greencon AAC Green Building Materials ik te E PRATICAL APPLICATION - 3" Edition = LAR ——# KIM HOE THYE INDUSTRIES SON BHD (Company No, 84951946)Notched Trowels (for each block width) Rubber Mallet Stirrer Mixing Container Steel Bracket Block Lifter Singuran ean) Industrial Hammer \ Chasing Tool for Wiring Hand saw Levelling Scraper Sanding Float Fibre Mesh Band Saw — Levela. BLOCK LAYING greencon Mortar Recommendation Like all other masonry bricks/blocks, AAG blocks, ‘AAC blocks can be laid with the customary types of mortar Block - laying Basically, AAC-Blocks, lke all masonry bricks and blocks, should be laid with filled joints in accordance with the rules of the trade. Filing.in pieces can be easily be cut true to size with the Widia saw or an electric saw. The usual prewetting of masonry bricks is unnecessary with AAC blocks, if mortar with water-retaining agents are used. Height or course gauge boards faciciltate adherence to exact heights. Any necessary adjusting courses muat be allowed for when planning courses. If the story height cannot be achieved with the standard formats, compensating blocks are used for the last course. The First Course is the Crucial Point Take delivery of blocks as close as possible to the working area. Blocks should be kept dry before laying The first course should be laid paticulary carefully in the interest of building progress in the following courses. Construction times for the remaining wall can be greatly reduced if paticular care is taken over alignment of the first course, The first block course above footings and above slab floors should be laid in a thick cement bed mortar to —! enclose subsequent course are true, level and plumb. Damp-proof materials should be used for the first course above footings. The thick bed mortar bed can be a pre-fabricated thick-bed-mortar or a Cement, and Sand mix (1:6 To 1:8) one part ‘Cement, and 6 To 8 parts clean sharp Sand, mixed in a mechanical mixer. Important : DO NOT USE THIN BED ADHESIVE TO BED FIRST COURSE BLOCKS OT — Greencon” AAC Blocks Levelling course cement sand mortor 1:6 To 1:8 Mix R.C Column / sti, 24". | Nominally 25 To 30mm Thick Steel Bracket Ties \_| sequent 600mm) Clg [st Damp - Proof Course (DPC) For Ground Floor, Wet Areas, ee eae cana Flat Slabs & Long Span Beams/Slabs.2. BLOCK LAYING greencon Slip - Joint ( Levelling Course ) (DPC ) Atter laying each corner pair of blocks, lay one second course of block in thin bed mortar at each comer. This is necessary for supporting the string line blocks and to act as ‘a weight to help prevent displacement of the comer blocks, when positioning the adjoining first course of blocks. coment Send L- 7 Groencon Block 2-:mm Joint with Thin Bed Adhesive IIILISSSZaZE}— ( Coment-Sand Mortar) 20-90 mm RC/FL (vec) Note : For Ground Floor and Wet Areas The Following Courses Mix the thin bed mortar in the mixing container. Place the water first to the gauge lines marked on the container, then add the mortar powder. Mix with the stirer in an electric drill to thoroughly blend the mixture. ‘The mortar is immediately ready for use. The consistency of the mixed thin bed mortar should be such that it flows easily through the teeth of the trowel leaving the shape of the teeth in the bed ‘On a hot day and during delays, sprinkle alittle water over the mixture toprevent drying out ‘Should the mix become too dry, add a littie water and re-mix. Before commencing to mix a new batch, wash out the bath to prevent any old mixture from accelerating the drying time of the new mix. Mortar droppings should not be re-used.Po BLOCK LAYING greencon ‘The comer block is laid with its face and ‘end up to the strings and tapped down to level alignment. Allow 10 mm for the final mortar bed thicknes. Double check the block for level and plumb as below. ‘Then lay the adjoining return comer block in the same manner. From the comer blocks stretch the string line through to align the first thin bed course. Use the Notched Trowel of the ‘same widthas the block beeing laid. Important : Trowel width = block width Spread thin bed mortar up the vertical perp of the previously laid adjoining block firs, then along the horizontal surface Only spread sutficent thin bed mortar to lay one block at a time. Ensure the thin bed mortar covers the full width of the blocks on perp and beds. When adjusting the mortar consistency, make sure that during the application the thin-bed mortar flows easily through the teeth of the plane-block trowel over the full surface. Under no circumstances should the consistency be such that the mortar strands visible on the horizontal an vertical joints run together again.BLOCK LAYING greenéoni wee we Stretch string lines between profiles to accurately align the face of the blocks. Level alignment will be established at each comer of the house using a water level or Theodolite on each comer block. ‘The thin bed mortar is now mixed to a heavy custard consistency and laid with a Notched Trowel ‘The mortar bed is furrowed to evenly spread it. The trowel is used to salvage the over Greencon™ AAC Blocks R.C Column / Stiff. 2 /— Levelling Course NG Steel Bracket Ties <| (First course ana Te Damp - Proof Course (DPC) coe ate For Ground Floor, Wet Areas, ez Precast Floors, Prestress Floors, J. 20 mm GAP Filled With Flat Slabs & Long Span (1:6 To 1:8) Cement Sand Mortar Beams/Slabs. R.C Column / Stif. Steel Bracket Ties (WM Subsequent 600mm | Thin Bed Mortar (2-3mm) Fi. 25 Greencon™ AAC Blocks Soffit Of R.C Beam/Slab *20 - 30m GAP Filled with (1:6 To 1:8) Cement Sand mortar / Pu Sealant R.C Column / Stiff. Levelling Course Steel Bracket Ties (First course and Subsequent 600mm) Fb Damp - Proof Course (DPC) 10-20 mm GAP Filed With For Ground Floor, Wet Areas, (1:6 To 1:8) Cement Sand Mortar Precast Floors, Prestress Floors, Flat Slabs & Long Span Beams/Slabs.BLOCK LAYING Alternative Placing Method Do not lower the perpend which is making the thin bed mortar contact first and take care not to lay the block too short of the perp bed and have no force it along the horizontal bed. This will strip thin bed mortar from the horizontal bed and squeeze it into the comer preventing full even contact with the perp. ‘ter placing the block, it should be hammered up to the adjoining block first to fully close the perpend joint, then firmed to alignment with the string line using the rubber mallet. Important : To use the rubber mallet in the bedding of each block to ensure the adhesive fully covers the block surface, However, the block should not be over-hammered to cause adhesive to squeeze out. The mortar bed should maintain a thickness of between 1 mm to 3 mm after bedding, Important : Use the water level, to control each block for the right position | in al directions. Bond dimensions must be adhered to. ‘The vertical joint of the lower course must be staggered at least 1/8 block length, better the half block length to the vertical joint of the overlaying course. Now use the rubber mallet to align accurately edge to edge and ‘ap firmly into place. Important : Pay attention to staggered joints. ‘To get better bonds in thin walls itis better to fix a quarter of a block next to the comer block, then go on laying with whole blocks. ‘Occasionally a block should be removed again - immediately after laying - to check whether mortar is spread over the full surface. Height or course gauge boards facilitate adherency to exact heights. ‘Adjusting courses may be necessary, which must be allowed for, when planning the courses. ‘On the other hand the 1 - 3 mm thick joints can be disregarded,For adhering the perps you must mix and apply Thin-bed-mortar. Overspilled thin bed mortar adhering to the wall should be scaped off as the work proceeds and Used to fil any broken edges or holes while ist sill moists. Itis the best to carry out this process during or after laying of each course rather than leave the process until the whole wall is built Overspilled mortar left to go hard overnight is a sign of poor workmanship. Note : When rain threatens, cover the top of walls with some plastic sheet. A piece of AAC block is useful for rubbing back ‘excess mortar. Should it be necessary to sand a wide area to smooth surface, the large sanding float is used. When walls are to be rendered, the surface ‘need only be prepared to a flat and flush plane with the levelling scraper. Sanding is not necessary. ‘Where the odd block is proud of the wall surface. Itcan be scraped back with the levelling scraper.Bandsaw Cutting ‘The Bandsaw is the ideal mechanised saw for cutting AAC material. Dust is minimised and 200 mm deep or {ull thickness cuts are easy to achieve. The table should be large enough to push a block through ist full 600 mm length from one side without toppling over the opposite end, ‘The motor should have sealed bearings and be protected from dust. Hardened teeth should be also considered. When cutting with the bandsaw, Itis best to first mark the line of ccut with a pencil, a. greencon Safety and Handling ‘When cutting all building Materials safety glasses or ventilating non-fogging goggles should be worn. Handcutting ‘AAC blocks can be cut to size and shape with ‘most carpentry saws, routers, and planners. The block is marked to size with a pencil, The line is squared across the block using the square, and can be sawn by hand. Remember the baok edge of the hand saw can also be used as a straightedge. A circular saw with masonry blade can be used for cross cutting type work and is quick. Alternatively a band saw will cut AAC blocks without throwing dust. Cutting Grooves and slots Grooves and slots can be cut with a the handsaw, or circular saw set to the required depht, or a routera BLOCK LAYING greencon wee Hl Imaginery Sides [ot Are — Arches and Curves ‘Two methods can be commonly applied with method A the most practical Method A 1. The blocks are laid without adhesive on the floor to form a replication of the arch down to just below the springing line which the arch commences. 2. Acchalk line is sprung through the springing line and if the arch is a half-circle, the centre of the mid span is marked on the chalk line. 3. Amake shift compass is made by stretching a string line from a nail with a pencil attached to the opposite end. The curve is then marked on the loosely laid arch blocks. 4, the blocks can the accurately cut out on a band saw and each one numbered for easy location. Method B ‘The wall is constructed and the blocks which surround the arch portion permitted to extend past the arch into the opening, ‘The arch is then marked on both sides of the wall and the arch cut out using a long bladed reciprocating saw. Then the shape is perfected with cement render. Important : A lintel is required above arch openings which exceed 800 mm in width,LINTEL & FRAMES Fixing of Lintels and Woodern Door-Frame more of the work-site Greencon™ blockwork delivery solidity and easy workability GREENCON BLOCK GREENCON LINTEL WITH 4 NOS OF Y10 RE-BAR ‘5mm GAP TO RFFILL SEALANT ( BY OTHERS ) STEEL DOOR FRAME ( BY OTHERS ) |< — FIRE RATED DOOR PANEL ( BY OTHERS ) HAE LNTEL DETAIL 5mm GAP TO REFILL STEEL BRACKET / FRAME TIES GROUTING / WEAK MORTAR FIRE RATED DOOR PANEL — GREENCON BLOCK ‘STEEL BRACKET / FRAME TIES DETAIL AT DOOR FRAMERC or Greencon™ AAC lintel with minimum of 200 mm width on both sides 2. greencon / +—}— Greencon" AAC Blocks Maintain fll block ~~ under inte! Wl ‘Anchor or fishtail to ‘manufacturer's detail ru Door frame LL Levelling course cement sand mortar (1:6 ~ 1:8) Mix ‘Nominally 25-30 mm thick RC lintel with minimum of 200 mm width on both sides Bottom of docr frame to be fastened to floor i A ru - U— Damp-Proot Course (OPC) Greencon™ AAC Blocks Maintain fll block under lintel ‘Anchor or fish tal to manufacturer's detail oor frame /— Leveling course cement sand mortar (1:6 ~ 1:8) Mix Nominally 25-30 mm thick ys RC Siti. to ‘engineer's detail 1. Door frames to be installed before laying of blocks 2. Applicable for standard flush plywood door only 3. All R.C members to engineer's detail. ‘Damp-Proof Course (DPC) uSTIFFENER greencon a BLOCK WALL / R.C. STIFFENER DETAIL GREENCON BLOCKWALL ————__-» RC. COLUMN / STIFFENER = ——————__» STEEL BRACKET TIE NAILED TO R.C. COLUMN / STIFFENER - = - AT EVERY 600 MM LIMITING HEIGHTS AND LENGTHS Height of Wall Length of Wall between Restraints (m) between Restraints (m) Thickness of greencon AAC Block 100mm&125mm 150mm 200mm 3.00 6.0 10.0 10.0 3.50 5.0 9.0 9.0 4.00 4.5 8.0 8.0 NOTE : WALL HEIGHT AND LENGTH ABOVE THE LIMIT, STIFFENER TO BE BUILT ACCORDINGLY.eo. STIFFENER greencon F.C Sif. Not needed i column exists R.C SLAB / BEAM iting heighis and lengths (page. 12) | Refer tothe "| Fete othe “limiting heights and lengths "(page. 12) - All R.C members to engineer's detail. . Steel Bracket ties to be provided between capping beam and wall. . Detail applies to internal wall on! For external walls, stiffener spacing is governed by wind load and may be closer. is pepe F.C St, Not needed i column exists FOR CSLAB/ BEAM Greencon!” AAC/BLOCKWALL iting heights and lengths “page. 12) 7 AAC-BLOCKWALL Greenc Rete tothe" Fete othe “limiting heights and lengths "(page. 12) 1. AIIR.C members to engineer's detail. 2. Detail apply to internal wall only. 4. For external walls the stiffener spacing and wall height is governed by wind load and may be closer. 13A.C Sti, continued into AC slab / beam above RCSLABIBEAM —— cortovel n RCline reencon” AAC_BLOCK\WALL JUNCTION greencon @® Tee - Joint ©@® interlocking Joint Greencon Stee! Bracket Internal walls are bonded in at junctions Straight joint (butted joint) with g.isties. (on foundations of same strength. Especially recommended if a) a wall is built-in at a later stage ) the fioor level is diferent, for example external wall on foundation, internal wall on ground floor. ‘Wall Junction to existing wall by fixing channel. 15WALL JUNCTION 2. grgencon Alternative Method [— BRICKWALL TO ARCHITECT'S DETAIL R.C STIFF. —— BY OTHERS [ PLASTERING / RENDER ON BOTHSIDES at 3 FILL WITH WEAK CEMENT SAND MORTAR . \ (4:6 TO 1:8 MIX.) § ‘STEEL BRACKET TIES AT EVERY 600 MM CENTERS Greencon” SKIM COATING OR RENDER ON BOTH SIDES —+ 20mm GAP, 20mm GAP R.C STIFF. BY OTHERS FIBRE MESH “ Greencon™ AAC a BLOCKWALL STEEL BRACKET TIES lg Greencon™ SKIM COATING OR AT EVERY 600 MM FILL WITH WEAK (CEMENT SAND MORTAR (4:6 TO 1:8 MIX. ) RENDER ON BOTH SIDES BRICKWALL TO ARCHITECT'S DETAIL PLASTERING / RENDER ON BOTH SIDES 16WATER PROOFING Water proofing for toilet / bathroom walls FLOOR LEVEL. TL neroon sassy orien |\¢—————_ Greencon" aac sockwat_ .———————>| warmuss sowcep use = ——————allft- arco renen MLE ADMERNe BY OMENS ocx Sten POLYMER MODIFIED CEMENTITIOUSOR ~=©———_—+4 P.U WATERPROOFING MEMBRANE BY OTHER 4} WATER PROOFING MIN. 1500 FLOOR TILES BY OTHERS ff] FLOOR LEVEL. Ly 4 F.C FLOOR SLAB. BY OTHERS ‘Water proofing for shower cubicle walls FLOOR LEVEL. |¢—————_ Greencon" aac atocxwat. ©——____—+} WAL TLES BONDED USING 4 ac THICK RENDER 4 THLE ADHESNE BY OTHERS ge THOX RENDE ge pouvMen MoDIieocEMENTTIOUS OR 38 PUWIATERPROOEING MENBAANE BY OTHER Zz UWATERPROOFING MEMBRANE BY OTHE! WATER PROOFING 38 5 FLOOR TILES BY OTHERS FLOOR Level. 4 fe t i WATERPROOFING MEMBRANE BY OTHER A.C FLOOR SLAB, 1. For waterproofing application, refer to waterproofing manufacturer / speacialist. 7a» CHASING DETAILS greencon Water Pipe Cutting Through The AAC Block Well Groove by using | | Electrical Wiring Hand or power dil when ing for chasing grooves to receive electra! ang plumbing {or wal pugs or fixing systems Min. 200mm ‘COATING [— Greencor” AAG BLOCKWALL : o = 4 Z| 3 Ceconour ene evan [een eae {____ bept oF ciasine nor mone Tan — 112 OF WALL THICKNESS PLAN 1. Chasing lines to be clearly marked using pencil. 2. Use circular diamond blade cutter to cut the lines. 3. Avoid overcutting / overchasing. 4. Use a sharp chisel to remove the waste material 5. If required, use thicker walls to accommodate bigger pipes. 6. Long horizontal chasing is not recommended 7. Cavity wall is recommended to accommodate large number of services. esis 18FIBRE MESH RC BEAM 1. Fiberclass mesh to be applied ‘on bothsides of the wall 2. Fiberclass mesh is recommended across all concrete / AAC interface. FIBREGLASS MESH (BELOW OPENING) a. greencon R.C COLUMN 19apin6 Burxy 0} 19401 6 an = (9: |) seWOW pues juss yum paitedes oq 0} aBeWeG OIG 'z |S PSAOWAL aq 0} @AISAUPY SSBOX3 * |, JEUOW PUBS -TUEWED( 81 OL 9: ) WWD} 1 pesn aq Oo} (wuugog Arana pue asin09 1) 106 wwoe-OF a aie alee eos yereig ais Jeyow pues uewie9 ‘euse14 100g pue Mop dd (ww og - 02) asinog Buena l > |" org In i x [ ’ \ Y wnoj00 O° own 5 } sa [vos uoouee15) ——] SS x a yore 1nd sew seq. woof ON 1b jeiun uooueeig seuss, $ E \ ‘ 7 seuowpues- : wwe - 02) sees wlor uoHey9q TIMMS OY ensoupy bea UL eae lww90} wnusjui 40 uiBua, wulor wi €-Z 4878016 @q 0} ou Bu'seyo jo deg 400}9 J0 JEU 8q 0} deLeN0 ¥00Ig 20