Factory Blocklaying

Factory Blocklaying Melbourne

Structural Precision for Melbourne’s Industrial Heartland

Why Factory Blocklaying Matters

Concrete blocklaying plays a critical role in Melbourne’s industrial infrastructure, especially within factory construction. Blockwork forms the structural skeleton for production plants, processing facilities, and manufacturing hubs throughout areas such as Dandenong South, Campbellfield, and Sunshine West. These builds require more than just walls—they demand robust, load-bearing, fire-rated, and acoustically sound construction that stands up to years of industrial activity.

At Quality Bricklayer Melbourne, our Commercial blocklaying contractors deliver factory blockwork tailored to heavy-duty environments, engineered in line with Australian building codes and project-specific performance criteria.

What Factory Blocklaying Involves

Factory blocklaying involves the construction of structural and non-structural walls using masonry units such as solid concrete blocks or core-filled CMUs. The goal is to build walls that can:

Support roof trusses, gantries, and mezzanine levels
Separate production zones from administration or storage areas
Contain machinery noise
Withstand mechanical damage from forklifts or loading equipment
Meet fire separation regulations under the National Construction Code (NCC)

These requirements make factory blocklaying a specialised task involving precise alignment, reinforcement detailing, and coordination with other trades like steel, roofing, and concrete slab teams.

Benefits of Factory Block Construction

Concrete blockwork remains a go-to material for Melbourne’s factory builds because of its unmatched performance characteristics in tough environments.

Structural Capacity: High compressive strength supports long-span roofing systems and mezzanines.
Fire Resistance: Complies with BCA requirements, offering up to 4-hour fire-rated walls.
Impact Tolerance: Durable against collisions from trolleys, machinery, and warehouse equipment.
Sound Control: Excellent for containing industrial noise in compliance with EPA guidelines.
Minimal Maintenance: Blockwork is low-maintenance and graffiti-resistant when sealed.

Where Factory Blocklaying is Applied

Factory blocklaying isn’t one-size-fits-all. Different facilities have different needs based on operations, compliance, and budget. Below is a table of practical use cases and what must be considered in each:

Factory Type	Blockwork Application	Engineering & Compliance Considerations
Manufacturing Plants	Internal load-bearing walls, fire walls	Requires reinforced blockwork and detailed wall tie integration
Packaging & Storage Sites	Dividing walls, dock areas, boundary fencing	Must handle high impact, core fill blocks often used
Cold Storage Facilities	External envelope and internal compartments	Thermal bridging considerations; blocks may require insulating liners
Textile & Printing Factories	Machinery enclosures, ventilation-ready partitions	Acoustic detailing and block cuts for mechanical ductwork
Recycling Centres	Bunker-style retaining blockwork for materials	High load retention and water-resistant mortar required
Food Processing Facilities	Hygiene-grade wall systems	Smooth-finished masonry, moisture-resistant sealants, HACCP compliant

Engineering Variables and Material Selection

Factory blockwork isn’t just about stacking blocks—it’s about choosing the right system for the intended load, temperature, and layout.

Key Block Types Used

190mm core-filled concrete blocks: Standard for load-bearing walls
Lightweight AAC blocks: Sometimes used in upper levels for thermal efficiency
Fair-faced blocks: Used where appearance matters, such as admin zones
Solid blocks with steel reinforcement: Used in high-retaining or forklift-bump zones

Important Engineering Factors

Wind Load & Seismic Resistance: Required under AS 1170 for tall walls or exposed zones
Expansion Joints: Control cracking over long factory wall runs
Moisture Barriers & Damp Proof Courses (DPC): Especially critical in food-grade environments
Structural Coordination: Blockwall tie-ins must align with slab footings and steel frames
Height Restrictions & Bracing: Factories with 6–8m walls often need engineered lateral bracing or steel core infills

Our Blocklaying Process

Site Inspection & Wall Setout
Coordination with surveyors to confirm wall lines and datum points.
Block Specification & Engineering Review
Ensure compliance with AS 3700 and any engineered documents.
Delivery & Onsite Staging
Material handling plan to ensure safe, staged deliveries.
Construction & QA
Progressive QA checks including wall plumb, tie-bar spacing, joint depth, and mortar consistency.
Finishing & Sealants
Smooth face finish or rendered blockwork, sealed or painted depending on spec.