News fromScott System, Inc.www.scottsystem.com

©2008 by Scott System, Inc.

T H E A R T O F C O N C R E T E T E X T U R E S

Spring 2008

TradiTional & durable Brick is classic. It has been used in construction for more than five thousand years. The perfect geometric shape for stacking, brick and block lend a human scale to both large and small structures. Brick’s earthy aspects (clay and shale) make it an ideal element to combine with other natural products like stone, wood and concrete – plus it is a lasting and low maintenance material.

VersaTile Masonry’s variety of colors, textures and sizes allow designers to be infinitely creative. There are numerous choices in pattern and materials, allowing builders to deliver traditional or modern structures, and to combine conventional with contemporary elements.

Above: A 4-color blend of brick is set in Stacked Bond coursing and rotated to create a checkerboard effect. Bradburn Retail Shops, Westminster, CO.

Below: Mock-up concrete panel shows a few brick color and coursing options: Soldier, Running Bond, Stacked Bond and Basket Weave.

Brick is the perfect element to combine with other natural materials like stone to produce a beautiful architectural exterior. Color variation and banding add even more interest.

A special issue dedicated to the wonders of embedded brick, block, stone and tile

Masonry’sMass Appeal

Masonry is a fundamental element

that has stood the test of time.

What is it about brick, block and

stone that appeals to us so much as

construction material?

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brick in the wallan

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Masonry’s Mass Appeal cont.

beyond brick and MorTar A great example of blending the old with the new is the combination of the beauty of brick with the structural integrity of concrete. In this process, thin brick (or block, tile or stone) is in-tegrally cast into precast concrete panels. Scott System pioneered this method in 1971 and today there are thousands of brick-embedded, precast structures in and outside the U.S.

As with brick production methods, brick-inlay systems have evolved and improved over time. Scott System’s original template system for brick-in-concrete was the brick gasket form liner. In 1995, Scott System introduced the Brick Snap®, a product that improved upon the gasket liner and also gave tilt-up contractors an opportunity to add brick to their product offer-ing. The idea took off. Tilt-up construction has seen record growth and so has brick-embedded concrete.

adVanTages Brick-embedded concrete has numerous ad-vantages over conventional masonry including reduced construction time, simplified engineer-ing, and the elimination of flashing, lintels and weep cavities. Additionally, no sand, mortars, mixers or scaffolding are required on site. There is no efflorescence and this method is recommended in seismic zones.

With a permanent bond between the masonry material and the concrete, this system is effi-cient, structurally sound, and beautiful.

6” x 6” quarry tile integrally-cast in precast concrete adds warmth and interest to Rose Hospital in Denver, CO.

The San Francisco Museum of Modern Art utilized brick-embedded precast panels to meet the seismic requirements of the region. The combination of Saw Tooth/Running Bond brick pattern and set back bands show the level of creativity and intricacy that can be achieved with integrally-cast brick veneer. Designed by renowned architect, Mario Botta of Switzerland. The SF MOMA was built in 1993.

Assembly of thin brick on pour bed is fast at approximately 100 square feet per man hour.

Scott System is taking vital steps to maintain the sustainability of our world for future generations. To help us understand what our company and employees can

do to leave a smaller footprint, we have joined the U.S. Green Building Council. www.usgbc.org.

This publication is printed on 50% recycled paper (25% post-consumer waste).

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Scott’s tried and true Brick Snap® system has evolved into an extraordinary product for integrally-casting block into precast or tilt-up concrete. The Block Snap™ is a recyclable single-use plastic template that snaps together in a variety of coursing patterns. The 8" x 16" x 1 ½" block is available in many colors and finishes, and since this method is compatible with the Brick Snap® system, the design possibilities are unlimited.

Concrete block is available in a multitude of colors, sizes and textures including polished and shot-blasted surfaces with rich aggregates and pigments. By varying the size, shape and surface treatment of concrete masonry, architects have the freedom to create unique wall finishes.

The Children’s Hospital Ambulatory Care Center in Broomfield, CO features thin brick and block integrally-cast in tilt-up panels. Architect Davis Partnership of Denver specified a blend of gold, red and blond brick with a buff-colored block wainscot. Inset bands and corner details complete the look.

Another tilt-up project which incorporated both brick and block in concrete is the Oddo Building in Lenexa, Kansas. Contractor Summit Concrete utilized a custom blend of red and blond concrete brick with a cream-colored concrete block. That’s right – concrete thin brick (not clay) and concrete block. The result is beautiful!

With this vast assortment of block and brick options, you are only limited by your imagination.

Above: Concrete sample panel shows integrally-cast thin brick and block.

Top: Children’s Hospital Ambulatory Care Center, Broomfield, CO.

Middle, Left and Bottom: Oddo 0Building, Lenexa, KS.

A Chip off the

Old Block

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EnvIrOnMEnTAL Advantages of Thin BrickHere’s another reason to use thin brick in your next brick façade project: turns out that thin brick uses 80% less raw material and natural gas to produce and deliver than conven-tional, full size brick. Thin brick’s manu-facturing process and lighter weight means that a reduced amount of clay and shale are needed and less energy is used to produce and ship the product.

You can receive up to 10 Leadership in Energy and Environmental Design (LEED®) credits when you choose to embed thin clay or con-

crete bricks in precast, tilt-up or poured-in-place concrete walls. Credits can be received in the

Sustainable Sites, Materials & resources and Innovation & Design Process categories estab-lished by the U.S. Green Building Council.

visit Scott’s website link http://www.scott-system.com/brick_product_guides.html for

specific information on thin brick and LEED credits and www.usgbc.org for more information

about LEED Accreditation.

Comparing a thin brick system to traditional hand-set brick is not an “apples to apples” equation. The better question is: What are the benefits of one building system over the other? Conventional brick construction is ideal for certain situations, and tilt-up, precast or poured-in-place concrete will be best in others.

In general, masons are efficient on most projects under two stories. As long as weather and site conditions are favorable, bricklayers can perform their task. On large-scale projects, however speed of erection is critical and contractors will realize a variety of savings by going with concrete construction. Concrete panel producers, especially those who fabricate and erect structures in cold weather, make the case for “time is money”.

A great example of savings with concrete is the Cumberland Elementary School in Eastern Ontario. Constructed in 5½ months, the 52,000 SF, two-story school utilized 117 brick-clad, tilt-up panels erected at a rate of 18-20 per day. According to project manager, Shawn Hickey of Site-Cast Construction, tilt-up with integrally-cast

Cumberland Elementary features brick-inlay in tilt-up panels. Tilt-up by SiteCast Construction Corporation, Nepean, Ontario, Canada.

brick shaved 2-4 months off the construction time.

Another case study supporting concrete over hand-set brick was prepared by Deal-Cain & Co. Architects of Franklin, Tn. Their study determined precast or tilt-up brick-clad panels saved $ .50 – 3.50 per square foot of wall panel over conventional brick and block construction.

It is all about differences in building systems. The following items are eliminated with brick-embedded concrete:

- Steel angles (lintels) to hold the brick- Weep joints- Mortar- Flashing details- Moisture details

So, for large scale/fast track jobs, savings will be realized with brick-clad concrete panels when engineering details are considered. Other factors affecting savings when comparing building systems are time, labor and weather delays; materials and availability, as well as weight, delivery and clean up.

Co$tConsiderations

of Brick-Embedded Concrete and

Conventional Masonry

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Feel free to color outside the lines.

Texture, color, size, finish – masonry has it all in thousands of combinations. Flashed, glazed and metallic looks are available in every hue. There are polished and honed finishes, rough and smooth finishes and hand-molded looks. Plus, masonry units with incorporated glass and aggregate particles can all combine to produce a variety of other striking surfaces.

now, picture concrete as your canvas and an array of beautiful tile, brick, block and stone units are your palette. Go ahead and color outside the lines, because now you don’t need to follow the lines at all. The only geometry constraints are those of the individual masonry units. Outside the limitations of rectangle and square shaped pieces, you are free to arrange these components to create your own mural. Mosaic combinations in a bold, confetti-type motif or a precise linear pattern are both equally possible with masonry-embedded concrete.

An artist’s rendering of a highway wall mural features glazed tile cast in concrete forms. Designed by Frankie Peyman, Art-O-Graph, Westminster, CO.

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Creat iveChoices

the

Magicof MasonrySome Common

Coursing Patterns

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FOR VERTiCAlly-CASTCONCRETE CONNECT wiTH HigHwAy DEpARTmENTS

This pour-in-place form is ready for concrete. Thin brick has been pressed into the Rim Snap™ system and rebar and ties have been set.

Highway and bridge departments are specifying poured-in-place concrete walls with integrally-cast brick, thanks to the rim Snap™ system. Minnesota DOT has constructed two projects featuring brick-embedded concrete: The valley Creek Bridge in Woodbury and the rebuild of Highway 36 in north St. Paul.

The valley Creek structure is a 2-span bridge that goes over I-494 and serves as the main entrance into the city of Woodbury. The city was active in the design process and selection of materials and chose brick with stone-textured concrete to fit the existing complexion of Woodbury.

The $24 million rebuild of Highway 36 (the second MDOT project with rim Snaps™), will be completed this year. Like valley Creek, Highway 36 features integrally-cast brick in poured-in-place forms along with limestone patterned concrete.

A third DOT project is the Collinswood bridge in new Jersey. The structure rises to a height of 24 feet over rt. 30 and tested the limits of the rim Snap™ system by requiring 14 different columns, each 24 feet high with embedded brick cast in all four sides.

The rim Snap™ features a rubber gasket border with suction-like grip to hold thin brick securely into a forming system. What’s more, the system can be reused after it is attached to the forms. The concept has been proven on wall projects with cast-in-place forms, on climbing forms and in column forms.

To watch a two-minute animation of rim Snap™, check out this link: http://www.scottsystem.com/rim_snaps.html on Scott System’s website.

The Valley Creek Bridge in Woodbury, MN displays the impressive use of the vertically-cast brick in four-sided columns and in wall panels. A limestone base on piers and abutments compliments the traditional brick design. The two-span bridge carries six lanes of traffic up and over busy Interstate 494.

Rim Snaps™ easily tab together to create a template to hold the brick in place. Then thin brick is pressed into the pockets of the grid.

Hwy 36 in North St. Paul is under construction and will be completed in 2008.

Rim Snaps™

solutionsconcrete

Smart Alec asks: which method appeals to you?

Brick in Concrete

When the wall goes up, the brick is already in place!

Hand-Set BrickScaffolding

Sand

Wet Trades

Moisture Details

Flashing

Lintels

Freeze/Thaw

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Clean Up

Delivery/ Removal

Weather Delays

How Secure is the Bond between Brick & Concrete?

“Will The brick fall ouT?

WhaT abouT freeze-ThaW issues?”

These are the two most common questions we receive about brick-embedded concrete. Here are the facts: independent tests conclude that the brick to concrete bond is excellent at over 3000 pounds per brick (21/4" x 75/8") with no failure. In accordance with ASTM C-666, freeze-thaw testing was performed on six composite brick/concrete samples. A total of 406 freeze-thaw cy-cles were completed. In all six samples, no delaminat-ing of brick to concrete occurred. The strength of the brick-to-concrete bond during freeze-thaw received another excellent rating.An 8” wide core from a brick-embedded concrete panel shows the

permanent bond between the thin brick and the concrete.

10777 East 45th AvenueDenver, CO 80239

www.scottsystem.com(303) 373-2500

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the inside story...• Masonry’s Mass Appeal

• Creative Choices

• Environmental Advantages of Thin Brick

• A Chip off the Old Block

• Ask Smart Alec

w w w. s c o t t s y s t e m . c o m • ( 3 0 3 ) 3 7 3 - 2 5 0 0