Carslberg Bjælker™

A selection of projects where Carlsberg Bjælker™ is involved as a partner

Pre-stressed brick beams

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The Hørning City Hall was built with red RT 307 machine-processed ”hand-made bricks”. The longest pre-stressed brick beam is 5 bricks long, 9 layers high and 8.84-m long. The pre-stressed brick beams have a visible side on both exterior sides.

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Pre-stressed brick beams treated with slurry plaster are supporting beams in finished buildings. Each beam is 4 bricks wide (47 cm), 10layers high and has a visible side on both exterior sides.

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A pre-stressed brick beam treated with slurry plaster is 3 1/2-brick wide (41 cm) and 9.25-cm long. The pre-stressed brick beam has a visible side on both exterior sides. Carlsberg Bjælker have produced some pre-stressed brick beams with over a 12metre span.

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The longest pre-stressed brick beam in free-standing masonry has a span of 7.93 m. To bear the wind load, there are wall binders inserted between the two wall braces, so that a grid effect is obtained in the hollow wall structure. The two lowest layers of the brick beams are 41 cm wide.

Ceilings made of facing bricks

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The coating of ceilings indoors and outdoors has been made with facing bricks. For the new DnB Nors headquarters in Oslo, Randers Tegl has supplied 600,000 RT 540 Pantheon for masonry and 400,000 RT 540 Pantheon for a. o. 5,725 lfdm. brick beams, and 1,400 qm brick ceilings pre-fabricated at Carlsberg Bjælker™, as well as 100,000 grey pavers for balconies and pathways.

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The covering of ceilings, indoors and outdoors, has been made using facing bricks.

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The covering of ceilings outdoors has been made with facing bricks. The structure was made in 5-brick wide (59 cm) and 2.35-m long sections. The brick sheets are produced with the help of the tension technique and were mounted under a concrete layer with hinges and bracket anchors. The element that builds the passage between the ceiling and the front is a 3-layer brick beam which is anchored with the help of brackets.

Front elements made of brick

Pre-fabricated front and wall elements made of brick fulfil alternative needs and visions of brick fronts in places where building traditional masonry would be difficult or costly. 

Façade elements made of bricks are based on our unique competence in producing pre-stressed brick elements, as well as pre-fabricated brick walls. The elements are available in sections of up to 4.10 x 9.30 cm, in all current bonding systems, and in thicknesses of 108, 80, 60 and 54/48 mm.

Front elements made of brick may be used as separate building elements, or as supporting elements/brick beams on traditional masonry. The elements are ready-made in the factory and don't require any additional processing. They are assembled on cast-in consoles and brackets, adjusted to the form of the supporting building.

The EU regulations for durable building encourage the use of construction materials and structures with a certified longer lifespan and lower maintenance costs. There is already huge interest in the many possibilities that the combination of pre-fabricated front elements made of brick and traditional masonry offer for new buildings, as well as for façade renovation.

Freely mounted masonry

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The client's idea is to create a façade out of horizontal window and brick bands - without visible supporting columns between windows.

The solution was to use pre-stressed 1-layer lintels that support the masonry between window bands. The 1-layer lintels - 2.62-m long with cast-in threads - are fixed with bolts on the masonry brackets, which in turn are fixed to the supporting structure.

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Based on their position in DnB Nors's new headquarters, the pre-stressed brick elements that support the freely mounted masonry are produced to a width of 1 or 3 bricks.

Brick arches

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The 3-point jack arch is generally familiar from classic architecture. The geometric form is determined through the measure of capacity and the chosen height of the arch. The load capacity of the 3-point jack arch is not optimal, but the arch can still be used in many cases. This 6 metre wide 3-point jack arch was fitted in an agricultural building.

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The arch was created as a jack arch with horizontal abutments. It will be embedded up to the arch element, over which a paper layer is embedded to retain humidity. Over the paper layer there is a pre-stressed double-layered lintel embedded. In this system, the arch element is designed to be self-supporting, just like the lintel and the brick-built section. 

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New building in a classic style with arched rises over all windows. The arches with accentuated light end bricks are produced as pre-fabricated brick elements.

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The arch element is produced as an element, which means that the horizontal edges and the arched section are a joint element. The element has is 1.08 m thick and has abutments embedded horizontally on the side edges. A protruding reinforcement is embedded on the surface of the arch that serves as a mounting on the structure behind it.

Special elements

Carlsberg Bjælker™ has been involved in some unusual projects over the years.

Art Museum Aros, Aarhus
The remarkable sun shields (”Brise Soleil”) on the front are 6-metre long, pre-stressed, self-bearing special elements made of red water-struck bricks in Flensburg format, with a surface of square brick tiles with an elevated edge on the back.  

The system was introduced in architecture in 1993 by le Corbusier.

Brick lintels

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Standard brick lintels in many widths for fronts. The pre-stressed brick lintels on the front simplify the work on the construction site and optimize quality, because pre-stressed brick lintels have a greater rigidity, and thus a greater supporting effect, preventing displacement cracks caused by support. Likewise, it prevents the lintel from pressing on the window or the door frame. Front lintels are produced in various widths and of the same bricks used for the rest of the masonry.

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Standard brick lintels in many widths for back=up masonry. The Carlsberg pressing technique offers strong advantages, as pre-stressed lintels have a higher rigidity and load capacity, thus preventing displacement cracks during support.  Likewise, it prevents the lintel from pressing on the window or the door frame. The sizing and static calculation are included in the price, in the case of pre-stressed lintels with standard sizes, from Carlsberg Bjælker™.

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Double layered brick lintels with glazed front. For the front double layered pre-stressed lintels with drip edge 4.31-m long have been used. The bricks are glazed on the front and underneath, while the milled drip edge is also glazed. In the window niches glazed shaped bricks are embedded as window sills.

Rowlock courses

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Pre-stressed rowlock courses are made of facing bricks. They are deliverable with steel threaded rods or support brackets. The crossbar was realized with the help of bricks lain in horizontal bond.

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Arched rowlock course with shaped bricks. The rowlock course is processed out of red water-struck arched shaped bricks, and hence adjusted to the façade's arching. Inserted steel mounting binders are used as crossbars.

Jack courses

Pre-stressed rowlock courses with oblique arch rise and horizontal crossbar. The arch rise is made of bevel-cut bricks in Wendish bond. The vertical size is 5 layers. The crossbar was realized with the help of bricks lain in horizontal bond. Pre-fabricated jack courses and arch rises are particularly strong building elements.

The production

Carlsberg Bjælker™ is the leading producer of pre-stressed brick beams and pre-fabricated brick elements. Advanced equipment with the capacity to process 1.8 million bricks a year ensures a rational and flexible production. All stages of production are subject to ongoing checks to ensure that all labelling requirements and requirements from the designers are strictly observed.

Casting is made with a special concrete mortar that is frost resistant and has a very high compressive and tensile strength, as well as excellent adhesion properties to brick.

Façade elements come with a 12 mm sunken joint on the façade and underside.

Carlsberg Bjælker's pre-stressed brick elements have no steel joists and the concrete cores have no steel. At least 65% of the brick's volume is preserved, so that the element works naturally with the rest of the brickwork.

Build the right house first time

It costs a little more to have a completely brick built house, but it's a very worthwhile investment. The inner walls made of bricks help to adjust the building's temperature, as they store heat and cool air.

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