EVENT | CPD Webinar Series 2024

We’re excited to announce the dates for our CPD Webinar Series for 2024. This series includes both our current CPDs: Specifying Sustainability and Achieving Intricate Brick Features.

The first CPD of the series, Specifying Sustainability, will be hosted on Thursday 14th March (12-12:30 pm) by our Specification Executive, Jemma Ison. Jemma will explore how offsite construction and conscious material selection can promote a circular economy. During the 30-minute webinar, she will delve deep into the global challenge and the need to decarbonise our sector, awareness of the sustainable benefits of offsite construction solutions, sustainable material selection to promote a circular economy, and how the Keystone Group is proactively delivering Net Zero applications.

The second CPD of the series, Achieving Intricate Brick Features, will be launching on Thursday 22nd March (12-1pm). The 60-minute webinar will explore topics such as bespoke brick slip solutions that comply with Document B: Fire Safety, traditional methods of forming brick soffits versus new technologies, why material selection is limited to stainless steel for masonry support systems, and levels of adjustability in the different masonry support systems to accommodate site tolerances.

These two CPD topics will be available monthly throughout 2024.

Our Specification Executive and Keystone Group Sustainability Manager Jemma Ison commented: “IG Masonry Support understands how important it is for architects, specifiers, and engineers to stay up-to-date on the latest construction trends and how they can help to enhance future projects. We understand that work time is precious and so is continuous professional development therefore we feel that short, concise webinar sessions will support this development in the most effective and time-conscious way.”

To find out more or book a CPD session throughout 2024, visit our CPD page.

BLOG | Prefabricated masonry techniques elevate brick’s status as a sustainable building material

Brick is one of the world’s most sustainable building materials. Reliable, durable, and recyclable, bricks’ evolution as a low-impact product has been hastened by the introduction of increasingly innovative masonry support systems. As Jemma Ison (Keystone Group Sustainability Manager and IG Masonry Support Specification Executive) highlights, these prefabricated techniques have not only expanded the architect’s palette in terms of brickwork design, they have advanced and simplified the build process to give bricks a sustainable advantage over other established materials.

Masonry is a classic and timeless building material that achieves superior, maintenance-free results. Utilising masonry in prominent areas can be essential to delivering an architect’s overall vision, or fulfilling a client’s brief to ensure a project remains in keeping with the local surroundings. Brick Slip Systems are adaptable to suit any application. Ideal for small openings over window heads but also deliver effortless results spanning an entrance of a commercial building. Whatever the desired finish, IG Masonry Support‘s prefabricated units provide high-quality results at low environmental impact.

Time and energy saver

The average time it takes to create intricate masonry details with prefabricated brick slip solutions is estimated to reduce time by 90% in comparison to traditional onsite methods. As well as the time-saving factor there are many other benefits associated with offsite production, from improved construction efficiencies and reduced onsite waste to minimal site impacts due to the fit-and-forget design. Furthermore, a prefabricated unit is produced in line with manual handling guidelines. Therefore, designed to be easily managed and handled onsite. This eliminates the consumption of any fuel or electricity needed to aid the installation process.

Skills shortage

Whilst highlighting the direct and indirect sustainable benefits of these prefabricated methods, it is also a recognised challenge that traditional techniques require the services of a highly-skilled bricklayer. In the current climate, this might not be an appointment that is easy to secure. The bricklaying sector, as with the construction industry as a whole, is in the midst of a well-publicised skills shortage. Indeed, the Construction Skills Network (CSN) has forecast a need for 1,450 more bricklayers per year over the next five years to help fulfil UK building projects. Therefore, it could mean an appropriately-qualified bricklayer travelling many miles to work on a particular project, a journey that would incur additional fuel consumption and environmental impacts.

Natural hindrances to efficient brick detailing 

When it comes to achieving intricate brick details, a building site is far from the ideal environment. Poor weather can hamper high-quality workmanship and build consistency. This can lead to reworks and additional project time, cost, and material waste. Whereas offsite manufacture takes place in a controlled environment, enabling products such as brick slip systems to be produced with greater skill and accuracy.

Safe and adaptable solution  

Due to their A1 fire-rated finish, IG Masonry Support’s prefabricated brick slip products provide peace of mind to specifiers due to their reliability and compliance with building regulations. The product range includes the company’s ultra-lightweight brick on soffit system, B.O.S.S A1. A component building part, the product’s superb performance is supplemented by its sustainable credentials, which are supported by its carbon neutral classification. In addition, IG Masonry Support’s Brick Slip Arches have increased design options for architects looking to use masonry in evermore striking and imaginative ways. Manufactured offsite, the Brick Slip Arches are bespoke designed to order, and delivered to site replete with brick slips adhesively bonded to a stainless-steel unit. These lightweight units facilitate fast and efficient installation and integrate seamlessly with brickwork constructed onsite.

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Environmental Product Declarations

IG Masonry Support is committed to becoming a net-zero carbon business in line with the Science Based Targets. Its adoption of Environmental Product Declarations (EPD) is further evidence of its sustainable ambition. The company is the UK’s first masonry support supplier to issue EPDs on its products, thus providing full transparency of their environmental impact. The declarations are in accordance with GreenBook Live EPD system.

A Type III environmental label, an EPD is generated using data obtained through Life Cycle Assessment (LCA). This is performed via a peer reviewed Product Category Rules document (PCR) in line with EN 15804 (the European Standard for the generation of EPD for construction products), ISO 14025, and other related international standards.

Dual benefit

In terms of their installation, IG Masonry Support is the only UK manufacturer to offer a solution that has dual security using an A1 fire-rated adhesive as well as a secondary stainless steel mechanical fix, providing safety and added aesthetic consistency.

In short, prefabricated brick slip systems are ideal for wherever an intricate brick detail is required. Their specification and installation are made all the easier and more effective through engagement with a prefabricated brick slip specialist such as IG Masonry Support. The company’s single point of contact controls the design, pricing, and manufacturing process, providing tentative support and expert communication throughout a project.

Quality, consistency, and greater sustainability are the ultimate outcomes of the correct specification of prefabricated brick slip solutions, which are gaining in popularity as developers and architects look to expand the use of one of the world’s oldest, most reliable building materials.

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EVENT | Free CPD Webinar Series for 2023

IG Masonry Support announces the launch of a free Continuous Professional Development (CPD) webinar series for 2023. The series features both of IG’s current CPDs; ‘Achieving Intricate Brick Features’ and Specifying Sustainability.

The first webinar ‘Specifying Sustainability’ will take place on Thursday 20th April from 12 – 12:30 pm and will be led by our Specification Executive, Jemma Ison. Jemma will explore how offsite construction and conscious material selection can promote a circular economy. During the 30-minute webinar, she will delve deep into the global challenge and the need to decarbonise our sector, awareness of the sustainable benefits of offsite construction solutions, sustainable material selection to promote a circular economy, and how the Keystone Group is proactively delivering Net Zero applications.

Two webinar sessions will be available per month throughout the whole of 2023. As well as the ‘Specifying Sustainability’ CPD, on offer is also our ‘Achieving Intricate Brick Features’ CPD. This webinar explores brick soffit systems and the support of masonry cladding on framed buildings.

Jemma Ison, Specification Executive and Keystone Group Sustainability Manager commented: “IG Masonry Support recognises the importance of architects, specifiers, and engineers keeping abreast of modern methods of construction and how they can support and improve future projects. We truly understand that work time is precious and so is continuous professional development therefore we feel that short, concise webinar sessions will support this development in the most effective and time-conscious way.”

To book or find out more about the CPDs and dates available throughout 2023, visit our CPD page.

BLOG | Evolution of masonry support solutions helps put a stylish new face on public buildings

Reliable, weather-resistant, and age-proof brick remains an ideal building material. Innovation, in terms of masonry techniques, means brick can be used in evermore inventive ways, allowing a solid, stylish finish to homes and a range of buildings. Here, Scott Denham, Sales Director at IG Masonry Support, looks at how manufacturing expertise and design technology are bringing a new look to traditional brickwork.

Due mainly to its consistent shape, compressive strength and ability to absorb water, many generations of architects have selected brick as their go-to building material. Its popularity hasn’t gone

unchallenged, however, with the past decade or so seeing the emergence of solutions such as cladding. But in keeping with the well-known phrase, ‘form is temporary, class is permanent’, brick is back in vogue as an inspiration to property owners and designers looking to emulate modern interpretations of classic architecture.

Architecturally, the intricate detailing that brickwork enables is without compare. Brick detail in the form of brick soffits, brick feature arches, deep reveals and flying beams continually make for stunning exteriors, enabling architects to create truly unique facades. Brick’s popularity in the UK and Ireland as a tried-and-trusted building source was unrivalled until modern composite cladding systems containing materials such as steel, concrete and aluminium offered a quicker, cheaper route to creating bright, contemporary-looking buildings. Such convenience comes at a cost, however. Aesthetically, modern cladding systems can begin to look tired and dated over time, thus regular and potentially costly maintenance can be needed to upkeep or upgrade them. This brings into question their long-term cost efficiency, but not-so-brick-built facades, which will retain their impressive look many years after their initial construction.

A bespoke solution

At IG Masonry Support, not only do we understand that architects need to be given creative authority over prefabricated brick features, we realise the importance of regulatory compliance and quality.

Achieving deep brick soffits and intricate brick bonds around window heads and openings is quick, easy and cost-efficient to achieve with our Brick On Soffit Systems (B.O.S.S. and B.O.S.S.+). These tailor-made bespoke solutions are designed and manufactured to meet the client’s specification. The systems are highly adjustable, enabling architects to design various shapes and depths of brick soffits whilst accommodating a wide range of bond patterns.

To meet changes to Building Regulations, IG Masonry Support engineered B.O.S.S.+, an A2 fire-rated system suitable for use on projects that require Building Regulations Document B compliance. The second generation of its original B.O.S.S. system, B.O.S.S.+ comprises a stainless-steel framework with a cement particle board backing element to which the brick slips are adhesively bonded and mechanically fixed. In short, this BBA-certified solution ticked the boxes in all of the required areas and was available to the market in 2019.

Not resting on its laurels, IG Masonry Support’s next step was to create a fully non-combustible and carbon-neutral product. The BBA-certified B.O.S.S. A1 system is ‘A1’ fire rated and has been subjected to hygrothermal testing. The product passed the rigorous examination with ease. As well as meeting current fire regulations regardless of the building’s height or purpose, the manufacturing process and environmental impacts will be significantly reduced.

Marlborough Primary School

IG Masonry Support’s B.O.S.S. system was selected as the ideal solution to create a stunning brick detail around large, circular windows, which form part of a major redevelopment at Marlborough Primary School in west London. The window feature, designed in conjunction with the project’s lead architect Dixon Jones, required IG Masonry Support to prefabricate a series of imposing circular-form B.O.S.S. deep soffit systems containing green-glazed slip bricks. The soffits’ shape and colour acknowledge the polychromy of a nearby 1911 Michelin building. In situ, this magnificent brick detailing brings an exciting, creative energy to the refurbished school’s vibrant new learning environment.

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Alison Gingell Building, Coventry University

A new health and science building at Coventry University offers a fine example of how innovative masonry techniques have revolutionised brick’s use as a design accessory. The Alison Gingell Building was created to provide students with ‘world-class facilities’, enabling them to learn in situations that mirror real-life scenarios. Following consultations with architect Broadway Malyan, IG Masonry Support supplied the building’s standout architectural feature: 23 large-scale brick slip fins, which appear throughout the health and science block’s south elevation. The prefabricated fins were designed and manufactured by IG Masonry Support using slip bricks within a brick panel system, which the company developed to allow designers and specifiers to achieve a deeper soffit that blended seamlessly with surrounding brickwork.

Coventry University

Time and cost savings

No matter how ambitious the design, IG Masonry Support’s easy-to-install solutions deliver significant reductions in installation time by up to 90%. Any higher initial costs can be offset by saving time and money in terms of labour. A quality finish that meets the required aesthetics and blends seamlessly with the surrounding brickwork can also be achieved.

As with a beloved work of art, brick is a design classic that will continue to be rediscovered by future generations. It will ensure brick’s relevance to private homes and public buildings that will gain in style but lose nothing in terms of stature and safety by the additional design possibilities it now allows. This is due in part to companies such as IG Masonry Support and their commitment to developing solutions that enable brick, a staple construction material, to be used in ways that fire the imagination of architects and builders alike.

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.