Brick

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Hello friends! My name is Mr. Brick and I’m here to present you...

EARTH, PLANET, HOUSE Archeological studies indicate that back in the year 6,000 BC, there were very well planned cities with mud houses that followed a certain pattern. From those times to today, the prime materials for construction are almost the same, but an extensive diversification of building techniques have been appeared in projects of highly recognized architects. Among the professionals that have made a revolution in architecture can be named the American Frank L. Wright, whom in 1923 used for the first time a modular system, using pre fabricated concrete pieces and structural steel reinforcement. At the same time his conception about urban development was considered very advanced. Those techniques ware very individualistic and mostly to fulfill the interest of his own projects. In the actuality the company SAHARA has developed a Modular Brick and its methods of application or use, which are totally innovative and very accessible, to give a response to the actual needs of construction from the simplest to the most complex ones. The simplest ones are the ones we present in this brochure.

...THE MODULAR AND ECOLOGICAL BRICK
Here we will show the advantages, its production, composition, and how it can be applied in construction

It looks funny, but in fact this brick is the result of 25 years of research, study and lots of work

Its excellent quality makes the Modular Brick relatively lighter than the commonly used bricks if we take into account the total amount of material required in the construction and finishing proess.

ALL THAT MAKES THE MODULAR BRICK A SUCCESS IN ITS APPLICATION TO MANY CONSTRUCTION PROCESSES, INCREASING THE QUALITY OF STRUCTURES AND FINISHING & REDUCING THE COST OF BUILDING UP TO ALMOST HALF OF THE PRICE.

THIS TECHNOLOGIC DEVELOPMENT IS SUPPORTED BY SAHARA, THE COMPANY RESPONSIBLE FOR THE PRODUCTION AND MANUFACTURING OF THE MACHINES THAT PRODUCE THE MODULAR BRICKS

Our Ecologic Brick is a module with standard or even regular textures and measurements and very well defined finishing. That is why the most common laying corrections are minimal, speeding up the building process

The Modular Brick or Ecologic Brick strength exceeds the limit required by technical norms

Its exposure to moisture will increase its strength because during its production process it is treated with water

Now if we compare the plastering of two different walls. For example this one with commonly used bricks

Commonly used bricks can lose their strength if not protected from moisture

The layer of plaster has to be very thick to level up the irregularities on that kind of brick

Due to its quality, beauty and finishing, the Modular Brick can be exposed just by coating its surface with any acrylic resin. As a result it gives a very nice facade to your building

Besides increasing the weight in construction, it will also increase the time of completion, cost of material, and labor

See now this wall built with the Ecologic Brick and the modular system of construction

Now you may ask: “What is the use of the holes on the Modular Brick?”

All this is because as the measurments of the bricks are precise, it will form walls with very parallel surfaces

On top of reducing the weight of the building there are more advantages that we will show you next:

The layer of plaster is very thin With these advantages and others you will get up to a 50% reduction of building costs.

The holes in the bricks form thermo acoustic chambers that control the interior temperature of the building and help with noise isolation.

Let’s see the following examples

DAY

FRESH AIR

HOT AIR

In the buildings with commonly used bricks it is necessary to use a very old method to install the hydraulic and electric piping. This consists of breaking the walls

...The wall breaker

NIGHT
NO DOUBT, THIS PREHISTORIC TECHNIQUE WILL WEAKEN THE WALL STRUCTURE.

WARM AIR

COLD AIR
Besides being thermo acoustic chambers, the holes in the bricks form conduits that are used to install the water pipes and electric cables avoiding breaking any wall.

Acoustic chambers protect the house from the day to day constant noise pollution

Another advantage of the holes is to facilitate the construction of the supporting columns

In the construction of the supporting columns, we will economize on wood and labor

WITH THE FABRICATION PROCESS OF THE MODULAR BRICK, WE CAN CONSIDER IT AS THE RISE OF ECOLOGICAL POTTERY, BECAUSE IT DOES NOT CAUSE ANY CONTAMINATION DUE TO WASTE OR BURNING AS HAPPENS IN THE TRADITIONAL POTTERIES.

Even more, we can have an advantage in the distribution of columns along the building, avoiding excessive weight concentration in a few points of the structure. See for example:

CONVENTIONAL SYSTEM
WEIGHT WEIGHT WEIGHT

To make the Modular Brick, the Ecological brick factory uses three basic elements; all this within a structured technical system.

SOIL

CEMENT

WATER

ECOLOGICAL BRICK

THERE ARE FEW SUPPORTING POINTS MODULAR SYSTEM

THE SOIL USED IN THE FABRICATION IS SELECTED PREVIOUSLY, TREATED BY GRIDING OR SIEVING, AND EVENTUALLY CORRECTED.

TREATED SOIL

THERE ARE MANY SUPPORTING POINTS

UNTREATED SOIL

PRESSURE

After the treatment process the soil-cement mixture is pressed up to 6 tons

The Ecologic Brick is a modular building system, approved by The Center of Civil Construction of Sao Paulo, helping with the modernization and renovation of the norms and patterns of civil construction and with the training of new professionals.

UP TO 6 TONS
OUR METHOD IS ALSO ADOPTED BY MANY REGIONAL TOWN PLANNING OFFICES TO BE USED BY THE PUBLIC WORKS IN THEIR PROGRAMS OF POPULAR (LOW COST) HOUSING, AIMED TO LOW COST AND HIGH STANDARD QUALITY.

After an efficient technique of curing ad drying... the Ecologic Brick is ready!! With a proven success the Ecologic Brick was presented publicly in a much known enterpreneurial TV program and also it has been material for construction, architecture and decoration magazines and prestigious news papers in Brazil

THE MODULAR BRICK COMES IN THREE DIFFERENT STANDARD DIMENSIONS

THE PRODUCTION PROCESS OF THE ECOLOGIC BRICK HAS TECHNICAL SUPPORT OF THE SAHARA COMPANY, THAT BESIDES PRODUCING THE MACHINES TO MAKE THE MODULES, HAS A DEVELOPED A TECHNIQUE WITH PROVEN EXPERIENCE FROM THE SOIL ANALYSIS TO THE MODERN SYSTEMS OF BRICK MODULAR FABRICATION.

SAHARA OFFERS AT NO COST, THE TRANING COURSES ON THE FABRICATION AND APPLICATION OF MODULES IN CIVIL CONSTRUCTION.

IN

THE MODULAR BUILDING SYSTEM

To avoid breaking them or causing an accident we should not throw them

There he goes... he’s creating an accident!

Hi, now we will see how the Modular Brick is easily used in construction.

STRAIGHT WALL

CORNERS

SOLID COLUMN

FILLED COLUMNS
The Modular Brick was projected and designed to stand pressure on its surface

But before we build, we need to transport the bricks and we have to be very careful in this operation

Another important facts is that the modular building system helps to keep a cleaner and more organized construction site

Remember that a clean and well organized working environment contributes for the staff security, and that is also one of our concearns

The modular building system largely contributes for a clean working environment and building materials economy. It is enough to apply just a fillete of white glue, special mortar or soil-cement mixture to lay the bricks

IF USING WHITE GLUE USE THE TUBE WITH THE DOSING HEAD

WHITE GLUE

Mr. Anta is very stubborn and disorganized. He still insists in working with the old traditional system

Special mortar is usually more used due to low cost and easy application

SPECIAL MORTAR FOR BRICK LAYING AND JOINT FILLING 12 Liters of soil 1 Liters of cement
P GL VA UE

1 Liters of PVA Glue

IN ORDER TO APPLY THE SPECIAL MORTAR OR THE SOIL-CEMENT MIXTURE WE CAN USE A TOOL SIMILAR TO THE ONE USED FOR CAKE DECORATION.

If you prefer you can make yourself a tool for aplying the soil-cement mixture by using an economic method

The purpose of the mortar in the brick laying is also to correct possible irregularities

HOW TO MAKE SOIL-CEMENT APPLICATOR
We can see that the modular brick has a fitting system that helps to orientate the brick laying

FUNNEL OLD TIRE INNER TUBE

MASKING TAPE

CUT THE OLD TIRE INNER TUBE

FIX THE FUNNEL TO THE TIRE INNER TUBE WITH MASKING TAPE

THE SOIL-CEMENT MIXTURE TO BE USED SHOULD BE THIN IN ORDER TO BE EASIER APPLIED

See how easy it is to use the soilcement applicator!

The small space on the joint is to allow for expansion

Let’s say that expansion happens, what are its consequences?

We just have to keep a distance of 1 to 2 mm between modules, the equivalent of a ruler

The modular brick, like all matter expands when exposed to heat and contracts when exposed to cold

HEAT

COLD

THE SMALL SPACES BETWEEN THE BRICKS ARE NECESSARY TO HELP THE PLASTER APPLICATION AND JOINT FILLING AND IN NO WAY DO THEY DAMAGE THE VISUAL EFFECT ON THE EXPOSED BRICK WALL.

If we don’t have space for expansion the modules will “crash” between themselves creating cracks and fissures

PLASTER

JOINT FILLING
THE EDGES OF THE MODULES HAVE A PROFILE THAT HELPS THE ADHERANCE OF FINISHING MATERIALS

But that can be avoided in order to guarantee the construction stability

Now we have here examples for the plumbing system When installing the electrical system you can choose to open holes on the modules instead of using boxes and conduits for the light switches and sockets.

We know that the bricks function is to fill in the space between columns and make up walls, but what really supports the construction are the columns and the whole structure

In our building system we have the advantage of embedding the columns in the walls as we will see now

STELL REIFORCING RODS

1.70 m
FOUNDATION

THE STEEL REINFORCING RODS OF 1.70 M HIGH ARE EMBEDDED IN THE FOUNDATION

IT IS IMPORTANT THAT THE FIRST LAYERS OF BRICKS ARE PERFECTLY LEVELED SO THAT THE WALLS ARE STRAIGHT. IF NEEDED THEY CAN BE LAID WITH TRADITIONAL MORTAR TO ENSURE PERFECT LEVELING.

THE STEEL REINFORCING RODS, BESIDES BEING EMBEDDED IN THE FOUNDATIONS SHOULD ALSO BE EMBEDDED IN THE FLOOR SLAB BEFORE THE WALLS ARE BUILT.

After applying the clamps you just have to fill the column holes with concrete

When the walls reach half a meter high we have to fill the supporting columns

To cut the bricks we should use a manual circular saw that will guarantee the quality of this operation

WITH THE HELP OF THE CIRCULAR SAW WE CAN OPEN SMALL TRENCHES ON THE BRICKS, DEEP AND WIDE ENOUGH TO EMBED THE STEEL CLAMPS THAT WILL JOIN THE BRICKS INTO COLUMNS.

See how easy it is? you just have to repeat the operation every half meter ensuring thus the construction strength

EVERY 50 CM OF HEIGHT AS THE WALL RISES, THE STEEL CLAMPS SHOULD BE APPLIED IN JOINING THE BRICKS INTO THE COLUMNS IN ORDER TO GUARATEE STABILITY OF THE CONSTRUCTION

Don’t forget that by filling the colmns every half meter we are avoiding possible air pockets which endanger the structure of the instruction

Knowing that the usual wall height is 2.80m, once we reach 1.70m high we should set up scaffolds

To raise a perpendicular wall we use a half brick where the two walls meet The total of columns varies according to the size of the construction, that’s why it is necessary to have an engineer that evaluates the amount and distribution of columns
100 cm

AFTER THAT WE ATTACH ANOTHER REINFORCED STEEL ROD WITH WIRE, COMPLETING THUS THE HEIGHT OF THE COLUMN

80 cm

In perpendicular walls we can choose from two types of clamping system

This is just an example of columns distribution in a three story construction

60 cm

DON’T FORGET THAT THIS IS NOT INCREASING THE AMOUNT OF STEEL OR CONCRETE, BUT IT IS JUST DISTRIBUTING THE COLUMNS IN A CORRECT WAY.

In the “binding ring” we use channeld bricks in which the steel reinforcing rods (SRR) should be laid

SAHARA has developed a simple and efficient binding technic as we will see below.
IN THE MODULAR BUILDING SYSTEM THE “BINDING RINGS” SUBSTITUTE THE LINTEL AND CONTRA LINTEL GUARANTEEING THE CONSTRUCTION STRENGTH.

IF THE CONSTRUCTION HAS ONE STOREY AND A SLAB ROOF, THE COLUMNS STEEL REINFORCING RODS (SRR) SHOULD BE 50CM HIGHER THAN THE HEIGHT OF THE CONSTRUCTION AND BENT INSIDE INTO THE SLAB BED.

AFTER THAT THE SLAB BED WILL BE FILLED WITH CONCRETE COVERING ALL THE STEEL REINFORCING RODS (SRR). THIS WAY THE COLUMNS ARE ATTACHED TO THE SLAB.

THE BUILDING OF A GARDEN WALL WITH THE MODULAR BRICK
IN THE CONSTRUCTION OF A GARDEN WALL WE SHOULD EMBED THE COLUMNS A METER APART

1 meter
THE BRICK HOLES ON THE WALL SHOULD BE COVERD WITH WADDED PAPER OR NEWSPAPER BEFORE THE CHANNELD BRICKS ARE FILLED WITH CONCRETE. IF THE CONSTRUCTION IS TWO OR MORE STOREYS HIGH, ONE OF THE COLUMNS SRR KEEP IS BENT INTO THE FIRST SLAB. THE OTHER SRR KEEP GOING UP THUS FOLLOWING THE COLUMNS. ONCE THE DESIRED WALL HEIGHT IS REACHED, WE MAKE A CLAMPING ARCH BY USING CHANNELD BRICKS IN WHICH WE INSTALL SRR IN THE TOTAL LENGHT OF THE WALL. THE VERTICAL SRR THAT COME OUT OF THE WALL ARE BENT INSIDE THE CHANNELS AND TIED TO HORIZONTAL ONES. AFTER THAT THE CHANNELS ARE FILLED WITH CONCRETE.

We have already seen that due to their finishing the modular bricks look good without the need for using plaster

IN THE BRICKS JOINTS WE CAN USE A TUBE WITH PLASTER / MORTAR TO DO THE FINISHING

To clean the walls we can use no 0 steel wool

Or if you prefer, apply a layer of plaster. For this use a long and very straight board which slopes in its width

Since the wall is ...in a movement starting lower already very straight, and lifting up the board, and the plaster will cover all the joint use the board and spaces between the bricks plaster... The plaster/mortar for the joints finishing can be the one used for ceramic tiles, cement mixed with colors, or just the soil-cement mixture

PLASTER

BOARD

ANOTHER HINT FOR THE FINISHING:

IN CASE YOU ARE USING AN EXPOSED BRICK WALL, IN ORDER TO MAKE THE JOINTS NEAT BETWEEN THE BRICKS WE CAN USE A SPIRALED STEEL ROD, 1/4 TO 3/8, DEPENDING ON THE DEGREE OF ROUNDNESS WE WISH.

We more the rod sideways between the bricks until we reach a good finishing.

With a spatula or chisel with rounded edge you can complete the finishing by cleaning off the excess plaster/mortar

Before applying any resin or paint we have to have the walls free from any impurities

Once the walls are clean and dry we can apply protective acrylic resin or layers of paint.

Let’s see now important hints and information that make this building system interesting and useful

IMPORTANT HINTS
HALF BRICK BRICK LAYING

Let‘s see now some important hints about the brick laying

LAYING THE BRICKS WITH THE FITTING RELIEF FACING DOWN IS ALWAYS USED

USE OF CHANNELED BRICK “BINDING RINGS” COLUMN DISTRIBUTION
THE HALF BRICK CAN BE PRODUCE BY THE MACHINE... IN LAYING THE BRICKS WE SHOULD NEVER USE “GLUE CEMENT” BECAUSE IT IS VERY RIGID AND IT DOESN’T FOLLOW THE EXPANSION AND RETRACTION OF THE BRICKS, WHICH HAPPEN WITH TEMPERATURE CHANGES.

Let’s first talk about the half brick which is so important in the meeting of walls

...IT CAN ALSO BE PRODUCED BY ADAPTING THE TOOL.

This facilitates the use of the level in order to do any corrections

C

EN EM G

T E

LU

THIS PRODUCTION BY TOOL ADAPTATION REQUIRES GREATER CARE IN PRODUCTION.

We can also get the half brick through cutting which is the method most corner

Because it’s done on site the use of a cutting saw for brick and fitting can adapt a disc for cutting concrete

...And can later cause cracks and fissures in the bricks

The best mortar for brick laying is the special mortar, PVA glue or, as we have already seen, the soil-cement mixture.

SPECIAL MORTAR

WHITE GLUE

If we keep in mind that the columns are those that support the construction and the bricks are to fill in the space between the columns we also have to consider that the mortar for brick laying has a specific function...

...That function is to level and stop the bricks from sliding but holding the bricks. Not a gluing function as most people think.

ANOTHER ADVANTAGE OF THE SAHARA BUILDING SYSTEM IS THE CHANNELED BRICK.

The channeled bricks do not need the use of lintels when building the “binding rings”.

WHEN THERE IS NO TOP SLAB IN CONSTRUCTION WE NEED TO USE A BACK UP “BINDING RING”.

mortar

Without the mortar that holds the bricks, these would be in a position which would cause them to break under the weight of the wall

The modular bricks with their efficient filling system present an efficient link between themselves

When filling the channeled bricks with concrete we have to protect the holes so they are not filled as well.

IN ORDER TO DO THIS WE CAN USE PVC PIPES, CUT AS SHOWN IN THE DRAWING

The bricks having a sequencial interconnection in multiple directions and downloading their weight in the support columns, occurs through the extension of the wall, ensuring therefore quality and safety in the construction.

We can also use wood cones or CONES AND PVC PIPES CAN BE REMOVED AND REUSED plastic glasses to protect the holes, IN OTHER CONSTRUCTIONS. depending on their diameter

AFTER THE CHANNELS ARE CONCRETED, THE WOOD

THE PLASTIC GLASSES SHOULD ALSO BE REMOVED SO THAT THE HOLES CHAMBERS REMAIN OPEN.

The open chambers formed by the holes are important so that moisture evaporation flow is not interrupted.

Besides the side columns on windows and doors, it is advised the distribution of columns along the construction.

THIS PROCESS AVOIDS HUMIDITY WITHIN THE WALLS WHICH MIGHT CAUSE HEALTH PROBLEMS AND DAMAGE BUILDING MATERIALS. AT THE TOP OF THE SLAB THE HOLES SHOULD BE LENGTHENED WITH PVC PIPES. IF THE SLAB IS WEATHER EXPOSED THE PVC PIPES SHOULD BE COVERED TO AVOID WATER GOING IN. IT IS VERY IMPORTANT THOUGH TO MAKE A SIDE HOLE ON THE PIPE SO EVAPORATION CAN GO OUT. In order to facilitate the columns distribution in the construction it is also advised to follow an order as it is shown in this example.

corners doors interconnections windows spaces between columns further apart than 1 m.

See how easy it is to work with the modular brick? Many professionals have adopted our system even has a hobby type of work such as repair or small home constructions such as dividing walls, bricks furniture, planters, barbecues, etc.

IF IT IS ONLY A TEMPORARY PROCESS, IT IS MORE ECONOMIC TO COVER THE PIPE WITH A PLASTIC HELD IN PLACE BY ELASTICS. PLASTIC

Besides the “binding rings”, the spaces between columns, the doors and windows are reinforced with columns on the sides

ELASTIC

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