From brick to roof.

Cast and cure

Each unit is cast in concrete with its face, interlocking pads and groove, then cured and checked.

Finished Greek Key concrete brick

Palletise and deliver

108 full units to a 48 × 40 in pallet, strapped and wrapped, moved on site with a pallet jack.

Palletise and deliver, site view 1

Palletise and deliver, site view 2

Slab and rods

A concrete slab with anchor holes on a 12-inch grid; vertical steel rods rise through every course.

Slab and rods, site view 1

Set the gantry

Two rails either side of the slab carry a rolling I-beam gantry with a beam trolley, electric hoist and scissor clamp.

Set the gantry, site view 1

Set the gantry, site view 2

Lay 36 courses

The gantry picks each brick from the pallet and sets it groove-on-pads; corners turn with a full corner unit and alternate courses start with a half, so the running bond closes and the rod holes stay aligned.

Loading assembly

Roof and glass

The gantry rolls off, the roof plate goes on and the full-height glazing goes in.

Roof and glass, site view 1