BLOG | Physical test data removes guesswork from masonry support specification

Masonry support systems have been crucial to improvements in both brick building design and safety. However, until IG Masonry Support drove the development of a new and reliable testing regime, assumption played a large part in the specification of ancillary masonry products for UK projects. So, how does IG Masonry Support’s testing system work, and why is there no uniform regulation regarding masonry support products? Emanuele Scarabino, IG Masonry Support’s R&D Manager explains. 

It’s very difficult to create a design code for masonry support products that can be shared, acknowledged and absorbed by other countries. In Italy and Spain, for example, masonry soffit systems and the like are not widely used due to brick not featuring as prominently within the architecture. Whilst in Britain and Ireland, where brick facades have been prevalent throughout the built environment for many decades, there has been no compelling reason to introduce regulatory testing guidelines because there have been no major issues with masonry support products in buildings.

Consistency is very important when it comes to the testing and design of building products. Without it, assessment methods and maintenance statements are a thing of individual responsibility. Whilst this approach might satisfy the requirements of one structural engineer, it might not be appropriate for another. Without uniform testing data in place, it leads to assumptions being made on a building product’s projected performance. The absence of such detail could lead to incorrect product specification dramatically increasing the risk of failure.

At IG Masonry Support, we developed a physical testing method to ensure the assumptions we made on our products’ performance were correct. In the five years since we devised the process, we’ve carried out more than 1,000 tests. It means if a consultancy engineer enquires as to why a particular masonry support system needs to allow for a specific deflection, we have the data to support our decision.

Test process

Our physical testing method was developed over several months. It’s carried out using a masonry support testing rig, a 2m x 3m steel structure that simulates the strength and response of a 10-storey building. Assessments take place at Queen’s University Belfast Laboratory using UKAS-accredited machinery. Such facilities are ideal for fulfilling IG Masonry Support’s philosophy: ‘test as much as possible in order to prove the assumptions you make’.

In terms of how we apply loads to assess the masonry support’s ‘real-life’ impact via our testing rig, we undertook finite element analysis (FEA) using three different software, the main two being SolidWorks and ANSYS. Through FEA, we identified how to replicate bricks’ weight and density and the optimum way to load them to the testing rig’s top shelf.

The process became the blueprint for hundreds of assessments, the results of which were included in a paper published in conjunction with Queen’s University, Belfast: “Experimental Study of Vertical Deflection on Bracket-Angle Stainless Steel Masonry Support Systems”. To our knowledge it is the first testing-based paper in relation to masonry support. Data and testing images included within the paper have since been shared at conferences hosted by Queen’s University Belfast and the Institution of Structural Engineers.

Software development

The need to develop products and processes that help improve building standards continues to drive us. Hence, we developed bespoke software which stores all of our test results on a single database. We designed the software to be capable of creating the ideal masonry support solution based on a set of key values including wall cavity, concrete slab height and brick density. As well as giving an accurate prediction of our masonry support system deflection, the software is capable of designing all of the other system values around it – the support’s stainless-steel thickness, for example. Will a 5mm or 4mm angle provide enough capacity? Our software will answer that question too, based on a list of stress checks that also include brackets and a range of general fixings.

The software provides a printout of the design specification of each IG Masonry Support product. From deflection estimation to fixing design, clients are provided with an accurate, reassuring summary of the system’s performance backed by test data. Industry reaction has been very positive about our innovation in masonry support test methodology, with associate engineering consultants telling us the system has instilled an additional layer of trust in IG Masonry Support products, compared to our competitors. But our innovation continues. Since we originated the software in 2018, we have carried out more than 50 updates in order to adapt and refine its performance.

IG Masonry Support’s software package benefits our engineers by bringing uniformity to the masonry support design process. It also helps our clients, as it not only selects the best system from a design perspective, it chooses the most cost-effective solution from all the available structurally-safe masonry support designs. Furthermore, the software package is very good news for the construction industry. It proves that our masonry support products are not assigned on assumptions but they have been physically tested setting the foundation for a process that can only improve building standards in terms of safety and design.

BLOG | A holistic approach is key to the construction sector fulfilling carbon zero targets

The delivery of sustainable buildings has been a focus for many years, writes Andy Neal, Managing Director of IG Masonry Support, but with the UK government requiring the country to be net zero by 2050, the need for the construction industry to improve its emissions output has become more acute.

Whilst buildings that offer low energy in-use are critical, the environmental impact of materials and their production is just as important. If manufacturers are to fully take ownership of their sustainable responsibilities, it will require making a holistic assessment of their overall environmental impact. This includes focusing on their day-to-day production processes, which will play a large part in delivering low carbon buildings of the future. Therefore, committing to a companywide approach, rather than focusing solely on the environmental credentials of its products, is integral to a successful carbon zero strategy.

Taking the initiative for product innovation

IG Masonry Support’s carbon zero programme was set up because we as a company wanted to be recognised as a sustainable organisation in our own right, regardless of what other businesses were doing. But it also dawned on us that manufacturers such as ourselves had a big responsibility to innovate the low carbon products the construction industry needed to increase the carbon efficiency of the UK’s future building stock.

Providing a wider range of sustainable products will give builders greater influence when it comes to the reducing environmental impacts of the properties they are creating. This is far from the case, currently. It’s estimated that even major housebuilders have only 1% control over the building process, because everything they build with is supplied by a host of different sources which vary in sustainable composition and performance. Therefore, to build with greater efficiency and consistency, construction companies need to engage with responsible sustainable manufacturers, who in-turn need to innovate products that result in less environmental impact.  Improving building sustainability isn’t a standalone exercise. Individual companies have the capability to control the eco-friendly aspect of their business and products. Ultimately, however, it’s the responsibility of the building supply chain to innovate solutions that provide end users with the best possible chance of creating sustainable buildings.

Sustainable steps

The first major steps in our sustainability journey were taken when we switched to 85% recycled stainless steel and reduced our landfill waste to 0% in 2018. We have continued to take leaps towards achieving our ambitions and more recently became a carbon neutral organisation. This was achieved by enlisting the services of an external body (Carbon Footprint) whose initial task was to clarify how far short we were from our target. Following this assessment, we embarked on an offsetting programme to reduce the business’s CO2 emissions. We further reduced our emissions footprint by changing to a ‘green’ utility supplier and swapping our diesel trucks for an electric fleet. Furthermore, our purchase of less energy intensive fibre laser cutting machinery has also reduced our material waste.

The introduction of our carbon neutral programme coincided with the launch of our B.O.S.S A1. an ultra-lightweight brick on soffit system. As a component building part, its carbon neutral status was important to us. Its certification soon led to the company’s carbon neutral classification in June 2021. Achieving this required us to do our homework to fully establish what carbon neutrality actually consisted of, as well as understand the legislation behind it. For this we recruited a Sustainability Manager from within the company. Having a staff member being trained by external bodies to ensure companies within our group were fully-versed in carbon neutral legislation was an important step for us. Our Sustainability Manager now heads-up a team of volunteer staff who meet weekly to discuss ways in which we can progress our net zero ambition.

In terms of our offsetting initiative, rather than simply plant trees, we’ve invested in long-term sustainability energy programmes. Hence, our commitment to wind and solar schemes. Through our acquisition of a gap analysis template, we hope to demonstrate how such schemes are significantly reducing our offsetting requirement less and less each year.

Following the science

Our actions do not stop there, however. We are following Science-Based Targets Methodology, which has achievement parameters of between five and 15 years into the future. This process is being carried out alongside our collaborative workshops with the British Standards Institution, which have helped sculpt a sustainable culture into IG Masonry Support. It’s helped formed an approach to sustainability that focuses on optimising our social, financial and intellectual capital, as well as our environmental wealth. These key elements ensure our strategy is inclusive, reflects our company values and importantly, will be successful. It is our mid-term aim to reduce our Scope 1 and Scope 2 emissions by 76% which covers direct emissions from owned or controlled sources, and indirect emissions from the generation of purchased electricity, steam, heating and cooling consumed by the reporting company, respectively.

I believe we attained carbon neutral status sooner than anticipated because of the company’s inherent desire to do the right thing, rather than wait to have measures forced upon us. Whether it’s achieving ISO 9001 certification or matters related to any form of industry compliance, our approach is always the same. We don’t carry out these processes as a box ticking exercise by rushing to get all the paperwork the day before the auditor comes in. We have a dedicated sustainability team set up who are passionate about driving this forward. We do it properly because we want to advance our business’s carbon zero status, the quality of our product and help facilitate a sustainably-built environment for future generations to enjoy.

Check out IG Masonry Support’s Sustainability Journey>>

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Photo caption: IG Masonry Support achieve Carbon Neutral Status (Left to right) Jemma Ison (Keystone Group Sustainability Manager), Kyle Alexander (Project & Engineering Manager), Andy Sharlot (Chief Designer), Andy Neal (Managing Director), Oliver Ball (Operations Manager) and Stephen Jennings (Financial Controller).

NEWS | Awards Success for IGMS

IG Masonry Support are delighted to have produced bespoke brickwork solutions to a number of the winners from the Brick Development Association (BDA) Brick Awards 2021.

The Awards, which took place on Wednesday 10th November 2021, celebrate the very best examples of clay in the UK’s built environment.

A total of 14 projects shortlisted at the annual awards contained IGMS products and four of these projects won their category or were highly commended including:

  • Lambeth Brick Palace Library – Supreme Winner and Public Category Winner
  • Pump House – Small Housing Development Category Winner
  • Catherine Hughes – Education Category Winner
  • St Leonard’s Court – Commended in Urban Regeneration Category

This success signifies the quality of IG Masonry Support products and services and the impact that we have on modern construction and architecture.