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MultiPurpose Autoclaved Aerated Concrete

Technical Manual

Installation

View Installation .PDF

General Installation Guidelines

CONSTRUCTION BENEFITS

• Fast and efficient panel installation reduces labor cost

• Modular components provide for ease of erection

• AERCON AAC puts your project on the fast track

• No reshoring accelerates finish trades

• No furring, insulation or drywall needed

• Workable like wood

Tremendous Benefits for Everyone

AAC building systems have been successfully developed and implemented for more than 65 years. They have been utilized in residential and commercial applications.

The short- and long-term benefits of these systems are realized by owners, developers, designers and contractors alike. The benefits are achieved by the various material properties and methods that are associated with the established AERCON approach to construction.

For the Owner

One of the main benefits of AERCON is safety. An owner using AERCON products creates a sound, functional and safe building. Another benefit of the AERCON system is versatility. AERCON can provide many architectural features that will enhance and project a unique architectural image for the building and its owner. AERCON construction is insect and termite proof. Therefore, the need for expensive insect and pest treatment as well as long term maintenance costs will be greatly reduced. To complete AERCON's concept of a great building system, the superior thermal properties associated with all of the AERCON products will translate into increased energy savings.

For the Developer

The cost savings realized when using AERCON products, mainly related to the shorter construction time, will be dramatic. The advantages of AERCON include low maintenance costs, good sound insulation and excellent thermal insulation. It easily meets hurricane and energy codes.

For the Designer

Creative designs cannot be realized without the use of a highly adaptable construction material. AERCON can be adapted to suit most architectural designs while still providing a simple construction system that can meet all load requirements.

For the Contractor

Buildings can be constructed quickly and safely using AERCON building systems. The product itself is lightweight; therefore easily handled.

AERCON's workability (e.g. anchoring, routing, and drilling characteristics) is well developed and can be easily performed. Typically, wall panel connections are installed with nails. AERCON material also produces less waste. By using the right combinations of AERCON products, productivity will be increased. AERCON will reduce the amount of time spent on job sites due to its ease of handling.

Conclusion

All these factors relate to cost, time and labor savings for the project. These factors epitomize AERCON's commitment to expediting construction, cost effectiveness and an aesthetically appealing building system.

Disclaimer: The information contained within this document shall be used as guidelines for workmanship and general construction practices for the installation of AERCON Products. This information should be recognized as recommendations and should be used with judgment. Implementation, interpretation and use of this document shall be the sole responsibility of the Installation Contractor.

AERCON MATERIALS

Material Handling Procedures

Please read the following instructions to insure proper handling and installation of Autoclaved Aerated Concrete (AAC). Damage may occur if AAC is moved or handled several times.

For All AERCON Special Considerations For Construction Products

Deliver material far enough in advance of the installation start date so schedule will not be delayed

Unload panels using pallet forks (either Unload panels using pallet forks (either forklift, nylon straps, slings or pallet fork on a crane cable). Consult your OSHA safety manual for "rigging" or other safety considerations.

Storage areas should be accessible to delivery trucks and convenient to material staging areas. If possible, drop-deliver the material right to the material staging areas.

Storage material should always be stored away from other construction activities on a flat-grade area that is not susceptible to standing water, erosion or settling. In adverse weather conditions, keep the material covered and banded until ready for installation.

AERCON Panel Construction

. Do not "shake-out" stored materials until they are ready to be installed. Excessive handling may cause damage. Set delivery schedule to match the erection sequence exactly.

Most chipped corners and edges can be repaired. If any reinforcing is visible, contact an authorized AERCON representative.

All damage must be repaired using an approved structural grade AERCON patching compound developed specifically for AERCON products.

Precast Autoclaved Aerated Concrete panels that have surface or minor cracks are usable, but contact an authorized AERCON representative when cracks continue completely through the panel.

Stored or staged materials should always be set on flat, load-bearing, stable grade on pallets or dunnage

Disclaimer: The information contained within this document shall be used as guidelines for workmanship and general construction practices for the installation of AERCON Products. This information should be recognized as recommendations and should be used with judgment. Implementation, interpretation and use of this document shall be the sole responsibility of the Installation Contractor.


INSTALLING AERCON BLOCK

AAC Masonry Products Tools Required For Installation

AAC Block

There are a full range of tools that are specially designed to assist the block layer in installing AAC masonry products and increase productivity at the job site. AAC masonry installation require the following masonry tools:

AAC Jumbo Block

Additional tools required for installing AAC jumbo masonry units.


AAC Masonry Products Leveling Course

Step 1 - Layout wall lines

Lay out wall lines on building slab by control lines.

Step 2 -Start the leveling bed.

At the highest corner of the slab place a full width 1/2" deep sand-cement mortar joint using a masonry trowel (Mortar to be either Ready-Mix or 3:1 Sand: Portland Cement ratio or approved then-bed mortar).

Do not use thin-bed mortar or large grain mortar for the leveling bed joint.

If moisture and wicking is a problem, add water resistance mixture to sand-cement mortar

Step 3 - Set the first corner block.

Set the first corner block in the sand -cement mortar and adjust the joint as needed. To achieve the required height, lower or raise the block by tapping down with a rubber mallet or by adding additional mortar beneath.

Step 4 - Mix thin-bed mortar.

Mix approved AAC thin-bed mortar in a clean mixing container (5-gallon bucket or pail) per manufacturer's directions. The consistency of the mixed thin-bed mortar should be such that it flows easily through the teeth of the notched trowel leaving the shape of the teeth in the mortar bed.

Thin-bed mortar droppings should not be used.




Step 5 - Set second corner block

Set the second corner block adding thin -bed mortar to the head joint with the ¼ inch notched trowel.





Step 6 – Repeat for additional corners.

Repeat subsequent steps for each corner using a builder's level to maintain an equal elevation. Triple check each lead corner in all three planes.

Step 7 - Fill -in completion of level course

After building the lead corners, pull a string between corners to complete the leveli ng course. Sand -cement mortar should be used for the bed joint and thin -bed mortar for each head joint. Level across each block to insure a plumb wall.

Do not use sand -cement mortar for courses other than the leveling course .




Step 8- Install lintels as required.

Install lintels with a minimum 8" bearing (overlap)where required

Lintels End bearing for lintels should normally be not less than 8". Where stresses under lintel bearing will exceed permissible values (e.g. under heavy concentrated loads), concrete spreaders or pad stones should be incorporated. Cold bridging at lintel positions can be avoided by the use of AAC in association with appropriate types of lintels. These allow the insulating properties of AAC blocks to be continuous across the wall face and can facilitate the placing of subsequent door and window fasteners. If multiple courses of U-Block are used, notching is required to allow concrete to get to the lowest course. Always pre-wet the u-block before pouring the grout.

AAC Masonry Products Points To Check

Point 1

Leveling course must be level and plumb. Do not proceed to subsequent courses until leveling course has set sufficiently

Point 2

Blocks must be installed in a running bond with a 8" bearing (overlap). Lintels must be installed with a minimum 8"bearing (overlap).

Point 3

All head and bed joints must be solid with approved AAC thin-bed mortar for full adhesion. Do not tooth.

Disclaimer: The information contained within this document shall be used as guidelines for workmanship and general construction practices for the installation of AERCON Products. This information should be recognized as recommendations and should be used with judgment. Implementation, interpretation and use of this document shall be the sole responsibility of the Installation Contractor.


INSTALLING AERCON VERTICAL WALL PANELS

AERCON Vertical Wall Panels

Tools required for installation

There is a full-range of tools that are specially designed to assist in installing Aercon wall panels and increase productivity at the job site. Aercon installation will also require the following standard industry tools:

Step 1

Check panel layout of approved Aercon shop drawings and deliver panels to jobsite accordingly.

Step 2

Unload the bundles of panels in a proper manner using approved unloading gear. Protect the Aercon panels from rain and water saturation by leaving them on pallets and away from standing water. Eliminate excessive handling by storing Aercon panels nearest to where they will be installed. Protect the Aercon panels when traveling on uneven ground.

Step 3

Lay out wall lines on building slab by control lines as well as field verify all dimensions and openings.

Step 4

Attach wood straight -edge (2x4) to the slab so that it is flush to the inside wall line of the panel. This will act as a guide to install the Aercon panels.

Step 5

Prior to setting Aercon panels, mobilize the job site crane to an optimum location to avoid excessive downtime from moving it too often. Attach approved lifting gear to the crane cable and begin installation.

Erection should start from a corner taking care to ÿt additional Aercon panels tightly together. The wall panel is lifted by using a WKV wall panel clamp that is attached to the panel and lowering it onto the Aercon large-grain mortar. See step 13 for alternative lifting device.

Step 6

At the highest corner of the slab place a full width of Aercon large-grain mortar using a notched masonry trowel. Use plastic shims as needed, along with Large-grain mortar to correctly level the slab or footing to the correct height. Do not use thin-bed only large-grain mortar to level slab of footing.

Step 7

As soon as the panel is adjusted to being plumb and level, attach temporary bracing from the upper third of the panel down to the floor. Follow OSHA guidelines for temporary bracing requirements.

Step 8

Mix the Aercon thin-bed mortar in a clean mixing container (5 gallon bucket or pail) per manufacturer's directions. The consistency of the mixed thin-bed mortar should be such that it flows easily through the teeth of the notched trowel leaving the shape of the teeth in the mortar bed. Thin-bed mortar droppings should not be used. Before mixing each new batch, wash out the bucket or pail to prevent any old thin-bed mortar from accelerating the drying time of the new mix

Step 9

Set the second corner panel tight against the previously set first corner panel using the following actions

First

Place thin-bed mortar in between the head joints of the vertical panels using a notched trowel. Either place thin bed mortar on the panel to be installed while it is in the resting position on the ground or place thin-bed mortar on the previously set panel prior to the next one being installed.

For large building areas, individual pallets of panels may be loaded on the floor and roof deck for ease of erection. Verify the capacity of the structure to support the pallets. Provide temporary shoring as required.

All floor and roof anchors noted on the project documents must be installed.

When erecting sloped roof panels, secure the first panel to prevent sliding during erection. Prior to filling the joints and pouring the perimeter bond beam, ensure the panels are snug together.

Prior to filling the joints with grout, remove all deleterious material from joints using compressed air. The joint reinforcement as indicated on the reinforcement drawing must be

placed and secured prior to filling the joints. Moisten all joints prior to filling. Verify all joint reinforcement is fully covered by grout.

Clean the panel surface of any loose material after joints and bond beam have set.

See Structural Design and Construction Details Sections for floor and roof panel details.

AERCON floor and roof panels are installed using a crane and clamp.


Installation of Non-Load Bearing Wall Panels

All items presented in Sub-Section A are applicable.

AERCON non-load bearing wall panels are attached to load bearing construction such as concrete or steel and can be oriented vertically or horizontally. The exterior support columns must be plumb and true for proper erection of wall panels. All wall anchor accessories must be installed prior to the erection of the wall panels. The base mortar joint must be level and true prior to placement of the first panel. Immediately after placing the panel, attach the wall anchor to the superstructure and the panel with the appropriate fas-teners as noted on the shop drawings. The back face of the panel must be flush with the face of the superstructure. Any gaps must be filled solid with non-shrink grout.

The joint width indicated on the shop drawings shall be maintained throughout the project.

Notching of the panel for erection, due to the interference from the wall anchor accessories, shall be accomplished by recommended tools.

Use extreme care so as not to damage the bearing areas of the panel and the wall anchor connection areas. All wall anchor fasteners must maintain a minimum edge distance of 2 1/2".

If the wall panels have a non-tongue and groove profile, the panels must be mortared together with AERCON mortar.

Horizontal non-load bearing wall panels attached to a load bearing superstructure; in this case steel.

Installation of Load Bearing Vertical Wall Panels

All items presented in Sub-Section A are applicable.

AERCON load bearing vertical wall panels are used to support floor and roof systems in single story or multi-story construction. These panels can be used for exterior and interior walls.

The panels are erected utilizing a crane and lifting clamp and are placed in a mortar bed joint.

All vertical joints are mortared together with AERCON thin bed mortar.

The panel erection should start from a designated corner of the building. Provide temporary bracing as required to prevent any incidental movements until the mortar has set.

See the Construction Details Section for panel details.

See information on Surf ace Treatment for expansion joint details, in the Architectural Design Section.

Load bearing vertical wall panels are used to support floor and roof systems in single story or multi-story construction.

Installation of Blocks and Lintels

An AERCON block wall will usually consist of a variety of AERCON products, integrated together to create a complete wall system that satisfies the project requirements. The installation process is basically the same regardless of the individual components. Blocks are typically installed directly on a foundation system, but can also be installed on an elevated floor for multi-story construction. In both conditions, the initial bed joint is a critical element. The base mortar joint must be level and true so that the construction can proceed with minimal adjustments. In order to provide adequate thickness for adjustment, the initial bed joint is usu-ally Type M or S mortar, 3/8 to 1/2 inch in thickness. Head joints in the starter course are mortared together with AERCON thin bed mortar. When thin bed mortar is used at a joint, it is to be applied with a trowel having the proper style, teeth and width to ensure coverage across the entire thickness of each block.

Lay successive courses plumb, level, and true to line, in running bond with 8-inch lap (6-inch minimum) for standard blocks;

when cored block is used, lap should equal the block thickness, in order to align the cores at the corners. Use thin bed mortar at all bed joints and for head joints of flat face blocks. Tongue and groove blocks do not require mortar at the head joints. Check each block as laid for levelness and plumbness, making adjustments as required using a rubber mallet, while the mortar is still soft and plastic.

When necessary to accommodate an odd dimension or configuration, blocks are to be cut with an appropriate hand saw or band saw that is specially designed for cutting autoclaved aerated concrete (AAC). Consider the layout of the wall before starting construction and install blocks in a manner that minimizes cutting. Provide temporary bracing as required.

Cored blocks are used at specified locations to provide a con-tinuous cell for a threaded rod or a reinforcing bar.

If a threaded rod is used to resist overturning of a shear wall or to resist direct uplift from a roof, the cell does not require grouting since the rod is strictly a tension element that can be tightened to achieve tautness for load transfer. If a reinforcing bar is used, then the cell must be grouted to ensure the rigidity of the bar during load application and to provide a lap splice when necessary. A reinforcing bar in a grouted cell can function as a tie-down in addition to increasing the flexural strength of the wall. A fine aggregate grout, with good flowability, should be used to fill the cells. The cells should be wetted prior to filling, and a vibrator should be used during the filling process. Cored block are installed in the same manner as standard block. At the base course, if a cleanout or inspection port is required, the cored block can be cut so that the core becomes exposed to one side. If necessary, repair mortar can be used to fill and seal the base course block where it was cut.


Thin bed mortar should be applied with a trowel having the proper style, teeth and width to ensure adequate coverage.

Filled U-blocks can be used as bond beam elements and as lintels. The U-shape is manufactured from standard blocks, which ensures dimensional and material compatibility with other types of AERCON blocks and panels. U-blocks are installed using thin bed mortar for the bed joint and head joints. Typically two reinforcing bars

are inserted in the U-shaped cavity, one above the other (not side-by-side). The U-blocks are then filled with a small aggregate concrete mix to complete the U-block installation. Prior to pouring the concrete, the cavity should be wetted to minimize the absorption of water from the poured concrete.

Solid, reinforced AERCON lintels are installed in the same manner as standard blocks mortaring the bearing bed joints and the head joints with thin bed mortar. Depending on the height of the opening that the lintel spans across, a filler piece of block may be required to achieve the desired bearing elevation; or the blocks that support the lintel can be notched downward if the coursing results in the bearing elevation being too high. Based on their internal reinforcing, AERCON lintels are intended to be installed in a particular orien-tation and are marked to indicate that orientation. AERCON lintels are not to be cut unless authorized by an AERCON Representative.

The large size of ValuBlocks enables more wall area to be installed per block, expediting installation, minimizing the number of blocks that are handled and minimizing the volume of mortar that is needed. Depending on the size and weight of the ValuBlocks, a minicrane and special lifting clamp may be required to lift and set the blocks accurately. Use thin bed mortar at all bed joints and for head joints of flat face blocks. Tongue and groove blocks do not require mortar at the head joints. ValuBlocks can be manufactured with cores and/or radiused edges. When two radiused edge blocks are installed adjacent to each other, a cell is created, dimensionally the same as the drilled cores.

Multiple configurations for inter-facing reinforcing bars and tie-downs at the foundation are available. Some are shown in the Construction Details Section. These include epoxying into the foundation to ensure accurate placement, casting in a hooked anchor, and using an embedded composite system.

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