Transcript No Slide Title

FIELD
INSTALLATION
INSTRUCTIONS
JANUARY 2004
TABLE OF CONTENTS
I
II
III
AAC MASONRY PRODUCTS:
Material Handling Procedures
3
Tools Recommended For Installation
4
Leveling Course - Steps 1-7
5
Typical Coursing - Steps 1-7
7
Points To Check 1-3 - Coursing
9
Routing Channels - Steps 1-6
10
HORIZONTAL AAC WALL PANELS
Tools Recommended For Installation
12
Installing Horizontal Wall Panels Steps 1-11
13
Points To Check 1-5 - Horizontal AAC Wall Panels
17
PRECAST FLOOR PANELS
Tools Recommended For Installation
18
Installing Panels - Steps 1-6
19
Filling Joints Steps 1-3
21
Panel Penetration Guidelines
22
Points To Check 1-4
23
Routing Channels - Steps 1-3
24
Points To Check 1-3
25
BABB TECHNOLOGIES, INC.
Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
Field Installation Instructions Rev. 1-07-2004
I
AAC MASONRY PRODUCTS:
Material Handling Procedures
General:
In general, all construction products are susceptible to minor damage if mishandled. Less
handling means lower potential for damaged. In some instances, damage may occur
from shipping.
For All AAC Construction Products:
• Deliver only an amount of material that can readily be installed.
• Unload panels using pallet forks (either forklift, nylon straps, slings or pallet fork on a crane
cable). Consult your OSHA safety manual for "rigging" or other safety considerations.
• Storage areas should be accessible to delivery trucks and convenient to material staging areas. If
possible, drop-deliver the material right to the material staging areas.
• Storage material should always be stored away from other construction activities on a flat-grade
area that is not susceptible to standing water, erosion or settling.
• Keep the material covered and banded until ready for installation.
Special Considerations For Panel Construction:
• As with most precast concrete products, the panels should be set directly from the delivery trailer,
if permissible.
• If the materials cannot be set directly from the delivery trailers, deliver only an amount of material
that can be installed readily.
• Do not "shake-out" stored materials until they are ready to be installed. Excessive handling may
cause damage. Set delivery schedule to match the erection sequence exactly.
• Most chipped corners and edges can be repaired. If any reinforcing is visible, contact an
authorized AAC representative.
• All damage must be repaired using an approved structural-grade AAC patching compound
developed specifically for AAC products.
• AAC panels that have surface or minor cracks are usable, but contact an authorized AAC
representative when cracks continue completely through the panel.
• Stored or staged materials should always be set on flat, load-bearing, stable grade on pallets or
dunnage.
BABB TECHNOLOGIES, INC.
Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
3
Field Installation Instructions Rev. 1-07-2004
I
AAC MASONRY PRODUCTS:
Tools Recommended For Installation
AAC Block
There are a full range of tools that are specially
designed to assist the block layer in installing AAC
masonry products and increase productivity at the
job site.
AAC masonry installation will also require the
following standard masonry tools.
Margin Trowel
Hand Saw
Small Hand Brush
Builder’s Level
Rasp
Sanding Float
Electric Bandsaw
4’ Level
String Line
Notched Trowel
Rubber Mallet
AAC
Jumbo® Block
Additional tools required for installing AAC
Jumbo® Masonry Units.
Low Speed Drill with Mixing Paddle
Electric Jumbo Bandsaw
Electric Minicrane
BABB TECHNOLOGIES, INC.
4
Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
Field Installation Instructions Rev. 1-07-2004
I
AAC MASONRY PRODUCTS:
Leveling Course
Step 1 - Layout wall lines.
Step 2 - Start the leveling bed.
Lay out wall lines building slab by control lines.
At the highest corner of the slab place a full width 1/2”
deep sand-cement mortar joint using a masonry trowel
(Mortar to be either Ready-Mix or 3:1 Sand: Portland
Cement ratio).
Salvage additional mortar. Do not use thin-bed mortar
for the leveling bed joint.
If moisture and wicking is a problem, add waterproofing
admixture to sand-cement mortar.
Step 3 - Set the first corner block.
Step 4 - Mix thin-bed mortar.
Set the first corner block in the sand-cement mortar
and adjust the joint as needed.
To achieve the required height, lower or raise the
block by tapping down with a rubber mallet or by
adding additional mortar beneath.
Mix approved AAC thin-bed mortar in a clean
mixing container (5 gallon bucket or pail) per
manufacturer’s directions.
The consistency of the mixed thin-bed mortar
should be such that it flows easily through the teeth
of the notched trowel leaving the shape of the teeth
in the mortar bed.
Thin-bed mortar droppings
should not be used.
BABB TECHNOLOGIES, INC.
Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
5
Field Installation Instructions Rev. 1-07-2004
I
AAC MASONRY PRODUCTS:
Leveling Course
Step 5 - Set second corner block.
Step 6 - Repeat for additional corners.
Set the second corner block adding thin-bed
mortar to the head joint with the notched trowel.
Repeat subsequent steps for each corner using a
builder’s level to maintain an equal elevation.
Triple check each lead corner in all three planes.
DO NOT TOOTH
Step 7 - Fill-in complete leveling
course.
After building lead corners, pull a string between
corners to complete the leveling course. Sandcement mortar should be used for the bed joint
and thin-bed mortar for each head joint.
Level across each block to insure a
plumb wall.
DO NOT PROCEED TO SUBSEQUENT
STOP COURSE UNTIL LEVELING COURSE
HAS SET SUFFICIENTLY.
BABB TECHNOLOGIES, INC.
Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
6
Field Installation Instructions Rev. 1-07-2004
I
AAC MASONRY PRODUCTS:
Typical Coursing
Step 1 - Mix thin-bed mortar.
DO NOT USE SAND-CEMENT
Mix thin-bed mortar.
STOP MORTAR FOR COURSES OTHER
THAN THE LEVELING COURSE.
Before mixing new batch, wash out the bucket or pail
to prevent any old thin-bed from accelerating the
drying time of the new mix.
DO NOT TOOTH
Step 2 - Clean bed joint surface.
Step 3 - Apply thin-bed mortar to head
and bed joints.
With a brush, sweep off all dust and loose
particles to insure adhesion of thin-bed mortar.
Using a clean, notched trowel the same width as the
block spread thin-bed mortar up the head joint of the
adjoining block and then along the bed joint.
Spread only enough thin-bed mortar to lay one block
at a time. The thin-bed mortar must cover the full
width of the joints.
Install block in a running bond
with a minimum 4” bearing
(overlap) or 40% of the block’s
height (whichever is greater).
BABB TECHNOLOGIES, INC.
Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
7
Field Installation Instructions Rev. 1-07-2004
I
AAC MASONRY PRODUCTS:
Typical Coursing
Step 4 - Set block.
Step 5 - Tap the end of the block.
Pick up each block and move it as close to the
head joint as possible before lowering the block
onto the bed joint
Excessive movement along the bed joint will force
the thin-bed mortar into the corner preventing full
adhesion with the head joint.
Tap the end of the block to insure a full surface
coverage of thin-bed mortar at the head joint and
align with string line.
Clean off spilled or dripped thin-bed mortar from
face of wall as work proceeds.
Repeat installation for subsequent courses.
Joints should
maintain a
thickness of
1/16” or 1/8”.
Step 6 - Rasp as needed.
Step 7 - Install lintels as required.
As needed, rasp (sand) the topside of the wall to
ensure a level bed-joint for the next course.
This is required less often if block is installed
within tolerances.
Install lintels with a minimum 8” bearing (overlap)
where required.
BABB TECHNOLOGIES, INC.
Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
8
Field Installation Instructions Rev. 1-07-2004
I
AAC MASONRY PRODUCTS:
Points To Check
Point 1
Leveling course must be level and plumb. Do not proceed to subsequent
courses until leveling course has set sufficiently.
Point 2
Blocks must be installed in a running bond with a minimum 4” bearing (overlap)
or 40% of the block’s height (whichever is greater). Lintels must be installed
with a minimum 8” bearing (overlap).
Point 3
DO NOT TOOTH
All head and bed joints must be solid with approved
AAC thin-bed mortar for full adhesion. Do not tooth.
BABB TECHNOLOGIES, INC.
Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
9
Field Installation Instructions Rev. 1-07-2004
I
AAC MASONRY PRODUCTS:
Routing Channels
Ensuring structural integrity.
1. Vertical routing
Cut channels as small as possible. Do not use impact
tools such as hammers or any other cutting tool that
will damage the adjacent wall.
Vertical channels may be cut by router or saw to a
width not to exceed 6”. Do not cut channels directly
under point loads.
Note: There are several methods for installing conduit in
AAC walls. This literature describes routing into a
completed block wall. Conduit may also be installed in a
small U on top of block as it is installed, or behind
sheetrock.
2. Horizontal routing
Cut horizontal channel(s) no deeper than 1/3 of the
wall thickness and no less than 24” from the top of
a bearing wall. Do not cut back-to-back channels.
Offset channels at least 12” when routing on both
sides of wall. Make access holes in the wall on the
opposite side of the channel where necessary.
Reduce the number of channels by taking services
behind wall where possible.
Do not route channels in floor or ceiling panels. A
perpendicular hole may be cored through the
reinforced panel if less than 1/4 panel width.
Tools needed:
AAC router
Chalk line
Chisel
Pencil
Plunge router
Straight edge
Circular saw
Step 2 - Cut along markings.
METHOD 1: Cut channel with a channel router.
(AAC Router)
METHOD 2: Set a blade on a circular saw or
concrete cutter to the necessary channel depth, if
using a concrete saw make cuts for each side of the
channel and an additional cut in the middle.
Do not cut the channel deeper than necessary.
Step 1 - Mark channel.
Using a straightedge mark both sides of the groove
with a pencil.
BABB TECHNOLOGIES, INC.
Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
10
Field Installation Instructions Rev. 1-07-2004
I
AAC MASONRY PRODUCTS:
Routing Channels
Step 3 - Remove waste and clean.
Step 4 - Cut holes for outlets.
If a circular saw or concrete cutter was used to cut
the channel the unwanted material can be removed
by snapping it away with a chisel.
Cut a template to the size of the hole or outlet and
temporarily secure to the wall. Remove AAC
material with a plunge router to the required depth.
Step 5 - Install conduit.
Step 6 - Install electric boxes.
Install cable, flexible, or rigid conduit in channel and
secure with channel clips. Observe local codes for
type of conduit, proper attachment and channel
depth.
Electrical boxes may be fixed to the wall with
course threaded screws. As an option, glue, foam
or thinbed mortar may be used.
BABB TECHNOLOGIES, INC.
Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
11
Field Installation Instructions Rev. 1-07-2004
II
HORIZONTAL AAC WALL PANELS
Tools Recommended For Installation
There are a full range of tools that are specially
designed to assist in installing wall panels and
increase productivity at the job site.
AAC installation will also require the following
standard industry tools.
Slings
Margin Trowel
Small Hand Brush
Builder’s Level
Quick Cut Saw
Rubber Float
4’ Level
Rasp
Chalk Box/String Line
Chamfering Tool
Pinch Bar
Grinder/Sander or
Electric Cut-Off Saw
Wall Panel Lifting Gear
Steel Bar Clamp
BABB TECHNOLOGIES, INC.
Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
12
Field Installation Instructions Rev. 1-07-2004
II
HORIZONTAL AAC WALL PANELS
Installing Panels
Step 1 - Check layout.
Check panel layout of approved AAC shop
drawings and deliver panels to job site
accordingly.
Step 2 - Unload bundles.
Unload the bundles of panels in a proper manner
using approved unloading gear.
Protect the panels from rain and water
saturation by leaving them on pallets
and away from standing water.
Eliminate excessive handling by storing panels
nearest to where they will be installed.
BABB TECHNOLOGIES, INC.
Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
13
Field Installation Instructions Rev. 1-07-2004
II
HORIZONTAL AAC WALL PANELS
Installing Panels
Step 3 - Check plumbness of column line.
Step 4 - Place first panel.
Check column line layout and plumbness. Varify layout
is within industry standards. Using a level and transit,
establish benchmark elevators onto the columns that will
act as a control line for setting the first AAC panels.
Measure down from the benchmark elevators to
establish the highest point on the slab. Install the
first panel, male side up, at the highest point of
the slab or stem wall, on top of preleveled shims
to establish a minimum depth of setting bed.
Place sand-cement mortar joint of at least 1/2
using a conventional masonry trowel (mortar to be
either Ready-mix or 3:1 Sand: Portland Cement
ratio) along wall line in between plastic shims or
pack with non-shrink grout. Other bays will require
adjusting the depth of the setting bed prior to
installing the first panel.
STOP
Alert General Contractor
to column line problems and
correct before proceeding.
Step 5 - Check panel height and plumbness.
Check the height, levelness and plumbness of the panel.
Temporarily suspend loose panel with clamps. See plans
and specification for allowable tolerances.
Step 6 - Notch each end of the panel.
Notch ends of each panel with grinder/saw to receive anchors.
BABB TECHNOLOGIES, INC.
Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
14
Field Installation Instructions Rev. 1-07-2004
II
HORIZONTAL AAC WALL PANELS
Installing Panels
Step 7 - Place and secure anchor.
Place anchor according to AAC shop drawings and
specifications into the notch at each end of the panel
and hammer tube nails through all of the nail holes
to secure. This must be accomplished before the
next panel is set.
Step 8 - Before setting the next panel.
Step 9 - Apply panel adhesive
between panels if specified.
Release panel clamp and remove all dust
particles from the top of the installed panel and
the bottom of the next panel with a brush.
BABB TECHNOLOGIES, INC.
Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
Apply beads of a recommended panel adhesive to
the top of the installed panel as per specifications
and/or shop drawings.
15
Field Installation Instructions Rev. 1-07-2004
II
HORIZONTAL AAC WALL PANELS
Installing Panels
Step 10 - Install the second panel.
Align the ends and groove of the second panel with
the ends and tongue of the first panel and set into
place. Repeat Steps 5 - 9 for the subsequent panels
in accordance with AAC shop drawings.
Step 11 - After installation.
After panels are installed, clean all horizontal and
vertical joints with a brush and apply exterior joint
sealers in accordance with AAC instructions.
BABB TECHNOLOGIES, INC.
Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
16
Field Installation Instructions Rev. 1-07-2004
III
PRECAST WALL PANELS
Points To Check
Point 1
Supporting columns must be plumb, level and within linear building line
tolerances.
Point 2
Protect the panels from rain and water saturation
by leaving them on pallets and away from standing water.
AAC horizontal
panels
Acrylic
coating
Point 3
Set panels with tongue side up and follow
specifications and shop drawings for
placement of adhesive and joint filler.
Fill joint
with
joint filler
2 beads of
adhesive
Point 4
Panel(s) must lay flush against face of column.
Point 5
In the event bowing occurs with the AAC panels within a column bay, stack
the AAC panels so that the bow is constant in one direction.
Correct installation
of bowed panels
Incorrect installation
of bowed panels
BABB TECHNOLOGIES, INC.
Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
17
Field Installation Instructions Rev. 1-07-2004
III
PRECAST FLOOR PANELS
Tools Recommended For Installation
Margin Trowel
Small Hand Brush
Slings/ Ropes
Builder’s Level
Quick Cut Saw
Rubber Float
Rasp
Hatchet Hammer
Chamfering Tool
4’ Level
Chalk Box/String Line
Pinch Bar
Lifting
Fork
Floor Panel Lifting Gear
Panel Turners
BABB TECHNOLOGIES, INC.
Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
18
Field Installation Instructions Rev. 1-07-2004
III
PRECAST FLOOR PANELS
Installing Panels
Step 1 - Unload Bundles.
Step 2 - Layout bearing lines.
Unload bundles of panels in proper manner using
approved unloading gear. If panels must be stored,
place them in a clean area without standing water
that is close to where work will begin.
Using tape measure, layout and chalk the bearing
(overlap) lines on top of AAC walls using detail
drawings approved for construction.
Make sure all bearing, top-of-wall surfaces are level.
Rasp or sand down high spots. Fill low spots
with shims.
Step 3 - Attach panel lifting gear.
Step 4 - Place first panel.
Place panels in a flat position with topside up. Attach
approved panel lifting gear (slings, forks, or clamps)
to the first panel. Be sure to observe manufacturer’s
proper attachment procedures and safety guidelines.
The first floor panel is lifted, placed and adjusted into
exact alignment along bearing lines. One worker is
required to steady and guide each end of the panel.
Note the direction of the tongue and position number
of the panel.
Maintain minimum bearing according to drawings.
BABB TECHNOLOGIES, INC.
Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
19
Field Installation Instructions Rev. 1-07-2004
III
PRECAST FLOOR PANELS
Installing Panels
Step 5 - Repeat for remaining panels.
Lay the remaining panels ensuring that each one is
seated firmly beside the preceding one.
Step 6 - Placing last panel.
The correct lifting gear will greatly assist
placement of the last panel. Special procedures
may be required if other lifting devices are used
(I.e. slings or ropes).
BABB TECHNOLOGIES, INC.
Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
20
Field Installation Instructions Rev. 1-07-2004
III
PRECAST FLOOR PANELS
Filling Joints
Step 1 - Set screen block.
Step 2 - Place reinforcement steel.
Set minimum 2” screen block in thin-bed mortar
around exterior perimeter for formwork for all ring
beams according to detail drawings.
Install reinforcing steel in panel joints, ring beams,
and lintels according to detail drawings.
Make sure all rebar is in correct position before
concrete is placed. Tie wire or chairs may be used to
hold rebar at correct heights.
Hanger wire for suspended ceilings may be installed
through floor panel joints at this time.
Step 3 - Fill joints with concrete.
Fill wet joints with concrete. Firmly tamp into all
joints, screed off excess and finish.
A Pencil Vibrator should be used for ring beam and
lintel pours.
BABB TECHNOLOGIES, INC.
Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
21
Field Installation Instructions Rev. 1-07-2004
III
PRECAST FLOOR PANELS
Panel Penetration Guidelines
STOP
PANELS WITH HOLES MUST BE DESIGNED
TO HAVE SUFFICIENT REINFORCEMENT
INCORRECT!
Less than or
equal to 6”
DO NOT PENETRATE THE PANEL
ACROSS IT’S WIDTH MORE THAN
ONCE WITH HOLES GREATER THAN
OR EQUAL TO 6”.
2’ - 0”
typical
panel
Opening may not
exceed 25% of
panel width
Less than or equal to
25% of panel width
AAC floor panel
INCORRECT METHOD
CORRECT METHOD
PLAN VIEWS
BABB TECHNOLOGIES, INC.
Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
22
Field Installation Instructions Rev. 1-07-2004
III
PRECAST FLOOR PANELS
Points To Check
Point 1
Supporting walls must be level.
Point 2
Minimum bearing as shown in detail drawings must be maintained.
Point 3
Concrete poured into joints must completely cover all reinforcement.
Point 4
Do not cut or modify a panel without first checking with AAC Building
Systems. Observe all guidelines for coring and other floor penetrations.
Never cut the floor panel to shorten it.
BABB TECHNOLOGIES, INC.
Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
23
Field Installation Instructions Rev. 1-07-2004
III
PRECAST FLOOR PANELS
Routing Channels
Step 1 - Routing bottom of floor panels.
The underside of floor panels may be routed to a depth no greater than 3/4” in the middle or no greater than
1 1/2” on the sides. Stop if reinforcing becomes exposed.
<1 1/2”
<1 1/2”
Less than 3/4”
< 2”
< 3”
Step 2 - Top of floor panels.
Grout joint
DO NOT ROUT the topside of panels.
Place conduit in the panel joints.
3/4” Conduit (maximum one piece per grout joint)
#3 Rebar
Step 3 - Conduit in floor panel joints.
DO NOT INSERT conduit in the
first joint from the exterior wall.
BABB TECHNOLOGIES, INC.
Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
24
Field Installation Instructions Rev. 1-07-2004
III
PRECAST FLOOR PANELS
Points To Check
Point 1
Do not rout horizontally less than 24” from the top of load bearing walls.
Point 2
Do not rout horizontally greater than 1/3 of the total wall thickness.
A + B < 1/3 of total thickness
Point 3
Do not rout back-to-back wall channels. Offset channels at least 12”.
BABB TECHNOLOGIES, INC.
Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
25
Field Installation Instructions Rev. 1-07-2004