Agrément Certificate 2008/346 Subject: Automapolyblock Building System

Transcription

1 Agrément Certificate 2008/346 Subject: Automapolyblock Building System Copyright Agrément South Africa, October 2008 The master copy of this document appears on the website: Validity Users of any Agrément certificate should check its status: all currently valid certificates are listed on the website. In addition, check whether the certificate is Active or Inactive. The certificate holder is in possession of a confirmation certificate attesting to his status. Subject: Cemforce GRC Building System Certificate holder: Cemforce CC P O Box 1348 KIMBERLEY 8300 Telephone: Fax: & P O Box 378 BRANFORT 9400 Telephone: Fax: SANS The application of the National Building Regulations Quick guide Contents page 3 Preamble page 4 Conditions of certification page 5 Assessment page 7 Compliance with the National Building Regulations page 8 Technical description page 11 P O Box 395 Pretoria 0001 Telephone Fax agrement@csir.co.za Use The certificate covers the use of the Cemforce GRC Building System in all areas of South Africa for the erection of single storey buildings for the uses (SANS 10400: Table 1 of Regulation A (20) (1)) set out below: non-residential school buildings (A3) moderate and low-risk commercial service buildings (B2 and B3) moderate and low-risk industrial buildings (D2 and D3) small shops (F2) offices (G1) hostels, semi-detached, row and detached houses (H2, H3 and H4). This certificate and Agrément South Africa s assessment apply only to Cemforce GRC Building System buildings that are designed and erected as described and illustrated in this certificate, and where the terms and conditions of certification are complied with. Agrément Certificate 2008/346: Cemforce GRC Building System Page 1 of 21

2 General description The Cemforce GRC Building System utilises factory produced wall panels. The wall panels are 78±2 mm thick consisting of a polystyrene beaded concrete core with a dry density of 450 to 750 kg/m 3 encapsulated in 8mm thick skins of glass reinforced cement (GRC). The panel widths vary from 300mm to 1200mm and are 2,4m or 3,0m high. Polyvinyl chloride (PVC) conduits 15 mm diameters are cast running horizontally at the top and bottom of the panels. Galvanised mild steel anchor straps are cast into the bottom of the panels and wallplate anchor bolts in the tops of the panels. The concrete floor slab is conventional with thickened edge beams cast on a damp-proof membrane. Bitumen emulsion dpc is applied to the bottom of all wall panels prior to erection. Wall panels are placed in position, starting from a corner, and the anchor straps are secured to the floor slab with drive-in nails. Mild steel post tensioning rods are threaded through the PVC conduits to secure the wall panels to one another. The wallplate is a mild steel box section secured to the anchor bolts. Roof construction is conventional timber with light or heavyweight cladding. Insulated or uninsulated ceilings are always installed. Window and door frames are secured to bolts cast into the wall panels. Agrément Certificate 2008/346: Cemforce GRC Building System Page 2 of 21

3 CONTENTS PREAMBLE PART 1: CONDITIONS OF CERTIFICATION PART 2: ASSESSMENT Table 1: Safety and health Table 2: Habitability Table 3: Quality management system PART 3: TECHNICAL DESCRIPTION General description Technical description Manufacturing Erection Foundations and surface beds Walls Windows and door frames Roof structure and anchorage Ceilings Finishes and Services Agrément Certificate 2008/346: Cemforce GRC Building System Page 3 of 21

4 PREAMBLE This certificate is issued by Agrément South Africa in terms of the powers granted to it by the Minister of Public Works. This certificate: has been granted after a technical appraisal of the performance of Cemforce GRC Building System buildings for the uses covered by the certificate, is independent of any patent rights that may or may not subsist in the subject of the certificate, and does not relieve the certificate holder from the obligation to obtain the prior approval of the building authority concerned for the use of the subject. Agrément South Africa s opinion is that the quality and performance of the Cemforce GRC Building System will be satisfactory, provided that the requirements stipulated in this certificate are adhered to. However, Agrément South Africa does not on behalf of itself, or the State, or any of its employees or agents guarantee such quality or performance. Responsibility for compliance with the requirements of this certificate and the quality of the finished buildings resides with the certificate holder. No action for damages, or any other claim whatsoever, lies against Agrément South Africa, its members, the State or any of its employees should the said components and materials fail to comply with the standard set out in this certificate. Building authorities or users who are in any doubt about any detail or variation, should contact Agrément South Africa. The validity of this certificate is reviewed every three years. The certificate shall remain valid as long as Agrément South Africa is satisfied that: the certificate holder complies with the general and specific conditions of certification and the technical requirements stipulated in the certificate, the performance-in-use of the subject is acceptable, and any changes in building legislation, regulations, relevant standards or Agrément performance criteria have not invalidated the technical assessment which formed the basis of certification. Agrément South Africa reserves the right to withdraw the certificate at any time, should reasonable cause exist. Notices affecting the validity of this certificate will be published in the Government Gazette. Agrément Certificate 2008/346: Cemforce GRC Building System Page 4 of 21

5 PART 1: CONDITIONS OF CERTIFICATION Licensee - any person or company appointed by the certificate holder and registered with Agrément South Africa to construct Cemforce GRC Building System buildings in accordance with this certificate and authorized by him to claim compliance with the certificate. It is the certificate holder s responsibility to ensure that the licensee carries out the works in compliance with this certificate and in accordance with the approved quality management system. The Cemforce GRC Building System described in this certificate must: be designed by certificate holder be erected by the certificate holder or a licensee, registered with Agrément South Africa be constructed in accordance with the technical description (see Part 3) and the certificate holder s detailed specifications and quality management documentation, comply with the Conditions of Certification. Any person required to check on details of construction must refer to the documentation listed above, which is available from the certificate holder. The Cemforce GRC Building System is a combination of innovative and conventional construction. A change to any one aspect could result in one or more of the other aspects no longer complying with Agrément South Africa s performance criteria. For these reasons, no change may be made to the Cemforce GRC Building System as described and illustrated in this certificate unless such change is approved in writing by Agrément South Africa before it is implemented. Cemforce GRC Building System Tested and approved fit for purpose when constructed as specified in CERTIFICATE 2008/346 General conditions This certificate covers single storey buildings that comply with the dimensional and structural requirements as set out in Part 3 of this certificate: should those design limitations be exceeded, the structural design becomes the responsibility of a professional engineer who will prepare a rational design that: o o will ensure the structural integrity of the entire building adheres to construction details within this certificate for which the professional engineer monitors those aspects of the works that are covered by the rational design, to verify that the design is being correctly interpreted and that the construction techniques being used are appropriate to the stability of the subject. Marking A plaque at least 100 mm x 75 mm, with Agrément South Africa s identification logo together with the number of this certificate, as depicted, must be fixed at an appropriate position to an external wall of all Cemforce GRC Building System. Validity The continued validity of this certificate is subject to a satisfactory review by Agrément South Africa every three years. Agrément Certificate 2008/346: Cemforce GRC Building System Page 5 of 21

6 Quality monitoring The certificate holder is required to participate in Agrément South Africa s post-certification quality management system, which requires: that the certificate holder shall continue to implement and manage the quality management system approved by Agrément South Africa in the assessment of the Cemforce GRC Building System the co-operation of the certificate holder in facilitating postcertification quality monitoring by Agrément South Africa or its authorised agents. Reappraisal must be requested by the certificate holder prior to making changes to the building system will be required by Agrément South Africa if there are changes to the National Building Regulations or Agrément South Africa. This certificate may be withdrawn if the certificate holder or a registered licensee fails to comply with these requirements. Requirements of Supplement to certificates that must be met The Supplement to certificates: good building practice (revised 2001) applies to those conventional aspects of the Cemforce GRC Building System that have not been specifically assessed (see Part 2: Scope of assessment on next page). Cognisance should be taken of the recommendations contained in the Supplement to certificates to ensure that an acceptable standard of construction is consistently maintained. On behalf of the Board of Agrément South Africa Signed Chairman 22 October 2008 Agrément Certificate 2008/346: Cemforce GRC Building System Page 6 of 21

7 PART 2: ASSESSMENT The conventional aspects of the construction are subject to the rules of good building practice (typically as described and illustrated in Agrement South Africa s Supplement to certificates and in the Home building Manual Parts 1, 2 & 3 issued by the National Home Builders Registration Council), and must comply with the National Building Regulations. For details see Agrément South Africa s Assessment criteria: building and walling systems Republic of South Africa. National Building Regulations, Government Notice R. 2378, Government Gazette No 12780, Pretoria, South Africa, 12 October 1990 Scope of assessment This assessment applies to those innovative aspects of the Cemforce GRC Building System described in Part 3 of the certificate. It also applies to those conventional aspects of the building system which, in the opinion of Agrément South Africa, are influenced by the innovative aspects. The innovative aspects referred to are: the use of sandwich wall panels comprising polystyrene beaded concrete core encapsulated in glass reinforced cement (GRC) the anchorage of wall panels to the foundation slab the use of mildsteel post tensioning rods which are threaded through the PVC conduits to secure the wall panels to one another. This assessment is based on: Documentation provided by the applicant Inspections of the applicants factory and completed installations Known behavior of the materials used in the building system The applicant s quality management system Assessment In the opinion of Agrément South Africa, the building system as described in the certificate is suitable for the construction of buildings of the types specified (page 1). The performance-in-use of buildings erected with this system will be such that they will satisfy: the relevant requirements for safety and health prescribed by Agrément South Africa the requirements of the National Building Regulations, where stated in Table 1 Agrément South Africa s performance criteria and requirements for durability and habitability. Agrément South Africa s detailed comments on the assessment are set out in Tables 1; 2 and 3 below. Each aspect of performance was assessed by experts in that field. Compliance with the National Building Regulations The innovative aspects of the Cemforce GRC Building System relate to the National Building Regulations as set out in Table 1. Any regulation not specifically referred to is considered to be outside the scope of this certificate and must be applied by the local authority in the normal manner. Agrément Certificate 2008/346: Cemforce GRC Building System Page 7 of 21

8 Table 1: Performance Aspects of performance Fitness-for-purpose of materials used Behaviour in fire Opinion of Agrément South Africa The materials described in Part 3 meet the requirements of the National Building Regulations. Walls are classified noncombustible (type FR) with a fire resistance rating of 60 minutes. National Building Regulations satisfied A13(1)(a) Materials K4 Walls T1 (1) (b), (c) and (d) are satisfied insofar as the walls are concerned. Comments made in Supplement to certificates must be taken into account when building plans are scrutinized by local authorities, to check compliance with Regulations T 1(1) (a), T1 (1) (d) with regard to spread of smoke, and T1 (1) (e). Deemed-to-satisfy rules TT5.1(c) and TT5.2(c) of Section 3 of SANS have been met. As defined in deemed-to-satisfy rule TT2.1 (a) of Section 3 of SANS 10400, the external walls of Cemforce GRC buildings are classified as noncombustible with fire-resistance rating of 60 minutes. The building system wall panels can also be used for division separation requirements for H3 provided a suitable door assembly with a similar rating is used. The safety distances as set out in the relevant rules of Part T can therefore be applied. Structural performance Satisfactory, provided the requirements of this certificate are complied with. J1(1) Floors K1, K3, K4 Walls Regulations B1 (1) and (2) are deemed to be satisfied when buildings are built in accordance with the technical rules and description set in Part 3. When these rules are not complied with the structural design and erection of each building is the responsibility of a professional engineer or competent person and deemed-to-satisfy rule BB4 of SANS is applicable. Regulations H1(1) and H1 (2), Foundations, are deemed to be satisfied as follows: H1 (1) on non-problematic soils; H1 (2) in all buildings where foundations are designed by a professional engineer or approved competent person and deemed-to-satisfy rule HH 1(a) applies. Water penetration and rising damp Satisfactory. Cemforce GRC Building System buildings meet Agrément South Africa s criteria for resistance to water penetration and rising damp throughout South Africa. K2 Walls J1(4) Floors Agrément Certificate 2008/346: Cemforce GRC Building System Page 8 of 21

9 Table 2: Health and Safety Aspects of performance Thermal performance and energy usage Opinion of Agrément South Africa Satisfactory. Maximum summer indoor temperature in Cemforce GRC dwellings will be 1 C warmer in dwellings with uninsulated ceiling but 1 C cooler with 40mm insulation ceilings. The winter energy heating requirements of Cemforce GRC dwelling without insulated ceilings will be more in Cape Town and less in Johannesburg but will be considerably less than that required for the standard brick house (SBH). Explanatory notes Agrément South Africa s opinion is based on the calculated likely maximum indoor air temperature in summer in a 53 m 2 Cemforce GRC dwelling in Cape Town, Durban and Johannesburg, and the calculated energy required to maintain an indoor temperature of 16ºC in winter in Cape Town and Johannesburg. When assessing the thermal performance of a dwelling, the calculated performance of the subject is compared with that of the standard brick house. This is of similar size, orientation and fenestration as the Cemforce GRC Building System dwelling and has: external walls of 230 mm brick and internal walls of 110 mm brickwork; plastered internal wall surfaces; a concrete floor; a sheeted roof that is fitted with a ceiling without insulation. Condensation Acoustic performance Durability Satisfactory. Cemforce GRC Building System buildings that are fitted with ceilings (with or without insulation) have superior performance to that of the (SBH). Satisfactory. Agrément South Africa s performance criteria for sound attenuation between adjacent rooms and between adjacent dwellings have been met. SANS 10218: Part 1: Acoustical properties of buildings Given regular and adequate maintenance, the durability of Cemforce GRC Building System buildings will be similar to that of conventionally constructed buildings. Condensation is generally a problem in the Southern Coastal Condensation Problem Area (SCCP Area). The assessment of this aspect of performance only applies to dwellings in this area. Agrément South Africa requires that the performance in relation to condensation occurring on walls and under roofs of dwellings in the SCCP area be at least equivalent to that of the standard brick dwelling which is itself not immune to condensation problems. Agrément South Africa s opinion is based on data from in situ airborne sound attenuation tests. The insitu airborne sound insulation that is likely to be obtained between adjacent rooms in the Cemforce GRC Building System is 47 db (DnT,w). These values meet Agrément South Africa s criteria and most of the recommended sound insulation values set out in SANS 10218: Part 1. A description of the degree of acoustic privacy that can be expected between specific rooms for various degrees of sound insulation is given in Supplement to certificates. Agrément South Africa s opinion is based on knowledge of the materials used and on inspection of buildings constructed using the Cemforce GRC system. For the external finishing a good quality alkali resistant primer and two coat pure acrylic emulsion paint should be used and the recesses for the sealant should be created in accordance with good joint design for the specific sealant. Agrément Certificate 2008/346: Cemforce GRC Building System Page 9 of 21

10 Table 3: Quality management system Aspects of performance Quality management system Opinion of Agrément South Africa The certificate holder s quality management system complies with Agrément South Africa s requirements. Properly applied, it will ensure that quality in the manufacture of GRC panels, design and erection of buildings will be consistently maintained. Explanatory notes Agrément South Africa s requirements are based on SANS SANS 9001 Quality management systems Requirements Agrément Certificate 2008/346: Cemforce GRC Building System Page 10 of 21

11 PART 3: TECHNICAL DESCRIPTION General description The Cemforce GRC Building System utilises factory produced wall panels. The wall panels are 78±2 mm thick consisting of a polystyrene beaded concrete core with a dry density of 450 to 750 kg/m 3 encapsulated in 8mm thick skins of glass reinforced cement (GRC). The panel widths vary from 300mm to 1200mm and are 2,4m or 3,0m high (see figure 2). Polyvinyl chloride (PVC) conduits15 mm diameters are cast running horizontally at the top and bottom of the panels. Galvanised mild steel anchor straps are cast into the bottom of the panels and wallplate anchor bolts in the tops of the panels. The concrete floor slab is conventional with thickened edge beams cast on a damp-proof membrane. Bitumen emulsion dpc is applied to the bottom of all wall panels prior to erection. Wall panels are placed in position, starting from a corner, and the anchor straps are secured to the floor slab with drive-in nails. Mildsteel post tensioning rods are threaded through the PVC conduits to secure the wall panels to one another (see figure 3). The wallplate is a mild steel box section secured to the anchor bolts. Roof construction is conventional timber with light or heavyweight cladding. Insulated or uninsulated ceilings are always installed. Window and door frames are secured to bolts cast into the wall panels. Design requirements This certificate covers single-storey buildings which are erected within the dimensional limitations set out below: maximum window size minimum distance of window from cross-wall maximum height of eaves wall 1,2 m 1,2 m 2,4 or 3,0 m maximum length of eaves wall between supporting crosswalls (no gable walls evaluated) 7, 2 m number and diameter of wallplate fixing bolts (8 mm) 2 per panel number and size for the securing of the roof structure 2 per panel (8 mm) Also see Part 1: General condition regarding the duties of a professional engineer. Manufacturing The Cemforce GRC Building System utilises factory produced wall panels. Mildsteel mould are cleaned, inspected for possible flaws and mould releasing oil applied. Galvanised base anchor straps, wall plates and window and door anchor bolts and 15 mm diameter horizontal conduits(250 mm from top and bottom of wall panels) are than positioned (see figure 4). The first layer of GRC is applied to a thickness of 8 mm to the face of the mould and 12 mm to all Agrément Certificate 2008/346: Cemforce GRC Building System Page 11 of 21

12 SANS Cement Part 1: Composition, specifications and conformity criteria for common cements SANS 1090 Aggregates from natural sources Fine aggregates for plaster and mortar Potable water: The water should be clean and preferably drinkable. Water that may be made drinkable by boiling may be used in its natural state. edges and the GRC lightly compacted. Electrical and plumbing apertures and conduits/piping are installed. The GRC constituents are ordinary Portland cement complying with SANS , Cem I or Cem IIA, sand complying with SANS 1090 (or blended by a specialist), potable water, super-plasticiser with accelerator, and alkali-resistant chopped glass-fibre. Core material comprising polystyrene beads, cement, plaster sand and potable water is mixed in a paddle mixer, poured into the mould and compacted to the correct thickness. The density of the core material is kg/m 3. A top layer of GRC, forming the outer surface of panels, is sprayapplied to a thickness of 8 mm and sponge-rolled for compaction and finishing texture. The panel (in the mould) is heat-cured in a curing chamber for 24 hours. The final product is inspected for surface flaws, colour, finish and overall product dimensions. Erection SANS 10161: The design of foundations for buildings SANS 952: Polyolefin film for damp and waterproofing in buildings SANS 317: Industrial bitumen Foundations and surface beds Cemforce GRC foundations are conventional. A competent person classifies the site in accordance with the site class designation set out in Table 3 of the South African Institute of Engineering Geologists (SAIGE) publication entitled Guidelines for Urban Engineering and Geological Investigations. In abnormal or problematic ground conditions, foundations are designed by a professional engineer in accordance with the requirement of SANS and constructed in accordance with this design. A damp-proof membrane in accordance with SANS 952 or one covered by a valid Agrément certificate, is laid on the compacted fill under the surface bed and taken under the external walls. Walls The bottom face of walls is coated in the factory with two layers of 0, 5 mm thick coating of a bituminous paint complying with SANS 317 and inspected on site before erection (see figure5). The wall panels are placed in position commencing from a corner and the galvanised mild steel anchor straps secured with drive-in nails to the foundation slab. Mildsteel post tensioning rods, 10 mm diameter, are threaded through the top and bottom PVC sleeves securing the panels from corner to corner or door to corner. The tensioning rods are screwed and hand tightened with 10 mm galvanised Fender washer and nut. On completion of the alignment of wall panels, the 75mm x 50mm x 2mm rectangular, galvanised mild steel wall plate is secured to the top of the wall panels through 8 mm predrilled holes and hand tightened to the cast-in anchors. The tensioning rods are torqued to a maximum of 13 Nm as is the wall plate. The wall panel joints are an 8 mm 45 bevel edge sealed internally and ex ternally with a flexible acrylic sealant (see figure 6). Agrément Certificate 2008/346: Cemforce GRC Building System Page 12 of 21

13 Windows and door frames Windows and door frames are fixed on site in openings left in the wall panels with 8 mm x 35 mm galvanized bolts through the frames. The frames are bolted onto the panels into a cast-in anchor with a cross pin on the side of the wall. (see figure7) Roof structure and anchorage Cemforce GRC buildings are constructed with hipped roof construction and lightweight roof coverings. 50 mm x 50 mm x 4mm mild steel angle iron brackets are welded to the 75 mm x 50 mm x 2 mm rectangular tubing (wall plate) at roof truss positions. Anchor straps of 32 mm x 1, 8 mm galvinised mild steel are bolted to the angle iron, folded over the roof truss and spiked to both sides of the roof truss. (see figure 8) Ceilings Ceilings are conventional and are normally provide, consisting of 6,4 mm thick gypsum plaster board fixed to branderring which in turn is nailed to the underside of roof trusses. Finishes and services All finishes such as glazing, tiling, painting, laying of carpets, the completion electrical, gas and services are carried out in the conventional manner but are not chased into the wall panels. For the external finishing a good quality alkali resistant primer and two coat pure acrylic emulsion paint should be used and the recesses for the sealant should be created in accordance with good joint design for the specific sealant. Agrément Certificate 2008/346: Cemforce GRC Building System Page 13 of 21

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