Technical Field

This disclosure relates to bricks and, in particular, clay bricks used in construction.

Background Art

Bricks have been used in the construction of buildings and other structures for thousands of years. Clay bricks have a particular allure due to the characteristic look they provide and the ease with which that can be adapted to particular aesthetics.

However, the correct laying of bricks is a skilful process and therefore particularly expensive and time consuming. Various attempts have been made to reduce the skill required to lay clay bricks.

Although clay bricks may be moulded and cured individually, an effective industrial scale process for forming clay bricks involves extruding a slug from raw material and cutting the slug to form bricks.

Summary of the Disclosure

Disclosed herein is a method of forming a fired clay brick and, in particular, a brick used in construction such as a clay brick, the brick, a construction system which involves the brick and a method of forming a construction comprising the brick.

A further embodiment extends to a method of forming a clay brick comprising the steps of: providing a die; extruding a clay material through the die to form a column; and cutting the column to form one or more bricks, each brick having an elongate shape defining a top bedding surface, a bottom bedding surface, a face, a back, a first side and a second side, wherein the method further comprises: forming a first side interlock in the first side, and forming a second side interlock in the second side, wherein the interlocks are formed so that the first side interlock is complementary to the second side interlock and so that when two such bricks are placed side-by-side, respective interlocks engage, wherein substantially the entire top bedding surface and the entire bottom bedding surface are planar.

As used herein the term “planar” means substantially plane-like. A surface is planar if it is smooth without any additional formations such as interlocks, grooves, protuberances etc. Imperfections from a perfect plane are inevitable due to the construction process and the specific characteristics of the surface may depend on the materials and methods used in the manufacture of the brick.

In an embodiment the top bedding surface is substantially parallel to the bottom bedding surface. In an embodiment, the variation in distance between the top bedding surface and the bottom bedding surface is 0.5 mm or less.

Substantially the entire top bedding surface and the bottom bedding surface are planar. Neither the top nor bottom bedding surfaces have any formations such as interlocks, grooves, protuberances etc. This applies to the entire top and bottom bedding surfaces i.e. the surfaces between the face and back, and between the two sides. In this embodiment, the brick is formed as a rectangular cuboid. The rectangular cuboid shape may ignore any deviations from this shape provided by the interlocks, rebates or texturing such as patterning etc.

During use of the brick, the top and bottom bedding surfaces of adjacent bricks in adjacent courses may be bonded to one another, the face may be a visible surface of the brick, the back may be a surface opposed to the face and the first and second sides may form engagement surfaces adjacent bricks in the same course.

The method may further comprise the step of grinding the top and bottom bedding surfaces so that they are substantially entirely planar. The grinding step may occur after the extruding step. The grinding step may occur after a step of firing the brick.

The method may further comprise forming one or more rebates in the brick.

A first rebate may be formed in the face. The first rebate may be formed at an edge between the face and the bottom.

A second rebate may be formed at an edge between the face and the second side.

The method may further comprise forming one or more of the rebates by cutting, grinding or by use of a shaper cap. When cutting is used, the cut may be applied to the bricks in a wet form. When grinding is used, the grinding may be applied to the bricks in their fired form. A combination of cutting and grinding may be used.

The shaper cap may form the first side interlock and the second side interlock.

The method may further comprise treating the one or more rebates with one or more of: smooth or wire cut texture; rendering; painting; or painting with textured paint.

In an embodiment the top bedding surface is substantially parallel to the bottom bedding surface. In an embodiment, the variation in distance between the top bedding surface and the bottom bedding surface is 0.5 mm or less.

The first side interlock and the second side interlock may comprise complimentary tongues and grooves.

One or more tongues may have a height of between 1 mm and 9 mm.

One or more grooves may have a depth of between 1.5 mm and 10 mm.

The method may comprise the additional step of forming one or more vertical cores in the brick. The vertical cores may extend between the top bedding surface and the bottom bedding surface.

The method may comprise the step of grinding one or more of the top or bottom bedding surfaces.

An embodiment extends to a fired clay face brick for use in construction having an elongate shape defining a top bedding surface, a bottom bedding surface, a face, a back, a first side and a second side, wherein the first side is formed with a first side interlock, and the second side is formed with a second side interlock, and wherein the interlocks are formed so that the first side interlock is complementary to the second side interlock and so that when two such bricks are placed side-by-side, respective interlocks engage wherein substantially the entire top bedding surface and the bottom bedding surface are planar.

By excluding interlocks on the top and bottom bedding surface it may still be possible to manufacture such bricks using an extrusion process.

The first side interlock and the second side interlock may comprise complimentary tongues and grooves. The first side interlock and the second side interlock may comprise bevelled edges.

One or more tongue may have a height of between 1 mm and 9 mm.

One or more groove may have a depth of between 1.5 mm and 10 mm.

The brick may further comprise one or more rebates. The rebates may be formed by grinding.

The one or more rebates may be formed in the face.

A first rebate may be formed at an edge between the face and the top.

A second rebate may be formed at an edge between the face and the second side.

The second rebate may be formed by a shaper cap.

The one or more rebates may be one or more of: smooth or wire cut textured; rendered; painted; or painted with textured paint.

The brick may comprise a length of 240mm or multiples of 240 mm.

The brick may have a height of less than 172 mm.

The brick may have one of the following sets of dimensions (length x width x height):

230 x 110 x 76 mm,

290 x 90 x 50 mm,

203 x 92 x 57 mm,

194 x 92 x 57 mm,

215 x 102.5 x 65 mm,

240 x 115 x 71 mm,

208 x 107 x 69 mm,

240 x 115 x 63 mm,

228 x 108 x 54 mm,

222 x 106 x 73 mm,

250 x 120 x 65 mm,

250 x 120 x 62 mm. The interlocks may be formed by a shaper cap.

The brick may comprise a plurality of vertical cores. The brick may comprise 10 vertical cores. In an alternative embodiment, the brick may comprise three vertical cores.

A further embodiment relates to a system for forming a construction comprising: a plurality of bricks as herein described arranged in a course with one of a first or second side interlock of a brick within the course engaging with an interlock of an adjacent brick.

The system may comprise a plurality of courses arranged vertically with the top bedding surfaces of bricks of a lower course adjacent to the bottom bedding surfaces of bricks of an upper course. The adhesive may have a thickness of less than 0.5 mm. The adhesive may have a thickness of 0.05 to 0.25 mm. The adhesive may be an adhesive other than mortar.

The top bedding surface of a brick may be adhered to the bottom bedding surface of a brick of an adjacent course with adhesive. The adhesive may be expanding polyurethane adhesive.

The system may comprise at least one alignment bar to align one or more courses of bricks.

The alignment bar may form part of an alignment frame, the alignment frame further comprising one or more vertical bars.

The system may further comprise brackets for joining the alignment bars to the frame. The brackets may comprise a quick release mechanism. The alignment bars may assist with lateral registration of bricks within a course. A quick release may allow the alignment bars to be moved from a position corresponding to one course to the next.

The system may further comprise a brick tie for joining one or more bricks to a support structure, the brick tie comprising a shank with a helical profile for screwing into at least one of said plurality of bricks and into the support structure.

The system may further comprise a sill, the sill comprising a plurality of bricks bonded together. The bricks of the sill may be as herein described. The system may further comprise filling a rebate between adjacent courses with mortar, wherein the mortar is moulded. The mortar may be moulded into one or more of the following shapes: flush; raked; ironed; weather struck or grapevine.

A further embodiment relates to a method of constructing a structure using one or more bricks as herein described.

An embodiment relates to a method of forming a construction comprising: providing a plurality of bricks as herein described; arranging the bricks in a course with side interlocks of a brick within the course engaging with at least one respective interlocks of an adjacent brick.

The method may further comprise arranging a plurality of courses vertically with the top bedding surfaces of bricks of a lower course adjacent the bottom bedding surfaces of bricks of an upper course.

The top bedding surface of a brick may be adhered to the bottom bedding surface of a brick of an adjacent course with adhesive. The adhesive may be expanding polyurethane adhesive.

The method may comprise using at least one alignment bar to align one or more courses of bricks.

The alignment bar may form part of an alignment frame, the alignment frame further comprising one or more vertical bars.

The method may further comprise providing a brick tie for joining one or more bricks to a support structure, the brick tie comprising a shank with a helical profile and screwing the tie into at least one of said plurality of bricks and into the support structure.

The method may further comprise providing a sill, the sill comprising a plurality of bricks bonded together. The bricks of the sill may be as herein described.

The method may further comprise filling a rebate between adjacent courses with mortar, and moulding the mortar. The mortar may be moulded into one or more of the following shapes: flush; raked; ironed; weather struck or grapevine.

A further embodiment extends to a method of forming a clay brick comprising extruding a clay material to form a brick having an elongate shape defining a top bedding surface, a bottom bedding surface, a face, a back, a first side and a second side, the top and bottom bedding surfaces spanning from side to side, and from the front to the back, and being substantially entirely planar, the method comprising forming complimentary first and second side interlocks in the brick. A further aspect extends to a corresponding brick and a method and system of construction using such bricks.

Brief Description of the Drawings

Non-limiting embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 is a top isometric view of a brick according to an embodiment;

Figure 2 is a bottom isometric view of the brick of Figure 1 ;

Figure 3 is a top isometric view of a brick according to a further embodiment;

Figure 4 is a top isometric view of a corner brick according to a further embodiment;

Figure 5 is a top isometric view of a brick according to a further embodiment;

Figure 6 is a top isometric view of a corner brick according to a further embodiment;

Figure 7 is a top isometric view of two courses of bricks including bricks according to an embodiment;

Figure 8 is a flow diagram of a method of manufacturing a brick according to an embodiment;

Figure 9 illustrates a shaper cap used in a method of manufacturing a brick according to an embodiment;

Figure 10 illustrates a brick column produced in a method of manufacturing a brick according to an embodiment;

Figure 11 illustrates the brick column of Figure 10 cut into slugs to fit a wire cutter;

Figure 12 illustrates bricks after the slug of Figure 11 has been cut by a wire cutter;

Figure 13 illustrates a single brick after being cut by the wire cutter;

Figure 14 illustrates bricks after being cut by a wire cutter according to an alternate embodiment; Figure 15 illustrates a wire cutter used to form the bricks shown in Figures 13 and 14;

Figure 16 is a schematic side view of the wire cutter of Figure 15;

Figure 17 is a view of a portion of the wire cutter of Figure 15;

Figure 18 illustrates a brick after being cut by the wire cutter of Figure 15; Figure 19 is a schematic side view of a wire cutter according to a further embodiment;

Figures 20A and 20B further illustrate the wire cutter of Figure 19;

Figure 21 illustrates a brick after being cut by the wire cutter of Figure 19;

Figures 22A and 22B illustrate a wire cutter according to a further embodiment;

Figure 23 illustrates a brick after being cut by the wire cutter of Figures 22A and 22B;

Figures 24 and 25 illustrate arrangements for forming rebates;

Figures 26 to 31 illustrate a system for forming a construction according to an embodiment;

Figure 32 illustrates a brick tie for use with embodiments of the invention; Figure 33 illustrates a sill for use with embodiments of the invention;

Figure 34 illustrates a lintel for use with embodiments of the invention; and

Figures 35A to 35E illustrate different mortar decoration. Detailed Description of Specific Embodiments

In the attached Figures similar numerals are used to denote similar features in different embodiments.

Figure 1 illustrates a brick 10 according to an embodiment of the invention. The brick 10 includes a front face 12 which is the side which could face the outside of a structure once the brick has been laid. The brick 10 further includes a first or left side 14; a top bedding surface 16 and, as shown in Figure 2, a second, right side 18, a bottom bedding surface and a back face.

The first side 14 is formed with a wedge-shaped interlock 22 and the second side 18 is formed with a complimentary interlock 24. The interlock 24 of the second side is formed as the ‘negative’ of the interlock of the first side 14 so that, when similar bricks are placed side by side, the interlocks engage. Since the respective interlocks in the embodiments illustrated here have a wedge shape it is to be realised that the term ‘interlock’ is used broadly and does not indicate that the respective brick features actually lock. Correspondingly, the term ‘engage’, in this context, is also used broadly to mean that the interlocks interact with one another. The term “engage” is used herein does not necessarily mean that the bricks are fastened to one another. As will be appreciated, the interlock 22 engages with a corresponding interlock 24 in an adjacent brick to inhibit movement of the two bricks relative to one another.

In certain embodiments, the interlocks interact with one another to limit the potential movement of one brick relative to one another. For example, where the interlocks extend vertically on the left and right sides, and the bricks are laid in courses, the interlocks may act to limit movement of adjacent bricks in the same course in a direction perpendicular to the face. This may significantly reduce the time, skill and material required to lay the bricks.

As illustrated, the edges of the first side interlock 22 and the second side interlock 18 have bevelled edges in that the edges are not perpendicular to the sides.

It is to be realised that the top 16 and bottom bedding surfaces, at least in this embodiment, are planar. The bedding surfaces do not include interlocks in the form of any protrusions or matching protrusions and voids which may function as interlocks. Furthermore, the top and bottom bedding surfaces are parallel to one another. It has been found that, using manufacturing methods described herein, it may be possible to achieve tolerances of 0.5 mm or less in the distance between the top and bottom bedding surfaces for any particular brick. In certain embodiments, such a low tolerance assists in providing a system involving many such bricks which are then able to be laid in consecutive courses without the need of a skilled bricklayer and a significant layer of mortar between courses to keep successive courses of bricks level with preceding courses.

It has been found that forming the bedding surfaces without interlocks may provide a reasonable balance between ease and cost of manufacture, whilst retaining advantages such as ease of laying.

The interlocks in the illustrated embodiment are wedge shaped, but it is to be realised that many other shapes are possible. For example, the interlocks may comprise a tongue and groove or a dove tail arrangement, or a combination of these.

The brick 10 is formed with a number of vertical cores 32 (10, in this embodiment although other embodiments may have more, fewer, or no vertical cores).

A horizontal rebate 30 comprising a recess of the front face 12 is formed at the edge between the top surface16 and the front face 12. A further horizontal rebate 34 formed between the top surface 16 and the back face 38. A vertical rebate 28 is formed at the edge between the second/right side 18 and the face 12.

Figure 3 is a top isometric view of a brick 50 according to a further embodiment. The brick 50 is similar to the brick 10 with the exception that the brick 50 does not have a rebate formed between the top surface 16 and the back face 38. Bricks without a back rebate may be used where the back face is not visible, for example in a double wall.

Figure 4 is a top isometric view of a corner brick 60 according to a further embodiment. The corner brick 60 includes a front face 62, a first or left side 64, a bottom bedding surface 66 a second or right side 68 and a top bedding surface 70. The bottom bedding surface, back side and right side are not shown in Figure 5. Since the corner brick 60 is intended for use with the bricks 10 and 50 illustrated in Figures 1 to 4, this brick is formed with a rebate 66 which runs around the periphery of the top of the brick. Figure 5 is a top isometric view of a brick 80 according to a further embodiment. The brick 80 is similar to the brick 50 illustrated in Figure 4, but has an additional horizontal rebate 82 formed between the top bedding surface 20 and the front face 12.

Figure 6 is a top isometric view of a corner brick 90 according to a further embodiment. The corner brick 90 is suitable for use with the brick 80 illustrated in Figure 6. Therefore, the corner brick 90 is similar to the corner brick 60 illustrated in Figure 5, but includes an additional bottom rebate 92 which runs around the periphery of the bottom of the brick.

Figure 7 illustrates a construction 100 involving bricks according to embodiments. The construction 100 comprises two horizontal courses of bricks 102 and 104. Each of the courses comprises a plurality of standard bricks 106 and corner bricks 108. Each of the standard bricks 106 is the type of brick is illustrated in Figure 1 whereas the corner bricks 108 are of the type of brick illustrated in Figure 4.

A system for constructing a construction such as the construction 100 illustrated in Figure 7 is described in further detail below. For now it is worthwhile noting that a course of bricks is formed by the placement of bricks 106 and corner bricks 108 in the desired configuration. The bricks in this embodiment are glued in place but it is to be realised that other forms of attachment such as mortar may be used instead. Suitable glues are expanding polyurethane adhesives such as Akfix 962P Concrete, Stone & Brick Adhesive, Weinerberger Porotherm DryFix and Soudal Soudabond Easy.

The vertical rebate 28 and the horizontal rebates 30 and 66 can be textured or painted to complete the desired appearance. Such finishing may include one or more of: filling with grout or mortar; smooth or wire cut texture; rendering; painting; or painting with textured paint.

It is to be realised however that not only the specific dimensions, but the relative dimensions of the bricks may be altered. For example, the brick may have one of the following sets of dimensions (length x width x height):

230 x 110 x 76 mm,

290 x 90 x 50 mm,

203 x 92 x 57 mm,

194 x 92 x 57 mm,

215 x 102.5 x 65 mm, 240 x 115 x 71 mm,

208 x 107 x 69 mm,

240 x 115 x 63 mm,

228 x 108 x 54 mm,

222 x 106 x 73 mm,

250 x 120 x 65 mm,

250 x 120 x 62 mm.

Other dimensions are possible too, depending on the specific requirements of the site where they are to be used.

Figure 8 illustrates a method 200 of manufacturing a brick according to an embodiment. In the initial step 202, the raw materials are formed. The choice of materials will depend on the desired appearance and composition of the brick and is known in the art. The raw material is then extruded to form a column in step 204.

The column is extruded through a shaper cap 230 illustrated in Figure 9. As shown, the shaper cap is shaped to form the side interlocks and the vertical rebates. The moulding cap is shaped as a ‘negative’ of the shape required. It is to be realised that the shaper cap may be easily adapted to change the shape of the interlocks and the vertical rebate. Therefore, it may be easy to adapt the method of manufacturing to many different brick shapes and forms.

A column 240 formed by this step is illustrated in Figure 10.

At step 206 the columns are cut to form slugs which are dimensioned to fit a wire cutting machine. Slugs 250 formed in this manner are illustrated in Figure 11.

At step 208, each slug is cut into bricks with wire cutters. As illustrated in Figures 12 and 13, the wires form cuts 262 which establish the face and back of the bricks 260. In a first embodiment, at the same time, a score 264 is made to establish part of the horizontal rebate (here made by a roller - see below). In this embodiment, the horizontal rebate is then completed during a cutting process by cutting perpendicular to the cut 264.

In an alternative embodiment, the entire horizontal rebate is formed by appropriately placed blades in the wire cutter.

A suitable wire cutter 270 is illustrated in Figures 15, 16, 17A and 17B. The wire cutter includes wires 272 to cut the slug into bricks. In this embodiment, the wire cutter also includes disc cutters 274 and knives 276 arranged both above and below the slugs, in this embodiment. The disc cutters 274 form a first cut at the top and bottom of the brick (in the orientation in which they enter the wire cutter). These first cuts are then widened by the knives 276 to form the horizontal rebates 266 as illustrated in Figure 14. It is to be realised that the brick 260 illustrated in Figures 17A, 17B and 18 corresponds to the brick 10 depicted in Figures 1 and 2. Therefore, the horizontal rebates 266 correspond to the rebates 30 illustrated in Figures 1 and 2.

Figures 19, 20A, 20B and 21 illustrate a wire cutter 280 according to a further embodiment. The wire cutter 280 includes wires 282 and disc cutters 284. As illustrated best in Figure 20B, as the slug passes through the wire cutter 280, the wires 282 separate the slug into individual bricks 286 and the disc cutters 284 form rebate cuts 288 at the top and bottom of the brick (in the orientation in which the bricks emerge from the wire cutter 280).

The wire cutter 280 differs from the wire cutter 270 illustrated in Figures 15,

16, 17A and 17B in that it excludes blades used to form the horizontal rebates. In this embodiment, the horizontal rebates are instead formed once the bricks have been fired in a manner described below.

The bricks 286 correspond to the brick 10 depicted in Figures 1 and 2. Therefore, the cuts 288 will help to form the horizontal rebates 266 of the brick 10.

Figures 22A, 22B and 23 illustrate a wire cutter 300 according to a further embodiment. The wire cutter 300 includes wires 302 and two double-disc cutters 304. As the slug enters the wire cutter, the wires 302 cut the slug into individual bricks 306. The double-disc cutters 304 form a first cut on either side of the cut formed by the wire 302 in both the top and the bottom of the brick (in the orientation in which the bricks enter the wire cutter 300).

Since the double-disc cutters 304 form cuts to either side of the cut formed by the wire 302, adjacent bricks will receive a rebate cut 310. In this manner, each brick will receive four rebate cuts (two at the top and two at the bottom and the orientation in which they enter the wire cutter 300). The rebate cuts 310 then form the basis for the horizontal rebates which are then formed after the brick has been fired in the process described below.

The bricks 306 formed with the wire cutter 300 correspond to the brick 80 illustrated in Figure 5. Therefore, the rebate cuts 310 will form the basis for the resultant rebates 30 and 82 illustrated in Figure 5.

Referring back to Figure 8 at step 210 the bricks are dried and then cured by firing in a kiln. Lastly, at step 212, the cured bricks are ground where required to form flat bedding surfaces. For bricks which do not use mortar such as bricks according to embodiments it may be important for the bedding surfaces to be flat and planar. The grinding of the horizontal rebates, for those bricks where this is required, would be carried out at step 212.

Figure 24 illustrates schematically the process whereby the rebate cuts are formed by the wire cutters 280 and 300 discussed above. Four grinding discs 320 grind the corners of the brick 306 to form the horizontal rebates 308. The grinding discs 320 oppose so that the rebate cuts 310 form a periphery of the horizontal rebates 308.

The bricks 306 illustrated in Figure 24 correspond to the brick 80 illustrated in Figure 5 and therefore, four horizontal rebates 308 are formed by the grinding discs 320. Florizontal rebates are formed in the bricks 286 illustrated in Figures 18, 19,

20A, 20B and 21 in a similar manner, but only two grinding discs are provided.

Figure 25 illustrates four grinding discs 330 which are used to form the horizontal rebates 308 of the brick 306. This could be applied where no score marks are applied to the wet brick (the horizontal rebates are formed via one post-firing grinding process using the grinding discs 330). It is to be realised that appropriate grinding discs may be chosen to form the desired cosmetic finish to the horizontal rebates 308.

A further embodiment extends to a method of manufacturing a structure using bricks as herein described. The bricks are laid in courses with side interlocks engaging with one another. Glue instead of mortar is used to adhere courses together. Once constructed, the rebates may then be filled with mortar so that the structure resembles a traditionally laid facing brick structure.

Figures 26 to 34 illustrate portions of a construction 400 formed with bricks according to embodiments. The construction 400 comprises a plurality of sequentially laid courses of bricks 408A, 408B, 408C and 408D (only four courses shown here but it is to be realised that a construction may comprise many more than four courses). Each of the courses of bricks is formed as illustrated in Figure 7 and comprises a plurality of both standard bricks 106 and corner bricks 108. As previously mentioned, one of the advantages of embodiments may be that the courses of bricks are easy to lay since cooperating interlocks of adjacent bricks may be used for quick registration. Furthermore, as mentioned the bricks have planar and substantially parallel bedding surfaces which may help to ensure level bedding of the courses without the use of a layer of mortar or skilled bricklaying. In order to further expedite the process it may be advantageous to provide an alignment frame 410 to potentially ensure that the courses of bricks are laid in the position and orientation required.

The alignment frame 410 comprises a plurality of vertical bars 412 and horizontal bars 414. The vertical bars 412 are attached at a top to a timber support frame 450 by means of top brackets 420. At the bottom, the vertical bars 412 are attached to the construction 400 by bottom spacers 422 which attach to the vertical bars with brackets 426. The horizontal bars 414 are attached to the vertical bars 412 by means of adjustable brackets 424.

As additional courses of bricks are added to the construction 400, the horizontal bars 414 provide a registration for the courses and are then moved up by loosening and tightening the adjustable brackets 424.

As illustrated in Figure 31 , the bracket 424 includes four holders 430, 432, 434 and 436 which support the horizontal bars. Two bars are provided on either side so that, as illustrated in Figure 26, two horizontal bars can be supported by the same bracket at the junction of two walls. Since the bedding surfaces of the bricks are substantially parallel, the horizontal guides are needed to provide vertical registration of the bricks of the course. Therefore, the exact vertical location of the horizontal bars within a course is not material.

The vertical bars 412 are used at the corners of the construction. As illustrated in Figure 26, the frame 410 further comprises vertical bars 442 for use on facades (non-corner) portions of the wall. In this case, (see Figure 29) the bracket 424 attaches the horizontal bar 414 to the vertical bar 442 and bracket 450 attaches spacers 422 to the vertical bar 442. Bracket 450 and spacers 422 are provided as a single unit.

The bracket 424 includes a spring release 428, and bracket 424 includes spring release 448, so that the corresponding brackets can be released from the vertical bar 412 and/or vertical bar 442 (when attached at that position) and moved up to the position corresponding to the next course and released. This may facilitate quick movement of the horizontal bars and may help to provide a system which may be used without extensive training whilst still facilitating quick laying of the bricks.

As illustrated at Figure 30, the system can be attached to external corner as well as the internal corner (Figure 28). The bracket for attaching the horizontal bars, but the bottom bracket for attaching the vertical bars to the lowest course via spacers has the three different arrangements shown in Figures 28 (internal corner), 29 (fagade or straight) and 30 (external corner).

Figure 32 illustrates a brick tie 460. The brick tie 460 is used to anchor the construction 400 to the support frame 450. The brick tie 460 in this embodiment has a helical shape which allows it to be screwed into the support frame 450 (which is usually comprised of timber). The brick tie 460 is drilled through the bed-rebates of the brick 106 and then into the support frame 450. Alternatively, the brick tie may also be used with the corner bricks discussed above.

Figure 33 illustrates a sill 470 formed with bricks 108 according to the embodiment. As illustrated, in this embodiment, corner bricks 108 are used. Five corner bricks are adhered to one another using the adhesive previously mentioned. Once the sill 470 is formed in this matter it can be inserted as a windowsill, for example, in a construction 478 as illustrated.

Figure 34 illustrates a lintel 580 installed in a construction 590 according to an embodiment. As illustrated, corner bricks 108 are modified to accommodate the lintel 580 by removing a portion of the top of the bricks defined by the horizontal rebates 308.

As mentioned above with reference to Figure 25, the horizontal rebates may have a cosmetic finish applied during the grinding step. An alternative is to apply mortar to the horizontal rebates. The mortar may be finished in various forms by providing different shapes to the mortar. Figure 35 illustrates a number of different shapes which can be applied:

Figure 35A flush;

Figure 35B raked;

Figure 35C ironed;

Figure 35D weather struck; and Figure 35E grapevine.

List of numerals

10 Brick

12 Front face

14 First/left Side

16 Bottom bedding surface

18 Second/right Side

20 Top bedding surface

22 First/left side interlock

24 Second/right side interlock

28 Vertical rebate

30 Florizontal rebate

32 Vertical cores

34 Florizontal rebate

38 Back face

60 Corner brick

62 Front face

64 First/left Side

66 Bottom bedding surface

68 Second/right Side

70 Top bedding surface80 Brick

82 Florizontal rebate

90 Corner brick

100 Construction

106 Brick

108 Corner brick

102, 104 Longitudinal grooves

120 Corner brick

200 to 212 Method and method steps

230 Shaper cap

240 Column

250 Slug

260 Bricks

262, 264 Cut

266 Florizontal rebates

270 Wire cutter 272 Wire 274 Disc cutters 276 Knives 280 Wire cutter 282 Wire 284 Disc cutters 286 Bricks 288 Rebate cut 300 Wire cutter 302 Wire

304 Double-disc cutters 306 Brick

308 Horizontal rebates 310 Rebate cuts 320 Grinding discs 330 Grinding discs 400 Construction 408 Courses 410 Alignment frame 412 Vertical bars 414 Horizontal bars 420 Top brackets 422 Bottom spacers 424 Adjustable bracket 426 Adjustable bracket 450 Support frame 460 Brick tie 470 Sill

478 Construction