The Apocalypse

Appearance

Simple construction ​

Solid, durable structures are essential for expanding survival capabilities beyond basic shelter. This section covers fundamental building materials and techniques including brick making, mortar preparation, and traditional wood joinery methods. Mastery of these skills enables construction of homes, workshops, storage facilities, and community buildings using locally available resources and simple tools.

Introduction to Simple Construction ​

In a post-collapse scenario, the ability to build reliable structures using minimal technology is critical. Modern construction materials and machinery may be unavailable, so knowledge of traditional building methods is invaluable. Simple construction focuses on using natural and salvaged materials such as clay, sand, lime, wood, and stone combined with manual labor and hand tools.

This section will guide you through:

  • Producing bricks from clay and other materials
  • Preparing mortar for binding bricks and stones
  • Basic wood joinery techniques for framing and finishing
  • Combining these elements to create durable, weather-resistant buildings

These skills form the foundation for early production and local industry, enabling communities to establish permanent settlements and infrastructure.

Brick Making: Materials and Methods ​

Bricks are one of the oldest and most versatile building materials. They provide strength, thermal mass, and fire resistance. Making bricks locally reduces dependence on external supplies and allows for scalable construction.

Types of Bricks ​

  • Adobe bricks: Made from a mixture of clay, sand, water, and organic fibers (straw, grass). These are sun-dried rather than fired, suitable for dry climates.
  • Fired bricks: Clay bricks hardened by baking in a kiln or open fire. They are stronger and more weather-resistant but require fuel and a kiln.
  • Compressed earth blocks (CEBs): Made by compressing moist soil with a mechanical or manual press. They can be stabilized with lime or cement for durability.

Materials Needed ​

  • Clay: The primary binding material. It should be plastic enough to mold but not overly sticky.
  • Sand: Provides bulk and reduces shrinkage during drying.
  • Water: For mixing and molding.
  • Fibers: Straw or grass to add tensile strength and reduce cracking.
  • Stabilizers (optional): Lime, cement, or ash to improve durability and water resistance.

Brick Making Process ​

  1. Soil Preparation: Identify suitable clay-rich soil. Remove stones, roots, and debris. Mix clay with sand in a ratio of approximately 1:2 (clay to sand) for adobe bricks.
  2. Mixing: Add water gradually to the dry mix until it reaches a workable consistency, similar to thick mud. Add fibers to the mix.
  3. Molding: Use wooden molds to shape bricks. The mold size typically ranges from 8x4x2.5 inches (20x10x6 cm) but can vary.
  4. Drying: Remove bricks from molds and place them on a flat surface in the sun. Turn regularly to ensure even drying. This process can take 1-3 weeks depending on weather.
  5. Firing (for fired bricks): Build a kiln or clamp using wood or coal. Stack dried bricks with spaces for airflow. Fire for several days at temperatures above 900°C (1650°F) to harden bricks.

Quality Indicators ​

  • Bricks should be uniform in size and shape.
  • They should not crumble easily when dry.
  • Fired bricks should have a hard, dense surface and a ringing sound when struck.

A stack of sun-dried adobe bricks arranged neatly outdoors on a wooden pallet, with a rustic rural background.

Mortar Preparation and Types ​

Mortar is the bonding agent that holds bricks or stones together. It must be strong, durable, and compatible with the building materials.

Common Mortar Types ​

  • Clay mortar: Made from clay and sand, used with adobe bricks. It is flexible but less water-resistant.
  • Lime mortar: Made from lime, sand, and water. It is breathable, durable, and self-healing but requires lime production.
  • Cement mortar: Made from Portland cement, sand, and water. It is very strong and water-resistant but less breathable and harder to produce without industrial materials.

Materials for Mortar ​

  • Sand: Clean, coarse sand is preferred.
  • Binder: Clay, lime, or cement depending on availability.
  • Water: Clean water for mixing.

Mortar Mixing Ratios ​

  • Clay mortar: 1 part clay to 2-3 parts sand by volume.
  • Lime mortar: 1 part lime to 3 parts sand.
  • Cement mortar: 1 part cement to 3-4 parts sand.

Mortar Preparation Steps ​

  1. Sift sand to remove debris and large particles.
  2. Mix binder and sand thoroughly while dry.
  3. Add water gradually and mix until a smooth, workable paste forms.
  4. Use mortar within 1-2 hours before it begins to set.

Application Tips ​

  • Wet bricks slightly before applying mortar to improve adhesion.
  • Apply mortar evenly with a trowel.
  • Fill joints completely to prevent water ingress.
  • Tool joints for a neat finish and water shedding.

A trowel applying mortar between bricks on a white background with black line art.

Wood Joinery: Fundamentals for Framing and Construction ​

Wood is a versatile construction material used for framing, roofing, flooring, and finishing. Proper joinery techniques ensure structural integrity without relying on nails or metal fasteners, which may be scarce.

Common Wood Joinery Techniques ​

  • Butt joint: Simple end-to-end or edge-to-edge joint, often reinforced with nails or dowels.
  • Lap joint: Overlapping two pieces partially for increased surface area and strength.
  • Mortise and tenon: A rectangular peg (tenon) fits into a matching cavity (mortise) for a strong, interlocking joint.
  • Dovetail joint: Interlocking wedge-shaped cuts for high tensile strength, commonly used in cabinetry.
  • Half-lap joint: Both pieces are notched halfway through thickness and overlapped flush.

Tools Needed ​

  • Handsaw or bow saw
  • Chisels
  • Mallet or hammer
  • Marking gauge or pencil
  • Square and measuring tape
  • Brace and bit or hand drill for holes

Wood Selection and Preparation ​

  • Use straight, seasoned wood to reduce warping.
  • Remove bark and smooth surfaces for better fit.
  • Cut joints precisely to ensure tight connections.

Step-by-Step Mortise and Tenon Joint ​

  1. Mark the tenon: On the end of one timber, mark the length and width of the tenon.
  2. Cut the tenon: Saw along the marks to create the projecting peg.
  3. Mark the mortise: On the mating timber, mark the cavity to receive the tenon.
  4. Chisel the mortise: Remove wood carefully to create a clean, rectangular hole.
  5. Test fit: Insert tenon into mortise; it should fit snugly without forcing.
  6. Secure joint: Optionally, use wooden pegs or wedges to lock the joint.

Advantages of Traditional Joinery ​

  • No reliance on metal fasteners, which may corrode or be unavailable.
  • Strong, durable connections that can bear heavy loads.
  • Allows for disassembly and repair.

A mortise and tenon joint assembly on white background with black line art, showing the tenon fitting into the mortise.

Combining Bricks, Mortar, and Wood in Construction ​

Wall Construction ​

  • Use bricks laid in courses with mortar joints.
  • Alternate brick orientation (stretcher and header) for strength (English or Flemish bond).
  • Incorporate wooden lintels or beams above openings for support.
  • Build corners and intersections carefully for stability.

Foundations ​

  • Excavate below frost line if possible.
  • Use large stones or compacted gravel as base.
  • Lay bricks or stones with mortar to form a level, stable foundation.
  • Ensure drainage away from foundation to prevent water damage.

Roofing ​

  • Construct wooden frames using joinery techniques.
  • Use wood planks, thatch, or salvaged metal sheets as roofing material.
  • Ensure proper slope for water runoff.
  • Install eaves to protect walls from rain.

Floors ​

  • Compact earth floors can be stabilized with clay or lime.
  • Wood plank floors require joists and beams joined securely.
  • Brick or stone floors provide durability and ease of cleaning.

Doors and Windows ​

  • Frame openings with wood or bricks.
  • Use wooden shutters or salvaged glass panes.
  • Install simple wooden doors with hinges made from wood or salvaged metal.

A partially constructed brick wall with wooden framing and a wooden lintel above a window opening, set on a stone foundation outdoors.

Durability and Maintenance ​

  • Regularly inspect for cracks in bricks or mortar.
  • Repair damaged mortar joints by repointing.
  • Protect wood from moisture by applying natural oils or paints.
  • Clear vegetation away from foundations and walls.
  • Maintain roof integrity to prevent leaks.

Safety Considerations ​

  • Use proper lifting techniques when handling heavy bricks.
  • Wear gloves and eye protection when cutting wood or mixing mortar.
  • Ensure scaffolding or ladders are stable during construction.
  • Ventilate enclosed spaces to avoid inhaling dust or fumes.

Conclusion ​

Mastering simple construction techniques using bricks, mortar, and wood joinery empowers survivors to build strong, lasting structures with limited resources. These skills form the backbone of early production and local industry, enabling communities to transition from temporary shelters to permanent settlements. With practice and resourcefulness, you can create safe, functional buildings that support long-term survival and growth.

For more advanced construction techniques and materials, see Simple construction and related chapters on Manual lumber processing and Charcoal production and clay kilns.

A completed small brick and wood shelter with a pitched roof, surrounded by greenery under a clear sky.