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Infra-Block

Pre-Insulated Hollow Masonry Units

Type 1

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Infra-Block

Type 1 Infra-Block R .7 Pre Insulated Hollow Concrete Masonry Units3.5 X the Thermal Resistance comparative to standard blocks.

Standard 190 x 190 x 39020 Mpa C.M.U

Aluminium Foil Cavity Cap for reducing vertical heat transfer through the cores.

25mm Expanded Phenolic Board. Reflective Aluminium Foil membrane laminated both sides of insulation.

Thermal Reflective InsulativeCartridge press fitted easily within core.

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Infra-BlockType 2

Type 2 Infra-Block R .96 Pre Insulated Hollow Concrete Masonry Units4.8 X the Thermal Resistance comparative to standard blocks.

Refer to pages 29 to 32

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Environmentally friendly and energy-efficient building.

In keeping with a growing need for environmentally friendly, low cost construction and energy-efficient houses, Infra-Block is proud to announce the launch of their new Insulating Construction Block coupled with an advanced Quick Construct Single Leaf walling system for home construction.

Infra-Block High Insulating Hollow Masonry Blocks are undoubtedly the best choice for environmentally friendly and energy-efficient building.

Some of the outstanding features of Infra-Block include:Unique Thermal PerformanceInfra-Block will thermally outperform any other hollow masonry block or walling system in the marketplace, setting a new benchmark in insulation with a total value of approximately R2.1.Infra-Block provides a superior insulation value compared to other concrete masonry units, it also adds usable thermal mass to the building structure.

Thermal mass is the ability of a product to store thermal energy and then gradually release it slowly into living areas. Thermal mass acts as a thermal bank - the thermal energy that is gained will be able to be drawn on later, resulting in your home maintaining a more stable internal climate.

Infra-Block is able to perform outstandingly well because of its unique insulative properties comprising Thermal Mass and reduction of heat transfer across the blocks cores air space due to the integral Infra-Red Reflective Air Cells and a lightweight Bulk Insulation contained within the cores. The result is an environmentally ideal building product with great insulation (R-value), combined with high thermal mass which reduces your energy bills and provides greater comfort in summer and winter.

Improved Waterproofing Qualities and Vapour Barrier.An added benefit of the Infra-Block Insulative Cartridge inserted within the cores of a standard hollow masonry block provides function of a vapor barrier whereto retard the migration of water vapor across the blocks air space and prevent interstitial condensation or dampness forming upon interior surfaces. Infra-Block is Carbon NegativeInfra-Block significantly reduces carbon gas emissions by sequestering carbon during the manufacture of our blocks. This is achieved by using an advance cement admixture containing Magnesium Oxide and Alumino-Silicates as a major part of the cement mix that enables the Infra blocks to absorb CO2 as they set because the magnesium and calcium hydroxide phases in them set by absorbing CO2 out of the air as they transform to carbonates, making them carbon-negative.

For every 1 tonne of MgO concrete that is used for making Infra-Block masonry units and associative fiber glass reinforced rendering cement sequesters by absorption up to 0.4 tonnes of CO2 equaling to about 100 kilograms of Carbon providing a combined outcome that results in an environmentally superior and thermally efficient product.

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Infra-BlockDry-stacked wall construction.

Today's modern world has many reasons to consider dry-stacked home construction using Glass Fiber reinforced Magnesium Oxide cementitious coating to bind the blocks as an economic alternative building medium, especially when you consider Thermal Mass Home (TMH) design energy savings.

Infra-Block Dry Stack construction projects are easy to plan, easy to price and easy to constructThe Infra Block Dry Stack construction technique is a fully certified building standard.

M16 ThreadedSteel Couplingfor joining FRPRebar segments

Dia-17mm Glass Fiber Reinforced Plastic Rebar

Dry Stacked Infra-Block for subsequent courses

Polymer ModifiedMortar Bed (1st course only)

Drawing 1.

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ABOUT INFRA-BLOCK DRY STACK CONSTRUCTION TECHNIQUE.

Infra-Block Dry Stack mortarless masonry has been specifically developed for Commercial andIndustrial applications whereto enable faster, simpler and more cost effective construction.

Infra-Block Dry Stack block work delivers these advantages without compromising any of the benefits of conventional masonry construction:

COST EFFECTIVEInfra-Block Dry Stack means quick and easy construction. You will achieve shorter project completion times than you would using conventional mortared masonry. Get the advantage of faster construction and fewer delays.

SPEED AND EFFICIENCYInfra-Block Dry Stack is fast. Only the first course of Infra-Block is mortared. The rest of the wall can be dry stacked, reinforced, propped and bonded together by rendering both sides of the wall with Glass Fiber Reinforced Cement very quickly. There is no need to clean out excess mortar and there is less waste to remove from site.

The Infra-Block Dry Stack technique achieves more with the same resources. Use Infra-Block Dry Stack for faster, more effective masonry construction and a competitive advantage due to speed of installation.

SIMPLICITY ITSELFThe Infra-Block Dry Stack masonry range typically utilise standard Portland cement blocks for construction of virtually any wall. However we have developed a range of standard dimensionHollow masonry units that are made from high strength Magnesium phosphate cement for increased fire rating, increased compressive strength and increased flexural strength.

ACCURATEInfra-Block Dry Stack Mortarless Masonry Units are manufactured to finite height tolerances so walls can be dry stacked quickly and accurately. Apart from laying the first course of Infra-Block with mortar to establish a level starting point, the rest of the wall is constructed without mortar.Keeping the first course of Infra-Block level and laid to a line is essential.

NO WEATHER DELAYSThere should be no stoppages due to weather (aside strong winds). You can keep on laying Infra-Block even when it rains. Less dependence on the weather means more reliable outcomes for you and your clients.

MASONRY CONSTRUCTIONInfra-Block Dry Stack combines the advantages of mortarless construction with all the benefits expected of conventional masonry: noise reduction, fire resistance, low maintenance, strength and durability.

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Background of Masonry Construction.Hollow structural blocks such as masonry blocks have been successfully employed for many years in the construction of load bearing and non-load bearing walls in commercial buildings, domestic dwellings and other structures such as retaining walls, fences and the like. Generally speaking, masonry block walls are constructed on reinforced concrete footings or a concrete floor slab as a base. Such walls include mortared joints.

Depending upon Wind loadings for such block walls, rigidity is conferred by the formation of integral reinforced piers wherein starter bars extend into the hollow wall cavity at spaced intervals steel reinforcing bars are inserted into the wall cavities occupied by the starter bars and fluid concrete is then poured into the wall cavities occupied by the steel reinforcing bars to form spaced, steel reinforced piers in the Wall structure.

In cyclone rated-areas it is necessary to be able to structurally tie a roof structure through steel rods to the footings or floor slab on which the masonry walls are constructed. While generally satisfactory for their intended purpose, such mortar jointed structural block wall constructions suffer a number of practical disadvantages.

Not only are these prior art block wall construction techniques extremely labour intensive, a high level of skill is required in block laying with mortared joints. Skilled labour is expensive and frequently difficult to obtain when required.

Benefits of Infra-Block Wall construction.In the construction of an Infra-Block structural wall, the Infra-Block method includes the steps of erecting on a base a wall of mortar less structural blocks, applying to opposite faces of the wall a Glass Fiber Reinforced cementitious coating and anchoring the wall to the base with mechanical fasteners (tie rods) contained within the blocks cavities at prescribed centers pending Wind Category regional location and a steel channel Ring Beam atop the wall structure whereto secure Trusses. The resultant wall possesses greater structural integrity wherein compressive loads are borne by the structure blocks and tensile loads are borne by the fiber reinforced skin extending over the surface of the Wall and onto the base to anchor the walls to the base.

Dry stacking reduces the requirement for skilled labour and a costly bonding material like cement and allows floor and roof Loadings to be applied immediately upon completion of walls. It reduces building costs due to savings in construction time and materials.

Overall savings of up to 27% compared to conventional masonry have been reported by using the Dry Stack Fiber Reinforced Cement Rendering method. The savings are mainly due to savings in cost of mortar, laying the block units and construction time.

Pending the regional Wind Loading category such mechanical roof tie down fasteners used in the Infra-Block system are made from a high tensile diameter 18mm Glass Fiber Reinforced Plastic Rod anchored within the footing or pad at regular centers within retro drilled holes and permanently affixed by the injection of high bond strength construction adhesives.

In cyclonic areas N500 Dia 16mm Rebar with bent cog embedded within the concrete footing at appropriate centers are used. All Rebar used in this construction system are segmented and joined by threaded steel couplings progressively as the blocks courses are laid whereby to eliminate lifting the blocks over long rebar heights and thereto eliminate the requirement of Core filling which reduces the efficiency of thermal performance.

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The construction industry is acknowledging the strong need to accelerate the masonry construction process, as the traditional method is labour intensive and hence slower due to the presence of a large number of mortar joints.

Early attempts were made to increase the size of masonry units (block instead of brick), thereby reducing the number of mortar joints, wherein the use of bedding mortar imposed constraints on the number of layers to be constructed in a day.

The need for further acceleration of the rate of construction has led to the elimination of bedding mortar and the novel development of a quicker non-conventional method of masonry construction technique, such as the Infra-Block Dry-Stack Block method bonded by Glass Fiber Reinforced cement coatings.

Sika®Anchorfix 3+ Rebar Anchor epoxy.

Thermal ReflectiveAir Cell

25mm Semi-Rigid Mineral wool batt

or Expanded Phenolic Foam board

Standard 20-01Hollow Masonry Unit

Dia-16mm Glass Fiber Reinforced

Plastic Rebar

Drawing 2.

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Dia-16mm N500 Thread Barwith 300mm COG

Threaded Coupler for Dia-16mm 500N Rebar

N16 Rebar

Drawing 3.

Drawing 4.

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The Threadbar used for tying down the roof assembly is made from Grade 500N reinforcing steel bar that is manufactured to ASNZ4671 with a distinctive thread formed throughout the length of the bar. This allows for the bar to be cut at any location and a coupler or terminator can be used without any need for further expensive threading of the bar.

It is available in diameters 16mm, 20mm 25mm, 28mm, 32mm and 40mm. It also comes with a wide range of couplers, nuts, terminators and accessories for most applications.

The Theadbar is a "Bar Break" product, meaning the bar breaks before the coupler fails.

Grade 500N Threadbar

Type No. Diameter (mm)

Ultimate tensile

load(KN)

Breaking load thread

Steel） (kN)

Ultimate tensile

strength (MPa)

Modulus Of elasticity

(GPa)Torsion (Nm)

Ultimate shear

strength (MPa)

F62-17 17 150 60 800≥45

50≥120

F62-22 22 250 120 750 100

Fiber Reinforced Plastic Anchorage bar

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Fiber Reinforced Plastic Anchorage

The resistance to corrosion and chemical attack, high strength-to-weight ratio, and ease of handling of Fiber Reinforced Polymer (FRP) reinforcing bars make them a better alternative to steel reinforcement in concrete members subjected to severe environmental conditions.

The post-installed adhesive anchor generally consists of a reinforcing bar inserted into a drilled hole in hardened concrete with a structural adhesive acting as a bonding agent between the concrete and the reinforcing bar .

The post-installed anchors can be driven in almost any desired position in hardened concrete by installing in holes drilled into concrete. These anchors are usually needed for strengthening or rehabilitation of deteriorated concrete structures, attaching structural concrete elements to an existing concrete structure and installation of equipment's.

The load-transfer mechanism of adhesive anchor is different from that of cast-in-place one. For adhesive anchor, the load is transferred through the adhesive to the concrete along the entire embedded portion of the anchor.

This load-transfer mechanism depends on the of the adhesive-bar interface, the adhesive-concrete interface, and also on the extent to which the adhesive impregnates the concrete surrounding the drilled-hole.

To install the GFRP adhesive anchors, locations of holes are marked on the concrete surface and then drilled using rotary hammer bits. The selected bit diameter is 19 mm in diameter corresponding to the GFRP bars of 16 mm diameter respectively and the bore drilled to a depth of 180 mm .

The holes are to be cleaned by a wire brush and compressed water since the type of epoxy-based adhesive that is utilised performs adequately in moisture. Following cleaning the holes, the two-component adhesive package is installed in the dispenser and then injected into the holes (wet and partially submerged). Subsequently, the bars are pushed into the holes in a screwing fashion.

The photos below shows typical installation of GFRP adhesive anchors.

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Glass Fiber Reinforced Magnesium OxideCement rendering applied both sides of wall.

Dry Stacked Infra-Block Wall Assembly.

GR 300-200mm x 75mm Hot dipped Galvanised Parallel Flange Channel Ring Beam Bolted to vertical Ties Threadbar anchored to foundation.

8mm Full Welded Parallel Flange Channel Ring Beam at Miter

Core FillBond Beam N500 Thread Bar with 100 COG cast

within poured window header.

Drawing 5.

Drawing 6. Drawing 7.

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Poured Window Header Formwork- Drawing 10.

GR350 75x75x5mm S.H.SGalvanised

F27 KD Hardwood 100x50mmPurlins (low wind category)

Drawing 8.

Drawing 9.

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GR350 40x40x2.5mm S.H.SGalvanised Purlin

GR300- 200mm x 75mm Hot dipped Galvanised Parallel Flange Channel Ring Beam Bolted to vertical Threadbar anchored to foundation.

GR350 75x65x6mm Galvanised Cleat6mm Continuous Fillet Weld.

GR350 75x75x5mm S.H.SGalvanised Truss Assy.

Galv. M12 x 60mm Hexagon Flange Bolt/Nut Assy

Truss Structure for High Wind category regions.

8mm Full Weld Parallel Flange Channel Ring Beam at Miter

Alternative Truss Structure for Low Wind category regions.

Drawing 11.

Drawing 12. Drawing 13.

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GR350 75x180x10mm Galvanised Cleat8mm Continuous Fillet Weld.

Galv. M12 x 100mm Hexagon Flange Bolt/Nut Assy

GR350 75x75x5mm S.H.SGalvanised Top Truss Chord

GR350 75x75x5mm S.H.SGalvanised Bottom Truss Chord

Fully-welded roof trusses for regions A, C & D

Drawing 14.

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Infra-Block Construction Sequence.

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Sequence of Infra-Block home construction:1. Wall Cell Rebar LocationsThe location of each reinforced wall cell must be determined before the foundation can be poured. This is achieved by comparing the Foundation Plan to the Wall Plan whereto show the location of the blocks hollow cells requiring reinforcement rods and/or core fill in order to insert the Starter rebar "L"s at the proper cell locations as the foundation is poured.

Alternatively, pending regulatory approval relative to regional Wind Load designation the above procedure may be omitted when retro -drilling bores within the cured Foundation to cater for chemical epoxy set fiber reinforced plastic anchor rods .

2. Mortar First RowOnce the Foundation has been poured and cured for at least seven days, commence mortar of the first row of blocks which establishes the shape of the building. Only the bottom of the blocks are mortared, there is no mortar required between adjacent blocks.

It is imperative to ensure that there is sufficient space for the second row of blocks to rest upon the first course of blocks. Failure to allow for ample space in the first course will result in closing blocks for each higher row that will not fit without cutting. This problem can occur when failing to account for half-block dimensions.

Another consideration for laying the first row is accurate block height. Because most foundations are not completely level, determination must be made so that the first course of blocks have differing mortar thickness which results in that first row of blocks being level. A level first row of blocks will result in dry-stacked walls that are straight and plumb.

The first row of blocks must be straight and have properly placed corner blocks and inspection blocks. Inspection blocks have one cell side cut out so a regulatory inspector can confirm the Starter Rebar / Threadbar is within the cell before that cell is poured full of concrete or subsequent joining of the Threadbar via the threaded couplings as herein specified when core filling is not required.

3. Striking the MortarThere is a mortar concept called striking the mortar, using a special tool to rub the fresh mortar where the block joins the foundation. The striking process compacts the mortar making it more dense, which makes it stronger and more water resistant.

4. Placing Row SegmentsEach concrete block is butted against the previous block (no mortar between the blocks), set the block reference height and level in both directions by tamping down on the block; which extrudes out excess mortar from under the block. The same string that is used to keep the wall straight is also used to set block reference height.

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5. Closing the First Row SegmentUpon laying the Infra-Blocks half way along the first course wall segment, it is required to start laying the blocks from the opposite corner and commence working back to the point where you stopped by following the same string line.

The closing block is where the two row half-segments join as one row segment. If sufficient space was allowed for between the blocks e.g. 1mm to 3mm, the closing block will be a little bit shorter and no cutting of blocks will be required to complete the first course.

6. Dry-stacking the WallsWith the first row mortared to the slab and allowed to cure overnight, commencement of dry-stackingthe subsequent courses can be executed.

It is preferred to work from the corners to the center of each wall segment.

The reasoning for this procedure is to ensure the wall face will be maintained relatively flat, and if such procedure is not undertaken the wall will probably become wavy at the top if dry-stacking from one end continuously to the other end.

Furthermore the procedure entails stacking the corners up a few rows high (e.g. stack six rows high), making sure that the corners remain plumb in both directions from the corner.

Whereupon stretching a mason's string between the said corners provides an index for dry-stacking the blocks plumb along this string line to close the wall row near the middle of that wall segment.

Thereafter move the string up one row and repeat the process.

It is imperative to brace the walls whereto prevent them from tipping over in very strong winds. Please Note: Improper bracing is very dangerous.

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7. Core filling Wall Cells around Window and Door areas.Thereafter inspection of the wall cell rebar by a Regulatory body the pouring of the wall vertical reinforcement cells can commence after closing off the inspection block openings.

For the core fill reinforcement of door and window openings, it is required to leave off the top and penultimate block as shown in the above picture. The rebar in the door and window openings will continue on up and tie in parallel with the bond-beam rebar.

Stop the door and window opening cell pours in the middle of the top block for that door or window opening whereby the header pour will overlap inside of this top block resulting in a stronger wall/header interface. For other wall cells, pour up to jus 100mm inside the top lintel block. This will lock that lintel block into place with the wall cell, and still allow the bond-beam concrete to interlock within this block at a later time.

Refer also to Drawing 6 and Drawing 9 within Pages 10 and 11 herein.

8. Form & Pour Headers and part of the Bond beamOnce the wall vertical reinforcement cells have been poured and allowed to harden overnight, these walls are now stable enough to install the header forms.

Upon fabricating the Formwork for the door and window headers and installation of the associated rebar for the header and bond-beam it is required for further inspection by a Regulatory body prior to pouring the headers with concrete.

When pouring the headers it is necessary to ensure the pour extends into the adjacent lintel blocks at least one-half block length. This will lock the lintel blocks into place, and provide structural overlap when the bond-beam is poured and or the Parallel Channel Ring Beam Is assembled and fastened to the reinforcement anchors embedded to and within the foundation or footing.

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9. Poured Bond-beamPending if the Wind Category designation is low and the associative Type of Trusses utilised (e.g. wooden) and allowable, it is necessary to insert the truss tie-down straps at the appropriate locations while pouring the headers.

Thereafter a few days the header forms are removed and the rest of the bond-beam is pored. The rebar locks together the separate pours. It is also requisite to insert the remaining roof truss tie-down straps whilst pouring the remaining bond-beam as depicted in the photo below.

Note: In High Wind designated areas omit inserting the roof Truss tie down straps if affixing atop of the wall the prefabricated and or site welded Parallel Flange Channel Ring beam with integral welded cleats to secure fully welded RHS Trusses at regulated centers as depicted per Drawing 11 Page 12 .

.9mm x 40 Galvanised Tie Strap .

Poured Bond Beam

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10. Surface Bonding the WallsInfra-Block Surface-Bonding Cement (SBC) is used to bond all the dry-stacked blocks into one continuous structural unit. Because the SBC contains a fiber reinforcement, this thin coating of cement is extremely strong.

The Surface Bonding Cement is applied either by manual application using a trowel or alternatively sprayed upon the wall surfaces to a minimum thickness of 3mm.

The reinforced render is either a quick cure Magnesium Oxide cement or slow cure Portland cement and fiber aggregate premix containing alkali resistant glass fibers and waterproofing additives making the product suitable for use as a high strength render. To decrease the cure time of using the cheaper Portland cement SBC, Acrybond (acrylic co-polymer) may be added.

The addition of the alkali resistant glass fibres makes a rendering mix with greatly enhanced performance compared with conventional mortar without fiber.

Once the wall is troweled smooth and flat, then any pattern can be applied for wall texture.

It is necessary to keep the wall wetted for a period of several days. This will lengthen the SBC cure time, and will help to increase the fully cured SBC strength and water-proof characteristics. It is to be realised for several weeks the Portland based SBC will get slightly darker when rained upon this is of no concern and indicates that it is not yet fully cured. When it is fully cured, it will get wet and not discolor to a slight darker shade.

Infra-Block Surface Bonding Cement Features-Reduced liability to cracking and greater resistance to water penetration and gives a high degree of impermeability compared to ordinary renders. Due to the mix formulation and the reinforcing fiber, SBC adheres strongly to clean substrates and the resistance of the hardened render to abrasion and impact is excellent.

Fire Resistance – Infra-Block SBC is not combustible.

Coverage- 3.2 m2 per 20kg of Infra-Block Surface Bonding Cement render admixture applied at 3.0 mm thick minima.

PerformanceCompression strength BS 455128 day40.00 N/mm2Flexural strength BS 4551 at 28 day is 8.8 N/mm2Water resistance FSTTP-0035 2.5mm thick coat 160kph wind for 8 hours.Water vapour transmission ASTM C-355 (desiccant method) -162 grams/24hr/m2Combustibility ASTM E-136- Non CombustibleWeather Resistance Twin AIC weather meter - no effect after 2,000 hours.

PreparationAny local deterioration (cracks, holes, mortar joints etc.) must be made good by cutting out and filling. New concrete walls must be free from mould , dust, oil etc. The surface to be rendered must be sound, clean of oil, dirt, mud, efflorescence and other contaminants. Smooth surfaces must be roughened or acid etched. Porous surfaces must be wet thoroughly.

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Portland SBC Small Batch MixingMix in a wheel barrow using a hoe or similar as a mixing tool.

•Place 4 liters of water and 1 liter of associated Acrylic Co-Polymer in a barrow progressively to every 20 kg of Infra-Block Surface Bonding Cement and mix to a thick creamy consistency.

•Avoid over-mixing as this will breakdown the fibres making the mixture lumpy and difficult to apply.

•More water can be added up to 30 minutes after mixing to adjust the mix to workers preference.

•Discard unused material after 1 hour.

Application• Apply the Infra-Block Surface Bonding Cement using the same techniques as that

adopted for normal rendering.

• Apply the SBC at 3mm thickness.

• To eliminate any show-through from the substrate then apply two 3mm coats as recommended.

• The second coat should be applied while the first is green–that is within 24 hours.

• The use of a water based acrylic emulsion Acrybond is recommended to optimise physical properties of the Portland cement/glass fiber render admixture. Apply when temperatures are between 5°-30°C, using upward diagonal strokes.

• Apply firmly but avoid excessive pressure. Avoid stops or cold joints in the centre of the wall by planning work to stop at natural stopping points, i.e. wall columns, tops, intersections and expansion joints.

FinishingInfra-Block SBC is Finished in a similar manner to normal renders. To hide show-through from the substrate textured finishes are recommended or two coats where a smooth finish is required.

Smooth finish is obtained with a normal plasterers trowel by troweling to a semi-smooth finish initially then re-trowel with a clean wet trowel while the render is still wet on the surface.

A stainless steel trowel should be used to reduce the risk of metallic blemishes.

Over troweling may lead to fine hairline crazing of the surface. Troweling a surface which has lost its moisture will result in dark trowel burns forming on the dry areas. Should this occur, the affected area should be immediately dampened, rubbed with a wood float and carefully re-troweled.

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Mix sufficient Infra-Block SBC Render to complete each section with one mix to avoid cold joint lines. Finishing time is extended by application to the shaded side of the wall. Finish the render while the surface is wet. Infra-Block SBC Render can be painted using masonry paints (e.g. Elastakote, Roltex) that are resistant to alkaline substrate. Paints that cure initially on the surface and rely on the substrate to absorb the remaining solvent are not suitable.

A stucco finish is achieved by applying more than 3 mm in a sweeping motion

A stippled effect is achieved by imprinting a semi-smooth finish with a mason’s float or textured roller.

A swirled finish is achieved by imprinting the semi-smooth finish with a hard bristled brush.

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Flexural strength ASTM C887• 1 day 450 psi (3.1 MPa)• 7 days 700 psi (4.8 MPa)• 28 days 800 psi (5.5 MPa)

Compressive strength ASTM C887• 1 day1600 psi (11 MPa)• 28 days3500 psi (24.1 MPa)

Properties of Infra-Block SBC Render

Infra-Block SBC Render meets the requirements of ASTM C887 as shown in Table 1.

The Infra-Block SBC block construction provides walls of superior strength as shown in Table 2. Infra-Block SBC Render not only provides improved flexural and racking strength, but greater impact resistance. Recommended design requirements for non reinforced surface bonded walls of hollow concrete masonry units are based on gross area of Concrete Masonry Units.

Allowable stress - Infra-Block SBC Render meets ANSI A41.1 except as follows:•Compressive, 45 psi (0.3 MPa)•Shear, 10 psi (0.07 MPa)•Flexural horizontal span, 30 psi (0.2 MPa)•Flexural vertical span, 18 psi (0.1 MPa)

Requirements for lateral supports, minimum wall thickness, and height-to-thickness ratios are the same for Infra-Block SBC Render as for mortared construction.

Table 1

Table 2

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CuringInfra-Block Portland Surface Bonding Cement mixed with Acrybond does not require mist spray curing. Protect the surface from rain for the first 3 days.

Alternatively, Mist Spray the surface 3-4 times daily for 3 days and repeat more frequently in hot windy conditions, in event the Portland SBC mixture was mixed with water instead of the Acrybond Acrylic Copolymer admixture.

Infra-Block Surface Bonding Cement render is like any cement based product and can be susceptible to staining from timber, clay and dirt whereby careful work practices should be followed or protect the surface to avoid staining.

Do not use structurally in areas that maintain high temperatures (80°C plus).

Colour VariationThe appearance of any cement based coating can vary depending on many factors.Some obvious variables are suction or porosity of the substrate, workmanship, rate of cure, water/cement ratio, weather conditions etc. In order to achieve the best appearance, experienced applicators should be employed.

Infra-Block Surface Bonding Cement is available in Gray and White and can be colored with available Oxide colorant's added to the admixture whereto have rendered finishes of varied hues.

Some tips to minimise colour variations are:

1.Accurately measure mixing water or Acrylic copolymer using the same amount in each batch.

2.Avoid application during extremes in temperature and apply to the wall when shaded and in cooler conditions.

3.Two coats are recommended to minimise variation in colour, applying the second coat an hour after the first.

4.Avoid finishes that require using wet sponges or splashing with water.

SafetyGlass fiber and cement can cause skin irritation when wet or can dry and burn the skin. Therefore, it is advisable to wear gloves and eye protection when applying Infra-Block Surface Bonding Cement render. Wash away thoroughly any wet render in contact with the skin.

Shelf LifeOne year, when stored unopened on pallets in a dry area protected from moisture.

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Advantages of Infra-Block Surface Bonding Cement Render .

• One-coat application provides both structural strength and textured finish.

• Integral color capability eliminates painting.

• Creates concrete block wall with greater flexural and racking strength than conventional mortar construction.

• Increased productivity and lower in-place cost when using dry-stacked concept.

• Improved fire, water, air and sound control properties.

• Thermal insulation benefits.

• Low maintenance costs.

• Variety of finishes and accent capabilities.

• SBC walls are almost impermeable to air and water, although they are not a vapor barrier.

• A one-coat application is all that is required as long as the surface texture is accomplished before the SBC attains initial set.

• Walls constructed by this technique are structurally twice the flexural strength of concrete block walls built with mortar.

• Resists air penetration, sound transmission and water penetration, while at the same time providing structural strength improvement.

• Applicable for both exterior and interior use.

Infra-Block SBC is a Portland cement based formulation combined with 12.7 mm long alkali resistant (AR) glass fibers. AR glass fibers give Infra-Block SBC its great strength by acting as reinforcing elements. AR glass fibers are utilised because of their resistance to the alkaline attack of the Portland cement matrix. AR glass fibers have a zirconia based composition.

SIZES Infra-Block SBC Sanded and Un-sanded is available in (22.7 kg) bags.

YIELDA 20.0 kg bag of Infra-Block SBC will cover approximately 3.2 m2 at 3.0 mm thickness.

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OPTIONAL ACRYBOND CONCENTRATE FOR INFRA-BLOCK SBC CURE ACCELLERATION.

Acrybond is a water based 100% acrylic polymer cement additive. It is a highly concentrated versatile additive for improving portland cement mixes, specially formulated to optimise physical properties of Portland cement based mixes in a wide variety of applications.

USES:When properly mixed with cement Durex Acrybond concentrate can be used for the following applications:•conventional site applied plaster base•concrete topping•repairs of honeycombed concrete•flash patching•parging coat for concrete blockwork•versatile general bonding additive

ADVANTAGES:When properly mixed with cement Acrybond Concentrate provides:•excellent durability and strength•superior compressive, flexural, adhesive and high impact strength•excellent abrasion resistance•high resistance to chloride penetration •low moisture absorption rate •excellent adhesion to a wide variety of concrete and masonry surfaces.•no requirement for moisture curing, optimum properties are obtained by air- curing at ambient temperatures•better and more complete hydration of cement•reduced shrinkage and cracking of the mixes.

LIMITATIONS:Not recommended for use when ambient, surface and material temperatures are less than 5°C during application and curing period.

MIXING PROCEDURE: Do not substitute Acrybond Concentrate with any other type of mixing liquid medium for the following recommended formulation.

Optimum properties of cement mixes are obtained when Acrybond Concentrate is added at a ratio of 20 % by weight of cement in the formula 9 litres of Acrybond Concentrate to 40 kg of Portland cement.

Surface Bonding Coat using Portland cement for rendering concrete blockwork:40 kg Portland cement Type 1068 kg of #35 mesh silica sand 9 litres of Acrybond Concentrate 4 litres of water4 kg AR glass -Alkaline Resistant Glass Fiber ( 6 – 12mm chopped strand )

Coverage: Approximately 9 m2 at 3.0mm thick

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Electrical and Plumbing Utility PlacementIt is recommended to use the Type 2 Services Utility Infra-Block refer to the overleaf pages 28 to page 32 regarding specification and utilisation.

Electrical Services optionally can be run within the Infra-Block wall cores prior to the top bond being poured and or the placement of the PFC Ring beam having appropriate clearance holes for plastic electrical conduit to be inserted at specified locations through the PFC Ring Beam into the wall blocks cores, however removal of the Infra-Blocks central located Insulative cartridges are required due to the conductive aluminium surfaces posing a potential hazard in event of electrical short.

For through-wall utility penetrations, the use of a conduit is recommended. Typically a rigid plastic pipe, the sleeve is inserted into the wall by the mason during construction. After the wall is constructed, the utility line is simply inserted through the sleeve. While the use of a conduit requires coordination between the electrical contractor and the mason during wall construction, it promotes ease of utility installation and expedites required maintenance.

Preferably, electrical wiring and components are mounted on the interior face of the exposed concrete masonry walls as the preferred method of installation. The electrical boxes are mounted on the wall with face plates and the wiring run in conduit or hidden behind decorative molding attached to the wall surface. Another alternative is to use electrical raceways commonly used in commercial buildings. Electrical raceways are available for residential applications regardless of the interior finish desired. Electrical raceways are available in white or wood-laminate versions to blend with décor and typically mounted at the base of the wall to resemble traditional baseboards. (refer to photo below)

Most of the utility services, light switches, power points and plumbing will be run through the Infra-Block dwellings internal partition cavity walls made from insulated MgO board affixed to Timber or galvanised C channel framework whereby to keep labour costs minimal and conceal the Electrical and Plumbing services by installing in a manner similar to light-frame construction, that is, vertical plumbing runs are placed between studs and horizontal plumbing runs are cut through studs.

Note: Plumbing is preferred not to be installed within the cores of an Infra-Block exterior concrete masonry wall due the consideration of cost, coordination, and access issues. Although the plumbing is not typically installed upon outside face of exterior walls, plumbing may be installed on the interior face of exterior concrete masonry walls in a manner similar to electrical utility installation.

This approach does not interfere with the wall’s construction. It lends itself to easy installation and provides access to wiring and components. This method enables Electrical wiring and associated components to be installed on the interior face of any concrete masonry wall whether the concrete masonry walls are hollow, partially or fully grouted, or solid.

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Services & Utility Concrete Masonry Unit

Type 2- High R-Value Infra Block

Reflective Aluminium Foil membrane laminated both sides of 25mm Expanded

Phenolic Board insulation.

8mm Aluminium Foil Faced Expanded Phenolic Board

Aluminium Foil Cavity Cap for reducing vertical heat transfer through the cores

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70 x 8 mm recess for retaining thermal insulative memberwhereto reduce Thermal Bridging via webs

190 x 190 x 390 mm 20 Mpa CMU

Double Infra-red ReflectiveAir Cells

Knock Out shear tabs to provide horizontal clearance for running services through wall

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Infra-Block with Knock Out tabsKnock-Out shear tabs with small mallet

when placing horizontal services

Or simply use assembly as a High R-Value CMU

Infra-Block, it’s a Knock-Out

Interference fit of Reflective Thermal Insulative Cartridges.

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20- 30 mm diameter heavy duty Electrical Conduit

Electrical Line

Central Thermal Insulative Cartridge removed for service line clearance

The Infra-Block T2 utility concrete masonry unit (CMU) features knockout web tab sections that can be removed by applying a small kinetic impact against the knock-out tab using a small mallet or hammer.

This is a versatile construction block which has excellent Thermal Insulative properties and can also cater for the placement of Electrical and Plumbing service lines within the cores.

The Infra-Block T2 utility concrete masonry unit can be used for many different construction projects either as a utility block or as an Insulative element comprising walls.

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12mm Copper Plumbing Line

22mm Core Drill for interior Line Thru

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Insulated Timber Framed Infill Walls

Infra-Block Infill walls are generally manufactured on site from C channel or Timber as individual elements that are pre-cut to length however they can be pre-fabricated as large panels with the cladding and most utility services and insulation already attached and embedded within. Typically, 6 mm Magnesium Oxide Board is used for cladding the internal separating walls for fire resistance and acoustic insulation. The insulated Infill walls have excellent resistance to loading and are mechanically secured to the masonry floor and external walls by Chemset anchors and or Dynabolts.

Gyprock or MGO Board Lining affixed to Timber or Roll Formed C channel Frame .

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Optimum Thermal comfort is obtained when using Infra-Block Type 1 or Type 2 Pre-Insulated Hollow Masonry Units for wall construction by affixing to the interior wall face a low density 31 mm rigid thermoset phenolic insulation board faced with a 6mm Magnesium Oxide (MGO) plaster Board or 10 mm Gyprock board.

The Insulative composite wall board is adhered directly to the interior block wall faceby dab gluing at regular centers utilising a gyprock adhesive or quick cure polyurethane adhesive.

The insulative composite wall board sheets are usually fixed horizontally to reduce the number of joints. Apply daubs of adhesive to the wall at 50mm in diameter and 15mm thick, 50mm from sheet edges and spaced at 230mm to the board ends and at 460mm centers elsewhere.

The board is positioned to the wall and subsequently plumbed by using a straight edge and tapping it into alignment vertically and horizontally whilst checking with a spirit level. The Boards are held in position by propping or with masonry nails, the adhesive reaches full bond strength typically within 24 hours.

If the wall face has surface irregularities that exceed 15mm, then furring channels are to be used.

Such adaptation of the Insulative composite wall board adhered to the interior side of a Single Leaf Infra Block wall provides superior Heat and Sound Insulation whilst also providing for a highly smooth planar finished wall which is further painted.

Infra-Block optimum Thermal R-Value

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Calibrated hot-box facilities—Calibrated hot-box test facilities are used to determine the static and dynamic response of wall specimens to indoor and outdoor temperatures. The hot box consists of two highly insulated chambers clamped tightly together to surround the test wall. Air in each chamber is conditioned by heating and cooling equipment to obtain desired temperatures on each side of the test wall.

The outdoor (climatic) chamber is cycled between various temperatures. These temperature cycles can be programmed to simulate outdoor daily temperature swings. The indoor (metering) chamber is typically maintained at a constant temperature between 18 and 27 °C to simulate indoor room conditions.

The chambers and test specimens are instrumented to monitor air and surface temperatures on both sides of the test wall and heating energy input to the indoor chamber. Instruments monitor the energy required to maintain a constant indoor temperature while the outdoor temperature is varied. This energy, when corrected for small thermal losses through the frame, provides a measure of transient heat flow through the test wall.

The calibrated hot box is used to quantify the time lag between outdoor and indoor peak temperatures and the reduction in peak temperatures from outside to inside. The time lag shows the response time of a mass wall to outdoor temperature fluctuations.

A long time lag and amplitude reduction relieves excessive cycling of the heating, ventilating, and air conditioning (HVAC) equipment and increase system efficiency.

Additional cost savings can result where utility companies offer reduced off-peak energy rates. With a reduction in peak temperatures, less cooling capacity is needed, and the cooling capacity of the HVAC system can frequently be reduced. Similar savings occur for heating. Thermal lag depends on the R-value as well as the heat capacity because both of these factors influence the rate of heat flow through a wall.

Wall Type. Thermal lag- hours

Amplitude reduction, %

1. 200 x 200 x 400 mm Uninsulated standard masonry wall 3.0 18

2. 200 x 200 x 400 mm Infra-Block wall with insulated cores. 3.5 28

35. 200 x 200 x 400 mm Uninsulated standard masonry wall with interior insulation plaster board

3.5 28

4. 200 x 200 x 400 mm Infra-Block wall with interior insulation plaster board 4.5 51

Table 1—Thermal lag and amplitude reduction measurements from calibrated hot box tests

Testing the advantages of Infra-Block Thermal Mass

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INFRA BLOCK Type 1 CMU Total R = 0.698 m2 K/W

Thermal Efficiency gain of Infra- Block T1 concrete masonry unit comparative to standard un-insulated block = 3.49 times

INFRA BLOCK Type 1 Wall with insulated plaster boardTotal R = 1.956 m2 K/W

Total Thermal Efficiency gain of Infra Block wall assembly comparative to standard uninsulated block wall per m2 = 9.78 x

TOTAL CONSTRUCTION COST PER METER SQUARE OF R 1.956 INFRA-BLOCK WALL WITH INSULATED PLASTERBOARD PAINTED FINISHED LINING =

AUD 187.78 per m2 (Labour inclusive- GST excluded )

INFRA BLOCK Type 2 CMU Total R = 0.960 m2 K/W

Thermal Efficiency gain of Infra- Block T2 concrete masonry unit comparative to standard un-insulated block = 4.5 times

INFRA BLOCK Type 2 Wall with insulated plaster boardTotal R = 2.26 m2 K/W

Total Thermal Efficiency gain of Infra Block T2 wall assembly comparative to standard uninsulated block wall per m2 = 11.3 x

TOTAL CONSTRUCTION COST PER METER SQUARE OF R 2.26 INFRA-BLOCK TYPE 2 WALL WITH INSULATED PLASTERBOARD PAINTED FINISHED LINING =

AUD 202.35 per m2 (Labour inclusive- GST excluded )

PRICE PER METER SQUARE

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INFRA-BLOCK PORTABLE ELECTRIC HOLLOW CONCRETE MASONRY UNIT MANUFACTURING MACHINE .

Used to make conventional hollow concrete bricks on site in remote regions or disaster relief areas. Accompanying moulds can form blocks of 100mm, 150mm and 200mm. One bag of cement is combined with four wheel barrows of quarry dust, desert sand or river sand from local resources to achieve the appropriate mixture and block compressive strength. Note- If using Portland cement the Blocks must air cure for 28 days before reaching full 20Mpa strength. If using Infra-Block Magnesium Oxide Cement the blocks cure time is 6 hours to reach20Mpa strength and 28 days to reach Maximum strength of 40 to 55 Mpa.

Dimension 1600*1200*2100mmVibrating power 35KNColor Orange or YellowPallet size 880*450*25mmMolding time 40sPower 10.4kw Weight 1.5T Mixer JD350 Rated voltage 380V

Item Size Pcs/Mould Pcs/HourHollow block 400*200*200 4 360Hollow block 400*150*200 5 450Porous block 240*115*90 9 810

Solid brick 240*115*53 21 1890

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Capacity - 300 Liters

Power source - Diesel engine

Operating staff - Minimum of 2 operators

Features - Top driven with heavy duty hydraulic motor and all mounted to a trailer making the pan mixer mobile.

Advantage- Less labour needed to mix soil and cement, increases production rate and assists in achieving faster block production and high block quality.

INFRA-BLOCK PORTABLE 300 LITRE DIESEL PAN MIXER

INFRA-BLOCK PORTABLE ROTARY SEIVE

The 240V Electric Rotary aggregate and sand sieve is fitted with loading and discharge shoots and replaceable 8mm hard wire mesh.

Sieved particle size will be approximately 3mm Ø and smaller.

Production: 1,5 – 2,5 cubic meters of screened material per hour.

Production will vary according to raw material type and loading rate.

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INFRA-BLOCK PORTABLE PETROL POWERED FIBER REINFORCED SURFACE BONDING CEMENT SPRAYER

Item PZ-5Output 3m3/hMax. Conv. Dist 200mWater Cement Ratio ＜ 0.4Max. Aggregate. Size 10mmHose Inner Size 42/51mmOperating Air Pressure 0.2~0.6MPaAir Consumption 5~6 m3/minMotor Power 5.5hpEngine brand Honda

Basic Chassis Rubber-Wheel, Skid, Rail-Wheel

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INFRA-BLOCK MAGNESIUM OXIDE ALKALINE GLASS FIBER REINFORCED SURFACE BONDING CEMENTS

Magnesium Oxide/Portland Based Cement Magnesium-based cements commonly achieve compressive strengths of 62 Mpa to 310 Mpa and tension strength of over 5.5 Mpa, many times stronger than that of conventional concrete.

Magnesium oxide combined with Cliniptonite form cements that breathe water vapors electro-magnetically offering a significant advantage by the Cliniptonite in magnesium oxide balances and enhances the movement of moisture. This materials continuously expels moisture and therefore never rot. Quick Cure Magnesium Phosphate Cement

Infra-Block Magnesium phosphate cements are formed by the reaction of magnesium oxide with a soluble phosphate, such as ammonium phosphate, either the mono or dibasic salt; or an agricultural fertiliser solution known as 10-34-0 (NPK designation) can also be used.

This magnesia cement has very good adhesion to a wide variety of aggregates and substrates, it rapidly sets within 15 minutes without a curing retarder and obtains a very high early strength which can be utilised as rapid set mortar or render for bonding blocks and for quick cure masonry block manufacture. By adding a Cure retarder the cure time can be increased to 45 minutes.

In contrast to Magnesium oxychloride and Magnesium oxysulphide cements, this cement system has good water and freeze thaw resistance. Magnesium phosphate cements typically reach a compressive strength of about 20 Mpa after 1 hour, with an ultimate strength of 55 Mpa.

The reaction mechanism is due to be an acid-base reaction between the MgO and the acid phosphate. This results in an initial gel formation followed by the crystallization of this gel into an insoluble phosphate, mainly magnesium ammonium phosphate hexahydrate, NH4MgPO4.6H2O.

The magnesium oxide used in this system is a fairly unreactive MgO, either hard or dead-burnt, and is used in conjunction with a set retarder, typically either borax or boric acid, to afford a workable set time.

A research study conducted on Magnesia–Phosphate cement reinforced with fibers, recorded that the test cement pastes develop after 3 hours mechanical properties comparable with ordinary Portland cement composites tested at 28 days.

This product is produced at low temperatures and the production of carbonates absorbs external CO2 - forming the foundation of "negative CO2 cement" claim.

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Example of MgO/Phosphate Cement (MPC) mix ratio

Raw Material: % of Formula by Weight:MgO (Dalian CR Science Development Co. Ltd. China) 28MKP (mono-Potassium Phosphate from ICL) 28Fly Ash (Class F from Boral) 39Boric Acid 5

An example of Cure Retardants for MgO/Phosphate Formulations

Raw Material: % of Formula by Weight:MgO (Dalian CR Science Development Co. Ltd.) 15Mono-Potassium Phosphate (MKP from ICL) 30Metakaolin or Cliniptonite (Zeolite Australia) 25Sand 22Amino Acid (Retardant from Sika Corp.) 4Boric Acid 4

Quick Cure Magnesium Phosphate Cement Formula

Example of formula to provide early carbonation to MPC matrices

Raw Material: % of Formula by Weight (before adding water): MgO (Dalian CR Science Development Co. Ltd.) 30MKP (mono-Potassium Phosphate from ICL) 20AR Glass Fiber (Chopped Strand 6-12mm) 25Silica Sand (dried) 17Sodium Bicarbonate 3Boric Acid 5

Examples of Surface coating materials on MgO to slow Set-Times of MPC Formulations

Surface Coating Material: % of MgO by Weight:Stearic Acid 7Ethylene Glycol 10n-Octyltriethoxy Silane 2Perfluoropolyether Fluid 0.1

Please note some admixtures in the above formulations have not been disclosed due to Trade Secret and Commercial in Confidence.

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Magnesium phosphate cements provide various additional/alternative possible benefits, including, but not limited to:

• Fire resistance and/or non-combustibility;

• Mold, bacteria, and insect resistance;

• Tenacious bonding strengths to a wide ranging choice of materials;

• High early and ultimate compression and tensile strengths;

• Low shrinkage and/or minimal shrinkage cracking; water resistance;

• Acid, sulfide, alkali, and chemical resistance;

• Low electrical conductivity;

• Improved thermal resistance;

• Oil, grease, and solvent resistance;

• Abrasion and/or wear resistance,

• Impact, indentation, and scratch resistance;

• Resistance to most chemicals;

• Ability to incorporate a wide variety of recycled materials, Including glass, wood

fibers, cellulose, bamboo, plastic etc.;

• Lightweight, resilient, minimal alkali silica reaction issues;

• Greener/sustainable technology with less fossil fuel consumption associated with

magnesium oxide preparation due to lower calcining temperatures;

• The ability to absorb carbon dioxide over time;

• The ability to incorporate a wide range of recycled materials in the cement matrix.

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Magnesium Oxide Quick Cure Cement (MOQC) for onsite manufacture of High Strength

Infra-Block masonry wall elements.

55 Mpa ultimate strength within 28 days

20 Mpa Strength achieved in 3 hours

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Comparative Costs of Infra-Block quick cure cementitious admixtures for block manufacture and surface bonding.

20 Mpa Standard Block - 200x200x400– admixture proportions per 16 kg block.5.28 kg Cement = AUD = 37.84 cents10.56 kg Sand = 31.68 cents2.37 kg water = 2.3 centsRatio= 1 part cement: 2 parts aggregateTotal Material cost = 71.89 cents per block = 4.49 cents per Kg Infra-Block 55 Mpa (MOQCC) Magnesium Oxide Quick Cure Cement admixture proportions-Cement = 2.26 kg AUD = 17.32 centsMagnesium oxide= 1.74 kg = 60.29 centsMono-ammonium phosphate =2.47 kg= AUD 3.06Sodium pyrophosphate= 1.6 kg = AUD 1.67Borax =153 g = 10.85 cents7.7 kg Sand = 23.00 cents1.4 kg water = 1.4 centsTotal Material cost = AUD 5.25 per block = 32.84 cents per Kg 20 Mpa Strength Cure = 3 Hours - 55 Mpa Full Strength within 28 Days Infra-Block Magnesium Oxide Quick Cure (MOQC) 55 Mpa Glass Fiber Reinforced rendering admixture proportions- Cement = 2.26 kg AUD = 17.32 centsMagnesium oxide= 1.74 kg = 60.29 centsMono-ammonium phosphate (Analytical Grade) =2.47 kg= AUD 3.06Sodium pyrophosphate= 1.6 kg = AUD 1.67Borax =153 g = 10.85 cents7.7 kg Sand = 23.00 cents80 grams AR Glass Fiber 12mm chopped strand @ 5% weight of pre-mix = AUD 10.42 CentsTotal Material cost = 37.18 cents per Kg 0r AUD 7.43 per 20 kg 20 Mpa Strength Cure = 3 Hours - 55 Mpa Full Strength within 28 Days Coverage per 20 Kg at 3 mm thick minima = 3.07 m2 Material Costs inclusive FOB from China to Port of Brisbane:Cost of 85% MgO AUD 345.36 per tonne Cost of AR glass chopped strand AUD1303.26 per tonneCost of Fine sand aggregate 100-160 mesh AUD 30 per tonne (local)Cost of Monopotassium phosphate AUD 1238.10 per tonne Cost of TRICALCIUM PHOSPHATE AUD 1042.61 per tonneCost of Water AUD 10 per tonne (local)Cost of Portland cement AUD 71.68 per tonneCost of Borax 704.18 AUD per tonne