1. Introduction

Habitat for Humanity – St. Louis has chosen to utilize Novabrik mortarless brick siding for installation on homes calling for brick siding. The Novabrik system provides an attractive alternative to the labor-intensive and skilled labor requirements of traditional brick siding. The installation procedures for the Novabrik system will require the supervision of a house leader or crew leader who is familiar with the process, however, volunteer labor will be utilized for the installation. Similar to installing siding, the Novabrik installation will provide volunteers with a satisfying experience as they work to visibly transform the look of the Habitat home. The Novabrik system is expected to be completed during 1-2 scheduled workdays.

2. Safety Issues

• Wear ear and eye protection when using power saws.
• Use a ladder that will reach the work. Move the ladder with your work and don't lean. Place ladders and scaffolding on solid footing and have spotters holding the bottom of the ladders.
• Don't bind the blade of any saw.
• Don't leave objects loose on a ladder or scaffolding. Keep your tools in your tool belt at all times.
• Use extra caution when on scaffolding and watch your footing at all times.
• Utility knives - keep your hands out of the path of the blade. Always retract blade when not in immediate use.
• Habitat requires that hard hats be worn if work is occurring overhead.
• The Novabrik mortarless brick siding product is made from concrete. The dust that is generated when the product is cut or drilled can be harmful if inhaled. When drilling, cutting, or abrading the product during installation or handling, try to work outdoors away from other volunteers where feasible. Wear a dust mask, and warn others in the area of the hazard this product represents.

3. Prior tasks to have been completed before starting

• Rough framing complete (overhangs and gable ends)
• Windows and doors installed
• Flashing installed above windows and doors
• Tyvek house wrap installed on exterior walls where brick siding is to be installed, and seams taped with Tyvek tape

4. Recommended Staff/Crew Assignments

The Novabrik mortarless brick siding is typically installed on the front or street facing side of the home. Since the area to be covered with the Novabrik product is confined to just one wall of the house, the crew staffing requirements for this job are minimal. One or two crews of 3-4 people with an experienced house leader or crew leader are recommended for staffing for this project. The job can be completed in two or three scheduled work days depending on the size of the area to be installed and the experience of the crew.

5. Order/Tasks to be completed By Whom?

____ 1. Set up ladder jacks / scaffolding All crews

____ 2. Install starter strip 1 crew

____ 3. Install corner bricks 1 crew

____ 4. Install Novabrik mortarless siding 1-2 crews

____ 5. Clean site, restack materials All crews

6. Tools/Equipment list

Tools & Equipment Needed at Each Site:

• Twelve-Gauge Drop Cords (50'-100' as needed for power at site)
• Heavy-duty Power Strips
• Circular Saw ( 7¼")
• Miter Saw with Diamond Blade or Masonry Saw
• ½"or 9/16" Hammer Drill
• 3/16" and 7/32" Masonry Drill Bits
• Cordless Drill
• Extension Ladders (16' Minimum)
• Step Ladders (8')
• Step Ladders (6')
• Metal Scaffolding with Walk Boards and/or
• Ladder jacks with Walk Boards
• Saw Horses

Tools Each Crew Leader Will Need:

• 30' Measuring Tape
• 4' Level
• Framing Square
• Chalk Line
• String Line
• Caulking Gun

Tools Each Crew Member Will Need:

• Hammer (16 oz. Min.)
• Rubber Hammer
• Nail Apron
• Handheld Brush
• Retractable Utility Knife with Extra Blades
• Measuring Tape (16' Min.)
• Square (Speed or Combination)
• 2 Pencils
• Safety Glasses
• Work Gloves
• Dust Mask
• Ear Protection
• Hard Hats (if work is going on overhead)

7. Material List

Siding

• Novabrik Siding Bricks
• Novabrik Corner Bricks
• Vinyl Starter Strip

Fasteners

• Siding Screws (2½" #8 corrosion-resistant screws)
• Siding Screws (1-5/8" #10 corrosion-resistant screws)

Miscellaneous

• Chalk
• Construction Adhesive
• Dry Paint Brush or Broom

8. Quality Checkpoints

____ Treated baseboard properly attached to wood framing

____ Corner bricks installed plumb

____ Ladders / ladder jacks securely braced

____ Siding bricks level and attached properly with corrosion-resistant screws

____ All materials restacked, site cleaned up, tools accounted for and put away

9. Construction Drawings and Text

NOTE: The following drawings, diagrams, and text are to be used on the job site when a question arises as to methods and procedures associated with the task. The notes on the drawings have been geared toward use as a quick reference. If a more in-depth explanation is needed, please read the text description. But most importantly, consult your Habitat Site Supervisor and Construction Manager for advice as needed.

This section is organized in one order of installation. Keep in mind that when the house is completed, the volunteers are gone, and the family moves in, the house’s exterior is an enduring representation of Habitat to all who pass and see it. Take the time to do the work correctly and well.

1. Starter Strip and Corner Block Installation

To prepare the wall for installation of the Novabrik mortarless siding, a plastic starter strip must first be installed at the base of the wall framing. Unlike the instructions found in the Novabrik installation guide, Habitat will not be installing furring strips to accommodate the Novabrik mortarless siding installation. Instead, the Novabrik mortarless siding will be attached directly to the wall framing. Use a laser level and string line to establish the position of the starter strip. Once the location is marked, attached the starter strip to the wall framing with #8 corrosion-resistant screws.

To prepare the exterior corners for installation of the specially designed Novabrik corner bricks, a steel corner strip is first installed. Fasten the first corner strip 2 inches from the base with corrosion-resistant screws at 10 inches on center. Correct out of plumb or uneven corners at this point by adjusting the steel corner strip.

Drill a hole at a 30° angle in each corner block prior to attaching to the wall. Slide the first corner block down the steel corner strip and screw into the strip with one 1 5/8" corrosion-resistant screw. Align the bottom of the corner block with the bottom of the first course of Novabrik on the wall. Apply a small amount of construction adhesive in between each corner block to lock them together.

Once the first few corner bricks installed, the full courses of Novabrik mortarless siding can be installed on the wall (see section 2).

As the wall of Novabrik mortarless siding is installed, additional corner blocks are installed the same way up to the end of the first steel corner strip. When you are ready to install an additional steel corner strip, insert one more block into the protruding strip. This provides a way to align the next steel corner strip with the first one. Slide down a second steel corner strip into the last block installed. Align the steel corner strip with the bottom strip and fasten it to the wall in the same manner as the first.

Continue up the wall to the end of the last full length steel corner strip.

Insert one more block into the protruding strip.

Measure the remaining length to the top of the wall. Cut the corner strip to length (this step is easier if you make the last strip 18 inches or less. Fasten the required number of blocks to the strip, cut the last block to fit and attach it to the block below it with construction adhesive. Test fit the assembly, and fasten the steel corner strip assembly to the wall.

2.Installing Novabrik Siding

With all the prep work completed, the Novabrik siding installation can begin. Pre-drill the bricks for the base course with two holes before placing them in position. Avoid drilling screw holes in the center of the bricks. When attaching the bricks to the wall framing, make sure you don’t set the screws too tight. Hold the brick flat and stop the screw when the head touches the brick. Install the screws at a slight downward angle. Always install the bricks in staggered rows. Be sure to mix four Novabriks from each of the pallets as you stack and install. This will blend the Novabriks together to ensure a random coloring pattern. The first course must absolutely be level. A long straight edge can help, or use a string line. Be sure to check for straightness every fourth course before fastening the bricks to the wall. Use a rubber mallet to tap the bricks in place and brush them down with a small broom or dry paint brush to remove dirt and dust.

On the first row you will use two screws for every brick. For subsequent rows you will stack the Novabrik four rows, and then install one screw at each wall framing stud location. Novabrik are attached on only every fourth row at the wall framing stud locations. This fastening pattern can carry 7 times the weight of the brick veneer. There is no need to increase the number of screws.

Install the last row of Novabrik mortarless siding by measuring the remaining space between the second to last row of brings and the top of the wall. Next, cut the bricks to the measured width and attach them to the wall with construction adhesive. Apply construction adhesive to the second to last row of bricks at the location where the last row will come into contact with them. Set the last row of bricks into the construction adhesive across the length of the wall.

3. Vertical/Horizontal Alignment Instructions

The Novabrik installation guide has detailed instructions for aligning the Novabrik mortarless siding along door and window openings. However, the Habitat homes have been designed to take into account the size of the Novabrik mortarless siding bricks. Each door and window opening has been sized and located in a way to avoid having to adjust the starting point for the installation of the first row of siding. By starting at the base of the wall, the bricks should line up flush with the tops of the window and door openings without any other adjustments.

4. Installation Above Window and Door Openings

Installation of Novabrik mortarless siding above door and window openings requires a couple of additional steps. First, waterproof flashing membrane should be installed across the entire length of the top of the window and door openings. This is usually done as part of the window or door installation, however, check to make sure this step has been completed prior to continuing. Next, a starter strip is installed at the top of the door or window opening. See the diagram below for an illustration of the components involved in installing Novabrik mortarless siding above door and window openings.

It may be impossible to have a full brick above all openings, especially on a 2-story wall. In this situation, you will need to cut the bricks above the opening horizontally. Cut the starter strip as well so that you have a level line from which to install the bricks.

5. Installing Soldier Course

A soldier course above windows and doors provides a more visually appealing look to the Novabrik mortarless siding. The following steps should be followed to properly install a soldier course:

• Install flashing over the top of the window or door opening.
• Mark the opening above the window or door for the soldier course (leaving a space above the window or door no larger than the length of one Novabrik soldier).
• Attach a starter strip to the wall to bridge the brick course above the soldier course opening. Install the starter strip so that the bottom edge of the bricks above the soldier course will hang flush with the mark for the location of the Novabrik soldiers.
• Install Novabrik with two corrosion-resistant screws per brick resting on the starter strip.
• Complete the installation of the standard Novabrik siding to the top of the wall and come back later to complete the soldier course.
• Cut to length the soldier course bricks and install the soldier course in the opening with two corrosion-resistant screws per brick. If you need to cut a brick to fit the width of the opening, start installing soldiers at both ends of the opening and cut the brick in the middle of the opening to fit.
• Remove the top part of the last Novabrik soldier and glue it in place with construction adhesive.

6.Making an Arch

For some door and window locations, the design may call for the installation of a decorative arch with the Novabrik mortarless siding. Arches are created by opening the joint between adjacent bricks at one end. The width of the gap is limited by aesthetics and should be carefully inspected as the arch is constructed. Generally, arches should be limited to openings with a large radius.

Reducing the height of the brick will allow for a shorter radius. Prepare the opening area for the arch installation with a plywood reinforcement header and housewrap. Start from one end, fastening each brick with 2 screws and applying a large bead of construction adhesive between the bricks.

To seal the arch, apply a large bead of construction adhe­sive between the bricks before you set them in place with two screws per brick. This will prevent water penetration. Remember to install aluminum flashing over the opening and cover with house­wrap to prevent moisture from entering behind the arch.

Printer-friendly version
Page last updated Saturday, May 3, 2008 at 6:40:02 PM