field installation instructions-102802 - r2.ppt
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FIELD
INSTALLATIONINSTRUCTIONSJANUARY 2004
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BABB TECHNOLOGIES, INC.Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
Field Installation Instructions Rev. 1-07-2004
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
Tools Recommended For Installation 12
Installing Horizontal Wall Panels Steps 1-11 13
Points To Check 1-5 - Horizontal AAC Wall Panels 17
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
TABLE OF CONTENTS
AAC MASONRY PRODUCTS:I
HORIZONTAL AAC WALL PANELSII
PRECAST FLOOR PANELSIII
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BABB TECHNOLOGIES, INC.Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
Field Installation Instructions Rev. 1-07-2004
Material Handling Procedures
General:
In general, all construction products are susceptible to minor damage if mishandled. Lesshandling 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 compounddeveloped 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.
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AAC MASONRY PRODUCTS:I
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BABB TECHNOLOGIES, INC.Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
Field Installation Instructions Rev. 1-07-2004
AAC BlockThere are a full range of tools that are specially
designed to assist the block layer in installing AAC
masonry products and increase productivity at thejob site.
Tools Recommended For Installation
AAC JumboBlock
Additional tools required for installing AAC
JumboMasonry Units.
AAC masonry installation will also require the
following standard masonry tools.
Electric Jumbo Bandsaw Electric Minicrane
Hand Saw
Rasp
Electric Bandsaw
Notched Trowel
Margin Trowel
Small Hand Brush
Builders Level
Sanding Float
4 Level
String Line
Rubber Mallet
Low Speed Drill with Mixing Paddle
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BABB TECHNOLOGIES, INC.Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
Field Installation Instructions Rev. 1-07-2004
Leveling Course
Step 1 - Layout wall lines.Lay out wall lines building slab by control lines.
Step 2 - Start the leveling bed.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.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.
Step 4 - Mix thin-bed mortar.Mix approved AAC thin-bed mortar in a cleanmixing container (5 gallon bucket or pail) per
manufacturers 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.
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BABB TECHNOLOGIES, INC.Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
Field Installation Instructions Rev. 1-07-2004
Leveling Course
Step 5 - Set second corner block.Set the second corner block adding thin-bed
mortar to the head joint with the notched trowel.
Step 6 - Repeat for additional corners.Repeat subsequent steps for each corner using a
builders level to maintain an equal elevation.
Triple check each lead corner in all three planes.
Step 7 - Fill-in complete leveling
course.After building lead corners, pull a string between
corners to complete the leveling course. Sand-
cement 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
COURSE UNTIL LEVELING COURSE
HAS SET SUFFICIENTLY.
STOP
DO NOT TOOTH
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BABB TECHNOLOGIES, INC.Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
Field Installation Instructions Rev. 1-07-2004
Typical Coursing
DO NOT USE SAND-CEMENT
MORTAR FOR COURSES OTHERTHAN THE LEVELING COURSE.
Step 2 - Clean bed joint surface.With a brush, sweep off all dust and loose
particles to insure adhesion of thin-bed mortar.
Step 1 - Mix thin-bed mortar.Mix thin-bed mortar.
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.
Step 3 - Apply thin-bed mortar to head
and bed joints.Using a clean, notched trowel the same width as the
block spread thin-bed mortar up the head joint of theadjoining 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 blocks
height (whichever is greater).
STOP
DO NOT TOOTH
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BABB TECHNOLOGIES, INC.Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
Field Installation Instructions Rev. 1-07-2004
Typical Coursing
Step 6 - Rasp as needed.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.
Step 7 - Install lintels as required.Install lintels with a minimum 8 bearing (overlap)
where required.
Step 5 - Tap the end of the block.Tap the end of the block to insure a full surfacecoverage 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.
Step 4 - Set block.Pick up each block and move it as close to thehead 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.
Joints should
maintain a
thickness of
1/16 or 1/8.
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BABB TECHNOLOGIES, INC.Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
Field Installation Instructions Rev. 1-07-2004
Points To Check
Point 1Leveling course must be level and plumb. Do not proceed to subsequentcourses until leveling course has set sufficiently.
Point 2Blocks must be installed in a running bond with a minimum 4 bearing (overlap)
or 40% of the blocks height (whichever is greater). Lintels must be installed
with a minimum 8 bearing (overlap).
Point 3All head and bed joints must be solid with approved
AAC thin-bed mortar for full adhesion. Do not tooth.
DO NOT TOOTH
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BABB TECHNOLOGIES, INC.Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
Field Installation Instructions Rev. 1-07-2004
AAC installation will also require the following
standard industry tools.
There are a full range of tools that are specially
designed to assist in installing wall panels and
increase productivity at the job site.
Slings
Quick Cut Saw
Rasp
Chamfering Tool
Grinder/Sander or
Electric Cut-Off Saw
Steel Bar Clamp
Margin Trowel
Small Hand Brush
Builders Level
Rubber Float
4 Level
Chalk Box/String Line
Pinch Bar
Wall Panel Lifting Gear
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HORIZONTAL AAC WALL PANELSII
Tools Recommended For Installation
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BABB TECHNOLOGIES, INC.Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
Field Installation Instructions Rev. 1-07-2004
Installing Panels
Step 2 - Unload bundles.Unload the bundles of panels in a proper manner
using approved unloading gear.
Eliminate excessive handling by storing panels
nearest to where they will be installed.
Step 1 - Check layout.Check panel layout of approved AAC shop
drawings and deliver panels to job site
accordingly.
Protect the panels from rain and water
saturation by leaving them on pallets
and away from standing water.
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HORIZONTAL AAC WALL PANELSII
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BABB TECHNOLOGIES, INC.Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
Field Installation Instructions Rev. 1-07-2004
Installing Panels
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 4 - Place first panel.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 ofthe 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.
Step 3 - Check plumbness of column line.Check column line layout and plumbness. Varify layout
is within industry standards. Using a level and transit,
establish benchmark elevators onto the columns that willact as a control line for setting the first AAC panels.
Alert General Contractor
to column line problems and
correct before proceeding.
Step 6 - Notch each end of the panel.Notch ends of each panel with grinder/saw to receive anchors.
STOP
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HORIZONTAL AAC WALL PANELSII
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BABB TECHNOLOGIES, INC.Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
Field Installation Instructions Rev. 1-07-2004
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.
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HORIZONTAL AAC WALL PANELSII
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BABB TECHNOLOGIES, INC.Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
Field Installation Instructions Rev. 1-07-2004
Points To Check
Point 1
Supporting columns must be plumb, level and within linear building linetolerances.
Point 2Protect the panels from rain and water saturation
by leaving them on pallets and away from standing water.
Point 3Set panels with tongue side up and follow
specifications and shop drawings for
placement of adhesive and joint filler.
Point 4Panel(s) must lay flush against face of column.
Point 5In 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.
AAC horizontal
panels
Acrylic
coating
2 beads of
adhesive
Fill joint
with
joint filler
Correct installation
of bowed panels
Incorrect installation
of bowed panels
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PRECAST WALL PANELSIII
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BABB TECHNOLOGIES, INC.Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
Field Installation Instructions Rev. 1-07-2004
Slings/ Ropes
Quick Cut Saw
Rasp
Hatchet Hammer
Chamfering Tool
Margin Trowel
Small Hand Brush
Builders Level
Rubber Float
4 Level
Chalk Box/String Line
Pinch Bar
Lifting
Fork
Panel Turners
Floor Panel Lifting Gear
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PRECAST FLOOR PANELSIII
Tools Recommended For Installation
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BABB TECHNOLOGIES, INC.Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
Field Installation Instructions Rev. 1-07-2004
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).
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BABB TECHNOLOGIES, INC.Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
Field Installation Instructions Rev. 1-07-2004
Filling Joints
Step 1 - Set screen block.Set minimum 2 screen block in thin-bed mortar
around exterior perimeter for formwork for all ringbeams according to detail drawings.
Step 2 - Place reinforcement steel.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.
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PRECAST FLOOR PANELSIII
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BABB TECHNOLOGIES, INC.Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
Field Installation Instructions Rev. 1-07-2004
Panel Penetration Guidelines
PANELS WITH HOLES MUST BE DESIGNED
TO HAVE SUFFICIENT REINFORCEMENT
Less than or
equal to 6
INCORRECT!DO NOT PENETRATE THE PANEL
ACROSS ITS WIDTH MORE THAN
ONCE WITH HOLES GREATER THAN
OR EQUAL TO 6.
Opening may not
exceed 25% of
panel width
Less than or equal to25% of panel width
2 - 0
typical
panel
INCORRECT METHOD CORRECT METHOD
PLAN VIEWS
AAC floor panel
STOP
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PRECAST FLOOR PANELSIII
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BABB TECHNOLOGIES, INC.Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
Field Installation Instructions Rev. 1-07-2004
Points To Check
Point 1Supporting walls must be level.
Point 2Minimum bearing as shown in detail drawings must be maintained.
Point 3Concrete poured into joints must completely cover all reinforcement.
Point 4Do 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.
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BABB TECHNOLOGIES, INC.Phone: (706) 965-4587
Fax: (706) 965-4597
website: www.SafeCrete.com
Field Installation Instructions Rev. 1-07-2004
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.
Step 2 - Top of floor panels.DO NOT ROUT the topside of panels.
Place conduit in the panel joints.
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Points To Check
Point 1Do not rout horizontally less than 24 from the top of load bearing walls.
Point 2Do not rout horizontally greater than 1/3 of the total wall thickness.
A + B < 1/3 of total thickness
Point 3Do not rout back-to-back wall channels. Offset channels at least 12.
PRECAST FLOOR PANELSIII