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PRC.06 · Construction Process

Load-bearing Wall in Porous Clay Block

A wall that carries, insulates and breathes with a single material: the porous clay block is the single-leaf answer to nZEB — but it forgives very little at the joints.

Thickness
38–45 cm
Vertical joint
dry tongue-and-groove
Mortar
thermal, beds only
Inertia
high, summer lag

Overview

TAV. 00

Porous clay traps millions of micropores in the body that slow heat down: a 38–45 cm block carries the floor and reaches the required transmittance at once, without external insulation. The single-leaf wall simplifies the site and gives mass and inertia — but it lives or dies at the joint: thermal mortar on the beds, vertical tongue-and-groove dry-butted, no through voids. Every open gap is a thermal bridge the single leaf cannot recover elsewhere.

The site score

TAV. H
The beats — with site daysbeat 1 of 5

click a beat · arrow keys ← → walk the site · dashed pauses are the chemistry at work

NOT TO SCALE1 of 2 layers in placePorous clay block

The detail of the crafta millimetre here, a centimetre at the eaves

TIE BEAMREFERENCE LINE
01Days 1–2

The starting course

Setting out on the kerbs and laying the first course on a levelling mortar bed, checking level and square around the whole perimeter.

Why it is done this wayThe porous block works with a thin joint: vertical tongues are dry-butted and mortar goes on the beds only. For that to work, the first course must be dead level — a millimetre out here becomes a centimetre at the eaves, and the blocks above stop interlocking.
± 1 mm · first-course tolerancemalta livellante · here only, generousbase · where the bridge starts
In handlaser levelline and squarestraightedge
no mortar below +5 °C
The mistake that costs dearlyFirst course out of level “we'll make it up later”: the vertical joints stop matching, get filled with random mortar, and every gap becomes a thermal bridge.
Site supervision checkLevel and flatness of the first course; square; base thermal break if specified (thermal-break block or insulated void).
You lay the first course with the level in hand and your hurry in your pocket: the whole wall sits on it.site notebook — editorial synthesis

The point of the single leaf

A wall with three jobs

TAV. G1

Carry, insulate, breathe: in porous clay the three jobs live in the same material. The price of that simplicity is that there is no other layer in which to fix a mistake.

SINGLE-PLYbears, insulates, breathesno reserve layerLAMINATEDeach function has its layermore parts, more faces

Schematic. The choice between them is not about quality but strategy: the single leaf simplifies the site and concentrates risk at the joints; the layered wall spreads functions and risks across more interfaces.

Where the heat is lost

The map of thermal bridges

TAV. G2

In a well-built single leaf the wall is not the problem: the problem is where it stops. Ring beam, lintel, base and window reveals matter more than a few extra centimetres of thickness.

TIE BEAMLINTELJAMBBASE · ground fixing

The four circled points are to be solved in design, not on site: once the ring beam is cast, correcting it costs ten times as much.

How it ages (and what betrays it)

TAV. P
FUGA FREDDAVertical joints filled with mortar (phase 02): a conductive rib is sewn into the wall and the single leaf loses what the block had gained.
MUFFA D'ANGOLORing beam with no insulation strip (phase 03): the cold perimeter band takes the internal surface below dew point and mould draws the floor line.
MURO TAGLIATODeep horizontal chases hacked with a chisel (phase 04): the block's ribs break, the pier loses strength and the crack follows the chase.
MURO CHIUSOCement render or film-forming paint (phase 05): the porous block stops drying, stays damp and underperforms its declared value for the building's life.
PRIMO CORSO STORTOAn out-of-level start (phase 01): the tongues stop matching, joints get filled at random and the error multiplies course after course up to the eaves.

Questions from the site

TAV. Q
Is a single leaf really enough for an nZEB?

With the best-performing blocks and 38–45 cm thicknesses, yes in most Italian climate zones — but only if the thermal bridges at ring beams, lintels and base are solved. That is where the single leaf wins or loses, not in the field of masonry.

Can I put external insulation over porous block?

Yes, and in cold zones it is often worth it: a thinner block plus a thin external insulation. Choose a breathable insulant, though, or you cancel the clay's ability to regulate moisture.

Why must blocks be sawn?

Because a clean cut preserves the vertical tongue and the internal ribs. A block broken with a hammer loses its profile, no longer butts up, and forces you to fill the gap with mortar — that is, to create a thermal bridge.

How does it behave in a seismic zone?

There are specific reinforced-masonry systems, with reinforcement in the vertical holes and mortar beds, designed as a load-bearing structure. It is not a laying variant: it is a structural choice to be sized in design.

Materials involved

TAV. M
MAT.56/79P
Honeycomb Clay Block
Porous Clay Block
MAT.30/53C
Rigid Hydraulic Mortar
Cement Plaster
MAT.05/28R
Structural conglomerate
Reinforced Concrete
MAT.27/50S
Repair mortar class R4 (EN 1504-3)
Structural Repair Mortar (R4)
MAT.31/54S
Mineral Paint
Silicate Paint

Stratigraphy

TAV. S
↑ OuterInner ↓
External render
Lime-based, breathable
Porous clay block
Load-bearing and insulating, 38–45 cm; internal plaster downstream

Advantages

TAV. V
  • One material carries and insulates: a simpler site, fewer layers to get wrong
  • Mass and inertia: in summer the heat arrives indoors hours late
  • Breathable and hygroscopic: it regulates indoor humidity
  • Non-combustible and durable: clay does not age
  • No external insulation to maintain or dispose of at end of life