Regarding ceramic blocks, or as they are also called - warm ceramics, there is a lot of controversy on the sidelines of construction. Some extol its virtues to the skies, while others bring us back to earth with their pessimistic moods.
In this article we will try to impartially evaluate all the advantages and disadvantages of this material, and also, using the video in this article for clarity, we will tell you how walls are built from ceramic blocks with brick cladding.
The main goal pursued by the creators of new structural wall materials is to increase the thermal efficiency of walls. A material that allows them to be erected quickly, without increasing their thickness too much and with minimal labor intensity is simply a godsend for any developer. And if at the same time it practically does not need insulation, then it simply has no price!
This is exactly how everything will be arranged with a relatively new look wall block, made from clay, and therefore rightfully called ceramic.
What is the peculiarity of the material?
Everyone knows that ceramics are cold material. How did it happen that the thermal conductivity coefficient of a ceramic block is almost equal to that of cellular structural concrete?
- The thing is that its structure is also maximally saturated with air - and not only due to the cracks in the body of the block, but also due to the large number of pores in the ceramic itself.
- To achieve a porous structure, sawdust is added to the clay during the production process. When fired, they burn out, leaving air cavities in their place. That is why such ceramics are called porous.
- However, not all ceramic products have such heat preservation abilities. In one of the photos presented above, you can clearly see the stages of evolution that wall ceramics have gone through from simple solid brick to the so-called superporous thermoblock.
- In the process of improving technology, solid brick first became slotted, then its format increased to 2.1NF, which corresponds to double size (with a standard length and width, height 138 mm).
- At the next stage, a large-format block appeared - including a maximum format of 14.5NF with dimensions of 510 * 253 * 219 mm, which at first was simply slotted.
- Porosization with the help of sawdust began to be used only later - they created that very warm ceramics, the thermal conductivity of which was reduced first to 0.12, and then, due to superporization, to 0.107 W/m*C.
Note: The thermal conductivity of the superporous block is equal to that of expanded clay and foam glass - and they are known to be full-fledged thermal insulation materials. In terms of thermal engineering, such walls are not inferior to wood, but at the same time they are much stronger and will last longer.
As for the strength of blocks made of porous ceramics, which skeptics doubt, nodding at the relative fragility of the material, we will always have something to answer them.
Opinion: Glass is also a fragile material, but not only internal partitions and stairs are made from it, but they also manage to completely glaze the facades of houses. Ceramic, like glass, does not like impact, but can be drilled perfectly - despite the thin partitions inside the blocks. And if you don’t hit the walls of the house with a sledgehammer, they certainly won’t be in any danger.
What to choose for construction
Today, all of the above types of wall ceramics are on sale, including finishing ones. Which ones to buy for building a house, you need to be guided by local climatic conditions. It is on them that the thickness of the walls depends, as well as the need for their insulation.
- Manufacturers mainly offer three full-size formats and one or two additional ones. You can see the dimensions in the table above.
- They are standardized, and if they vary between different manufacturers, then only slightly. For example, one brand has a block length of 375 mm, while another has 380 mm. By the way, this size (380*250*219 mm) is the only one with which walls need to be insulated.
- Larger stones, 440 or 510 mm long, do not require additional insulation. Such walls are simply faced with decorative bricks during the laying process, without a ventilation gap.
... turns into two additional ones
- For ease of masonry, when you need to get, for example, the distance from a corner to an opening, you often need half a block, since a whole stone does not fit. However, this is not a solid brick, and if you try to cut it, it can simply be damaged.
- The additions are made like this: in appearance they appear as a solid stone of full size, but along its axis it is visually divided into two halves, which are fastened to each other by thin ceramic bridges.
- It is enough for the mason to lightly hit them with a pick, and the block itself will split into two parts, the side edges of which are also equipped with grooves and ridges, like full-fledged blocks.
- To eliminate cold bridges, masonry is carried out not with ordinary mortar, but with heat-insulating mixtures, the filler for which is not quartz, but perlite sand.
- They are sold in bags of 17-25 kg and are simply diluted with water before use. The facing brick is laid on a regular cement-sand mortar.
Also, for the convenience of installing jumpers, you can purchase U-shaped blocks, which are shown in the picture above.
The main nuances of constructing walls with cladding
The thickness of the walls of the house is calculated based on what building materials are chosen for it. If this is a block measuring 380*250*219 mm, which, as already mentioned, must be insulated, then the total thickness of the pie for an area with an average winter temperature of -32 degrees will be about 640 mm.
Of these:
- 380 mm porous block brand M100;
- 100 mm insulation (2 layers of 50 mm each);
- 40 mm ventilated gap;
- 120 mm facing brick.
Note: The gap inside the wall pie in this case is necessary for ventilation of the insulation. Its presence will not only save the walls from freezing in winter, but will also prevent them from overheating in summer. That is why insulated ventilated facades are the most the best option for residential buildings.
To ensure that the air in the internal space of a multi-layer wall does not stagnate and it can be ventilated, vents are left in the brickwork. These are either quarter-brick windows at the bottom of the wall, or vertical seams unfilled with mortar (every fifth). To prevent insects or rodents from getting into the vents, they are covered with a plastic mesh.
When masonry of ceramic blocks is carried out without insulation - that is, if the brick fits tightly to the ceramic block, they are used to bind them together. steel mesh. To connect them at a distance (if there is insulation and a ventilation gap), use fiberglass rods with sand tips, which are embedded in the masonry joints.
By the way, in ceramic block masonry there are only horizontal seams - the vertical edges of the stones are connected through the tight interlocking of the groove and the ridge.
Currently, to create capital load-bearing walls Instead of traditional solid bricks, large-format ceramic blocks are increasingly being used. This provides many advantages, first of all, the speed of wall construction increases. In size, a large-format ceramic block is much larger than a brick, while having a relatively low weight. It is easy and convenient for builders to work with such blocks; the walls from them grow by leaps and bounds and, most importantly, they can be lined with any finishing materials.
Opportunities and prospects
Large-format ceramic blocks are produced by several companies; in particular, Porotherm blocks are presented on the market, which have proven themselves well in our climatic conditions and enjoy deserved popularity among home builders. The blocks last a long time, the wall they make is strong and reliable, so there is essentially only one problem - the need for cladding. Like the vast majority of wall materials, ceramic block requires exterior finishing. And if some wall materials, let’s say, are “capricious” in terms of cladding - one cannot be plastered, another is undesirable to be finished with natural stone, which ultimately creates more headaches for both builders and homeowners - then there is no such problem with ceramic blocks. Of course, there is no common technology for all facing materials, and in each case both the methods and the accompanying materials will be different.
One of the most common questions is how to properly bandage/attach a veneering material to a ceramic block. In practice, several methods of such fastening are used. One of them involves the use of flexible ties made of basalt plastic in the amount of five to seven pieces per square meter. Basalt-plastic flexible connections combine strength, durability and lightness. These connections connect the load-bearing and facing layers. Flexible connections can also connect the load-bearing wall with the facing layer through the insulation. In addition, finishing or insulating materials can be attached to a load-bearing wall made of ceramic blocks using anchors made of stainless steel. Thus, a wall made of ceramic blocks can be faced, for example, with facade (facing) brick, which is considered the most durable finishing material. There are different varieties of it in color and texture modern market- hundreds, if not thousands, especially if you count imported bricks. Designed facade brick For exterior finishing walls and foundations and performs both protective and decorative functions. You can also use ceramic clinker tiles with the same success; the material is just as strong and durable.
An excellent option for cladding large-format blocks can be natural or artificial stone. It is noteworthy that no special technologies will have to be used; the process is carried out standard, which means in an inexpensive way. A wall of ceramic blocks is first prepared plaster composition with a mesh, after which the prepared cladding elements are glued with special glue. If desired, a wall made of ceramic blocks can be completely covered with plaster; it is applied according to the manufacturer's instructions plaster mixture. As an option, you can use today’s popular and very inexpensive siding. In this case, the wall is also pre-plastered, after which the frame is mounted and siding is hung.
Finally, ceramic blocks interact perfectly with technology such as a ventilated (or curtain) façade. IN recent years it is used more and more often, allowing, on the one hand, to protect the wall from external influences, and on the other, to ensure ventilation and normal humidity balance in the wall mass. The curtain facade is a system consisting of cladding and the so-called sub-cladding structure, the arrangement of which leaves a gap between outer covering and a wall. This gap ensures the free movement of air flow and, among other things, significantly improves the sound and heat insulation of the wall structure. Modern construction market differs in the variety of panels for facades. Facade panels can be single-layer or composite (multilayer). Today we offer clinker panels, porcelain stoneware, metal (iron, aluminum or copper), natural stone panels, as well as fiber cement panels. Such panels are dyed in bulk, have a natural range of colors, do not fade when exposed to sunlight and successfully withstand any external influences. In general, it should be noted that finishing walls made of ceramic blocks is, in principle, no different from finishing walls made of other materials. The main thing here is to choose the right one necessary materials(dry mixtures, etc.) and use them according to the manufacturer's instructions supplied.
Nuances of technology
To ensure the quality of the coating in the process of facing walls from ceramic blocks, it is important to observe certain nuances of technology. Questions that arise in practice require unambiguous answers, for example, the question of the need ventilation gap between facing bricks and ceramic blocks. Is it needed at all? Experts say that if there is no insulation, there is no need to create a gap. If between load-bearing wall and the front layer has insulation, the gap is needed to dry it.
Or take such a nuance as the need to insulate a wall during the cladding process. This insulation may or may not be done if the wall, for example, is insulated from the inside. The decision in each specific case is determined thermotechnical calculation and depends on the design of the wall and the type of wall material used. At one time, large-format porous ceramic blocks were created specifically in order to exclude insulation from the so-called wall pie. Therefore, when using them neither internal nor external additional insulation, as a rule, is not required.
If the decision to insulate the walls outside is nevertheless made, subtleties may also arise here. You can take, for example, standard mineral wool insulation. However, in some cases it is preferable to install an external heat-insulating layer using facade thermal panels. Such thermal panels are a complex multi-layer system consisting of a moisture-insulating layer, insulation (polyurethane foam or polystyrene foam) and a decorative and protective layer, which can be clinker tiles (ceramic bricks). Fixed to the sheathing of buildings, these durable panels provide excellent protection against all adverse weather conditions.
If we talk about comparatively new technology facing walls made of ceramic blocks - the so-called ventilated (curtain) facades - it should be taken into account that since their development and introduction into construction, methods of thermal insulation have changed fundamentally. In the recent past, thermal insulation materials were often mounted to inner surface walls, which not only reduced usable area premises, but also did not provide a sufficient level of heat conservation. The main difference of this technology was the transfer of heat-insulating materials from the interior of buildings to the outside. In conclusion, it is worth mentioning such a seemingly trifle as calculating the number of facing bricks. It is also produced in a special way. The basis for the calculation is the area of the front part of the brick, as well as the width of the vertical (10 mm) and horizontal (12 mm) seams. In this case, you should always have a five percent reserve, since during the cladding process some of the material may become unusable for one reason or another.
Text: Vladimir Mikhailov
Time is the most impartial judge, and it clearly shows that the outer walls of buildings decorated with ceramic materials are practically not subject to destruction and retain their original appearance for many decades. Therefore, today manufacturers offer us not only traditional tiles and bricks.
One of the new products that recently appeared on the building materials market is a porous ceramic block with cladding. What is this material, what are its advantages and disadvantages?
You will learn about this and much more by reading the information we offer, as well as by watching the video in this article.
If ceramic facing materials try to somehow classify, then two main categories can be distinguished. The first is materials mounted on finished walls: tiles for adhesive cladding (see Cladding with ceramic tiles: a job that anyone can handle), panels for arranging ventilated facades (see Cladding a house with external panels: choosing).
The second category includes materials that are both finishing and structural. This various types ceramic bricks and ceramic blocks on the cladding, which will be discussed now.
It is possible to finish walls with such materials only during the masonry process, otherwise it would be necessary to top up the old one or build a new foundation. The reason for this is the significant weight and large format of the cladding elements - and this can equally be both a disadvantage and an advantage.
Advantages of structural ceramics
We cannot deny the advantages of clay brick, which has been used for centuries to build walls and has long become a classic in construction. But this method has one significant drawback - it takes a lot of time, and this cannot but affect the cost of objects.
So:
- In this regard, facing ceramic blocks have a huge advantage over brick. A full-size block has an average format of 380*250*219 mm, which is double more sizes bricks Accordingly, the speed of construction of enclosing structures also doubles - and this is at least.
- It is very convenient to work with such material, especially since where the wall thickness should be 1.5 bricks, it is enough to lay one block. For those who are going to build a house with their own hands, this is a great advantage: the geometry of the masonry is ideal even for those who do not have mason qualifications and are taking on such work for the first time.
- Ceramic blocks are called porous not only because there are voids in the structure of the products. It's all about the technology of their manufacture. The raw material for the production of blocks consists not only of sand and clay, it also contains filler in the form of small sawdust. During the firing process, the wood filler burns out, forming pores in the material itself. And what about the voids and corrugated sides finished goods obtained by passing through vacuum presses.
- The presence of closed cavities, which we see in the photo, significantly reduces the thermal conductivity of the material, and this indicator for porous blocks is many times higher than for traditional brick. For this reason, they are also called warm ceramics. It is clear that this is a godsend for housing construction, since walls built from such blocks do not require insulation.
- Moreover, the presence of pores and voids does not in any way reduce the compressive strength of the material - let alone sound insulation! Everyone knows that the porous structure of materials provides excellent sound absorption. The undoubted advantages of warm ceramics include hundreds of freeze-thaw cycles, as well as low water absorption (within 6-12%) and high fire resistance.
The price of a ceramic block is on average 110 rubles. per piece. The cost of a brick, even an ordinary one, is at least 15 rubles; facing brick costs 18-21 rubles. But in one cubic meter there are only 40 pieces of blocks, while there are 510 pieces of single bricks in a cube - the mathematics is simple, and everyone can calculate which is more profitable.
Well, the instructions in the next chapter will tell you about the technical side of building walls from ceramic blocks.
Features of masonry work
Thanks to the large format of the ceramic blocks, the joints between them occupy only five percent of the wall area. Compared to brickwork, this is not much, but this may be quite enough for the wall to lose a significant part of the heat. For this reason, ordinary cement-sand mortar is not used for the installation of porous ones.
Masonry mortar
To install porous blocks - and not only ceramic, but also cellular concrete - it is necessary to use mixtures that contain a heat-insulating filler. These are natural raw materials: perlite and vermiculite, which have excellent thermal insulation qualities.
In addition, warm solutions contain fiber fiber (a reinforcing additive) and plasticizers that make the hardened seam impermeable to moisture.
- As for reinforcing additives, their use does not allow the freshly applied mixture to settle into the cavity of the blocks, and the seams that have gained strength become more resistant to deformation. Modifying additives make the solution more plastic and significantly reduce its consumption.
- Preparation of a solution from a dry mixture consists of only two operations: adding water (about 10 liters per bag) and mixing with a mixer or concrete mixer. The viability of the solution lasts approximately 2 hours, so it makes no sense to make a large volume at once.
- When the viscosity of the solution used increases, it is strictly forbidden to add water to it - just mix it in a container. The mixtures are sold dry, in 20 kg bags. This amount makes approximately 30 liters ready solution, and, given the thickness of the seam of 12 mm, it is enough for 1 m2 of masonry.
- A bag of warm masonry mixture costs about 300 rubles, and this, of course, is a considerable expense. To reduce mortar consumption, as well as for reinforcing horizontal rows, many manufacturers recommend laying blocks on a fine-mesh fiberglass mesh.
It keeps the mixture from falling into the voids of the underlying blocks. There is one more important nuance: the solution entering the voids of the blocks displaces air from them, which reduces the resistance of the masonry to heat transfer. Therefore, a grid is needed, no matter how you look at it.
The feasibility of using ceramic stone
Ceramic blocks, or, as their name standard indicates: ceramic stones - like bricks, can be either ordinary or facing. Ordinary ones are used for the construction of walls, and front ones, respectively, for their parallel cladding.
This division does not mean at all that the strength of the front blocks is lower than that of ordinary ones - they can be used for the main masonry in the same way. Just due to the improved front surface, their cost is slightly higher.
So:
- In principle, both of these materials are produced according to the same standards, and the calculation of wall thickness depends on the maximum winter temperatures in the region. Let’s say in the south, where the average winter temperature is -10 degrees, the thickness of the walls should be at least 380 mm, that is, one and a half brick lengths.
- If walls are erected from ceramic blocks, then use blocks measuring 380*250*219 mm and lay them in one row. The largest standard size is 510*250*219 mm, it can also be mounted in one row, but in regions with winter temperatures of -20 degrees. In this case, blocks with a front finish are used.
- But in the northern regions, where winter temperatures often exceed -40 degrees, the thickness brickwork should be 770 mm (three bricks + seams). There are no blocks of this size, and if necessary, the masonry is made up of ordinary blocks 510 mm long and facing blocks 250 mm long.
- If such a wall is laid out of brick, a lot of material is wasted, and the load on the foundation is incredibly large. This leads to overconsumption of not only wall materials, but also those used for the construction of the zero cycle of the building.
Pay attention! In order to obtain at least some savings when constructing brick walls, well masonry methods are used, laying insulation in the resulting cavities, and widening the seams. But even all these methods together are unable to make masonry more than two bricks thick economically feasible.
- That's why brick houses for districts Far North– this is very rare. With the advent of ceramic porous blocks, the situation has changed radically, and now northerners can also build prefabricated and warm houses from ceramics.
- What simplifies masonry work most of all is the tongue-and-groove system for connecting blocks. This joining limits the displacement trajectory of the masonry elements relative to each other, therefore the curvature of the masonry, which differs brick walls, is basically impossible here.
- Another huge advantage is that vertical joints do not need to be filled with mortar. Since it is the side edges that are connected by a ridge into a groove, there are no cold bridges in the masonry, which are always seams.
In the struggle for buyers, many manufacturers offer not only standard full-size blocks, but also additional elements, corners, door and window lintels made of ceramics, as well as blocks for the construction of internal enclosing structures. All this is coordinated by standard sizes and ideally assembled into a single complex.
Such important nuances
Despite the fact that porous blocks have a front surface, they are still like any other construction material, need finishing. Or rather, not so much in finishing, but in protection from the effects of precipitation.
For this purpose, decorative bricks, clinker tiles or natural stone are used. In general, adhesive finishes are an excellent option for porous block masonry.
- There is no need to insulate such walls; in extreme cases, you can use warm plaster (see Knauf Grünband warm plaster), which, by analogy with masonry mortar, contains perlite. But if you really want to, you can insulate it and even finish it frame method. You just need to take into account one very important nuance.
To attach lathing to a ceramic wall, as well as hang cabinets on it, you cannot use the usual dowel-nails, since the thin partitions inside the block may not withstand the load. For this, there are special long expansion anchors, as well as chemical dowels, which you see in the picture. Use them and you won't have any problems with fasteners!
Porous hollow ceramic blocks are materials that help preserve and accumulate heat in the house. But despite this, in some cases walls made of this material also require insulation.
Heat loss in a house occurs through walls, windows, doors, roofs and even the basement. Through the walls low-rise buildings no more than 20% of heat is lost, since the areas of the roof and walls are almost equal. Significant heat losses (up to 40%) occur through air exchange, and the rest occurs on the roof. In the first climate zone, building codes(GSN) for energy saving provide a heat transfer coefficient for enclosing structures (walls) of 2.8 (was 2.2), and for the roof - 4.95 (was 2.8). During the transition period we are in today, this coefficient for roofs could be 3.3.
Is it necessary to insulate walls made of blocks 38, 44 and 50 cm wide?
When building a house from hollow porous ceramic blocks, the walls can be of two types: single-layer, that is, made only from one block, or multi-layer. The latter, in turn, are divided into two-layer, consisting of a block and insulation, and three-layer, which includes a block, insulation and facing brick. For the construction of single-layer walls, porous blocks with a width of 38, 44 and 50 cm are used. It is not practical to insulate such walls, since wall material, from which they are made, has a sufficient coefficient of resistance to heat transfer. The funds that are supposed to be spent on insulating such walls are better used for exterior finishing or installing translucent structures of higher quality from the point of view of energy saving - doors and windows. However, with the introduction of new energy saving standards, even walls made of ceramic blocks with a width of 38 cm are subject to insulation.
Which ceramic blocks require insulation?
Sometimes walls are erected from ceramic porous hollow blocks 25 and 30 cm wide. This happens when the wall material has not yet been selected, but construction work are already underway. For example, if a foundation is made, and its width does not correspond to the width of the porous block, which can provide the required thermal conductivity coefficient of the walls of the house. Then, when choosing a material for external walls, they are tied to the thickness of the block.
Since these blocks are originally intended for the construction of internal load-bearing walls, they do not have a sufficient heat transfer resistance coefficient.
When insulating a wall made of porous blocks, you must remember to install windows in the house with a heat transfer resistance coefficient of 0.5 m² - °C/W and, accordingly, insulate the roof - only then can the house be considered fully insulated.
Laying insulation
It is better to insulate walls made of porous ceramics with mineral wool slabs, which, unlike expanded polystyrene, have good vapor permeability. The insulation is attached to the wall with glue or with dowels so that it fits tightly to the wall surface. Further finishing of the walls is done at the discretion of the house owner. As for the thickness of the insulation for ceramic porous blocks, for a block 25 cm wide it is 100 mm, for a block 30 cm wide it is 60 mm.
Another important point, which must be taken into account when insulating a house, is the use of so-called “light” (“warm”) masonry mortar when laying blocks, rather than the usual cement-sand mortar. This solution also contains cement, which acts as a binder. Used as a filler thermal insulation material- perlite or expanded clay sand.
The area of joints with a thickness of 12 mm is only 4% on a wall made of ceramic porous hollow blocks. If you replace the cement-sand mortar with a “light” one, then the thermal characteristics of the wall will improve by 17% due to the large difference in the thermal conductivity coefficient of these solutions: for cement-sand it is 0.9 W/(m*°C), and for warm solution— 0.3 W/(m*°С). The production of such dry mixtures has not yet been developed in Ukraine, so they are imported from abroad.
