Instead of real brick, facades today can feature flexible resin-cast brick shapes to achieve a variety of unique designs. These materials give designers freedom when it comes to color choice, and they consume significantly less energy to manufacture and transport, compared to traditional heavy bricks.
From a health perspective, there is no dust generated from resin-cast brick, and because it contains very little silica, it keeps production workers and installers safe. Further, these resin-based bricks and organic mortars are cement-free and significantly reduce the risk of efflorescence, which is the whitening of the material due to the migration of salt to the surface of porous materials, often occurring with real brick or concrete. From an installation perspective, these thin, pre-formed brick shapes are fast and easy to install, no special tools are needed to cut them, and there are no concerns about hauling a load of heavy bricks around the job site.
More visual options for lightweight claddings include those used to create facades resembling split face block concrete masonry units (CMU). Designers can circumvent having to specify heavy CMUs and instead choose lightweight cladding systems that offer products that achieve the look
of a true cement block.
The construction community has access to ready-mixed, acrylic-based materials that are applied to a building’s substrate using simple tools such as a finishing trowel. Once completely dry, applicators sand down the surface to the desired texture, wash the finished facade, add formwork marks, and apply a clear coat sealer for the desired gloss. The end result is an exterior wall that looks like CMU, but is much lighter and can also be finished in a variety of colors or textures. In addition to a CMU appearance, this same method can be used to create the look of brick, stone, tile, wood, limestone, metal, and more. Plus, behind the facade finish, these aesthetic options can be part of an integrated wall system that combines insulation and weather barrier layers to ensure long-term building performance and thermal efficiency.
User-friendliness
It is clear that installing lightweight claddings is simpler and safer for construction crews. Consider the scenario of installing cladding on a multi-story commercial building. Installing heavy cladding panels requires specialized equipment and lifting substantial materials high above ground; and this brings inherent safety risks. Compare this to applying lightweight materials to the face of a building.
Made for the retrofit market
While lightweight materials make sense in any construction environment, they are particularly suited to the retrofit market.
