Table of Contents
1. Background 2. ACICO Aerated Concrete: Better than natural stone 3. Production 4. ACICO Roof Slabs Product and Application 5. Planning 6. Design Criteria 7. Erection 8. Details 9. Properties and Advantages Thermal insulation Heat storage and cooling Diffusion behaviour Sound insulation Fire resistance
Background
1
The Kuwait plant is an independent, selfreliant enterprise. These independence enherits a high degree of flexibility, to adjust the products the local and foreign markets and for use the main advantages of the ACICO products as: Best thermal insulation of all solid building materials. Light weight for transport, handling and structures. Ideal for fire proofing. Adequate sound insulation. Big sizes of the reinforced products. Independent of gravel resources, - the production needs only sand, cement and lime.
Autoclaved Aerated Concrete, AAC, is a type of light weight concrete developed in the twentieth of last century. In 1943, Builder Josef ACICO founded the first factory for reinforced AAC products in Germany producing panels and slabs. During 1945 to 1960, the demand of this superior building material grew dramatically. Additional plants were built in Germany and the first step abroad was laid down in Japan in 1967. The production of ACICO A.A.C. under its license soon followed world wide. With more than 45 licensed plants all over the world, ACICO is a leading producer of A.A.C. blocks and reinforced material. Especially in development and application of reinforced products the company has superb knowledge and experiences. Since the beginning of 1994, Aerated Concrete Industries Co. - ACICO - has been producing ACICO products in a new plant in Kuwait which is equipped with the most modern production technology.
Production
2. Expanding:
The aluminium paste reacts chemically with the other raw materials. Hydrogen gas forms. The cake expands and attains its porous structure the precondition for the exceptional thermal insulation, good acoustic properties and easy workability.
3. Cutting:
After the expansion process is completed the malleable cake is cut into the desired end product form, i.e. blocks or slabs, very precisely by sophisticated cutting machines with maximum tolerance of +/- 1.5 mm.
4. Steam curing:
Following the cutting process the cut cake is steam cured under a pressure of 12 bar and temperature of only 180C. After steam curing the construction material and products are ready for delivery to sites.
Production
Reinforcing
Cutting to Length
Raw Materials
Sand Grinding Mill
Lime
Ground
Sand
Cement
Expanding Agent
Metering
Water
Mixing
Assembly
Casting
Expanding
Cutting
Nonvisible Joint
Visible Joint
L th. W
Length: Up to 600 cm Width: 62.5 cm. (min. 25 cm) Thickness: 10, 12.5, 15, 17.5, 20, 25, 30 cm Special Formats can be also produced on request.
Planning
Dimensioning must be done in accordance with the static calculations. Generally, slab thickness depends on the span and design load but improving thermal insulation, sound insulation or even for greater fire resistance, it is recommended to increase the statically required minimum thicknesses. For design and construction see the tables and details in this manual. The technical office of ACICO gives advise and more informations when required. After contract structural design, roof slab drawings and parts list for production will be prepared in ACICO technical office.
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Design Criteria
6.1 Introduction
ACICO roof slabs are applied for both, flat roofs and sloped roofs. In case of sloped roofs anchoring with the support is required. The basis of analysis and design is the German code DIN 4223. Design of reinforced A.A.C. products is approximately similar to conventional reinforced concrete. The differences are mainly in compressive strength and anchoring the reinforcement. Calculation sheets is prepared in accordance with design tables by ACICO technical office. Spans, thicknesses and loads are shown in the following tables:
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Design Criteria
6.3 Max. Spans and Moments
Roof Slabs GB 3.3 Slab Self IMPOSED LOAD (KN/m2) M max. Thick100 150 200 250 300 350 400 450 500 525 550 575 600 load ness mm kNm/m 125 100 MAX. SPANS (m) kN/m2 090 072 254 327 302 273 251 234 219 207 199 190
200 1146 600 558 516 482 454 431 410 400 380 370 364 358 352 144
175
150
864 554 501 461 429 403 381 363 350 335
618 491 438 401 372 348 329 312 303 290
126
108
250 1842 600 600 600 585 554 527 504 483 456 456 449 441 434 180 300 2694 600 600 600 600 600 600 592 565 548 538 530 521 513 216
Roof Slabs GB 4.4 IMPOSED LOAD (KN/m2) Self Slab M max. Thick100 150 200 250 300 350 400 450 500 525 550 575 600 load ness mm kNm/m 100 125 150 MAX. SPANS (m) kN/m2 0.84 090
3.62 3.50 3.50 3.19 2.95 2.75 2.58 2.45 5.96 4.48 4.32 3.95 3.66 3.43 3.24 3.7 2.94 2.81
8.83 5.46 5.06 4.66 4.33 4.07 3.85 3.66 3.50 3.36 3.39 3.23 3.17 3.12 1.26
175 12.35 5.90 5.77 5.34 4.99 4.70 4.46 4.25 4.07 3.91 3.83 3.76 3.70 3.64 1.47 200 16.37 6.00 5.90 5.90 5.60 5.29 5.03 4.80 4.60 4.43 4.35 4.27 4.20 4.1 1.68 250 26.32 600 600 600 6.00 6.00 6.00 5.88 5.65 5.45 5.35 5.26 5.18 5.10 10.2 300 38.45 600 600 600 600 600 600 6.00 5.90 5.90 5.90 5.90 5.90 5.90 2.52
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Design Criteria
6.4 Reinforcement
Standard slabs are reinforced with double steel mesh. The top mesh is mainly designed for transport and deflection. The steel meshes are welded and corrosion-protected in ACICO factory, individually for each slab-position. Reinforcement cover is approx. 10 mm.
6.6 Supports
The slabs are usually supported directly on masonry, concrete beams or steel beams, without mortar. Only for non plane support surface cement mortar is applied for adjusting the top surface. The min. resting length on the support is 7.5 cm for masonry and concrete supports and 5 cm for steel beams.
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Erection
7.1 General
After production, ACICO ROOF SLABS are packed and loaded on trucks; then delivered to site. SLABS should be carefully handled during transport, storing and erection. The damages can be easily avoided. A mobile or a minitower crane is used for both unloading and lifting slabs in site. The maximum weight for single roof slab with dimensions 600 x 62.5 x 25 cm is approximately 700 kg. While storing, if turning of ACICO slabs are required, use an old big tire to overturn them. If visible joints are required, chamfers are prepared using chamfer-plain before lifting the slabs. It is easier and controlled.
The top surfaces of all types of supports must be checked and adjusted in a plane horizontal level by cement mortar if needed, before starting the erection. Whenever cement mortar is laid, minimum 24 hours is required before laying roof slabs. Safety instructions for site works must be generally followed and controlled by site engineers in charge. One of them is using the safety chain across clamp during lifting the slabs. Also, it is not permitted for labors or persons to be under the crane boom path.
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Erection
7.3 Cutting and Repairing
Generally, when cutting of a slab is required, it is already done in the factory in accordance with the parts list for the specific delivery order. Sometimes, it is required to cut a slab in other dimensions in site after delivery. Then a grinder machine is the suitable tool for this job. Also holes are allowed of maximum 20 cm to cut slabs as shown in figures. If other cutting shapes in different dimensions is required, contact ACICO technical office. For repairing damaged slabs, a special ready-mix repair mortar is produced by ACICO plant to be used for repairing. Instructions and applications are illustrated on the repair mortar bags. But never repair cracked or damaged slab whenever structural risk is there.
20
20
40
variable Length
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Details
Supports
7.5
7.5
7.5
7.5
Masonry support
10
25
External wall
20
Internal wall
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Details
Ring beam on concrete structure
2 12 2 12
10
External wall
5
Internal wall
7.5
10
U shaped bar 4
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Details
Roof coverings and parapet details
Anchor Bars for ParapetColumns Styropor Strip Th. Min. 3 cm Membrane Tiles in Mortar and Sand Foam Concrete
Infill Blockwork
3 cm Space to avoid them exp. pressure Slope cut ACICO block Membrane Tiles in Mortar and Sand Screed Foam Concrete
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Details
Sloped Roof Supported on internal Bearing Masonry, and anchored by Ring beam.
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Details
Finishing of Ceilings
A- Nonvisible Joints
Finishing by ACICO ready mix plaster and paint. (The slab-joints are covered with fiber or wire mesh strips.)
B- Visible Joints
C- False Ceilings
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Details
Installation of Conduits and AC. - Ducts For finishing by plaster:
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Conduits are fixed before foam concrete. (Holes for light points by drill.)
Light Point
Fixing AC-ducts:
By threaded bolts. (Holes by drill.)
Or by Fischer plug GB 10. (Plug-holes by hammering and bolts.) perm. load 30 kg/plug.
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Details
ACICO Loft Slabs
Concrete skeleton
Concrete slabs
False ceiling Room for AC Equipments etc. ACICO Partitions ACICO Lintel ACICO Lintel ACICO slabs th. 10 or 12.5 cm supported on int. walls.
Window
Door
Wall tiles fixed by cement glue directly on ACICO walls. For connection of water proofing use thinner block in the first course.
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Details
Steel Hanger for openning 62.5 cm
8
Flat steel 80 x 5 mm 62.5 cm L 100 x 7 mm 20
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125 cm
20
24
Strength Thermal Thickness Resistivity category Conductivity cm 1/8 l W/mK m2 K/W G.B. 3.3 0.14 G.B. 4.4 0.16 10 12.5 15 17.5 20 25 30 10 12.5 15 17.5 20 25 30 0.71 0.89 1.07 1.25 1.43 1.79 2.14 0.63 0.78 0.94 1.09 1.25 1.56 1.88
Heat Transmission Coefficient k W / (m2.K) 1.13 0.94 0.80 0.70 0.62 0.51 0.43 1.25 1.05 0.90 0.79 0.70 0.58 0.49
Some typical roof details to achieve the regulations of the Ministry of Electricity and Water K 0.4 w/ (m2 k) or u 0.07 Btu/ ft2 h F
Tiles in Mortar and sand screeds and membrane Membrane Screed
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60 dB
Tiles in Mortar and sand screeds and membrane
50 dB
Membrane Screed
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A/ Without Plaster
For F30, For F60, For F90, For F120, u = 10 mm u = 20 mm u = 30 mm u = 40 mm
th
u
B/ With Plaster
u = 10 mm u = 22 mm u = 34 mm u = 42 mm*
th u
* In this case Plaster with Wire Mesh Note: The reinforcement for concrete slabs need more covering, because in case of fire, ACICO material has better fire resistance than concret.
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