This code provides comprehensive recommendations for installing burnt clay brick flooring, detailing the selection of materials, preparation of surfaces, and laying techniques to ensure long-lasting and high-quality floors. It is applicable to professionals designing and constructing both light and heavy duty brick floors in buildings and pavements.
Overview
This code provides comprehensive recommendations for installing burnt clay brick flooring, detailing the selection of materials, preparation of surfaces, and laying techniques to ensure long-lasting and high-quality floors. It is applicable to professionals designing and constructing both light and heavy duty brick floors in buildings and pavements.
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Contents
Structure
This section outlines the scope of the code covering the design and installation of burnt clay brick flooring. It addresses factors such as floor area coverage, intended usage (load and traffic conditions), type and dimensions of bricks, details of the sub-grade or base layer, materials for bedding and jointing, floor elevation relative to a reference datum, and provision for openings within the flooring. All values and test outcomes must be rounded following the guidelines in IS 2-1960. The standard aligns with global practices while adapting to local Indian conditions. Typical parameters include nominal brick size (190 x 90 x 90 mm), bedding thickness (25-40 mm using sand or cement mortar), joint thickness (5-10 mm), and floor load considerations depending on use (residential or industrial). The section also provides a process flowchart to guide the flooring project from assessment through execution.
This part defines technical terms related to flooring materials and construction practices as per the code. It emphasizes rounding off final calculations and test results in accordance with IS 2-1960, maintaining the same decimal precision as specified values. Base concrete thickness requirements are detailed: a minimum of 75 mm for light-duty floors and 150 mm for heavy-duty floors. The cement types referenced include Ordinary Portland Cement, Rapid Hardening Cement, Low Heat Portland Cement, Portland Blast Furnace Slag Cement, and Portland Pozzolana Cement. Additional materials such as lime concrete, lime mortar, and various types of burnt clay bricks (common, heavy-duty, paving) are also specified. Illustrative examples of rounding off values are provided alongside a flow diagram summarizing material classifications.
This section discusses the necessary information for planning and executing brick flooring projects. Key data include floor area, type of usage (light or heavy duty), brick type and dimensions, sub-grade characteristics, bedding and jointing materials, floor level relative to a datum, and details about openings. The sub-grade is defined as the prepared base layer onto which bedding mortar is applied. Base concrete thickness recommendations are reiterated: at least 75 mm for light-duty and 150 mm for heavy-duty floors. The section references applicable standards for cements, lime concrete and mortar, brick types, and storage practices. A flowchart is included to outline the planning sequence from determining floor area to deciding on base concrete thickness.
The materials segment specifies base concrete thickness minimums for different floor types, cement categories referenced (including various Portland cements and slag cement), and aggregates complying with IS 383-1963 standards. It also details the types of burnt clay bricks suitable for flooring (ordinary, heavy-duty, paving) and recommends lime concrete and lime mortar usage according to their respective codes. Rounding off of test results follows IS 2-1960. A summary table illustrates base concrete thickness values for light and heavy-duty floors, ensuring compliance and durability.
This part stresses minimizing brick handling to prevent damage during delivery and storage. It recommends clean, dry, and covered storage areas for bricks, cement, and lime, adhering to IS 4082-1967 storage guidelines. Cement and lime must be protected from moisture. The section reiterates base concrete thickness requirements and brick specifications for different floor uses. A process diagram depicts material delivery, handling, and storage steps to ensure maintenance of material quality and floor longevity.
This section covers planning considerations such as floor dimensions, load types, brick selection, sub-grade and bedding conditions, floor elevation, and openings. Coordination among trades is emphasized to avoid conflicts during construction. Material handling best practices include storage in dry, clean spaces and minimizing brick handling. The base concrete layer is laid first as a firm foundation, with thickness and mix design based on expected loads and sub-grade. Typical bedding materials include fine sand (20-40 mm thickness) and cement-sand mortar (1:4 mix, 20-30 mm thickness). Joint filling with mortar or sand ensures stability. A flow diagram summarizes the installation stages from planning through finishing and curing.
This segment details dry brick paving practices where bricks are laid without soaking in water. Light-duty floors and dry pavements use bricks conforming to IS 1077-1966, while heavy-duty areas require bricks meeting IS 2180-1962 or IS 3583-1966. Bricks are placed flat or on edge over a 12 mm mud mortar bedding, prepared from clayey soil and water. Patterns such as plain, diagonal, and herringbone are suitable. No base concrete is necessary for dry paving. Curing for cement-lime mortar floors starts two days post-laying and lasts seven days; mud mortar floors require wet curing for at least seven days. A summary table and flowchart illustrate the dry paving process.
This section specifies curing durations and methods essential for achieving strength and durability. Cement mortar floors should remain wet for at least seven days after completion. For cement-lime mortar floors, curing begins two days after laying and continues for seven days. The purpose is to retain moisture for proper cement hydration, preventing shrinkage cracks. Recommended curing methods include regular sprinkling, ponding, or covering with wet gunny bags or plastic sheets. Base concrete thickness requirements for different floor types are reiterated. A summary table outlines curing start times and durations based on mortar type, supported by a flow diagram.
This final section highlights critical quality control measures such as rounding off test results per IS 2-1960 to match specified precision. Base concrete thickness minimums must be verified (≥75 mm for light-duty, ≥150 mm for heavy-duty). Materials must comply with respective IS standards for cement types, burnt clay bricks, lime mortars, and aggregates (IS 383-1963). A checklist ensures proper material selection, mix preparation, thickness verification, and inspection. A flowchart depicts the quality control workflow from material selection to final approval, ensuring adherence to IS 5766 standards.
Frequently Asked
The standard specifies distinct types of burnt clay bricks for various floor loads. For light-duty floors, which endure pedestrian and light wheeled traffic, bricks complying with IS 1077-1966 (Ordinary Burnt Clay Building Bricks) should be used. These are suitable for applications like temporary sheds, courtyards, and footpaths. Heavy-duty floors, subjected to substantial pedestrian and moderate wheeled loads such as trolleys or carts, require bricks conforming to IS 2180-1962 or IS 3583-1966 (Heavy Duty Burnt Clay Building Bricks). These are ideal for industrial platforms, railway stations, warehouses, and other high-wear environments. Additionally, bricks laid on edge exhibit improved durability compared to flat-laid bricks. Ensuring brick quality and proper bedding is crucial for performance.
The sub-grade must be properly leveled and cleaned to support the bedding mortar. For dry brick flooring, a 12 mm thick mud mortar layer (a mixture of clayey soil and water) is applied with the necessary slope to the sub-grade as per Clause 7.1. Base concrete is generally not required for dry brick paving; however, if used, it should be clean, level, and fully cured to provide a stable foundation. Bedding mortar, either lime or cement-based as outlined in Clause 6.3.3, is used to bed the bricks, which should be laid flat or on edge and gently tapped to ensure full contact. Mortar should be applied to brick faces before placing subsequent bricks. Surface leveling is maintained by frequent checks with a 2-meter straightedge.
The code endorses several brick laying arrangements for burnt clay flooring to balance aesthetics and load distribution. Common patterns include the Plain (Straight) pattern where bricks are aligned in straight rows; the Diagonal pattern, with bricks set at 45 degrees to the edges for decorative effect and improved load distribution; and the Herringbone pattern, characterized by a V-shaped zigzag, offering high strength and appealing visuals. Bricks can be laid flat (frog side down) or on edge, with edge laying generally providing superior durability. For flat-laid bricks, joints should be staggered by half the brick length for stability. Mortar beds of lime or cement are used for bedding, with joints fully filled and the surface level frequently checked using a straightedge.
Mortar types include cement mortar (1 part cement to 3 parts sand) and lime mortar, the latter conforming to IS 1625-1962. For dry brick paving, mud mortar composed of clayey soil free from roots, gravel over 2 mm, and excess coarse sand (maximum 10%) with plasticity index between 9-12% is used. Joints between bricks should be 8 to 10 mm thick and completely filled with mortar during installation. After initial setting, joints are raked out to a depth of 10 mm while the mortar is still green, cleaned of dust, wetted, and then refilled with cement mortar (1:3) and finished flush. Bricks must be properly bedded flat or on edge, pressed into the mortar bed, and vertical joints fully filled.
The code requires that cement mortar brick floors remain moist for no less than seven days following installation. For cement-lime mortar floors, curing begins two days after laying and continues for seven days. Curing ensures adequate moisture retention for cement hydration, preventing shrinkage cracks and enhancing strength and durability. Recommended curing practices include continuous sprinkling, ponding, or covering the surface with wet gunny sacks or plastic sheeting to maintain moisture levels throughout the curing period.
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