Durox product guide

Transcription

Durox product guide

CI/SfB
(21)
Ff
January 2015
To contact us:
››› Technical telephone number: 0870 242 1489
››› Technical email address: [email protected]
››› Sales telephone number: 0845 606 2468
Salisbury House, 2a Tettenhall Road, Wolverhampton, West Midlands, WV1 4SA
Durox
product guide
2
Blockwork solutions
Durox
Durox
Durox is a modern construction material,
whose versatility, light weight, thermal
and acoustic properties make it the
ideal solution for a wide variety of
applications in all types of building.
Applications
For more detailed product applications,
please see pages 16-24
Walls – standard mortar
Cavity inner leaves, solid
external walls and internal
walls
Supabloc
Coursing bricks
Separating walls
Supabloc 4
Supabloc 7
Supabloc 8
Coursing bricks
Higher strength loadbearing
walls
Supabloc 4
Supabloc 7
Supabloc 8
Coursing bricks
Cavity inner leaves, solid
external walls and internal
walls
System 500
System 600
14 Durox System
Separating walls
System 600
System 700
16 Aircrete block applications
Higher strength loadbearing
System 600
System 700
Contents
3
Applications
4
Benefits and attributes
6
Durox Supablocs
8
Durox Foundation
10 Durox Coursing bricks
11 Durox Coursing slips
12 Durox Floor Blocks
17 Separating walls
Blockwork solutions
Walls – thin joint
walls
System 700
20 Internal walls
21 Internal floors
22 Walls below DPC
23 External walls
24 Structural elements
Foundations
Solid walls below DPC
Cavity walls below DPC
Foundation
Foundation 7
26 Thermal performance
Supabloc
Supabloc 4
Supabloc 7
Supabloc 8
30 Durox packs
Floor
Beam and block floors
Floor
Coursing slip
Product identification
Supabloc
Supabloc 4 Brown
(zig-zag mark on both faces)
Technical services: 0870 242 1489
From 9.2014 all Supabloc
products (packs) will
be identified with inkjet
codes as shown, right.
Supabloc 7 Black
Supabloc 8 Red
3
4
Blockwork solutions
Durox
Durox
Blockwork solutions
Durox can be used below ground in foundation
walls, in suspended beam and block floors and in
all types of internal and external walls. It provides
many benefits for specifiers and contractors making
it the natural choice where blockwork is specified.
Note the paint stripe system of block identification is being superseded with ink jet codes, effective after September 2014. See the Block Identification section on page 30 for further details.
01 Easy to work
Cutting, chasing and finishing are all
straightforward and quick to achieve
using standard tools.
02 Excellent acoustic
and thermal performance
Good U-values and Rw values, as well
as Robust Details help specifiers more
easily meet or exceed Code for
Sustainable Homes and BREEAM
requirements.
03 Speedy cost
effective construction
Durox is lightweight, easy to handle and
fast to lay, reducing build times and with
thin joint, even faster.
See also:
14 Durox System
16 Applications
26 Thermal Insulation
30 Packs
›››
Excellent technical
performance
• Durox aircrete blocks have a low
thermal conductivity which aids
compliance with Part L Thermal
Standards as well as the Code for
Sustainable Homes’ requirements.
• Standard cavity widths of 100mm
can be built to meet U-values of
0.30W/m2K or better.
• The excellent thermal conductivity of
Durox can result in a reduction in the
amount of cavity insulation required to
meet U-values compared with denser
blocks.
• Walls below ground constructed with
Durox Foundation blocks are not only
quick to build, but when compared to
conventional cavity walls, their use
avoids the cost of forming cavities,
concrete infill and wall ties.
• Durox can be used in specifications
to meet the requirements of Part E
Sound Insulation for houses and flats,
including compliance with Robust
Detail specifications.
Modules sized for speed
• The environmental performance of
Durox can help to achieve compliance
with the ‘Materials’ section (MAT III)
of the Code for Sustainable Homes,
including ratings in accordance with
the Green Guide to Specification.
• Independently monitored trials have
demonstrated that Durox Supabloc is
over 20% faster to build with than
conventional size aircrete blocks and
over 30% faster than dense blocks.
• Compressive strengths of 3.6, 4.2, 7.3
and 8.7N/mm2 cover virtually all structural
needs and meet Category 1 manufacturing
control requirements of BS EN 5628-1.
On site and
construction economy
• At 620mm long, Durox is 40% longer than
conventional size blocks meaning they
lay at 7 per m2 including mortar joints.
• Use of thin joint blockwork using Durox
System can yield exceptionally fast build
times and many other associated benefits.
Workability
• Durox products are straightforward to
work with as they are light, easy to
handle and quick to install.
• Faster Durox build-time means lower
construction costs.
• They are easily cut, chased and fixed
too.
• Due to fewer mortar joints, mortar
savings of up to 22% can be made when
compared to conventional size blocks.
• They can be finished with render*,
cladding, plaster or drylining. Durox
System, thin joint blockwork, is particularly
suited to the application of thin-coat
spray plasters and insulated renders.
• The light weight of Durox means more
blocks per load, resulting in more
environmentally-friendly transportation.
Sustainability
All TBP manufacturing plants operate an
Environmental Management System (EMS)
conforming to ISO:14001. All sites are
independently certified for compliance by
BSI. Use of Durox products supported by
a certified ‘Very Good’ to BES 6001
provides the evidence to comply with the
Responsible Sourcing element of the Code
for Sustainable Homes. This, together with
a responsible supply chain, allows Durox to
contribute in a number of ways towards
sustainable construction. Summary Green
Guide ratings applicable to Durox
constructions can be found in the BRE
Green Guide to Specification.
Authority and standards
All Durox products are BSI Kitemarked to
EN 771-4, and are manufactured under a
quality system complying with ISO 9001.
Durox blocks are Category 1 masonry units
in accordance with BS 5628-1. This allows
an enhanced partial safety factor to be
used for the material strength in design
calculations. Durox Floor is covered by
British Board of Agrément Certificate (BBA)
97/3371, while all other Durox products are
covered by BBA Certificate 00/3776.
All Durox products have been awarded
‘Very Good’ to BES 6001.
All Durox products are CE marked in
accordance with the Construction
Products Regulations (CPR). Further
information can be obtained from
www.tarmacbuildingproducts.co.uk/ce
* subject to block strength contact TBP for guidance.
www.tarmacbuildingproducts.co.uk
5
6
Blockwork solutions
Durox
Durox
Durox Supablocs combine low unit weight with
high thermal insulation and acoustic performance,
in strengths of 3.6, 4.2, 7.3 and 8.7 N/mm2.
Note the paint stripe
system of block
identification is being
superseded with ink jet
codes effective after
September 2014. See
the Block Identification
section on page 30 for
further details
215mm
620mm
100 200mm
Loadbearing walls
Table 2: Technical properties
Supabloc
Supabloc 4
Supabloc 7
Supabloc 8
3.6
4.2
7.3
8.7
Material dry density (kg/m )
460
630
680
720
Material thermal conductivity
@ 3% moisture content
0.11
0.16
0.19
0.19
Moisture movement (m/mm)
shrinkage
< 0.70
< 0.70
< 0.70
< 0.70
Typical product air tightness*
(m3 (hr/m2) @ 50Pa)
0.12
0.12
0.12
0.12
Mean compressive strength
to BS EN 771-4 (N/mm2)
3
Working size (mm): 620 x 215. Reaction to fire: Class A1
* 100mm blocks, no finish
Table 3: Fire resistance of walls (single leaf wall)
Low unit weight
No finish (hours)
Easy to handle, high strength to weight,
lower overall build weight
1
2
4
Loadbearing (minimum width (mm))
100
125
150
Non-loadbearing (minimum width (mm))
70
70
150
Loadbearing (minimum width (mm))
100
100
150
Non-loadbearing (minimum width (mm))
100
100
100
Supabloc
Excellent acoustic and
thermal performance
Supabloc 4, 7 or 8
Good U-values and Rw values, as well
as Robust Details
Range of strengths
Blockwork solutions
4 options available for wide range of
specifications
Durox Supabloc 4, 7 and 8 are suitable for
more demanding loadbearing applications,
whilst retaining the characteristic low unit
weight of aircrete.
Supabloc 7 is typically used in the ground
floor of 3 storey housing in accordance
with Approved Document A. It may also
be used in separating walls including those
conforming to Robust Details E-WM-6 and
E-WM-15.
Like all Durox products, Supabloc 8 is
produced to Category 1 manufacturing
control as defined in BS 5628-1. This can
provide an equivalent wall strength to that
of conventional 10.4N/mm2 blocks
produced to less rigorous category of
manufacturing control.
Fire
Durox blocks provide excellent periods
of fire resistance which can satisfy
building regulations and other imposed
requirements e.g. those by insurers. All
Durox products conform to a fire rating
of Class A1 to BS EN 13501-1: 2002.
Typical fire resistance values for Durox
constructions are shown and are based
on the UK National Annex to Eurocode 6:
Design of masonry structures (Part 1-2).
Sound insulation
General purpose walling
Table 1: Standard units and weights
Block width (mm)
100
115
125
140
200
Unit weight (kg)
6.3
7.3
7.9
8.8
12.6
Laid weight (kg/m2)
55
64
69
77
111
Unit weight (kg)
8.7
–
–
–
17.4
Laid weight (kg/m2)
72
–
–
–
143
Unit weight (kg)
9.3
10.7
11.7
13.1
18.6
Laid weight (kg/m2)
77
88
110
107
153
Supabloc
Supabloc 4
Supabloc 7
Supabloc 8
Unit weight (kg)
9.9
–
–
13.8
–
Laid weight (kg/m2)
80
–
–
113
–
Notes
(i) Unit and laid weights, which are given for design purposes, are approximate and calculated based on
the specified dry density with a moisture content of 3% by weight added to provide equilibrium weights.
(ii) Dimensional tolerance to BS EN 771-4: Length +3/-5mm, width +3/-3mm, height +3/-5mm.
Durox Supabloc is recommended for
general-purpose walling applications
including inner leaves, solid external
walls, internal partitions and walls below
DPC*. They are particularly suited for
cavity and solid wall construction that
require low U-values to be met. The use
of Supabloc will minimise the amount of
additional thermal insulation required,
compared to the use of denser blocks.
Table 4: Sound reduction values (single leaf wall)
Weighted sound reduction
index (RwdB)
Durox Supabloc 4, 7 and 8 are
recommended for use in separating walls
including those conforming to Robust
Details E-WM-6, E-WM-15, E-WM-23 and
E-WM-24 as well as other key applications
such as the rendered outer leaf of cavity
walls*, and in loadbearing situations where
a 4.2N/mm2 strength block is demanded.
Lightweight
plaster
Drylining
100mm
38
41
40
140mm
41
43
43
215mm
46
48
48
100mm
40
41
42
140mm
44
46
46
215mm
49
50
50
100mm
41
44
43
140mm
45
47
47
215mm
50
51
51
Supabloc
Supabloc 4
* Subject to soil sulphate conditions - see Table 14
on page 22 for further details
Separating walls
No finish
Durox blocks may be used to provide
acoustic insulation between internal
rooms. The Building Regulations
Approved Document E requires certain
internal walls and floors in dwellings to
meet a performance standard of 40RwdB.
This can be met, for example, using
100mm Supabloc finished with plaster
or drylining. Sound reduction values of
other Durox products are shown in Table 4.
For further advice including use in
separating wall constructions, including
Robust Details, please refer to pages
18-24.
Supabloc 7 or 8
Notes
(i) Finishes to both wall faces are assumed.
(ii) Values are based on technical assessment and tests to BS EN 140.
* see Table 15 on page 23 for further details
7
8
Blockwork solutions
Durox
Durox
Blockwork solutions
Durox Foundation blocks are produced
specifically for use below DPC in solid walls.
215mm
310mm
350mm
Applications
Increased productivity
One block for inner and outer leaf,
no wall ties, faster construction times
Foundation
Foundation 7
Mean compressive strength to BS EN 771-4 (N/mm )
3.6
7.3
3
460
680
Thermal conductivity (W/mK) @ 3% moisture content
0.11
0.19
2
Excellent thermal
performance
Helps improve the U-value of ground
floors
Range of strengths
Screed
Fig 1: Durox Foundation
blocks below DPC
DPC
Block width (mm)
310
350
Foundation
Unit weight (kg)
11.1
11.1
Laid weight (kg/m2)
177
200
16.4
16.4
Foundation 7
Unit weight (kg)
The appropriate thickness of Durox
Foundation should be selected to suit the
width of cavity or solid wall that requires
supporting above DPC. For advice on the
selection of mortar, please contact the
Technical Services Team on 0870 242 1484.
Foundation blocks
Table 5: Size and unit
weights (kg)
Laid weight (kg/m2)
242
273
Number of blocks
required per m2 of wall
13.0
14.0
Notes
(i) Unit and laid weights, which are given for design
purposes, are approximate and calculated based on
the specified dry density with a moisture content of
3% by weight added to provide equilibrium weights.
(ii) The calculation of number of blocks per m2 of
wall assumes all joints are filled with mortar.
(iii) Dimensional tolerance to BS EN 771-4. Length
+3/-5mm, width +3/-3mm, height +3/-5mm.
Durox Foundation blocks replace the inner
and outer leaf, wall ties and concrete cavity
fill associated with traditional build
methods. Construction time can be halved
compared to cavity construction and the
Foundation wall becomes stable soon after
laying, allowing the early start of above
ground work.
Durox
Foundation
Installation
In response to increasing standards
of energy efficiency, Durox Foundation
blocks 310mm x 350mm x 215mm have
been introduced. These blocks can
accommodate cavity walls above ground
of up to 350mm width whilst maintaining
a conventional block bedding height.
310mm
350
125mm
Fig 2: Typical corner bonding
of Durox Foundation blocks
Because of its excellent insulating
properties, the product contributes
towards the perimeter insulation of ground
floors. For typical ground floor U-values,
please contact the Technical Services
Team on 0870 242 1484.
Durox Foundation is suitable for use in soil
conditions up to and including DS-2 and
Foundation 7 is suitable for use in soil
conditions up to and including DS-3, as
confirmed by British Board of Agrément
Certificate No. 00/3776.
Insulation
Two strength options available for a
wide range of specifications
Durox Foundation can be used to support
cavity, solid walls, or frame constructions.
For below ground use (excluding work in
retaining or basement walls), Foundation
blocks can be used with unfilled vertical
joints, provided the blocks are built with
their ends closely butted together to
restrict the passage of vermin. This advice
is consistent with the guidance given in
BRE information paper IP7/05. The
blockwork should be set out to achieve
adequate block bonding at corners.
A typical solution is shown in Figure 2.
Both strengths of our 310 x 350 x 215mm
Foundation Blocks are below the 20kg
manual handling weight.
125mm
9
10 Blockwork solutions
Durox Coursing bricks used to avoid
thermal bridging and minimise wastage.
Durox Coursing slips for use with
Floor blocks to reduce thermal bridging.
67mm
width
40mm
215mm
100mm
215mm
Reduced thermal
bridging
Reduced thermal
bridging
Minimises thermal bridging
maximises efficiency
Minimises thermal bridging
maximises efficiency
Less wastage
Less wastage
Ideal for infilling over lintels and
between floor joists
Ideal for infill beneath Durox Floor
blocks at the perimeter walls
Application
Application
Coursing bricks are designed for use with
the range of Durox blocks and should be
used to avoid thermal bridging and
minimise wastage.
Coursing slips are specifically
manufactured for use in combination with
Floor blocks.
Durox Coursing bricks should be used
for general coursing work, in-filling small
areas of wall such as between timber floor
or roof members as well as at sills and
over lintels. Their use will eliminate cutting
and wastage.
Blockwork solutions 11
Durox
Durox
Fig 3: Typical application
Table 7: Size and unit weights (kg)
Block width (mm)
100
115
125
140
Brick (3.6N/mm )
0.71
0.82
0.89
1.00
Brick (7.3N/mm )
1.05
1.21
1.32
1.47
Brick (8.7N/mm )
1.18
–
–
1.60
No. bricks per pack
480
400
320
320
2
2
2
Notes
Unit and laid weights, which are given for design purposes, are approximate and based on 3% moisture content.
They can be used beneath floor blocks at
the bearings where the floor block bears
directly on to the inner leaf or an internal
wall. They eliminate thermal bridging by
providing continuity of thermal insulation.
In addition, the use of Coursing slips
minimises the need for labour-intensive
cutting and reduces wastage. Coursing
slips are supplied in packs of 600.
Coursing slips
Bricks
Face size (mm)
215 x 67 for all products
Mean compressive strength to BS EN 771-4 (N/mm2)
3.6
3
460
Unit weight
0.5
3.6
7.3
8.7
0.11
Material dry density (kg/m3)
460
680
720
Reaction to fire
0.11
0.19
0.19
Reaction to fire
Air tightness (m3 (m2.h) @ 50Pa)*
Class A1
(i) Dimensional tolerance to BS EN 771-4. Length +3/-5mm, width +3/-3mm, height +3/-5mm.
Class A1 for all products
0.12 for all products
* 100mm blocks, no finish
Durox
Durox
Transverse load
Durox Floor blocks used in ground floors to
reduce the U-value and minimise wastage.
The blocks have been tested spanning
530mm and 620mm to sustain a point
load of 3.5KN transferred via a 100mm
x 100mm steel plate.
Thermal insulation
The use of Durox Floor blocks may
reduce the amount of ground floor
insulation needed compared to the
use of denser floor blocks. This will
be further improved when used in
combination with Durox Foundation
blocks. For examples please visit
100mm
530 or
215mm
620mm
Applications
Durox Floor blocks are suitable for use in
beam and block suspended ground and
internal floors in single occupancy
dwellings under domestic loading. Where
high point loading is anticipated, such as
in garages, a reinforced structural topping
must be used. Where the floor loading
dictates closer beam spacing, a 620 x 215
x 100mm Durox Supabloc block should be
used, spanning its 215mm dimension only.
Easy installation
Lightweight and easy to handle
and install
Good thermal
performance
Improves the thermal performance of
internal ground floors and provides
acoustic performance for internal floors
Coursing slips to in-fill at the perimeter
are available in a 40mm bedding height.
For 175mm deep beams Durox Coursing
bricks are available.
Durox floor blocks
Table 10: Size and unit weights (kg)
Length x width (mm)
620 x 530
620 x 215**
Thickness
100
100
Floor
15.6
6.3
28
70
No. blocks per pack
Notes
Unit and laid weights, which are given for design purposes, are approximate and based on 3% moisture content.
** Available as Supabloc, in standard packs, and laid only at 215 mm span.
Floor
3.6
3
460
0.11
Transverse strength KN
3.5
Reaction to fire
Acoustic tests confirm that the airborne
sound reduction (Rw) for this floor
construction is 51RwdB. This exceeds
the minimum required value of 40RwdB.
Floor blocks are suitable for use in
suspended ground and internal floors in
conjunction with precast concrete beams.
They are light and quick to install, and
provide effective sound and thermal
insulation for ground and internal floors
meeting the requirements of the Building
Regulations (40RwdB).
Note: An ‘internal floor’ is a floor within a house.
It is not a separating floor.
The use of Durox Floor blocks can achieve
economy in the overall design of the floor.
Firstly by a reduced dead load, secondly,
the size of the block allows much more
flexibility in beam spacing allowing fewer
beams to be used.
Class A1
The requirements of 40RwdB, set by
Building Regulation E2 ‘Protection
against sound within a dwelling house’,
can be easily met using a beam and block
internal floor finished with a minimum
50mm sand and cement screed and
plasterboard ceiling.
Durox
Durox
Durox System
Durox System rapid build large format
blockwork for use with thin joint mortar.
Note the paint stripe
system of block
identification is being
superseded with ink jet
codes effective after
September 2014. See
the Block Identification
section on page 30 for
further details
214 or
299mm
620mm
100 or
200mm
Productivity gains
Large format, thin joint, rapid
construction
Robust details
Available for separating walls
Excellent thermal properties
Achieves good U-values
Table 12: Standard units and weights
Block width (mm)
100
140
200
System 500* coursing heights
214mm
6.3
–
–
299mm
8.8
–
–
214mm
8.6
12.1
–
299mm
12.1
16.8
–
9.3
13.0
18.5
Durox System is a fast-build method that
allows rapid construction of blockwork,
offering the potential for better
construction and enabling early
commencement of the finishing trades.
System comprises dimensionally accurate,
620mm long Durox blocks for use with
quick setting Durox thin-layer mortar.
Loadbearing walls
Manufactured in a range of strengths and
coursing heights, System may be used for
solid, inner leaf and partition walls in all
types of buildings. System is particularly
suitable for housing and commercial
projects where long runs of blockwork
yield maximum productivity gains.
System 600 or 700 may be used in cavity
separating walls built to various Robust
Details including E-WM-10 and E-WM-13.
Both of these Robust Details may have a
fully filled cavity using a mineral wool with
a maximum density of 40kg/m3.
214mm
Notes
(i) Unit weights are approximate and calculated based on the specified dry density with a moisture content of
(ii) Tolerance to BS EN 771-4: height +2/-2mm.
* All sizes made to order subject to minimum quantities
System 500
System 600
System 700
Mean compressive strength
to BS EN 771-4 (N/mm2)
3.6
4.2
7.3
3
460
630
680
3
0.11
0.16
0.19
Reaction to fire
Typical product airtightness (m2 (h.m2) @ 50Pa)**
Class A1 for all products
0.12 for all products
Notes
(i) Unit weights are approximate and calculated based on the specified dry density with a moisture content of
(ii) Tolerance to BS EN 771-4: height +2/-2mm.
(iii) Stock items. Other sizes normally available within 3 weeks, subject to minimum quantities.
** 100mm blocks, no finish
Durox
Aircrete applications
TBP aircrete blocks are suitable for a wide
range of applications.
Durox
Separating walls The Building Regulations
require separating walls to provide reasonable
resistance to sound transmission.
Guidance on suitable Durox and Toplite
constructions capable of meeting the
specified performance given in Approved
Document E is shown on 18-21. This
includes constructions that can be built to
satisfy Robust Details E-WM-6,
E-WM-10, E-WM-13, E-WM-15, E-WM-23
and E-WM-24.
The use of Robust Details provides an
alternative to pre-completion testing for
demonstrating compliance with Part E for
new build dwellings. Robust Details should
be used in accordance with the scheme
requirements including plot registration.
The performance of separating walls is
highly dependent on the design, detailing
and workmanship of the associated
flanking construction.
Further guidance on use of Aircrete in
flats and the design and detailing of
separating walls is available from Technical
Services Team on 0870 242 1489.
Pre-completion testing
Constructions requiring pre-completion
testing in accordance with Approved
Document E or other technical guidance
(e.g. BBA certification or field test data).
1
13mm plaster (10kg/m2 min.)
or 13mm drylining on dabs
2
75mm min. cavity
2
3 2x 100mm Durox Supabloc 4, 7 or 8
2x 100mm Durox System 600 or 700
2x 100mm Toplite Standard
2x 100mm Toplite 7
1
3
Fig 6: TBP cavity separating walls.
Durox
Durox
Separating walls The Building Regulations
require separating walls to provide reasonable
resistance to sound transmission.
New dwellings – Robust Details
E-WM-6*
(conventional mortar)
2 x 100mm Durox Supabloc 4, 7 or 8,
or Toplite Standard or 7, minimum 75mm
cavity, plasterboard (nominal 8kg/m2)
on dabs on cement/sand render with
scratch finish.
E-WM-10* (thin joint mortar)
2 x 100mm Durox System 600 or 700
minimum 75mm cavity (using Ancon
Staifix HRT4 or Clan PWT4 wall ties),
plasterboard (nominal 8kg/m2) on
dabs on cement/sand render with
scratch finish.
E-WM-13* (thin joint mortar)
2 x 100mm Durox System 600 or 700
minimum 75mm cavity (built without
wall ties) plasterboard (nominal 8kg/m2)
on dabs on cement/ sand render with
scratch finish.
no site
testing
required
E-WM-15 (conventional mortar)
2 x 100mm Durox Supabloc 4, 7, 8 or
Toplite Standard or 7 minimum 75mm
cavity incorporating 35mm Saint Gobain
Isover RD35 acoustic batt, plasterboard
(nominal 9.8kg/m2) on dabs.
E-WM-23 (conventional and thin
joint mortar)
or Toplite Standard or 7 minimum 100mm
cavity incorporating Superglass party
wall roll (gypsum based board).
New build rooms for residential purposes
Any of the recommended solutions
shown for the New Build Dwellings,
page 36 can be specified for separating
walls for use in rooms for residential
purpose. In addition, the solutions shown
below may be used.
1
2
3
215mm Toplite Standard
215mm Toplite 7
Constructions requiring pre-completion
testing in accordance with Approved
Document E or other technical guidance
e.g. BBA certification or field test data.
2
Rooms for residential purposes include
hotels, hostels, boarding houses, halls
of residence and residential houses but
exclude hospitals or similar establishments
used for patient accommodation.
1
3
E-WM-24 (conventional mortar)
or Toplite Standard or 7 minimum 100mm
cavity incorporating Saint Gobain-Isover
RD party wall roll (gypsum based board).
Fig 8
Parge coat
Pozament Parge Coat provides an
economical means of achieving increased
sound insulation for wall constructions in
accordance with Robust Detail
specifications.
* The cavity may be fully filled with mineral wool
(max. density 40kg/m3) to provide a ‘zero U-value’
separating wall.
2
1
3
Parge coat can be applied directly to the
wall surface prior to drylining to seal any
air paths, forming an effective sound coat.
In addition, Pozament Parge Coat provides
improved airtightness of the building
contributing to improved energy efficiency
and lower heating costs.
Available in 25kg bags.
1
Drylining on dabs
2
75mm min. cavity
3
Nominal 8mm parging
Visit the Pozament website at:
www.pozament.co.uk
Fig 7
Durox
Durox
Internal walls* Any grade of Durox or Toplite
can be used for the construction of internal walls.
Internal floors* Approved Document ‘E’ prescriptive
solutions or TBP constructions which have been
shown by testing to meet the regulations.
For partitions in dwellings, these products
can be used to provide good levels of
airborne sound insulation as well as a
suitable background for fixings and
finishes.
Approved Document E requires that
internal floors in dwellings provide the
minimum sound insulation of 40RwdB.
Durox and Toplite Floor floors have been
shown to exceed this standard.
For commercial and industrial applications,
Durox and Toplite may be used to provide
sound insulation, fire resistance and
structural strength.
Certain internal walls are required to
provide a level of sound insulation as
required by the Building Regulations E2.
Walls between bedrooms, or a room
containing a water closet, and other rooms,
need to provide the minimum sound
insulation of 40RwdB. The constructions
on pages 38-39 have been assessed
and/or laboratory tested to demonstrate
the performance level required by
Approved Document E.
Approved Document E solution
Approved Document E prescriptive
solutions or TBP constructions which
have been shown by testing to meet
the regulations.
1
Plaster or drylining
2
Wall blocks comprising
100mm Durox Supabloc
100mm Durox Supabloc 4, 7 or 8
100mm Durox System 500, 600 or 700
100mm Toplite GTi
100mm Toplite Standard
100mm Toplite 7
Fig 9
* Internal walls and floors are elements within a dwelling and are not separating elements.
no site
testing
required
1
Approved Document E solution
1
50mm min. sand-cement screed
2
Any ceiling finish
3
Infill blocks comprising 100mm
Durox or Toplite Floor
no site
testing
required
1
2
3
2
Fig 10
* Internal walls and floors are elements within a dwelling and are not separating elements.
Durox
Durox
Walls below DPC Durox and Toplite products
can be used to construct walls below ground.
External walls Durox and Toplite blocks may
be used to construct cavity and solid external walls.
TBP products can be used in sulphate soil
conditions as shown in Table 24 and as
confirmed by British Board of Agrément
Certificate No. 00/3776 and 12/3896. In
addition, they are resistant to the
freeze/thaw conditions likely to occur
below the DPC, as confirmed by tests to
MOAT 12.
For cavity construction, the minimum
leaf thickness will normally be 90mm.
Durox or Toplite blocks are suitable for
a range of external finishes as shown in
Table 15, below.
In a single leaf wall, the minimum
thickness of Durox or Toplite, with or
without rendering, may be selected
from BS 5628-3.
Durox or Toplite Foundation blocks should
be specified to construct 200-350mm solid
walls below ground. They are intended to
support cavity or solid walls of equivalent
thickness above ground. All Durox
Supabloc and Toplite Standard or Toplite 7
products can be used to construct internal
and external walls below ground,
depending on the sulphate soil conditions.
Toplite GTi should only be used for the
inner leaf of cavity walls or internal walls
below DPC.
Table 14: Sulphate soil conditions
Aircrete blocks
Durox Foundation
Durox Foundation 7
Durox Supabloc
Durox Supabloc 4
Durox Supabloc 7
Durox Supabloc 8
Toplite Foundation and Foundation 7
Toplite GTi*
Toplite Standard
Toplite 7
* Inner leaf cavity walls or internal walls
Table 15: Guidance for the use in external cavity walls
DS-1










DS-2

DS-3















External finish
Cavity wall construction
Comments
Any external cladding material such as timber
boarding or hanging tiles on battens.
Clear cavity, Partial cavity fill,
Full fill
Both leaves may be any grade of Durox or Toplite
blocks. Additional insulation will be required.
Two coats of designation
(iii) sand/cement render
Clear cavity
The inner leaf may be any grade of Durox or
Toplite block. The outer leaf should be a Durox
Supabloc 4, 7, 8 or Toplite Standard or 7’s.
Partial cavity fill
Toplite block. The outer leaf should be a Durox
Supabloc 4, 7, 8 or Toplite Standard or 7’s.
Full fill
Toplite block. The outer leaf should be a TBP
Hemelite or Topcrete block.
Facing brick
Clear cavity, Partial cavity fill
Full fill
Toplite block.
Notes
Any grade of Durox includes Supabloc, Supabloc 4, 7 or 8. Any grade of Toplite includes Toplite GTi, Standard or 7’s.
For advice on Durox System or solid walls, contact technical services.
Durox
Durox
Structural elements The Tarmac Building
Products aircrete block range provides
a combination of strength, coupled with
excellent thermal and acoustic performance
which makes them ideal for house building.
Condition A
2.9 N/mm²
blocks min.
Underside
of
Hs structural
roof
The strength of the blockwork for many
domestic and other small buildings can be
determined using the simple rules given in
the Building Regulations Approved
Document A: Structural Safety.
Condition B
7.3 N/mm²
blocks min.
Condition C
7.3 N/mm²
blocks min.
Where
Hf less than equal to 1m, Condition A
2.9 N/mm² blocks min.
Topside of
structural floor
Where
Hf greater than 1m, Condition B
7.3 N/mm² blocks min.
Fig 11
Using the minimum block strengths
indicated in Figures 11-13, the correct
block strength may be selected without
the need for a structural design calculation.
Therefore, in most cases either Supabloc
or Toplite GTi would be adequate for the
inner leaf and internal walls of two storey
dwellings. For three storey housing the
ground floor inner leaf and load bearing
internal walls can be constructed using
either Supabloc 7 or Toplite 7. The inner leaf
and internal walls on the upper floors could
revert to either Supabloc or Toplite GTi.
Underside
of
Hs
structural
roof
Underside
of
Hs
structural
roof
In cases where a structural design is
carried out, it may be possible to justify
a block strength of 3.6 or 4.2N/mm2 on
the ground floor of a three storey dwelling
rather than the 7.3 N/mm2 indicated in
Figure 13.
Cavity
wall
Underside
Hs of
structural
roof
Hf
Topside of
structural floor
This wall to be at least
140mm thick blockwork
or 215mm thick brickwork
below ground floor level
if height Hf exceeds 1m
Fig 12
Aircrete blocks
Internal
wall
This wall to be
at least 140mm
thick blockwork
or 215mm thick
brickwork
Topside of
structural floor
Fig 13
For additional guidance on the use of
BS 5628 and Euro Code 6 (BS EN 1996),
please contact Technical Services Team
on 0870 242 1489.
Table 16: Durox and Toplite block strengths
Cavity
wall
Underside
of
Hs
structural
roof
Internal
wall
Underside
of
Hs
structural
roof
Note that, where there are separating walls
within attached dwellings, the minimum
block strength will be dictated by the
density requirements that are necessary
for acoustic purposes.
Notes
Compressive strength (N/mm2)
Supabloc and System 500
3.6
Supabloc 4 and System 600
4.2
Supabloc 7 and System 700
7.3
Supabloc 8
8.7
Toplite GTi
2.9
Toplite Standard
3.6
Toplite 7
7.3
1 If Hs is not greater than 2.7m, the
minimum compressive strength of
bricks or blocks should be used in
walls as indicated by the key.
2 If Hs is greater than 2.7m, the
compressive strength of bricks or
blocks used in the wall should be at
least Condition B, or as indicated by
the key, whichever is the greater.
3 If the external wall is solid construction,
the masonry units should have a
compressive strength of at least that
shown for the internal leaf of a cavity
wall in the same position.
4 The guidance given in the diagram for
walls of two and three storey buildings
should only be used to determine the
compressive strength of the masonry
units where the roof construction is
of timber.
Durox
Durox
Thermal performance The suite of Building
Regulations Approved Documents L1A and B
and L2A and B (2013) gives detailed guidance
on how a building may be designed to meet the
requirements for the conservation of energy.
The overall thermal design of a building,
in simple terms, depends on many factors
including the U-value of the exposed
elements, the air tightness of the structure,
the efficiency of the heating and hot water
system and the lighting.
Further U-values and a more detailed
explanation of the requirements of the
Approved Documents can be obtained
from Technical Services Team on
0870 242 1486.
The thermal efficiency of the building fabric
for new dwellings is set out in Approved
Document L1A and will be determined by
carrying out a calculation to SAP 2012.
However, there are two key U-values for
the external walls depending on how the
SAP calculation is performed. When
adopting the ‘Elemental recipe’ approach,
the U-value will be 0.18W/m2K.
Alternatively, the U-value can be relaxed
if compensating measures are taken
elsewhere, to a value approaching the
limiting U-value of a external wall of
0.30W/m2K. In this case, the U-value could
be in the order of 0.26W/m2K depending
upon what compensating measures are
employed.
Extensions to existing houses are treated
in a much simpler way by assigning
maximum ‘elemental’ U-values of various
elements. The maximum U-value for the
external walls is 0.28W/m2/K.
Tables 17-19 are intended to provide
some typical wall U-values but are not
exhaustive.
Alternatively, for specific U-values using
your preferred insulation material, please
contact our Technical Services Team on
0870 242 1489.
Table 17: U-values for clear cavity walls with thermal
laminates and 100mm blocks
Internal finish
Thermal laminate
Supabloc
Supabloc 4
Supabloc 7
Toplite GTi Toplite Standard Toplite 7
Supabloc 8
60mm ThermaLine Super
(R-value = 2.56m2K/W)
0.26
0.27
0.28
0.28
70mm ThermaLine Super
(R-value = 3.06m2K/W)
0.23
0.24
0.24
0.24
Note: Thermal laminates are assumed to be fixed using adhesive dabs.
All U-values calculated in accordance with BR 443.
Table 18: U-values for partial fill cavity walls and 100mm blocks
Insulation
Internal finish
Supabloc
Supabloc 4
Supabloc 7
Supabloc 8
40mm Kingspan TW50 or similar (k= 0.022 W/mK)
13mm Lightweight plaster
0.28
0.30
0.30
0.30
13mm Plasterboard on dabs
0.27
0.29
0.29
0.29
50mm Kingspan TW50 or similar (k= 0.022 W/mK)
0.25
0.26
0.27
0.27
0.24
0.25
0.26
0.26
70mm Kingspan K8 or similar (k= 0.02 W/mK)
0.20
0.21
0.21
0.21
0.19
0.20
0.20
0.20
Note: Similar materials include Celotex and Xtratherm, etc.
The resistance of the Low-E cavity taken as 0.674m2W/K.
Table 19: U-values for full fill cavity walls and 100mm blocks
Insulation
Internal finish
Supabloc
Supabloc 4
Supabloc 7
Supabloc 8
100mm Crown DriTherm 37 or similar (k= 0.037 W/mK)
0.27
0.29
0.29
0.29
0.26
0.28
0.28
0.28
100mm Earthwool DriTherm 32 or similar (k= 0.032 W/mK)
0.24
0.26
0.26
0.26
0.24
0.25
0.25
0.25
100mm XtraTherm CavityTherm* (R= 4.52 m2 W/K)
0.17
0.18
0.18
0.18
0.17
0.18
0.18
0.18
* includes a 5mm air gap r= 0.11m W/K.
2
Durox
Durox
Durox System is a flexible building technique
that allows walls to be built more quickly than
using conventional mortar.
Durox System is a flexible building
technique that allows walls to be built more
quickly than using conventional mortar.
The use of a rapid-setting proprietary thin
joint mortar allows the blockwork to be
built in advance of the brickwork, and in
the case of housing means the roof can be
installed and made weathertight at a much
earlier stage.
Durox System may be used in both
housing and commercial buildings as the
inner leaf of cavity walls, solid external
walls, separating walls and for internal
loadbearing and nonloadbearing partitions.
These blocks are available in three grades,
System 500, 600 and 700, all of which are
manufactured to exacting dimensional
tolerances. These products are
manufactured in coursing heights of 214mm
and 299mm and in a range of thicknesses.
For a full technical specification, size,
availability and detailed guidance on the
design and applications of these blocks,
refer to the Durox System brochure.
Thin joint mortar
TBP has specifically developed Durox Thin
Joint Mortar for use with Durox System
blocks. It is normally supplied in 25kg bags
and is a dry packed, 1:3 blended mix of
cement/sand, containing admixtures to aid
workability and water retention. The bags
are moisture resistant and as with all
cementitious materials, they should be
stored in a dry environment.
The mortar should be mixed in a suitable
container using a powered whisk to
achieve a creamy consistency. A full bag
of mortar should be poured onto and fully
mixed with 5.0–6.0 litres of clean water.
There is no requirement for admixtures as
these are already incorporated in the dry
mix. Small batches of mortar may be mixed
by hand trowel in a standard builder’s
bucket, adding a reduced amount of water.
The consumption of mortar is dependent
on the coursing height and width of Durox
System blocks being used.
For guidance, the consumption rates are
shown in Table 20, opposite, which is
based on a 3mm mortar joint thickness.
The mixed mortar will stay workable for
around four hours, depending upon the
ambient conditions on site and, as with any
mortar, it should not be re-tempered by
adding additional water. Once the mortar is
applied to the bedding faces of the blocks
it will remain workable for 6-9 minutes,
allowing time for the blocks to be placed in
their final position. Within a further 10
minutes the mortar will set. At this point the
blockwork becomes very stable, enabling
storey height lifts to be built without
compression of the mortar joints.
Mortar application
The mortar is spread on the blocks using
a serrated applicator. The purpose of this
tool is to lay the mortar on the bedding
surface in a series of ribbons, similar to the
process of applying tiling adhesive, which
controls the amount of mortar, giving a
consistent bed depth. This not only
ensures that the joints are fully filled, but
means that less levelling of individual
blocks is required.
Cold weather working
As with all cementitious mortars, Durox
Thin Joint Mortar should only be used
when the outside air temperature is 3°C
and rising.
However, TBP has developed a cold
weather additive for use when the air
temperature is between 1 and 5°C.
Supplied in 500g bags, the additive is
mixed in with the Thin Joint Mortar as
necessary. Some additional water and
mixing time may be required to achieve the
right consistency of the mortar. For further
details contact our Technical team.
The wall ties are positioned at nominal
centres, depending upon site conditions,
i.e. to give a tie density of 2.5 ties/m2
based upon the coursing height of the
blocks.
Cutting blocks
At free edges, such as openings or
movement joints, ties should be positioned
at a maximum of 300mm centres. Where
partial fill cavity insulation is built into the
cavity, plastic retaining clips should be used.
Normally, it is only necessary to cut blocks
vertically in order to maintain the bonding
at corners and around openings.
To maintain the required accuracy of
perpend, blocks should be cut square
using either a handsaw, electric alligator
saw, bench saw or a band saw, depending
on which is most suited to the project in
question. The off-cuts from blocks should
be put to one side as they can often be
reused when a smaller cut is required,
helping to reduce wastage.
Movement control mesh
The use of movement control mesh or
bed joint reinforcement is an integral part
of thin joint blockwork. Its purpose is to
compensate for the strength of the mortar
and distribute any movement stresses that
may build up within the blockwork.
In all cases, the operatives must use the
correct personal protective equipment
(PPE) when using cutting equipment.
In recent years, nylon mesh has become
a popular material for this purpose, as it is
more cost effective and easier to use on
site than traditional steel reinforcement.
Wall ties
It is a large, open-weave mesh, which is laid
on the bed joint prior to placing the blocks.
As the bed joints in the blockwork do not
coincide with those in the outer leaf of
brickwork, conventional wall ties cannot be
used with Durox System. A range of wall
ties is available that can be face fixed into
the blocks and embedded into the
brickwork in the normal way. These ties are
driven directly into the blockwork, or fixed
with expanding nylon anchors, as the
brickwork proceeds.
Movement ties
In long runs of blockwork, with or without
openings, it will be appropriate to introduce
vertical movement joints. These joints are
formed in the same way as those used in
conventional brick and blockwork. Stainless
steel ‘in line’ movement ties are inserted
across the joints at every block course and
the joint is filled with a suitable material.
Abutment ties
Short runs of blockwork and internal
partitions can often be butt jointed. This
means that the inner leaf can be built
without bonding in partitions, leaving the
area clear for access. An ‘abutment’ tie is
face fixed to one wall and embedded into
the bed joints of the other.
Installing Durox System
To avoid having to make a horizontal cut all
round the building, typically at the bearing
of built-in joists or to the underside of floor
slabs, a combination of block heights may
be used. Usually, the first course of blocks,
at DPC level, will be 214mm or 299mm in
height and be bedded in conventional
mortar and adjusted to the required level.
The subsequent courses may be either
214mm or 299mm coursing height, or
214mm in the case of solid walls, with
3mm bed joints, finishing at the bearing
height for the joists or floor. It should be
noted that where floor joists are spanning
onto separating walls, care should be taken
to ensure that the acoustic performance of
the wall is not impaired. In the case of joist
hangers the blockwork will be coursed to
coincide with the underside of the hanger
support.
If split courses are genuinely unavoidable,
then cut courses should be introduced at
either the base course or wall plate course
where any discrepancies arising from the
cuts can be accommodated in the
conventional mortar beds.
Table 20: Consumption rates of
mortar per 25 kg* bag of mortar
m2 of walling built per
width (mm) of blocks
Coursing height (mm)
100
200
214
8.3
3.9
299
10.5
–
Notes
* Excludes any allowance for wastage
The blockwork to subsequent floors should
be coursed in a similar manner. At eaves
level, the wall plate should be bedded in
conventional mortar, as is normal practice.
Durox
Durox
Durox pack sizes
All packs of Durox blocks are double banded horizontally
before wrapping in polythene. They are supplied either
with or without a pallet. The 5 row pallets are returnable
and the 4 row pallets for Minipacks, Floor and System
blocks are non-returnable.
Table 21: Durox Supablocs (standard packs)
Block Thickness (mm)
100
115
125
140
200
Coverage per pack* (m )
10
8.57
7.86
7.14
5.0
Number of blocks per pack
70
60
55
50
35
Pack width (mm)
1400
1380
1375
1400
1400
Supabloc pack weight (kg)
600
600
600
600
600
Supabloc 4 pack weight (kg)
800
–
–
–
800*
870
870**
870**
870
870
920
–
–
–
920*
2
620mm
Pa
ck
wi
dt
h
10
mm
75
x
ws
ro
(5
m)
5m
21
Notes
* Area of built wall including 10mm mortar joints
** Made to order
The pallet has not been shown for clarity. The pallet weighs approximately 20kg
Table 22: Durox Supabloc (minipacks)
100
125**
8
6.29
56
44
Pack width (mm)
1400
1375
480
480
2
620mm
Pa
ck
wi
dt
h
86
m
0m
ws
ro
(4
mm
15
x2
)
Notes
** Made to order
Block identification and pack sizes
Block identification and pack sizes
Durox pack sizes (continued)
Table 23: Durox Foundation (standard packs)
620mm
(2 x
310mm)
Pa
ck
wi
dt
h
mm
75
10
(5
x
ws
ro
m)
5m
21
Table 26: Durox Coursing bricks (standard packs)
310**
350**
Coverage per pack* (m2)
3.42
2.86
Coverage per pack (m2)
40
40
Pack width (mm)
1400
1400
Foundation pack weight (kg)
600
600
Foundation 7 pack weight (kg)
870
870
Pack
height
14
00
mm
Notes
** Foundation blocks can be laid at either 310 or 350mm wide
(20
ro
ws
x
70
mm
)
m
0m
86
(4
ws
ro
)
mm
15
x2
214
299
214
214
100**
100**
140**
200**
7.57
7.90
5.41
3.75
56
42
40
28
Pack width (mm)
1400
1400
1400
1400
System 500 pack weight (kg)
480
500
–
–
640
667
–
–
695
–
695
695
620mm
2
Pa
ck
wi
dt
h
m)
4m
21
x
m)
9m
ws
ro
29
(4 or s x
m
w
ro
6m
(4
85
m
7m
89
Notes
** Made to order
Table 25: Durox Floor (standard packs)
Coverage per pack* (Linear m)
620mm
Pa
ck
wi
dt
h
6
10
0m
m
x
ws
ro
(2
m)
0m
53
100**
14.841 / 17.362
28
Pack width (mm)
1400
600
New Supabloc
identification system
125
140
480
400
320
320
Pack height (mm)
600
575
500
560
Coursing brick (3.6N/mm ) pack weight (kg)
432
414
359
400
625
600
520
583
683
–
–
837
2
2
2
Notes
brick cutters. These Coursing bricks will
have a label on the packaging giving the
relevant information.
Table 27: Block identification
Product
Block code
Other
Supabloc
S
None
Supabloc Minipacks
S
None
Supabloc 4
S4
Zig-zag marking on both working faces
Supabloc 7
S7
None
S8
None
Coursing bricks (3.6N/mm )
B
None
Coursing bricks (7.3N/mm )
B7
None
Foundation
F
None
Foundation 7
F7
None
Floor blocks
FL
Unique size 620 x 530 x100mm
Floor slips
FS
Unique size 215 x 100 x40mm
System 500
T5
None
System 600
T6
Zig-zag marking on both working faces
System 700
T7
None
Supabloc 8
2
2
From September 2014, the coloured
paint stripe that appears on the top end
of the blocks is phased out. It has been
be replaced with an ink jet block code
on one block per pack. The block code
shown in Table 135 will appear with
two sets of dates from which we will
be able to identify production batches.
In addition to this, the packaging will
be ink jetted with the product name,
block size and the number of blocks in
the pack.
115
sold in packs
Coursing bricks are either made in the
factory, in which case they will be identified
as shown in Table 26, or cut externally at a
Table 24: Durox System thin joint blockwork (standard packs)
Block Coursing height (mm)
100
Once a wall has been built, the face marks on Supabloc 4 and System 600 will be clearly visible.
Notes
* Area of floor excluding beams
** Floor blocks have a face size of 620 x 530mm and can be laid to span in either direction
1
laid at 620mm span
2
laid at 530mm span

Durox product guide

Transcription

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