stop build ing and hardware - king of … technical manual final sp.pdf · stop build ing and...

STOP BUILDING AND HARDWARE

Suppliers of: (Ecol-One Mega Range (AAC))

Ecol-Mega Panels (Autoclave Aerated Concrete Panels), Ecol-Mega Facade Systems, Ecol-Mega Blocks, Tsimento Blue-Board, Tsimento Fibre Cement Sheets, Fasteners, Renders and Textures

� SUPERIOR PRICE, SUPERIOR PRODUCT, SUPERIOR SERVICE�

� FINALLY, YOU HAVE A CHOICE!�

Eco-Friendly

HIA AD.indd 1 25/6/08 4:26:47 PM

ECOL-MEGA PANELSAutoclaved Aerated Concrete

Wall & Floor Technical Manual

ECOL-MEGA PANEL AAC October 2010 Page 1

ECOL-MEGA PANEL

Autoclaved Aerated Concrete

Wall & Floor Technical Manual

STOP BUILDING AND HARDWARE





Eco-Friendly

HIA AD.indd 1 25/6/08 4:26:47 PM


Contents

Preface

1. ECOL-MEGA PANEL Autoclaved Aerated Concrete

2. Structural Design

3. Fire Design

4. Acoustic Design

5. Thermal Design

6. Detailing

7. Construction Specification

Appendix A - Structural Design

Appendix B - Construction Specification


Preface ECOL-MEGA PANEL (AAC) ECOL-MEGA PANEL (AAC) (Autoclaved Aerated Concrete) is an innovated light-weight cement-based material, incorporating small uniformly distributed bubbles that result in its unique properties of lightless, high thermal resistance, workability and strength. ECOL-MEGA PANEL (AAC) is normally available as reinforced (AAC) wall or floor panels. This manual also covers the (AAC) blocks laid in thin-bed mortar. Technical Manual to be used by Professional Architects, Engineers and Builders This manual is intended for use by qualified and experienced architects, engineers and builders. The authors, publishers and distributors of this manual, sample specification and the associated drawings do not accept any responsibility for incorrect, inappropriate or incomplete use of this information. Using this Manual This manual, including design recommendations, sample specification and the associated drawings, are available in electronic format, with the express intention that designers will edit them to suit the particular requirements of specific construction projects. Basis of the Specification and Drawings This manual has been prepared in the context of the Building Code of Australia. Architects, engineers and builders should make themselves aware of any recent changes to these documents, to any Standards referred to therein, or to local variations or requirements. The authors, publishers and distributors of this specification and the associated drawings do not accept any responsibility for failure to do so. In the preparation of these specifications and drawings, the following convention has been adopted.

• All building design and construction must comply with the relevant Building Code of Australia and any relevant Standards referred to therein.

• If the construction is not covered by deemed-to-satisfy provisions in the Building Regulations or Standards, then it shall comply with the following document:

Aroni, S., de Groot, G.J., Robinson, M.J., Svanholm, G., & Wittman, F.H. (Editors), “RILEM Recommended Practice – Autoclaved Aerated Concrete – Properties, Testing and Design”.

• If the construction is not covered by either of the above, then it construction should comply with a balanced combination of current practice, engineering principles and supplier’s information.

Acknowledgements This manual has been prepared for One Stop Building and Hardware by Electronic Blueprint, based on engineering input by Quasar Management Services Pty Ltd. For further technical assistance, please contact www.electronicblueprint.com.au . Copyright & Licence © Quasar Management Services Pty Ltd. All rights are reserved. A licence for the unlimited use of this material is granted to One Stop Building and Hardware. Permission is also granted to Architects, Engineers and Builders to use this material in the preparation of specific designs, specification and contracts.


1. ECOL-MEGA PANEL Autoclaved Aerated Concrete Introduction ECOL-MEGA PANEL (AAC) (Autoclaved Aerated Concrete) may be used as the external or internal wall cladding panels for residential, commercial or industrial buildings. It may also be used for the flooring in some residential applications.

(AAC) consists of a combination of lime and/or cement combined with finely divided sand and other filer materials. This is cured under high pressure and temperature to provide a relatively strong, light-weight cellular structure, incorporating small uniformly distributed bubbles.

This structure results in the unique properties of lightless, high thermal resistance, workability and strength. ECOL-MEGA PANEL (AAC) is normally available as reinforced AAC wall and floor panels. This manual also covers the (AAC) blocks laid in thin-bed mortar.


Design Steps The design process is broadly as follows:

1. Determine the building use Building Class, as defined in the

Building Code of Australia.

2. Determine the structural support arrangements (concrete slabs, steel or timber frames and the like), together with the spacings and spans. Check the robustness limits of AS 3700.

3. Using the Building Code of Australia, determine the acoustic requirements (if any), and whether the ECOL-MEGA PANEL (AAC) wall panels, floor panels, or masonry, have sufficient sound attenuation. Consider whether this needs to be augmented.

4. Using the Building Code of Australia, determine the thermal insulation requirements (if any), and whether the ECOL-MEGA PANEL (AAC) wall panels, floor panels or masonry have sufficient thermal resistance. Consider whether this needs to be augmented.

5. Using the Building Code of Australia, determine the fire resistance requirements of structural adequacy, integrity and insulation (if any), and whether the ECOL-MEGA PANEL (AAC) wall panels, floor panels or masonry have sufficient fire resistance. For structural adequacy, the support locations, strength and stiffness must be considered.

6. Carry out structural design checks: • Determine the wind loads, using AS/NZS 1170.2 (or

AS 4055 for detached dwellings). Determine the earthquake loads, using AS 1170.4. Determine all other structural loads and loading combinations, using AS/NZS 1170.0, 1 and 3.

• Check the bending, shear, compression,

reinforcement-anchorage and connection strength for out-of-plane loads such as wind or earthquake on walls, or permanent and imposed loads on floors.

• Check the shear resistance and connection strength

for in-of-plane horizontal loads such as wind or earthquake on walls.

• Check the compressive capacity and resistance to

concentrated loads for gravity and other vertical loads on walls. Where appropriate, check connection strength.

7. Design and detail associated items, such as lintels, roof

anchorages, flashings and the like.

8. Prepare a comprehensive materials and construction specification.


2. Structural Design Scope This section covers the structural design of ECOL-MEGA PANEL (AAC) for compliance with the structural requirements of the Building Code of Australia. Loads ECOL-MEGA PANEL (AAC) walls and floors should be designed to withstand the loads set out in the Building Code of Australia and Standards, as listed below:

• AS/NZS 1170.0 Structural design actions Part 0: General principles • AS/NZS 1170.1 Structural design actions Part 1: Permanent, imposed and other actions • AS/NZS 1170.2 Structural design actions Part 2: Wind actions • AS/NZS 1170.3 Structural design actions Part 3: Snow and ice actions • AS 1170.4 Structural design actions Part 4: Earthquake actions in Australia • AS 4055 Wind loads for housing

Design and Construction Standards The Building Code of Australia provides the overall regulatory framework for the design and construction of buildings in Australia.

• ECOL-MEGA PANEL (AAC) as steel reinforced autoclaved aerated wall and floor panels are designed in accordance with the recommendations of “RILEM Recommended Practice – Autoclaved Aerated Concrete – Properties, Testing and Design”.

1 Because this system is

outside the scope of the most relevant Building Code of Australia referenced document, AS 3700, its use must be treated, under the Building Code of Australia, as an Alternative Solution.

• ECOL-MEGA PANEL (AAC), provided as autoclaved aerated blocks set in thin-bed adhesive

to form unreinforced walls, are designed in accordance with AS 3700-2001 Masonry Structures.

The design process outlined below, which has been adopted in this manual, is demonstrated in Appendix A. Capacity Reduction Factors Capacity reduction factors given in AS 3700 Table 4.1 are used in this manual for both walls and floors. This represents a degree of conservatism generally in excess of that in the other closely related standard, AS 3600 Concrete structures.

AAC Wall Resistance to Uniform Compression Design in accordance with AS 3700 Clause 7.3 is applicable to Unreinforced AAC Masonry. “RILEM Recommended Practice – Autoclaved Aerated Concrete – Properties, Testing and Design” provides a method for Unreinforced AAC, but does not provide a separate method for Reinforced AAC. Therefore, the method based on AS 3700 Clause 7.3 has also been used for Reinforced ECOL-MEGA PANEL AAC.

1 Aroni, S., de Groot, G.J., Robinson, M.J., Svanholm, G., & Wittman, F.H. (Editors),

“RILEM Recommended Practice – Autoclaved Aerated Concrete – Properties, Testing and Design”


Design of AAC Walls for Robustness Notwithstanding the requirement to design for loads in the Standards, it is possible for the lateral loads on some walls to be neglected. For example, internal loadbearing basement walls of an apartment building may not be required to be designed for wind, fire or earthquake. However it is possible for all three loads, as well as vehicle impact, to impinge on such basement walls. The robustness provisions are a practical means of providing an upper limit on the dimensions of walls and isolated piers, thus ensuring that unreasonably large spans are not specified. They are not a substitute for rational design for calculated loads, but rather a global limit beyond which even the most lightly loaded walls and piers should not be built. The robustness provisions must not be used to justify structures which would otherwise fail to meet the design for calculated loads. Close consideration must be given to chasing and the consequent reduction in support. The robustness coefficients of AS 3700 Table 4.2 are applicable to Unreinforced AAC Blocks in thin-bed adhesive. In this manual, the robustness criteria are also applied to Reinforced AAC Panels, which are outside the scope of AS 3700, to maintain consistency. The horizontal robustness coefficient is not applicable to Reinforced AAC Panels, which span in one direction only. AAC Wall Resistance to Concentrated Loads Design in accordance with AS 3700 Clause 7.3.5 is applicable to Unreinforced (AAC) Masonry. RILEM “RILEM Recommended Practice – Autoclaved Aerated Concrete – Properties, Testing and Design” provides a reasonably similar approach for Unreinforced (AAC), but does not provide a separate method for reinforced method. Therefore, the method based on AS 3700 Clause 7.3.5 has also been used for Reinforced ECOL-MEGA PANEL (AAC). Summary of Product Codes and Physical Properties Set out below are the principal properties of the ECOL-MEGA PANEL (AAC) products. Further details are shown on the following pages.

Important Design and Construction Checks The tabulated properties are based on advice from the suppliers.

• The designer must check the availability of the particular products and design accordingly, selecting the appropriate properties from the table.

• In the case of wall panels, the designer must consider loading from both sides

of the wall. The required construction detail must be indicated clearly on the drawings.

• The builder must check compliance of the product supplied to site against this

table of properties. See also the checklist that forms part of the specification.

• Where the reinforcement is not in the centre of the panel, the designer must indicate clearly on the drawings which sides of the wall it must be placed, and the builder must install it correctly.

• The designer must correctly detail the required connections, and the builder must ensure that they are correctly installed, properly fixing the (AAC) panels into the building. See the worked example in Appendix C.


Summary of Properties of the ECOL-MEGA PANEL (AAC) Products

Product Code 75 W37 75 W30 100 W18 75 F30 75 F37

Application Wall Wall Wall Floor Floor

Panel thickness, T, mm 75 75 100 75 75

Panel width, W, mm 600 600 450 600 600

Panel length, L, mm Varies Varies Varies 1,800 1,800

Panel dry density, ρd, kg/m3 520 520 520 520 520

Panel bulk density, ρb, kg/m3 565 565 565 565 565

Charact compressive strength, f'ck, MPa 4.0 3.5, 4.5 4.0 4.0 3.5, 4.5

Characteristic flexural strength, f'f , MPa 1.0 1.0 1.0 1.0 1.0

Characteristic tensile strength, f't, MPa 0.35 0.35 0.35 0.35 0.35

Mean elastic modulus, E, MPa 1,800 1,800 1,800 1,800 1,800

Reinforcement strength, f’y, MPa 250 250 250 250 250

Number of layers of reinforcement 1 1 2 1 1

Main reinforcement diameter, mm 5 5 5 5 5

No of reinforcement strands 5 5 3 5 5

Reinforcement centres, mm 37/37 45/30 18/64/18 45/30 37/37

Effective reo depth, d, mm 37 45 30 82 45 30 37

Moment capacity, kN.m/panel 0.574 0.712 0.436 0.827 0.712 0.436 0.574

Simple span, m Capacity kPa

0.90 9.45 11.72 7.17 18.16

1.20 5.31 6.59 4.04 10.21

1.50 3.40 4.22 2.58 6.54

1.80 2.36 2.93 1.79 4.54

2.10 1.74 2.15 1.32 3.33

2.40 1.33 1.65 1.01 2.55

2.70 1.05 1.30 0.80 2.02

3.00 0.85 1.05 0.65 1.63

3.30 0.70 0.87 0.53 1.35

Notes:

1. In a 75 mm thick panel where the main reinforcement is 45 mm from one face and 30 mm from the other face, the designer must nominate which face of panel is to be oriented in which direction. In a 75 mm thick panel where the main reinforcement is 55 mm from one face and 20 mm from the other face, the designer must nominate which face of panel is to be oriented in which direction.

2. There must be sufficient secondary reinforcing strands across the panel, to provide sufficient anchorage.

3. Dimensional Category DW4.

4. General Purpose Salt Attack Resistance Grade, except for applications requiring Exposure Grade.

Applications requiring Exposure Grade are saline wetting or drying, aggressive soils, severe marine environments, saline or contaminated water including tidal or splash zones, or within 1 km of a industry producing chemical pollutants.


75 mm ECOL-MEGA PANEL (AAC) Steel Reinforced Autoclaved Aerated Wall Panels with Reinforcement Offset

Product Code: 75 W30


75 mm ECOL-MEGA PANEL (AAC) Steel Reinforced Autoclaved Aerated Wall Panels with Reinforcement In Centre



100 mm ECOL-MEGA PANEL (AAC) Steel Reinforced Autoclaved Aerated Wall Panels



75 mm ECOL-MEGA PANEL FLOOR (AAC) Steel Reinforced Autoclaved Aerated Floor Panels

Product Code: 75 F30 75 mm ECOL-MEGA FLOOR PANEL (AAC) Steel-Reinforced Autoclaved Aerated Concrete Floor Panels, spanning over joists at 450 mm centres, are are suitable for the support of 3.5 kPa distributed or a 1.8 kN point load over and area of 350 mm

2 (located at least 100 mm

from the panel edge).

Important Note A force of 1.8 kN vertical load, spread over an area of 350 mm

2, corresponds to a bearing

stress of 5.1 MPa. “RILEM Recommended Practice – Autoclaved Aerated Concrete – Properties, Testing and Design” does not give any limits for bearing strength for point loads bearing on AAC floor panels. However, an indication of the probable bearing capacity may be gauged from the two following two sources:

1. For unreinforced AAC, the RILEM Recommended Practice provides a formula for concentrated forces on walls. Using this formula, it is possible to predict a factored bearing strength for point loads on floors of:

φ fb = φ f’ck 1.3 .1.5 = 0.75 x 3.5 x 1.3 x 1.5 = 5.1 MPa

2. For reinforced concrete, AS 3600 Clause 12.3 permits a factored bearing

strength for point (anchorage) loads on concrete of:

φ fb = φ 2 f’ck = 0.75 x 2 x 3.5 = 5.25 MPa

The designer should understand the limitations of these two references, and should account for concentrated point loads accordingly.

75 mm ECOL-MEGA PANEL Steel Reinforced Autoclaved Aerated Floor Panels

Product Code: 75 F30 75 mm ECOL-MEGA PANEL AAC Steel-Reinforced Autoclaved Aerated Floor Panels,

Spanning joists at 450 mm centres, are suitable for the support of 3.0 kPa distributed or a 1.8 kN point load over an area of 350 mm2 (located at least 100 mm from the panel edge). This corresponds to balcony loads for domestic housing.

Spanning joists at 600 mm centres, are suitable for the support of 1.5 kPa distributed or a 1.8 kN point load over an area of 350 mm2 (located at least 100 mm from the panel edge). This corresponds to the internal loads for domestic housing.

Important Notes The designer and builder must ensure that there is provision to prevent and/or control cracking of any brittle floor coverings, such as tiles, particularly at 600 mm joist spacing. In the case of 600 mm joist spacing, ductile surfaces are more appropriate. A force of 1.8 kN vertical load, spread over an area of 350 mm2, corresponds to a bearing stress of 5.1 MPa. “RILEM Recommended Practice – Autoclaved Aerated Concrete – Properties, Testing and Design” does not give any limits for bearing strength for point loads bearing on AAC floor panels. However, an indication of the probable bearing capacity may be gauged from the following two sources:

1. For unreinforced AAC, the RILEM Recommended Practice provides a formula for concentrated forces on walls. Using this formula, it is possible to predict a factored bearing strength for point loads on floors of: fb = f’ck 1.3 .1.5 = 0.75 x 3.5 x 1.3 x 1.5 = 5.1 MPa


strength for point (anchorage) loads on concrete of: fb = 2 f’ck = 0.75 x 2 x 3.5 = 5.25 MPa



75 mm ECOL-MEGA PANEL FLOOR (AAC) Steel Reinforced Autoclaved Aerated Floor Panels








φ fb = φ f’ck 1.3 .1.5 = 0.75 x 3.5 x 1.3 x 1.5 = 5.1 MPa



φ fb = φ 2 f’ck = 0.75 x 2 x 3.5 = 5.25 MPa



75 mm ECOL-MEGA FLOOR PANEL (AAC) Steel Reinforced Autoclaved Aerated Floor Panels








φ fb = φ f’ck 1.3 .1.5 = 0.75 x 3.5 x 1.3 x 1.5 = 5.1 MPa



φ fb = φ 2 f’ck = 0.75 x 2 x 3.5 = 5.25 MPa


75 mm ECOL-MEGA PANEL Steel Reinforced Autoclaved Aerated Floor Panels

Product Code: 75 F37 75 mm ECOL-MEGA PANEL AAC Steel-Reinforced Autoclaved Aerated Floor Panels,

Spanning joists at 450 mm centres, are suitable for the support of 3.0 kPa distributed or a 1.8 kN point load over an area of 350 mm2 (located at least 100 mm from the panel edge). This corresponds to balcony loads for domestic housing.

Spanning joists at 600 mm centres, are suitable for the support of 1.5 kPa distributed or a 1.8 kN point load over an area of 350 mm2 (located at least 100 mm from the panel edge). This corresponds to the internal loads for domestic housing.

Important Notes The designer and builder must ensure that there is provision to prevent and/or control cracking of any brittle floor coverings, such as tiles, particularly at 600 mm joist spacing. In the case of 600 mm joist spacing, ductile surfaces are more appropriate. A force of 1.8 kN vertical load, spread over an area of 350 mm2, corresponds to a bearing stress of 5.1 MPa. “RILEM Recommended Practice – Autoclaved Aerated Concrete – Properties, Testing and Design” does not give any limits for bearing strength for point loads bearing on AAC floor panels. However, an indication of the probable bearing capacity may be gauged from the following two sources:

1. For unreinforced AAC, the RILEM Recommended Practice provides a formula for concentrated forces on walls. Using this formula, it is possible to predict a factored bearing strength for point loads on floors of: fb = f’ck 1.3 .1.5 = 0.75 x 3.5 x 1.3 x 1.5 = 5.1 MPa


strength for point (anchorage) loads on concrete of: fb = 2 f’ck = 0.75 x 2 x 3.5 = 5.25 MPa



75 mm ECOL-MEGA FLOOR PANEL (AAC) Steel Reinforced Autoclaved Aerated Floor Panels








φ fb = φ f’ck 1.3 .1.5 = 0.75 x 3.5 x 1.3 x 1.5 = 5.1 MPa



φ fb = φ 2 f’ck = 0.75 x 2 x 3.5 = 5.25 MPa



ECOL-MEGA PANEL (AAC) Unreinforced Autoclaved Aerated Masonry

Product Code: 75 M G Out-of-plane bending resistance is designed in accordance with AS 3700 Clause 7.4. Vertical bending moment capacity, Mcv = 0.405 kN.m/m Horizontal bending moment capacity, Mch = 0.147kN/m Using the method set out in Appendix 2, and AS 3700 Clause 7.4, the designer may calculate the capacity of various panels. The following table gives some typical capacities, for walls without openings that are simply supported top and bottom and at both ends.

75 mm ECOL-MEGA PANEL Unreinforced AAC Masonry

Factored ultimate bending capacities (expressed as uniform pressures (kPa)

Height between top and bottom supports, H (m) Length between vertical supports, L (m)

1.8 2.4 3.0 3.6 4.2 4.8 5.4 6.0 6.6

3.0 1.25 0.64 0.40 0.29

2.8 1.22 0.64 0.41 0.29

2.6 1.19 0.63 0.41 0.30

2.4 1.16 0.63 0.42 0.31

2.2 1.14 0.63 0.43 0.32 0.25

2.0 1.12 0.64 0.44 0.33 0.27

1.8 1.12 0.66 0.46 0.36 0.29

1.6 1.13 0.69 0.49 0.38 0.32 0.27

1.4 1.16 0.73 0.54 0.42 0.35 0.30 0.26

1.2 1.23 0.80 0.60 0.48 0.40 0.34 0.30 0.27

1.0 1.34 0.90 0.69 0.56 0.47 0.40 0.36 0.32 0.29

Notes: 1. This table is based on the assumption that the wall is supported on four sides. 2. Values under 0.25 kPa are considered impractical and have been deleted from the table. 3. Robustness and other design considerations must be checked, and shall comply with AS 3700.

When a wall is exposed to a fire, theexposed face becomes heated andexpands, causing the wall to bow towardsthe fire.

Collapse occurs when the unexposed facepasses under the line of the load,“breaking the back” of the wall.

Fire source

Imposed verticalload and/orself weightcompresses wall


3. Fire Design Building Code of Australia Requirements BCA Volume 1 Part C defines the fire resistance requirements for Class 2 to 9 buildings. BCA Volume 2 Part 3.7.1 defines the fire resistance requirements for Class 1 and 10a buildings. The precise quantified requirements should be determined from the relevant parts of the BCA, but may be summarized generally as requiring:

• Structural adequacy (resistance to collapse), when subject to fire • Integrity (resistance to the passage of flame and hot gasses), when subject to fire • Insulation (resistance to the passage of heat), when subject to fire • Resistance to the spread of flame • Resistance to the generation and spread of smoke

. Fire Resistance of ECOL-MEGA PANEL (AAC) Walls The Fire Resistance Level (FRL) for Structural Adequacy is the ability of a wall to remain stable when exposed to fire. Structural Adequacy is a function of:

• Thermal expansion of the material • Slenderness (affected by thickness, vertical span and horizontal span between supports)

• Reinforcement.

When a wall is exposed to a fire, the exposed face becomes hot and heat passes through the wall.

Failure occurs when the unexposed face reaches a particular temperature.

When a wall is exposed to a fire, the exposedface becomes hot and expands. If unable to bow (because of restraints) the unexposed face willcrack).

Failure occurs when flames are visible from the unexposed face.

Fire source

Fire source


The Fire Resistance Level (FRL) for Integrity is the ability of a wall to resist the passage of flames and hot gasses from one side to the other. Integrity is a function of:

• Material type

• Material thickness

The Fire Resistance Level (FRL) for Insulation is the ability of a wall to resist the passage of heat from one side to the other. Insulation is a function of:

• Material type

• Equivalent thickness

• Render (if present)

Fire Test to AS 1530.4

• The material properties may be determined from fire tests to AS 1540.4.

• This information may be then interpreted using the formulae given in AS 3700 or similar standards to predict wall behaviour.

Wall panels may be supported at the top and bottom and subjected to an applied load. This is known as a "loadbearing test". Alternatively the panels may be supported on one side and not subjected to any externally applied load. This is known as a "non-loadbearing test". The terminology is a little misleading, since experience has shown that collapse of a wall (structural adequacy failure) is more influenced by the


number of sides supported and the corresponding wall slenderness than by the magnitude of this applied vertical load. A more informative description would be "test with supports at top and bottom" and "test with supports on four sides".

The standard fire test in AS 1530.4 uses the same three failure criteria, mentioned in the BCA and AS 3700, of structural adequacy, integrity and insulation. Performance of ECOL-MEGA PANEL AAC Walls Fire performance data, used to support designs to BCA Volume 1 Part C or BCA Volume 2 Part 3.7, should be determined in accordance with AS 1530.4. 60/60/60 FRL for Residential Applications 75 mm ECOL-MEGA PANEL Autoclaved Aerated Concrete Wall Panels, fixed to either timber or steel stud framing complying with BCA Volume 2 Part 3.4, satisfy the requirements on BCA Volume 2 Part 3.7.1.5 (a) (i) for fire resistance

3.7.1.5 Construction of External Walls (a) External walls (including gables) required to be fire resisting ………… and must – (i) have an FRL of not less than 60/6/60 when tested from the outside; or (ii) …………….. (iii) …………….

The basis of this conclusion is a combination of the following:

1. BCA Volume 2 Part 3.7.1.5 (a) (i) clearly states that the fire is “from the outside”.

2. The deemed-to-satisfy (DTS) provisions in 3.7.1.5 (a) (ii) permits the use of 90 mm external masonry veneer, without differentiating between suporting frames of steel or timber.

3. Bodycote Warringtonfire Fire Test 2303900 for 75 mm AAC (mounted on a steel frame) indicated that the 75 mm AAC panels provided an insulation fire resistance of 207 minutes before exceeding the temperature rise criteria. There was no breach of the Integrity criterion. Up to an exposure time of approximately 200 minutes the temperature rise was only 80

oC

(approximate). This clearly indicates that the temperature rise on the inside surface of the 75 mm AAC Panel is well below the ignition temperature of timber and softening point of steel. In other words, the 75 mm AAC Panels adequately protect the frames (irrespective whether they are steel or concrete). The fixings are also afforded sufficient protection to ensure their adequate performance.


Fire Test No 1 Refer to fire test Bodycote Warrington (Australia) Pty Ltd Report 2256400. Fire Tests to AS 1530.4 (as described above) for 75 mm Reinforced ECOL-MEGA PANEL AAC Wall Panel (Product Code: 75 W G) give the following results. This information may be used to check the fire performance of a proposed structure. Wall tested:

ECOL-MEGA AAC 75 mm Reinforced AAC Panels (Product Code: 75 W G) with Bradford R1.5 fibre glass batts, fixed to steel framing and 10 mm standard plasterboard

Wall Dimensions

Height: 3,000 mm Length: 3,000 mm Thickness: 75 mm Insulation: R1.5 fibreglass Plasterboard Standard 10 mm thick Framing 75 x 45 x 1.0 mm galvanized channel section.

Time to failure :

Structural Adequacy In excess of 301 minutes (at least 240 minutes)* Integrity In excess of 301 minutes (at least 240 minutes)* Insulation: 286 minutes (at least 240 minutes)*

Notes:

1. Fire Resistance Levels 240/240/240 (Structural adequacy / Integrity / Insulation) is only applicable to the form of construction (75 mm AAC panels + steel framing + R1.5 fibreglass insulation + 10 mm plasterboard as described in Bodycote Warrington (Australia) Pty Ltd Report 2256400, under the tested support conditions (top, bottom and one side) and not subject to any additional vertical load.

2. Bodycote Warrington (Australia) Pty Ltd Report 2256400 reports no structural failure at 301 minutes, but does not report a FRL (Structural Adequacy). This is presumably because no external load has been applied and the wall was supported on one side. However, provided the form of construction, support conditions and lack of load are as described in the report, the wall can be considered to have a FRL (Structural Adequacy) of 240 minutes.

3. The fire performance of 100 mm Reinforced ECOL-MEGA PANEL (AAC) Panel would be in excess of values given above for 75 mm thick panels.


Fire Test No 2 Refer to fire test Bodycote Warrington (Australia) Pty Ltd Report 2303900. Fire Tests to AS 1530.4 (as described above) for 75 mm Reinforced ECOL-MEGA PANEL AAC Wall Panel (Product Code: 75 W J) give the following results. This information may be used to check the fire performance of a proposed structure. Wall tested:

ECOL-MEGA PANEL (AAC) 75 mm Reinforced AAC Panels (Product Code: 75 W J) fixed to steel framing.

Wall Dimensions

Height: 3,000 mm Length: 3,000 mm Thickness: 75 mm Insulation: Nil Plasterboard Nil Framing 75 x 45 x 1.0 mm galvanized channel section.

Time to failure :

Structural Adequacy In excess of 301 minutes (at least 240 minutes)* Integrity In excess of 301 minutes (at least 240 minutes)* Insulation: 207 minutes (at least 180 minutes)*

Notes:

1. Fire Resistance Levels 240/240/180 (Structural adequacy / Integrity / Insulation) is only applicable to the form of construction (75 mm ECOL-MEGA (AAC) panels + steel framing as described in Bodycote Warrington (Australia) Pty Ltd Report 2256400, under the tested support conditions (top, bottom and one side) and not subject to any additional vertical load.

2. Bodycote Warrington (Australia) Pty Ltd Report 2303900 reports no structural failure at 301 minutes, but does not report a FRL (Structural Adequacy). This is presumably because no external load has been applied and the wall was supported on one side. However, provided the form of construction, support conditions and lack of load are as described in the report, the wall can be considered to have a FRL (Structural Adequacy) of 240 minutes.

3. The fire performance of 100 mm Reinforced ECOL-MEGA PANEL (AAC) Panel would be in excess of values given above for 75 mm thick panels.


4. Acoustic Design When sound impinges on a wall, it may be reflected or absorbed.

• Reflected sound may manifest in a room as undesirable echoes, and may be controlled by a variety of techniques, including surface treatment and masonry unit design.

• Absorbed sound may be dissipated within the wall, transmitted through or radiated through wall vibration.

There are three distinct modes of sound transmission through walls:

1. Below the resonant frequency, the stiffness of the wall is of greatest importance, and the mass and damping have little effect. As the frequency increases, the mass of the wall becomes more important and the wall begins to resonate.

2. Beyond resonance, the mass of the wall provides a damping effect, and “high mass” systems have an advantage over lightweight alternatives. The resistance to sound transmission increases by approximately 6 dB for each doubling of the frequency or for each doubling of the mass.

3. Above the critical frequency, the coincidence of the sound waves control the behaviour. The

critical frequency for heavy wall systems is relatively low. A coincidence dip immediately above the critical frequency indicates a loss in airborne sound resistance.

In order to report a “single number” as a index, the plotted sound reduction results are compared to a series of plots for standard spectrums of various intensities. The standard spectrum that best fits the plot of the test results is adopted as the Rw (weighted sound reduction index). C and Ctr are reduction coefficients, which are applied to describe the effect of sound of particular frequencies. Impact Sound Resistance When bedrooms or other quiet areas are adjacent to bathrooms, kitchens and the like, it is important to reduce the sound transmitted through the wall as a result of a blow to the other side of the wall or attached furniture The impact sound resistance of a wall is measured by generating noise with a machine having multiple steel hammers, which impact on a steel plate placed in contact with the wall. The sound passing through the wall may be measured in a manner similar to that used for airborne sound resistance. Resistance to impact sound requires properties different from those for resistance to airborne sound. A dense stiff material will vibrate when it is struck, while a soft material will simply absorb the blow without transmitting it. For example, hard dense plaster or render has a lower impact sound resistance than the softer commercially available plasterboards. Soft or resilient connections between the external skin and the body of the wall will also reduce the amount of impact that is transmitted. The impact sound resistance of a wall can generally be improved over a bare wall by the use cladding fixed directly to steel furring channels. The use of resilient impact clips can improve the impact insulation performance over a bare wall by typically 3 dB. The use of free-standing cladding without any attachment to the masonry will provide better results.


BCA Vol 1 Clause F5.5 Requirements • Walls that separate sole occupancy units in a Class 2 or 3 building or between two Class 1

buildings Rw + Ctr (airborne) not less than 50, and Impact sound resistance, if the wall separates a habitable room in one sole occupancy unit from a bathroom, sanitary compartment, laundry or kitchen of another unit or plant room or lift shaft).

• Walls that separate a sole occupancy unit from a plant room, lift shaft, stairway, public

corridor, public lobby or the like in a Class 2 or 3 building: Rw (airborne) not less than 50, and Impact sound resistance, if the wall separates a habitable room in one sole occupancy unit from a plant room, or lift shaft.

• Walls that separates two sole occupancy units or separates a sole occupancy unit from a kitchen, bathroom, sanitary compartment (not en-suite), laundry, plant room or utilities room in a Class 9c aged-care building Rw (airborne) not less than 45, and Impact sound resistance if the wall separates a habitable room in one sole occupancy

unit from a kitchen or laundry.

• A door incorporated in a wall that separates a sole occupancy unit from stairway, public corridor, public lobby or the like in a Class 2 or 3 building and a door incorporated in a wall that separates a sole occupancy unit from a kitchen or laundry in a Class 9c aged care building. Rw (airborne) not less than 30.

Walls requiring impact sound resistance shall consist of two leaves separated by a gap of at least 20 mm (and in Class 2 or 3 where required, connected by resilient ties). BCA Vol 2 Clauses 3.8.6.1 to 3.8.6.4 Requirements

• Walls that separate a bathroom, sanitary compartment, laundry or kitchen of one Class 1 building from a habitable room (other than a kitchen) in an adjoining Class 1 building (dwelling) shall have: Rw + Ctr (airborne) not less than 50 and Discontinuous construction. For cavity walls, a minimum of 20 mm cavity between

two separate leaves, which may be connected, if required for structural purposes, with resilient ties. Northern Territory, Queensland and Western Australia have varied this requirement to Rw not less than 50 and Impact Sound Resistance.

• Walls are required to be detailed in accordance with BCA Vol 2 Clause 3.8.6.3, which make provision for the sealing of sound insulated walls at junctions with perimeter wall and roof cladding. This clause also requires that masonry joints be filled and provides for sound insulated articulation joints. BCA Vol 2 Clause 3.8.6.4 makes provision for services in sound insulated walls.

• Walls required to have a sound insulation shall be constructed to the underside of:

a floor above a ceiling with the same acoustic rating a roof above.


Effect of Joints and Gaps Gaps reduce the sound attenuation of a wall. Laboratory tested walls have full joints. Site construction must also have full joints to ensure similar sound attenuation. Gaps around the vertical edges of a wall and at the ceiling will diminish the sound resistance of a wall. A gap 0.l% of wall area (corresponding to a 3 mm gap along the length of a 3 m high wall) can reduce the sound transmission resistance by typically 10-20 dB. Gaps around the periphery of walls should be sealed using a high-density acoustically-rated mastic or similar sealant. Sealants should have a typical density of 1600 kg/m

3. Sealants should be applied to both faces of the wall and should be applied to a depth equal to

the width of the gap. Typical penetrations in walls include mechanical services ducts, refrigerant pipes, hydraulic reticulation lines, waste pipes and fire sprinklers and electrical cables. It is essential to provide an acoustically rated seal around the penetration. Surface Treatment If cladding and render are applied to masonry walls to achieve a target sound transmission resistance, the treatment should be applied full-height, from floor slab to soffit. Chases Chases in walls diminish the sound attenuation. Chases should not extend deeper than 25mm into the wall. All chases should be rendered over after the pipes or cables are installed. Acoustic Performance of AAC Generic The following generic information for the prediction of weighted sound index is taken from “RILEM Recommended Practice – Autoclaved Aerated Concrete – Properties, Testing and Design”

2.

Weighed sound index, Rw = 27.7 log10(M) – 11.6 dB Where M = the surface mass of the wall in kg/m

2.

Based on a bulk density of 520 kg/m

3 and a panel thickness of 75 mm, the resulting predicted

weighted sound index would be 32 dBA

Based on a bulk density of 520 kg/m3 and a panel thickness of 100 mm, the resulting

predicted weighted sound index would be 36 dBA Weighted sound index data, used to support designs to BCA Volume 1 Part F5 or BCA Volume 2 Clause 3.8.6, should be determined in accordance with AS/NZS 1276.1.

ECOL-MEGA PANEL AAC Wall Panel Tests 75 mm Reinforced ECOL-MEGA PANEL AAC Wall Panel (Product Code: 75 W J) was tested give the following results. Rw (C, Ctr) 38 (-2, -2)

Rw 38 Rw + C 36 Rw + Ctr 36

It can be seen that the test results are reasonably consistent with (although in excess of) the generic predictions.

Refer to: Vipac Engineers and Scientists Ltd,

Report No 50B-08-0036-TRP-771622-0

2 March 2010

2 Aroni, S., de Groot, G.J., Robinson, M.J., Svanholm, G., & Wittman, F.H. (Editors), “RILEM Recommended Practice – Autoclaved Aerated Concrete – Properties, Testing and Design”

Radiation - Heat energyenters the building throughthe glazing

Convection - warm airflows through openingstaking heat either in or outof the building

Conduction - Heatflows throughbuilding fabric


5. Thermal Design Factors Affecting Thermal Efficiency The main factors influencing good solar design are as follows:

• Adequate solar access in cold climates. The building should be oriented such that the warmth can be harnessed in winter, and cooling breezes captured in summer.

• For warm areas, large eaves, verandas, sun-shades and heavy curtains prevent sunshine

from entering and overheating a building during hot weather. Good ventilation and light-coloured roofs assist the summer cooling process.

• For temperate and cool areas, north-facing windows permit the entry of winter sun, while

correctly proportioned eaves restrict the entry of summer sun. Properly sealed doors and windows allow cross-ventilation in summer and restrict air and heat leakage in winter.

• The inclusion of roof and ceiling insulation, together with wall and floor insulation in some

circumstances, will limit heat flows to and from the building. This is further discussed below.

• The thermal mass of tiled roofs, AAC and masonry walls and concrete floors will act as a dampener to heat flows.

Thermal Performance – Heat Transfer Heat transfers through the fabric of a building by a combination of:

• Conduction

• Convection

• Radiation.

Thermal Mass If a building with high thermal mass experiences a heating and cooling cycle which crosses the comfort zone, the roof, walls and floor will store the heat energy for an extended period, gradually releasing it over time. In winter, high thermal mass buildings will remain relatively warm, while in summer, they will remain relatively cool.

Day

Day

Winter Heat

Summer Heat

Night

Night


In winter, heat trying to pass through the wall will become trapped in the wall and part will slowly pass back into the room. In summer the reverse occurs. Heat trying to pass through the wall from the outside will become trapped in the wall and part will slowly pass back out of the building. The thermal mass of the member (wall, roof/ceiling, floor etc) is the combination of the properties of each of the components (e.g. AAC, insulation, foil etc) and is a function of the mass and specific heat.

Thermal Resistance of ECOL-MEGA PANEL (AAC) The following generic information for the prediction of thermal resistance is adapted from RILEM Recommended Practice – Autoclaved Aerated Concrete – Properties, Testing and Design

3. The

thermal conductivity, k, of AAC increases with density and moisture content, and may be estimated by k = (0.00027 p – 0.011).(1 + 0.04 w) W/m.K, where p = the oven-dried density in kg/m

3 and w =

moisture content expressed as a percentage.

Example Oven-dried density p = 520 kg/m

3

Moisture content (45 kg/m

3)

w = 45 / 520 = 8.7%

Thermal conductivity k = 0.00027 p – 0.011).(1 + 0.04 w) W/m.K

= (0.00027 x 520) – 0.011) . (1 + [0.04 x 8.7]) = 0.129 x 1.35 =0.175 W/m.K Thickness

t = 75 mm = 0.075 m Thermal resistance R = t / k = 0.075 / 0.175 = 0.43 m

2.K/W

3 Aroni, S., de Groot, G.J., Robinson, M.J., Svanholm, G., & Wittman, F.H. (Editors), “RILEM Recommended Practice – Autoclaved Aerated Concrete – Properties, Testing and Design”

External air film

AAC Panel

Studs

Added insultation(and airspace if appropriate)

Internal plasterboard

Internal air film


Thermal Resistance of 75 mm AAC External Walls

Thermal Properties 75 mm ECOL-MEGA PANEL AAC AAC Single Leaf Walls and AAC Veneer Walls

Material External thickness

mm Thermal resistance, R

m2.K/W

External air film 0.04

75 mm AAC panel 75 0.43

Internal air film 0.12

Total (without insulation) 0.59



Air space 38 0.17

Internal plasterboard 10 0.06


Subtotal (without insulation) 0.82

Added insulation R1.5 R2.0 R2.5 1.50 2.00 2.50

Total (with insulation) 2.32 2.82 3.32

Notes This table provides the thermal resistance of AAC single leaf walls and AAC veneer walls, without added insulation. The thermal resistance for ECOL-MEGA PANEL AAC is based on the published thermal conductivity, k, of 0.175 W/m.K. This value is consistent with the method of calculation in RILEM Recommended Practice – Autoclaved Aerated Concrete – Properties, Testing and Design. It is considerably more conservative that the values given in Building Code of Australia. Studs should incorporate a thermal break. If alternative additional insulation is required to bring the total thermal resistance up to the requirements of the Building Code of Australia, it may be added externally (provided it is weatherproof and protected), internally (provided it is protected) and/or within the cavity (provided allowance is made for thermal bridging by the studs and reduction thermal resistance of a pre-existing cavity.)

External air film

AAC Panel

Studs

Added insultation(and airspace if appropriate)

Internal plasterboard

Internal air film


Thermal Resistance of 100 mm AAC External Walls

Thermal Properties 100 mm ECOL-MEGA PANEL AAC AAC Single Leaf Walls and AAC Veneer Walls

Material External thickness

mm Thermal resistance, R

m2.K/W




Total (without insulation) 0.73



Air space 38 0.17

Internal plasterboard 10 0.06


Subtotal (without insulation) 0.96

Added insulation R1.5 R2.0 R2.5 1.50 2.00 2.50

Total (with insulation) 2.46 2.96 3.46

Notes This table provides the thermal resistance of AAC single leaf walls and AAC veneer walls, without added insulation. The thermal resistance for ECOL-MEGA PANEL AAC is based on the published thermal conductivity, k, of 0.175 W/m.K. This value is consistent with the method of calculation in RILEM Recommended Practice – Autoclaved Aerated Concrete – Properties, Testing and Design. It is considerably more conservative that the values given in Building Code of Australia. Studs should incorporate a thermal break. If alternative additional insulation is required to bring the total thermal resistance up to the requirements of the Building Code of Australia, it may be added externally (provided it is weatherproof and protected), internally (provided it is protected) and/or within the cavity (provided allowance is made for thermal bridging by the studs and reduction thermal resistance of a pre-existing cavity.)


6. Detailing Introduction All buildings are required to be built such that:

• The assumed support for walls (and other members) can be achieved, to resist gravity, wind, earthquake, and other loads;

• The building is weatherproof;

• The structure is durable, able to resist salts or any other expected corrosive materials.

Structural Supports The connections and supporting structure must have sufficient combined capacity to transmit the horizontal in-plane and out-of-plane loads from the wall to the supports. They must also be such that the assumed action of the wall panel can be achieved. For example, if two-way action has been assumed, the connections at the top, bottom and each side must be cosistent with the assumed support configuration. For top, base and sides, the connection capacities may be provided by connectors, such as proprietary ties. Weather-Proofing Buildings must be constructed such that they are weather proof. This may be achieved by ensuring that:

• The AAC (including its units and joints) do not permit the ingress of water;

• The AAC does not crack, due to shrinkage, footing movement or other sources of building movement;

• The AAC is protected by a damp-proof course from moisture and salts that otherwise would

rise through the wall by capillary action; and

• Any moisture that penetrates the building fabric, through the walls, roof, openings and the like, can be easily collected and concentrated by flashings and removed via weep holes.

Ingress of Water through the AAC and Joints An appropriate surface coating should be applied to ECOL-MEGA (AAC) panels and masonry, to prevent the ingress of water through the (AAC) and its joints. “RILEM Recommended Practice – Autoclaved Aerated Concrete – Properties, Testing and Design” recommends the application of a two-coat acrylic paint coating. Prior to the application of the coating, the joints should be pointed and any control joint sealed with flexible sealing compounds. Wall Does Not Crack Notwithstanding the fact that walls constructed of ECOL-MEGA PANEL (AAC) are impervious to moisture penetration (as per the statement above), it is necessary to ensure that the walls are properly supported on footings or other structures, which have adequate strength and stiffness to limit movement that would cause the (AAC) to crack. Such movement generally results from foundation expansion or contraction, thermal expansion and contraction, wind, earthquake or imposed loads. Moisture movements in clay or similar soils result in expansion and contraction, causing the building to either “hog” or “sag”. Trees roots suck the moisture out of the soil causing it to shrink. Poor or badly maintained drainage systems allow a build up of moisture in the soil causing it to expand. Unreinforced AAC may crack sympathetically with deflected concrete footings, and the inclusion of articulation joints will control the position and width of cracks. In a wall exposed to the weather, articulation joints must incorporate flexible sealants, which should be regularly inspected and maintained. The incorporation of reinforcement into ECOL-MEGA (AAC) walls will assist resistance to cracking in the most extreme cases of foundation movement.


Buildings should be regularly maintained, to ensure that: • Trees have not grown too close to the footings; • The plumbing system does not leak; and • The storm water drainage system effectively removes rainwater

Damp-proof Course AS 3700 and the Building Code of Australia Volume 2 provide rules for construction and specifications of appropriate damp-proof courses to exclude rising ground water and the accompanying salts from attacking the AAC. Flashings and Weep Holes Attention to detail is important.

• Flashings and weep holes should be constructed in accordance with AS 3700 and the Building Code of Australia Volume 2 as appropriate.

• Building must be correctly detailed to account for weatherproofing requirements, foundation movement, shrinkage and the efficient removal of rain water.

• Gutters and rainwater downpipes must be regularly inspected and kept clean, free of

corrosion, and connected to a functioning storm water system.

• Flashing must be secured and joints sealed with flexible sealant (e.g. silicone or similar), which should be renewed over time as they deteriorate.

Durability Cladding must have sufficient durability to resist erosion of the blocks and to prevent corrosion of any steel reinforcement, ties, connector, lintels or fittings. AS 3700 Section 5 sets out the durability requirements for masonry units, mortar (not applicable in the case of AAC), built-in components and reinforcement. The performance must be met throughout the design life of the structure. Table 5.1 defines the required classifications for masonry units, mortar, built-in components and cover for reinforcement or tendons for the particular environments and positions within the structure. AS 3700 Clause 5.2 defines the exposure environments for which the masonry and its components must be designed and Appendix E gives further explanation and examples of each environment. The associated clauses and standards referred from Table 5.1 are:

• AS/NZS 4456.10 provides a test and means of classifying the durability of masonry units. • AS 3700 Appendix F provides performance requirements for built-in components and deemed-

to-comply corrosion resistance of galvanising and other treatments. ECOL-MEGA PANEL (AAC) AAC, which may be subject to salt attack, must have salt resistance, determined in accordance with AS/NZS 4456.10. Built-In Components Ties, connectors and lintels should be galvanized to the required thicknesses. In aggressive environments, they should be manufactured from stainless steel or other non-corrosive materials in accordance with AS/NZS 2699.1, AS/NZS 2699.2 or AS/NZS 2699.3. Testing criteria for components in categories R0 to R4 are quite severe:

(a) Maximum temperature of 55oC or 40

oC if the component is embedded.

(b) Daily temperature cycles from ambient (18

oC) to 40

oC.

(c) The medium surrounding the accessory being initially alkaline pH up to 10 but reducing over

time to become not less than 10 (i.e. close to neutral).

(d) Remaining wet for a 3 month period.


(e) Aerosol penetration to an extent depending on distance from the coast:

R0 - Nil R1 - 10 g/m

2/day

R2 - 20 g/m2/day

R3 - 60 g/m2/day

R4 - 300 g/m2/day

(f) Exposure to ultra-violet radiation of 20 MJ/m

2 for a period of up to 4 weeks corresponding to the

period of construction. Reinforcement Unlike conventional masonry, AAC incorporates thin-bed adhesive in lieu of relatively permeable cement-based mortar joints. This feature, together with impermeable blocks, means that the risk of corrosion of both horizontal and vertical reinforcement is significantly reduced.


Reinforced ECOL-MEGA (AAC) Wall Cladding for Domestic Dwellings The following specification and details are generally suitable for Reinforced ECOL-MEGA (AAC) wall cladding for domestic dwellings, subject to confirmation by the Design Engineer. A suitable support framing system must also be provided. Reinforced ECOL-MEGA (AAC) Panels shall be screw fixed to horizontal light-gauge steel battens, which are fixed to vertical steel studs. There shall be not less than four horizontal battens per panel, with this number increasing for higher wind loads and for panels within 1,200 mm of the building corners. Panels within 1,200 mm of each end of each external wall of a building (i.e. the two 600 mm wide panels closest to the corners) are subject to higher local wind pressures and suctions, and therefore require more battens and more screw fixing than other panels. Unless specified otherwise by the engineer, the following details and tables shall be used for the cladding of domestic dwellings with 75 mm thick or 100 mm thick Reinforced ECOL-MEGA (AAC) Panels. Light gauge steel battens shall comply with the Drawings, Building Regulations and relevant Standards (AS/NZS 4600, AS 3623). Cold-formed sections and accessories shall be manufactured from Z350 galvanised steel (Grade G550) complying with AS 1397, with a zinc coating not less than 350 g/m2 and shall comply with AS4600. All battens shall be Lysaght Topspan 22 (22.5 x 63 x 0.55 BMT, Grade G550) or equivalent. The surfaces of zincalume battens that are in contact with the AAC panel shall be painted with a suitable high build paint to guard against adverse chemical reaction. All screws shall be No 14g x 100 mm Bugle-headed batten self drilling class 3 galvanized screws, fixed from the outside of the building through the ECOL-MEGA (AAC) panels into the horizontal steel light gauge battens behind.

General Notes: 1. All wind classifications and ultimate pressure calculations are based AS 4055-2006.

2. If ECOL-MEGA (AAC) Panels are required to provide racking resistance, the screws

and supports shall be determined by the structural engineer, taking into account the wind classification and the overall building dimensions.

3. Top and bottom battens shall be positioned within 150 mm of the ends of the panels.


ECOL MEGA PANELS (AAC) D08020701-4 May 2008 Page 21

AAC Panel fixed to steeltop-hat section, which isfixed to the supportingstructural frame

AAC Panel

AAC Panel

Window

AAC Panel fixed to steeltop-hat section, which isfixed to the supportingstructural frame

Combined flashingand damp-proofcourse

75 mm minimum to provide for termite inspection

Structural frame

Structural frame

Concrete slab/footing/piersystem, includingreinforcement, membraneetc, designed to AS2870 orAS 3600 as appropriate


Party Wall Applications

Fixing AAC Wall Panels to Existing Brickwork Party Walls

1. Apply “Seal N Flex” Bostick adhesive in dabs onto the panel to glue it directly onto the existing brickwork wall.

2. Prop the panel overnight to cure. Do not remove props until the panel is properly secured by the permanent framing supports.

3. When the flexible sealant is cured, fix the wall frame (including the steel top-hat sections) to the panel, using screws inserted from the inside of the building (rather than the normal method of fixing from the outside of the building). The number of screw fixings should be doubled from normal requirements.

Note Because the screws are inserted 72 mm and the head is not on the outside of the panel, the lateral load capacity could be approximately half of that of the fixing from the outside. This should be provided for by doubling the number of screws. Notwithstanding the reduced capacity, there will be virtually no lateral load on the panel, provided the existing brickwork wall remains in place. If the existing brickwork wall is removed, the wall could be subject to full external wind suction.

75mm ECOL-MEGA PANEL

Top hats to each side of ECOL-MEGA PANELS

Top hats fixed to frame and ECOL-MEGA

PANELS

Fire rated rod and mastic sealant as per plan specification

Floor joists may be vertical or parallel to wall

Fire rated rod or any supplementary fire rated material

as per plan specification

600mm max span from top hat to join in ECOL-MEGA PANEL

Insulation as per plan specification

Timber or steel frame as per plan specification

20-25mm gap on each side

1200

mm

max

. spa

n fo

r ea

ch to

p ha

t sec

tion

Top hat fixed to ECOL-MEGA PANEL using 65mm hex head screws

Top hat fixed to timber or steel frame using hex head screws


Fixing Details Two 600 mm Wide Panels Closest to the Corners of the Building

Screw fixing of External Reinforced AAC Panels to Steel Battens Two 600 mm Wide Panels Closest to the Corners of the Building

Wind Classification

Ultimate Suction kPa

Number of horizontal top hat supports

No of screws on top & bottom

supports

No of screws on

internal supports

N1 1.0 3 2 2

N2 1.4 3 2 2

N3 2.3 4 2 2

N4, C1 3.3 4 2 3

N5, C2 4.9 5 2 3

N6, C3 6.7 6 2 4

Notes This table applies for a distance of 1,200 mm from each end of each external wall of a building. i.e. It applies to the two 600 mm wide panels closest to the corners, and not required to provide racking resistance. All screws shall be No 14g x 100mm Bugle-headed self drilling class 3 galvanized screws (100 mm long for 75 mm thick panels, 125 mm long for 100 mm thick panels), fixed from the outside of the building through the ECOL-MEGA (AAC) panels into the horizontal steel light gauge battens behind.

Screw fixing of Steel Battens to Steel Studs

Two 600 mm Wide Panels Closest to the Corners of the Building

Wind Classification

Ultimate Pressure or Suction kPa



supports

No of screws on

internal supports

Stud Spacing,

mm

N1 1.0 3 2 2 600

N2 1.4 3 2 2 600

N3 2.3 4 2 2 600

N4, C1 3.3 4 2 3 450

N5, C2 4.9 5 2 3 450

N6, C3 6.7 6 2 3 450

Notes This table applies for a distance of 1,200 mm from each end of each external wall of a building. i.e. It applies to the two 600 mm wide panels closest to the corners, and not required to provide racking resistance. All battens shall be (22.5 x 63 x 0.55 BMT, Grade G550) or equivalent. The surfaces of zincalume battens that are in contact with the ECOL-MEGA (AAC) panel shall be painted with a suitable high build paint to guard against adverse chemical reaction. All screws shall be No 14g x 100mm Type No 17 self drilling class 3 galvanized screws (or as required by the engineer), fixed to the horizontal steel light gauge battens to the studs.


Fixing Details Panels Not at Corners of the Building

Screw Fixing of External Reinforced AAC Panels to Steel Battens

Panels Not at Corners of the Building

Wind Classification




supports

No of screws on

internal supports

N1 0.7 3 2 2

N2 1.0 3 2 2

N3 1.5 4 2 2

N4, C1 2.2 4 2 2

N5, C2 3.3 5 2 2

N6, C3 4.4 6 2 3

Notes This table applies to the external reinforced ECOL-MEGA (AAC) panels that are positioned further than 1,200 mm from the corners of the building, and not required to provide racking resistance. All screws shall be No 14g x 100mm Bugle-headed self drilling class 3 galvanized screws (100 mm long for 75 mm thick panels, 125 mm long for 100 mm thick panels), fixed from the outside of the building through the ECOL-MEGA (AAC) panels into the horizontal steel light gauge battens behind.


Panels Not at Corners of the Building

Wind Classification




supports

No of screws on

internal supports

Stud Spacing,

mm

N1 0.7 3 2 2 600

N2 1.0 3 2 2 600

N3 1.5 4 2 2 600

N4, C1 2.2 4 2 2 450

N5, C2 3.3 5 2 2 450

N6, C3 4.4 6 2 3 450

Notes This table applies to the external reinforced ECOL-MEGA (AAC) panels that are positioned further than 1,200mm from the corners of the building, and not required to provide racking resistance. All battens shall be (22.5 x 63 x 0.55 BMT, Grade G550) or equivalent. The surfaces of zincalume battens that are in contact with the ECOL-MEGA (AAC) panel shall be painted with a suitable high build paint to guard against adverse chemical reaction. All screws shall be No 14g x 100 mm Type No 17 self drilling class 3 galvanized screws (or as required by the engineer), fixed to the horizontal steel light gauge battens to the studs.


Fixing Details Internal Panels

Screw Fixing of Internal Reinforced ECOL-MEGA (AAC) Panels to Steel

Battens Internal Panels

Wind Classification




supports

No of screws on

internal supports

Any 0.7 3 2 2

Notes This table applies to the internal reinforced ECOL-MEGA (AAC) panels that are fully enclosed within a building, and not required to provide racking resistance. The system is designed for a nominal 0.7 kPa pressure or suction. All screws shall be No 14g x 100mm Bugle-headed self drilling class 3 galvanized screws (100 mm long for 75 mm thick panels, 125 mm long for 100 mm thick panels), fixed through the ECOL-MEGA (AAC) panels into the horizontal steel light gauge battens behind.


Internal Panels

Wind Classification




supports

No of screws on

internal supports

Stud Spacing,

mm

Any 0.7 3 2 2 600

Notes This table applies to the internal reinforced ECOL-MEGA (AAC) panels that are fully enclosed within a building, and not required to provide racking resistance. The system is designed for a nominal 0.7 kPa pressure or suction. All battens shall be Lysaght Topspan 22 (22.5 x 63 x 0.55 BMT, Grade G550) or equivalent. The surfaces of zincalume battens that are in contact with the ECOL-MEGA (AAC) panel shall be painted with a suitable high build paint to guard against adverse chemical reaction. All screws shall be No 14g x 100 mm Type No 17 self drilling class 3 galvanized screws (or as required by the engineer), fixed the horizontal steel light gauge battens to the studs.


Reinforced ECOL-MEGA Flooring (AAC) for Domestic Dwellings The following specification and details are generally suitable for Reinforced ECOL-MEGA FLOORING (AAC) for domestic dwellings, subject to confirmation by the Design Engineer. A suitable supporting joist system must be provided. Reinforced ECOL-MEGA FLOOR (AAC) Panels shall be screw and adhesive fixed to timber or light-gauge steel joists, at centres not greater than 450 mm centres. Joists and bearers shall comply with the Drawings, Building Regulations and relevant Standards.

• Timber joists and bearers shall comply with AS 1684.

• Light gauge steel joists and bearers shall comply with (AS/NZS 4600, AS 3623). Cold-formed sections and accessories shall be manufactured from Z350 galvanised steel (Grade G550) complying with AS 1397, with a zinc coating not less than 350 g/m2 and shall comply with AS4600. The surfaces of zincalume battens that are in contact with the ECOL-MEGA (AAC) panel shall be painted with a suitable high build paint to guard against adverse chemical reaction.

Screws shall be bugle-headed class 3 galvanized screws, fixed through ECOL-MEGA (AAC) panels into the joists.

• Timber joists: No 14g x 125 mm bugle-headed class 3 galvanized • Cold-formed steel joists: No 14g x 100 mm bugle-headed class 3 galvanized

Construction Adhesive shall be applied between adjacent panels and between panels and joists, in accordance with the manufacturer’s recommendations.

Floor Covering to manufacturer’s recommendations

Bugle-headed class 3 galvanized screws, fixed through (AAC) FLOOR panels into joists

Timber joists: No 14g x 125mm Cold-formed steel joists: No 14g x 100mm

Timber or steel joists, in accordance with AS 1684 or AS 4600, designed with sufficient strength and stiffness to prevent cracking or delamination of floor coverings

450 m

axim

um jo

ist ce

ntres

75mm ECOL-MEGA FLOOR PANEL Steel Reinforced Autoclaved Aerated Floor Panels

600

75

Construction Adhesive between adjacent panels and between panels and joists.


Reinforced ECOL-MEGA Flooring (AAC) for Domestic Dwellings The following specification and details are generally suitable for Reinforced ECOL-MEGA FLOORING (AAC) for domestic dwellings, subject to confirmation by the Design Engineer. A suitable supporting joist system must be provided. Reinforced ECOL-MEGA FLOOR (AAC) Panels shall be screw and adhesive fixed to timber or light-gauge steel joists, at centres not greater than 450 mm centres. Joists and bearers shall comply with the Drawings, Building Regulations and relevant Standards.

• Timber joists and bearers shall comply with AS 1684.

• Light gauge steel joists and bearers shall comply with (AS/NZS 4600, AS 3623). Cold-formed sections and accessories shall be manufactured from Z350 galvanised steel (Grade G550) complying with AS 1397, with a zinc coating not less than 350 g/m2 and shall comply with AS4600. The surfaces of zincalume battens that are in contact with the ECOL-MEGA (AAC) panel shall be painted with a suitable high build paint to guard against adverse chemical reaction.

Screws shall be bugle-headed class 3 galvanized screws, fixed through ECOL-MEGA (AAC) panels into the joists.

• Timber joists: No 14g x 125 mm bugle-headed class 3 galvanized • Cold-formed steel joists: No 14g x 100 mm bugle-headed class 3 galvanized

Construction Adhesive shall be applied between adjacent panels and between panels and joists, in accordance with the manufacturer’s recommendations.





600 m

axim

um jo

ist ce

ntres


600

75



7. Construction Specification Introduction The building design and construction process involves three principle functions:

• Design, including product selection;

• Manufacture and supply of all components; and

• Construction, including the attendant supervision, inspections and certification. Design The design process must encompass the selection of the appropriate product for the particular design application. The Architect and Engineer for any building project share responsibility (and authority) to determine and communicate the design (within the constraints of Building Code of Australia) to the builders. They are required to consider all relevant matters affecting the building and its components, and determine their designs drawing on professional training, experience, peer practices, ethics, client requirements, published standards, research and the like. Building Code of Australia DTS (Deemed-to-Satisfy) provisions play an important part in this decision making (and in many cases will be adopted by the Engineer or Architect), although there are also many cases where the Engineer or Architect may specify details that are different from these. This information is communicated to builders by Drawings and Specifications. Manufacture and supply There are two principal requirements of manufacturers.

• Ensure that the Company has a properly functioning Management System, capable of delivering consistent product and service to predetermined specifications. Substantial compliance with the provision of AS/NZS ISO 9001 is considered to be an indicator of such a properly functioning system.

• Ensure that the nominated products satisfy the requirements of nominated Building Code of

Australia clauses. Construction The construction process must faithfully ensure that the design expectations have been met, and that the product has been installed in accordance with the manufacturer’s instructions. However, the Builder and the Contractors must assume responsibility for the quality of the construction work. Designers often take it for granted that builders and tradesmen understand the detailed requirements for the construction of good quality buildings. This is not so - They need to be clearly guided by competent and informed designers. Appendix B sets out a sample Construction Specification for ECOL-MEGA PANEL (AAC), also available in electronic format that may be adapted and edited for particular projects.

4

4 To download electronic specifications, visit www.electronicblueprint.com.au


Appendix A Structural Design The purpose of the following worked examples is to provide guidance to structural engineers on the structural design considerations and methodology for ECOL-MEGA PANEL AAC reinforced walls, reinforced floors and unreinforced masonry.

• ECOL-MEGA PANEL (AAC), provided as steel reinforced wall panels, are designed in accordance with the recommendations of RILEM Recommended Practice – Autoclaved Aerated Concrete – Properties, Testing and Design.

5 Because this system is outside the

scope of the most relevant Building Code of Australia referenced document, AS 3700, its use must be treated, under the Building Code of Australia, as an Alternative Solution.

• ECOL-MEGA PANEL (AAC), provided as steel reinforced floor panels, are designed in accordance with the recommendations of RILEM Recommended Practice – Autoclaved Aerated Concrete – Properties, Testing and Design.

• ECOL-MEGA PANEL (AAC), provided as autoclaved aerated blocks set in thin-bed adhesive,

are designed in accordance with AS 3700-2001 Masonry Structures.

Notes

1. Because these systems are outside the scope of the most relevant Building Code of

Australia referenced documents, AS 3700 and AS 3600, their use must be treated, under the Building Code of Australia, as an Alternative Solution.

5 Aroni, S., de Groot, G.J., Robinson, M.J., Svanholm, G., & Wittman, F.H. (Editors),

“RILEM Recommended Practice – Autoclaved Aerated Concrete – Properties, Testing and Design”


Example No 1 - Walls Brief Using both unreinforced and reinforced ECOL-MEGA PANEL AAC, determine the load capacities of the principal external walls (3.8 m high to top support x 6.6 m long between steel portal frames) building subject to lateral wind load and supporting a concrete slab. The wall does not have an opening.

Wall Dimensions Height of wall (or pier) H = 3,800 mm Length of wall (or pier) L = 6,600 mm Thickness of wall (or pier) T = 75 mm

Is at least one end of the member supported?

Are both ends of the member supported?

Is the masonry continuous past at least one support?

Is the masonry continuous past both supports?

Is the member supported laterally at the top?

Is the member loadbearing?

Does the member support a concrete slab?


Robustness These robustness coefficients are applicable to Unreinforced ECOL-MEGA (AAC) Blocks in thin-bed adhesive, which are within the scope of AS 3700. In this manual, the robustness criteria are also applied to Reinforced ECOL-MEGA (AAC) Panels, which are outside the scope of AS 3700, to maintain consistency with the approach applied to reinforced masonry. Vertical robustness coefficient AS 3700 Table 4.2 Cv = 48.0 for Reinforced (AAC) Panels; and

= 36.0 for Unreinforced (AAC) Blocks in thin-bed adhesive, both laterally restrained and supporting a concrete slab

Horizontal robustness coefficient AS 3700 Table 4.2 Ch = 36.0 for Unreinforced (AAC) Blocks in thin-bed adhesive, with two vertical supports Note

The horizontal robustness coefficient is not applicable to Reinforced (AAC) Panels, which span in one direction only.

Height for calculating robustness Hr = H / 1,000

= 2.700 m

Length for calculating robustness Lr = IF(Lo > 0, Lt, L) / 1,000 = 6.600 m Thickness for calculating robustness tr = IF(Construction = "Single", tu, MAX( 0.6667 (tu + tu minor), tu , tu minor)) / 1,000

= 0.075 m Maximum permissible height based on robustness criteria (Unreinforced AAC) Hmax = MAX( Cv tr kt, IF(Lr / tr > Ch, tr ( Cv + Ch /( Lr - Ch tr)), infinite)) 1,000 = MAX( [36 x 0.075 x 1.52],

IF(6.600 / 0.075 > 36, 0.075 ( 36 + 36 /( 6.600 –[36 x 0.075])),infinite)) 1,000 = 4,125 mm

Maximum permissible height based on robustness criteria (Reinforced AAC Panels) Hmax = Cv tr kt, 1,000 = 48 x 0.075 x 1.52 x 1,000

= 5,500 mm OK Capacity Reduction Factors Capacity reduction factor for compression in unreinforced masonry AS 3700 Table 4.1

φc = 0.45

Capacity reduction factor for bending & shear in unreinforced masonry AS 3700 Table 4.1

φb = 0.60

Capacity reduction factor for reinforced masonry AS 3700 Table 4.1

φr = 0.75

Capacity reduction factor tension and compression in wall ties etc AS 3700 Table 4.1

φt = 0.95

Capacity reduction factor for other actions in wall accessories AS 3700 Table 4.1

φo = 0.75


ECOL-MEGA PANEL AAC Steel Reinforced Autoclaved Aerated Wall Panels

ECOL-MEGA PANEL AAC, Steel Reinforced Autoclaved Aerated Panels have the following properties:

Ultimate Capacities

6

Characteristic compressive strength of AAC f'ck = 4.0 MPa Reinforcement strength grade f'sk = 235 MPa Strain in AAC at compressive yield εcy = 0.002

6 Where appropriate, some of the symbols used in “RILEM Recommended Practice – Autoclaved

Aerated Concrete – Properties, Testing and Design” have been changed to be consistent with Australian practice and AS 3700.


Strain in AAC at compressive rupture

εcu = 0.003

Strain in steel at tensile rupture

εsu = 0.005

Capacity reduction factor (Based on AS 3700 Clause Table 4.1)

φ = 0.75

Width of panel b = 600 mm Total depth of section D = 75 mm Diameter of tensile reinforcement Rt = 5 mm Number of tensile reinforcement strands in each reinforced member Nt = 5 Diameter of compressive reinforcement Rc = 5 mm Number of compressive reinforcement strands in each reinforced member Nc = 0 Tension face to centroid of tensile steel d1 = 30 mm Compression face to centroid of compression steel d2 = 0 mm Depth to the centroid of the tensile steel from the compression face d = D - d1

= 75 - 30 = 45 mm

Area of one tensile reinforcing strand Ast1 = 3.1416 x Rt

2 / 4

= 3.1416 x 52 / 4

= 19.6 mm2

Design area of tensile reinforcing strands in each reinforced member As = Ast1 Nt

= 19.6 x 5 = 98.2 mm

2

Area of one compressive reinforcing strand A’s1 = 3.1416 x Rt

2 / 4

= 3.1416 x 02 / 4

= 0 mm2

Design area of tensile reinforcing strands in each reinforced member A’s = Ast1 Nt

= 0 x 0 = 0 mm

2

Reinforcement constant


αmax = 0.667


βmax = 0.361

Tensile reinforcement factor c = (As f’sk) / (b d f’ck)

= (98.2 x 235) / (600 x 45 x 4.0) = 0.214

Compressive reinforcement factor c' = 0.75 c A’s / As

= 0.75 x 0.214 x 0 / 98.2 = 0


a1 = (c - c’) εcy / εsu

= (0.214 - 0) 0.002 / 0.005 = 0.0854


k = εcy / (2 εsu)

= 0.002 / (2 x 0.005) = 0.200

Depth to neutral axis / effective depth (medium reinforcement, 0.286 < s < 0.375) s = (k + c - c’) / (1 + k)

= (0.200 + 0.214 - 0.0) / (1 + 0.200) = 0.345

Depth to neutral axis / effective depth (light reinforcement, s < 0.286) s = (a1

2 + 2 a1)

0.5 - a1

Depth to neutral axis / effective depth (heavy reinforcement, 0.375 < s)

s = (c – c’) / αmax


α = 1 - [(1 – s) k / s]

= 1 - [(1 – 0.345) 0.200 / 0.345] = 0.620

Is this value not greater than 0.667? OK Reinforcement constant

β = {2 k (1 - s) [-1 + 2 k (1 - s) / (3 s)] + s} / {2 s – 2 k (1 - s)}

= {(2 x 0.200) x (1 - 0.345) [-1 + (2 x 0.200) x (1 – 0.345) / (3 x 0.345)] + 0.345} / {(2 x 0.345) – (2 x 0.200) (1 – 0.345)}

= 0.349 Is this value not greater than 0.361? OK Moment capacity (medium reinforcement, 0.286 < s < 0.375)

φ Mu = φ f’ck b d2 [ α s (1 – β s) + c’ (1 – d2/d) ]

= 0.75 x 4.0 x 600 x 452 [ {0.620 x 0.345} x (1 – {0.349 x 0.345}) + c’ (1 – 0/30) ]

= 0.685 kN.m

Moment capacity (light reinforcement, s < 0.286)

φ Mu = φ f’ck b d2 [ s

2 [(1 – s/3) εsu]/ [(1 – s) εsu] + c’ (1 – d2/d) ]

Moment capacity (heavy reinforcement, 0.375 < s)

φ Mu = φ f’ck b d2 [ αmax s (1 – βmax s) + c’ (1 – d2/d) ]


ECOL-MEGA PANEL (AAC) Unreinforced Autoclaved Aerated Masonry Resistance to Bending (Unreinforced Masonry)

Unit length lu = 600 mm Unit height hu = 600 mm Unit thickness tu = 75 mm Unit material is “Lightweight” Basalt content = Under 45% Unit density

ρ = 520 kg/m3

ECOL-MEGA PANEL AAC

Brochure Density classification Class = "Under 1800” Unit compressive strength ECOL-MEGA PANEL AAC Brochure f'uc = 4.0 MPa Unit lateral modulus of rupture AS 3700 Clause 1.5.2.9 f'ut = 0.8 MPa Properties Flexural strength AS 3700 3.3.3 f’mt = 0.20 MPa Shear strength AS 3700 3.3.4 f’vm = 0.35 MPa Shear factor AS 3700 3.3.5, Table 3.3 kv = 0.30 Proprietary thin-bed adhesive Adhesive joint thickness tj = 2 mm maximum Minimum overlap of units in successive courses sp = (lu + tj)/2- tj

= (600 + 2)/2 – 2 = 299 mm


Bedding surface width ts = 75 mm Section modulus of the perpendicular joints (per metre length) Zp = 1,000 tu

2 / 6

= 1,000 x 75 2 / 6

= 938,000 mm3/m

Section modulus of the units (per metre length) Zu = 1,000 tu

2 / 6

= 1,000 x 75 2 / 6

= 938,000 mm3/m

Section modulus of the bedding surface (per metre length) Zd = 1,000 tu

2 / 6

= 1,000 x 75 2 / 6

= 938,000 mm3/m

Net area of section Ab = tu . 1,000 = 75 x 1,000 = 75,000 mm

2/m

If it is intended that the wall should include openings, it is necessary to support the edges of the opening by external supports. Vertical compressive unfactored stress due to external load (unfactored vertcal permanent line load) fd t = 1,000 Wp v / Ab = 1,000 x 20.0 / 75,000

= 0.27 MPa The calculated vertical bending capacity of the wall is contingent on the vertical compressive

stress induced by any external loading. In this case, an unfactored vertical compressive load of 20 kN/m has been used.

Vertical compressive unfactored stress at mid height of wall due to self weight

fd sm = ρ H te 9.81/ (2 Ab 106)

= 520 x 3,800 x 75 x 9.81/ (2 x 75,000 x 106)

= 0.01 MPa Vertical compressive unfactored stress at base of wall due to self weight

fd sb = ρ H te 9.81/ (Ab 106)

= 520 x 3,800 x 75 x 9.81/ (75,000 x 106)

= 0.02 MPa Vertical compressive unfactored stress at mid height of wall fd m = fd t + fd sm = 0.27 + 0.01 = 0.28 MPa Vertical compressive unfactored stress at base of wall fd b = fd t + fd sb = 0.27 + 0.02 = 0.29 MPa Bending moment capacity factor kmt = 1.0

For "AAC" 1.3


Perpend spacing factor kp = MIN( sp/tu, sp/hu, 1.0)

= MIN (299/75, 299/600, 1.0) = 1.0

Vertical bending moment capacity AS 3700 Clause 7.4.2 (b) Mcv = MIN (φb kmt f’mt Zd + fd m Zd , 3 φb kmt f’mt Zd ) / 10

6

= MIN( [0.60 x 1.3 x 0.20 x 938,000] + [0.28 x 938,000], [3 x 0.60 x 1.3 x 0.20 x 938,000])/10

6

= MIN (0.405 , 0.439) = 0.405 kN.m/m

Horizontal bending moment capacity AS 3700 Clause 7.4.3.2 (b) Mch = φb (0.22 f’ut + 0.33 f’mt) Zd / 10

6 ,

= 0.6 ( [0.22 x 0.80] + [0.33 x 1.3 x 0.20) x 938,000 / 106

= 0.147kN/m Vertical bending coefficient AS 3700 Table 7.5 bv = 1.0 Horizontal bending coefficient AS 3700 Table 7.5 bv = 1.0 Lateral load capacity for two-way action (limited by AAC bending) AS 3700 Table 7.4.4.3

φ wd2 b = 12 (bv Mcv / H2 + bh Mch / L

2) H / L . 1,000,000

= 12 ([1.0 x 0.405 / 3,8002 ] + [1.0 x 0.147/ 6,600

2]) x 3,800 / 6,600 x 1,000,000

= 0.223 kPa Lateral load capacity for one-way action (limited by AAC bending)

φ wd1 b = 8 Mcv / H2 x 10

6

= 8 x 0.405 / 3,8002 x 10

6

= 0.225 kPa Lateral load capacity (limited by AAC bending)

φ w b = MIN (φ wd2 b , φ wd1 b)

= MIN (0.223 , 0.225) = 0.223 kPa


ECOL-MEGA PANEL (AAC) Steel Reinforced Autoclaved Aerated Panels and Unreinforced Autoclaved Aerated Masonry Resistance to Uniform Compression The following design in accordance with AS 3700 Clause 7.3 is applicable to Unreinforced (AAC) Masonry. RILEM Recommended Practice – Autoclaved Aerated Concrete – Properties, Testing and Design” provides a method for Unreinforced AAC, but does not provide a separate method for reinforced method. Therefore, this AS 3700 Clause 7.3 method has also been used for Reinforced ECOL-MEGA PANEL (AAC). Engaged Piers

This example includes engaged piers tied to the walls, normally used to stiffen the walls and to provide support fro bearers. Whilst such details are not common for ECOL-MEGA PANEL (AAC), they are not impossible. For this reason, engaged piers have been included in the worked example. Pier outstand tpo = 75 mm Pier width tpw = 600 mm Pier spacing tps = 2400 mm Overall thickness of the member’s cross section tw = 75 mm

Thickness of pier (wall + outstand) twp = tpo+ tu

= 75 + 75 = 150 mm

Pier thickness ratio twp/tu = twp / tu

= 150 / 75 = 2.00

Pier spacing / pier width bps/bpw = bps / bpw

= 2,400 / 400 = 6.0

Thickness coefficient for walls stiffened monolithically be engaged piers kt = 1+0.002062*(20-MIN(20, bps/bpw))

2. (MIN(twp/tu ,3) - 1)

1.3

= 1+0.002062*(20-MIN(20, 6.0)) 2. (MIN(2.0 ,3) - 1)

1.3

= 1.53


Characteristic masonry strength AS 3700 Clause 3.3.2 (ii)

f'm = f’uc

= 4.0 MPa Density factor AS 3700 Clause 7.3.2 kc = 1.20 Basic compressive strength capacity

Fo = φ c (f’m Ab + kc (f’cg / 1.3)0.5

Ac ) / 1000

= 0.45 ([4.0 x 75,000] + [1.20 x (0 / 1.3)0.5

x 0]) / 1,000 = 135. kN/m

Vertical slenderness coefficient av = 0.75

No top support 2.5 Partial top support, laterally restrained, and partially rotationally restrained at bottom 1.5 Laterally restrained at top and bottom, no rotational restraint 1.0 Laterally restrained at top and bottom, partially rotationally restrained at one of them

0.85 Laterally restrained, partially rotationally restrained at top and bottom

0.75 Horizontal slenderness coefficient ah = 1.00 Laterally supported at both vertical ends 1.0

Laterally supported at one vertical end 2.5

Slenderness for refined calculation Sr = MIN (av H / (kt tw) , 0.7 ( av H ah IF (Lo > 0, Lt , L))

0.5 / tw )

= MIN (0.75 x 3,800 / (1.53 x 75) , 0.7 ( 0.75 x 3,800 x 1.00 x 6,600)0.5

/ 75 ) = MIN (24.9, 40.5) = 24.9

Eccentricity at the top e1 = 12.5 mm Eccentricity must be determined by the engineer. Eccentricity at the base e2 = 12.5 mm Eccentricity must be determined by the engineer. Eccentricity ratio at the top of the wall e1/tw = e1 / tw

= 12.5 / 75 = 0.167

Reduction factor (for eccentricity and slenderness) ke,s =IF(e1/tw > 0.499 , 0 , MAX(0 , MIN(1 , IF( e1/tw >0.05,

0.5(1+e2/e1)*((1-2.083e1/tw)-(0.025-0.037e1/tw)(1.33Sr-8))+0.5(1-0.6 e1/tw)(1-e2/e1)(1.18-0.03Sr) 1.18 - 0.03 Sr ))))

= IF(0.167 > 0.499 , 0 , MAX(0 , MIN(1 , IF( 0.167 >0.05, 0.5*(1 + 12.5 / 12.5) x ((1 – [2.083 x 0.167]) - (0.025 – [0.037 x 0.167]) ([1.33 x 24.9] - 8)) + 0.5 (1 – [0.6 x 0.167]) x (1 – 12.5 / 12.5) (1.18 – [0.03 x 24.9]) , 1.18 – [0.03 x 24.9] ))))

= 0.181


Reduction factor (for eccentricity and slenderness) kcrush = For "Solid/Cored" units, 1 - 2 e1/tw ,

For “Hollow” units, MIN( (1 - ts / tw )/(1 - ts / tw + 2 e1/tw ) , (1 - 2 e1/tw) / (2 ts / tw) )) = 1 – (2 x 0.167) = 0.667

Reduction factor (for eccentricity, slenderness and crushing) k = MIN (ke,s , kcrush ) = MIN ( 0.181 , 0.667 ) = 0.181 Design compressive strength k Fo = k Fo

= 0.181 x 135. = 24.4. kN/m

Design compressive strength of the whole length of member k Fo L = k Fo . L / 1,000

= 24.4 x 6,600 / 1,000 = 161. kN

Resistance to Concentrated Loads The following design in accordance with AS 3700 Clause 7.3.5 is applicable to Unreinforced AAC Masonry. RILEM Recommended Practice – Autoclaved Aerated Concrete – Properties, Testing and Design” provides a reasonably similar approach for Unreinforced AAC, but does not provide a separate method for reinforced method. Therefore, this AS 3700 Clause 7.3.5 method has also been used for Reinforced ECOL-MEGA PANEL AAC.

Distance from the end of the wall to the point load (if near the end) a1 = 300 mm Distance to the closest point load on the right a2 = 600 mm Distance to next point load on the right a3 = 600 mm


Length over which the point load is spread (at the point of contact) a4 = 100 mm Effective dispersion length of the concentrated load close to the end of the wall Le e = MIN (L , MIN(a1 e , H/2 ) + a4 e + MIN(a2 e / 2 , H/2)) = MIN (6,600 , MIN(300 , 3,800 / 2 ) + 100 + MIN ( 600 /2 , 3,800 / 2 )) = 700 mm Effective dispersion length of concentrated load away from the end of the wall Le i = MIN (a2 i / 2 , H/2 ) + a4 i + MIN (a3 i / 2 , H/2) = MIN ( 600 / 2 , 2,700 / 2 ) + 100 + MIN ( 600 / 2 , 2,700 / 2 ) = 700 mm Effective dispersion area of concentrated load at mid-height Adc = tu Le = 75 x 700 = 52,500 mm

2

Bearing area Ads = tu a4 e

= 75 x 100 = 7,500 mm

2

Concentrated bearing factor kb e = MAX ( 1 , MIN( 0.55 (1 + 0.5 a1 e / L ) / ((Ads e / Adc e)

0.33 ) , 1.5 + a1 e / L)) , 1)

= Max ( 1 , MIN( 0.55 (1 + [0.5 x 300 / 6,600] ) / ((7,500 / 52,500 )0.33

) ,1.5 + 300 / 6,600 )) , 1)

= 1.0

Compressive strength capacity immediately under concentrated load (modified for concentration) kb Fo a4 e= kb . Fo . a4 e / 1,000 = 1.0 x 135 x 100 / 1,000 = 13.5 kN Dispersed compressive load at mid-height of the wall Wmid e = P max e / Le e x 1,000 = 19.5 / 700 x 1,000

= 27.9 kN/m

Concentrated point loads P conc = 19.5 kN

Number of point loads Ncl = 11 Total of concentrated point loads P tot conc = P conc Ncl

= 19.5 x 11 = 215 kN


Example No 2 - Floors Brief Determine the load capacities of 75 mm ECOL-MEGA PANEL (AAC) Steel-Reinforced Autoclaved Aerated Floor Panels, spanning over joists at 450 mm centres.

75 mm ECOL-MEGA PANEL Steel Reinforced Autoclaved Aerated ECOL-MEGA Floor Panels





450 m

axim

um jo

ist ce

ntres


600

75



Ultimate Capacities7

Characteristic compressive strength of AAC f'ck = 4.0 MPa Reinforcement strength grade f'sk = 250 MPa Strain in AAC at compressive yield

εcy = 0.002

Strain in AAC at compressive rupture

εcu = 0.003

Strain in steel at tensile rupture

εsu = 0.005

Capacity reduction factor (Based on AS 3700 Clause Table 4.1)

φ = 0.75

Width of panel b = 600 mm Total depth of section D = 75 mm Diameter of tensile reinforcement Rt = 5 mm Number of tensile reinforcement strands in each reinforced member Nt = 5 Diameter of compressive reinforcement Rc = 5 mm Number of compressive reinforcement strands in each reinforced member Nc = 0 Tension face to centroid of tensile steel d1 = 30 mm Compression face to centroid of compression steel d2 = 0 mm Depth to the centroid of the tensile steel from the compression face d = D - d1

= 75 - 38 = 37 mm

Area of one tensile reinforcing strand Ast1 = 3.1416 x Rt

2 / 4

= 3.1416 x 52 / 4

= 19.6 mm2

7 Where appropriate, some of the symbols used in “RILEM Recommended Practice – Autoclaved

Aerated Concrete – Properties, Testing and Design” have been changed to be consistent with Australian practice and AS 3700.


Design area of tensile reinforcing strands in each reinforced member As = Ast1 Nt

= 19.6 x 5 = 98.2 mm

2

Area of one compressive reinforcing strand A’s1 = 3.1416 x Rt

2 / 4

= 3.1416 x 02 / 4

= 0 mm2

Design area of tensile reinforcing strands in each reinforced member A’s = Ast1 Nt

= 0 x 0 = 0 mm

2

Bending Reinforcement constant αmax = 0.667


βmax = 0.361

Tensile reinforcement factor c = (As f’sk) / (b d f’ck)

= (98.2 x 250) / (600 x 37 x 3.5) = 0.312

Compressive reinforcement factor c' = 0.75 c A’s / As

= 0.75 x 0.214 x 0 / 98.2 = 0


a1 = (c - c’) εcy / εsu

= (0.312 - 0) 0.002 / 0.005 = 0.1247

Reinforcement constant k = εcy / (2 εsu)

= 0.002 / (2 x 0.005) = 0.200

Depth to neutral axis / effective depth (heavy reinforcement, 0.375 < s)

s = (c – c’) / αmax

= (0.312 - 0.0) / 0.667 = 0.467

Depth to neutral axis / effective depth (light reinforcement, s < 0.286) s = (a1

2 + 2 a1)

0.5 - a1

Depth to neutral axis / effective depth (medium reinforcement, 0.286 < s < 0.375) s = (k + c - c’) / (1 + k)


α = Min (1 - [(1 – s) k / s] , 0.667 )

= Min (1 - [(1 – 0.467) 0.200 / 0.467] , 0.667) = 0.667



β = Min [ 0.361, {2 k (1 - s) [-1 + 2 k (1 - s) / (3 s)] + s} / {2 s – 2 k (1 - s)} ]

= Min [ 0.361, {(2 x 0.200) x (1 - 0.467) [-1 + (2 x 0.200) x (1 – 0.467) / (3 x 0.467)] + 0.389} / {(2 x 0.467) – (2 x 0.200) (1 – 0.467)}

= 0.361 Moment capacity (heavy reinforcement, 0.375 < s)

φ Mu = φ f’ck b d2 [ αmax s (1 – βmax s) + c’ (1 – d2/d) ]

= 0.75 x 3.5 x 600 x 452 [ {0.667 x 0.467} x (1 – {0.361 x 0.467}) + 0 (1 – 0/38) ]

= 0.57 kN.m

Moment capacity (light reinforcement, s < 0.286)

φ Mu = φ f’ck b d2 [ s

2 [(1 – s/3) εsu]/ [(1 – s) εsu] + c’ (1 – d2/d) ]

Moment capacity (medium reinforcement, 0.286 < s < 0.375)

φ Mu = φ f’ck b d2 [ α s (1 – β s) + c’ (1 – d2/d) ]

Shear

Distance from support to shear force

a = Span / 2

= 450 /2

= 225 mm

Shear capacity

φ V =φ [(0.035 f’ck + 1.163 (100 As / b.d) d / a -0.053)] b.d /1,000

= 0.75[(0.035 x 3.5) + 1.163 (100 x 98.2/{600 x 37}) 37 / 225 – 0.053] 600 x 37/ 1000

= 2.60 kN Bearing “RILEM Recommended Practice – Autoclaved Aerated Concrete – Properties, Testing and Design” does not give any limits for bearing strength for point loads bearing on AAC floor panels. However, an indication of the probable bearing capacity may be gauged from the two following two sources:

For unreinforced AAC, the RILEM Recommended Practice provides a formula for concentrated forces on walls. Using this formula, it is possible to predict a factored bearing strength for floor point loads. Bearing Capacity

φ fb = φ f’c 1.3 .1.5

= 0.75 x 3.5 x 1.3 x 1.5 = 5.1 MPa

For reinforced concrete, AS 3600 Clause 12.3 permits a factored bearing strength for point (anchorage) loads on concrete. Bearing Capacity

φ fb = φ 2 f’c

= 0.75 x 2 x 3.5 = 5.3 MPa

Notes:

1. The designer should understand the limitations of these two references, and should account for concentrated point loads accordingly.

2. Typical bearing stresses for some residential applications, using the requirements of AS 1170.1, are 1.8 kN spread over 350 mm

2, giving 5.1 MPa.


Appendix B Construction Specification

Scope This sample specification covers the construction of ECOL-MEGA PANEL (AAC) in buildings, including Reinforced ECOL-MEGA PANEL (AAC) and Unreinforced ECOL-MEGA PANEL (AAC) Masonry in thin-bed adhesive. This sample specification is available in electronic format, with the express intention that designers will edit them to suit the particular requirements of specific construction projects. The design, construction and costing of structures must be carried out by qualified and experienced architects, engineers and builders. This sample specification has been prepared in the context of the Building Code of Australia. Architects, engineers and builders should make themselves aware of any recent changes to these documents, to any Standards referred to therein or to local variations or requirements. The authors, publishers and distributors of this specification and the associated details do not accept any responsibility for incorrect, inappropriate or incomplete use of this information. To prepare a working specification for a particular contract, obtain and electronic version, and edit as appropriate. Building Code of Australia and Standards All materials and construction shall comply with the most recent version of:

• the relevant parts of the Building Code of Australia;

• the Standards referred to therein;

• other Standards nominated in this specification; and

• other relevant Regulations.

Relevant Standards and Documents Aroni, S., de Groot, G.J., Robinson, M.J., Svanholm, G., & Wittman, F.H. (Editors), “RILEM Recommended Practice – Autoclaved Aerated Concrete – Properties, Testing and Design” AS/NZS 2904 Damp-proof courses and flashings AS/NZS 2699.1 Built-in components for masonry construction - Wall ties AS/NZS 2699.2 Built-in components for masonry construction - Connectors and accessories AS/NZS 2699.3 Built-in components for masonry construction - Lintels and shelf angles durability AS 3660.1 Termite management – New Building work AS 3660.2 Termite management – In and around existing buildings and structures - Guidelines AS/NZS 4680 Hot-dip galvanised (zinc) coatings on fabricated ferrous articles AS/NZS 4534 Zinc and zinc/aluminium-alloy coatings on steel wire AS 2837 Wrought alloy steels – stainless steel bars and semi-finished products AS/NZS 4792 Hot-dip galvanised (zinc) coatings on ferrous hollow sections, applied a continuous or specialised process AS/NZS 4791 Hot-dip galvanised (zinc) coatings on ferrous open sections, applied by an in-line process


AS/NZS 4671 Steel reinforcing materials AS 1397 Steel sheet and strip AS 3600 Concrete structures AS 2870 Residential slabs and footings – Construction

Commencement Work shall commence as soon as practical after, but not before, (a) The Builder has issued:

• a written order • the relevant contract drawings, specifications and schedule of work • written approval of any details provided by the Contractor

(b) Completion of supporting structures such as footings, concrete slab-on-ground or suspended concrete slabs.


Occupational Health and Safety The following table sets out the principal considerations of occupational health and safety for the construction of ECOL-MEGA PANEL AAC panels.

Activities Covered by these Procedures

1. Receive all materials required for ECOL-MEGA PANEL AAC panels construction onto the site and store off the ground in a safe, secure location.

2. Move the materials to work site. 3. Lift & Support Panels - Using appropriate cranes and slings, lift the panels into position and

immediately brace with supports that have been designed and specified by the Structural Engineer.

4. Permanent Fixings - As soon as practical, complete all permanent fixing of the panels to the

structure. All such fixings must be designed and specified by the Structural Engineer. Do not remove temporary supports until permanent fixings are secured.

5. Flashing & Weatherproofing - Apply all flashings, renders, weatherproof coatings, and other

finishing, as specified in the Drawings and/or Specification. 6. Clean-up - Remove rubbish, carry out final check, hand over the project.

Limitations: The worker is not authorized to:

• Use electrical equipment, welding equipment and the like

• Use motorized equipment, except cranes. Separate procedures for the safe use of cranes must be prepared and used.

Risks Precaution

Impact by mobile equipment Wear brightly coloured shirt or vest

Impact from falling items Wear a safety helmet near elevated work

Back injury or muscle injury Do not lift heavy items – max 14 kg Avoid strenuous activity if unfit or suffering back or muscle strain

Foot injury Wear strong boots, preferably with steel caps

Heat exhaustion Drink plenty of fluids, Rest in shaded areas

Sun damage to skin Wear a hat, shirt & sunscreen

Fall from ladder Ensure top of ladder is secured & protruding at least 1.0 m above the floor

Electrocution Ensure electrical equipment is safe & tagged Do not use electric power in wet conditions Wear insulated footwear Avoid overhead & hidden power cables

Fall from scaffold, roofs or elevated floors Ensure all handrails are installed Do not lean on handrails

Chemical attack to skin by cement in concrete grout, in some cases leading to dermatitis

Wear gloves and other protective clothing to avoid rash and itchiness

Inhalation of dust, particularly while cutting AAC

Wear respirators complying with AS/NZS1715 and AS/NZ1716, and eye protection, complying with AS1336, when cutting and chasing AAC.

Collapse of structure Ensure structure is correctly braced. In particular, ensure that unfinished AAC not tied to permanent supports is braced.


Reinforced ECOL-MEGA (AAC) Panels

Reinforced AAC Wall Panels shall be ECOL-MEGA PANEL AAC complying with the following:

• Architectural and Engineering Drawings

• Building Code of Australia

• Relevant Australian Standard listed previously in this specification

• Requirements of “RILEM Recommended Practice – Autoclaved Aerated Concrete – Properties, Testing and Design”

• Properties not less than specified in the following schedule.

Important Design and Construction Checks The tabulated properties are based on advice from the suppliers.

• The designer must check the availability of the particular products and design accordingly, selecting the appropriate properties from the table.

• In the case of wall panels, the designer must consider loading from both sides of the wall. The required

construction detail must be indicated clearly on the drawings.

• The builder must check compliance of the product supplied to site against this table of properties. See also the checklist that forms part of the specification.

• Where the reinforcement is not in the centre of the panel, the designer must indicate clearly on the drawings which sides of the wall it must be placed, and the builder must install it correctly.

• The designer must correctly detail the required connections, and the builder must ensure that they are correctly installed, properly fixing the AAC panels into the building.

Definitions • Dimensional Category DW0 - No Requirements

• Dimensional Category DW1 - Average deviation of a sample of 20 units; +,- 2.5 mm (dimensions under

150 mm); +,- 4.5 mm (dimensions 150 to 250 mm); +,- 5.0 mm (dimensions over 250 mm) • Dimensional Category DW4 - For a sample of 20 units, the standard deviation of work sizes shall be not

more than 2 mm, and the difference between the mean and the work size shall be not more than 3 mm. For split faces, the dimensional deviations shall not apply to the width of the unit, provided the average width is not less than 90% of the work size.

• General Purpose Salt Attack Resistance Grade - Performance such that it is possible to demonstrate

that the product has a history of surviving under non-saline environmental conditions similar to those existing at the site considered, but not expected to meet the mass loss criterion for Exposure Grade Salt Attack Resistance Grade.

• Exposure Grade Salt Attack Resistance Grade - Performance such that it is possible to demonstrate that

the product has a history of surviving under saline environmental conditions similar to those existing at the site considered; and less than 0.2 grams mass loss in 40 cycles in AS/NZS 4456.10, Method B test.


Summary of Properties of the ECOL-MEGA PANEL AAC Products

Product Code 75 W37 75 W30 100 W18 75 F30 75 F37

Application Wall Wall Wall Floor Floor

Panel thickness, T, mm 75 75 100 75 75

Panel width, W, mm 600 600 450 600 600

Panel length, L, mm Varies Varies Varies 1,800 1,800

Panel dry density, ρd, kg/m3 520 520 520 520 520

Panel bulk density, ρb, kg/m3 565 565 565 565 565

Charact compressive strength, f'ck, MPa 4.0 3.5, 4.5 4.0 4.0 3.5, 4.5

Characteristic flexural strength, f'f , MPa 1.0 1.0 1.0 1.0 1.0

Characteristic tensile strength, f't, MPa 0.35 0.35 0.35 0.35 0.35

Mean elastic modulus, E, MPa 1,800 1,800 1,800 1,800 1,800

Reinforcement strength, f’y, MPa 250 250 250 250 250

Number of layers of reinforcement 1 1 2 1 1

Main reinforcement diameter, mm 5 5 5 5 5

No of reinforcement strands 5 5 3 5 5

Reinforcement centres, mm 37/37 45/30 18/64/18 45/30 37/37

Effective reo depth, d, mm 37 45 30 82 45 30 37

Moment capacity, kN.m/panel 0.574 0.712 0.436 0.827 0.712 0.436 0.574

Simple span, m Capacity kPa

0.90 9.45 11.72 7.17 18.16

1.20 5.31 6.59 4.04 10.21

1.50 3.40 4.22 2.58 6.54

1.80 2.36 2.93 1.79 4.54

2.10 1.74 2.15 1.32 3.33

2.40 1.33 1.65 1.01 2.55

2.70 1.05 1.30 0.80 2.02

3.00 0.85 1.05 0.65 1.63

3.30 0.70 0.87 0.53 1.35

Notes:

1. In a 75 mm thick panel where the main reinforcement is 45 mm from one face and 30 mm from the other face, the designer must nominate which face of panel is to be oriented in which direction. In a 75 mm thick panel where the main reinforcement is 55 mm from one face and 20 mm from the other face, the designer must nominate which face of panel is to be oriented in which direction.

2. There must be sufficient secondary reinforcing strands across the panel, to provide sufficient anchorage.

3. Dimensional Category DW4.

4. General Purpose Salt Attack Resistance Grade, except for applications requiring Exposure Grade.

Applications requiring Exposure Grade are saline wetting or drying, aggressive soils, severe marine environments, saline or contaminated water including tidal or splash zones, or within 1 km of a industry producing chemical pollutants.


Thin Bed Adhesive Thin Bed Adhesive shall be mixed and applied in accordance with the manufacturer’s instructions. Damp-Proof Course Damp-proof-courses shall be built into the wall in accordance with the Drawings, Building Code of Australia and relevant Standard (AS 3700). Unless stated otherwise, damp-proof-courses shall be: • Placed under walls to provide a continuous damp-proof barrier around the building • Lapped not less than 150 mm at joints • Projecting through the entire width of the wall and project beyond the external face • Stepped at changes of floor level • Positioned (if applicable) under the coping of any parapet more than 300 mm above adjoining

roof cladding • Positioned (if applicable) in chimney stacks, 150 mm to 300 mm above the highest junction of

roof and chimney • At least 75 mm above finished surface level of adjacent paved, concreted or landscaped

areas that slope away from the wall • At least 50 mm above finished paved or concreted areas sloping at least 50 mm over the first

1 m from the building and protected from the direct effects of the weather by a carport, verandah or similar

• At least 150 mm above the adjacent finished ground in all other cases.

Flashings Flashings shall be built into the wall in accordance with the Drawings, Building Code of Australia and relevant Standard (AS 3700). Unless stated otherwise, flashings shall be: • Fixed with clouts to timber studs as applicable • Built into the external leaf of walls exposed to weather, extending across the cavity, • Turned up 150 mm and nailed to the frame, • Positioned at openings (unless they are protected by an overhang), where they shall extend

100 mm past the end of opening and be turned up to prevent leakage.

Termite Protection Termite protection measures shall comply with the Building Code of Australia and the relevant Standard (AS 3660.1) The aim of most termite barriers is to force the termites to the surface of the structure, where they are visible and can be easily eradicated. Some termite barriers also include chemicals that deter the termites from passing. Other systems, involving chemical dosing and graded stone barriers may be applicable, but must be properly maintained. Refer to the relevant materials specifications. Termite protection shall provide a continuous barrier that prevents termites from entering the building undetected. The critical areas for termite entry, including the external perimeter, construction joints and plumbing penetrations, shall be protected and treated by a termite management system. The system installation shall conform to the manufacturer’s guidelines. A manufacturer’s warranty for a minimum of fifty (50) years shall be provided. The warranty shall be renewable on an annual basis, base on annual inspection by the system installation organisation. Such a warranty shall provide for timber replacement should a system breach occur. A certificate permanently fixed to the building in a prominent location, such as a meter box, kitchen cupboard, or similar, shall indicate the following: • Method of protection. • Date of installation. • Life expectancy of any termiticide and the required re-injection date. • Installer’s or manufacturer’s recommendations for the scope and frequency of future

inspections for termite activity, not greater than 12 months.

Sheet material acting as a termite barrier and their joints shall be constructed of termite-resistant materials, such that termites are unable to pass through them. The maximum aperture size of a perforated sheet material barrier shall be sufficiently small as to deny access to foraging termite


species of the region. Combinations of materials likely to cause electrolytic reaction shall not be used, e.g. stainless steel mesh shall not be used in contact with mild steel reinforcement. Slip Joints Slip joint material shall be placed between walls and any supported concrete slab. Lintels and Arch Bars Lintels and arch bars shall be built in over openings in excess of 1.0 metre accordance with the Drawings, Building Code of Australia and relevant Standard (AS 3700). Anchorages Anchorages, including those to tie down roof structures, shall be installed at specified locations; and in accordance with the Drawings, Building Code of Australia and relevant Standard (AS 3700). Provision for Corrosion When construction is:

• within 10 kilometres of a non-surf coast; • within 1 kilometre of a surf coast; or • exposed to rainwater,

the ends or any cut surfaces of Reinforced AAC Panels shall be sealed with anti-rust sealant specified by the manufacturer. Provision for Timber Shrinkage In AAC veneer construction, a gap in accordance with schedule below shall be left between the timber frame and the top of the AAC, and at window sills, to accommodate timber shrinkage.

Location in timber framed buildings

Minimum Clearances (mm)

Unseasoned hardwood frame

Other timber frame

Sills of lower or single storey windows

10 mm 5 mm

Roof overhangs of single storey buildings

16 mm 8 mm

Sills of second storey windows

20 mm 10 mm

Roof overhangs of two storey buildings

24 mm 12 mm


Control Joints and Articulation Joints Vertical control joints or articulation joints shall comply with the Drawings, Building Code of Australia and relevant Standard (AS 3700). Unless stated otherwise, vertical control joints or articulation joints shall be built into the wall at the following locations: • Centres not exceeding the following in straight continuous walls without openings

For sand and rock sites (Class A), and slightly reactive sites (Class S), with little or no ground movement from moisture changes – Articulation is not required For moderately reactive clay or silt sites, which can experience moderate ground movement from moisture changes (Class M or MD) and highly reactive clay sites, which can experience high ground movement from moisture changes (Class H or H-D) –

External face finish, rendered or painted 7.0 m Internal sheeted and/or face finished 6.0 m Internal rendered and/or painted 5.0 m

• Not closer than the height of the wall away from corners • Not more than 5 metre centres in a wall with openings more than 900 x 900 mm, and

positioned in line with one edge of the opening • At the position where a wall changes height by more than 20% • At a change in thickness of a wall • At control joints or construction joints in supporting slabs • At the junctions of walls constructed of different materials • At deep rebates • At a distance from all corners not less than 600 mm and not greater than 3000 mm.

Articulation and control joints shall not be placed adjacent to arches. Control joints in ECOL-MEGA PANEL (AAC) arches shall be saw-cut to half the depth of the AAC unit and positioned at the centre of the arch. Control joints and articulation joints, shall be 10 mm wide and shall consist of a polystyrene backing rod and a polyurethane material gunned into the joint to form a 10 x 10 mm flexible seal. The backing rod shall be placed into the ECOL-MEGA PANEL (AAC) at a depth, which permits the finish of the control joints to match the mortar joints. Where an articulation joint is adjacent to a door or window frame, a 10 mm gap shall be provided between the edge of the frame and the ECOL-MEGA PANEL (AAC) to allow for movement. Render and Paint Schedule The following render and paint system shall be applied to ECOL-MEGA PANEL (AAC) walls. Refer to Render and Paint Specification for suitable products.

Substrate: Autoclaved Aerated Concrete (AAC) Finish: Acrylic-painted render. Performance: Water-resistant and vapour-permeable decorative coating, capable of

bridging up to a 1 mm substrate crack. Surface Preparation: Clean, patch and remove any dags. Ensure that the surface is free of

all incompatible materials, such as silicone sealants. If subject to sea spray or within 1 km of a surf coast, wash with clean fresh water to remove all traces of salt.

First Coat: Skim coat 2 to 4 mm thick acrylic render, hawk or steel trowel to level small irregularities. Do not render over control joints.

Second Coat: Primer suitable for acrylic overcoats. Dry for at least 45 minutes before applying further coat.

Third Coat: Trowel-on or roll-on texture acrylic coating. Dry for 24 hours before applying further coat.

Fourth Coat: Roller, airless spray or brushed 100% acrylic heavy duty durable coating.


Associated Materials Specifications

Renders and Paints

Renders and paints shall comply with the following:: First Coat: Skim coat 2 to 4 mm thick acrylic render, hawk or steel trowel to level small irregularities. Second Coat: Primer suitable for acrylic overcoats. Third Coat: Trowel-on or roll-on texture acrylic coating. Fourth Coat: Roller, airless spray or brushed 100% acrylic heavy duty durable coating.

Specified requirements Complying product reference Contact for further details

Acrylic Render Wallcote FR Render

Primer Acryloc Prime Seal

Textured acrylic coating

Acryloc Texture Coatings: Trowel-on Acryloc Marblecote medium/coarse Trowel-on Acryloc Sandcote Fine/Medium/Coarse Trowel-on Scratch 1.mm / 1.5 mm / 2 mm Roll-on Tuscan fine/Moroccan medium/Rustic coarse

Acrylic heavy duty durable coating

Acryloc Armourflex

Acryloc Building Products 174 Cavan Rd DRY CREEK SOUTH AUSTRALIA 5094 P: +61 8 8368 0222 E: [email protected] F: +61 8 8368 0223 W: www.acryloc.com

Joint Material Joint material shall comply with the Drawings, Building Code of Australia and relevant Standard (AS 3700). Unless stated otherwise:

• Backing rod for control joints, expansion joints and articulation joints shall be expanded polystyrene tube or bead or, rigid steel backing profile with closed cell foam adhered to the metal profile face.

• Joint sealant shall be gun grade multi-purpose polyurethane sealant. • Control joints and articulation joints shall incorporate de-bonding tape.

Intumescent seals shall be acrylic co-polymer sealant capable of providing the requisite fire performance as specified in the Drawings and/or Building Code of Australia as appropriate.

Damp Proof Course

Damp-proof courses (DPCs) shall comply with the Drawings, Building Code of Australia and relevant Standard (AS 3700, AS/NZS 2904). Unless stated otherwise damp-proof courses (DPCs) shall consist of one of the following options.

• A material complying with the Standard AS/NZS 2904; • Embossed black polyethylene film of high impact resistance and low slip, with a nominal thickness of 0.5

mm prior to embossing, and meeting the requirements of the relevant Standard (Clause 7.6 of ..AS/NZS 2904);

• Polyethylene coated metal damp proof courses with an aluminium core not less than 0.1 mm thick, shall be coated both sides with bitumen adhesive enclosed in polyethylene film not less than 0.1 mm thick on each face, and has a nominal total thickness of not less than 0.5 mm prior to embossing;

• Bitumen impregnated materials of not less than 2.5 mm thickness, that meet the requirements of the relevant Standard (Clause 7.5 of AS/NZS 2904), when used in walls that are not higher than 7.8 m above the level of the DPC;

• Termite shields (with no penetrations) continuous throughout the wall or pier . Notes: Metal and metal-cored damp-proof courses and termite shields shall not be used in locations with saline ground water or subject to rising salt damp.


Flashings

Flashings shall comply with the Drawings, Building Code of Australia and relevant Standard (AS 3700, AS/NZS 2904).

• Metal and metal-cored flashings shall not be used in locations that expose them to saline ground water or rising salt damp.

• Metal flashings shall be compatible with the materials with which they are in contact, and shall not give rise to electrolytic action. If there is potential for electrolytic action to occur, flashings shall be isolated by inert materials.

• Flashings intended to hold their shape shall be manufactured from rigid material. (e.g. metal cored material)

Unless stated otherwise flashings shall consist of one of the following options: Flashing in Concealed Locations (e.g. cavity flashings) shall be one of the following:

• Uncoated annealed lead having a mass not less than 10 kg/m2 in lengths not exceeding 1.5 m, but

shall not be used on any roof that is used to catch potable water; • Uncoated copper having a mass not less than 2.8 kg/m

2 and having a thickness of 0.3 to 0.5 mm;

• Bitumen coated metal (normally aluminium) with a total coated thickness of 0.6 mm to 1.0 mm; • Zinc coated steel with a thickness not less than 0.6 mm; • Embossed/quilted polyethylene sheet with an average thickness not less than 0.5 mm

Flashings in Exposed Locations (e.g. flashings from the roof to wall) shall be one of the following:

• Uncoated annealed lead having a mass not less than 20 kg/m2 in lengths not exceeding 1.5 m, but

shall not be used on any roof that is used to catch potable water; • Uncoated copper having a mass not less than 2.8 kg/m

2 and having a thickness of 0.3 to 0.5 mm;

• Bitumen coated metal (normally aluminium) with a total coated thickness of 0.6 mm to 1.0 mm; • Zinc coated steel of thickness not less than 0.6 mm.

Slip Joint Material

Slip joint material shall comply with the following requirements. Metal slip joint materials shall not be used in locations that are subject to rising salt damp.

• Bitumen-coated aluminium • Embossed polyethylene • Polyethylene-and-bitumen coated aluminium.

Reinforced Concrete Lintels

Reinforced concrete lintels shall comply with the Drawings, Building Code of Australia and relevant Standard (AS 3700, AS 3600).

Anchorages

Anchorages shall comply with the Drawings, Building Code of Australia. Mechanical expansion anchors shall not be used where the expansion action is likely to damage the AAC.


Termite Barriers Consisting of Woven Stainless Steel Mesh Woven stainless steel mesh acting as a termite barrier shall comply with the Drawings, Building Code of Australia and relevant Standard (AS 3660.1). Unless stated otherwise, properties shall be not less than the following:

• Mesh shall be woven wire from a fine wire loom. • Wire shall be stainless steel grade 304 or 316 (AS 1449). • Wire diameter shall be not less than 0.18 mm. • Aperture size shall be not greater than 0.66 mm × 0.45 mm, except in those locations where a very

small species of heterotermes vagus is present (e.g. parts of northern Australia), the aperture shall be reduced to a maximum of 0.40 × 0.40 mm

• Pipe collars, manufactured from woven stainless steel mesh with a 50 mm annulus, shall be attached to any penetrating service by a stainless steel clamp. Such collars shall be:

Embedded in the concrete; or Clamped and parged to the top surface of the slab, and protected from damage by covering with a tile mortar bed or a false floors of cupboards or vanities. The clamp shall be sealed with the parging mix.

Termite Barrier Parging Material for Woven Stainless Steel Mesh Parging material, for woven stainless steel mesh acting as a termite barrier, shall comply with the Drawings, Building Code of Australia and relevant Standard (AS 3660.1). Unless stated otherwise, parging material shall be a highly modified cementitious grout of a water-dispersed copolymer with a dry mixture of Type GP portland cement and sieved aggregate of a size that passes readily through the woven stainless steel mesh. Hardened parging material shall provide:

• Termite resistance, when in contact with soil and termite workings; • Bond strength (mesh to substrate) of not less than 1 kN/m at 28 days for a temperature range of 10°C

to 30°C at a relative humidity range of 10%RH to 70%RH; and for at least 60 freeze-thaw cycles in saline solution between −15°C and 18°C.

Termite Barriers Consisting of Composite Fibre Blanket and Plastic Membrane with Termiticide Impregnation Termite barriers, consisting of composite fibre blanket and plastic membrane with termiticide impregnation, shall comply with the Drawings, Building Code of Australia and relevant Standard (AS 3660.1). Unless stated otherwise, properties shall be not less than:

• Internal non-woven fibre blanket, not less than 200 grams per square metre, • Impregnated with termiticide of pyrethroid deltametherin crystals to a loading of not less than 1 gram

per square metre (low toxicity to warm blooded animals which both strongly repels and kills termites), • Bonded to a top moisture vapour barrier of low density polyethylene (LDPE), not less than 200

microns thick, • Bonded to a bottom membrane of low density polyethylene (LDPE) not less than 50 microns thick, to

prevent the termiticide leaching into soil.


Steel Lintels and Arch Bars

Steel lintels and arch bars shall comply with the Drawings, Building Code of Australia and relevant Standard (AS 3700, AS/NZS 2996.3 as defined in the following schedule. Note: Although most lintels are not “below a damp-proof course” or “in contact with ground”, these cases have been included in the schedule for completeness and because it is possible for them to occur. For elements in a mild environment, elements in an interior environments above a damp-proof course and enclosed within a building except during construction, elements above the damp-proof course in non-marine exterior environments, elements above the damp-proof course in other exterior environments, with a waterproof coating, properly flashed junctions with other building elements and a top covering (roof or coping) protecting AAC, elements below a damp-proof course or in contact with ground, that are protected from water ingress by an impermeable membrane, steel lintels and arch bars shall be designated R2 or greater. For elements in interior environments that are subject to non-saline wetting and drying, elements below the damp-proof course in contact with non-aggressive soils, elements in marine environments, elements in fresh water; steel lintels and arch bars shall be R3 or greater. For elements in external applications 1 km or more from breaking surf or 100 m or more from salt water not subject to breaking surf (Classified “Moderate”), BCA Vol 2 Clause Table 3.4.4.2 permits the following protection:

2 coats alkyd primer, or 2 coats alkyd gloss, or Hot dip galvanised to 300 g/m

2, or

Hot dip galvanised to 100 g/m2 plus 1 coat solvent based vinyl primer or 1 coat vinyl gloss or alkyd.

For elements in interior environments subject to saline wetting and drying, elements below a damp-proof course or in contact with ground in aggressive soils, elements in severe marine environments; steel lintels and arch bars shall be designated R4 or greater. For elements in saline or contaminated water including tidal splash zones, elements within 1 km of an industry producing chemical pollutants; steel lintels and arch bars shall be designated R5. For external applications in heavy industrial areas (classified “Severe”), steel lintels may be hot dip galvanised to 600 g/m

2.

Maximum Opening for Steel Lintels and Arch Bars (mm) 1 2

Span mm

Load Type A 3

Supporting AAC only

Load Type B 4

Supporting Tiled Roof

Load Type C 5

Supporting Metal Roof

Load Type D 6

Supporting Timber Floor

Load Type E 7

Supporting Brickwork Only (up to 3000 mm)

75 x 8 FMS 640 250 640

100 x 10 FMS 820 250 250 250 820

90 x 90 x 6 EA 3060 1550

1930

1680

2640

90 x 90 x 8 EA 3310 1670

2100

1820

2800

100 x 100 x 6 EA 3400 1730

2160

1870

2870

100 x 100 x 8 EA 3660 1870

2340

2020

3040

150 x 90 x 8 UA 4200 2710

3380

2840

3920

150 x 100 x 10 UA 4330 3490 3610 3010

150 UB 14.0 4200 3140

3840

3270

4200

150 UB 18.0 4200 3480

4140

3590

4200

180 UB 22.2 4200 4000

4200

4050

4200

1. The spans tabulated are clear opening widths. To determine the overall length of a lintel, add at least 300 mm to the clear opening, thus providing at least 150 mm bearing length at each end.

2. For openings up to 1000 mm, the required bearing length may be reduced to 100 mm at each end. 3. Load Type A applies to lintels supporting an AAC leaf up to 600 mm high without roof or floor loads. 4. Load Type B applies to lintels supporting up to 600 mm of AAC and a tiled roof up 6.6 metres load

width. 5. Load Type C applies to lintels supporting up to 600 mm of AAC and a metal roof up 6.6 metres load

width. 6. Load Type D applies to lintels supporting an AAC leaf over 2100 mm high with or without tiled roof or

metal roof up 6 metres load width and/or timber floor up 3.0 metres load width. 7. Load Type E applies to lintels supporting an AAC leaf up to 3000 mm high without roof or floor loads.


Cladding of Domestic Dwelling The following specification is generally suitable for cladding domestic dwellings, subject to confirmation by the Design Engineer. A suitable support framing system must also be provided. Reinforced AAC Panels shall be screw fixed to horizontal light-gauge steel battens, which are fixed to vertical steel studs. There shall be not less than four horizontal battens per panel, with this number increasing for higher wind loads and for panels within 1,200 mm of the building corners. Panels within 1,200 mm of each end of each external wall of a building (i.e. the two 600 mm wide panels closest to the corners) are subject to higher local wind pressures and suctions, and therefore require more battens and more screw fixing than other panels. Unless specified otherwise by the engineer, the following details and tables shall be used for the cladding of domestic dwellings with 75 mm thick Reinforced AAC Panels.

Light Gauge Steel Battens

Light gauge steel battens shall comply with the Drawings, Building Regulations and relevant Standards (AS/NZS 4600, AS 3623). Cold-formed sections and accessories shall be manufactured from Z350 galvanised steel (Grade G550) complying with AS 1397, with a zinc coating not less than 350 g/m

2 and

shall comply with AS4600. All battens shall be (22.5 x 63 x 0.55 BMT, Grade G550) or equivalent. The surfaces of zincalume battens that are in contact with the ECOL-MEGA (AAC) panel shall be painted with a suitable high build paint to guard against adverse chemical reaction. All screws shall be No 14g x 100 mm Bugle-headed self drilling class 3 galvanized screws, fixed from the outside of the building through the ECOL MEGA (AAC) panels into the horizontal steel light gauge battens behind.

General Notes: 1. All wind classifications and ultimate pressure calculations are based AS 4055-2006.

2. If ECOL-MEGA (AAC) Panels are required to provide racking resistance, the screws

and supports shall be determined by the structural engineer, taking into account the wind classification and the overall building dimensions.

3. Top and bottom battens shall be positioned within 150 mm of the ends of the panels.


Inspections and Tests All new work shall remain open until it has been inspected and approved by the Builder. The following inspections shall be performed.

Item or Product Inspection Required Accept Criteria Hold Witness

Drawings & Specifications Inspect controlled documents

Controlled copy of latest issue on site

Hold

AAC, including dimensions, density, reinforcement (Note 1)

Spot check As specified Hold

Adhesive

Spot check Manufacturer’s instructions Hold

Termite barrier

Visual In position Hold

Flashings & DPCs

Visual spot check In position Hold

Control Joints

Visual spot check As specified Hold

Lintels

Visual spot check As specified Witness

HD Bolts and straps

Visual spot check As specified Witness

Surface treatment

Visual Manufacturer’s instructions Witness

Cleaning

Visual As specified Witness

Notes. 1. Due to a lack of clear advice from the overseas suppliers, the minimum likely grade, diameter and number of reinforcing bars have been assumed. This should be checked on site. 2. The minimum checks, carried out in Australia by the supplier and/or builder, are recommended. Bulk Density

• Weigh the panel (M kg). • Measure the external dimensions (L, W, T metres). • Calculate the bulk density = M / (L x W x T). • Check that the bulk density approximates 565 kg/m

3.

Reinforcement Number, Diameter and Depth

• Saw off the end of one panel (approximately 200 mm from the end), cutting through the main reinforcement.

• Note the number of main bars. • Measure the diameter of the main bars. • Measure the depth from the furthest edge of the panel to the centre of the main bars. • Compare the number, diameter and depth to the standard drawings.


Amendments

Amd Date Detail

Changed to three top hat sections for N1 and N2 wind.

Insulation values added to the tables

16 23/7/10

FRL 60/60/60 Opinion added

Screws changed to galvanised 17 10/8/10

Party wall construction added

p68 Inspection Plan. Note 1 amended.

pp 8,59 75 W20 panels deleted

pp 25, 26 “Internal air” changed to “Internal air film

pp 25, 26 “External air” changed to “External air film”

18 5/10/10

pp 32, 33,34 “internal support” changed to “intermediate” support


ELECTRONIC BLUEPRINT is the principal point

of reference for Architects, Engineers and Builders and the only package that fully integrates regulatory and standards requirements with

comprehensive, editable specifications, CAD details and approved industry training.

Quasar Management Services Pty Ltd ABN 21 003 954 210 Inc in NSW

ABN 31 088 338 532 Inc in NSW

www.electronicblueprint.com.au [email protected]

This document has been prepared by Electronic Blueprint, with engineering input by Quasar Management Services Pty Ltd.

STOP BUILDING AND HARDWARE Ph: 08 8243 0930 Fax: 08 8243 0763 Email: [email protected]

www.osbh.com.au





Eco-Friendly

126 Days Road, Ferryden Park SA 5010

HIA AD.indd 1 25/6/08 4:26:47 PM

ECOL-ONE PRODUCT RANGE WARRANTYEcol-Mega Panel / Ecol-Mega Floor / Ecol-Mega Blocks (AAC Wall Panels / AAC Floor Panels / AAC Blocks)

One Stop Building and Hardware Pty Ltd (OSB&H) warrants that this product will be free from defects in material and workmanship for a period of 7 years from the date of purchase. This warranty will not apply if, in the opinion of OSB&H, the product has been:

• installed and maintained other than in compliance with the manufacturer’s specifications and technical manual;

• handled in a manner which contravenes OSB&H’s warnings or Material Safety Data Sheet;

• misused, abused, altered or damaged by you in any way;

• attached to materials of poor quality, workmanship, design or detailing or which are subject to movement whether structural or otherwise;

• attached or used in a project that has not been designed and constructed in strict compliance with current Building Code of Australia regulations and standards; or

• damaged through normal wear and tear including exposure to the elements (on both exposed and unexposed surfaces) resulting in the growth of any organism including but not limited to mildew, mould, bacteria or other growth on the Product.

• OSB&H reserves the right at its sole discretion to determine whether to repair or replace any faulty product free of charge for parts and labour or to give a refund in respect of the faulty product.

The benefits conferred by this warranty are in addition to all other non-excludable rights and remedies in respect of the product which the you may have under the Trade Practices Act and any similar laws in Australia or elsewhere. To the maximum extent permitted by law, OSB&H’s liability for any non-excludable condition or warranty is limited, at OSB&H’s discretion to the replacement of the relevant product or supply of equivalent product, the repair of the relevant product, the payment of the cost of having the relevant product replaced or acquiring equivalent product, or paying the costs of any necessary repair. To the maximum extent permitted by law, OSB&H excludes all other conditions and warranties implied by custom, the general law or statute. OSB&H also excludes the provisions of the United Nations Convention on Contracts for the International Sale of Goods.Proof of purchase must be provided when making any claim under this warranty, and should be retained by the purchaser at all times.