Method Statement

CKYIBS Blocks


Step 1 – PROVIDE US WITH A FULL SET OF YOUR ARCHITECTURAL DRAWINGS

  • Contact a CKYIBS representative and submit a copy of your architectural drawings. Once submitted, we will come up with a special set of drawings suited for CKYIBS blocks. This includes drawings for each wall and dimension as well as indication of how many pieces of each CKYIBS block is required.

Step 2 – START WITH THE FOUNDATION

  • Once all the drawings have been obtained, begin casting the foundation based on the engineer’s design. While casting the foundation and floor slab, it is crucial that the finishing floor is levelled. The level variation should not exceed 25mm in height.

Step 3 – CAST FOUNDATION 

  • Cast the foundation based on the design drawn by your engineer.
  • Ensure all the starter bars and underground piping and openings are placed in the correct location according to the design plan.
  • While casting the foundation and floor slab ensure the finishing floor is levelled. The level variation should not exceed 25mm in height. Proper levelling control is highly recommended to avoid the need of cutting the 1st layer of block to match the uneven finished floor level.
  • Wait for concrete to cure (at least 3 days) before laying CKYIBS blocks. 

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Step 4 – START OFF BY ROUGHLY LAYING OUT THE FIRST COURSE 

  • Based on the provided drawing/plan, start by setting out the first course of the blocks according to the plan. Note the different types of blocks used for the various positions (eg. Corner block used for joints and corners and column blocks used for various columns) as per our provided drawing. Pay close attention to the positioning of the rebars. Ensure it is located in the correct position with the rebars going through the respective holes of the blocks as per the drawing provided.
  • This portion is done to provide a rough idea of the size, dimensions and positioning of each wall. This will just be a temporary placement of the blocks, therefore you do not have to put the mortar mix yet. If any adjustment is required, this would be the best time to do so.
  • Ensure all locations are correct with the door frames in place. At this stage, you will be able identify if any required blocks are missing. Kindly contact a CKYIBS representative should you need any additional blocks.

Step 5 – LAY OUT THE FIRST COURSE PROPER

  • Once the blocks are in place, you can begin laying a permanent first course. If there should be any variance in the floor level, study the level variance and start laying at the highest point of the floor. 
  • Mix cement and sand mortar (1 part cement to 3 parts sand ratio), place the mortar mix on the ground where the block is meant to be positioned and place the block on top of the mortar mix with the tongues of the block facing downwards and the grooves facing up. It is advised to start laying with the corners and work your way progressively to the other end of the building. It is highly recommended that the door frames should be fixed along with the first course.
  • While laying, use a spirit level to ensure that the first course is properly levelled. Lightly knock the blocks into position using a rubber hammer if it is not properly levelled.
  • Once the first course is completed, allow for it to set for 24hours before laying the upper layers.

Step 6 – SECOND COURSE ONWARDS

  • Once the first course has been set, you can begin laying the second course. Begin with making a batch of mortar adhesive mix (same as first course). With the mortar mix, fill it along the grooves of the block on the first course and place a new block on top of the first block with the tongues facing downwards. As you continue laying, make sure that each block interlocks with each other. In the event there is a noticeable gap between blocks, fill the said gaps with the mortar mix (this is to prevent any potential cracking).

  • Continue laying the subsequent courses until you reach the window opening. At this point, form the relevant lintels using the beam blocks with the number of bars as specified in the shop drawing. Bars are also to be placed through the blocks (and concreted) on the left and
    right side of every door/window opening forming a full frame.

  

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  • Proceed with the laying of the blocks up to the 7th course (or half of the wall height). Then place rebar at column and stiffener area. Concrete the required areas before proceeding with the upper floor.      

            

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Step 13 – Bond Beam Construction

  • Continue the block laying until you have reach the bond beam level. With our Bond Beam blocks, cut off the left and right ends of the block (following the provided groove lines) and place rebar through (as pictured below) and fill the hole with concrete.
  • If roof trusses is to sit on the bond beam, make sure all holding down bar is in the correct position. 

              

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CKYIBS Interlocking Bricks Installation

 

     Building a wall using CKYIBS Interlocking brick wall is simple. In order for it to be strong and stable it is essential that it is properly planned and prepared.

     A brick wall can be constructed in several patterns. ‘Stretcher Bond’ or also known as ‘Running Bond’ is the recommended type of pattern for laying CKYIBS interlocking bricks as shown in the picture below. All the bricks are laid lengthways with the stretcher face exposed. This method is recommended as it provides for even load distribution and strength.

     A large brick wall may need a structural engineer’s specification. A dowel bar is strictly required at every 4th course of a CKYIBS brick wall at the area adjacent to any column or wall of a building. This is to prevent any cracking derived from the two walls pulling apart. Stiffeners are to be introduced at every 3 meters length of wall. Usage of Ex-mat is not required in the building of a CKYIBS brick wall. 

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TYPES OF CKYIBS INTERLOCKING BRICKS 

     CKYIBS Interlocking bricks are made of concrete and come in various types and sizes. CKYIBS interlocking bricks also come with a unique ‘tongue’ and ‘groove’ design which provide greater strength in between joints and better alignment when installing.

 

DESCRIPTION OF BRICKS

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CEMENT GLUE

      Cement glue is used to bond the CKYIBS interlocking bricks together. The cement glue is a mixture of 1:1 ratio of tiling adhesive and cement. Thoroughly mix these 2 parts evenly and add sufficient water until the mix becomes a non-dripped smooth paste when the brick is dipped with this cement glue mixture.  


CKYIBS BRICKLAYING

1. A solid and well leveled base is ESSENTIAL in determining the straightness of CKYIBS interlocking brick wall.

2. Attach builder’s line in setting out the position of wall to achieve straightness

3. For floor slab on ground level, it is advised to lay a layer of Damp Proof Coarse (DPC) before carrying out the leveling and brick laying process.

4. Take a few spot levels on the brick laying area and choose the highest point as standard level for the starting of the 1st course of brick.

5. For ground level which is lower than the set level, make up these uneven levels by spreading the required thickness screed of 1:3 cement sand mortar over the DPC (for ground floor level) or concrete slab before laying the 1st course of bricks.

6. When laying the bricks, ensure the top tongue is facing upwards for the 100mm and 200mm width bricks and the top tongue to be facing downwards for the 142mm width brick.

7. To lay the first course of bricks, should the wall not be of a modular size following the sizes of the bricks, start laying the first brick from the far side of the wall and continue towards the center, then start again from the other far end of the wall. Ensure that one end has the groove facing outward and the other end to have the tongue facing outward. Cut the non-modular size pieces required at the center of the wall. It is recommended that a concrete cutter be used to cut the bricks.

8. For the remaining courses, mix cement glue mortar (mix ratio 1:1; tile adhesive: cement), add water until it is paste-like.

9. Again, it is important to ensure first course of bricks are levelled.

10. To lay the remaining CKYIBS bricks, either:

      A) Apply brick bonding mortar by dipping the bottom and the side surface of the bricks into the mortar mix.

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       B)   Apply cement glue on the top face of the bricks below as well as some cement glue on the side face of the brick that is to be laid.

 

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11. Place on top of the brick below and slide to the edge. Repeat and slide the next brick to interlock with the previously laid brick. The tongue and groove on the bricks will interlock with each other.

12. Place a spirit level along the course and tap the bricks into place using a rubber hammer or the shaft of a trowel to ensure a leveled surface.

13. Repeat either process no.10, 11, 12 until you reach the fourth course.

14. After laying each course, be sure to remove any access cement glue from the front faces of the bricks for easier application of any finish coat.

15. A dowel bar the length of 1 CKYIBS brick (200mm, not including the portion embedded in the wall) is strictly required at every 4th course of the brick wall adjacent to any columns of the

      

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8.  Should the dowel bar be missed during the construction of the building columns, ensure to drill the dowel bar a minimum of 100mm depth into the adjacent column and bonded with epoxy for better strength.

9.  There are several ways to lay the soldier course (last course) of the wall.

 A)  The bricks may be laid in a slanting manner (similar to laying conventional bricks). Ensure the gaps are fully filled with cement mortar before skim coat or plastering.

 

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 B)   The bricks may be laid in a horizontal manner (same as the rest of the courses). Ensure there is at least 20mm at the remaining gap available to be filled with cement mortar.

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C)   The bricks may be laid in a vertical manner. Ensure there is a 20mm gap on the top, measure the required size of the brick and use a cutter to cut the bricks to size.

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LAYING A T-JUNCTION WALL

1.  Before constructing a T-junction wall, chip off the top tongue of half the surface of the brick to make the surface flat. This is to provide toothing for every 2 courses.

                   

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CONSTRUCTING A LINTEL

1.Lintels are made by using CKYIBS ‘H’ Bricks. The location and length of the lintel will be specified in the shop drawings produced by CKYIBS.

2.Lintels are to be pre-fabricated before being installed with the rest of the brick wall.

3.To fabricate a lintel, join required numbers of H- bricks in a row and place a pre-cut rebar to the required length inside the top drain. Ensure the rebar is extended beyond the length of the row of H-bricks on both sides.

4.Fill the drain with concrete and compact it to obtain the required strength.

5.After the concrete is dry, turn the H-bricks upside down and repeat item no. 3 and 4 on the other side.

6.Allow the pre-fabricated lintel 7 days to cure before utilizing it.

 

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