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THERMAL WALL SOLUTIONS Email: offi[email protected] www.clayblock.ie

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Page 1: THERMAL WALL SOLUTIONS - clayblock.ieclayblock.ie/wp-content/uploads/2015/07/Clayblock_Porotherm...Porotherm® products are produced by ... the Porotherm® system brings cost and timesaving

THERMAL WALL SOLUTIONS

Email: [email protected]

www.clayblock.ie

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approved & supported

Porotherm® products are produced byWienerberger the world’s market leader in claytechnology and have been used successfully inEurope for over 30 years.

Porotherm® products comply with BritishStandard BS EN 771-1:2003, CE marked, LABCRegistered Details-Registration No. RD1820312,and can be used in masonry designed inaccordance with Euro code 6 (UK).

Use of the Porotherm® system is supported by atechnical report and design guidance publicationby Lucideon Limited.

Why choose clay?

Used for thousands of years in constructionworld-wide, clay remains the most sustainablesolution for modern buildings. It’s naturalproperties means that it provides a complete,long term sustainability, not only offeringincreasingly sophisticated low-carbon productmanufacture, but giving a building life over 150years with little or no maintenance.

Strong and durable, yet lighter and easier to work with than many of the alternatives, clay also builds-in sound and temperature-controlbenefits wherever it’s used—creating the idealinternal living environment.

From sustainability credentials and build qualityto the ease of use on-site, clay is a materialequipped to meet every demand of modernconstruction.

SucceSSful & SuStainable

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The heart of the system-and the secret of it’s speed and efficiency—is the precision-engineered clayblock. A unique interlocking design rules out the need for mortar in the vertical joints and consistentmanufacturing quality allows for true 1mm bed joints. Used successfully for decades across Europe,and now well-established as a building solution for Ireland and UK working conditions, Porotherm®products can be used in load-bearing and non-load-bearing applications and are ideal for:

With it’s lean laying process and rapid daily output, the Porotherm® system brings cost and timesavingbenefits throughout the build while it’s thermal and acoustic efficiencies bring further advantages fordecades to follow—the design life for a Porotherm® wall is over 150 years.

It’s extremely fast, virtually dry, safe and simple touse, immensely strong, efficient for stock-holding

and storage and environmentally friendly.

about the Porotherm® SyStem

Single leaf (monolithic) internal & external walls

Partition walls and separating walls

Inner leaf of brick-faced cavity walls

Inner and outer leaves of rendered cavity walls

Infill panels within framed structures

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dryer

In comparison to traditional block work,Porotherm® construction uses around 90%less water. In a typical 212m² building,concrete blocks will require 3900 litres ofwater compared to just 515 litres for thePorotherm® system

The system takes less time to achieve awatertight shell thus accellerating the project schedule

faster

With no mortar needed in vertical joints and aminimal 1mm bed joint, the Porotherm®system rises rapidly. An average of 30-40m²per man per day is easily achievable, muchfaster than traditional masonry

The Porotherm® system is capable of beingbuilt to storey height in one day

Floors can be placed without the need fornormal backing up so the external envelopecan be completed more quickly

While surpassing masonry structures for fireresistance, longevity and sustainability,

Porotherm® construction can even be fasterthan timber frame construction—with theadded benefit of allowing parallel working forinternal and external trades earlier in theprogramme

Our thin bed mortar can be used from 0degrees celsius and above, meaning thatprojects can gain days/weeks extra in workingtime during winter which would otherwise belost with traditional masonry

Porotherm® in dePth

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To get the best use from the Porotherm® system, it’s important first to understand the tools andmaterials that define the process:

Porotherm® in uSe

Thin Bed Mortar is a mix of fine-ground sand,cement and other ingredients specific toPorotherm® construction. A Roller to apply thethin bed mortar allows for the swift and simplecreation of true 1mm bed joints

Mixed locally to laying, it allows for thin jointswhich will achieve full strength in just 24hours

Unlike traditional mortar, which is oftenlimited to use only when the temperatureexceeds 3°C, our mortar can be used from0°C, allowing block layers to minimiseweather related delays

Each 15kg pack requires just 3.6 litres of waterand will lay 1 No. pack of blocks when appliedwith the correct rolling tools

Parge coat

A high performance parge coat is analternative to a wet plaster parge coat toprovide an airtight barrier prior to theapplication of plasterboard on dabs or otherinternal finishes

Our parge coat product is a high performancemodern parge coat that has been specificallydesigned and tested for fast application ontothe Porotherm® walling systems. It has beenengineered to increase airtightness and tooptimise the sound and thermal performanceof the system.

Our parge coat canbe easily appliedby brush or rollerensuring fast, de-skilledapplication

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note 1: The maximum depth of the recess orchase should include the depth of any holereached when forming the recess or chase.

note 2: Vertical chases which do not extendmore than one third of the storey height abovefloor level may have a depth up to 80mm and awidth up to 120mm, if the thickness of the wallis 225mm or more.

note 3: The horizontal distance betweenadjacent chases or between a chase and a recessor an opening should not be less than 225mm.

note 4: The horizontal distance between anytwo adjacent recesses, whether they occur on the same side or on opposite sides of the wall, or between a recess and an opening, should notbe less than twice the width of the wider of thetwo recesses.

note 5: The cumulative width of vertical chasesand recesses should not exceed 0.13 times thelength of the wall.

note 6: When installing gas pipework intochases cut into the Porotherm® wall thepipework should be secured using proprietaryside fixed clips into the face of the block and notinto the inner face of the chase. As with allmasonry types, the sealing of the chase shouldbe in line with Gas Safe regulations. If in doubt,the advice of a Heating Engineer should besought.

If chases are too deep or back-to-back the structural integrity of the wall will have been altered andtherefore will be subject to a structural engineers survey and report. The person chasing for electricalwork may not be the same person who hangs a picture or cuts a retrospective window, therefore, allchases should be sensibly placed allowing everyone the opportunity of working out where servicesare in relation to lights, switches, sockets and appliance points.

Contractors must follow guidelines to make the installation of electrical cables as safe as possible.Ideally works pertaining to chasing and making good should be completed prior to applying a pargecoat. Should chasing and making good be undertaken after a parge coat is applied then an additionalparge coat must be applied over the chased area.

chases

Installing chases for the purposes of runningservices is best achieved by using a proprietarytool designed specifically for the purpose e.g. a wall chaser with two parallel diamond tippedcutting wheels. A bolster chisel can then be usedto remove the cut section. The chase should thenbe sealed for air tightness using a parge coat/ orplaster application.

Porotherm® in uSe

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Porotherm® in uSe

Safer

Porotherm® products are generally lighterthan concrete (optimum weight under 11kg)allowing workers to maintain steadyproduction rates without the risk of repetitivestrain injuries

Precision engineering means no sharpcorners, reducing the risk of cuts and grazes

Thin bed mortar is applied with a roller,reducing dermatological risk

The thin bed joint mix is mixed locally to theworkplace, which means a reduction inforklift movements, less plant/pedestriancontact and no need for noisy cement mixers

more efficient

Thermally efficient in helping to regulatevariations in temperature and humidity; air-tightness is maximised with a parge coator wet plaster

Acoustically efficient

Fire resistance is outstanding – Porotherm®achieves a Class A1 rating

Breathable – assists in regulating seasonalhumidity

No moisture shrinkage – no disruption tofinishes, fewer movement joints (1:20 linearmetres) and reduced risk of cracking due toshrinkage

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Porotherm® in uSe

the method

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1. Lay the first course on a traditional sand-cement mortar bed

2. Ensure the first blocks are level, horizontal in bothdirections and vertically plumb. This is the most crucialstage of the process, as it determines the levelness ofeach of the subsequent build storeys, and the speedand accuracy of the construction as a whole

4. Apply the mortar (mixed close to the build) to the blocks with a roller

3. Mix thin bed mortar according to guideline quantities –don’t mix more than you need

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Porotherm® in uSe

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5. Repeat until a precision wall is complete – up to fourtimes faster than traditional methods

6. Wall ties are easily installed(see other products)

8. Block-cutting is straightforward

7. If insulation is preferred than itcan be applied simply

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lintels

A range of system-compliant lintels from all leadingmanufacturers are widely available.

fixings

Many off-the-shelf fixings are suitable for use with Porotherm® products covering thecomplete range of light to heavy requirements.

Wall ties

Clayblock Ireland supply the compatible wall ties whatis can be used with the Porotherm® 1mm thin joints.System-compliant stainless steel ties widely available.

A wide variety of fixtures and accessories are available for use with Porotherm® products somespecifically created to work with the system (in conjunction with industry-leading partners) and others available as standard items.

fixtureS and acceSSorieS

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understanding exactly how Porotherm® works in practice is absolutelyvital to getting the maximum benefit from the system, which is whyclayblock ireland and Wienerberger will do everything we can to ensurewe provide the site training and support contractors need. our expertlyrun courses are designed to suit tradesmen, designers, productionpersonnel and management.

Porotherm® training and SuPPort

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If you are interested or just need more informationabout our training, please contact us:

Email: [email protected]: www.clayblock.ie

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the Porotherm® core range

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For more product and technical information please visit to our website www.clayblock.ie

All lintels need 120mm bearing

blockslocationfor use

dimensions lxWxh (mm)

(W=wall thickness)

Quantity/Sqm

Quantity/PK no/

Sqm

Weight/each (kg)

conductivity dry block

lambda/W/mK

acoustic resistance

rw(db)

compressive Strenght

nm/Sq.mm

Porotherm ZWP Plant T 115 Interior walls 498x115x249 8 80/10 11,2 0.39 >40 8

Porotherm Plan T 175

Interior and/or

load bearingwall

498x175x249 8 56/7 17,4 0.42 >40 12

Plan T12 240 External wall or

Internal load bearing wall

373x240x249 11 80/7.3 17.8 0.42 >40 12

Porotherm T8 365 Exterior walls 248x365x249 16 60/3.7 13.5 0.08 >40 6

Porotherm T10 365 Exterior walls 248x365x249 16 60/3.7 14.7 0.1 >40 8

Porotherm T8 425 Exterior walls 248x425x249 16 48/3 15.7 0.08 >40 6

Porotherm T7 365 MW (Mineralwoll)

Exteriorinsulated

blocks248x365x249 16 60/3.7 15.9 0.07 >40 6

u blocksdimension

lxWxh (mm)Weight

(kg)Package content

U-Cup 175 250x175x238 5.8 150

U-Cup 240 250x240x238 7.4 96

U-Cup 365 250x365x238 10 72

U-Cup 425 250x425x238 13.1 48

WU-Cup Available for wallthickness: 365 or 425mm

lintelsdimension Wxh (mm)

lengthWeight(kg/m)

Internal Lintel 71x115Available

from1m to 2.5m

14.5

External Lintel 71x115Available

from1m to 2.5m

20

External Lintel 113x365Available

from1m to 2.5m

45

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other ProductS

toolS & acceSSorieS

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RECIPROCATING ALLIGATOR SAW

THIN BED ROLLER

SPIRIT LEVEL

PADDLE DRILL

TAPE MEASURE

STANDARD PPE

Clayblock products can be laid using a widerange of standard construction and masonrytools and equipment. however there are anumber of specialised tools availble to assistwith speed and efficiency of laying.

Please contact us for specific requirements

monolithic u-blocK

Optional SizesInsulated or not

inSulated clay lintelS

Optional SizesInsulated or not150mm bearing

tieS for internal WallJunctionS

Also cavity wall tiesBrick and stone tiesProfile less than 1mm

abutment tie forPerimeter Wall

No cross bond requiredAlso joist hangersProfile less than 1mm

dryfix SyStem

Alternative to mixedmortarFast and effective

fixingS

Most standard fixings are suitable

call to discuss your specific requirements

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technical

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Please note: Sizes of vertical chases and recesses in masonry, allowed without calculation

chases and recesses formed afterconstruction of masonry

chases and recesses formed duringconstruction of masonry

thickness of wallmm

max depth mm

max width mm

maximum wallleaf thickness

remaining mm

max width mm

85-115 30 100 70 300

116-175 30 125 90 300

176-225 30 150 140 300

226-300 30 175 175 300

>300 30 200 215 300

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SuStainable

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Porotherm® products have...

Up to 30% MARSS materials from alternative,recycled and secondary sources

Low embodied energy

An end of life function as a useful crushedhard-core – 150+ years

95% less water use in construction

Minimal waste during use

Clay is a natural material equipped to meet every demand of modern construction. Used forthousands of years in construction worldwide, clay remains the most sustainable solution for modernbuildings. Its natural properties means that it provides a complete, long term sustainability, not onlyoffering increasingly sophisticated low-carbon product manufacture, but giving a building life of over150 years with little or no maintenance.

Create an optimum living environment, ask for comfort without complication, simplify construction,reduce trades and increase workflow.

While matching masonry structures for fire-resistance, longevity and sustainability, Porotherm®construction can even be faster than timber frame construction – with the added benefit of allowingparallel working for internal and external trades earlier in the programme

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robert JohnstonTechnical Director

Phone: 087 451 3278Email: [email protected]

Szilárd czakóSales Director

Phone: 087 774 5465Email: [email protected]

diSclaimerClayblock Limited as well as its directors, employees, agents and representatives disclaim any responsibility, express or implied, for the accuracy or completeness of the informationcontained in this brochure or its suitability for a certain purpose. This brochure does not constitute a complete description of all articles distributed by Clayblock Limited and cannot containall relevant information for their use. All products, components, methods etc. described herein are subject to continuous technical development and may therefore be modified by ClayblockLimited without further notice. Such modification may cause the information herein to become partially or entirely inapplicable. This brochure cannot and does not substitute the client’sown necessary assessment and evaluation of the items described herein as well as the involvement of professional advice as to planning and construction. This also applies to technicalnorms applicable to a certain project, which should be reviewed by qualified consulting engineers and/or architects. If and to the extent the brochure contains statements in relation to thirdparty products, such statements are based on Clayblock Limited and its suppliers own experience made under certain circumstances. Such statements may prove correct or incorrect underdifferent circumstances. Clayblock Limited shall not be liable for the correctness and completeness of the information, conclusions and predictions contained in such statements. Any liabilityof Clayblock Limited in connection with the products and methods described in this brochure is valid only if and to the extent agreed upon in writing between Clayblock Limited and theclient, e.g. in the form of a definitive written purchase agreement. If the client chooses to use or process articles or components displayed herein in a way differing from the methodsrecommended herein, the client in such circumstances has to obtain Clayblock Limited written approval in order to preserve liability claims, if any.

Email: [email protected]

www.clayblock.ie

THERMAL WALL SOLUTIONS Authorised Distributor