Table of Contents. 1 Introduction. 2 Description. 3 Tools and materials. 4 Footings or slabs. 5 Coursing placement. 6 Reinforcing steel

Transcription

1 Table of Contents 1 Introduction 2 Description 3 Tools and materials 4 Footings or slabs 5 Coursing placement 6 Reinforcing steel 7 Alignment scaffold installation 8 Concrete placement 9 Exterior and interior finishes 1

2 1 Introduction This manual is a guide for the contractor or installer of the Amvic Building System. This manual is intended to supplement the basic construction knowledge of the professional. Structures built with the Amvic Building System must be designed and erected in accordance with all applicable building codes and regulations. We believe the Amvic Building System is the best insulating concrete forming system available today. Competitive pricing, product distribution and technical support combine to provide our clients with a simplified approach to a superior finished product at an installation cost less than that of other comparable systems. We at Amvic Inc. thank you for choosing Amvic Building Systems and look forward to working with you. 2 Description Amvic Building System is a stay in place insulating concrete wall forming system that consists of expanded polystyrene panels connected by plastic webs. The system combines the insulating effectiveness of expanded polystyrene (EPS) with the advantages of a reinforced monolithic concrete wall. The EPS has a built in flame retardant agent and is manufactured at a 1.5 pcf density (type II). When filled with concrete, the Amvic Building System delivers a monolithic concrete wall thickness of 4, 6 and 8, an insulation value of R- 22, a fire resistance rating of three hours, and a sound transmission class of 50. Amvic Building System consists of 48 x16 straight forms, left and right 90-degree corner forms, left and right 45-degree corner forms. The plastic webs that are on 6 centers have three rebar support slots able to accommodate up to two horizontal #5 ( 15 mm ) bars. This feature eliminates the need to tie horizontal reinforcing. Each web has two end plates or studs on both sides of the block that can be used for attaching of interior and exterior finishes. The 90-degree corner block has a pocket in which a square plastic tubing Fig.2.1 Inserting of Amvic 1 x1 (Amvic Corner rod ) may be inserted Corner rod and used for mechanically attaching finishes. 2

3 The forms have a preformed interlocking mechanism on top, bottom and end edge to secure courses together, prevent movement of the forms during concrete placement, and prevent concrete leakage. 3 Tools and materials 3.1 Tools list Hand Saw Power Saw Keyhole Saw Table Saw (optional, for convenience) Hammerdrill, Cordless Drill Rebar tie tools Hot Knife, Router Hammer Carpenters Apron Framing square Concrete tools Level Laser Level Plumb Bob Mason s Line and Chalk Line Rebar Bender and Cutter Scaffold Planks Wall Alignment System Concrete Vibrator, 1 maximum 3.2 Materials list Reinforcing as required plus accessories, e.g. rebar ties, stirrups. Screws (1 5/8 inch, 2 ½ inch, #10 course thread), Concrete Screws 1 ¾. Do not use fine thread screws, as they will not hold in the built-in studs/strapping. Use only coarse thread screws. Material for rough openings (i.e. 2x12, 2x3 and 2x2 lumber or plywood for fabricating wood bucks, anchors e.g. spikes, anchor bolts or nails) Sleeves for mechanical and/or electrical. Polyurethane gun type low expansion foam ( spray foam ). 3

4 3.3 Estimating For an estimate follow these steps. 1. Determine wall height divide by 16 and round up. This is the number of courses required. 2. Count the number of 90-degree corners in the structure. Determine the number of 90-degree corner forms required (multiply the number of 90-degree corners in the structure by number of courses required as calculated in step 1 ). Note that each course must alternate left or right forms. 3. Count the number of 45-degree corners in the structure. Determine the number of 45-degree forms required (multiply the number of 45-degree corners in the structure by number of courses required as calculated in step 1 ). Note that each course must alternate left or right forms. 4. Determine the square foot area of wall to be formed, subtract 4.43, 3.33 or 3.33 (for 4, 6 or 8 forms) square foot for each 45-degree corner form to be used and 4.88, 4.0 or 4.44 (for 4, 6 or 8 forms) sq. foot for each 90-degree corner form. Divide remaining square footage of wall by 5.33 to determine the number of straight forms required. Add a small amount of forms for possible waste. 5. Estimate the concrete volume required by the following: Divide total square footage of wall to be formed, including corners, by 78, 53 or 40 (for 4, 6 or 8 forms). This equals to the number of cubic yards of concrete required. Add additional for waste and pump. 4 Footings or slabs Footing or slabs must be level in all directions for best results (within ¼ in all directions). When pouring footings or slab place reinforcing dowels as Project Engineer and/or local building code requirements. Place dowels at 4 ½, 4 ¾ or 5 (for 4, 6 and 8 forms) from outside edge of Amvic forms, spaced as required. Dowels should be set so that they do not interfere with the webs. Where a step footing is required we recommend that the step be set at 16 to align courses. 5 Coursing placement Prior to setting forms, determine the exact wall height required for the project. If the wall height required is not divisible by 16 then one or two courses may need to be rip cut. When determining rip cuts, care must be taken to preserve all cross web members. 4

5 Build first coursing - set corner forms - set straight forms, starting from corners to the center of the wall or a window or door location. - cut the final form to be placed on the wall. Cut must be made at a 2 increment line (center between two interlocks). To accommodate this some wall dimensions may need to be adjusted slightly if possible. If it is not possible to adjust wall dimensions a stack joint will be created. If so, additional bracing will be required. Fig. 5.1 Cutting forms. Fig.5.2 Cutting forms. Build second course in the same manner as the first course. Vertical joints of all coursing must be staggered by a minimum of 12. Create a stagger of vertical joints by alternating the use of left and right corner forms. Fig.5.3 Setting forms. Fig.5.4 Setting forms. 5

6 For footings or slabs that are out of level, use foam cuttings as shims to level the wall at every vertical joint of the forms. Once the first two courses have been set use low expansion foam adhesive to set shims in place. Once the wall has been leveled and checked for square, use low expansion foam adhesive to glue the base of the wall to the slab or footing. Glue only the side of the wall that will have the wall alignment system attached. After two courses have been set remove forms at door openings. The forms have to be set through the door opening initially in order to maintain the interlock. Cut the form ½ greater than the opening. This allows for minor adjustments. Set all courses the same way as the first and second, cut forms at window openings, place reinforcement as required. Fig.5.5 Setting forms around openings Using the Bracing System brace the walls at 6 intervals and 2 at corners (see fig.7.2). A string line should be set at each corner. Adjust walls to the string line. Ensure that each corner is plumb and square. Check the walls thoroughly for any unsupported cuts. Brace or glue as needed. Check to ensure all utility penetrations have been installed, including dryer vent, etc. Fig.5.6 Adhering of exterior wall to base. Fig.5.7 Sealing window buck to forms. 6

7 Use foam adhesive sealant such as EnerFoam 42 to adhere exterior wall to footing or base. Seal window and door bucks to the Amvic forms after ensuring they are set plumb and square. T corners are field cut if you need them. Remove 9,11 or 13 (for 4,6 or 8 forms) of EPS from the wall that is being intersected and make T connection. Glue forms at this connection. A vertical brace must be used on the opposite side of the intersecting wall. This brace should have 3 diagonal supports to resist the pressure of the concrete to move the wall. 6 Reinforcing steel For reinforcing placement follow requirements of the Project Engineer and/or local building codes. Note that horizontal reinforcing must be placed as the Amvic forms are stacked. Snap the horizontal reinforcing into the grooves of the web for the first course. Place the rebar in the gripper of the web closest to the EPS panel. In the second course, for which horizontal rebar is specified, stagger the position so that the bar is placed in the next gripper toward the center of the web. In the third course where horizontal rebar is specified, the rebar should be placed directly above the first bar. Continue to stagger in this manner. By staggering the horizontal rebar in this way, one can slide the vertical bar (not drop) through the horizontal reinforcing after stacking of the formwork. Horizontal reinforcing will hold the vertical bar in the correct position. By staggering the reinforcing in this way, you can place vertical bars close to the EPS panel, which is usually required for basements. For above grade walls in most cases you have to place vertical bars in the middle of the wall and stagger horizontal bars in the grooves next to the center of the wall. In all cases follow project specifications including local building code requirements. Fig.6.1 Reinforcing stagger. Fig.6.2 Inserting vertical bar. 7

8 If the walls will be continuing upwards beyond the level of the first concrete pour, follow conventional forming practices by extending the height of the vertical rebar, or planning for appropriate placement of steel reinforcing dowels in the wet concrete of the first pour. This will add integrity to the cold joint. Make overlap splices equivalent to 40 times the bar diameter (or as per local building code) to ensure that the reinforcing strength is continuous in its capability to carry building loads. If the top course of the block is rip cut, be certain that the top horizontal reinforcing will have a minimum 1 concrete cover. 7 Alignment Scaffold Installation Most manufactured alignment systems are comprised of 5 main components. Diagonal braces (which are typically adjustable), uprights or vertical whalers, guardrails, platform brackets, and planking. We advise checking with the local Amvic representative to ensure that the system you are going to use is well matched. After stacking four courses the alignment scaffold is typically installed. Make sure that the wall is fastened to the uprights at every other course. If this is not done, the walls between the fasteners may bow. Do not fasten the alignment system to the top course forms. Always fasten the alignment system to the two closest ties of one form. Bracing /alignment systems that fasten to one set of ties per form are not advised; deflection of the wall may result. Fig.7.1 Fastening the alignment system to the forms. Fig.7.2 Alignment system. 8

9 8 CONCRETE PLACEMENT Prior to pouring concrete in Amvic Building System forms use the following checklist. Are walls straight, plumb, square and level? Are window and door openings located correctly and plumb and square? Is reinforcing steel placed in accordance with Project Engineer and/or local building code requirements? Is alignment and scaffold system installed properly? Have all penetrations (i.e. electric, plumbing, HVAC, dryer vent) been accommodated? Is the concrete ordered acceptable for the method of placement and engineering or code requirements? Have anchor bolts and tie down straps been located and/or marked? Have beam pockets been provided? Pour concrete by chute (below grade), boom pump or line pump. Fig.8.1 Placing concrete with a boom pump. 9

10 In order to reduce the concrete velocity when utilizing a concrete pump it is essential to place 3 reducers (fittings that decrease the diameter of the hose) and angle fittings near the end of the hose. To prevent spontaneous surges of concrete, be very careful when utilizing a chute. It is suggested that a funnel be placed at the end of the chute in order to slow down the flow of concrete prior to it entering to formwork. The concrete mix design should only include 3/8 or 1/2 aggregate size and a 5-6 slump. It is important to dump the pump prime (sludge that initially comes out of the hose) outside of the formwork or back into the pump when initially preparing the concrete pump.. Pour heights of up to ten feet are possible if the formwork is correctly installed. Concrete should be placed with a constant, moderate and steady flow, using two or three passes for pour heights up to eight-ten feet. It is necessary for the crew to spot walls for alignment as the pour takes place. Final alignment of each wall must be performed before the concrete has set. Fig.8.2 Placing and vibrating concrete 10

11 Begin at a corner and pour towards the midpoint along a wall. Run a one-inch pencil vibrator between webs to the bottom of every lift as the pour continues. To avoid blowouts of the formwork, do not utilize vibrators bigger than one inch. Window and door bucks should not be fully filled on one side at one time. Fill both sides of the opening using a back-and -forth rhythm. As the pour continues, make sure that the space below the bottom of any window opening or pipe sleeve is filled entirely. Continue filling the walls as quickly as possible to eliminate the possibility of cold joints and to make wall alignment adjustments simple. Do not terminate the initial pour at the top of the formwork when the Amvic Building System will be utilized beyond the level of the initial concrete pour. Keep concrete level down one inch or more. An excellent bond will develop by leaving the concrete unfinished. Anchor bolts should be put into the wet concrete after finishing. 9. Exterior and Interior Finishes 9.1 Waterproofing In today s market, there are numerous waterproofing products. Amvic Building System recommends Polyguard or Elastoseal 2000 membrane. The membrane must be installed as per manufacturer recommendations. A protection barrier should be used depending on the backfill material being utilized. During the backfill procedure the barrier will provide protection from rocks that may penetrate the membrane. Fig.9.1 Polyguard membrane placement 11

12 9.2 Exterior Finishes Acrylic stuccos that are applied on EPS in traditional construction methods are compatible with the Amvic Building System. Siding may be attached directly to the internal studs or to strapping. The studs are six inch on center and are 1 ½ wide. The studs are recessed in the EPS panel centered behind the larger deep groove on the Amvic forms. To permit securing at the corner for steel, vinyl, or wood siding an Amvic Corner Rod is placed into the preformed pocket in Amvic corner forms as the formwork is being built. Masonry veneers are secured to the Amvic wall with conventional masonry ties that are fastened with appropriate screws to the Amvic studs. Brick ledges are accommodated by various methods such as steel angles, tapered forms, etc. 9.3 Interior Finishes Drywall or gypsum board is the most common interior finish material. Use coarse thread drywall screws. The built-in studs are a standard 1 ½ wide, located at six inches on center. They are indicated by a deep groove on the exterior of Amvic Forms. 12