"Panellised bricks", is a new production method for cladding buildings with the outside appearance of natural bricks, but much lighter, cheaper (4 to 5 times less expensive than traditional), stronger environmentally friendly, insulting and mainly without need for skilled tradesmen while a fraction of the build/installation time of conventional.


The rapid infusion composite production rate and the flexibility of the process means it is particularly suited for making brick slips (traditionally known as mathematical tiles) replacing facing bricks and for synthetic clay roof tiles, and slates. The flexibility of the process means the surfaces of brick slips can be randomised so they appear to be traditionally made clay bricks.

Accelerated weathering tests carried out by Marley Roofing at their Crawley research facility (now part of the Lafarge Group) showed that the anticipated life of an infusion composite roof tile would at least match that of its clay, concrete or slate equivalent. However, the infusion process produces materials which weigh far less, contain far less embodied energy, are stronger (e.g. far more impact-resistant), and cost far less to make and transport than their clay and concrete-based equivalents. Properties that will be necessary to withstand increasingly common climate change- related effects (e.g. high winds and large hailstones).

They are also far easier and quicker to use than conventional products, which usually means unskilled labour can roof and clad buildings much more productively and cost-effectively than skilled roofers and bricklayers using products made from traditional building materials. A competent bricklayer can lay 200 to 300 bricks per day (4 to 6 square metres of wall). An unskilled, but experienced, brick slip worker can fix 40 to 60 sq. m. of slips of wall per day. A square metre of brick slips in the UK currently costs about £20 sq.m. (exclusive of labour and VAT). Infusion brick slips are expected to cost roughly half that figure, due mainly to energy and logistics-related cost savings. Overall cost savings achievable with Infusion brick slip faced walls are expected to be roughly 60% lower than the outer brick skin of cavity walls. Overall cost savings for infusion roof tiles and slates are expected to be 20% - 30% lower than their traditional equivalents.


It's worth mentioning that the strength and low weight of infusion products, combined with the tight control of dimensional accuracy of attachment points on the rear faces of the slips and tiles means they will be ideally suited to the offsite robotic assembly of large lightweight prefabricated wall and roof panels. Such panels would cut material and site labour costs for housebuilders considerably, and could also impact strongly on cost reductions in other areas, e.g. by eliminating the use of scaffolding, avoiding inclement weather-related delays, and cutting build times.

In addition to being stamped out under high pressure presses, Infusion Compositeproducts can also be formed as continuous lengths under high pressure rollers. The resulting composite angle and channel sections could be used in some building applications, e.g. as alternatives to light gauge galvanised steel sections in internal partitioning and rainwater guttering.