility) w/joint • Single brick module is 2.66” x 8” w/joint Layout Basics
Take Off Ideas
• 8” Module (12” w/Uitility) w/joint • 3 Bricks & Joints = 8” (12” w/Utility) Layout Basics
Take Off Ideas
• Corners • 4 ½ bricks in 1 LF • LF figured as vertical “run” Layout Basics
Take Off Ideas
Take Off Ideas
Running Bond Flats – red Specials – white Corners
Edge Caps Soldier*
Take Off Ideas
Specials Corners – red Edge Caps - blue
Take Off Ideas
100 sf brick extra, cost $300 - $400 100 sf brick short, cost Possibly 8-10 weeks for production Likely color/shade will not match $300 - $400 cost of brick $300 – $600 cost of shipping brick
Anatomy of Versaliner ®
Design &Layout Liner Part - CAD
Anatomy of Versaliner ®
Design &Layout Liner Part - CAD
C
D
A
B
E
F
Anatomy of Versaliner ®
“Toolpath” - CAD
Anatomy of Versaliner ®
Design &Layout Tool / Part - CAD
Anatomy of Versaliner ®
Tool – Wood for custom parts
Anatomy of Versaliner ®
Single sheet production - custom parts
Anatomy of Versaliner ®
Single sheet production - custom parts
Anatomy of Versaliner ®
The “toaster”
Anatomy of Versaliner ®
The Vac process
Anatomy of Versaliner ®
Removal
Anatomy of Versaliner ®
Hand Trimmed
Anatomy of Versaliner ®
Scrap – 100% Recycled!
Options - Versaliner ® C
D
A
B
C
F
E
D
C
D
B
A
E
A
F
C
E
B
C
MITER
D
B
F
A
F
A
B
E
E
A
D
E
R4'-2 3/16"
B
C
F
F
COPED EDGE
Options - Versaliner ®
C
C
D
D
B
E
B
A
E
C
A
D
F
F
C
A
D
B
E
A
F
E
B
F
Options - Versaliner ®
C
D
C
D
A
A
E
B
B
E
F
F
C
3/8"
D
E
C
D
12"
A
F
A
E
B
B
F
Options - Versaliner ®
C
E
A
B
C
C
F
D
C
D
E
D F
A
A
E
B
B
E
3'-1 53/64"
F
A
F
C
1'
C
B
D
D
R6'
A
B
C
E
D
E
B
A
F
F
A
E F
B
Options - Versaliner ®
1/4"
7/16"
DEEP COMPRESSION
JOINT
1/4"
V JOINT
1/2"
R1/16"
3/16"
STONE RAKE
COMPRESSION JOINT
TILE JOINT
1/4"
R7/16"
R1/16"
1"
1/4"
R1/16"
1/4"
R1/16"
COVE JOINT
RAKE JOINT
GRAPEVINE JT
SPLIT FACE BLOCK
Options - Versaliner ®
Embedded Thin Brick Installation “Laid down vs. laid up”
Install reveals
Set up forms
Mark for coursing accuracy
Embedded Thin Brick Installation
Install brick liner…
And thin bricks
Embedded Thin Brick Installation
Cast concrete
Embedded Thin Brick Installation
Lift panels
Embedded Thin Brick Installation
Peel and wash panels
Step back and admire your work
Options - Versaliner ®
Options - Versaliner ®
Options - Versaliner ®
Options - Versaliner ®
Page 1 Page 2 Page 3 Page 4 Page 5 Page 6 Page 7 Page 8 Page 9 Page 10 Page 11 Page 12 Page 13 Page 14 Page 15 Page 16 Page 17 Page 18 Page 19 Page 20 Page 21 Page 22 Page 23 Page 24 Page 25 Page 26 Page 27 Page 28 Page 29 Page 30 Page 31 Page 32 Page 33 Page 34 Page 35 Page 36 Page 37 Page 38 Page 39 Page 40 Page 41 Page 42 Page 43 Page 44 Page 45 Page 46 Page 47 Page 48 Page 49 Page 50 Page 51 Page 52 Page 53 Page 54 Page 55 Page 56 Page 57 Page 58 Page 59 Page 60 Page 61 Page 62 Page 63 Page 64 Page 65 Page 66 Page 67 Page 68 Page 69 Page 70 Page 71 Page 72 Page 73 Page 74 Page 75 Page 76Powered by FlippingBook