Handcrafted Prefabricated Flint Blocks for New Builds and Restoration

Prefabricated Concrete Flint Blocks for Traditional Flint Wall Construction

The method for laying traditional loose flint requires highly skilled craftsmen and can be a time consuming and expensive process. In practical terms, this means there are a limited number of applications in which this natural material is a viable construction option. All Brick & Stone supply high-quality prefabricated concrete flint blocks with bespoke flint facings, designed to replicate the appearance of traditional hand-laid loose flint walls. For architects, developers, contractors and conservation professionals and teams working on residential, commercial, education and heritage schemes.

 

What is a flint block?

Flint blocks are a pre-fabricated concrete block with made to order flint facings. The flint – whether knapped, unknapped or a combination of both are pressed into each block by hand giving each one a unique and traditional effect. Our flint is gathered from fields or sourced from chalk deposits and then worked by hand to produce the flint facings and flint blocks.  They are designed to replicate hand-laid loose flint whilst maintaining an authentic, traditional facade they offer practical benefits of modern construction.

Flint blocks can be laid in a conventional way reducing the requirement for a specialist flint layer, reducing material waste and are quick to lay.  They are manufactured to the highest standards and are widely specified by architects, developers, contractors, and conservation professionals for residential, commercial, education, and heritage projects.

 

Why choose our flint blocks?

Our prefabricated flint blocks offer several advantages over other flint walling systems.

Size and minimal mortar joints 

All Brick & Stone blocks are unique in being manufactured slightly oversized at 445 x 220 mm and are designed to be laid with a 5 mm mortar bed. The reduced joint size creates a tighter, more seamless finish that closely resembles traditional flint wall construction and enhances the overall appearance of the façade.

Authentic Traditional Appearance

Every block is individually handcrafted using an average of 13–15 pieces of natural flint, ensuring no two blocks are identical, effectively replicating a traditionally laid product. Traditionally flint offers a decorative effect to a facade and our flint blocks provide a cost effective solution to achieve an authentic appearance.

Faster Installation

Our concrete flint blocks can be laid using conventional masonry methods, making installation significantly quicker than traditional flint walling. This reduces labour costs removes the need for specialist flint-laying skills.

 

Our Flint Blocks

Flint Block              50 50 Chalk Flint Block                    Unkanpped Chalk Flint Block

 

Knapped Field Flint Block50 50 Field Flint Block    Unknapped Field Flint Block

 

What are the benefits of All Brick & Stone flint blocks?

  • Any natural random laid flint can be supplied in flint block form
  • Blocks can be manufactured to match any existing random stone structure, subject to availability of the matching material
  • Actual block size: 445 x 220 x 100 mm – designed for use with 5 mm mortar beds to reduce visibility of joints
  • Easy to install. No specialist skills or tradesmen required
  • Arch, angle, gable and corner blocks can be made in ¼, ½, ¾ and full block sizes
  • Regular block testing is undertaken by independent laboratories
  • Our lightweight block (weighing 17kg) falls well within the Manual Handling Regulation Guidelines published by the Health & Safety Executive
  • Our blocks conform with all legislative requirements and carry full product liability insurance
  • Flint blocks are handcrafted and no two blocks are identical
  • All blocks maintain a compressive strength in excess of 10 N/sqm and a thermal transmittance (U value) in the order of 3.75 W/m 20C
  • Our team of experienced technical staff are available for laying, pointing and specification advice

 

flint block size chart:

 

our services include:

  • We can produce sample panels for client approval on site
  • Create a bespoke mix of flint
  • Advise on mortar and practical elements of using loose flint
  • Specification to match in both historic and contemporary design
  • Consultation on material selection
  • We can provide samples for delivery and on site
  • View our flint blocks in our showroom