aggregate block technical manual

7/26/2019 Aggregate Block Technical Manual

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Aggregate Blocks

aggregate blocks

technical manual

CI/SfB Ff2

February 2007

Uniclass L32232: P2


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Contents

Introduction 2-3

1. Product data

Product summaries 6-9

Facing blocks 10-15

Background blocks 16-29

2. Performance

Structural 32-39

Thermal insulation 40-47

Sound insulation 48-53

Fire resistance 54

Movement control 55-57

Moisture penetration 58-59

Durability 60

3. Sitework

Health and safety 63

CDM Regulations 63

Block laying 64-65

Mortar 66-67

Internal finishes 68-69


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Therm alite introduced the autoc

aerated concrete block over 50 ago, and now produces the besrange of building blocks in the UK ingdom .?????

Thermalite aircrete blocks

IntroductionH anson is a m arket leader in th

m anufacture and supply of aggblocks, annually producing 7.5 mU sing naturally occurring denselightw eight aggregates, H anson

aggregate blocks are a robust poffering high com pressive strenexcellent sound insulation to hethe requirem ents of B uilding Re

Hanson provides a unique wealth of knowledge, choice and resources, offering custom

products for the Housing, Commercial and DIY sectors, all backed by the sales suppor

that is the strength of this division.

All products are manufactured to the requirements of BS EN 771-3 and are available in

densities, strengths, sizes, configurations and finishes to suit most applications.


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Standards and regulations

The B ritish/European S tandards and B uilding

Regulations that apply to the m anufacture and use of

aggregate blocks are alw ays subject to revision and

im provem ent. C ertain docum ents that are either in the

process of change, or whose publication is im m inent,cannot be fully accom m odated at the tim e of

publication, although, w herever possible, reference has

been m ade in the text.

The H anson w ebsite at w w w.hanson.biz/uk w ill be

updated as im portant changes occur, but if the

reader has specific queries relating to the m anufacture

or application of the product please contact Product

Services on 08706 0 97091.

ustainability and the environment

M anaging environm ental issues is an integral part of

H ansons business strategy and the com pany is

com m itted to m inim ising the im pact of its operations on

local com m unities and the natural environm ent.

H ansons aggregate blocks are m anufactured by

m ost efficient m ethods available and w here possi

using specially selected recycled aggregates and

secondary aggregate m aterials. A strict w aste

m inim isation schem e is also operated to ensure th

w aste m aterials from the production process are ereused or recycled.

Quality

H ansons aggregate blocks are m anufactured to

the requirem ents of BS EN 771-3, ensuring

com pliance w ith all relevant standards and codes

of practice.

Services

H anson continually researches the needs of custo

in order to develop the range of products available

Additionally, a com prehensive range of literature is

available w ith technical advice on all aspects of th

application and use of aggregate block products i

construction.

See Sales and Technical Advice, page 74-75 .


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1 Product data

Product summaries 6-9

Facing blocks

Evalast Facing 10 -11

Evalast Paint Grade 10 -11

Evalite Facing 12-13

Evalite Paint Grade 12-13

Superlite Facing 14- 15

Superlite Paint Grade 14- 15

Background blocks

Evalast Background 16-17

Fenlite and Fenlite 15 00 Background 18 -21

Evalite Standard Background 22-23

Superlite Background 24-25

Ultralite Background 26-27

Party Wall 28-29


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Facing and Paint Grade bl

product sum m ary

Product data - product summ aries

Evalast Facing and Evalast Paint Grade pages 10-11

Superior quality dense blocks, m anufactured using a m ix form ulated to

close face texture. Evalast Facing is designed specifically for aesthet

left fair faced, allow ing the natural colour of the aggregate to dom inat

a sm ooth, consistent texture,** ideal for receiving a painted finish.

M ean com pressive strength: 3.6, 7.3, 10.4, 17.5

Therm al conductivity (): 1.22 W /m .K

D ry density: 1900 kg/m 3

Evalite Facing and Evalite Paint Grade pages 12-13

M edium density products, intended for internal applications w here w e

Facing is ideal for aesthetic applications and can be left fair faced*. E

consistent and sm ooth texture** perfect for receiving a painted finish.

M ean com pressive strength: 3.6, 7.3 & 10.4 N /m

Therm al conductivity (): 0.47 W /m .KD ry density: 1450 kg/m 3

Superlite Facing and Superlite Paint Grade pages 14-15

These lightweight, low -to-m edium density products are designed spec

applications w here low w eight is critical, particularly in the larger sizes

intended for aesthetic applications and can be left fair faced, allow ing

aggregate to dom inate*. Superlite P aint G rade has a consistent and sm

receiving a painted finish.

M ean com pressive strength: 3.6 & 7.3 N /m m 2

Therm al conductivity (): 0.36 W /m .KD ry density: 1000 kg/m 3

*The colour of facing products can vary from w orks to w orks, so sam ple view ing is highly recom m e

betw een all parties is confirmed if the products are to be left untreated.

**W hilst Paint Grade products have a consistency of texture, colour consistency cannot be guarante

Hansons Facing and Paint Grade blocks have been desigfor aesthetically important block work. These superior qumanufactured with a consistent close face texture and arewide range of shapes and sizes to suit a variety of applicaAll products are produced to the requirements of BS EN 7

Other strengths and sizes may be available on request.


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Background blocks product

Product data - product summ aries

Evalast Background pages 16-17

D ense concrete blocks that can be used in virtually any part of a proje

in norm al conditions. Their perform ance m akes them especially applica

separating w alls w here good sound insulating qualities and high streng

also be used as infill blocks in beam and block flooring system s.

M ean com pressive strength: 3.6, 7.3, 10.4, 17.5,



Fenlite and Fenlite 1500 Background pages 18-21

M edium density blocks suitable for use in the m ajority of standard app

of cavity w alls w hen used w ith secondary insulation, separating or part

beam and block flooring system s and externally w here a finish is appli

M ean com pressive strength: 3.6, 7.3, 10.4 & 15

Therm al conductivity (): 0.45, 0.48 W /m .K

D ry density: 1350, 1500 kg/m 3

Evalite Background pages 22-23

M edium density blocks suitable for use in the m ajority of standard app

of cavity w alls w hen used w ith secondary insulation, separating or part

beam and block flooring system s and externally w here a finish is appli

M ean com pressive strength: 3.6, 7.3 & 10.4 N /m



Superlite Background pages 24-25

Low -to-m edium density blocks w ith good insulating properties ideal for

internal block w alls. The product can achieve high therm al values using

secondary insulation.

M ean com pressive strength: 3.6 & 7.3 N /m m 2



The products contained within the Background block rangare available in a wide range of shapes, sizes and strengthThey are not intended to be left fair-faced, but used with afinish. All products are manufactured to the requirementsOther strengths and sizes may be available on request.


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Product data - facing blocks

Evalast Facing and Evalast Pain

Mean compressive strength: 3.6 - 22.5N/mm2

Thermal conductivity: 1.22W/m.K internal, 1.31W/m.K external

Dry density: 1900 kg/m3

Evalast Facing

Evalast Facing blocks are produced from selected

aggregates com plying w ith B S EN 12620, and P ortland

cem ent. They are m anufactured to B S EN 771 -3 and

are subject to rigorous quality control. These superior

quality dense blocks are produced w ith a m ix design

form ulated to produce a close face texture, w ith a

consistent shade of colour*, w hich is ideal for

aesthetically im portant block w ork. Evalast Facing

products can be left fair faced, allow ing the natural

Applications

Evalast Facing and Paint G ra

all situations w here durable, r

in the case of Evalast Paint G

required. They are an econom

such as:

factory units

w orkshops

sports centres

offices


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Material properties

Therm al conductivity W /m .K internal 1.22

external 1.31

D ry density kg/m 3 1900

Total m oisture m ovem ent m m m -1 < 0.50

Vapour resistivity M N .s/g.m 100

M ean com pressive strength solid 7.3, 10.4, 17.5, 22.5

N / m m 2 cellular/hollow 3.6, 7.3, 10.4

W ater absorption by capillary g/m 2.s0.5 < 375

Shear bond strength N /m m 2 0.15

Fire classification A1

Flatness m m < 0.5

W ater vapour perm eability 5/15

D im ension tolerance classification D 1

Configuration G roup 1

Group 2

Dimensions, weights and properties

Work Width Configuration Thermal resistance Dry Weight Sound Fire resistance (hours)

size mm mm m2 K/ W block laid reduction Single leaf - no applied finish

inte rnal exte rnal we ight kg kg/ m 2 dB non loadbe aring loadbe aring

Class 1 Class 2 Class 1 Claagg agg agg

440 x 215 75* Solid 0.061 0.057 13.5 146 41 2 1 -

90* Solid 0.074 0.069 16.2 175 43 2 11/2 1

100 Solid 0.082 0.076 18.0 195 43 2 2 2

140 Solid 0.115 0.107 25.2 273 45 4 3 3

150 Solid 0 123 0 115 270 291 46 6 4 6

Evalast Paint G rade

Evalast Facing


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Evalite Facing and Evalite Paint

Mean compressive strength: 3.6, 7.3, 10.4N/mm2

Thermal conductivity: 0.47W/m.K internal

Dry density: 1450kg/m3

Evalite Facing

Evalite Facing blocks are a m edium density product,

intended for internal applications w here w eight is

critical. M anufactured to the requirem ents of

B S EN 771-3, from selected aggregates and Portland

cem ent, Evalite products are subject to rigorous quality

control. The blocks are m anufactured w ith a m ix design



aesthetically im portant block w ork. Evalite Facing

Applications

Evalite Facing and Evalite P a

for use w here appearance an

consideration. They are inten

w here a lightw eight, econom

paintable block is required fo

projects such as:

shopping precincts

offices

sports centres


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size mm mm m2 K/ W block laid reduction Single leaf - no applied finis

inte rnal we ight kg kg/ m 2 dB non loadbearing loadbea

Class 1 agg Class 1

440 x 215 75* Solid 0.160 10.3 114 40 2 -

90* Solid 0.191 12.3 136 41 2 1

100 Solid 0.213 13.7 151 42 2 2

140 Solid 0.298 19.2 212 44 4 3

150* Solid 0.319 20.6 226 44 6 6

190 Solid 0 404 26 1 288 46 6 6

Material properties

Therm al conductivity W /m .K internal only 0.47




M ean com pressive strength solid 7.3, 10.4

N / m m 2 cellular/hollow 3 .6 , 7.3 ,




Flatness m m < 0.5




Group 2

Evalite Paint G rade

Evalite Facing

P d t d t f i bl k


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Superlite Facing and

Superlite Paint G radeMean compressive strength: 3.6, 7.3N/mm2

Thermal conductivity: 0.36W/m.K internal


Superlite Facing

Superlite Facing blocks are a lightw eight product,

m anufactured to the requirem ents of B S EN 771-3,

from pyro-processed lightw eight aggregates, com plying

w ith B S EN 13055-1, and Portland cem ent. Superlite

Facing blocks are m anufactured w ith a m ix design



aesthetically im portant block w ork. Superlite Facing

products can be left fair faced, m aking a feature of the

Superlite Paint Grade

Superlite Paint Grade blocks

selected aggregates, com ply

standards as Superlite Facing

sm ooth texture, w hich is idea

finish**.

Applications

The light weight of Superlite

G rade, m akes them ideal for

low w eight is critical, particula


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size mm mm m2 K/ W block laid reduction Single leaf - no applied f

internal weight kg kg/ m2 dB non loadbearing

Class 1 agg Class

440 x 215 75* Solid 0.208 7.1 81 38 2 -

90* Solid 0.250 8.5 98 39 2 1

100 Solid 0.278 9.5 108 39 2 2

140 Solid 0.389 13.2 151 42 4 3

150* Solid 0.417 14.2 161 42 6 6

190 Solid 0 528 18 0 205 44 6 6

Material properties

Therm al conductivity W /m.K internal only 0.36




M ean com pressive strength N /m m 2 solid only 3.6, 7.3




Flatness m m < 0.5




N .B. B lock w eights not greater than 20kg can be achieved for solid

blocks up to and including 2 00m m thickness.

Superlite P aint G rade

Superlite Facing

Product data background blocks


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Product data - background blocks

Evalast B ackground


Thermal conductivity: 1.32W/m.K internal, 1.42W/m.K external

Dry density: 1990 kg/m3

Evalast Background

M anufactured to B S EN 771 -3 from crushed rock or

gravel aggregates to B S EN 12620 and Portland

cem ent.

Evalast B ackground blocks are dense aggregate blocks

w hich can be used in virtually any part of a project

above or below ground, in norm al conditions.

Their perform ance m akes them especially applicable to

partition and separating w alls w here good sound

insulating qualities and high strengths are required.

They can also be used as infill blocks in beam and block

Strength

H aving high density, w ith ass

B ackground blocks easily ach

requirem ents for use above a

be used in norm al and sulpha

equivalent to classification D

Thermal

Evalast B ackground blocks, i

thicknesses of insulation, are

of therm al insulation. Sam ple

U -Values of 0.27, 0.30 and 0

on pages 42-47.

Fire

C oncrete is an excellent fire

Evalast B ackground products

either C lass 1 (lim estone) or

crushed stone) aggregates. Wim portant it is essential that t

specified. Full details are give

Coursing blocks

To com plem ent the range, 22

units (brick size) are available

w ith 7.3N /m m 2 100m m Eval

and 10.4N /m m 2 units are av

thick products.

Finishes

The nature of Evalast B ackgr

for the purpose of rendering

relatively low suction backgro

sm ooth or rough in texture, d

m anufacturing location. As su


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Work Width Configuration Thermal Resistance Dry Weight Sound Fire resistance (hours)


inte rnal e xte rna l w eigh t k g k g/ m 2 dB non loadbearing loadbearing

C lass 1 C lass 2 Class 1 C la s

agg agg agg ag

440 x 215 75 Solid 0.057 0.053 14.1 153 42 2 1 - -

90 Solid 0.068 0.063 16.9 183 43 2 11/2 1 1

100 Solid 0.076 0.070 18.8 203 43 2 2 2 2

140 Solid 0.106 0.099 26.4 285 46 4 3 3 2

150 Solid 0.114 0.106 28.2 304 46 6 4 6 2

Material properties


external 1.42




M ean compressive solid 7.3, 10.4, 17.5, 22.5, 30

strength N /m m 2 cellular/hollow 3 .6, 7.3 , 10 .4

103m m coursing unit 22.5




Flatness m m < 1.0



Configuration G roup 1 G roup 2

Evalast Background



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Product data background blocks

Fenlite B ackground


Thermal conductivity: 0.45 - 0.48W/m.K

Dry density: Fenlite - 1350, Fenlite 1500 - 1500kg/m3

Fenlite blocks

Fenlite and Fenlite 1500 blocks are m anufactured to

B S EN 771 -3 from natural aggregates to B S EN

12620, pyro processed lightw eight aggregates to

B S EN 13 055-1, and Portland cem ent.

These m edium density blocks are suitable for use in the

m ajority of standard applications i.e. the inner leaf of

cavity w alls w hen used w ith secondary insulation,

separating or partition w alls, infill blocks in beam and

block flooring system s and externally w here a finish is

applied.

Fenlite blocks can be used in all parts of the project

above and below ground (7.3N /m m 2 strength if used on

the outer leaf below dpc and unprotected)*.

Their perform ance m akes them em inently suitable for

general load bearing conditions, sound insulation,

internal partitions and w here ease of handling andw eight are of im portance.

Applications

Acoustic

The density of Fenlite and Fenlite 1500 blocks gives

them excellent sound insulation properties. W hen laid to

form a cavity sound separating w all they w ill achieve the

required m ass as given in the B uilding Regulations and

Robust D etails. Typical exam ples of how Fenlite and

Fenlite 1500 blocks m ay be used to form soundseparating w alls are show n on pages 50-53.

Flooring

Fenlite and Fenlite 1500 blocks are suitable as in-fill

blocks for beam and block flooring system s.

They should be specified as for flooring, in order that


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Fenlite and Fenlite 1500 blocks offer a m edium s

background w hich is ideal for the direct applicatio

sand cem ent renders and plasters, together w ith

proprietary lightw eight plasters.

Material properties

M aterial properties for Fenlite and Fenlite 1500 a

show n overleaf (pages 20-21).


D im ensions, w eights and properties for Fenlite an

Fenlite 1500 are show n overleaf (pages 20-21).

Specification and performance

B eing m anufactured from C lass 1 aggregates, all

Fenlite B ackground blocks provide the highest po

levels of fire resistance together w ith good sound

insulation properties.

Strength

The strength of all Fenlite blocks dictates their

application in exposed conditions. B lock strengths of

7.3N /m m 2 and greater should be specified if they are to

be used on the outer leaf of a cavity w all below dpc

level and left unprotected. In all other norm al situations

3.6N /m m 2 blocks w ould be suitable.

Fenlite and Fenlite 1500 blocks, in conjunction w ithsuitable thicknesses of insulation, are able to reach high

levels of therm al insulation. Sam ple constructions

achieving U -Values of 0.27, 0.30 and 0.35W /m 2.K are

illustrated on pages 42-47.

C oncrete is an excellent fire resistant m aterial.

Fenlite and Fenlite 1500 blocks are m anufactured using

C lass 1 aggregates w hich provides the highest level of

fire resistance for a given size.

H aving good strengths, excellent fixing can be achieved

using a variety of patent fixings.

To com plem ent the range, 10.4N /m m 2 coursing units

(brick size) are available for use in conjunction w ith

3.6N /m m 2 100m m blocks and full length units are

available for 140m m w idth products.



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Fenlite B ackground, continued

Fenlite dimensions, weights and properties

Work Width Configuration Thermal resistance Dry Weight Sound size mm mm m2 K/ W block laid reduction Si

inte rnal e xte rnal we ight kg kg/ m 2 dB no

Cl

440 x 215 75 Solid 0 .167 0.156 9.6 106 39

90 Solid 0.200 0.188 11.5 128 41

Fenlite material properties


external 0.48




M ean com pressive solid 3.6, 7.3, 10.4

strength N /m m 2 cellular/hollow 3.6, 7.3





Flatness m m < 1.0



C onfiguration G roup 1

Group 2

Fenlite B ackgr


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Fenlite 1500 dimensions, weights and properties

Work Width Configuration Thermal resistance Dry Weight Sound Fire resistance (hourssize mm mm m2 K/ W block laid reduction Single leaf - no applied fini

inte rnal e xte rnal weight kg kg/ m 2 dB non loadbearing loa

Class 1 Class 1

agg agg

440 x 215 75 Solid 0.156 0.144 10.6 117 40 2 -

90 Solid 0.188 0.173 12.8 141 41 2 1

Fenlite 1500 material properties


external 0.52




M ean com pressive solid 3.6, 7.3, 10.4, 15

strength N /m m 2 cellular/hollow 3.6, 7.3





Flatness m m < 1.0




Group 2

Fenlite 150 0 B ackground



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Evalite B ackground


Thermal conductivity: 0.47 W/m.K internal, 0.505W/m.K external


Evalite Background

Evalite B ackground blocks are a m edium density

product offering good sound insulation, ideal for use in

all parts of the project, above and below ground.

Produced to the requirem ents of B S EN 7713, theirperform ance m akes them em inently suitable for general

load bearing conditions and w here ease of handling and

w eight are im portant.

Applications

Acoustic

Flooring

Evalite B ackground blocks ar

for beam and block flooring s

specified as for flooringin o

m anufacturing base is source

Thermal

Evalite S tandard blocks in co

thicknesses of insulation are

of therm al insulation. Sam ple

U -Values of 0.27, 0.30 and 0


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size mm mm m2 K/ W block laid reduction Single leaf - no applied fini

internal external weight kg kg/ m2 dB non loadbearing loadb

Class 1 Class 1

agg agg

440 x 215 75 Solid 0.160 0.149 10.3 114 40 2 -

90 Solid 0.191 0.178 12.3 136 41 2 1

100 Solid 0.213 0.198 13.7 151 42 2 2

140 Solid 0.298 0.277 19.2 212 44 4 3

150 Solid 0.319 0.297 20.6 226 44 6 6

Material properties


external 0.505




M ean com pressive

strength N /m m 2 solid 3.6, 7.3, 10.4





Flatness m m < 1.0




Evalite Background



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Superlite B ackground

Mean compressive strength: 3.6, 7.3N/mm2

Thermal conductivity: 0.40 W/m.K internal, 0.43W/m.K external


Superlite Background

Superlite B ackground blocks are a lightw eight product,

m anufactured to the requirem ents of B S EN 771-3,

from pyro-processed lightw eight aggregates, com plying

w ith B S EN 13055-1, and Portland cem ent. Superlite

products offer good sound insulation and are ideal for

use in m ost parts of the project, above and below

ground. Their perform ance m akes them suitable for

general load bearing conditions, particularly where ease

of handling and w eight are im portant.

Strength

The strength of Superlite blo

application in exposed condit

7.3N /m m 2 and greater shoul

blocks are to be used on the below dpc level and left unpr

situations 3.6N /m m 2 blocks

Thermal

Superlite blocks in conjunctio

of insulation are able to reach


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internal external weight kg kg/ m2 dB non loadbearing loadClass 1 Class 1

agg agg

440 x 215 75 Solid 0.188 0.174 7.8 88 38 2 -

90 Solid 0.225 0.209 9.4 106 39 2 1

100 Solid 0.250 0.233 10.4 118 40 2 2

140 Solid 0.350 0.326 14.6 165 42 4 3

Material properties


external 0.43




M ean com pressive

strength N /m m 2 solid 3.6, 7.3





Flatness m m < 1.0


Superlite B ackground



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U ltralite B ackground

Mean compressive strength: 3.6N/mm2

Thermal conductivity: 0.295W/m.K internal, 0.32 W/m.K external


Ultralite Background

U ltralite B ackground blocks are a lightw eight product,

m anufactured to B S EN 771-3, from pyro-processed

lightw eight aggregates, com plying w ith B S EN

13055-1, and Portland cem ent. These blocks can beused in m ost parts of the project above ground and on

the inner leaf below ground. Their perform ance m akes

them suitable for general load bearing conditions,

particularly w here low w eight for handling is im portant.

Applications

Fixings and finishes

H aving good strengths, exce

using a variety of patent fixin

U ltralite blocks offer a m ediu

w hich is ideal for the direct a

renders and plasters, togethe

lightw eight plasters.

N ote: U ltralite Background blocks are no

painted, and should have a finish (plaster

applied w here the w all is to have visual im


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internal external weight kg kg/ m2 dB non loadbearing load

Class 1 Class 1agg agg

440 x 215 75 Solid 0.254 0.234 6.0 70 37 2 -

90* Solid 0.305 0.281 7.2 85 38 2 1

100 Solid 0.339 0.313 8.0 94 39 2 2

140 Solid 0.475 0.438 11.3 131 41 4 3

Material properties


external 0.32




M ean com pressive

strength N /m m 2 solid 3.6

cellular 3.6




Flatness m m < 1.5



U ltralite Background



29/81

Party W all

Mean compressive strength: 24N/mm2

Thermal conductivity: 1.46W/m.K internal, 1.56 W/m.K external


Party Wall blocks

Produced to B S EN 771-3, using natural aggregate and

Portland cem ent, for fast and econom ical construction

of strong and sturdy party w alls. The blocks are laid on

190m m bed and due to their high density elim inate theneed for thicker blocks or cavity construction - one

block replacing tw o cavity w all blocks - thus saving tim e

and costs.

Applications

Acoustic

Fire

C oncrete is an excellent fire

Party W all blocks are m anufa

aggregate. W here fire resista

essential that the fire resistanof aggregate is checked.

Finishes

The nature of Party W all bloc

purposes of plastering, as a r

suction background. As such


30/81


Work Width C onfigration Thermal resistance Dry Weight Sound Fire resistance (hours)


interna l exte rnal weight kg kg/ m2 dB non loadbearing loadbearing

Class 2 agg Class 2 agg

440 x 65 190 Solid 0.130 0.122 11.4 400 48 4 2

Material properties


external 1.56




M ean com pressive

strength N /m m 2 solid 24






Party W all

Product data


31/81


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2 Performance

Structural 32-39

Thermal insulation 40-47

Sound insulation 48-53

Fire resistance 54

Movement control 55-57

Moisture penetration 58-59

Durability 60

Performance


33/81

Structural

General

It is the purpose of design to ensure that the building

be constructed so that the com bined dead, im posed

and w ind loads are sustained and transm itted by it to

the ground:

a) Safely

b)W ithout causing such deflection or deform ation of

any part of the building, or such m ovem ent of theground, as w ill im pair the stability of any part of

another building.

In order to achieve the above requirem ents, the

recom m endations for the structural design of m asonry

are given in B S 5628: Parts 1 and 2 . Additional

guidance is given in B S 5628: Part 3 for walls subject

to im posed lateral load only and internal w alls or

partitions not designed for im posed loading.

W here the building type is lim ited to:

a) Residential buildings of not m ore than three

storeys.

b) Sm all single storey non-residential buildings.

c) Sm all buildings form ing annexes to residential

buildings (including garages and out buildings).

G uidance is given in A pproved D ocum ent A of the

B uilding Regulations 2000 (2004 edition) (England andW ales) or Technical Standard C of the B uilding

Standards (Scotland) Regulations.

Table 1: Partial safety factors f

Category of

m asonry unit

Com pression, ()m C ategory IC ategory 2

Flexure, ()m C ategory I and

All aggregate concrete m aso

H anson are m anufactured tocontrols. Fig. 1 gives guidanc

strength of brick and block u

and three storey buildings in

the roof construction is of tim

durability, m ay dictate the nee

or thickness depending on lo

greater than the sizing or loa

approved docum ent, the desi

B S 5628: Parts 1 or 2 to enssafety against the ultim ate lim

W hen carrying out the design

necessary to consider the ch

safety factors for loading, tog

characteristic strength of the

factors for the m aterial stren

the characteristic com pressiv

given in Table 2 (page 34) f

concrete bricks and blocks lam ortar, (M 4).


34/81

Cavity wall InternaUnderside ofstructural roof

Hs

Cavity wallUnderside ofstructural roof

Topside ofstructural floor

Hs Internal wall

Compressive strength of masonry units

Aggregate concrete masonry unit strength toBS EN 771-3

Blocks Bricks

C ondition A 2.90N /m m 2 6.00N /m m 2

C ondition B 7.30N /m m 2 9.00N /m m 2

C ondition C 7.30N /m m 2 18.00N /m m 2

W here

H f Less than or equal to 1m , C ondition A

W here

H f G reater than 1m , C ondition B

N otes

Figure 1

1 If H s is not greater than 2 .7m , the com pressive strength of bricks or

should be used in w alls as indicated by the key.

2 If H s is greater than 2 .7m , the com pressive strength of bricks or bloc

in the w all should be at least Condition B, or as indicated by the key, w

is the greater.

3 If the external w all is solid construction, the m asonry units should ha

com pressive strength of at least that show n for the internal leaf of a c

in the sam e position.

4 The guidance given in the diagram , for walls of tw o and three storey

buildings, should only be used to determ ine the com pressive strength

m asonry units w here the roof construction is of tim ber.

One storey

Performance


35/81

Structural

Table 2: Characteristic compressive strength of m asonry, fk, in N/ mm 2

Block Aspect Unit strength N/ mm2

size ratio

3.60 7.30 10.40 15.00 17.50 22.50

Group 1 Units (void content < 25% ) in designation (iii) Mortar (M4)

440 x 215 x 75 2.87 3.50 6.40 8.20 9.43 10.10 12.00

440 x 215 x 90 2.39 3.50 6.40 8.20 9.43 10.10 12.00

440 x 215 x 100 2.15 3.50 6.40 8.20 9.43 10.10 12.00

440 x 215 x 140 1.54 2.91 5.35 6.85 7.89 8.46 10.03

440 x 215 x 150 1.43 2.77 5.10 6.53 7.52 8.06 9.56

440 x 215 x 190 1.13 2.38 4.41 5.65 6.52 6.99 8.27

440 x 215 x 200 1.08 2.32 4.30 5.51 6.35 6.81 8.06

440 x 215 x 215 1.00 2.21 4.11 5.27 6.09 6.53 7.71

215 x 215 x190 1.13 - 4.41 5.65 6.52 6.99 8.27

290 x 215 x 140 1.54 - 5.35 6.85 7.89 8.46 10.03

290 x 140 x 215 0.65 - 3.31 4.25 4.92 5.28 6.21

440 x 65 x 190 0.34 - - - - - -

215 x 65 x 103 0.63 - - 4.19 - - 6.13

440 x 65 x 140 0.46 - - 3.69 - - -

Group 2 units (void content > 25% but < 60% ) in designation (iii) mortar (M4)440 x 215 x 140 1.54 2.91 5.15 6.11 - - -

440 x 215 x 150 1.43 2.77 4.92 5.88 - - -

440 x 215 x 190 1.13 2.38 4.30 5.24 - - -

440 x 215 x 215 1.00 2.21 4.03 4.96 - - -

G 1 it l id fl t i d i ti (iii) t (M4) t th t t d i ht

Characteristic compressive strength of masonry, fk

For norm ally bonded m asonry, defined in term s of the shape and com pressive strength o

classification of the m ortar, the values given in Table 2 m ay be taken to be the character

fk, of w alls constructed under laboratory conditions, tested at an age of 28 days.


36/81

Reinforced masonry

W hen considering reinforced m asonry design, guidance

is given in B S 5628: Part 2. A particular application of

this form of construction is the form ation of lintels over

openings, w here the block pattern is to be m aintained.

In order to achieve this, trough lintel or bond team units

(half length trough lintels used w here a fair faced soffit

is required) are laid on tem porary form w ork w ith an

extra unit at each end to form the bearing. The voidachieved is then filled w ith the necessary reinforcem ent

and infill concrete to w ithstand the applied load.

The w hole assem bly is allow ed to cure before the

form w ork is struck.

A typical exam ple is show n in Fig. 2.

Table 3 gives guidance on the m axim um spans for

single layer reinforced m asonry trough lintels used in

internal applications. W here it is necessary to have

greater spans, the use of double layer reinforced

sections should be considered (as illustrated).

Local bed-joint reinforcement

Bond beam units witwe s knocke out

B ond beam s can also be used:

a) As horizontal beam s to distribute loads to colum

b) As heads of w alls to distribute vertical loads

c) B elow large panel openings to assist w ith m ove

control.

The reinforcem ent quantities in the table are

for guidance only, exact detail and specification

should be approved by a structural engineer.

Table 3 : Maximum spans for single layer reinforced mas

above openings

Trough lintel (face size)

Full length Half length Width Maximum Reinforc

mm span (m) (high yie

440 x 215 215 x 215 100 2.4 1 x 12m

440 x 215 215 x 215 140 2.2 1 x 12m

440 x 215 215 x 215 190 2.2 1 x 12m

440 x 215 215 x 215 215 2.1 1 x 12m

The m axim um spans indicated above have been based on:

1. Loads assessed in accordance w ith B S 5977: Part 1(no additional loads or openings in load triangle or interazone other than m asonry above).

2. M ortar designation (ii) (M 6)

3. B lock strength 7.3N /m m 2

4. C oncrete infill(a) 1:0-1/4:3:2 cem ent:lim e:sand:10m m m ax. size aggre

(b) Concrete grade C 30 215m m

5. M inim um bearings 215m m

Performance


37/81

Internal walls or partitions not designated for

imposed loading

W hen an internal w all or partition is not intended to

carry an im posed load, it should be laterally restrained

by horizontal or vertical, continuous or interm ittent

supports. The length or height of the w all in relation to

its thickness should be w ithin the lim its given in

Figs. 3, 4 and 5, page 37.

C onsideration should also be given to the follow ing,

w hich m ay affect stability:

a) O penings

b) Accom m odation of m ovem ent

c) C hasing

d) Exceptional lateral loading

e) W ind load

W here w alls are to be plastered and the plaster

thickness is included in the w all thickness calculation,

the w all m ay require tem porary bracing prior to

plastering.

The type of restraint em ployed should allow for the

m ovem ent of the w all due to shrinkage or therm al

changes, together w ith any deflection of the structure,

w ithout inducing unacceptably high stresses w hich m ay

result in cracking and potential instability.

Mortars

The specification and choice of the m ortar is a

fundam ental determ inant of the structural and visual

properties of a blockw ork w all.

F llH bl k d i l

Table 5 : Internal and external dim(all dimensions nominal)

Half length trough lintels (fair faced

Work size Width

mm (t)

215 x 215mm a

b

Other sizes are available, cut from s

a

t

a

t

c

Block dimensions: hollow/cellulars

Work size Width

mm (t) 140c

440 x 215mm a 30

b 30

c 50

Voids vary in size depending on mablocks, the void does not pass throaverage a 25mm bottom thickness.

Structural


38/81

1.0

1.0

100

125

140150

190

200

215

Notrecommended

Wallheightm

Wall length m

2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

1.0

1.0

100

125

140150

190

200

215

Notrecommended

Wallheightm

2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

Wall length m

Figure 3 : Recommended block width non-loadbearing unplastered wallsrestrained at the top only

Performance


39/81

Structural

Radius walls

Standard blocks can be laid in stretcher bond to form

circular or curved w alls. The length and thickness of the

block w ill determ ine the w idth of the perpend on the

outer face and the overhang betw een successive

courses for a particular radius.

Length of block

T

Externalperpend width(see table)

Width of internalperpend 10mm

Overhang betweenalternative courses

Figure 6: Typical radius wall

Fig. 6 and Table 6 give guida

on the size of the unit w ith a

joint on the internal face. To l

perpend joint, the joint on the

reduced, or the block cut on


40/81

Table 6: Overhang and perpend joint widths for radius walls

Wall Work size: 440 x 215mm Work size: 215 x 215mm

radius W = 100 L = 440 W = 140 L = 440 W = 100 L = 215 W = 140 L = 215

mm Overhang Perpend Overhang Perpend Overhang Perpend Overhang Perpend

joint joint joint

600 44 86 46 120 10 50 11 68

800 32 68 33 93 8 40 8 53

1000 25 56 26 76 6 34 6 44

1200 21 48 21 65 5 29 5 29

1400 18 43 18 57 4 27 4 34

1600 16 39 16 51 4 24 4 31

1800 14 36 14 46 3 23 3 28

2000 12 33 13 42 3 22 3 26

2500 10 28 10 36 2 19 2 23

3000 8 25 8 31 2 18 2 21

3500 7 23 7 28 2 17 2 19

4000 6 21 6 26 1 16 1 18

4500 5 20 5 24 1 15 1 17

5000 5 19 5 23 1 15 1 16

5500 4 18 4 22 1 14 1 16

6000 4 18 4 21 1 14 1 15

W= Width L= Length

Performance


41/81

Thermal Insulation

Introduction

N ew m easures to im prove the energy efficiency of

buildings have been introduced by the G overnm ent.

The intention is to m eet the requirem ents of The

Energy Perform ance of Buildings D irective (EPB D )

w hich aim s to further com bat clim ate change and

requires buildings to be both better insulated and to

m ake use of m ore efficient heating system s.

The changes to Approved D ocum ents (conservation of

fuel and pow er) of the B uilding R egulations for

England and W ales cam e into force on 6th A pril

2006.

The revised Approved D ocum ent w ill also m ake air

leakage pressure testing of buildings m andatory,

thereby im proving com pliance w ith the regulations.

The use of Robust D etails for airtightness of dw ellingsm ay provide an alternative to routine testing, although

at present the required details have not yet been

developed.

G uidance is given below on com pliance to satisfy the

requirem ents of B uilding Regulation L1 (England and

W ales) 2006, w ith respect to H ansons aggregate

blocks.

D ifferent requirem ents apply in Scotland. Please refer

to technical standard J of the B uilding Standards

(Scotland) Regulations.

Approved Documents

The new Part L A pproved D ocum ents are in 4 sections

as follow s:

com pliance can be assessed

procedure know n as the Sim

M odel (SB EM ). Conservatori

than 30m 2 m ust com ply w ith

Part L1A requirements - d

The 2006 am endm ents to Pa

about a 20% reduction in car

com pared to dw ellings built t

of therm al insulation. C om plia

dem onstrated using a revised

Procedure (SAP 2005) calcu

SAP 2005 & Emission rates

The use of SA P 2005 w ill re

em issions from :

1. Space and w ater heating,

2. The use of internal fixed li

The Target C O 2 Em ission Ra

determ ined. This is calculated

based on SAP 2005 and is, i

notional building w hich assum

on the 2002 regulation desig

form ula is used to determ ine

TE R = (C H x fuel factor + C

factor).

The fuel factor is a tabulated

D ocum ent L1 and is depende

The D w elling C O 2 Em ission R

based on the energy features

It needs to be carried out tw i


42/81

Table 7: Design limit U-Values

Element (a) Area - weighted (b) Worst individual

Stage 2

The dw elling fabric and the fixed services should have

perform ance values no w orse than the specified

design lim its.

Stage 3

The dw elling should include appropriate passive control

m easures to lim it the effect of solar gains on indoor

tem peratures.

Stage 4

The perform ance of the dw elling, as built, is consistent

w ith the D ER. This requires a check to ensure that any

changes in perform ance and specification of m aterials

betw een design and construction do not affect the TE R.

A final calculation of the D ER is required to confirm

com pliance.

Stage 5

Inform ation concerning the energy efficient operation ofthe dw elling should be provided to the occupier. This w ill

include operating and m aintenance instructions

produced in such a w ay that householders can

understand.

This inform ation is expected to be included as part of

the H om e Inform ation P ack.

Limits on design flexibility

For design purposes, the lim iting U -Values show n in

Table 7 should not be exceeded. In practice, the

envelope standards w ould need to be better than the

lim iting values.

O ther steps could include an appropriate com bina

w indow size and orientation, solar protection throu

shading, ventilation etc. Reference should be m ad

C E 129 Reducing O verheating - A D esigners G u

for m ore inform ation.

Quality of construction

It is im portant to note that insulation should be

continuous over the w hole dw elling envelope and

the air perm eability is w ithin a reasonable lim it.

To ensure that the perform ance of the dw elling as

is consistent w ith the D ER, a check is required to

ensure that any changes in perform ance and

specification of m aterials betw een design and

construction do not affect the TER. A final calcula

the D ER is required to confirm com pliance. If the

dw elling does not com ply, then appropriate rem ed

be required. A checklist is provided in Approved

D ocum ent L1A to aid identification of non-confor

For details of how to com ply w ith the requirem ent

Parts L1B , L2A and L2B , please consult the relev

Approved D ocum ents. D etails of the changes rela

Part L w ere reproduced from the technical data s

com piled by the C oncrete B lock Association.

Aggregate block solutions

Although the perform ance values of the building

envelope w ill depend on factors such as air perm evalues, fuel type and heating efficiency, it is likely

w all U -Values of 0.27- 0.35W /m 2K w ill be require

Exam ples of aggregate block solutions to m eet th

level of perform ance are detailed on pages 42-47

Th U V l i i thi b h t t

Performance


43/81

Full fill construction

Table 8: minimum thickness of insulation to achieve a 0.27 W/ m2.K U-Value (actual U-Value in brackets). 100 mm inner leaf block wid

Insulation Evalast Fenlite Fenlite Evalite Superlite Ultra

conductivity W/ m.K 1500 Standard

0.032 n/a 100 (0.27) 100 (0.27) 100 (0.27) 100 (0.27) 100

0.034 n/a n/a n/a n/a n/a n/a

0.036 125 (0.27) 125 (0.26) 125 (0.27) 125 (0.26) 125 (0.26) 125

0.040 145 (0.27) 140 (0.27) 140 (0.27) 140 (0.27) 135 (0.27) 135

0.032 n/a 100 (0.27) 100 (0.27) 100 (0.27) 100 (0.27) 100

0.034 n/a n/a n/a n/a n/a n/a0.036 125 (0.27) 125 (0.26) 125 (0.26) 125 (0.26) 125 (0.26) 125

0.040 125 (0.27) 135 (0.27) 135 (0.27) 135 (0.27) 135 (0.27) 135

0.032 100 (0.27) 100 (0.26) 100 (0.26) 100 (0.26) 100 (0.26) 100

0.034 n/a n/a n/a n/a 100 (0.27) 100

0.036 125 (0.26) 125 (0.26) 125 (0.26) 125 (0.26) 125 (0.25) 125

0.040 140 (0.27) 130 (0.27) 135 (0.27) 135 (0.27) 130 (0.27) 130

0.032 n/a 100 (0.27) n/a 100 (0.27) 100 (0.27) 100


0.036 125 (0.27) 125 (0.27) 125 (0.27) 125 (0.27) 125 (0.26) 125

0.040 145 (0.27) 140 (0.27) 140 (0.27) 140 (0.27) 140 (0.27) 135

0.032 n/a 100 (0.27) 100 (0.27) 100 (0.27) 100 (0.27) 100


0.036 125 (0.27) 125 (0.26) 125 (0.26) 125 (0.26) 125 (0.26) 125

0.040 140 (0.27) 135 (0.27) 135 (0.27) 135 (0.27) 135 (0.27) 135

0.032 100 (0.27) 100 (0.26) 100 (0.26) 100 (0.26) 100 (0.26) 100

0.034 n/a n/a n/a n/a n/a 100

0.036 125 (0.27) 125 (0.26) 125 (0.26) 125 (0.26) 125 (0.26) 125

0.040 140 (0.27) 135 (0.27) 135 (0.27) 135 (0.27) 130 (0.27) 130

0.032 100 (0.27) 100 (0.27) 100 (0.27) 100 (0.27) 100 (0.26) 100

0.034 n/a n/a n/a n/a n/a 100

0.036 125 (0.27) 125 (0.26) 125 (0.26) 125 (0.26) 125 (0.26) 1250.040 140 (0.27) 135 (0.27) 135 (0.27) 135 (0.27) 135 (0.27) 130

0.032 100 (0.27) 100 (0.27) 100 (0.26) 100 (0.26) 100 (0.26) 100

0.034 n/a n/a n/a n/a 100 (0.27) 100

0.036 125 (0.26) 125 (0.26) 125 (0.26) 125 (0.26) 125 (0.25) 125

0.040 135 (0.27) 130 (0.27) 130 (0.27) 130 (0.27) 130 (0.27) 130

0.032 100 (0.26) 100 (0.26) 100 (0.26) 100 (0.26) 100 (0.25) 100

Therm al insulation

Brick outer leaf

Full fill insulation

Inner leaf block

Internal finish

Evalast outer leaf


Render

Inner leaf block

Internal finish

Fenlite outer leaf


Render

Inner leaf block

Internal finish

0.27


44/81


Table 9: minimum thickness of insulation to achieve a 0.30 W/ m2.K U-Value (actual U-Value in brackets). 100 mm inner leaf

Insulation Evalast Fenlite Fenlite Evalite Superlite


0.032 100 (0.28) 100 (0.27) 100 (0.27) 100 (0.27) 100 (0.2

0.034 100 (0.30) 100 (0.29) 100 (0.29) 100 (0.29) 100 (0.2

0.036 125 (0.27) 100 (0.30) 100 (0.30) 100 (0.30) 100 (0.3

0.040 125 (0.30) 120 (0.30) 120 (0.30) 120 (0.30) 120 (0.3

0.032 100 (0.28) 100 (0.27) 100 (0.27) 100 (0.27) 100 (0.2

0.034 100 (0.29) 100 (0.28) 100 (0.28) 100 (0.28) 100 (0.20.036 125 (0.27) 100 (0.30) 100 (0.30) 100 (0.30) 100 (0.3

0.040 125 (0.30) 120 (0.30) 120 (0.30) 120 (0.30) 120 (0.3

0.032 100 (0.27) 85 (0.30) 85 (0.30) 85 (0.30) 85 (0.3

0.034 100 (0.29) 100 (0.28) 100 (0.28) 100 (0.28) 100 (0.2

0.036 100 (0.30) 100 (0.29) 100 (0.29) 100 (0.29) 100 (0.2

0.040 120 (0.30) 115 (0.30) 115 (0.30) 115 (0.30) 115 (0.3

0.032 100 (0.28) 100 (0.27) 100 (0.28) 100 (0.27) 100 (0.2

0.034 100 (0.30) 100 (0.29) 100 (0.29) 100 (0.29) 100 (0.2

0.036 125 (0.27) 100 (0.30) 100 (0.30) 100 (0.30) 100 (0.3

0.040 130 (0.30) 120 (0.30) 125 (0.30) 125 (0.30) 120 (0.3

0.032 100 (0.28) 100 (0.27) 100 (0.27) 100 (0.27) 100 (0.2

0.034 100 (0.30) 100 (0.29) 100 (0.29) 100 (0.29) 100 (0.2

0.036 125 (0.27) 100 (0.30) 100 (0.30) 100 (0.30) 100 (0.3

0.040 125 (0.30) 120 (0.30) 120 (0.30) 120 (0.30) 120 (0.3

0.032 100 (0.27) 85 (0.30) 85 (0.30) 85 (0.30) 85 (0.3

0.034 100 (0.29) 100 (0.28) 100 (0.28) 100 (0.28) 100 (0.2

0.036 100 (0.30) 100 (0.29) 100 (0.29) 100 (0.29) 100 (0.2

0.040 120 (0.30) 115 (0.30) 115 (0.30) 115 (0.30) 115 (0.3

0.032 100 (0.27) 85 (0.30) 85 (0.30) 85 (0.30) 85 (0.3

0.034 100 (0.29) 100 (0.28) 100 (0.28) 100 (0.28) 100 (0.2

0.036 100 (0.30) 100 (0.29) 100 (0.29) 100 (0.29) 100 (0.2

0.040 125 (0.30) 115 (0.30) 120 (0.30) 120 (0.30) 115 (0.3

0.032 100 (0.27) 85 (0.30) 85 (0.30) 85 (0.30) 85 (0.3

0.034 100 (0.29) 100 (0.28) 100 (0.28) 100 (0.28) 100 (0.2

0.036 100 (0.30) 100 (0.29) 100 (0.29) 100 (0.29) 100 (0.2

0.040 120 (0.30) 115 (0.30) 115 (0.30) 115 (0.30) 115 (0.3

0.032 100 (0.27) 85 (0.30) 85 (0.30) 85 (0.30) 85 (0.3

Brick outer leaf


Inner leaf block

Internal finish

Evalast outer leaf


Render

Inner leaf block

Internal finish

Fenlite outer leaf


Render

Inner leaf block

Internal finish

0.30

Performance


45/81


Table 10 : minimum thickness of insulation to achieve a 0.35 W/ m2.K U-Value (actual U-Value in brackets). 100 mm inner leaf block wi



0.032 85 (0.33) 75 (0.35) 75 (0.35) 75 (0.35) 75 (0.34) 75

0.034 85 (0.34) 85 (0.33) 85 (0.33) 85 (0.33) 85 (0.33) 75

0.036 90 (0.34) 85 (0.34) 85 (0.35) 85 (0.35) 85 (0.34) 80

0.040 100 (0.34) 95 (0.34) 95 (0.34) 95 (0.34) 95 (0.34) 95

0.032 85 (0.33) 75 (0.34) 75 (0.34) 75 (0.34) 75 (0.34) 750.034 85 (0.34) 85 (0.32) 85 (0.33) 85 (0.32) 75 (0.35) 75

0.036 90 (0.34) 85 (0.34) 85 (0.34) 85 (0.34) 80 (0.35) 80

0.040 95 (0.35) 90 (0.35) 90 (0.35) 90 (0.35) 90 (0.35) 90

0.032 75 (0.35) 75 (0.33) 75 (0.33) 75 (0.33) 75 (0.33) 75

0.034 85 (0.33) 75 (0.35) 75 (0.35) 75 (0.35) 75 (0.34) 75

0.036 85 (0.34) 80 (0.34) 80 (0.35) 80 (0.35) 80 (0.34) 75

0.040 95 (0.34) 90 (0.34) 90 (0.34) 90 (0.34) 85 (0.35) 85

0.032 85 (0.33) 75 (0.35) 75 (0.33) 75 (0.33) 75 (0.33) 75

0.034 85 (0.35) 85 (0.33) 85 (0.33) 85 (0.33) 85 (0.33) 75

0.036 90 (0.35) 85 (0.35) 85 (0.35) 85 (0.35) 85 (0.34) 85

0.040 100 (0.35) 95 (0.35) 95 (0.35) 95 (0.35) 95 (0.34) 90

0.032 85 (0.32) 75 (0.34) 75 (0.35) 75 (0.34) 75 (0.34) 75

0.034 85 (0.34) 85 (0.33) 85 (0.33) 85 (0.33) 85 (0.32) 75

0.036 90 (0.34) 85 (0.34) 85 (0.34) 85 (0.34) 85 (0.34) 80

0.040 100 (0.34) 95 (0.34) 95 (0.34) 95 (0.34) 90 (0.35) 95

0.032 75 (0.35) 75 (0.33) 75 (0.33) 75 (0.33) 75 (0.33) 75

0.034 75 (0.35) 75 (0.35) 75 (0.35) 75 (0.35) 75 (0.35) 75

0.036 85 (0.35) 80 (0.35) 80 (0.35) 80 (0.35) 80 (0.34) 75

0.040 95 (0.35) 90 (0.34) 90 (0.35) 90 (0.34) 90 (0.34) 85

0.032 75 (0.35) 75 (0.33) 75 (0.34) 75 (0.34) 75 (0.33) 75

0.034 85 (0.33) 75 (0.35) 75 (0.35) 75 (0.35) 75 (0.35) 75

0.036 85 (0.35) 80 (0.35) 80 (0.35) 80 (0.35) 80 (0.35) 80

0.040 95 (0.35) 90 (0.35) 90 (0.35) 90 (0.35) 90 (0.34) 85

0.032 75 (0.34) 75 (0.33) 75 (0.33) 75 (0.33) 75 (0.33) 65

0.034 85 (0.33) 75 (0.35) 75 (0.35) 75 (0.35) 75 (0.34) 75

0.036 85 (0.34) 80 (0.34) 80 (0.34) 80 (0.34) 80 (0.34) 75

0.040 95 (0.34) 85 (0.35) 90 (0.34) 90 (0.34) 85 (0.35) 85

0 032 75 (0 33) 65 (0 35) 75 (0 32) 75 (0 32) 65 (0 35) 65

Therm al insulation

0.35

Brick outer leaf


Inner leaf block

Internal finish

Evalast outer leaf


Render

Inner leaf block

Internal finish

Fenlite outer leaf


Render

Inner leaf block

Internal finish


46/81

Partial fill construction

Table 11: minimum thickness of insulation to achieve a 0.27 W/ m2.K U-Value (actual U-Value in brackets). 100 mm inner lea



Foil faced 65 (0.27) 65 (0.26) 65 (0.27) 65 (0.27) 65 (0.26

C avity insulation(k= 0.023W /m .K ) 65 (0.27) 65 (0.26) 65 (0.26) 65 (0.26) 60 (0.27

C avity (low em issivity)

= 0.644m 2K /W 65 (0.26) 60 (0.27) 60 (0.27) 60 (0.27) 60 (0.27

Foil faced 65 (0.27) 65 (0.27) 65 (0.27) 65 (0.27) 65 (0.26

C avity insulation

(k= 0.023W /m .K ) 65 (0.27) 65 (0.26) 65 (0.26) 65 (0.26) 65 (0.26


= 0.644m 2K /W 65 (0.27) 60 (0.27) 60 (0.27) 60 (0.27) 60 (0.27

Foil faced 65 (0.27) 60 (0.27) 60 (0.27) 60 (0.27) 6 0 (0.27

C avity insulation

(k= 0.023W /m .K ) 65 (0.26) 60 (0.27) 60 (0.27) 60 (0.27) 6 0 (0.27


= 0.644m 2K /W 60 (0.27) 60 (0.26) 60 (0.26) 60 (0.26) 60 (0.26

Fenlite outer leaf

50mm clear cavity

Partial fill insulation

Render

Inner leaf block

Internal finish

Everlast outer leaf

50mm clear cavity


Render

Inner leaf block

Internal finish

Brick outer leaf

50mm clear cavity


Inner leaf blockInternal finish

0.27

Performance


47/81


Table 12 : minimum thickness of insulation to achieve a 0.30 W/ m2.K U-Value (actual U-Value in brackets). 100 mm inner leaf block wi



Foil faced 60 (0.29) 50 (0.30) 50 (0.30) 50 (0.30) 50 (0.30) 50 (0

C avity insulation

(k= 0.023W /m .K ) 55 (0.30) 50 (0.29) 50 (0.29) 50 (0.29) 50 (0.29) 45 (0C avity (low em issivity)

= 0.644 m 2K /W 50 (0.30) 45 (0.30) 50 (0.29) 50 (0.29) 45 (0.30) 45 (0

Foil faced 6 0 (0.29) 50 (0.30) 50 (0.30) 50 (0.30) 50 (0.3 0) 50 (0C avity insulation

(k= 0.023W /m .K ) 55 (0.30) 50 (0.30) 50 (0.30) 50 (0.30) 50 (0.29) 50 (0


= 0.644 m 2K /W 50 (0.30) 50 (0.29) 50 (0.29) 50 (0.29) 45 (0.30) 45 (0

Foil faced 50 (0.30) 50 (0.29) 50 (0.29) 50 (0.29) 50 (0.29) 45 (0

C avity insulation

(k= 0.023W /m .K ) 50 (0.30) 45 (0.30) 45 (0.30) 45 (0.30) 45 (0.3 0) 45 (0


= 0.644 m 2K /W 50 (0.29) 45 (0.30) 45 (0.30) 45 (0.30) 45 (0.29) 45 (0

Therm al insulation

0.30

Fenlite outer leaf

50mm clear cavity


Render

Inner leaf block

Internal finish

Brick outer leaf

50mm clear cavity



Everlast outer leaf

50mm clear cavity


Render

Inner leaf block

Internal finish


48/81


Table 13 : minimum thickness of insulation to achieve a 0.35 W/ m2.K U-Value (actual U-Value in brackets). 100 mm inner lea



Foil faced 45 (0.33) 40 (0.34) 40 (0.34) 40 (0.34) 40 (0.34

C avity insulation

(k= 0.023W /m .K ) 40 (0.35) 40 (0.34) 40 (0.34) 40 (0.34) 40 (0.33C avity (low em issivity)

= 0.644m 2K /W 40 (0.34) 35 (0.35) 35 (0.35) 35 (0.35) 35 (0.35

Foil faced 45 (0.33) 40 (0.34) 40 (0.35) 40 (0.34) 4 0 (0.34C avity insulation

(k= 0.023W /m .K ) 45 (0.33) 40 (0.34) 40 (0.34) 40 (0.34) 40 (0.34


= 0.644m 2K /W 40 (0.34) 35 (0.35) 40 (0.33) 35 (0.35) 35 (0.35

Foil faced 40 (0.35) 40 (0.33) 40 (0.33) 40 (0.33) 35 (0.35

C avity insulation

(k= 0.023W /m .K ) 40 (0.34) 35 (0.35) 35 (0.35) 35 (0.35) 35 (0.35


= 0.644m 2K /W 35 (0.35) 35 (0.34) 35 (0.34) 35 (0.34) 35 (0.34

0.35

Fenlite outer leaf

50mm clear cavity


Render

Inner leaf block

Internal finish

Brick outer leaf

50mm clear cavity



Everlast outer leaf

50mm clear cavity


Render

Inner leaf block

Internal finish

Performance

S d i l i


49/81

Sound insulation

Introduction

Approved D ocum ent E (AD E) of the B uilding

Regulations cam e into force on 1st July 2003. It w as

am ended again in July 2004 to enable R obust D etails

to be included as a valid m ethod of m eeting the

requirem ents of the regulations.

The aim s of the review w ere to broaden the scope of

Part E, to raise standards of sound insulation, and of

particular im portance, to im prove com pliance w ith theperform ance standards in order to reduce the potential

for com plaints regarding noise from neighbours.

ADE RequirementsE1 Protection against sound from other parts of the

building and adjoining buildings

(a) This requirem ent now includes room s for residential

purposes as w ell as dw elling houses and flats.

Room for residential purposesm eans a room , or suite

of room s, w hich is not a dw elling-house or flat and

w hich is used by one or m ore persons to live and sleep

in, including room s in hotels, hostels, boarding houses,

halls of residence and residential hom es, but not

including room s in hospitals, or other sim ilar

establishm ents, used for patient accom m odation.

(b) Perform ance standards are given for w alls, floors

and stairs having a separating function, in new buildings

and buildings form ed by change of use.

E2 Protection against sound within a dwelling-house etc

(c) This is a new requirem ent that sets standards for the

sound insulation of w alls and floors in dw elling-houses,

flats and room s for residential purposes.

Meeting the regulationsSatisfying E1

O ne m ethod of satisfying req

separating w alls, separating f

separating function, together

flanking construction, in such

the sound insulation values f

flats set out in Table 1a of AD

14 below ), and the values for

purposes set out in Table 1b

below ) or by using Robust D

houses or flats.

Table 1 4: Dwelling-houses and ffor separating walls, separating fseparating function.

Airb orne insulationDnT,w + Ct(Minimum

Purpose built dwellinghouses and flatsW alls 45Floors and stairs 45

Dwelling houses and flats formby a material change of use

W alls 43Floors and stairs 43

Table 1 5: Rooms for residential pstandards for separating walls, sthat have a separating function.

Airb orne insulationDnT,w + Ct(Minimum


50/81

Compliance

C om pliance w ith R egulation E1 (party w alls) can be

achieved by the follow ing one of m ethods detailed

below using aggregate concrete blocks-

B uild to the prescriptive m ethods detailed in the

Approved Docum ent.

or alternatively

B uild to the designs detailed in the Robust D etailsM anual.

Pre-Completion Testing

Sound insulation testing to dem onstrate com pliance

w ith requirem ent E1 should be carried out on site as

part of the construction process. In the Approved

D ocum ent it is referred to as Pre-Com pletiontesting.

U nder Regulation 20A and Regulation 12A, the duty of

ensuring that appropriate sound insulation testing is

carried out falls on the person carrying out the buildingw ork, w ho is also responsible for the cost of the testing.

Testing should be carried out for:

a)Purpose built dw elling-houses and flats;

b)D w elling-houses and flats form ed by m aterial change

of use;

c)Purpose built room s for residential purposes;

d)Room s for residential purposes form ed by m aterial

change of use.

The Pre-Com pletion Test regim e and procedure are

detailed in S ection 1 of the Approved D ocum ent.

Table 16: Laboratory values for new internal walls and flwithin dwelling houses, flats and rooms for residentialpurposes, whether purpose built or formed by material of use.

Airborne sound insulationRw dB(minimum values)

W alls 40

Floors and stairs 40

Internal walls (no testing required)

C om pliance w ith regulation E2 (internal w alls) can

achieved by follow ing the m ethod detailed below

aggregate concrete blocks:

B uild to the prescriptive m ethod detailed in the

Approved Docum ent.

Exam ples of internal w all constructions that m eet

laboratory sound insulation values set out in Table

are detailed below :

Specification

C oncrete block w all, plaster or plasterboard finish

both sides

M inim um m ass per unit area, excluding finish

= 120 kg/m 2

A ll joints w ell sealed

Plaster or plasterboard finish on both room side

Compliant constructions

75m m Evalast solid

90m m Evalast solid

100m m Evalast solid

100m m Evalast Solo

Performance

S d i l ti


51/81

Sound insulation

Approved Document Met

Testing required)

The constructions detailed be

should achieve the sound ins

houses and flats set out in Ta

room s for residential purpose

(page 48).

Achieving the required perfor

upon good w orkm anship in sand also in the associated fla

G uidance is provided in the A

suitable designs at these crit

Wall Type 1.1 Solid wall

215m m Evalast solid dense a

laid flat), w et plaster on both

M inim um m ass per unit are

415kg/m 2

Fig. 7

Weighted sound reduction index single leaf

masonry (Rw)

It has becom e the norm for designers to specify noise

control requirem ents in term s of the W eighted Sound

Reduction Index (Rw) w hich represents the airborne

sound insulation perform ance of a building elem ent.

Tables 17 and 18 illustrate a selection of R w values for

our Evalast and Evalite range of products w hich have

been established through testing and evaluation.

Table 17: Evalast sound insulation

Blockwork and type Estimate of weighted sound

reduction index Rw (dB)

fair-faced dry lined plaster

75m m solid 37 45 47

90m m solid 39 46 48

100m m solid 42 48 50

125m m solid 46 50 52

140m m solid 51 52 54

150m m solid 52 52 54

190m m solid 53 53 55

200m m solid 54 55 55

215m m solid 55 56 56

100m m cellular 37 45 47

140m m hollow 43 49 51

150m m hollow 42 48 50

190m m hollow 46 50 52

215m m hollow 47 51 52

T bl 18 E lit d i l ti


52/81

Robust Details

The H B F (H ouse B uilders Federation) have deve

and tested a portfolio of Robust D etails (R D ) that

generic m asonry and floor constructions. The D C L

(form erly O D PM ) and H B F agreed the testing reg

and m inim um perform ance standards for R D sepa

w alls and floors. These m inim um standards are fa

higher (5dB ) than those in the Approved D ocum e

The testing regim e requires that these enhancedstandards be achieved for each R D based on at le

thirty tests, w ith not m ore than eight of the tests o

the sam e site, and involving m ore than one builde

(to ensure that a range of w orkm anship and supe

is covered). The perform ance standards are in ter

the m ean of the thirty tests.

Robust Details method (no Pre-CompletionTesting required for dwelling-houses and fla

Achieving the required perform ance level is depenupon good w orkm anship in separating w alls and f

and also in the associated flanking construction,

guidance is provided in the R obust Details M anua

suitable designs at these critical junctions, it is a

requirem ent that these recom m endations and

procedures are adhered to as deviation w ill result

invalid construction.

The follow ing details (pages 51-53) show R D

constructions using aggregate blocks.

Two leaves of 100m m Evalast solid dense aggregate

blocks w ith 50m m m inim um cavity, w et plaster on both

room faces.

M inim um m ass per unit area including plaster

415kg/m 2.

M inim um cavity w idth of 50m m required in party w all.

13m m w et plaster on both room faces.

Plaster

Masonry

Cavity

Plaster

M

Plaster 13mm(minimum)

Cavity walblock dens

Fig. 8

Wall Type 2.1 Cavity wall

E-WM-1

Wall Type 2.2 Cavity wall

Performance

Sound insulation


53/81

Sound insulation

Tw o leaves of 100m m Fenlite, Fenlite 1500 or Evalite

Standard solid m edium dense aggregate blocks w ith75m m m inim um cavity, w et plaster on both room faces.

The external w all (flanking w all) should be

constructed of tw o leaves of m asonry.

M inim um cavity width of 75m m required in party wall.

13m m w et plaster (m inim um 10kg/m 2) on both

room faces.

Plaster 13mm(minimum)

Cavity wall,block density(1350-1600kg/m3)

75mm

275mm(minimum)

Fig. 11

12.5mm gypsum based boarnominal 8kg/m2mounteon dabs

Internal render,scratch finish nomin8mm (6mm minimum

Two leaves of 100m m Evala

blocks w ith 75m m m inim um (m inim um 8kg/m 2) on 8m m

scratch finish on both room f

The external w all (flanking

constructed of tw o leaves

M inim um cavity width of 7

G ypsum -based board nom

sand: cem ent render w ith

room faces.

Fig. 12

E-WM-2 E-WM-3


54/81

Block density 1350-1600kg/m3

Insulation 35mmHi-therm RD35 fomineral wool acou

Wall ties Insularetaining wall ties (tie type A)

Cavity width 75minimum (leaf to l

External flanking wMasonry both leav50mm minimum c

Wall finish gypsboard nominal 9.8mounted on dabs

Tw o leaves of 100m m Fenlite, Fenlite 1500 or Evalite

Standard solid m edium dense aggregate blocks w ith75m m m inim um cavity, drylining board (m inim um

8kg/m 2) on 8m m sand:cem ent render w ith scratch

finish on both room faces.



M inim um cavity width of 75m m required in party wall.

G ypsum -based board nom inal 8kg/m 2 on 8mm

sand:cem ent render w ith scratch finish on both

room faces.

12.5mm gypsum-based boardnominal 8kg/m mounteon dabs

Internal render,scratch finish nominal8mm (6mm minimum)

Cavity wall,block density(1350-1600kg/m3)

27 mm(minimum)

Tw o leaves of 100m m Fenlite, Fenlite 1500 or Ev

Standard solid m edium dense aggregate blocks w75m m m inim um cavity incorporating 35m m Isow o

H i-therm R D 35 foil faced m ineral w ool acoustic b

gypsum board (m inim um 9.8kg/m 2) on both room



M inim um cavity width of 75 m m required in part

G ypsum -based board nom inal 9.8kg/m 2

m ounted on dabs.

Fig. 13 Fig. 14

E-WM-4 E-WM-8

Fire resistance

Performance


55/81

Fire resistance

Introduction

Fire resistance of m asonry w alls relates to fitness for

use and is a property of the com plete elem ent of a

structure. The period of fire resistance of a m asonry w all

is taken to be the tim e (from 30 m inutes to 6 hours)

from the start of the test to failure of stability and

integrity.

All H ansons aggregate blocks have an A1 fire

classification rating and have been tested to relevantB ritish and European Standards.

N otional periods of fire resistance for m asonry w alls to

com ply with A pproved D ocum ent B (AD ) are given in

Table 14 of B S 56 28 : Part 3.

Criteria for fire resistance

This table takes cognisance of the relevant factors

affecting the use of m asonry units for fire resistance

purposes. These are as follow s:

a The form of the units involved i.e. w hether solid or

otherw ise.

b The thickness of the units involved.

c The aggregates used in the m anufacture of the units,

i.e C lass 1 or Class 2 aggregates.

Class 1 aggregates com prise lim estone, pum ice,

sintered pulverised fuel ash, furnace bottom ash,

foam ed or expanded slag and various other types of

aggregate.

Class 2 aggregates, com prise all gravels and crushed

natural stone, excluding lim estone.

In general tem s, all lightweight blocks are m ade from

Class 1 aggregates.

Th E l t f d t b d d f

The fire resistance quoted on

sheets are based on:

i Loadbearing or non-loadbe

ii N o finish

iiiM ade w ith C lass 1 or Clas

iv Single leaf

For alternative form s of cons

H ansons Product Services d

In w alls designed to resist fir

joints necessary should be fil

m aterial capable of accepting

and sealed w ith an appropria

sam e fire resistance as the b

Movement control


56/81

Positioning of movement joints

M ovem ent joints are used to elim inate or control

cracking w ithin the fabric. The joints are located in

strategic positions and allow slight, predeterm ined

m ovem ent w ithout subsequent cracking to the m asonry.

Spacing, design and location of m ovem ent joints

depends principally on the dim ensions and shape of

the w all in question, detailing techniques and the

com plexity of the structure. The joints should be located

at junctions w hich m ay be vulnerable to cracking.

The position of m ovem ent joints w ill be strongly

influenced by structural and architectural considerations

but the follow ing m ay prove useful as an indication of

w here control joints m ay be necessary.

Straight walls

C racking is m ost likely to occur in long, straight w alls.

B lockw ork w alls of excessive length should be divided

into a series of rectangular panels w ith m ovem ent jointsbetw een each panel. The effects of end restraint need

to be assessed w hen deciding on the panel length.

This can add either 25% or 50% to the actual length, if

one or tw o ends are fully restrained. It is upon this total

length that the em pirical rules are then applied. In the

case of lightweight aggregate blocks, the m axim um

length betw een m ovem ent joints is 6m and 9m for

dense aggregate blocks. The length of each panel

should not norm ally be in excess of tw ice the height ofthe panel and areas of blockw ork above and below

openings should be treated as individual panels.

The follow ing gives general guidance for m ethods of

controlling m ovem ent in blockw ork panels.

Changes of height, thickness and profile

M ovem ent joints should be provided w here chang

height, thickness and profile (either on plan or sec

occur in the w all since these junctions are particu

vulnerable to cracking (Figs. 15, 16 and 17).

Movement control

Fig. 15: Movement joints adjacent to openings

Fig. 16: Movement joint at change of height

Performance

M ovem entcontrol


57/81

M ovem ent control

Types of movement joints

Continuous vertical joints

Various form s of m ovem ent j

these should be 10m m w ide

not greater than 6.0m centre

blocks and 9.0m centres for

The sim plest version is to con

vertical joint as w ork proceed

com pressible boards (e.g. bit

fireboard) betw een the joints

com patible m astic for externa

or m etal cover strips are avai

joints (Figs. 21, 22, 23 and 2

Bed joint reinforcement

Internal and external finishes

across the m ovem ent joint un

m ade. B ed-joint reinforcem en

be used to increase joint spa

stresses around openings. In

reinforcem ent should be loca

panels where openings occu

betw een m ovem ent joints ha

The reinforcem ent should be

above and below the opening

extended at least 600m m be

The reinforcem ent m ust be c

discontinuous at m ovem ent j

Flat bar joints

W here increased stability of p

m ovem ent joint is im portant,

debonded at one end, can be

Fig. 19: Movement joints at junctions to columns

(plan view)

Fig. 18: Movement joints at wall junctions(plan view)

Movement control joints

C ontrol joints w ill be required at the junctions of

intersecting w alls and junctions w ith colum ns, and also

w here w alls are penetrated by m ajor service pipes and

ducts, or w here large chases are incorporated to

accom m odate services (Figs. 18, 19 and 20).


58/81

Fig. 21: Movement joint at steel column (plan view)

Flexible stripwith sealant

Fig. 22: Movement joints at steel column (plan view)

Fig. 23: Movement joint in block cavity walls (plan view)

Fig. 24: Movement joint

600mm 600mm

Performance

Moisture penetration


59/81

Moisture penetration

Introduction

The type and m ethod of w all construction w ill influence

its ability to resist w ind-driven rain.

For both single-leaf and cavity w alls, total resistance to

rain penetration can only be achieved by cladding.

W hilst rendering can substantially enhance the rain

resistance of the w all, it is essential to select the right

type of m ix, thickness and num ber of coats.

The use of m asonry paint system s and other proprietary

external finishes m ay increase the resistance to rain

penetration, but m ay also reduce the rate of evaporation

of any w ater from the w all.

Joint protection

It is essential to fill all the joints to m inim ise the risk of

rain penetration. Tooled m ortar joints are m ore resistant

to rain penetration than joints which have not been

tooled. Recessed joints increase the risk of w ater

penetration.

Rain resistance

The rain resistance of rendered and un-rendered single

leaf concrete m asonry w alls is dependent on the

thickness as show n in Table 20.

Use of hollow blocks

W here hollow blocks are use

of shell bedding m ay reduce

inner surface and so give som

cavity w all construction. In un

air space is considered satisf

prevent w ater passing from t

leaf. Partial filling of cavity w a

resistance to w ind-driven rain

w idth of the rem aining air spa

W hen fully filling the cavity w

m anufacturers of the insulan

obtain the lim iting exposure c

particular insulation type. The

w ill be reduced by using a ca

than 50m m .

Table 20: Assessment of resistance to rain penetration of single leaf walls with or without rendering

Exposure Rendered Rendered Unrenderedcategory dense concrete lightweight dense

blocks concrete blocks concrete blocks

Very severe Not recom m ended. Cladding should be used.

Severe 250m m 215m m not recom m ended -

M oderate 215m m 190m m 440m m


60/81

York

Ripon

Darlington

Inverness

Dornoch

Lerwick

Aberdeen

DundeePerth

Stirling

Edinburgh

Dunbar

Glasgow

Ayr

Newcastle

Alston

Workington

Carlisle

Hebden Bridge

Skelmersdale

Colwyn Bay ManchesterSheffield

DoncasterGrimsby

Hull

WhitbyMiddlesbrough

Londonderry

Dungannon

EnniskillenBelfast

Exposure zones Approx wind-driv

(litres/m2 per spe

1 S heltered less than 3 3

2 M oderate 33 to less than 56.5

3 S evere 56.5 to less than 10

4 Very severe 1 00 or m o re

This m ap is an extract from Therm al Insulat

avoiding risksand is reproduced w ith kind

perm ission of the B R E.

Figure 26 Exposure to wind-driven rain

Performance

Durability


61/81

y

Introduction

H ansons aggregate blocks are inherently durable and

if used in accordance w ith the appropriate

B ritish/European Standards, w ill last the lifetim e of the

construction into w hich they have been built.

They possess good frost resistance and in general,

provided they are selected follow ing the

recom m endations of B S 5628: Part 3, clause 5.6 and

Table 12, problem s should not occur.

Strength and durability

D urability is governed by the characteristics of the units.

The strength of concrete bricks w ould determ ine the

suitability of the units (16.5 or 22.5 N /m m 2, depending

on the application and exposure condition). In the case

of aggregate blocks to be used near or below ground

level, the unit should m eet one of the follow ing criteria.

a)B lock density of at least 1500kg/m 3, or

b)M ade w ith dense aggregate to B S EN 12620, or

c)H aving a com pressive strength of at least 7.3N /m m 3

All dense blocks, together w ith 7.3N /m m 2 lightw eight

blocks, w ould be suitable for the above condition. In the

case of contact w ith foul drainage, Engineering Q uality

C oncrete B ricks (EQ C B ) of 48N /m m 2 should be used.

Sulphate resistance

W here the m asonry rem ains

present, the selection of the

consideration. H ow ever, aggr

used successfully below grou

w ith a proportion used on sit

present and yet no failures h

W hilst blocks m eeting the ge

use below d.p.c. have been a

use in sulphate soil classifica

C oncrete B lock Association,

7.3N /m m 2 aggregate blocks

w ithstand conditions equivale

classification D S-3.

C arbonation is a m ajor factor

durability and results from the

perm eability of the aggregate

surface to dry betw een the mbackfilling operations.

7.3N /m m 2 Evalast blocks m a

O PC -PFA, or SR PC binder w

and including sulphate soil cl

determ ined by the m ethod gi

D igest 1. W here O PC is the s

should not take place for 28

H ans