EsiBloc
Transcription
EsiBloc
EsiBloc ™ MORTARLESS MASONRY CBI 3321/3323 November 2009 INTRODUCTION THE EsiBloc™ ADVANTAGE Firth EsiBloc™ Mortarless Masonry has been specifically developed for commercial and industrial applications to enable faster, simpler and more cost-effective construction. EsiBloc™ delivers these advantages without compromising any of the benefits of conventional masonry construction: thermal mass, excellent aesthetics, low maintenance, strength, durability, noise reduction, fire resistance and earthquake resistance. masonry is factory calibrated to fine tolerances in height, only minimal wedging is needed to maintain correct levels. In conjunction with best practice end propping, specially formulated moisture cure glue is used between courses at wall ends, corners and Tjunctions to prevent blowouts caused by hydrostatic pressure during grouting. With EsiBloc™ there are no fiddly, expensive plastic bridges. There are no delays due to the weather. More speed and greater efficiencies revolutionise the economics of masonry construction, delivering lower costs and creating a competitive advantage for firms building with EsiBloc™. EsiBloc™ will help achieve shorter critical paths, more completed projects and more satisfied customers, without the need for additional people or resources. EsiBloc™ can be rapidly dry stacked and grouted with EsiBloc Fill™, without delay on the same day, whatever the weather. It is a very simple construction process. The blocks are laid course after course, without needing any mortar. Because EsiBloc™ EsiBloc™ is a unique Firth proprietary masonry product protected by copyright and New Zealand Design Registration Number 406471. Firth EsiBloc™ MORTARLESS MASONRY The EsiBloc™ Mortarless Masonry family is comprised of just seven masonry units. Open End EB 20.03 0 Left-hand Corner EB 20.15L 199 0 20 20 20 190 398 190 Bond Beam Depressed Web EB 20.16 398 200 0 Knock-in Half Bond Beam Depressed Web EB 20.14 0 0 20 398 398 200 Knock-in Half Bond Beam EB 20.44 20 190 Right-hand Corner EB 20.15R 0 0 20 20 190 stacked quickly and accurately. Apart from laying the Firth EsiBloc™ means quick and easy construction. You will achieve shorter project completion times than you would using conventional mortared masonry. Get the EsiBloc™ advantage of faster construction, lower total costs, and fewer penalties due to hold-ups. first course of EsiBloc™ with mortar, to establish a Speed and Efficiency Mortarless masonry is widely used and is a recognised construction technique in Europe and North America. Firth has developed EsiBloc™ Mortarless Masonry especially for New Zealand conditions. EsiBloc™ has been tested extensively and proven to meet the exacting standards required for construction in New Zealand. Half EB 20.02 Cost Effective 199 190 398 level starting point, the rest of the wall is constructed without mortar. Keeping each course of EsiBloc™ level and laid to a line is essential. Firth provides simple wedges to adjust the level where required, though the need for wedging is EsiBloc™ is fast. Only the first course of EsiBloc™ is mortared. The rest of the wall can be dry stacked, reinforced, propped and grouted with EsiBloc Fill™, all in one day. There is no need to clean out excess mortar and there is less waste to remove from site. minimal as each EsiBloc™ is precisely calibrated to a EsiBloc™ achieves more with the same resources. Use EsiBloc™ for faster, more cost-effective masonry construction and a competitive advantage. can keep on laying EsiBloc™ even when it rains. Less Simplicity Itself Masonry Construction The EsiBloc™ masonry range comprises seven standard blocks for construction of virtually any wall. EsiBloc™ projects are easy to plan, easy to price, and easy to construct. EsiBloc™ can be mixed and matched, if necessary, with mortared blocks from the Firth 20-Series masonry range. EsiBloc™ combines the advantages of mortarless Accurate summer. Masonry buildings have excellent aesthetics; EsiBloc™ Mortarless Masonry is factory calibrated to exacting height tolerances so walls can be dry windows and doors with deep reveals provide a strong consistent height. No Weather Delays There should be no stoppages due to weather. You dependence on the weather means more reliable outcomes for you and your clients. construction with all the benefits expected of conventional masonry: noise reduction, fire resistance, earthquake resistance, low maintenance, strength and durability. The high thermal mass of masonry buildings makes them easy to keep warm in winter and cool in and permanent appearance. DESIGN, SPECIFICATION AND INSTALLATION CONSIDERATIONS COMPLIANCE WITH THE NEW ZEALAND BUILDING CODE Specific design is required for buildings constructed with EsiBloc™ Mortarless Masonry. The performance and specific design methods for EsiBloc™ are the same as for conventional mortared masonry construction. Reference should be made to NZS4230 Design for Masonry Structures. Buildings constructed with EsiBloc™ Mortarless Masonry, like all buildings constructed with masonry, must meet the requirements of several clauses within the New Zealand Building Code. Construction with EsiBloc™ complies with existing masonry Standards without alteration. EsiBloc™ can be used wherever conventional Firth 20-Series masonry would be used. EsiBloc™ Mortarless Masonry is always solid filled with EsiBloc Fill™. Construction shall comply with NZS4210 Masonry Construction: Materials and Workmanship. • A pplied weatherproofing membranes. These systems typically include high build acrylics, bitumen emulsions (if compatible with subsequent coatings), or paint on cementitious coatings. As these systems have limited rendering ability, a proprietary plaster should be applied to fill the unmortared joints and plaster the wall. Weatherproofing membranes are normally applied in three coats or in accordance with the manufacturer's specification. • Cement plaster complying with NZS 4251:98 and weatherproof coatings. • EIFS systems, comprising of exterior insulation (typically polystyrene) coated with a modified plaster and weatherproof coating. Noise Reduction Strength B2 Durability Walls built with EsiBloc™ provide excellent sound insulation, with a sound attenuation of STC55* (i.e. a reduction in sound by 55dB) meeting the Standard required for inter-tenancy walls. EsiBloc™ is manufactured to a compressive strength in accordance with NZS4210. Because concrete masonry forms the structure of the building it must be durable for a minimum of 50 years. *Based on testing of Firth 20-Series masonry blocks at the University of Auckland Fire Resistance EsiBloc™ performs in the same manner as conventional masonry and provides a fire rating of 240/240/240* (4 hours) when used in a wall. *Based on New Zealand Concrete and Masonry Association published performance for 20-Series block Holmes Solutions Limited, a subsidiary of Holmes Group Limited, confirms that tests show the overall structural performance of an EsiBloc™ Mortarless Masonry wall is similar to that expected for conventional masonry walls. 19th September 2006 Firth Industries Earthquake Resistance Newmarket Walls constructed with EsiBloc™ will perform to the same level of earthquake resistance as those built with conventional masonry. When designed to the appropriate Standards, EsiBloc™ construction exceeds New Zealand earthquake performance requirements. To whom it may concern, Care should be taken to select an appropriate plastering system. Refer to the plaster manufacturer for recommendations. Weatherproofing EsiBloc™ Mortarless Masonry should be coated to ensure weatherproofing. The designer will typically determine the appropriate solution based on consideration of aesthetics, insulation, maintenance, and consequences of minor breach of the system. Some of the options for external weatherproofing systems include: All buildings constructed with EsiBloc™ should be designed in accordance with NZS4230 (parts 1 & 2), Design for Masonry Structures. Timber and other methods of construction used in conjunction with EsiBloc™ should comply with the relevant Acceptable Solutions or Verification Methods. Structural Performance Private Bag 99904 Plastering B1 Structure AUCKLAND STRUCTURAL PERFORMANCE OF WALLS UTILISING FIRTH MORTARLESS MASONRY Holmes Solutions is a subsidiary of Holmes Group Limited, specializing in product development and testing. Other subsidiaries of Holmes Group include Holmes Consulting Group and Holmes Fire and Safety Ltd We were asked to review a series of structural wall tests that were completed by UniServices intended to determine the feasibility of mortarless construction using Firth EsiBloc Mortarless Masonry, and to investigate the suitability for use in the construction industry in New Zealand. There is a common perception that mortarless masonry walls behave differently under applied loading than conventional masonry walls due to the removal of the mortar from between the blocks introducing points of high stress into the face shells of the blocks hence resulting in the early cracking and failure of the wall. The Firth EsiBlocs are honed and height calibrated to mitigate this problem. The testing completed by UniServices showed the mortarless construction resulted in relatively even loading on the individual masonry units. In addition, very little evidence of grout leakage was present indicating that the junctions between the blocks were relatively smooth and flat with few voids. The mortarless masonry walls continued to show a high degree of resistance even after the peak load had been achieved. The overall performance was similar to that expected for conventional masonry walls. It is our opinion that the results obtained from this testing can be used as an indicator of the expected wall performance, and that Firth EsiBloc Mortarless Masonry construction can be used as a structural wall if designed to the performance provisions of the current New Zealand Standards. Chris Allington, B.E (Hons), PhD (Civil) MANAGING DIRECTOR HOLMES SOLUTIONS LIMITED Clause 2.1.1 of NZS4210, Masonry Construction: Materials and Workmanship, states that a concrete masonry building will fulfill the requirements of B1 if it complies with Appendix 2.E (of NZS4210). Refer to the table in this appendix for the durability requirements applicable for different New Zealand locations. E2 External Moisture Concrete masonry must meet the objective, functional and performance requirements of E2 External Moisture: • W alls and structural elements prevent the penetration of moisture. • Ground moisture is not transmitted to the building elements. • Sub-floor spaces, concealed spaces and cavities to be protected from moisture. • Construction moisture to be dissipated. The provisions of E2 can be met by following guidance provided in publications such as The NZ Concrete Masonry Association's publication "Concrete Masonry - a guide to weathertight construction" or the BRANZ Publication "Weathertight Solutions" Volume 4 Masonry. These publications provide a variety of "good practice" details. H1 Energy Efficiency Acceptable Solution H1/AS1 states that construction in accordance with NZS4243, Energy Efficiency – Large Buildings, satisfies the requirement of NZBC H1.3.1 (a) for the thermal resistance of the building envelope for non-residential buildings of more than 300m2. Construction in accordance with NZS4218, Energy Efficiency – Housing and Small Building Envelopes, satisfies NZBC H1.3.1 (a) for all buildings with a floor area of less than 300m2. Table 2(b) H.1 permits buildings of solid construction to have lower R-values than those of non-solid construction. Maintenance Normal maintenance is the work generally recognised as necessary to achieve the expected durability and weathertightness for a given building element. In the case of concrete masonry that is 50 years. It is the responsibility of the person specifying the building to determine the normal maintenance requirements. Where a proprietary membrane coating is specified, refer to the manufacturer’s maintenance recommendations for the project. Scheduled maintenance comprises the inspection, maintenance and reporting procedures for building elements required to have a compliance schedule. Details of the requirements for a Compliance Schedule are included in Sections 100 to 107 of the Building Act 2004. Cutting EsiBloc™ CONSTRUCTION AND INSTALLATION DETAILS Standard Foundations Dry Stack the Wall Foundations for EsiBloc™ are to be prepared as for a conventional masonry wall. Before commencing construction ensure the position of the wall is correct and in accordance with the plans. Now erect the wall by simply dry stacking EsiBloc™ in a running bond pattern. See Figure 3. See also corner and T-junction details in Figures 7 and 8b. Starter Bar Layout Figure 3 It may be necessary to cut an individual EsiBloc™ to length so that a specific wall dimension is achieved. The cut block should not be placed at the end of the wall. See Figure 5. Optionally the edge of the cut end can be ground to form a matching chamfer. Figure 6 Figure 5 Correct placement of starter bars is critical since reinforcing set-out differs from that for conventional masonry construction. The first starter bar is placed 100mm in from the ends and corners. The second starter bar is 300mm from the first bar. Other starter bars are spaced at 400mm or 200mm as required by the engineer design. See Figure 1. 100 300 200 or 400 as per engineer 300 100 100 Figure 7 300 Figure 1 200 or 400 300 100 Starter bar spacing from ends and corners Mortar the First Course The first course of EsiBloc™ must be laid with mortar to overcome any variances in the foundations and to ensure that the base of the wall provides a level starting point. Dricon Trade Mortar is recommended. It is worth investing the extra time to ensure the base is level because any inaccuracies will be reflected and multiplied as the height of the wall increases. See Figure 2. Figure 2 Adjust with Wedges where Necessary to Maintain Levels EsiBloc™ is factory calibrated to fine height tolerances to minimise the need to make adjustments. However, it is essential that levels are maintained to a line and EsiBloc™ wedges are to be used where required to achieve this. See Figure 4. Every 3 courses check that the wall is plumb and straight. If an individual EsiBloc™ is out of plumb it can be lightly tapped into place. Figure 4 Gluing to Avoid Blowouts when Grouting During grouting, there is the possibility of blowouts caused by hydrostatic pressure at the end of the walls, corners and at T-junctions. To eliminate this potential for blowouts, the last metre of blocks at the end of each course, at corners and at T-junctions, must be glued horizontally using a construction adhesive suitable for use on masonry. Wherever used, cover the full width of the shell face edge of the blocks with the construction adhesive. Best practice end propping of the wall is also required. See Figure 10. The construction adhesive should be gap filling, moisture cure polyurethane glue which develops rapid early strength and is specially formulated to be unaffected by wet construction site conditions. Corners Right hand corners and left hand corners are achieved using EsiBloc™ as shown in Figure 7. T-Junctions T-Junctions are achieved by butting EsiBloc™ units at right angles as shown in Figure 8a below. Cut with a hand grinder as necessary to allow reinforcing steel to pass through the T-Junction as in Figure 8b. Figure 8a Figure 8b Horizontal Steel Placement Figure 11 Control Joint Horizontal steel as specified in the design is to be placed in the same manner as for standard Firth 20-Series masonry blocks. Propping Vertical Steel Placement Vertical steel reinforcement is to be placed as per the specific design after the blocks have been stacked. As for mortared masonry, vertical steel is to be tied to the vertical starter bars with access via “cutouts”. Care must be taken to ensure cutouts are cut in the first course of laid blocks at the required intervals adjacent to the starter bars. See Figures 9a and 9b below. The need for temporary propping or bracing of masonry walls during construction is often overlooked. An unfilled wall is very susceptible to failure from strong winds. Typically walls over 1m in height are at significant risk. It is important to take some measures to brace the wall in order to prevent its premature failure. Typically bracing at 3m centres is recommended in line on both sides of the wall. See Figure 10. Figure 10 R16 Lapping bars 800mm long debonded one side with grease or plastic tape Horizontal reinforcing Sealant Concrete masonry Vertical reinforcing Backing rod NB: External and internal finishing systems omitted for clarity. Figure 9a Control joints are also recommended wherever: • Wall height changes • Wall thickness changes • Main walls intersect other walls • There are control joints in the floors • Major services penetrate the walls If the wall is subsequently plastered, the control joint should be expressed in the plaster and the joint in the plaster should extend the full height of the wall to the top of the bond beam. Figure 9b Control Joints Pre-Grouting Checklist EsiBloc™ Mortarless Masonry requires specific design. The design engineer will determine if control joints are required. The circumstances in which control joints are needed are the same as for solid filled conventional masonry. Prior to commencing grouting, ensure: • The wall is plumb and straight. If an individual EsiBloc™ is out of plane it can be lightly tapped into place, this should be done within 3 courses of the laying height. • The face, ends and corners of the wall have been propped. • All vertical reinforcement steel is in place and tied to the starter bars. • Where services are to run through the wall, that all conduits are correctly installed and will not interfere with the flow of the grout around vertical and horizontal steel. • The structural engineer has inspected and approved the wall. Vertical shrinkage control joints to minimise cracking should be introduced at the lesser of 5 metre centres or twice the height of the wall. Designers should refer to NZS4230, Design for Masonry Structures and NZS4210, Masonry Construction: Materials and Workmanship. See Figure 11 below. Grouting EsiBloc™ walls should be always solid filled with EsiBloc Fill™. Dampen the block cavities prior to pouring the wall to assist the flow and compaction. EsiBloc Fill™ should be compacted by rodding until settlement stops. Placement can be done using a grout pump, but care should be taken to avoid displacement of masonry units or creep in the wall. Any of the grouting methods specified in NZS4210 may be followed. The low lift grouting method, the high lift grouting method with expansive admixture, or the high lift grouting method without expansive admixture are all acceptable options for use with EsiBloc™. Remove Plastic Wedges Once the grout has cured any protruding plastic wedges can be removed or clipped off with a trowel. FINISHING AND WEATHERPROOFING Openings Figure 13 Weatherproofing Parapets Exteriors Interiors Lay EsiBloc™ in a stretcher bond pattern. The chamfered edges of EsiBloc™ are designed to match the aesthetics of conventional mortared masonry. The exterior wall must be sealed using a proprietary membrane coating system. Refer to Figure 12 for details on weatherproofing walls and foundations and Figure 13 for weatherproofing parapets. The interiors can be left raw or finished in a variety of ways, such as: solid plaster, strapping and lining with GIB® Standard plasterboard or direct fixing GIB® Standard plasterboard to EsiBloc™. Consideration shall be given to the insulation requirements of H1. Metal flashing side fixing only - joints as per E2/AS1-70 mm cover to waterproof finishes on both sides Waterproof membrane returning over parapet beneath parapet capping 5º slope down towards roof 5º 70mm Selected membrane roofing Top plate DPC Bond beam in accordance with engineered design Triangle fillet Concrete masonry in accordance with engineered design Figure 12 Weatherproofing Walls and Foundations DPC Roofing substrate External waterproofing system Roof framing Ceiling insulation Ceiling lining External waterproofing system Internal wall lining Figure 14 gives details of weatherproofing around windows where the interior is optionally strapped and lined with GIB® plasterboard. Concrete masonry reinforced in accordance with engineered design Waterproof membrane 200mm min. below FFL Figure 14 Weatherproofing Window - Head and Sill Detail with Optional Strap and Gib® Lined 100mm reinforced concrete floor slab Mortared rebate half 50mm Refer to engineer for ground clearances D.P.M Sand blinding on compacted hardfill Reinforced foundation wall as per engineered design Openings will require the use of standard Firth 20-Series masonry units, which are to be mortared. Weatherproofing systems used around openings must be durable. It is important that water does not intrude into the joint between joinery and the rebate at the head and jambs of the opening. Provision should be made against the possibility of moisture getting into this joint. Moisture is to be allowed to drain away without seeping into the walls or the interior of the building. Provision also must be made for drainage, weatherproofing and pressure equalization at the base of any external joinery. Reinforced concrete footing as per engineered design Mortared Sill block Weatherproofing details for around hinged doors are shown in Figure 15 while the details required for a sliding door are shown in Figure 16. It is also recommended that reference be made to BRANZ pulbication "Weathertightness Solutions" Vol 4 - Masonry, and NZCMA publication "Concrete Masonry - a guide to weathertight construction". Figure 15 Weatherproofing Hinged Door - Head and Sill Detail Mortared rebate half FREQUENTLY ASKED QUESTIONS engineered design Who can build with EsiBloc™? Only registered block layers who have been trained by Firth using EsiBloc™ Mortarless Masonry. How does EsiBloc™ enable faster masonry construction? It can be rapidly dry stacked and grouted the same day, whatever the weather and with only minimal wedging. Why is mortar needed to lay the first course of EsiBloc™? Mortar is essential to overcome any variances in the foundations and to provide a level base for the rest of the wall. How does EsiBloc™ Mortarless Masonry perform compared with mortared masonry? Walls constructed with EsiBloc™ perform the same as those built with conventional mortared masonry in terms of: thermal efficiency, aesthetics, low maintenance, structural performance, durability, noise reduction, fire resistance and earthquake resistance. How is the wall kept straight and plumb without mortar? Firth provides EsiBloc™ wedges to be used where necessary as each course is laid. However, during manufacture each EsiBloc™ is finely calibrated to a height tolerance so there is minimal need for wedging to keep the wall plumb. Are EsiBloc™ Mortarless Masonry walls partial or solid filled? EsiBloc™ masonry walls are always solid filled with EsiBloc Fill™. How many different types of blocks are there in the EsiBloc™ range of masonry? There are seven different blocks in the EsiBloc™ range. See page 2 for details. Leave a vertical and in plane 4-5mm gap between Figure 16 Weatherproofing Sliding Door - Head and Sill Detail Mortared rebate half engineered design Leave a vertical and in plane 4-5mm gap between FREQUENTLY ASKED QUESTIONS IMPORTANT NOTICE How high can an EsiBloc™ wall be dry stacked before it needs to be grouted? As with mortared masonry, it is recommended that EsiBloc™ masonry walls are built no higher than 3 metres prior to grouting with EsiBloc Fill™. Walls shall always be propped. What prevents wall end blowouts due to hydrostatic pressure during grouting? The potential for blowouts during grouting will be eliminated by using Sika Boom G Foam to horizontally glue the last metre of each course of EsiBloc™ at the end of walls, at corners and at T-Junctions. Best practice end propping is also required. When building with EsiBloc™ can standard mortared masonry ever be used in the same structure? Yes. While it is recommended that EsiBloc™ be used wherever possible, Firth 20-Series masonry and Dricon Trade Mortar can be incorporated if required. Are control joints required? Yes. Although subject to specific design, control joints generally are required where walls change in height or thickness, where main walls intersect other walls, where there are control joints in the floor or where walls are penetrated by major services. Building with mortared masonry is tried and true, so how reliable is the new EsiBloc™ technology? Firth has developed the manufacturing and honing technology used to make EsiBloc™ specifically for New Zealand conditions. While mortarless construction may be new to New Zealand it has been widely accepted in Europe and North America for many years. This Manual has been prepared by Fletcher Concrete and Infrastructure Limited trading as Firth as part of its Firth Industries Division ("Firth"), solely to provide general information on construction with EsiBloc™ and not as specific advice to any particular recipient or person. Notwithstanding the contents of this Manual, construction with EsiBloc™ should be undertaken in accordance with the New Zealand Building Code, all relevant statutory and regulatory requirements and all relevant New Zealand Standards. Any person contemplating construction with EsiBloc™ should carry out their own investigations and inquiries as to their specific requirements. The information contained in this Manual is believed to be correct at the time it was prepared but no representation or warranty, express or implied (other than as may be implied by law) is made by Firth, its officers, employees or agents as to its accuracy, reliability or completeness. To the fullest extent permitted by law, Firth excludes all liability for: • any negligent misstatement, error or omission in relation to the information and/or recommendations contained in this Manual; and • any damages, losses, costs or expenses including, without limitation, direct, indirect, special or consequential damages (including but not limited to damages arising from negligence) arising from or in connection with any access to, use of or reliance on the contents of this Manual. Further, successful construction with EsiBloc™ is dependent on numerous factors outside Firth's control - for example, quality of workmanship, particular design requirements and non-Firth products. Firth will not be liable in relation to any of these factors. Firth is not under any obligation to update any information and/or recommendations contained in this Manual or to notify any person should any such information and/or recommendations cease to be correct after the date this Manual is published. If you are using this Manual for business purposes, you agree that the provisions of the Consumer Guarantees Act 1993 will not apply, to the extent that contracting out is permitted by that Act. EsiBloc™ is a trademark of Fletcher Building Ltd ® SUSTAINABILITY: THE FIRTH CONCRETE & CONCRETE MASONRY SUSTAINABILITY LIFECYCLE 4 Environmentally compliant manufacturing plants n 4 Surplus water and some aggregates recycled n 4 Low transport impacts n 4 Leftover concrete returned from construction sites n 4 Passive solar heated thermal mass makes completed buildings n more energy-efficient 4 n 4 n 4 n 4 n 4 n 4 n Most wash water returned from construction sites For Highly durable, low maintenance buildings and no rot contribution to building a High degree of noise control sustainable tomorrow today, Inherent fire resistance visit www.firth.co.nz or call Overall longer effective building life us on 0800 800 576 Demolished concrete can be recycled as hard fill or aggregate for our free brochure. © Copyright Firth 2008 more on Firth’s July 2011 Chalis FIR20285 Available in 0800 800 576 www.firth.co.nz www.masterspec.co.nz