ESPAC Brochure

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Tel. : +9661 46 288 30 Fax : +9661 29 303 04 P.O Box 25507 Riyadh 11476 Saudi Arabia

www.espac.com

‫ نــبــنـــــي‬.. ‫ نــ�صــــنـع‬.. ‫ن�صـمـــم‬

A.A.C PRODUCTS

www.espac.com

Contents 03 - 04 Introduction 05 - 09 Manufacturing 11- 16 Properities 17 - 19 Benifets 21 - 24 Products 25 - 46 Usages 47 - 51 Design 53 - 57 Erection 59 - 65 Finishes 67 - 71 Our Projects

We are committed to clean air

ESPAC factory in Saudi Arabia

ESPAC

INTRODUCTION

ESPAC is the green trademark in AAC world.

ESPAC is a Saudi- Emirati company specialized in Precast Aerated Concrete (PAC) by using latest technologies and in accordance to best quality standards, highly qualified experts with good architectural and engineering skills in planning, Manufacturing, designing and constructing green building using Precast Aerated concrete (PAC).

ESPAC provide great quantity of blocks, Panels, and Roofs to meet the needs of the Saudi market in establishing trading center and residential compounds. It also provides necessary technical support to ensure best products.

ESPAC team has the best scientific knowledge besides specialization experts in manufacturing, constructing and installing products safely and properly, using all available advantage and opportunity in project environment.

Our Commitment EESPAC is committed to high levels of responsibility in all processes of production, installation and technical support for projects the company

executes, to ensure efficiency in execution and perform the required work professionally and at a level exceeds the expectations of project owners.

We are also committed to preserve and maintain the environment in which we live and work.

Our Vision We are aspiring that ESPAC becomes the leader in Precast Aerated Concrete (PAC) in accordance to scientific and professional methods, which is able to achieve an added value to this creative product.

Our Mission Providing products, services and valuable engineering alternatives that is characterized with high quality, based on a creative vision and scientific methods provided by a specialized and experienced team that is highly qualified and has professional knowledge in order to achieve success to our clients through activation their potentials.

3

Historical A.A.C was perfected in the mid-1920 in Sweden by Dr. John Axel Eriksson, an architect working with professor Henrik Krevger at Royal Institute Of Technology, it was produced first in Sweden in 1923 then industries volume production in 1929. Since that time, its production and use have spread to more than 40 countries on all continents, including Europe, The Middle East, The Far East, North America, Central and South America, and Australia.

This wide experience has produced many case studies of use in different climates and Under different building codes.

In Saudi Arabia A.A.C was started in 1977 and used for thousand of projects up to now.

Definitions Autoclaved aerated concrete (AAC) a cementitious product based on calcium silicate hydrates in which low density is attained by the inclusion of an agent resulting in macroscopic voids and is subjected to High-pressure steam curing (ASTM C1386).

4

1- MANUFACTURING

MANUFACTURING 11MANUFACTURING 1.1 Overview 1.2 Overview Raw Materials Raw Materials 1.3 Batching 1.4 Batching Plan & Layout Plan 1.5 Steel& Layout 1.6 Steel Casting Casting 1.7 Cutting & Milling & Milling 1.8 Cutting Autoclaving 1.9 Autoclaving Packaging Packaging

1- MANUFACTURING

1MANUFACTURING 1.1 Overview Unlike most other concrete applications, AAC is produced using no aggregate larger than sand. Under high control quartz sand, aluminium powder, cement and water are mixed. Aluminum powder is used at a rate of 0.05%–0.08% by volume (depending on the pre-specified density). When AAC is mixed and cast in forms, several chemical reactions take place that gives AAC its light weight (25% of the weight of concrete) and thermal Properties. Aluminum powder reacts with calcium hydroxide and water to form hydrogen. The hydrogen gas foams and doubles the volume of the raw mix (creating gas bubbles up to 3mm (1/8 inch) in diameter). At the end of the foaming process, the hydrogen escapes into the atmosphere and is replaced by air.

When the forms are removed from the material, it is solid but still soft. It is then cut into either blocks or panels, and placed in an autoclave chamber for 15 hours. During this steam pressure hardening process, when the temperature reaches 190° Celsius (374° Fahrenheit) and the pressure reaches 8 to 12 bars, quartz sand reacts with calcium hydroxide to form calcium silica hydrate, which accounts for AAC’s high strength and other unique properties. After the autoclaving process, the material is ready for immediate use on the construction site.

1.2 Raw Materials The basic raw materials are cement, Sand, Aluminum Powder (expansive agent), Lime and Water.

Aluminum Powder

Sand

Water

1.3 Batching Sand is ground to the required fineness in a ball mill, and is stored along with other raw materials. The raw materials are then batched by weight and delivered to the mixer. Measured amounts of water and expansive agent are added to the mixer, and the cementitious slurry is mixed.

6

Lime

Cement

1- MANUFACTURING

1.4 Manufacturing flow chart Components 1 Sand Slurry 2 Water

Miling

3 Cement 1

2

3

4

4 Lime

5

5 Aluminium

Straightening Steel \ Cutting

Welding Calliboration components

Rust Protecting Batching Drying

Assembly

Casting

Rising and forming of pores

Loading

Cutting

Autoclaving

Packaging

7

1- MANUFACTURING

1.5 Steel Steel coils are straightened, cut and spot-welded into mats, where crossbars provide anchorage to the longitudinal reinforcements. Blocks are not reinforced.

After dipping the welded mats in a homogenized anti-corrosion mix for rust protection, they are dried and assembled into cages and set accurately in the moulds before the slurry is poured in.

1.6 Casting Molds are prepared to receive the fresh AAC. If reinforced AAC panels are to be produced, steel reinforcing cages are secured within the molds. After mixing, the slurry is poured into the molds.

The expansive agent creates small, finely dispersed voids in the fresh mixture that increases the volume by approximately 45% in the molds within 3 hours.

1.7 Cutting & Milling Within a few hours after casting, the initial hydration of cementitious compounds in the AAC gives it sufficient strength to hold its shape and support its own weight.

The material is removed from the molds and fed into a cutting machine by wires used, sections the blocks and panels cut into the required sizes

8

and shapes. After cutting, the units remain in their original positions in the larger AAC Mass.

The panels are demoulded and milled to required profile. All panels are singled out for proper marking, and if required, dry cut and stacked for further handling and storage.

1- MANUFACTURING

1.8 Autoclaving After cutting, the aerated concrete product is transported to a large autoclave, where the curing process is completed. Autoclaving is required to achieve the desired structural properties and dimensional stability.

The process takes about 15 hours under a pressure about 12 bars and at a temperature of approximately

374 째F (190 째C), depending on the grade of material produced. During autoclaving, the wire-cut units remain in their original positions in the AAC block.

After autoclaving, the individual units are dimensionally stable and are specified to have a drying shrinkage of no more than 0.02% (ASTM C1386).

1.9 Packaging The blocks are demoulded, strapped, marked and stored on wooden pallets. Pallets for shipping. Unreinforced units are typically shrink- wrapped, while reinforced elements are typically banded only, using edge guards to minimize localized damage from the banding.

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2- PROPERTIES

2PROPERTIES

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15

Microstructure Chemical Characteristics Density Compressive strength Compressive strength test Thermal conductivity Acoustic properties Fire resistance Durability Quake resistance Thermal expansion Shrinkage Melting point Air tightness Water absorption

2- PROPERTIES

2PROPERTIES 2.1 Microstructure A.A.C consists of a micro calcium silicate bind matrix.

In aerated concrete the method of pore formation influences the microstructure, and thus its properties. The micro pores are formed due to the expansion of the mass caused by aeration and the micro pores appear on the walls between the macro pores. The products orientation of hydration of cement is significantly altered due to the pressure of voids. On autoclaving, a part of the fine siliceous material reacts chemically calcareous material like lime and lime liberated by cement hydration, Forming a microcrystalline structure with much lower specific surface. The pores be distributed uniformly in mass to obtain products uniform density. The pores present in A.A.C matrix as micro pores 0.1 mm and macro pores 0.1 to 1.0 mm.

Table 1. Porosity characteristics of AAC products different in density Apparent Density kg/m3

Macro Pores %

Micro Pores %

Total Porosity

100

83

13

0.96

150

77

17

0.94

350

70

16

0.86

400

65

19

0.84

600

45

21

0.76

800

27

41

0.68

2.2 Chemical Characteristics The reaction in the autoclave required (cement, lime, silica and water) the sequence of the chemical reaction in the autoclave .The temperature (190 ⁰C) and pressure (12 bars) time of the autoclaving determine which form of CSH is produced. The tobermorite group of calcium silicate hydrates (C-S-H). The reaction product of mixture of crystalline, semi-crystalline, and near amorphous tobermorite. The AAC are plate shaped crystal of 11.3 A⁰ tobermorite with a double chain silicate structure.

The tobermorite (Ca5Si6O16(OH)2·4H2O )is usually the main hydration product in AAC. AAC remains constant after manufacturing, there is no change in the composition after autoclave curing in the production process. The construction process does not change the chemical composition of the materials itself.

AAC material does not have toxic or radioactive contents.

12

2.3 Density Normally A.A.C was produced nominal dry density 550 kg/m3, other densities from 250 to 800 kg/m3 can be produced upon request. Many physical properties of aerated concrete depend on the density, it is essential that its properties be qualified with density. See table 2.

Dry density (kg/m3)

Compressive strength (MPa) Static modulus of elasticity (kN/mm2)

Thermal conductivity (W/m oc)

400

1.3 -2.8

0.18 -1.17

0.07 - 0.11

500

2.0 -4.4

1.24 -1.84

0.08 - 0.13

600

2.8 - 6.3

1.76 – 2.64

0.11 – 0.17

700

3.9 – 8.5

2.42 – 3.58

0.13 – 0.21

2- PROPERTIES

Table 2. Physical properties with density

2.4 Compressive strength Up from 350 kg/m3 density AAC can be used as load bearing construction material. The material lower in density is used for thermal insulation purpose. Normally A.A.C was produced nominal dry density 550 kg/m3. Autoclaving increase the compressive strength significantly, as high temperature pressure result in a stable form of tobermorite.

Strength is achieved in this case, depending on the pressure and duration of autoclaving. Generally compressive strength increase linearly with density. See table 3.

Table3. Properties at nominal dry density of 550 kg/m3 At nominal dry density of 550kg/m3 Compressive strength

35 – 45 kg/m3 ( 3.5 – 4.4 MPa )

Tensile strength

20 to 40% of compressive strength

Shear strength

20 to 30% of compressive strength

Modulus of elasticity

16000 kg/cm2

2.5 Compressive strength test Compressive strength varies inversely with moisture content. On drying to equilibrium with normal atmosphere, there is an increase on the strength and even larger increase on complete drying out. Must be follow this steps for Compressive strength testing: 1. The test set shall consist of three cubes specimens with an edge length of 100 mm or 150 mm.

2. The test specimens shall be conditioned at a temperature not exceeding 60 oC until their moisture content is expected to be (3 to 6 )% by specimens mass. (By using special oven) 3. The longitudinal Axis of the test specimens shall be perpendicular to direction of rising.

150 mm

Axis test direction

150 mm

Direction of rising

13

2.6 Thermal conductivity

2- PROPERTIES

No aggregate, low density, air bubbles, amount of pores and their distribution are critical factors for thermal insulation but the thermal conductivity is direct proportion influenced by the moisture content. at nominal density 550 kg/m2.

The thermal conductivity K- value for A.A.C material is 0.144 at completely dry this confirmed by the international codes Like ASTM – ACI – British standards …) & Saudi Electricity Co. (SCECO), King Fahd University and Saudi Arabian Standards Organization (SASO).

Based on the above: 1. The U-value of A.A.C 20 cm thickness is 0.62 w/m2 oc = 0.11 BTU /f t2hof.

2. The U-value of A.A.C 25 cm thickness is 0.51 w/m2 oc = 0.08 BTU /f t2hof.

• Note: 1 BTU/f t2hof = 5.678 w/m2 oc.

1.6 1.4 1.2 1 0.8 0.6 0.4 0.2 0

1.097

1.129

1.355

0.55 0.144

K-Value

AAC

CLAY BRICKS

CONCRETE BLOCKS

SANDLIME BRICKS

PREFAB CONC.

2.7 Acoustic properties

90 db

42 db

Jet Take-off

SOUND PRESSURE LEVEL

20cm A.A.C Wall

The reason stated is that transmission loss of air-borne sound is dependent on the mass law, which is a function of frequency and surface density of the component – its mass to area –, in addition to the rigidity. The A.A.C has a high surface mass dampens mechanical and absorption barrier.

Sound reduction is the ratio of sound energy at its source to at another location expressed as decibel (db) and its Scale by logarithmic.

Pneumatic Chipper

Noisy Workplace

Street Traffic

Business Office

Meeting Room

Living Room

Sound Insullation Garden

Table 4. Sound pressure reduction by (db) A.A.C thickness

10 cm

15 cm

20 cm

25 cm

Plain

39

43

45

48

Painted

41

45

48

50

Plaster

46

49

51

53

Gypsum Board

47

50

53

54

Finishes type

14

2.8 Fire resistance

2- PROPERTIES

A.A.C is inorganic and incombustible material application the porous structure allows steam to escape without causing surface spilling. And it won’t lead to harbor or encourage vermin.

So it is especially suited for fire – rated applications. Depending on the application and thickness of the blocks or Panels fire rating up to 7 hours.

Table 5. Fire resistance Thickness (cm)

10

15

20

25

Fire ratings (hours)

4

7

7.5

8

Heat penetration in the case of fire after 6 hours Concrete

1000 ˚C

270 ˚C

Concrete.

150 mm wall thickness

A.A.C

1000 ˚C

68 ˚C

Aerated concrete.

150 mm wall thickness

Prevention of secondary fires

Other building materials: Spread of fire by melting and burning material dripping down.

Aerated concrete does not melt in the case of fire and does not drip burning material.

A.A.C used in warehouse building 15

2.9 Durability

2- PROPERTIES

A.A.C mainly consists of tobermorite which is much more stable than products formed in normally cured aerated concrete, and hence it is durable. A.A.C resists the harsh climate conditions and does not degrade structurally if exposed to moisture. No organic continents, high control mixing, strong temperature – steam curing and protected steel by antirust coating make A.A.C materials more durability. A.A.C building has built since 1930 up to now.

2.10 Quake resistant The law mass of A.A.C material reduces total dead load of the buildings and results reducing the applied seismic.

The connection between the walls and the foundation is enough but not rigidity . In addition in A.C.C. system the rectangular shape of the wall makes it as shear wall.

2.11 Thermal expansion A.A.C thermal expansion is 8x10-6/ oC while in regular concrete has ranges between 4 to 14x10-6/ oC, so A.A.C concrete is more dimensional stability than regular concrete.

2.12 Shrinkage o

o

A.A.C shrinkage is 200x10-6/ C but in regular concrete is 500x10-6/ C. The autoclaving (high temperature and high pressure steam curing) is the mainly reason in the lower shrinkage for A.A.C.

2.13 Melting point o

A.A.C melts on 1200 C

2.14 Air tightness At a reference pressure of 50 Pa, the A.A.C building air changes 1 to 2.5 per hour.

2.15 Water absorption Water absorption of materials can be classified by the water absorption coefficient. The water absorption coefficient gives information about how much water is absorbed in a defined time period. The special inner structure of AAC, which consists mainly of closed pores (micro pores and macro pores), prevents the capillary transport of moisture over long distances. In table 6 the water absorption coefficient for some selected building materials are shown.

Table 6. Water Absorption Material Dispersion coating

1.2E-6 – 4.7E-6

Concrete

2.4E-6 – 1.2E-5

Cement plaster

4.7E-5 7.1E-5

AAC

5.9E-5 – 1.7E-4

Solid sand-lime bricks

9.5E-5 – 1.9E-4

Hollow bricks

2.1E-4 – 5.9E-4

Solid bricks

4.7E-4 – 7.1E-4

Gypsum Gypsum board 16

Water absorption coefficient [Ib/(in2.s0.5)]

8.3E-4 8.3E-4 – 1.7E-3

3BENIFETS 3- BENIFITS

3- BENIFITS

3BENEFITS

1

2 High thermal insulation & energy saving

4

Strong & Durability

5 Easy Workability

7

Light Weight

6 Fast Construction

8 Quake Resistant

18

3

Economical

9 Fire Resistance & No Emission of Gases

Noise Resistance

Fast Construction HighGreen thermalBuild insulation

Quake Resistance 10

11 Clean Implementation Site

13

12 Sustainability & Long Life

14 Multi Purpose

16

15 High Dimensional Stability

17 Environment Friendly

Green Build

Not Toxic or Radioactive Material

18 Breathable Buildings

High Quality Control 19

3- BENIFITS

EasyLight Workability Build Wieght

4- PRODUCTS

4PRODUCTS

4.1 Reinforced products 4.2 Profile shape 4.3 Non reinforcement products

4PRODUCTS 4.1 Reinforced products table:Product name

Description

Thickness

Reinforced products with double mat steel reinforcement depending on design.

4- PRODUCTS

Image

Dimensions by mm with tolerance is +3mm for thickness & width and +- 5 mm for length

22

width

Usages

length • Load bearing • Partion wall • Cladding wall • Parapet wall

PAC vertical wall panels

75, 100, 125, 150, 175, 200, 225, 300

HP

PAC horizontal wall panels

75, 100, 125, 150, 175, 200, 225, 300

Up to 600 mm

Up to 6000 mm

FSP

PAC floor slabs panels

100, 150, 175, 200, 250, 300

Up to 600 mm

Up to 6000 mm

• Floor slabs with design load up to 600 kg/m2

RSP

PAC roof slabs panels

100, 150, 175, 200, 250, 300

Up to 600 mm

Up to 6000 mm

• Roof slabs with design load up to 250 kg/m2

LP

PAC wall lintels panels

100, 150, 200, 250, 300

LX

PAC box lintels panels

100, 150, 200, 250, 300

VP

Up to 600 mm

400 to 600 mm

200, 250, 300

Up to 6000 mm

• Boundary wall • Cladding wall • Parapet • Partion • Filling wall

Up to 6000 mm Depend on designs

• Load- bearing lintels over window or door opening for external or internal walls

Up to 3600 mm

• Load- bearing box lintels over window or door opening for external walls

4.2 Profile shape

4- PRODUCTS

Slabs Profile

Horizontal Panel Profile (HP)

Vertical Panel Profile (VP)

23

4. 3 Non reinforcement products (Block) table:Image

Product name

Description

Dimensions by mm with tolerance is +3mm for thickness & width and +- 5 mm for length

4- PRODUCTS

Thickness

24

S - Blocks

Standard PAC blocks

100, 125, 150, 175, 200, 250, 300

J - Blocks

Jumbo PAC blocks

200 – 250 – 300

H – Blocks

Hordi PAC blocks

PT

PAC roof tiles

400

width

length

200 – 250

600 mm

600

Up to 1200 mm

250

50x250x600 75x250x600 75x600x600

Usages

600 mm

• Thermal insulation wall • Load bearing wall • Non load bearing • light weight partitions • Solid blocks • External & internal walls • Instead of C.M.U or red clay blocks

• Light weight hordi blocks infill between concrete ribbed slabs

• Insulate conventional roof

5- USAGES

5 USAGES

5.1 Complete System 5.2 Connecting To Concrete Frame 5.3 Connecting To Steel Frame 5.4 Partitions 5.5 Boundary Wall 5.6 Blocks & Hordi

5USAGES 5.1 Complete System - Details.

5- USAGES

Aerated concrete products constitute a complete system.

VP LP 26

: PAC Vertical Panel : PAC Panel Lintel

LX : PAC Box Lintel HP : PAC Horizontal Panel

RSP FSP

: PAC Roof Slab : PAC Floor Slab

Aerated concrete used in several structures such as:

5- USAGES

Complete System - Photos.

27

5- USAGES

Detail No. D1

INTERNAL WALL WITH FOUNDATION CONN.

28

EXTERNAL WALL WITH FOUNDATION CONN.

5- USAGES

Detail No. D2

PAC SLAB

EXTERNAL NONE LOAD BEARING WALL CONN.

EXTERNAL LOAD BEARING WALL CONN.

29

5- USAGES

Detail No. D3

INTERNAL LOAD BEARING WAL CONN.

30

PANEL VP WITH PANEL VP CONN.

Detail No. D4

5- USAGES

SLAB WITH INTERNAL WALL CONN.

Detail No. D5

SLAB WITH STEEL BEAM CONN. 31

5- USAGES

5.2 Connecting to Concrete Frame 5.2-a Filling to Concrete Frame - Photos.

32

Filling to Concrete Frame - Details.

5- USAGES

PART ELEV. NO. 1

TYPICAL WALL ELEV.

PART ELEV. NO. 2

33

Filling to Concrete Frame - Details.

DET. A CONNECTIONS SEC.

5- USAGES

DET. A CONNECTIONS PLAN

DET. B FIRST PANEL FIXING SEC.

DET. D LAST PANEL FIXING SEC.

34

DET. C BRACKET FIXING PLAN

5.2 Connecting to Concrete Frame 5.2-b Cladding to concrete frame

LEV. D

LEVEL. D

LEVEL. C

RC BEAM

RC BEAM

LEV. C LEVEL. B

SEC.

LEVEL. A

5- USAGES

CLADDING TO CONCRETE FRAME ELEV.

RC BEAM

TYPICAL DETAIL LEV. B

LEV. A GROUND LEV

CLADDING TO CONCRETE FRAME SEC،

35

5- USAGES

5.3 Connecting to Steel Frame 5.3-a With Vertical Panel - PhotosŘŒ

36

5- USAGES

Connecting to Steel Frame With Vertical Panel - Details.

EXTERNAL CLADDING SEC. 37

5- USAGES

5.3 Connecting to Steel Frame 5.3-b With Horizontal Panel - Photos.

38

Connecting to Steel Frame With Horizontal Panel - Details.

SIDE VIEW

5- USAGES

PARTIAL ELEVATION

TOP VIEW SECTIONS

39

5- USAGES

5.4 Partitions - Photos.

40

Partitions - Details.

(OPTION - 1 WITH FALSE CEILING USED)

PARTITION WALL CONN.

(OPTION - 2 WITHOUT FALSE CEILING USED)

5- USAGES

PARTITION WALL CONN.

41

5- USAGES

5.5 Boundary Wall 5.5-a With concrete columns - Photos.

Boundary Wall With concrete columns - Details.

ELEVATION

PLAN 42

SIDE VIEW SECTION

5- USAGES

5.5 Boundary Wall 5.5-a With concrete columns connection.

CORNER COLUMN 

 MIDDLE COLUMN

43

5.5 Boundary Wall 5.5-b With steel columns - Photos.

5- USAGES

Boundary Wall With steel columns - Details.

150/200X600X3000 PANEL HP

ELEVATION ELEVATION

SECTION

150/200X600X3000 HORIZANTAL PAC PANEL PH

PLAN PLAN

44

IPE-180 FOR 150MM THK. PANEL

5- USAGES

5.6 Blocks & Hordi - Photos.

45

Blocks & Hordi - Details.

5- USAGES

PLAN

DETAIL - A

46

DETAIL - B

6- DESIGN

6DESIGN

6.1 ARCHITECTURAL PRINCIPLES 6.2 STRUCTURAL PRINCIPLES 6.3 APPROVALS & CODES

6DESIGN 6.1 Architectural Principles 1. Vertical wall panels, floor slabs panels and lintels combine to form complete precast system as load bearing structure buildings.

2. The maximum span of A.A.C panels is 6m that is mean maximum clear span dimensions between the load bearing walls should not exceed 5.80.

3. We will use a steel or concrete beam to support the slabs if the clear span more than 5.80.

4. Upper wall panels, direct wall on floor slabs is not allowed without steel or concrete support beams but you can put 10 cm thickness non bearing partitions after structural calculations approved.

5. We prefer 3 meters storey heights, because we get full mould utilization and can quote better prices.

See Ideal section.

6. Try to design according to 600 mm module for zone dimensions or for windows openings.

7. Non modular windows openings width also can be formed with cut panels preferably 300 mm width.

8. Doors are generally made to sizes that suit but we prefer not exceed 2200 mm in height and 1000 mm in width.

9. A.C units are wider than 600 mm through (between) the wall panel, this best and easiest positioning.

10. Exhaust fan opening: opening for exhaust fan ducts are best centered on wall panel joints.

600

Wall Maximum 6000 mm

600

75 mm

Lintel

Window 3000

3000

200 200 mm

600

600

1200

600

Wall

Wall

Wall

6- DESIGN

11. Lintels supports: do opening space with sufficient supports, we prefer 600 mm for both sides but you can use End Bearings 300 mm when necessary as minimum.

2p

20 mm

Architectural Ideal Section 48

1200

VP Under Window

6.2 Structural principles 1. AAC structural material approximately less than one quarter the weight of conventional concrete, which reduce the foundations volume, so we often use a strip ground foundations for AAC buildings.

2. The foundation should be made high enough such that the wall panels will not catch the soil.

3. Vertical wall panels (VP) are reinforced for load bearing applications. Table 6 – 1 shows permissible compressive stress on vertical wall panels (VP) based on ACI codes. And table 6-2 show the maximum length of VP & HP with various design lateral loads.

Permissible Compressive Stress (Newton/cm2) at the following Wall Wall Height (m)

Thickness (mm) 100

150

200

250

2.50

53

65

68

69

2.75

47

63

67

69

3.00

40

61

66

68

3.75

12

53

63

66

4.00

-

49

61

66

4.50

-

40

58

64

5.00

-

29

53

61

5.50

-

16

47

58

6.00

-

-

40

55

Table 6-1 Permissible Compressive Stress 800

1200

1600

2000

75

250 cm

-

-

-

100

400 cm

375 cm

325 cm

275 cm

125

500 cm

475 cm

450 cm

400 cm

150

600 cm

475 cm

550 cm

500 cm

175

600 cm

600 cm

600 cm

575 cm

200

600 cm

600 cm

600 cm

600 cm

225

600 cm

600 cm

600 cm

600 cm

250

600 cm

600 cm

600 cm

600 cm

300

600 cm

600 cm

600 cm

600 cm

6- DESIGN

Maximum Length of Wall Panels design wind load (n/m2)

Thickness (mm)

Table 6-2 Maximum Length Of Wall Panels with various lateral loads.

4. Lintels used as load bearing members over window and door openings for external or interior walls, tables 6-3 & 6-4 shows the maximum clear span of lintels with design loads.

Design Load

Thickness of Lintel Panel LP (600 mm height) 100

150

200

250

300

5000 n/m

250 cm

450 cm

450 cm

540 cm

600 cm

10000 n/m

200 cm

325 cm

400 cm

450 cm

500 cm

15000 n/m

100 cm

275 cm

325 cm

375 cm

410 cm

Table 6-3 Maximum Clear Span of (LP) With Various Design Loads Design Load

Thickness of Lintel Box LX (250 cm height) 100

150

200

250

5000 n/m

250 cm

350 cm

360 cm

360 cm

10000 n/m

150 cm

250 cm

260 cm

265 cm

15000 n/m

75 cm

200 cm

210 cm

210 cm

Table 6-4 Maximum Clear Span of (LX) with Various Design Loads 49

5. AAC PAC slabs attain their design strength during the high – pressure steam curing process in the autoclaves. Thus slabs can be erected and ready for occupancy use immediately after delivery to the site.

Slabs are reinforced with double steel welded mats and anticorrosion coated.

FSP & RSP slabs are produced in various thickness and spans depending on the required load bearing capacities. The table 6 – 5 shows the permissible spans of slabs with different design loads.

Design impossed DL+LL (n/m2)

Permissible Spans (mm) of Various Slab Thickness and Design Loads 100

150

200

250

300

1100 n/m2

4250

6000

6000

6000

6000

1600 n/m2

4000

5750

6000

6000

6000

2100 n/m

2

3500

5500

6000

6000

6000

2500 n/m

2

3500

5250

6000

6000

6000

3000 n/m

2

3250

5000

6000

6000

6000

3500 n/m2

3000

4750

6000

6000

6000

4000 n/m

2

2750

4500

5750

6000

6000

5000 n/m

2

2500

4000

5250

5750

6000

Table 6-5 Permissible Spans by (mm) of Various Slab Thickness and Design Loads 6.

For 20 cm wall thickness the minimum required End Bearing are 75 mm and 60 mm for 15 cm wall or steel supports. a

b

a

6- DESIGN

AAC Support a ≥ 60 mm b ≥ 30 mm

ACC Load Bearing Wall

Typical vertical joint profile at AAC lintel 50

Wall section for multiple stories

6.3 Approvals & Codes A.A.C materials approved by Saudi Government Authorities like Municipality, Civil Defense, Royal Commission, Aramco, SCECO, Health ministry, SASO ....etc.

A.A.C materials are supported (Covered) by several international codes like:-

ASTM

SASO

Green Building Council

6- DESIGN

ACI

51

7.1 Man Power 7.2 Consumables 7.3 Tools & Equipments 7.4 Erection Procedures

7- ERECTION

7ERECTION

7ERECTION 7.1 Man power In normal cases with PAC complete systems as residential ( Housing ) 3 floor stories projects the ideal work group like this:Crane 20 tons with its operator

-

Crane regards

1

Mark number labor

2

Technical erectors

3

Labor erectors

3

Level & repair plaster worker

2

Grout & ring beam labor

2

Supervisor

1

Man power total

14

Notes • This group produces approximately 30 cubic meters as a range per day.

• Must be provision all PAC material, consumables, tools and auxiliary materials in site before works starting.

• Normal to need 10-15 ton crane depends on projects conditions & requirements.

• Installation increases ascending up to reaches the indicated rate.

7.2 Consumables

We want Erictions Required Consumables approximately as follows 7-2-1 Panels glue mortar: 1m3 x 10 Kg Note: PAC glue mortar = 25 Kg

7- ERECTION

7-2-2 Panels Repair mortar: 1m3 x 4 Kg 7-2-3 Blocks mortar: 1m3 x 30 Kg Note: For block masonary 7-2-4 Sand papers: 1m3 x 0.06 L.m 7-2-5 Fiber glass tape: • For panels 20 thickness: 1m3 x 17 L.m • For panels 15 thickness: 1m3 x 23 L.m • For panels 10 thickness: 1m3 x 34 L.m Note: 1 roll = 90 L.m 7-2-6 Bounding agent: fiber glass tape L.m X 0.6 Kg 54

7-2-7 Ring beam steel: 1m3 x 2.2 Kg (ø10mm steel) 7-2-8 Starter bars & top bars: 1m3 x 3.5 Kg (ø10mm steel) 7-2-9 Stretch dowels bars: 1m3 x 0.15 Kg (ø 6mm steel) 7-2-10 Grout & ring beam cement: 1m3 x 14 Kg cement 7-2-11 Plastic wedgies: 1m3 x 2 pieces

7.3 Tools & equipments The following tools are provided for PAC material erection: 1- Hook

2- Wall Braces

3- Lever

4- Nipper

5- Slabs Clamb

6- Sling

7- Lintel Grab

8- Saw

7.4 Erection Procedures

1. Foundation: Note that R.C foundationmust be cast with right angels and smooth level surface to receive the precast panels.

2. Delivery: Check panel layout of approved Pac shop drawings and deliver panels to jop site accordingly nearest to where they will be installed.

3. Corner: Select corner to start and check carefully its per perpendicular (ninetieth ) angle.

7- ERECTION

4. Layout: Mark the layout of the wall on top of the concrete foundation by using chalk lines

5. Starter bar: Drill for 10 mm dowels in foundation (Ground Beam) at each joint panels or put the dowels in their positions when casting the foundation

55

7.4 Erection Procedures

6. Glue mortar: Mix the glue as per manufacturer’s instructions then put the mixture as bed for the wall panels.

7. Lifting: Select the wall panels (VP) as per mark numbers shown on shop drawings then lift it by hock tool and bed the panels on glue mortar. Don’t forget that erection should start from a corner tacking care to fit the panels lightly together.

8. Alignment: Use the nylon offset lines and aluminum straight edge to ensure the alignment, plumb and leveling for face panels inside & outside.

7- ERECTION

9. Wall Braces: Put one wall braces with horizontal stage wood at every 3 panels to make it stable and steady.

10. Dowels: Hummer steel dowels of 0 5mm x300 mm long between top the panels as stitches.

11. Grouting: Fill the groove channels between the panels by wetting cement sand grout (1:3) and then put steel dowels (starter bars) for next work.

56

7.4 Erection Procedures

12. Lintels: Fix the lintels by lintel grab tool using the glue & steel dowels.

13. Leveling: Settle mortar on top of wall & lintels panels to provide a true level bearing surface for floor or roof slabs panels.

14. Slabs: Place carefully the slabs panels by grab tool on level leveled wall panels and connect the tongue with grove panels together by cramp tool.

7- ERECTION

15. Ring Beam: Cast the reinforcement ring beam as the connection details and fill the notches formed above roof slabs panels.

57

8.1 Repairing 8.2 Painting on AAC Panels 8.3 Finishes photos on AAC 8.4 Roof 8.5 Electrical/ Plumping 8.6 Fixing on AAC material 8.7 Consumables use in erection & finishing works

8- FINISHES

8 FINISHES

8 FINISHES 8.1 Repairing 8.1-a AAC damaged panels which are structurally defective or which would impair strength of the panel or its structural integrity should be rejected, in addition any cropped slabs or lintels should be rejected and replaced with new panels.

8.1-b Slight damages such as chipping, cracks, holes and conduit openings in the panels surfaces or the edges are normal and can be repaired as follows:-

1. Deep holes or deep conduit openings can be filling with ordinary cement mortar mixed with bound agent. Then paste fiberglass on the repaired surfaces Show Fig. No.1 2. Shallow damages or small openings can be filling with PAC glue mortar directly.

8.2 Painting on AAC Panels 8.2-a Wall Panels AAC PAC Panels do not need plastering works so finishes work can be started immediately after closure of all the openings and after repairing all the damages.

Procedure for painting on PAC walls as follow:1.

Clean the surface and remove all loose and dirty material.

2. Make sanding complete surfaces by sand papers or sand machine, it should be carefully done as these is very important step to get a good finishes on AAC surfaces.

3. Clean the surfaces by water and remove the excess dust or powder.

4. Use the bounding agent to tape the fiber glass on the panel joints and on the openings which are closed or repaired by mortar.

5. Apply primer coat on the surface.

8- FINISHES

6. Apply 2 coats of putty layers on the surface.

7. Apply the last finishing layer by choice paints or any designed textures.

60

Glue 3cm

Cement Mortar

B A

Fig No.1

8.2-b Ceiling V-grove ceiling can be finished by spray paints directly but non V-grove should follow the steps same as AAC wall panels painting procedures in 8.2-a.

8.3 Finishes photos on AAC

8- FINISHES

AAC material can receive any finishing material.

61

8.4 Roof PAC roofs slabs need to make water proof; the following section shows the ideal layer finishes on top of PAC roof slabs

ROOF FINISH LAYERS SECTION

8.5 Electrical/ Plumping

8- FINISHES

Electrical/ Plumping conduits are cut by hummer or by cutting machine like Makita or equivalent.

62

8.6 Fixing on AAC material The bolt with plastic plug recommended for fixing on AAC materials or by AAC nails.

AAC nails

Recomended anchores (Fisher, Hilti, Thorsman, Tox VLF, Universal, .... etc )

Screw Length

1

2

3

5

4

7

6 Anchor Length Element

Ideal installation steps by fisher anchors

Type

Designation

Permissible Tension

Permissible Shear

Cut nails

100 mm long

10 kg

25 kg

125 mm long

12 kg

35 kg

150 mm long

18 kg

40 kg

HGN 8

30 kg

35 kg

HGN 10

50 kg

60 kg

HGN 12

65 kg

70 kg

HGN 14

80 kg

80 kg

S 10

18 kg

40 kg

S 10 H 90

40 kg

80 kg

S14

50 kg

100 kg

S 16

60 kg

120 kg

Hilti

Fisher

8- FINISHES

Permissible loads of some suitable fixing to AAC:-

63

8.6 Fixing on AAC Materials 8.6-A Aluminum door/ window fixing on AAC

8- FINISHES



64

8.6-B Wooden door fixing on AAC

8.6-C Pipe fixing above AAC wall

8.6-D Wisher fixing

8.6-E Tile fixing by tile glue By ordinary tile glue using.

8.6-F Marble fixing

SECTION

ELEVATION

PRESPECTIVE

8.7 Consumables use in erection & finishing works.

8.7-B PAC MORTAR: For Block masonry without cement mortar Repair damaged panels, filling openings & conduct.

8.7-C Bounding agent: Added to cement mortar for masonary or plastering.

Paste fiber glass.

8- FINISHES

8.7-A PAC GLUE: For Panel Fixing

Bounding Agent 65

9 OUR PROJECTS

9- OUR PROJECTS

9.1 Maskan Arabia Project 9.2 Al Dar Project 9.3 Other Projects

9- OUR PROJECTS

9 OUR PROJECTS

68

Project

Client

Contractor

Consultant

Year

1

Al Zenia Tower

Al DAr

Al Dar Laing O'Rouke

Turner

2009

2

Burj Al Yaqut

Rasyat Real State

Belbadi

Hanouver

2009

3

Al Reef Villas

Manazel

Fibrex

Crang & Boake

2009

4

Park Hyatt Hotel

AHDN/TDIC

Alec

Ehaf

2010

5

Khalifa Port Industrial Zone

Abu Dhabi ports company

Al Masaood Bergum

Dutco

2010

6

Mubarak Juma Tower

Mubarak Juma Al Khaily

Al Fusaifesa

Tameer

2010

7

Yazeem Villas

Private Villa

Al Yazeem constructions

Tameer

2010

8

Development Projects in Sir Bani Yas

TDIC

ASTCC-LLC

Atkins

2010

9

Al Falh community

Al Dar

SPK constructions

Turner

2010

United Printing 10 Press Labor Accommodation

United Printing Press

Alba Tech

Tameer

2011

11 64 Villas In Riyadh

Maskan Arabia

Maskan Arabia

Hatmia

2011

12 30 Individual Villas

Different Project and Locations

13 Export to GCC

Kuwait, Qatar,Oman and Iraq

69

9- OUR PROJECTS

9.1 Maskan Arabia Project in Riyadh

9- OUR PROJECTS

9.2 Al Dar Project

70

71

9- OUR PROJECTS

9.3 Other Projects

* This technical ESPAC catalogue prepared by technical & projects dept. manager, for any notes contact him on tamer@espac.com, or visit www.espac.com

Head Office Riyadh Tel. : 0096614628830 Tel. : 00966546060647 Fax. : 0096612930304 P.O. Box: 25507, Riyadh 11476 E-mail: info@espac.com Saudi Arabia

Our Branches Khobar Tel. : 0096638631111 Tel. : 00966546060651 Fax. : 0096638632222

UAE: Abu Dhabi Tel. : 00967125500011 Tel. : 009671501312423 Fax. : 00967125500033

Bahrain: Manama Tel. : 0097317214000 Fax. : 0097317214333 Web. : www.espacbh.com

Qatar Tel. : 0097433543113 Tel. : 0097470377588 Web. : www.pac-qa.com

Kuwait Tel. : 0096597828261 Tel. : 0096560777737 FAx. : 0096524330892

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a gre

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in build

Tel. : +9661 46 288 30 Fax : +9661 29 303 04 P.O Box 25507 Riyadh 11476 Saudi Arabia

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