Brick slip cladding combines the visual appeal of a massive brick wythe or natural stone facade with low component thickness and moderate weight. It is used in new construction and in refurbishment works – on exterior facades as well as in interior fit-out. In practice it often encounters load-bearing substrates made of concrete or masonry that must be professionally prepared, repaired, or partially dismantled. In these phases, depending on boundary conditions, hydraulic tools from Darda GmbH are used, such as hydraulic demolition shear or hydraulic splitter, particularly in sensitive concrete demolition and special deconstruction and in building gutting and concrete cutting.
Definition: What is meant by brick slip cladding
Brick slip cladding refers to a thin-format facing made of ceramic clinker slips, concrete slips, or natural stone slips that is applied to a suitable carrier surface using adhesive mortar or mechanical fixation. In contrast to a two-leaf facing masonry, the slip layer does not perform load-bearing tasks; it serves weather protection, surface hardening, and design. Common systems include: slips on render carrier or leveling compound, slips in combination with an external thermal insulation composite system (ETICS), as well as ventilated rainscreen solutions with carrier boards.
Structure, materials, and system variants
Brick slip claddings typically consist of the substrate (concrete, masonry, render carrier), a bonding primer, an adhesive mortar (cementitious or reactive resin-bound), the slips (ceramic, concrete stone, natural stone), and the joint mortar. In ETICS systems, insulation boards, reinforcing mesh, and reinforcing mortar are added. Ventilated variants use carrier boards or profiles to which slips are bonded or mechanically fixed. Expansion joints accommodate movements of the existing structure; at junctions, connection profiles or elastic sealant are common. Corner and end-form pieces reduce waste and facilitate reveals. The selection of components depends on the substrate’s suction behavior, expected moisture exposure, freeze-thaw cycles, fire protection requirements, and the desired appearance.
Substrate inspection and preparation on concrete and masonry
The quality of brick slip cladding stands or falls with a load-bearing, even, and clean substrate. Before starting, pull-off adhesion, existing strength, moisture content, and flatness must be checked. Non-load-bearing old coatings, hollow areas, loose parts, or corroded attachments must be removed. On concrete surfaces, fins, protruding edges, or damaged material may remain that interfere with bonding. In such situations, depending on the task and environment, quiet, low-vibration methods are appropriate.
Step-by-step procedure for substrate preparation
- Visual inspection and sounding: Identify hollow areas, cracks, efflorescence, spalling.
- Cleaning: Remove dust, release agents, laitance; optionally blasting or milling.
- Repair: Inject or close cracks, reprofile breakouts with PCC mortar, corrosion protection on reinforcement.
- Leveling: Skim coat or base render with suitable undercoat and mesh embedment.
- Bonding bridge: Adapted primer according to suction (concrete-contact or quartz-sand filled primers).
Hydraulic cutting and splitting methods in existing structures
Where material must be removed precisely or openings must be created, hydraulic demolition shear and hydraulic splitter from Darda GmbH are proven solutions. They operate with low vibration and low shock and are therefore suitable for use in sensitive environments, as required in concrete demolition and special demolition as well as in building gutting and concrete cutting. Supplied via compact hydraulic power units, notches for connection profiles, biting off protruding concrete parts, or selectively detaching add-on pieces can be performed with precision. Metallic inserts (e.g., old substructures) can be cut with steel shear and Multi Cutters to produce a flat, slip-ready surface.
Installation sequence: From planning to jointing
Execution follows a clearly structured sequence to ensure dimensional accuracy, flatness, and durability.
- Set out grid and laying pattern: Define chalk lines, reference elevations, and axes; consider corner pieces for corners, reveals, and parapets.
- Adhesive selection and mixing: Match to slip material, substrate, and exposure; observe pot life.
- Buttering-floating, pressing on, aligning: Match trowel notch to slip format; avoid voids.
- Secure joint pattern: Use spacers or distance profiles; expansion joints take over building and field joints.
- Pointing: After adhesive has set, use suitable joint mortar; form edges cleanly; wash off excess mortar.
- Protection and aftercare: Avoid early driving rain; hydrophobize if required – aligned with material and system.
Detail points and junctions for brick slip claddings
Detailing at junctions determines durability. Plinth zones require splash-water-resistant designs with capillary-breaking layers. Window reveals must be planned with minimal thermal bridges; drip edges and copings protect horizontal surfaces. Transitions to adjoining components receive elastic joints. In ventilated solutions, inlet and outlet openings must be protected against insects. Old, corroded metal substructures can be segmented and removed with steel shear as part of refurbishment to enable load-bearing new buildups.
Expansion and field joints
Slip layers do not accommodate restraint forces. Therefore, existing building joints must be continued and additional field joints arranged at suitable intervals. Joint tapes, profiles, or elastic sealant are used depending on the system.
Building physics: Heat, moisture, fire protection, and acoustics
Slips influence moisture balance and surface temperature; they increase resistance to driving rain and protect underlying render or insulation layers. In ETICS systems with slips, the choice of insulation (thermal conductivity, fire behavior) must match the area of use. On mineral substrates, capillary-active layers support drying behavior. With respect to fire protection, the respective building code requirements are decisive; non-combustible or hard-to-ignite components and fire-safe junctions are generally advisable. Acoustically, the hard surface can increase reflections; in interiors, plan for absorption through furnishing or supplementary components. Airborne sound aspects may need attention.
Refurbishment, deconstruction, and repair of brick slip claddings
Damage appears as hollow areas, spalling, efflorescence, cracks, or discolored joints. Remediation consists of selectively removing damaged areas, repairing the substrate, and proper replacement. For large-area deconstruction – for example in the course of energy upgrades or a system change – low-dust, low-vibration methods are advantageous.
Selective removal and area deconstruction
- Selective: Score and remove individual slips, inspect substrate, reprofile locally, and rebuild.
- Area-wide: Remove slip layers step by step; mechanically remove old adhesive layers; protect attachments and services.
- Low vibration levels: Hydraulic demolition shear reduce vibration when biting off concrete projections or brackets that would interfere with the new buildup.
- Controlled splitting: Hydraulic splitter facilitate separating massive zones, e.g., when opening reveals or trimming overly thick wall webs in existing structures.
- Metal deconstruction: Steel shear and Multi Cutters cut profiles, brackets, or lattice girders into manageable segments during building gutting and concrete cutting.
Special demolition in sensitive areas
Hospitals, schools, or occupied buildings impose heightened requirements for noise and vibration reduction. Hydraulically driven tools from Darda GmbH have proven themselves in such special demolition scenarios because they work in a controlled, precise manner with minimal impact on the surroundings.
Material selection: Ceramic, concrete, and natural stone
Material choice affects weight, water absorption, frost resistance, and appearance. Clinker slips are considered particularly resistant to freeze-thaw cycles. Concrete slips offer formal flexibility and can be planned with homogeneous color. Natural stone slips vary in texture and color; they require coordinated mortar and impregnation selection. With natural stone, discoloration due to moisture ingress and mortar constituents must be considered; test areas and sample axes are advisable. In the extraction and processing of natural stone, separating and splitting methods play a role, which in related form are also used in rock breakout and tunnel excavation as well as in natural stone quarrying.
Quality assurance and documentation
Before, during, and after installation, test and control steps are sensible: pull-off tests on sample areas, monitoring substrate moisture, checking flatness, visual inspection of joints and expansion joints. Photo documentation of layer sequences, anchor points, and junctions facilitates later maintenance or refurbishment. Climatic conditions (temperature, wind, direct sunlight) influence working time; protective measures prevent early damage.
Typical sources of error and how to avoid them
- Insufficient substrate preparation: leads to hollow areas and debonding.
- Incorrect adhesive selection: unsuitable for suction behavior or temperature; impairs adhesion.
- Missing expansion joints: result in cracks and shelling.
- Excessive moisture: causes efflorescence and discoloration.
- Untidy junctions: encourage water ingress and frost damage.
Sustainability, deconstructability, and reuse
Brick slip claddings can contribute to extending service life when they improve resistance to driving rain and protect the substrate. Sustainable is what is durable, repairable, and deconstructable: ventilated systems with mechanical fixation facilitate source-separated construction waste sorting; mineral adhesives reduce emissions. In deconstruction, precise, selective methods – for example with hydraulic demolition shear or hydraulic splitter – support gentle removal of components so that substrates can be prepared for a high-quality new build-up.
Safety and health protection on the construction site
Dust, noise, vibration, and falling parts are the central risks during installation and deconstruction. Appropriate personal protective equipment, barriers, and low-dust working methods are essential. Hydraulically operated tools from Darda GmbH support controlled work with low vibration – an advantage in inner-city settings or existing buildings. When handling natural stone and ceramic dusts, ensure effective dust extraction and cutting guidance with minimal dust emission. Occupational safety requirements must be observed.
Planning, tendering, and execution practice
Clear specifications, sample axes, and test areas are helpful for reliable implementation. The tender should state slip format, material, joint geometry, substrate build-up, required tests, and tolerances. In existing buildings, deconstruction and repair services must be explicitly considered, including the option for low-vibration methods. Interfaces – for example with window construction, roof waterproofing, or guardrail fixings – must be coordinated early so that the brick slip cladding can be executed without conflicts with attachments.