field installation instructions-102802 - r2.ppt

8/10/2019 Field Installation Instructions-102802 - r2.ppt

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FIELD

INSTALLATIONINSTRUCTIONSJANUARY 2004


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BABB TECHNOLOGIES, INC.Phone: (706) 965-4587

Fax: (706) 965-4597

website: www.SafeCrete.com

Field Installation Instructions Rev. 1-07-2004

Material Handling Procedures 3

Tools Recommended For Installation 4

Leveling Course - Steps 1-7 5

Typical Coursing - Steps 1-7 7

Points To Check 1-3 - Coursing 9

Routing Channels - Steps 1-6 10


Installing Horizontal Wall Panels Steps 1-11 13

Points To Check 1-5 - Horizontal AAC Wall Panels 17


Installing Panels - Steps 1-6 19

Filling Joints Steps 1-3 21

Panel Penetration Guidelines 22

Points To Check 1-4 23

Routing Channels - Steps 1-3 24

Points To Check 1-3 25

TABLE OF CONTENTS

AAC MASONRY PRODUCTS:I

HORIZONTAL AAC WALL PANELSII

PRECAST FLOOR PANELSIII


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Material Handling Procedures

General:

In general, all construction products are susceptible to minor damage if mishandled. Lesshandling means lower potential for damaged. In some instances, damage may occur

from shipping.

For All AAC Construction Products:

Deliver only an amount of material that can readily be installed.

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.

Keep the material covered and banded until ready for installation.

Special Considerations For Panel Construction:

As with most precast concrete products, the panels should be set directly from the delivery trailer,if permissible.

If the materials cannot be set directly from the delivery trailers, deliver only an amount of material

that can be installed readily.

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 AAC representative.

All damage must be repaired using an approved structural-grade AAC patching compounddeveloped specifically for AAC products.

AAC panels that have surface or minor cracks are usable, but contact an authorized AAC

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.

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AAC BlockThere are a full range of tools that are specially

designed to assist the block layer in installing AAC

masonry products and increase productivity at thejob site.

Tools Recommended For Installation

AAC JumboBlock

Additional tools required for installing AAC

JumboMasonry Units.

AAC masonry installation will also require the

following standard masonry tools.

Electric Jumbo Bandsaw Electric Minicrane

Hand Saw

Rasp

Electric Bandsaw

Notched Trowel

Margin Trowel

Small Hand Brush

Builders Level

Sanding Float

4 Level

String Line

Rubber Mallet

Low Speed Drill with Mixing Paddle

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Leveling Course

Step 1 - Layout wall lines.Lay out wall lines 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).

Salvage additional mortar. Do not use thin-bed mortar

for the leveling bed joint.

If moisture and wicking is a problem, add waterproofing

admixture 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 cleanmixing container (5 gallon bucket or pail) per

manufacturers 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.

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Leveling Course

Step 5 - Set second corner block.Set the second corner block adding thin-bed

mortar to the head joint with the notched trowel.

Step 6 - Repeat for additional corners.Repeat subsequent steps for each corner using a

builders level to maintain an equal elevation.

Triple check each lead corner in all three planes.

Step 7 - Fill-in complete leveling

course.After building lead corners, pull a string between

corners to complete the leveling 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 PROCEED TO SUBSEQUENT

COURSE UNTIL LEVELING COURSE

HAS SET SUFFICIENTLY.

STOP

DO NOT TOOTH

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Typical Coursing

DO NOT USE SAND-CEMENT

MORTAR FOR COURSES OTHERTHAN THE LEVELING COURSE.

Step 2 - Clean bed joint surface.With a brush, sweep off all dust and loose

particles to insure adhesion of thin-bed mortar.

Step 1 - Mix thin-bed mortar.Mix thin-bed mortar.

Before mixing new batch, wash out the bucket or pail

to prevent any old thin-bed from accelerating the

drying time of the new mix.

Step 3 - Apply thin-bed mortar to head

and bed joints.Using a clean, notched trowel the same width as the

block spread thin-bed mortar up the head joint of theadjoining block and then along the bed joint.

Spread only enough thin-bed mortar to lay one block

at a time. The thin-bed mortar must cover the full

width of the joints.

Install block in a running bond

with a minimum 4 bearing

(overlap) or 40% of the blocks

height (whichever is greater).

STOP

DO NOT TOOTH

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Typical Coursing

Step 6 - Rasp as needed.As needed, rasp (sand) the topside of the wall to

ensure a level bed-joint for the next course.

This is required less often if block is installed

within tolerances.

Step 7 - Install lintels as required.Install lintels with a minimum 8 bearing (overlap)

where required.

Step 5 - Tap the end of the block.Tap the end of the block to insure a full surfacecoverage of thin-bed mortar at the head joint and

align with string line.

Clean off spilled or dripped thin-bed mortar from

face of wall as work proceeds.

Repeat installation for subsequent courses.

Step 4 - Set block.Pick up each block and move it as close to thehead joint as possible before lowering the block

onto the bed joint

Excessive movement along the bed joint will force

the thin-bed mortar into the corner preventing full

adhesion with the head joint.

Joints should

maintain a

thickness of

1/16 or 1/8.

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Points To Check

Point 1Leveling course must be level and plumb. Do not proceed to subsequentcourses until leveling course has set sufficiently.

Point 2Blocks must be installed in a running bond with a minimum 4 bearing (overlap)

or 40% of the blocks height (whichever is greater). Lintels must be installed

with a minimum 8 bearing (overlap).

Point 3All head and bed joints must be solid with approved

AAC thin-bed mortar for full adhesion. Do not tooth.

DO NOT TOOTH

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AAC installation will also require the following

standard industry tools.

There are a full range of tools that are specially

designed to assist in installing wall panels and

increase productivity at the job site.

Slings

Quick Cut Saw

Rasp

Chamfering Tool

Grinder/Sander or

Electric Cut-Off Saw

Steel Bar Clamp

Margin Trowel

Small Hand Brush

Builders Level

Rubber Float

4 Level

Chalk Box/String Line

Pinch Bar

Wall Panel Lifting Gear

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Installing Panels

Step 2 - Unload bundles.Unload the bundles of panels in a proper manner

using approved unloading gear.

Eliminate excessive handling by storing panels

nearest to where they will be installed.

Step 1 - Check layout.Check panel layout of approved AAC shop

drawings and deliver panels to job site

accordingly.

Protect the panels from rain and water

saturation by leaving them on pallets

and away from standing water.

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Installing Panels

Step 5 - Check panel height and plumbness.Check the height, levelness and plumbness of the panel.

Temporarily suspend loose panel with clamps. See plans

and specification for allowable tolerances.

Step 4 - Place first panel.Measure down from the benchmark elevators to

establish the highest point on the slab. Install the

first panel, male side up, at the highest point ofthe slab or stem wall, on top of preleveled shims

to establish a minimum depth of setting bed.

Place sand-cement mortar joint of at least 1/2

using a conventional masonry trowel (mortar to be

either Ready-mix or 3:1 Sand: Portland Cement

ratio) along wall line in between plastic shims or

pack with non-shrink grout. Other bays will require

adjusting the depth of the setting bed prior to

installing the first panel.

Step 3 - Check plumbness of column line.Check column line layout and plumbness. Varify layout

is within industry standards. Using a level and transit,

establish benchmark elevators onto the columns that willact as a control line for setting the first AAC panels.

Alert General Contractor

to column line problems and

correct before proceeding.

Step 6 - Notch each end of the panel.Notch ends of each panel with grinder/saw to receive anchors.

STOP

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Installing Panels

Step 10 - Install the second panel.Align the ends and groove of the second panel with

the ends and tongue of the first panel and set into

place. Repeat Steps 5 - 9 for the subsequent panels

in accordance with AAC shop drawings.

Step 11 - After installation.After panels are installed, clean all horizontal and

vertical joints with a brush and apply exterior joint

sealers in accordance with AAC instructions.

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Points To Check

Point 1

Supporting columns must be plumb, level and within linear building linetolerances.

Point 2Protect the panels from rain and water saturation

by leaving them on pallets and away from standing water.

Point 3Set panels with tongue side up and follow

specifications and shop drawings for

placement of adhesive and joint filler.

Point 4Panel(s) must lay flush against face of column.

Point 5In the event bowing occurs with the AAC panels within a column bay, stack

the AAC panels so that the bow is constant in one direction.

AAC horizontal

panels

Acrylic

coating

2 beads of

adhesive

Fill joint

with

joint filler

Correct installation

of bowed panels

Incorrect installation

of bowed panels

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PRECAST WALL PANELSIII


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Slings/ Ropes

Quick Cut Saw

Rasp

Hatchet Hammer

Chamfering Tool

Margin Trowel

Small Hand Brush

Builders Level

Rubber Float

4 Level

Chalk Box/String Line

Pinch Bar

Lifting

Fork

Panel Turners

Floor Panel Lifting Gear

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Installing Panels

Step 5 - Repeat for remaining panels.Lay the remaining panels ensuring that each one is

seated firmly beside the preceding one.

Step 6 - Placing last panel.The correct lifting gear will greatly assist

placement of the last panel. Special procedures

may be required if other lifting devices are used

(I.e. slings or ropes).

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Filling Joints

Step 1 - Set screen block.Set minimum 2 screen block in thin-bed mortar

around exterior perimeter for formwork for all ringbeams according to detail drawings.

Step 2 - Place reinforcement steel.Install reinforcing steel in panel joints, ring beams,

and lintels according to detail drawings.

Make sure all rebar is in correct position before

concrete is placed. Tie wire or chairs may be used to

hold rebar at correct heights.

Hanger wire for suspended ceilings may be installed

through floor panel joints at this time.

Step 3 - Fill joints with concrete.Fill wet joints with concrete. Firmly tamp into all

joints, screed off excess and finish.

A Pencil Vibrator should be used for ring beam and

lintel pours.

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Panel Penetration Guidelines

PANELS WITH HOLES MUST BE DESIGNED

TO HAVE SUFFICIENT REINFORCEMENT

Less than or

equal to 6

INCORRECT!DO NOT PENETRATE THE PANEL

ACROSS ITS WIDTH MORE THAN

ONCE WITH HOLES GREATER THAN

OR EQUAL TO 6.

Opening may not

exceed 25% of

panel width

Less than or equal to25% of panel width

2 - 0

typical

panel

INCORRECT METHOD CORRECT METHOD

PLAN VIEWS

AAC floor panel

STOP

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Points To Check

Point 1Supporting walls must be level.

Point 2Minimum bearing as shown in detail drawings must be maintained.

Point 3Concrete poured into joints must completely cover all reinforcement.

Point 4Do not cut or modify a panel without first checking with AAC Building

Systems. Observe all guidelines for coring and other floor penetrations.

Never cut the floor panel to shorten it.

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Routing Channels

Step 1 - Routing bottom of floor panels.The underside of floor panels may be routed to a depth no greater than 3/4 in the middle or no greater than

1 1/2 on the sides. Stop if reinforcing becomes exposed.

Step 2 - Top of floor panels.DO NOT ROUT the topside of panels.

Place conduit in the panel joints.


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Points To Check

Point 1Do not rout horizontally less than 24 from the top of load bearing walls.

Point 2Do not rout horizontally greater than 1/3 of the total wall thickness.

A + B < 1/3 of total thickness

Point 3Do not rout back-to-back wall channels. Offset channels at least 12.


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