www.espac.com

Tel. : +9661 46 288 30Fax : +9661 29 303 04

P.O Box 25507Riyadh 11476Saudi Arabia

a green building

A.A.C PRODUCTS www.espac.comن�صـمـــم .. نــ�صــــنـع .. نــبــنـــــي

Contents03 - 0405 - 0911- 16

17 - 1921 - 2425 - 4647 - 5153 - 5759 - 6567 - 71

IntroductionManufacturingProperitiesBenifetsProductsUsagesDesignErectionFinishesOur Projects

We are committed to clean air

INTRODUCTION

ESPAC is the green trademark in AAC world.ESPAC is a Saudi- Emirati company specialized in Precast Aerated Concrete (PAC) by using latest technologies and in accordance to best quality standards, highly qualified experts with good architectural and engineering skills in planning, Manufacturing, designing and constructing green building using Precast Aerated concrete (PAC). ESPAC provide great quantity of blocks, Panels, and Roofs to meet the needs of the Saudi market in establishing trading center and residential compounds. It also provides necessary technical support to ensure best products.ESPAC team has the best scientific knowledge besides specialization experts in manufacturing, constructing and installing products safely and properly, using all available advantage and opportunity in project environment.

Our Commitment EESPAC is committed to high levels of responsibility in all processes of production, installation and technical support for projects the company

executes, to ensure efficiency in execution and perform the required work professionally and at a level exceeds the expectations of project owners.We are also committed to preserve and maintain the environment in which we live and work. Our Vision We are aspiring that ESPAC becomes the leader in Precast Aerated Concrete (PAC) in accordance to scientific and professional methods, which is able to achieve an added value to this creative product.

Our Mission Providing products, services and valuable engineering alternatives that is characterized with high quality, based on a creative vision and scientific methods provided by a specialized and experienced team that is highly qualified and has professional knowledge in order to achieve success to our clients through activation their potentials.

ESPACESPAC factory in Saudi Arabia

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4

A.A.C was perfected in the mid-1920 in Sweden by Dr. John Axel Eriksson, an architect working with professor Henrik Krevger at Royal Institute Of Technology, it was produced first in Sweden in 1923 then industries volume production in 1929. Since that time, its production and use have spread to more than 40 countries on all continents, including Europe, The Middle East, The Far East, North America, Central and South America, and Australia. This wide experience has produced many case studies of use in different climates and Under different building codes.

In Saudi Arabia A.A.C was started in 1977 and used for thousand of projects up to now.

Autoclaved aerated concrete (AAC) a cementitious product based on calcium silicate hydrates in which low density is attained by the inclusion of an agent resulting in macroscopic voids and is subjected to High-pressure steam curing (ASTM C1386).

Historical

Definitions

1MANUFACTURINGOverviewRaw MaterialsBatchingPlan & LayoutSteelCastingCutting & MillingAutoclavingPackaging

1MANUFACTURINGOverviewRaw MaterialsBatchingPlan & LayoutSteelCastingCutting & MillingAutoclavingPackaging

1.11.21.31.41.51.61.71.81.9

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1.2 Raw Materials The basic raw materials are cement, Sand, Aluminum Powder (expansive agent), Lime and Water.

Aluminum Powder Sand Water Lime Cement

1.3 Batching

1.1 Overview

Sand is ground to the required fineness in a ball mill, and is stored along with other raw materials. The raw materials are then batched by weight and delivered to the mixer. Measured amounts of water and expansive agent are added to the mixer, and the cementitious slurry is mixed.

Unlike most other concrete applications, AAC is produced using no aggregate larger than sand. Under high control quartz sand, aluminium powder, cement and water are mixed. Aluminum powder is used at a rate of 0.05%–0.08% by volume (depending on the pre-specified density). When AAC is mixed and cast in forms, several chemical reactions take place that gives AAC its light weight (25% of the weight of concrete) and thermal Properties. Aluminum powder reacts with calcium hydroxide and water to form hydrogen. The hydrogen gas foams and doubles the volume of the raw mix (creating gas bubbles up to 3mm (1/8 inch) in diameter). At the end of the foaming process, the hydrogen escapes into the atmosphere and is replaced by air.

When the forms are removed from the material, it is solid but still soft. It is then cut into either blocks or panels, and placed in an autoclave chamber for 15 hours. During this steam pressure hardening process, when the temperature reaches 190° Celsius (374° Fahrenheit) and the pressure reaches 8 to 12 bars, quartz sand reacts with calcium hydroxide to form calcium silica hydrate, which accounts for AAC’s high strength and other unique properties. After the autoclaving process, the material is ready for immediate use on the construction site.

1MANUFACTURING

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ComponentsSand Slurry

Water

Cement

Lime

Aluminium

1

2

3

4

5

Miling

Calliborationcomponents

Batching

Casting Rising andforming of pores

Rising andforming of pores

Rising and AutoclavingCutting

StraighteningStraighteningSteel \ CuttingSteel \ CuttingStraighteningSteel \ CuttingStraighteningStraighteningSteel \ CuttingStraightening

WeldingWelding

RustRustProtectingProtecting

DryingDrying

AssemblyAssembly

1 2 3 4 5

1.4 Manufacturing flow chart

PackagingLoading

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1.6 Casting

1.7 Cutting & Milling

Molds are prepared to receive the fresh AAC.If reinforced AAC panels are to be produced, steel reinforcing cages are secured within the molds. After mixing, the slurry is poured into the molds.The expansive agent creates small, finely dispersed voids in the fresh mixture that increases the volume by approximately 45% in the molds within 3 hours.

Within a few hours after casting, the initial hydration of cementitious compounds in the AAC gives it sufficient strength to hold its shape and support its own weight.The material is removed from the molds and fed into a cutting machine by wires used, sections the blocks and panels cut into the required sizes

and shapes. After cutting, the units remain in their original positions in the larger AAC Mass.The panels are demoulded and milled to required profile. All panels are singled out for proper marking, and if required, dry cut and stacked for further handling and storage.

1.5 Steel

Steel coils are straightened, cut and spot-welded into mats, where crossbars provide anchorage to the longitudinal reinforcements. Blocks are not reinforced.After dipping the welded mats in a homogenized anti-corrosion mix for rust protection, they are dried and assembled into cages and set accurately in the moulds before the slurry is poured in.

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1.8 Autoclaving

1.9 Packaging

After cutting, the aerated concrete product is transported to a large autoclave, where the curing process is completed. Autoclaving is required to achieve the desired structural properties and dimensional stability.The process takes about 15 hours under a pressure about 12 bars and at a temperature of approximately

374 °F (190 °C), depending on the grade of material produced. During autoclaving, the wire-cut units remain in their original positions in the AAC block.After autoclaving, the individual units are dimensionally stable and are specified to have a drying shrinkage of no more than 0.02% (ASTM C1386).

The blocks are demoulded, strapped, marked and stored on wooden pallets. Pallets for shipping. Unreinforced units are typically shrink- wrapped, while reinforced elements are typically banded only, using edge guards to minimize localized damage from the banding.

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2PROPERTIESMicrostructureChemical CharacteristicsDensityCompressive strengthCompressive strength testThermal conductivityAcoustic propertiesFire resistanceDurabilityQuake resistanceThermal expansionShrinkageMelting pointAir tightnessWater absorption

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2PROPERTIES

2.1 MicrostructureA.A.C consists of a micro calcium silicate bind matrix.In aerated concrete the method of pore formation influences the microstructure, and thus its properties. The micro pores are formed due to the expansion of the mass caused by aeration and the micro pores appear on the walls between the macro pores. The products orientation of hydration of cement is significantly altered due to the pressure of voids. On autoclaving, a part of the fine siliceous material reacts chemically calcareous material like lime and lime liberated by cement hydration, Forming a microcrystalline structure with much lower specific surface. The pores be distributed uniformly in mass to obtain products uniform density. The pores present in A.A.C matrix as micro pores 0.1 mm and macro pores 0.1 to 1.0 mm.

2.2 Chemical Characteristics

The reaction in the autoclave required (cement, lime, silica and water) the sequence of the chemical reaction in the autoclave .The temperature (190 ⁰C) and pressure (12 bars) time of the autoclaving determine which form of CSH is produced. The tobermorite group of calcium silicate hydrates (C-S-H). The reaction product of mixture of crystalline, semi-crystalline, and near amorphous tobermorite. The AAC are plate shaped crystal of 11.3 A⁰ tobermorite with a double chain silicate structure.The tobermorite (Ca5Si6O16(OH)2·4H2O )is usually the main hydration product in AAC.AAC remains constant after manufacturing, there is no change in the composition after autoclave curing in the production process. The construction process does not change the chemical composition of the materials itself.AAC material does not have toxic or radioactive contents.

Table 1. Porosity characteristics of AAC products different in densityApparent Densitykg/m3

Macro Pores%

Micro Pores%

Total Porosity

100 83 13 0.96

150 77 17 0.94

350 70 16 0.86

400 65 19 0.84

600 45 21 0.76

800 27 41 0.68

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Axis test direction

150

mm

150 mm

2.3 Density

Normally A.A.C was produced nominal dry density 550 kg/m3, other densities from 250 to 800 kg/m3 can be produced upon request. Many physical properties of aerated concrete depend on the density, it is essential that its properties be qualified with density. See table 2.

Table 2. Physical properties with densityDry density (kg/m3) Compressive strength (MPa) Static modulus of elasticity

(kN/mm2)Thermal conductivity (W/m oc)

400 1.3 -2.8 0.18 -1.17 0.07 - 0.11

500 2.0 -4.4 1.24 -1.84 0.08 - 0.13

600 2.8 - 6.3 1.76 – 2.64 0.11 – 0.17

700 3.9 – 8.5 2.42 – 3.58 0.13 – 0.21

2.4 Compressive strength

2.5 Compressive strength test

Up from 350 kg/m3 density AAC can be used as load bearing construction material. The material lower in density is used for thermal insulation purpose. Normally A.A.C was produced nominal dry density 550 kg/m3. Autoclaving increase the compressive strength significantly, as high temperature pressure result in a stable form of tobermorite.Strength is achieved in this case, depending on the pressure and duration of autoclaving. Generally compressive strength increase linearly with density. See table 3.

Table3. Properties at nominal dry density of 550 kg/m3

At nominal dry density of 550kg/m3

Compressive strength 35 – 45 kg/m3 ( 3.5 – 4.4 MPa )

Tensile strength 20 to 40% of compressive strength

Shear strength 20 to 30% of compressive strength

Modulus of elasticity 16000 kg/cm2

Compressive strength varies inversely with moisture content. On drying to equilibrium with normal atmosphere, there is an increase on the strength and even larger increase on complete drying out. Must be follow this steps for Compressive strength testing:

1. The test set shall consist of three cubes specimens with an edge length of 100 mm or 150 mm.2. The test specimens shall be conditioned at a temperature not exceeding 60 oC until their moisture content is

expected to be (3 to 6 )% by specimens mass. (By using special oven)3. The longitudinal Axis of the test specimens shall be perpendicular to direction of rising.

Direction of rising

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Table 4. Sound pressure reduction by (db)A.A.C thickness

Finishes type

10 cm 15 cm 20 cm 25 cm

Plain 39 43 45 48

Painted 41 45 48 50

Plaster 46 49 51 53

Gypsum Board 47 50 53 54

SOU

ND

PRE

SSU

RE L

EVEL

Street Traffic

Business Office

Living Room

Meeting Room

Garden

Jet Take-off

Pneumatic Chipper

Noisy Workplace

2.7 Acoustic properties

The reason stated is that transmission loss of air-borne sound is dependent on the mass law, which is a function of frequency and surface density of the component – its mass to area –, in addition to the rigidity. The A.A.C has a high surface mass dampens mechanical and absorption barrier.Sound reduction is the ratio of sound energy at its source to at another location expressed as decibel (db) and its Scale by logarithmic.

20cm

A.A

.C W

all

90 db 42 db

Sound Insullation

2.6 Thermal conductivityNo aggregate, low density, air bubbles, amount of pores and their distribution are critical factors for thermal insulation but the thermal conductivity is direct proportion influenced by the moisture content. at nominal density 550 kg/m2.The thermal conductivity K- value for A.A.C material is 0.144 at completely dry this confirmed by the international codes Like ASTM – ACI – British standards …) & Saudi Electricity Co. (SCECO), King Fahd University and Saudi Arabian Standards Organization (SASO).

Based on the above:

1. The U-value of A.A.C 20 cm thickness is 0.62 w/m2 oc = 0.11 BTU /f t2hof.2. The U-value of A.A.C 25 cm thickness is 0.51 w/m2 oc = 0.08 BTU /f t2hof.• Note: 1 BTU/f t2hof = 5.678 w/m2 oc.

K-Value

1.61.41.2

10.80.60.40.2

00.144

0.55

1.097 1.1291.355

PREFABCONC.

SANDLIMEBRICKS

CONCRETEBLOCKS

CLAYBRICKS

AAC

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2.8 Fire resistance

A.A.C is inorganic and incombustible material application the porous structure allows steam to escape without causing surface spilling. And it won’t lead to harbor or encourage vermin.So it is especially suited for fire – rated applications. Depending on the application and thickness of the blocks orPanels fire rating up to 7 hours.

Table 5. Fire resistanceThickness (cm) 10 15 20 25

Fire ratings (hours) 4 7 7.5 8

Aerated concrete.150 mm wall thickness

Concrete.150 mm wall thickness

Heat penetration in the case of �re after 6 hours

68 ˚C1000 ˚C270 ˚ C1000 ˚ CConcrete A.A.C

Prevention of secondary �res

Aerated concrete does not melt in the case of

�re and does not drip burningmaterial.

Other building materials:Spread of �re by melting and

burning material drippingdown.

A.A.C used in warehouse building

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2.9 Durability

2.10 Quake resistant

A.A.C mainly consists of tobermorite which is much more stable than products formed in normally cured aerated concrete, and hence it is durable. A.A.C resists the harsh climate conditions and does not degrade structurally if exposed to moisture. No organic continents, high control mixing, strong temperature – steam curing and protected steel by antirust coating make A.A.C materials more durability. A.A.C building has built since 1930 up to now.

The law mass of A.A.C material reduces total dead load of the buildings and results reducing the applied seismic. The connection between the walls and the foundation is enough but not rigidity . In addition in A.C.C. system the rectangular shape of the wall makes it as shear wall.

2.15 Water absorption Water absorption of materials can be classified by the water absorption coefficient. The water absorption coefficient gives information about how much water is absorbed in a defined time period. The special inner structure of AAC, which consists mainly of closed pores (micro pores and macro pores), prevents the capillary transport of moisture over long distances. In table 6 the water absorption coefficient for some selected building materials are shown.

2.11 Thermal expansion

2.12 Shrinkage

2.14 Air tightness

2.13 Melting point

A.A.C thermal expansion is 8x10-6/ C while in regular concrete has ranges between 4 to 14x10-6/ C, so A.A.C concrete is more dimensional stability than regular concrete.

A.A.C shrinkage is 200x10-6/ C but in regular concrete is 500x10-6/ C. The autoclaving (high temperature and high pressure steam curing) is the mainly reason in the lower shrinkage for A.A.C.

At a reference pressure of 50 Pa, the A.A.C building air changes 1 to 2.5 per hour.

A.A.C melts on 1200 C

Table 6. Water Absorption

MaterialWater absorption coefficient

[Ib/(in2.s0.5)]

Dispersion coating 1.2E-6 – 4.7E-6

Concrete 2.4E-6 – 1.2E-5

Cement plaster 4.7E-5 7.1E-5

AAC 5.9E-5 – 1.7E-4

Solid sand-lime bricks 9.5E-5 – 1.9E-4

Hollow bricks 2.1E-4 – 5.9E-4

Solid bricks 4.7E-4 – 7.1E-4

Gypsum 8.3E-4

Gypsum board 8.3E-4 – 1.7E-3

o

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ITS

3BENIFETS

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ITS

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Easy Workability Fast Construction Economical

4 5 6

High thermal insulation& energy saving

Strong & Durability Light Weight

1 2 3

Quake Resistant

7 8 9Fire Resistance & No Emission of Gases

Noise Resistance

3BENEFITS

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ITS

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Quake ResistanceQuake ResistanceQuake ResistanceGreen BuildGreen BuildQuake ResistanceGreen BuildGreen Build

BuildBuildHigh thermal insulationHigh thermal insulationGreen BuildGreen BuildHigh thermal insulationGreen BuildGreen BuildQuake ResistanceQuake ResistanceHigh thermal insulationQuake ResistanceQuake ResistanceGreen BuildGreen BuildQuake ResistanceGreen BuildGreen BuildHigh thermal insulationGreen BuildGreen BuildQuake ResistanceGreen BuildGreen BuildFast ConstructionFast ConstructionBuildBuildFast ConstructionBuildBuild

High thermal insulationHigh thermal insulationFast ConstructionHigh thermal insulationHigh thermal insulationLight WieghtLight Wieght

Fast ConstructionFast ConstructionLight Wieght

Fast ConstructionFast ConstructionEasy WorkabilityEasy WorkabilityBuildBuildEasy WorkabilityBuildBuildLight WieghtLight WieghtEasy WorkabilityLight WieghtLight Wieght

Multi Purpose High Dimensional Stability

Not Toxic orRadioactive Material

13 14 15

Green Build

10 11 12Clean Implementation Site

Sustainability & Long Life

Environment Friendly Breathable Buildings High Quality Control

16 17 18

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Reinforced products Profile shape Non reinforcement products

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Image Product name Description

Dimensions by mm with tolerance is +- 3mm for thickness & width and +- 5 mm for

length UsagesThickness width length

VP PAC vertical wall panels

75, 100, 125, 150, 175, 200, 225,

300

Up to 600 mm

Up to 6000 mm

•Load bearing•Partion wall•Cladding wall•Parapet wall

HP PAC horizontal wall panels

75, 100, 125, 150, 175, 200, 225,

300

Up to 600 mm

Up to 6000 mm

•Boundary wall •Cladding wall•Parapet •Partion•Filling wall

FSP PAC floor slabs panels

100, 150, 175,

200, 250, 300

Up to 600 mm

Up to 6000 mm

•Floor slabs with design load up to 600 kg/m2

RSP PAC roof slabs panels

100, 150, 175,

200, 250, 300

Up to 600 mm

Up to 6000 mm

•Roof slabs with design load up to 250 kg/m2

LP PAC wall lintels panels

100, 150, 200, 250,

300

400 to 600mm

Up to 6000 mm

Depend on designs

•Load- bearing lintels over window or door opening for external or internal walls

LX PAC box lintels panels

100, 150, 200, 250,

300

200, 250, 300

Up to 3600 mm

•Load- bearing box lintels over window or door opening for external walls

4PRODUCTS

4.1 Reinforced products table:-

Rei

nfo

rced

pro

du

cts

wit

h d

ou

ble

mat

ste

el r

ein

forc

emen

t d

epen

din

g o

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esig

n.

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4.2 Profile shapeSlabs Profile

Horizontal Panel Profile (HP)

Vertical Panel Profile (VP)

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Image Product name Description

Dimensions by mm with tolerance is +- 3mm for thickness & width and +- 5 mm for

length UsagesThickness width length

S - Blocks Standard PAC blocks

100, 125, 150, 175, 200, 250,

300

200 – 250 600 mm

•Thermal insulation wall

•Load bearing wall•Non load bearing• light weight

partitions•Solid blocks•External & internal

walls• Instead of C.M.U or

red clay blocks

J - Blocks Jumbo PAC blocks

200 – 250 – 300 600 Up to

1200 mm

H – Blocks Hordi PAC blocks 400 250 600 mm

•Light weight hordi blocks infill between concrete ribbed slabs

PT PAC roof tiles50x250x60075x250x60075x600x600

• Insulate conventional roof

4. 3 Non reinforcement products (Block) table:-

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Complete SystemConnecting To Concrete FrameConnecting To Steel FramePartitions Boundary WallBlocks & Hordi

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5.1 Complete System - Details.

5USAGES

Aerated concrete products constitute a complete system.

LX : PAC Box LintelHP : PAC Horizontal Panel

VP : PAC Vertical PanelLP : PAC Panel Lintel

RSP : PAC Roof SlabFSP : PAC Floor Slab

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Complete System - Photos.Aerated concrete used in several structures such as:

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Detail No. D1

INTERNAL WALL WITH FOUNDATION CONN. EXTERNAL WALL WITH FOUNDATION CONN.

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PAC SLAB

Detail No. D2

EXTERNAL NONE LOAD BEARING WALL CONN. EXTERNAL LOAD BEARING WALL CONN.

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Detail No. D3

INTERNAL LOAD BEARING WAL CONN. PANEL VP WITH PANEL VP CONN.

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Detail No. D4

Detail No. D5

PANEL VP WITH PANEL VP CONN.

SLAB WITH INTERNAL WALL CONN.

SLAB WITH STEEL BEAM CONN.

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5.2-a Filling to Concrete Frame - Photos.5.2 Connecting to Concrete Frame

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Filling to Concrete Frame - Details.

TYPICAL WALL ELEV.

PART ELEV. NO. 2

PART ELEV. NO. 1

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Filling to Concrete Frame - Details.

DET. A CONNECTIONSPLAN

DET. B FIRST PANEL FIXINGSEC.

DET. C BRACKET FIXINGPLAN

DET. D LAST PANEL FIXINGSEC.

DET. A CONNECTIONSSEC.

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5.2-b Cladding to concrete frame5.2 Connecting to Concrete Frame

RC BEAM RC BEAM

SEC

.

LEVEL. D

LEVEL. C

LEVEL. B

LEVEL. A

LEV. C

LEV. D

LEV. A

LEV. B

GROUND LEV

RC BEAM

CLADDING TO CONCRETE FRAMESEC،

CLADDING TO CONCRETE FRAMEELEV.

TYPICAL DETAIL

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5.3 Connecting to Steel Frame5.3-a With Vertical Panel - Photos،

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Connecting to Steel FrameWith Vertical Panel - Details.

EXTERNAL CLADDING SEC.

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5.3 Connecting to Steel Frame5.3-b With Horizontal Panel - Photos.

5- U

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Connecting to Steel FrameWith Horizontal Panel - Details.

PARTIAL ELEVATION SIDE VIEW

TOP VIEW SECTIONS

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5.4 Partitions - Photos.

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Partitions - Details.

PARTITION WALL CONN.

PARTITION WALL CONN.

(OPTION - 1 WITH FALSE CEILING USED)

(OPTION - 2 WITHOUT FALSE CEILING USED)

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5.5-a With concrete columns - Photos.

With concrete columns - Details.

5.5 Boundary Wall

Boundary Wall

ELEVATION

PLAN

SIDE VIEW SECTION

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5.5-a With concrete columns connection.5.5 Boundary Wall

CORNER COLUMN MIDDLE COLUMN

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5.5-b With steel columns - Photos.

With steel columns - Details.

5.5 Boundary Wall

Boundary Wall

PLAN

ELEVATION

150/200X600X3000 PANEL HP

SECTION

150/200X600X3000 HORIZANTAL PACPANEL PH

IPE-180 FOR 150MM THK. PANEL

ELEVATION

PLAN

SECTION

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5.6 Blocks & Hordi - Photos.

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Blocks & Hordi - Details.

PLAN

DETAIL - A

DETAIL - B

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ARCHITECTURAL PRINCIPLESSTRUCTURAL PRINCIPLESAPPROVALS & CODES

6.16.26.3

48

3000

3000

600

1200

1200

Lintel

Window

VP UnderWindow

200 mm

20 mm

Wal

l

600 600 600 600

200

2p

Wal

l

Wal

l

Wal

l

Maximum 6000 mm75 mm

6.1 Architectural Principles1. Vertical wall panels, floor slabs panels and lintels combine to form complete precast system as load

bearing structure buildings.

2. The maximum span of A.A.C panels is 6m that is mean maximum clear span dimensions between the load bearing walls should not exceed 5.80.

3. We will use a steel or concrete beam to support the slabs if the clear span more than 5.80.

4. Upper wall panels, direct wall on floor slabs is not allowed without steel or concrete support beams but you can put 10 cm thickness non bearing partitions after structural calculations approved.

5. We prefer 3 meters storey heights, because we get full mould utilization and can quote better prices. See Ideal section.

6. Try to design according to 600 mm module for zone dimensions or for windows openings.

7. Non modular windows openings width also can be formed with cut panels preferably 300 mm width.

8. Doors are generally made to sizes that suit but we prefer not exceed 2200 mm in height and 1000 mm in width.

9. A.C units are wider than 600 mm through (between) the wall panel, this best and easiest positioning.

10. Exhaust fan opening: opening for exhaust fan ducts are best centered on wall panel joints.

11. Lintels supports: do opening space with sufficient supports, we prefer 600 mm for both sides but you can use End Bearings 300 mm when necessary as minimum.

Architectural Ideal Section

6DESIGN

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6.2 Structural principles

1. AAC structural material approximately less than one quarter the weight of conventional concrete, which reduce the foundations volume, so we often use a strip ground foundations for AAC buildings.

2. The foundation should be made high enough such that the wall panels will not catch the soil.

3. Vertical wall panels (VP) are reinforced for load bearing applications. Table 6 – 1 shows permissible compressive stress on vertical wall panels (VP) based on ACI codes. And table 6-2 show the maximum length of VP & HP with various design lateral loads.

4. Lintels used as load bearing members over window and door openings for external or interior walls, tables 6-3 & 6-4 shows the maximum clear span of lintels with design loads.

Table 6-1 Permissible Compressive Stress

Table 6-2 Maximum Length Of Wall Panels with various lateral loads.

Thickness(mm)

Maximum Length of Wall Panels design wind load (n/m2)

800 1200 1600 2000

75 250 cm - - -

100 400 cm 375 cm 325 cm 275 cm

125 500 cm 475 cm 450 cm 400 cm

150 600 cm 475 cm 550 cm 500 cm

175 600 cm 600 cm 600 cm 575 cm

200 600 cm 600 cm 600 cm 600 cm

225 600 cm 600 cm 600 cm 600 cm

250 600 cm 600 cm 600 cm 600 cm

300 600 cm 600 cm 600 cm 600 cm

Table 6-3 Maximum Clear Span of (LP) With Various Design Loads

Design LoadThickness of Lintel Panel LP (600 mm height)

100 150 200 250 300

5000 n/m 250 cm 450 cm 450 cm 540 cm 600 cm

10000 n/m 200 cm 325 cm 400 cm 450 cm 500 cm

15000 n/m 100 cm 275 cm 325 cm 375 cm 410 cm

Table 6-4 Maximum Clear Span of (LX) with Various Design Loads

Design LoadThickness of Lintel Box LX (250 cm height)

100 150 200 250

5000 n/m 250 cm 350 cm 360 cm 360 cm

10000 n/m 150 cm 250 cm 260 cm 265 cm

15000 n/m 75 cm 200 cm 210 cm 210 cm

Permissible Compressive Stress (Newton/cm2) at the following Wall

Wall Height(m)

Thickness (mm)

100 150 200 250

2.50 53 65 68 69

2.75 47 63 67 69

3.00 40 61 66 68

3.75 12 53 63 66

4.00 - 49 61 66

4.50 - 40 58 64

5.00 - 29 53 61

5.50 - 16 47 58

6.00 - - 40 55

6- D

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50

5. AAC PAC slabs attain their design strength during the high – pressure steam curing process in the autoclaves. Thus slabs can be erected and ready for occupancy use immediately after delivery to the site. Slabs are reinforced with double steel welded mats and anticorrosion coated. FSP & RSP slabs are produced in various thickness and spans depending on the required load bearing capacities. The table 6 – 5 shows the permissible spans of slabs with different design loads.

Design impossed

DL+LL (n/m2)

Permissible Spans (mm) of Various Slab Thickness and Design Loads

100 150 200 250 300

1100 n/m2 4250 6000 6000 6000 6000

1600 n/m2 4000 5750 6000 6000 6000

2100 n/m2 3500 5500 6000 6000 6000

2500 n/m2 3500 5250 6000 6000 6000

3000 n/m2 3250 5000 6000 6000 6000

3500 n/m2 3000 4750 6000 6000 6000

4000 n/m2 2750 4500 5750 6000 6000

5000 n/m2 2500 4000 5250 5750 6000

6. For 20 cm wall thickness the minimum required End Bearing are 75 mm and 60 mm for 15 cm wall or steel supports.

Table 6-5 Permissible Spans by (mm) of Various Slab Thickness and Design Loads

Typical vertical joint profile at AAC lintel Wall section for multiple stories

ACC Load Bearing Wall

AAC Supporta ≥ 60 mmb ≥ 30 mm

a b a

6- D

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A.A.C materials approved by Saudi Government Authorities like Municipality, Civil Defense, Royal Commission, Aramco, SCECO, Health ministry, SASO ....etc.A.A.C materials are supported (Covered) by several international codes like:-

6.3 Approvals & Codes

ACI ASTM

SASO Green Building Council

7- E

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ION7ERECTION

Man PowerConsumablesTools & EquipmentsErection Procedures

7.17.27.37.4

54

7.1 Man powerIn normal cases with PAC complete systems as residential ( Housing ) 3 floor stories projects the ideal work group like this:-

Crane 20 tons with its operator -

Crane regards 1

Mark number labor 2

Technical erectors 3

Labor erectors 3

Level & repair plaster worker 2

Grout & ring beam labor 2

Supervisor 1

Man power total 14

Notes• This group produces approximately 30 cubic meters as a range per day. • Must be provision all PAC material, consumables, tools and auxiliary materials in site before works starting.• Normal to need 10-15 ton crane depends on projects conditions & requirements. • Installation increases ascending up to reaches the indicated rate.

7.2 ConsumablesWe want Erictions Required Consumables approximately as follows

7-2-1 Panels glue mortar: 1m3 x 10 Kg

Note: PAC glue mortar = 25 Kg

7-2-2 Panels Repair mortar: 1m3 x 4 Kg

7-2-3 Blocks mortar: 1m3 x 30 KgNote: For block masonary

7-2-4 Sand papers: 1m3 x 0.06 L.m

7-2-5 Fiber glass tape:•For panels 20 thickness: 1m3 x 17 L.m•For panels 15 thickness: 1m3 x 23 L.m•For panels 10 thickness: 1m3 x 34 L.m

Note: 1 roll = 90 L.m

7-2-6 Bounding agent: fiber glass tape L.m X 0.6 Kg

7-2-7 Ring beam steel: 1m3 x 2.2 Kg(ø10mm steel)

7-2-8 Starter bars & top bars: 1m3 x 3.5 Kg (ø10mm steel)

7-2-9 Stretch dowels bars: 1m3 x 0.15 Kg (ø 6mm steel)

7-2-10 Grout & ring beam cement: 1m3 x 14 Kg cement

7-2-11 Plastic wedgies: 1m3 x 2 pieces

7ERECTION

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7.3 Tools & equipments

7.4 Erection Procedures

The following tools are provided for PAC material erection:

1- Hook 2- Wall Braces 3- Lever 4- Nipper

5- Slabs Clamb 6- Sling 7- Lintel Grab 8- Saw

1. Foundation:Note that R.C foundationmust be cast with right angels and smooth level surface to receive the precast panels.

2. Delivery:Check panel layout of approved Pac shop drawings and deliver panels to jop site accordingly nearest to where they will be installed.

3. Corner:Select corner to start and check carefully its per perpendicular (ninetieth ) angle.

4. Layout:Mark the layout of the wall on top of the concrete foundation by using chalk lines

5. Starter bar:Drill for 10 mm dowels in foundation (Ground Beam) at each joint panels or put the dowels in their positions when casting the foundation

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6. Glue mortar:Mix the glue as per manufacturer’s instructions then put the mixture as bed for the wall panels.

7. Lifting:Select the wall panels (VP) as per mark numbers shown on shop drawings then lift it by hock tool and bed the panels on glue mortar. Don’t forget that erection should start from a corner tacking care to fit the panels lightly together.

8. Alignment:Use the nylon offset lines and aluminum straight edge to ensure the alignment, plumb and leveling for face panels inside & outside.

9. Wall Braces:Put one wall braces with horizontal stage wood at every 3 panels to make it stable and steady.

10. Dowels:Hummer steel dowels of 0 5mm x300 mm long between top the panels as stitches.

11. Grouting:Fill the groove channels between the panels by wetting cement sand grout (1:3) and then put steel dowels (starter bars) for next work.

7.4 Erection Procedures

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12. Lintels:Fix the lintels by lintel grab tool using the glue & steel dowels.

13. Leveling:Settle mortar on top of wall & lintels panels to provide a true level bearing surface for floor or roof slabs panels.

14. Slabs:Place carefully the slabs panels by grab tool on level leveled wall panels and connect the tongue with grove panels together by cramp tool.

15. Ring Beam:Cast the reinforcement ring beam as the connection details and fill the notches formed above roof slabs panels.

7.4 Erection Procedures

8- F

INIS

HES

8 FINISHESRepairingPainting on AAC PanelsFinishes photos on AACRoofElectrical/ PlumpingFixing on AAC materialConsumables use in erection & finishing works

8.18.28.38.48.58.68.7

60

Slight damages such as chipping, cracks, holes and conduit openings in the panels surfaces or the edges are normal and can be repaired as follows:-

1. Deep holes or deep conduit openings can be filling with ordinary cement mortar mixed with bound agent. Then paste fiberglass on the repaired sur-faces Show Fig. No.1

2. Shallow damages or small openings can be filling with PAC glue mortar directly.

8.1 Repairing

8.2 Painting on AAC Panels

8.1-b

8.1-a AAC damaged panels which are structurally defective or which would impair strength of the panel or its structural integrity should be rejected, in addition any cropped slabs or lintels should be rejected and replaced with new panels.

Glue

A

B3cm

CementMortar

Fig No.1

8.2-a Wall PanelsAAC PAC Panels do not need plastering works so finishes work can be started immediately after closure of all the openings and after repairing all the damages.

Procedure for painting on PAC walls as follow:-

1. Clean the surface and remove all loose and dirty material.

2. Make sanding complete surfaces by sand papers or sand machine, it should be carefully done as these is very important step to get a good finishes on AAC surfaces.

3. Clean the surfaces by water and remove the excess dust or powder.

4. Use the bounding agent to tape the fiber glass on the panel joints and on the openings which are closed or repaired by mortar.

5. Apply primer coat on the surface.

6. Apply 2 coats of putty layers on the surface.

7. Apply the last finishing layer by choice paints or any designed textures.

8 FINISHES

8- F

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V-grove ceiling can be finished by spray paints directly but non V-grove should follow the steps same as AAC wall panels painting procedures in 8.2-a.

AAC material can receive any finishing material.

8.3 Finishes photos on AAC

8.2-b Ceiling

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8.4 RoofPAC roofs slabs need to make water proof; the following section shows the ideal layer finishes on top of PAC roof slabs

8.5 Electrical/ PlumpingElectrical/ Plumping conduits are cut by hummer or by cutting machine like Makita or equivalent.

ROOF FINISH LAYERS SECTION

8- F

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63

ElementAnchor Length

Screw Length

7

8.6 Fixing on AAC materialThe bolt with plastic plug recommended for fixing on AAC materials or by AAC nails.

Recomended anchores (Fisher, Hilti, Thorsman,Tox VLF, Universal, .... etc )

Ideal installation steps by fisher anchors

Permissible loads of some suitable fixing to AAC:-

AAC nails

Type Designation Permissible Tension Permissible Shear

Cut nails 100 mm long 10 kg 25 kg

125 mm long 12 kg 35 kg

150 mm long 18 kg 40 kg

Hilti HGN 8 30 kg 35 kg

HGN 10 50 kg 60 kg

HGN 12 65 kg 70 kg

HGN 14 80 kg 80 kg

Fisher S 10 18 kg 40 kg

S 10 H 90 40 kg 80 kg

S14 50 kg 100 kg

S 16 60 kg 120 kg

1

6

2

5

3

4

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8.6 Fixing on AAC Materials

8.6-A Aluminum door/ window fixing on AAC

8.6-B Wooden door fixing on AAC

8.6-D Wisher fixing

8.6-C Pipe fixing above AAC wall

8.6-E Tile fixing by tile glueBy ordinary tile glue using.

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65

8.6-F Marble fixing

BoundingAgent

8.7 Consumables use in erection & finishing works.

For Panel Fixing8.7-A PAC GLUE:

For Block masonry without cement mortarRepair damaged panels, filling openings & conduct.

SECTION ELEVATION

PRESPECTIVE

8.7-B PAC MORTAR:Added to cement mortar for masonary or plastering. Paste fiber glass.

8.7-C Bounding agent:

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9 OUR PROJECTSMaskan Arabia ProjectAl Dar ProjectOther Projects

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Project Client Contractor Consultant Year

1 Al Zenia Tower Al DAr Al Dar Laing O'Rouke Turner 2009

2 Burj Al Yaqut Rasyat Real State Belbadi Hanouver 2009

3 Al Reef Villas Manazel Fibrex Crang & Boake 2009

4 Park Hyatt Hotel AHDN/TDIC Alec Ehaf 2010

5 Khalifa Port Industrial Zone

Abu Dhabi ports company

Al Masaood Bergum Dutco 2010

6 Mubarak Juma Tower

Mubarak Juma Al Khaily Al Fusaifesa Tameer 2010

7 Yazeem Villas Private Villa Al Yazeem constructions Tameer 2010

8Development Projects in Sir Bani Yas

TDIC ASTCC-LLC Atkins 2010

9 Al Falh community Al Dar SPK constructions Turner 2010

10United Printing Press Labor Accommodation

United Printing Press Alba Tech Tameer 2011

11 64 Villas In Riyadh Maskan Arabia Maskan Arabia Hatmia 2011

12 30 Individual Villas Different Project and Locations

13 Export to GCC Kuwait, Qatar,Oman and Iraq

9 OUR PROJECTS

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9.1 Maskan Arabia Project in Riyadh

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9.2 Al Dar Project

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9.3 Other Projects

This technical ESPAC catalogue prepared by technical & projects dept. manager,for any notes contact him on tamer@espac.com, or visit www.espac.com

*

KhobarTel. : 0096638631111Tel. : 00966546060651Fax. : 0096638632222

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Tel. : +9661 46 288 30Fax : +9661 29 303 04

P.O Box 25507Riyadh 11476Saudi Arabia

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