Bricks are one of the crucial construction materials that have been in use for thousands of years. Although bricks use different raw materials, clay bricks are widely preferred, which leads to the development of numerous clay bricks. There are several clay bricks in the market, and one among them is Porotherm brick. These bricks are hollow with gaps within the structure and gain wide attention. Here we take a look at what porotherm bricks are and everything you need to know about them.
What are Porotherm Bricks?
Porotherm bricks are perforated clay bricks that are made up of natural clay, rice husk, coal ash, and granite slurry. They come in both horizontal and vertical blocks that offer thermal insulation properties to the structure. They are a good energy-efficient option and are highly sustainable to rapid climate change.
Importance of Porotherm Bricks
Porotherm bricks are made using natural materials that are safe and environmentally friendly. They are designed to provide energy efficiency, durability, and support various construction projects. They are modern wall solution that reduces the usage of steel and concrete. They are strong and have natural thermal properties, which help the building maintain the climate in all weather conditions. Porotherm bricks are best suitable for G+1 buildings and are used in both load-bearing and non-load-bearing walls.
Properties of Porotherm Bricks
Weight
Porotherm bricks are 60% lighter when compared to conventional wall materials. The lightweight properties make them easy to handle and save the overall structural cost by reducing the dead load.
Thermal Insulation
They provide excellent thermal insulation properties and are 45% more effective than other bricks. The natural thermal properties save the energy spent on maintaining the room temperature. They help maintain the room temperature throughout the year in all weather conditions.
Acoustic Insulation
The pore gaps in the bricks play a major role in protecting the structure from external noises. They have good acoustic insulation and are highly suitable for buildings where noise reduction is crucial.
Eco-friendly
Porotherm bricks are manufactured from clay that is de-silted from dead water tanks. The additives used are clay, coal ash, rice husk, and sawdust, which are completely natural. They are free from chemical and artificial substances. The bricks are also recyclable after their lifespan, making them one of the most natural and sustainable bricks.
Strength
Porotherm bricks have a high compressive strength of 10 N/mm² compared to concrete bricks. Due to their high compressive strength and lightweight characteristics, they can be used for both load-bearing and non-load-bearing walls.
Water Consumption
They consume up to 95% less water both during the manufacturing and during the construction process. These bricks are easily curable and only need less water and less time to cure.
Fire Resistance
These bricks have high resistance to fire, as it has already been exposed to extreme temperatures of up to 1000°C during the production process. They have a fire rating of F240, which means they can withstand extreme temperatures for 240 minutes.
Durability
Porotherm bricks are highly durable and have a high life expectancy. Generally, the lifespan of these bricks is over 150 years. They are also recyclable after their lifespan has expired.
Applications of Porotherm Bricks
- They provide high privacy and good sound insulation, which are vital for partition walls in both residential and commercial buildings.
- They have high durability, fire resistance, and strength and can be used in external walls.
- Due to their high strength and lightweight properties, they can be used in both load-bearing and non-lead-bearing walls.
- As they have excellent fire resistance properties, they are a great fit for fireplaces and chimneys.
- These bricks are also used in constructing retaining walls, garden beds, and other landscaping structures.
Advantages and Disadvantages of Porotherm Bricks
Advantages
- These bricks are strong and durable and can be used for both load-bearing and non-lead-bearing walls.
- They are lightweight and easy to handle. They also reduce the overall dead load of the structure.
- They are highly durable and have a lifespan of up to 150 years.
- They have excellent thermal and acoustic insulation.
- They are highly resistant to fire and water, that they can sustain in all extreme weather conditions.
- They are made completely using natural resources and are suitable for green buildings.
- They help the building maintain the room temperature all through the year.
- They are easy to install, maintain, and repair.
Disadvantages
- These bricks are not suitable for large and high-raised structures.
- They form a white powdery layer when exposed to water due to a high efflorescence rate.
- The manufacturing and construction of these bricks need skilled labour.
- These bricks have limited availability.
- They are limited to design.
Installation process of Porotherm Bricks
Preparing the base course
A sand-cement mortar bed is made on the floor before laying the first course. The porotherm bricks are placed over the bed in a straight line. It is crucial to ensure that the bricks are level both horizontally and vertically using the plumb and the string.
Mixing ZeroPlus Mortar
ZeroPlus mortar is a mix of fine-ground sand, cement, and other ingredients that are specially made to install Porotherm bricks. The mortar is mixed with an adequate amount of water to bring it to the right consistency for laying the Porotherm bricks. This mortar provides a thin layer and can be used at temperatures down to zero degrees Celsius.
Brushing Down the Bricks
The top portion of the brick should be brushed off to remove dirt and grit before applying the ZeroPlus mortar and to have uniform levelling.
Applying Mortor
A Porotherm roller is used to apply the ZeroPlus mortar to the brick and spread it all over the brick surface. The mortar is poured on the roller, and it is rolled backwards along the wall. This roller can be helpful in providing even spread and controlling wastage.
Laying
It is important to check whether the first course is laid in a straight line and place the blocks the near center of the previous course. A wooden mallet is used to properly seal the brick over the existing course. The strings and bobs are used to ensure vertical levelling.
Cutting
Due to the interlocking design, the Porotherm bricks are cut to fit the gaps. These bricks can be cut either by hand or through an electrical tool. These bricks are suppressed inside the water before cutting to reduce dust.
Fitting Wall Ties
Two-part wall ties are used for the Porotherm wall, which eliminates the danger or injury caused by rapid installation and the problems caused by the cavity wall. The first part is used during the building process and the second part is attached to the outer skin of the wall.
Applying a parge coating
After constructing the wall, the Poroparge and Eco-parge coating is applied to the internal facing of the wall with a soft-headed broom. It is applied in a way that fills all the vertical joints and is free from gaps or cavities.
Comparison between Porotherm Bricks & Concrete Bricks
| Porotherm Bricks | Concrete Bricks |
| These bricks can be laid in a faster phase, with a worker can cover 30 to 40 m² per day. | The laying of concrete bricks is slow compared to Porotherm bricks. Where a worker can cover 12 to 15 m² per day. |
| The mortar starts to set in just 30 minutes. The full strength of the mortar can be achieved within 24 hours. | The mortar is slower to set, and it takes around 2 days (48 hours) for the mortar to achieve full strength. |
| They are lightweight and have no sharp corners. | They are heavy and have sharp corners. |
| They have a compressive strength of 10 N/mm², which is greater than concrete bricks. | They have comparatively low compressive strength, that is 7 N/mm². |
| They produce minimal mortar waste and 2% brick waste while cutting. | An average of 40% of the mortar and 15% block waste. |
| They have high thermal efficiency. | They have lower thermal efficiency. |
Conclusion
Porotherm bricks have numerous benefits and have been gaining attention in the construction field. They are highly resistant to water, fire, and sound and have high strength and durability. The usage of Porotherm bricks are evolving and are used in almost every type of building. If you are looking for an allrounder brick for your dream house or commercial site, you can consider Protherm brick as a choice.