Bautex Wall System. Design & Engineering Guide

Transcription

1 Bautex Wall System Design & Engineering Guide TM

2 BAUTEX IS A HIGH-PERFORMANCE COMPOSITE CONCRETE WALL SYSTEM THAT MEETS THE DEMANDS OF TODAY S RETAIL, HOSPITALITY, OFFICE, MEDICAL, AND GOVERNMENT BUILDING PROGRAMS. EXCEEDING THE DEMANDS OF DESIGN The Bautex Wall System is based on the Bautex Block, which is made from a unique insulating composite material that utilizes 90% recycled components. The Bautex Block is used to construct structurally reinforced concrete walls with integrated insulation that provide superior strength, durability, energy efficiency and design flexibility, all at competitive first costs versus traditional building methods, while providing long-term operating and life cycle value. As part of a complete commercial wall system, Bautex provides the technical resources and support needed to successfully design and construct the Bautex Wall System. The purpose of this Design & Engineering Guide is to provide architects and engineers with an overview of the design characteristics, performance specifications, construction methods, exterior finish options, and engineering tables and theory. Additional resources including 3D Revit models, 2D AutoCAD details, CSI Master Guide Specifications, product data sheets, Material Safety Data Sheets, and installation manual are available for download at

3 TABLE OF CONTENTS DESIGN AND PERFORMANCE Structure Design Flexibility Thermal Fire Sound CONSTRUCTION METHODS Construction Steps Construction Support EXTERIOR FINISHES Masonry Stucco Rain Screen DESIGN & ENGINEERING Theoretical Design Tables Testing & Certifications

4 DESIGN AND PERFORMANCE STRUCTURE The Bautex Block is a non-structural element with hollow circular cores and half cores that, when stacked together and filled with rebar and structural concrete, form an open grid of 6-inch cylindrical columns and beams on 16-inch centers. This grid structure requires significantly less concrete than traditional flat concrete wall construction, and, as a result, the system provides substantial strength while decreasing weight and reducing costs. The Bautex Block remains in place after the concrete is poured to become the insulating component of the wall system. The Bautex Wall System can be used to construct: Structural exterior walls Interior demising walls Non-structural curtain walls Below grade walls Sound walls Structural design of the Bautex Wall System is based on ACI For details on theoretical load calculations, refer to the Theoretical Design section at the end of this guide.

5 DESIGN FLEXIBILITY The Bautex Wall System provides a simple and flexible building solution that opens up new design possibilities. Architects and engineers can utilize this strong, light, versatile material to create innovative and effective building designs by incorporating a variety of design elements, including: Arches Radiused walls Non-standard corner angles Extended window and door openings Custom beams and lintels Columns and pilasters All of these design elements can be created by cutting and shaping the standard Bautex Block elements at the job site using standard construction tools. There is no need for any specialty blocks or accessories other than what is required to brace and support the wall section until concrete pouring is completed. THERMAL The combination of insulation, air barrier and thermal mass allows the Bautex Wall System to deliver extreme thermal efficiency and indoor air quality that is superior to buildings constructed with traditional methods and materials. The Bautex Wall System creates a solid 10- inch thick, continuously insulated wall that eliminates infiltration of outside air into the structure through the wall envelope. This, along with the ability of the concrete wall to to delay heat or cold transfer, allows the building s heating and cooling system to be much more energy efficient compared to structures using traditional wall systems with similar static R-values. ASTM C518: Standard Test Method for Steady-State Thermal Transmission Properties by Means of the Heat Flow Meter Apparatus. R-value: 1.84/in.

6 DESIGN AND PERFORMANCE FIRE The Bautex Wall System delivers lab-tested fire-resistant characteristics exceeding standards set forth by the National Fire Prevention Association, and is approved and certified for use in virtually all commercial construction types. The Bautex Wall System has been tested following standard prescribed test methodologies outlined by ASTM and NFPA and certified by QAI Laboratories, a premier third-party testing organization. SOUND The Bautex Wall System s custom engineered composite material, air tightness and concrete mass create sounddeadening walls that enhance any work or living space. The Bautex Block significantly reduces ambient noise from the surrounding environment and creates a quiet work or living space in any location. The Bautex Wall System can be effective at controlling noise transmission in both exterior and interior wall applications. NFPA 286: Standard Methods Of Fire Tests For Evaluating Contribution Of Wall and Ceiling Interior Finish To Room Fire Growth. Unfinished Bautex Wall: Passed Finished with 5/8 gypsum board: Passed ASTM E84: Standard Test Method for Surface Burning Characteristics of Building Materials. Flame Spread = 0 Smoke Development = 20

7 The Bautex Block holds up to direct, high-intensity flame.

8 Step 1: Place blocks. Step 2: Install steel reinforcement. CONSTRUCTION METHODS CONSTRUCTION STEPS Construction of the Bautex Wall System is simple and straightforward, utilizing existing construction techniques, skills, and tools. In many cases, the Bautex Wall System can be installed with less labor, less heavy equipment and on a faster schedule than traditional wall systems. The Bautex Wall System can be installed in four easy steps: Step 1 Place the Blocks Blocks are laid end-to-end starting from one corner until a full course is completed. Blocks are glued together to provide temporary alignment until the cores are filled with concrete. Wall penetrations and design details are easily formed as the courses are placed. rebar chairs and tie wire as courses are laid. Vertical reinforcement bars are placed within each vertical block core and tied to the horizontal bars once the full height of the wall has been reached. Step 3 Brace and Pour Concrete: Once the walls are braced and inspected, the hollow cores formed by the blocks are poured with high-flow structural concrete. Step 4 Apply Barriers and Finishes: In the final step, attachments, air and moisture barriers and finishes are applied on interior and exterior wall surfaces. Step 2 Install Steel Reinforcement Horizontal reinforcement bars are placed within each horizontal block core using commonly available

9 Step 3: Brace and pour concrete. Step 4: Apply barriers and finishes. CONSTRUCTION SUPPORT Bautex provides start-to-finish support on every project, and will provide help when needed to ensure a timely and successful implementation. Bautex will make sure your building crews understand exactly how to use the Bautex Wall System to ensure mastery of installation for realizing immediate and long-term benefits. Bautex personnel can be on site, whenever and wherever they re needed to answer questions and provide technical support as a part of your design and construction team.

10 EXTERIOR FINISHES : MASONRY The Bautex Wall System easily integrates with Masonry Cavity wall construction. Virtually all elements of this assembly follow traditional building methods and practices from the masonry ties to the flashing, moisture barrier and weep holes. 1. Bautex block 2. Reinforced concrete filled cavity 3. Bautex air and moisture barrier over parge coat per installation guide. 4. Reinforced concrete to be field formed as required. 5. Window system 6. Interior wall system 7. Masonry system 8. Masonry tie 9. Roof structure 10. Membrane roofing

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13 EXTERIOR FINISHES : STUCCO Finish of the Bautex Wall System with stucco is extremely straight forward. Any variety of moisture resistant stucco combinations will produce a long lasting beautiful wall that provides barrier to air and moisture penetration. The structural stability of the Bautex Block leads to the elimination of cracking and flaking sometimes seen in this finish with other structure types. THIN VENEER The Bautex Wall System provides a stable substructure for the application of directly applied thin veneer. The Bautex Wall System fits in with almost any commercially available finish system for thin stone veneer. 1. Bautex block 2. Reinforced concrete filled cavity 3. Scratch coat with integral moisture barrier 4. Reinforced concrete to be field formed as required. 5. Window system 6. Interior wall system 7. Stucco system 8. Roof structure 9. Membrane roofing

14 EXTERIOR FINISHES : RAIN SCREEN Installation of any commercially available rain screen or product applied to exterior furring systems can be done to meet the highest demands for wind or any other extreme loading condition. Due to the concrete core strength of the Bautex Wall System, direct attachment with commercially available concrete anchors is done easily and economically. 1. Bautex block 2. Reinforced concrete filled cavity 3. Bautex air and moisture barrier over parge coat per installation guide. 4. Reinforced concrete to be field formed as required. 5. Window system 6. Interior wall system 7. Rain screen system 8. Roof structure 9. Membrane roofing

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16 DESIGN & ENGINEERING : THEORETICAL DESIGN 6 CORE ICF BLOCK STRENGTH CAPACITY EQUATIONS Design Code: ACI Racking Shear Capacity: fv c = f *2* f c *b*d * (12 in/ft)*( 1/16 in) (lb/ft) ACI Eq fv c = Racking shear capacity. f = 0.75, Shear strength reduction factor. ACI Section b = b eq = equivalent wall thickness of 4-1/2 in. d = distance from centroid of compression zone to centroid of longitudinal tension reinforcement (inch) f c = Concrete compressive strength (psi) NOTE: These resources are intended as a design aid only and subject to change without notice; users are required to have a registered engineer independently review building requirements and use of Bautex products so that the design will comply with applicable building codes, safety standards, and construction practices.

17 Axial Compression Capacity: Axial compression capacity based on ACI Section for a compression member braced against side-sway. fp n, max = 0.8 * f * [ 0.85 *f c * (Ag Ast) + fy *Ast] ACI Eq fp n, max = Design axial compression strength (lb) f = 0.65, Compression strength reduction factor. ACI Section b A g = Gross area of concrete section (inch 2 ) A st = Total area of longitudinal reinforcement (inch 2 ) f y = 60,000 psi; Specified yield strength of longitudinal reinforcement. f c = Concrete compressive strength (psi) f K P c = π2*ei, Critical buckling load (lb) ACI Eq (k*lu)2 EI = flexural stiffness of compression member (inch 2 * lb) EI = (0.2*Ec*Ig+Es*Ise) 1+ bdns ACI Eq Ec = Concrete Modulus of Elasticity = 57,000* f c (psi) ACI Section Ig = Moment of inertia of gross concrete section. (inch 4 ) Es = 29,000,000 psi ; Modulus of elasticity of reinforcement. k = 1.0; Effective length factor for compression members. lu = unsupported length of compression member. ACI Section b dns = Ratio of maximum factored axial sustained load to maximum factored axial load associated with the same load combination. ACI Section b 0.4*Pu dns = ; Assuming factored axial sustained load is 40% of total factored load applied. Pu Pu = Factored axial load (lb) fk = 0.75; Stiffness reduction factor ACI Section R Cm dns = ; Non-sway moment magnifier. ACI Eq Pu fkpc Cm = * M1 M2 Factor relating actual moment diagram to an equivalent uniform moment diagram. ACI Eq M1 = Smaller factored end moment on a compression member. (ft * lb) M2 = Larger factored end moment on compression member. (ft * lb) M2 = M2, min = Pu * ( * h) h = Overall thickness of member. (inch) Cm = 1.0; Assuming M1 is equal to M2 and compression member is bent in single curvature. fkpc fpn, max Pu

18 f'c = 3.0 ksi #4 16" o.c. Maximum Allowable Axial Load (plf) for wind loads (psf) Wall Height (ft) ' 0" ' 4" ' 8" ' 0" ' 4" ' 9" Axial load assumed to be 40% dead load and 60% Live load. 2. Axial loads calculated with an eccentricity of 5 1/2" at the top of the wall. 3. Values based on ACI Section Moment magnification procedure Nonsway. 4. Values controlled by the Critical buckling load as determined per ACI Equation Effective length factor, k, equal to 0.9 for pinned conditions at the top and partial fixity at bottom. 6. Out of Plane deflection limit of L/360, shaded regions represent Out of Plane deflection limit of L/240. DESIGN & ENGINEERING : TABLES ALLOWABLE IN PLANE SHEAR CAPACITY OF 6 INCH CORE BAUTEX WALLS REINFORCED WITH #4 REBAR AT 16" O.C. CONCRETE COMPRESSIVE STRENGTH, f'c (PSI) ALLOWABLE IN PLANE SHEAR CAPACITY (PLF) For SI: 1 foot = 304.8mm; 1 plf = 14.6 N/m ALLOWABLE OUT OF PLANE SHEAR CAPACITY OF 6 INCH CORE BAUTEX WALLS REINFORCED WITH #4 REBAR AT 16" O.C. CONCRETE COMPRESSIVE STRENGTH, f'c (PSI) ALLOWABLE OUT OF PLANE SHEAR CAPACITY (PLF) For SI: 1 foot = 304.8mm; 1 plf = 14.6 N/m

19 f'c = 3.0 ksi #5 16" o.c. Maximum Allowable Axial Load (plf) for wind loads (psf) Wall Height (ft) ' 0" ' 4" ' 8" ' 0" ' 4" ' 9" Axial load assumed to be 40% dead load and 60% Live load. 2. Axial loads calculated with an eccentricity of 5 1/2" at the top of the wall. 3. Values based on ACI Section Moment magnification procedure Nonsway. 4. Values controlled by the Critical buckling load as determined per ACI Equation Effective length factor, k, equal to 0.9 for pinned conditions at the top and partial fixity at bottom. 6. Out of Plane deflection limit of L/360, shaded regions represent Out of Plane deflection limit of L/240. ALLOWABLE IN PLANE SHEAR CAPACITY OF 6 INCH CORE BAUTEX WALLS REINFORCED WITH #5 REBAR AT 16" O.C. CONCRETE COMPRESSIVE STRENGTH, f'c (PSI) ALLOWABLE IN PLANE SHEAR CAPACITY (PLF) For SI: 1 foot = 304.8mm; 1 plf = 14.6 N/m ALLOWABLE OUT OF PLANE SHEAR CAPACITY OF 6 INCH CORE BAUTEX WALLS REINFORCED WITH #5 REBAR AT 16" O.C. CONCRETE COMPRESSIVE STRENGTH, f'c (PSI) ALLOWABLE OUT OF PLANE SHEAR CAPACITY (PLF) For SI: 1 foot = 304.8mm; 1 plf = 14.6 N/m

20 f'c = 3.0 ksi #6 16" o.c. Maximum Allowable Axial Load (plf) for wind loads (psf) Wall Height (ft) ' 0" ' 4" ' 8" ' 0" ' 4" ' 9" Axial load assumed to be 40% dead load and 60% Live load. 2. Axial loads calculated with an eccentricity of 5 1/2" at the top of the wall. 3. Values based on ACI Section Moment magnification procedure Nonsway. 4. Values controlled by the Critical buckling load as determined per ACI Equation Effective length factor, k, equal to 0.9 for pinned conditions at the top and partial fixity at bottom. 6. Out of Plane deflection limit of L/360, shaded regions represent Out of Plane deflection limit of L/240. DESIGN & ENGINEERING : TABLES ALLOWABLE IN PLANE SHEAR CAPACITY OF 6 INCH CORE BAUTEX WALLS REINFORCED WITH #6 REBAR AT 16" O.C. CONCRETE COMPRESSIVE STRENGTH, f'c (PSI) ALLOWABLE IN PLANE SHEAR CAPACITY (PLF) For SI: 1 foot = 304.8mm; 1 plf = 14.6 N/m ALLOWABLE OUT OF PLANE SHEAR CAPACITY OF 6 INCH CORE BAUTEX WALLS REINFORCED WITH #6 REBAR AT 16" O.C. CONCRETE COMPRESSIVE STRENGTH, f'c (PSI) ALLOWABLE OUT OF PLANE SHEAR CAPACITY (PLF) For SI: 1 foot = 304.8mm; 1 plf = 14.6 N/m

21 DESIGN & ENGINEERING : TESTING & CERTIFICATIONS TESTING ASTM C518: Standard Test Method for Steady-State Thermal Transmission Properties by Means of the Heat Flow Meter Apparatus. TEST RESULTS R = 1.839/in. NFPA 286: Standard Methods Of Fire Tests For Evaluating Contribution Of Wall and Ceiling Interior Finish To Room Fire Growth. 5/8 Gypsum: Passed No interior finish: Passed ASTM E84: Standard Test Method for Surface Burning Characteristics of Building Materials. Flame Spread = 0 Smoke Developed = 20 NFPA Class A IBC Class A

22 Bautex Wall System Design & Engineering Guide 2013 Rev. 1 Bautex Systems, LLC 101 Thermon Drive, Suite 10 San Marcos, Texas USA T: info@bautexsystems.com , Bautex Systems LLC. All rights reserved. You are only permitted to download, possess, print, use, or reproduce this document if you have agreed to Bautex s Terms of Use ( This document is only a constuction aid; you are required to have a registered engineer independently review your requirements and certify that your plans and your use of Bautex products satisfy all applicable building codes, safety standards, and construction practices. You represent and warrant that you are not relying and will not rely upon any representation or statement from Bautex Systems or its personnel in determining whether, when and how to use a Bautex product; instead, you will rely solely on your own judgment and the advice you independently obtain from your own registered engineer and other licensed construction professionals. This document is subject to change without notice. TM The Bautex Logo, bautex, and all products denoted with or are registered trademarks or trademarks of Bautex Systems, LLC.