formblock tech manual 2010 · colour and texture of units as specified by architect. ... 300mm...

The FormblockTechnical Manual

2010

FORMBLOCK MASONRY CODE - STANDARDS Applicable to FORMBLOCK

All components and installation shall comply with the Building Code of Australia (BCA) and therelevant Australian Standards, including AS 3700 and the Standards referred to therein.Unless noted otherwise, masonry units shall comply with AS 4455 and the followingrequirements:1. Dimensional Category 42. General purpose salt attack resistance grade – protected3. Minimum characteristic compressive strength – 15 MPA4. Units shall have a maximum permeability of 2mm / minute, and efflorescence potential of Nilor slight, and a characteristic modulus of rupture of 0.8 MPA5. Colour and texture of Units as specified by Architect.

All grout used for core filling to be 25 MPA with a slump spread of 550 mm

Prop walls where necessary to ensure stability. Retaining walls are to be cured for a minimum of oneweek prior to being back filled. Walls to remain propped during Backfilling. Waterproofing ofwalls to Architects specification.

All reinforcing is to be centrally located unless otherwise noted by the Engineer. All reinforcement tobe in accordance with the Engineers design and specification

Project Conditions1. Protection of Formblock : During construction, cover tops of walls, projections, columns and

sills with waterproof sheeting at the end of the day’s work. Coverpartially completed masonry when construction is not in progress. Extend cover a minimum of600mm down all faces and hold cover securely in place.

2. Do not apply uniform floor and roof loads for at least 12 hours and concentrated loads for atleast 3 days after building masonry walls or columns. Such loads shallbe suitably propped to minimize load on masonry until grout has fully cured as determined bythe Engineer.

3. Stain Prevention : Immediately remove grout seepage and other materials from the face of wallsand columns to prevent staining.i. Protect base of walls from rain-splashed mud by spreading coverings on ground and over wallface surfaces.ii. Protect walls, columns, sills, ledges and projections from debris dropping into cavity prior tocore filling.iii. Protect surfaces of window and doors as well as similar products from damage resultingfrom grout fill.iv. Turn scaffold boards near the masonry face on edge at the end of each day to prevent rainfrom splashing dirt onto completed masonry.

Formblock Masonry Units: (FMU’s)All Formblock Masonry Units are to be manufactured only by Manufacturers under License toFormblock. Strict quality control guidelines for block size, tolerances and characteristics are to bestrictly adhered to. Any defective masonry units delivered to site are to be set aside and returnedto the Manufacturer.

Shapes: Formblock Units provide for 6 shapes :-i. Standard block 400mm x 200mm x 200mm nominalii. Half block 200mm x 200mm x 200mm nominaliii. End block 400mm x 200mm x 200mm nominaliv Left hand block 400mm x 200mm x 200mm nominalv. Right hand block 400mm x 200mm x 200mm nominalvi. Uni-block 400mm x 200mm x 200mm nominal

Execution

Examine conditions with Installer present, for compliance with requirements for installationtolerances and other conditions affecting performance of work.i. For the record, prepare written report, endorsed by Installer, listing conditions detrimental toperformance of work.ii. Verify that foundations are within tolerances specified.iii. Verify that reinforcing dowels are properly placed to suit Formblock masonry units.iv. Layout walls in advance for accurate spacing of surface bond patterns with accuratelocations of openings. Movement-type joints, returns and offsets.Avoid using less-than-half-size units, particularly at corners, jambs and where possible, atother locations.v. Stopping and resuming work: Stop work by raking back units in each course from those incourse below: do not tooth.vi. Form up and grout fill spaces between masonry and built-in items unless otherwiseindicated on Architects detailing.vii. Inspectors: Owner will engage qualified independent Inspectors to perform inspections andprepare reports. Allow Inspectors access to scaffolding and work areas, as needed to performinspections.viii. Place grout fill only after inspectors have verified compliance of grout spaces and grades,sizes, and location of reinforcement.ix. Testing Agency: Owner will engage a qualified independent Testing and Inspection Agencyto perform field tests and inspections and prepare test reports. Payment of these services willbe made by the Owner. Retesting of materials failing to comply will be done at the Contractor’sexpense.x. Testing Frequency: One set of tests for each 460 sq. mtr. of wall or portion thereof.xi. Formblock Masonry Unit Test: For each type of unit provided, per AS 3600 - 2001. Sourcedocumentation from manufacturer as a minimum.xii. Grout Test (Compressive Strength): For each mix provided, per AS 3600 – 2001xiii. Pargeting and below ground Membranes: External masonry walls below ground levelshall be protected from rising damp causing stain and dampness to the wall. Only industryapproved methods of pargeting or membrane applications shall be used.

Waterproofing

Any single skin concrete masonry unit regardless of grout fill is not waterproof. Manyoptions are available for waterproofing external walls such as:a. Cavity wallb. Externally applied membrane.c. Combination of a. and b.

Additives that are mixed into the grout fill and block composition are only beneficial asa second line of defense to water penetration. As there are numerous products on themarket for such additives and external membranes that vary in colour range andtextures it is considered the responsibility of the Architect, Contractor or Specifierto determine which method of weatherproofing, suitable to the on-site projectconditions, that should be used.

Particular attention is required around openings to ensure that water penetration isprevented from getting into the joint between the masonry and the insert, e.g. Windowframes, door frame. Issues for consideration:-(i) Weatherproofing should be durable.(ii) Rebates in the form of treated timber or concrete are used.(iii) Water that penetrates through to the weather stop should be capable of drainingaway.(iv) Pressure equalization at the base of joinery should be provided.

Coordination of Trades

The General Contractor should note that it is necessary to coordinate all trades thatrequire in-wall product such as electrical conduit, plumbing and the like prior to corefilling the wall.

• Introduction:-

Formblock is a fast, easy to install, dry stack, concrete blockwall system that can provide significant savings in labourand construction times over traditional masonry blockwork. The system can also reduce costs associated withlintels, bond-beams, scaffold and plant hire, mortar mixes,waste and clean up costs. Overall, Formblock is a faster,more effective walling system.

Formblock walls are laid in a conventional stretcher bondpattern using a specially designed plastic bridge whichhelps locate the position of each block and holds thehorizontal and vertical steel reinforcing bars in the correctposition, ensuring correct cover is always maintained. Inaddition, vertical bars do not need to be tied to the starterbars, as the bridge locates them within a minimumallowable distance of each other. See BRANZ test reportsST0597-2 and 3.

It is important to understand that Formblock is a masonryunit not dissimilar to conventional masonry however itdoes not require mortar between the blocks. Until it isreinforced and core-filled it is not considered a structuralelement and therefore, like it’s conventional counterpart, itrequires engineering computations if it is to be used inload-bearing or retaining capacity.

The Formblock building system is the subject of intellectualproperty owned by Global Ryder Holdings Pty Ltdincluding patents, design rights, trademarks and copyrightproperty worldwide.

200 Series Formblock shapes:-

As the Formblock profile differs from standard masonry, inparticular when using corner blocks and the Uni-Block, thereinforcement placement will differ from the standard400mm grid set-out.

Standard Right hand

Half Uni-block

Left hand End block

16" nominal

8"no

min

al20

0mm

nom

inal

400mm nominal

• Step By Step Procedure:

Footing Set-up

Preferably the footing, or slab, needs to be as level as possible before commencing the block laying, as

conventional block work can compensate for any imperfections through the number of courses in thewall and by providing a near as possible level base it makes the initial base course of Formblock mucheasier to lay level and plumb.

Each Formblock measures 400mm x 200mm x 200mm nominal making it very easy to set out on the

construction site.

Step 1.

Lay the first course ofFormblocks on a bed ofconventional mortar ensuringthat the side face of the block isplumb and the top face level.Spend a little extra time on thefirst course to achieve thisresult. Each corner will consistof left hand and right handcorner blocks.

Step 2.

Insert the plastic Form Bridges acrossthe ends of the blocks. There are twotypes of plastic Form Bridge, thestandard bridge – black and thecorner bridge – red.

Step 3.

As with all block laying, ensure that allblocks are plumb and level

STARTER BARLAYOUT

100mm

300mm 200mm multiples of 200mm

300mm 200mm multiples of 200mm

100mm

The standard bridges, when inserted,have up-stands that form a key for thenext course, whilst the corner bridgessit flush with the top of the block.

This allows the course above, whichhas a center web, to lay directly acrossthe bridge without obstruction

41 mm

The plastic bridge also ensures that theverticalreinforcement splice bars do not have tobe tied to starter bars as they are spacedwithinthe minimum distance of each other.See Auckland University test results page 3Executive Summary and BRANZ testresults

• Step 4.Lay the required horizontal or lateral steel into the plastic Form Bridge.There are three lateral steel placement locations and one centre holefor the vertical steel within the bridge.

The structural engineer with specify the size and location of all reinforcingand nominate it’s position within the wall.

The reinforcement steel simply clips into the bridge and at the same timeallows the blocks align to with each other and will add strength to thewalleven before the wall is filled with concrete grout.

• Step 5.

Lay the next course of Formblocks in astretcher bond pattern on top of the previouscourse. Repeat steps two to five. To level orstraighten a Formblock wall, use a string lineand set it about 25mm above the last coursealong one face of the wall.

If there are any blocks leaning off this line,insert a plastic wedge between the courses ofblocks to adjust the block back to the line.

(Breakaway wedges are found in the center ofeach bridge).

• Step 6.

Once the wall is set at the required height, check thatthe wall is plumb and in alignment. Brace the walladequately to ensure stability as determined by theengineer or general contractor.

Insert the vertical steel reinforcing into the requiredchambers and in accordance with the structuralengineers specification.

Ensure that the vertical steel is fully inserted to thedepth required by the engineer. An indication that thishas been achieved is by bouncing the steel off theconcrete footing or slab resulting in a ‘pinging’ sound,alternatively by measurement of steel to wall height.The wall can now be core-filled.

• Cut Blocks

When reducing wall dimensions, simply cut therequired block to length and bond as illustrated.Place the plastic bridges into the insets of the blockwherever possible to help the bonding. The steelreinforcement is then placed into the locatorsprovided in the bridges, locking the blocks in placelaterally.

Note: Always place a cut Formblock in the middleof the wall – never use a cut Formblock as the lastblock. Box and brace over this area. If the cut blockonly has one center web left, inspect the block tomake sure that the remaining web is in good

condition.

A: B:

D:C:

Core-filling Formblocks

So as to reduce the risk of hydrostatic pressure,pour slowly and carefully over steel and/or thecenter web of the block to slow the flow of grout.

The wall will automatically fill diagonally asshown in the diagram. Allow grout to fill to thetop block before moving the pump nozzle. Thenslowly move the nozzle along the wall allowingremaining parts of the wall to diagonally fill.

There will be no need to vibrate. Gently rod asyou go, to settle the pour and to eliminate voidswithin the wall.

When rodding do not remove rod in one motion,‘rod’ as you gently remove.

As shown in the BRANZ testresult ST0597-2, the full widthof the Formblock can be usedin calculations less anyexternal chamfers as shown inthis drawing.

595

nominal95

5

400cut

400 400 400to size

Concrete Core-fill

Core-filling Formblocks requires a flowable grout with a maximum aggregate or stone of 6 to 8mm andneeds to be sufficiently fluid so as to fill all the voids. It will then bond together the adjacent masonry units,to bond steel reinforcement into the cores, and to unify the wall into a single monolithic structure. SeeAuckland University test results page 5.

Use conventional core-fill mixcommon to the area with thefollowing requirements:-

a. Mix strength to structural engineers specification i.e.: 20MPA

b. Plasticiser as specified by engineer to achievecontinuous smooth flow and spread. DO NOT keepadding water to achieve required spread.

c. Spread to be 600mm and maintained during the pour.The initial spread test is to be done on site prior to pourand check spread midway through each pour.

d. Maximum aggregate size to be 6 to 8mm for 200 and150 block series

• Concrete core-fill

• As weather conditions effect the life span of concrete before it begins to set, consideration must begiven to the mix to ensure that the plasticity and fluency of the core-fill is constant. It is recommendedthat the blocks walls are thoroughly watered down prior to core-filling, along with the concrete pumpand hoses.

• There is no need to use mechanical vibrators. It’s only necessary to gently rod the mix whilst pouringto ensure that the core-fill flows adequately into all voids within the blocks. A slow bleed will be seenbetween the blocks as the wall fills.

• Testing has shown that Formblocks can be poured at a height of 3 meter. However, all care must betaken when doing so. Blocks must be inspected for damage/cracks, prior to laying and brace the walladequately. We recommend pouring at the industry standard.

Using Formblock in columns and piers

100

200

400 300 100

9

400300100

400 300 100

9

400300100

100

200

100

100

400

400

100

100 100

100

300 100

300

100

300

100

300100 300 100

300

100

300

100

300

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400300

100

400 300 200

100

200

100 200

400300

100

400

100300400

100

300

400

400

200

300

400

expa

nsio

njo

int

expa

nsio

njo

int

300100

100

300

100

400 300 100

9

400 300 200

100

200

100 200

100300400

100

300

400

COLUMN TYPE 22nd course

COLUMN TYPE 21st course

PIER TYPE 12nd course

PIER TYPE 11st course





CORNER2nd course

CORNER1st course

COLUMN TYPE 12nd course

COLUMN TYPE 11st course

400

400

100

100

400

200

300

300

200

400

400

400 200 300

uni-b

lock

Cut open endto uni-block andpartial open endas per fig.1

fig.1

400 200 300

Cut open endto uni-block andpartial open endas per fig. 2

uni-b

lock

fig. 2

uni-b

lock

uni-b

lock

4"8"

4"

100

EXPANSION JOINT

300 1009

neoprene gasketbacking rodsealant








neoprene gasket

backing rod

sealant

300100

neoprene gasket

backing rod

sealant

400300100

400 300 100

9

400300100

100

300

100

100

800

200

900

1300

2200

3000

WINDOW DETAILOPTION - 1

SECTION

Concrete slab as perEngineers design.

HEAD DETAIL

SILL DETAIL

800

200


SECTION


HEAD DETAIL

SILL DETAIL

1300

900

2200

3000

win

dow

open

ing

varie

s

cutb

lock

tosu

itsi

llhe

ight

cutb

lock

tosu

itsi

llhe

ight

200 x 50mm timberboxing to supportlintel,braced asrequired.

150mm wide formplyfixed to timber head

Reinforce and corefill to Engineers detail.


Remove boxingand secure timberwindow bucks.


to suit sillheight

cut blocks



ELEVATION

Condition where only the sill requires cutting

Invert lintel blocks toenable horizontal steelto be positioned at bottom

win

dow

open

ing

varie

s

OPTION - 1

LINTEL PROCEEDURE

7'-7

"

125

200

1375

900

2300

3000

600

125

200


SECTION


HEAD DETAIL

SILL DETAIL

1375

900

2300

3000


SECTION


HEAD DETAIL

SILL DETAIL

win

dow

open

ing

varie

s

cutb

lock

tosu

itsi

llhe

ight

cutb

lock

tosu

itsi

llhe

ight





Remove boxingand secure timberwindow bucks.


to suit sillheight

cut blocks



ELEVATION

Condition where both sill and head require cutting

600Use 1/2 block turned

end up where lintelrequires cutting.

This condition wouldapply where windowhead is not on blockcoursing.

Use 1/2 block turnedend up where lintelrequires cutting.

At each end use standard block cut in halfto allow for steel and core fill to flow through

win

dow

open

ing

varie

s

OPTION - 2

LINTEL PROCEEDURE

SUMMARY OF FORMBLOCK INTERNATIONAL TEST REPORTS:

FULL DETAIL COPIES OF THESE REPORTS ARE AVAILABLE UPON REQUEST ORFROM WEB SITE www.formblock.net

• Auckland University Test ResultsIn plane shear – It was noted that “ NZ4230:2004; BS 5628-2:2004; AS3700:2001; and US masonry standardMSJC (2005), testing indicated that the Formblock wall system exhibited excellent displacement ductilitycapacity, substantially in excess of the maximum value of µ = 4 that is stipulated in NZS 4230:2004. Nosignificant slip was observed in the non-contact lap splices at the base of the wall, and the use of Form-fillconcrete was found to ensure masonry compression strengths well in excess of the values specified in NZS4230:2004. Overall the Formblock concrete masonry system performed in a manner compliant with NZS4230:2004, BS5628-2:2005; AS3700:2001 and US masonry standard MSJC (2005) ”.

•BRANZ Test Result ST0597-2It is considered acceptable to assume that the outside edge of the horizontal contact area ( i.e. 88mm from thecenter of the block – see drawing on following page ) may be taken as the outer edge of the compression stressblock and the depth of the stress block may be calculated using normal reinforced concrete masonry ultimatelimit state design principles, where the compressive strength of the masonry is assumed it be 15MPa sincethere is no mortar present to limit the design stress, as in NZS 4230:2004.

• BRANZ Test Result ST0597-3“Non-contact splice bars between vertical bars and the corresponding starter bars are acceptable withFormblock walls, given that they are constrained within the plastic bridges used to maintain alignment of theblocks. 12mm starter bars must lap the main vertical steel over a minimum length of 400mm. For walls thatspan vertically under face loading, the horizontal bars must be placed alternately on either side of the verticalbars to maintain the vertical bar at a position near the center of the wall. Because the walls are dry stacked,there are no mortar droppings and because the bars are non-contact spliced, there is no need to provide clean-out/access ports at the bottom of the walls.”

• CSIRO Fire TestPerformance observed in respect of the following AS1530:Part 4-1997 criteria: Formblock 200mm wall

Structural adequacy - No failure 240 minutesIntegrity - No failure 240 minutesInsulation - No failure 240 minutesPerformance observed in respect of the following AS1530:Part 4-1997 criteria: Formblock 150mm wallStructural adequacy - No failure 241 minutesIntegrity - No failure 241 minutesInsulation - 112 minutes

CSIRO Sound TestThe measurement was performed in compliance with the requirements of AS1191-2002 and recorded a STCrating of 52 for the 150mm corefill Formblock wall.

Exploded view of Formblock duringconstruction

.

.

Grout fillAll cores

Horizontal and Vertical steel laidto Engineers requirements

Vertical reinforcing to lapalong side of starter bars

Vertical starter barsformed into footing

No need forCleanout blocks

No need to tie starter barsas testing showed that aslong as they are inside thePlastic bridge then they arewithin allowable distancethere will be no slip.

Lap

toE

ngin

eers

Spe

cific

atio

n

Formblock wall poured and lifted, demonstrating the ductility of the system.

This demonstration panel is one of 6 built in Florida showing how a 1.5tonnepanel can hang from a Formblock lintel. The sides of the display are cut toshow how well the grout penetrates throughout the wall.

Formblock used as lintels above door and windowopenings. This eliminates expensive boxing and pouredcolumns and beams.

Formblock maintains a spotless work site.

Formblock used in Uptown Motorcity as supporting columns and piers. By usingFormblock, the builder - Al Futtaim Carillion - was able to reduce their expensiveon site labour from some 500 men to only 50 and also bought the site tocompletion well ahead of schedule.

Formblock was able to be laid to suit the uniquearchitectural circular design for Uptown Motorcity.

Training labourers ready for Uptown Motorcity site, UAE

Using the Formblock system, enabled the developer to reduce onsite labour from 500 men to 50

Formblock Training Site in Dubai

Formblock Training Site in Dubai

Formblock On Uptown Motorcity Site in Dubai

Formblock used as a services culvert for aprison in New Zealand

Formblock supporting the M7 freeway – Sydney,Australia. The walls are 200mm Formblock, retainingfull 12 meters.

The trompe l’oeil was a pleasant addition tothe walls but was not part of the contract.

Formblock in civil contracts

More Formblock completed apartment buildings

formblock tech manual 2010 · colour and texture of units as specified by architect. ... 300mm...

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