Building on solid foundations

Building with Common Sense

Technical Information for Planning and Construction

ACICO Manual for ACICO Roof Slabs

A technical information manual of the ACICO plant in Kuwait published by ACICO, Kuwait and ACICO International GmbH & Co. Emmering-Fstenfeldbruck. Reproduction, whether wholly or in part, only with the consent of the publisher. All advice provided in our publications is accurate to the best of our knowledge and belief and in accordance with the latest state of the art in AAC application engineering on going to press. Since the use of structural elements of autoclaved aerated concrete is subject to DIN standard specifications and official approval, which are subject to change, the cited data are not legally binding.

SAUDI AERATED CONCRETE INDUSTRIES CO. LTD. (ZAMIL-ACICO)

Phone: 03-3580506 - Fax: 03-3580507 - Universal Access Number: 920025655 www.saudiacico.com

Table of Contents
1. Background 2. ACICO Aerated Concrete: Better than natural stone 3. Production 4. ACICO Roof Slabs Product and Application 5. Planning 6. Design Criteria 7. Erection 8. Details 9. Properties and Advantages Thermal insulation Heat storage and cooling Diffusion behaviour Sound insulation Fire resistance

Background

1
The Kuwait plant is an independent, selfreliant enterprise. These independence enherits a high degree of flexibility, to adjust the products the local and foreign markets and for use the main advantages of the ACICO products as: Best thermal insulation of all solid building materials. Light weight for transport, handling and structures. Ideal for fire proofing. Adequate sound insulation. Big sizes of the reinforced products. Independent of gravel resources, - the production needs only sand, cement and lime.

Autoclaved Aerated Concrete, AAC, is a type of light weight concrete developed in the twentieth of last century. In 1943, Builder Josef ACICO founded the first factory for reinforced AAC products in Germany producing panels and slabs. During 1945 to 1960, the demand of this superior building material grew dramatically. Additional plants were built in Germany and the first step abroad was laid down in Japan in 1967. The production of ACICO A.A.C. under its license soon followed world wide. With more than 45 licensed plants all over the world, ACICO is a leading producer of A.A.C. blocks and reinforced material. Especially in development and application of reinforced products the company has superb knowledge and experiences. Since the beginning of 1994, Aerated Concrete Industries Co. - ACICO - has been producing ACICO products in a new plant in Kuwait which is equipped with the most modern production technology.

ACICO Aerated Concrete: Better than natural stone.

ACICO aerated concrete consists of the same raw material as natural stone but has these significant advantages. ACICO aerated concrete is made of quartz sand, lime, cement and water - raw materials that are easily and naturally available the patented production process takes relatively little energy since ACICO aerated concrete is steam cured at only 180C During the production process a natural element air expands the volume. 5 cubic metres of construction material are produced from 1 cubic metre of raw materials. Resources can hardly be used more sparingly. Millions of air cells, entrained in ACICO aerated concrete, give this construction material its exceptional physical characteristics and its combination of properties that make it superior to any natural stone: high thermal insulation balanced heat storage good vapor diffusion characteristics light weight, large volume easy, rational workability good acoustic properties non-combustible impervious to insects weather-resistant long-lasting environmentally compatible virtually maintenance free

ACICO Aerated Concrete:

Production

The production of ACICO aerated concrete:

1. Preparation of raw materials measuring, mixing, pouring:

Quartz sand is very finely milled and then mixed with precisely measured amounts of lime, cement, water and a minimal amount of aluminium paste as expanding agent. This slurry is poured into molds. When producing reinforced material the corrosion protected reinforcement is inserted into the mold prior to pouring.

2. Expanding:
The aluminium paste reacts chemically with the other raw materials. Hydrogen gas forms. The cake expands and attains its porous structure the precondition for the exceptional thermal insulation, good acoustic properties and easy workability.

3. Cutting:
After the expansion process is completed the malleable cake is cut into the desired end product form, i.e. blocks or slabs, very precisely by sophisticated cutting machines with maximum tolerance of +/- 1.5 mm.

4. Steam curing:
Following the cutting process the cut cake is steam cured under a pressure of 12 bar and temperature of only 180C. After steam curing the construction material and products are ready for delivery to sites.

Production
Reinforcing
Cutting to Length

Raw Materials
Sand Grinding Mill

Lime

Ground

Sand

Cement

Mesh and Basket Welding

Expanding Agent

Metering

Water

Immersion Corrosion protection

Mixing

Assembly

Casting

Expanding

Cutting

Steam Curing Storage/ Construction Site

ACICO Roof Slabs: Product and Application

4.1 Product and Application
ACICO roof slabs are reinforced aerated concrete products which are produced in accordance with German standard DIN 4223. Being ready-to-use, prefab structural elements have their full load-bearing capacity directly after production. After delivery, slabs can be simply erected in a short time. There is no need for shuttering work. Only the joints must be grouted with concrete. Finishing work can be started directly after erection which saves time and costs. ACICO roof slabs are produced in various thicknesses and spans with different load bearing capacities. Furthermore, the thermal insulation and well balanced heat storage properties of ACICO roof slabs ensure a pleasant internal environment with balanced room-temperatures. ACICO roof slabs are used for flat roof area and sloped one. They can be laid with chamfered edges for visible joints or without chamfers for plastering. For cantilever purpose, slabs with special reinforcement can be produced with cantilever span up to two meter. ACICO roof slabs are incombustible and therefore they meet all the requirements of fire-resistance categories.

4.2 Shapes and Formats

Nonvisible Joint

Visible Joint

Chamfered by Chamfer plain before erection

L th. W
Length: Up to 600 cm Width: 62.5 cm. (min. 25 cm) Thickness: 10, 12.5, 15, 17.5, 20, 25, 30 cm Special Formats can be also produced on request.

ACICO Roof Slabs: Product and Application

4.3 Product Characteristics Data
Strength category Breaking strength (Test blocks) Dry density max. Thermal conductivity Design value for dead load incl. reinforcement and joint concrete Elastic modulus Thermal expansion coefficient Shrinkage GB 3.3 3.5 600 0.14 720 2000 8 -0.2 GB 4.4 5.0 700 0.16 840 2250 8 -0.2 Units N/mm2 Kg/m3 W/(mK) kg/m2 N/mm2 10-6/K mm/m

Quality Control Room 9

Planning
Dimensioning must be done in accordance with the static calculations. Generally, slab thickness depends on the span and design load but improving thermal insulation, sound insulation or even for greater fire resistance, it is recommended to increase the statically required minimum thicknesses. For design and construction see the tables and details in this manual. The technical office of ACICO gives advise and more informations when required. After contract structural design, roof slab drawings and parts list for production will be prepared in ACICO technical office.

ROOF SLABS (Sample Plan)

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Design Criteria
6.1 Introduction
ACICO roof slabs are applied for both, flat roofs and sloped roofs. In case of sloped roofs anchoring with the support is required. The basis of analysis and design is the German code DIN 4223. Design of reinforced A.A.C. products is approximately similar to conventional reinforced concrete. The differences are mainly in compressive strength and anchoring the reinforcement. Calculation sheets is prepared in accordance with design tables by ACICO technical office. Spans, thicknesses and loads are shown in the following tables:

6.2 Self Loads for ACICO Slabs

Strength category Max dry density Kg/m3 Design value kN/m3 Thickness mm 100 125 150 175 200 250 300 100 125 150 175 200 250 300 Self load kN/m2 0.72 0.90 1.08 1.26 1.44 1.80 2.16 0.84 1.05 1.26 1.47 1.68 2.10 2.52

G.B. 3.3 600 7.2 G.B. 4.4 700 8.4

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Design Criteria
6.3 Max. Spans and Moments
Roof Slabs GB 3.3 Slab Self IMPOSED LOAD (KN/m2) M max. Thick100 150 200 250 300 350 400 450 500 525 550 575 600 load ness mm kNm/m 125 100 MAX. SPANS (m) kN/m2 090 072 254 327 302 273 251 234 219 207 199 190

200 1146 600 558 516 482 454 431 410 400 380 370 364 358 352 144

175

150

864 554 501 461 429 403 381 363 350 335

618 491 438 401 372 348 329 312 303 290

417 409 37 339 313 292 275 261 249 238

126

108

250 1842 600 600 600 585 554 527 504 483 456 456 449 441 434 180 300 2694 600 600 600 600 600 600 592 565 548 538 530 521 513 216

Roof Slabs GB 4.4 IMPOSED LOAD (KN/m2) Self Slab M max. Thick100 150 200 250 300 350 400 450 500 525 550 575 600 load ness mm kNm/m 100 125 150 MAX. SPANS (m) kN/m2 0.84 090

3.62 3.50 3.50 3.19 2.95 2.75 2.58 2.45 5.96 4.48 4.32 3.95 3.66 3.43 3.24 3.7 2.94 2.81

8.83 5.46 5.06 4.66 4.33 4.07 3.85 3.66 3.50 3.36 3.39 3.23 3.17 3.12 1.26

175 12.35 5.90 5.77 5.34 4.99 4.70 4.46 4.25 4.07 3.91 3.83 3.76 3.70 3.64 1.47 200 16.37 6.00 5.90 5.90 5.60 5.29 5.03 4.80 4.60 4.43 4.35 4.27 4.20 4.1 1.68 250 26.32 600 600 600 6.00 6.00 6.00 5.88 5.65 5.45 5.35 5.26 5.18 5.10 10.2 300 38.45 600 600 600 600 600 600 6.00 5.90 5.90 5.90 5.90 5.90 5.90 2.52

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Design Criteria
6.4 Reinforcement
Standard slabs are reinforced with double steel mesh. The top mesh is mainly designed for transport and deflection. The steel meshes are welded and corrosion-protected in ACICO factory, individually for each slab-position. Reinforcement cover is approx. 10 mm.

6.7 Ring Beams (Tie Beams)

One of the significant components of ACICO slab structural system is the ring beam. It provides stability to the whole slab area. Ring beams are cast in situ (in connection with slab joints) directly at the top of supports with the same height as ACICO slabs and at the slab level. Ring beams are reinforced with two single steel bar (diameter 12mm) top and bottom connected with the steel bar of slab joints (diameter 8 mm). In case of high horizontal loads, concrete cover of min. thickness 4 cm is cast situ above ACICO slabs for disc effect.

6.5 Cantilever Slabs

With the typical mesh, length of cantilever span up to 60 cm is possible without any calculation. The max cantilever for roof slabs is 200 cm using special reinforcement as per calculations. (Note that the max. overall length is 6.00m)

6.6 Supports
The slabs are usually supported directly on masonry, concrete beams or steel beams, without mortar. Only for non plane support surface cement mortar is applied for adjusting the top surface. The min. resting length on the support is 7.5 cm for masonry and concrete supports and 5 cm for steel beams.

Typical Reinforcement Main-Bars and Cross Bars

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Erection

7.1 General
After production, ACICO ROOF SLABS are packed and loaded on trucks; then delivered to site. SLABS should be carefully handled during transport, storing and erection. The damages can be easily avoided. A mobile or a minitower crane is used for both unloading and lifting slabs in site. The maximum weight for single roof slab with dimensions 600 x 62.5 x 25 cm is approximately 700 kg. While storing, if turning of ACICO slabs are required, use an old big tire to overturn them. If visible joints are required, chamfers are prepared using chamfer-plain before lifting the slabs. It is easier and controlled.

The top surfaces of all types of supports must be checked and adjusted in a plane horizontal level by cement mortar if needed, before starting the erection. Whenever cement mortar is laid, minimum 24 hours is required before laying roof slabs. Safety instructions for site works must be generally followed and controlled by site engineers in charge. One of them is using the safety chain across clamp during lifting the slabs. Also, it is not permitted for labors or persons to be under the crane boom path.

7.2 Erection (Laying slabs)

Use slab clamp, after releasing strapping bands, lift slab by slab individually with the site crane for laying it in the right position in accordance with the drawings. The first slab must be laid in perfect alignment leading the next slabs in the right positions avoiding more adjustments later on. After laying roof slabs for the whole roof area, steel reinforcement 8 mm for joints and 12 mm for ring beams, are placed as per typical details. The joints and ringbeams must be well wett before casting the fine aggregate concrete. If the start of laying roof layers (foam concrete, membrane etc) is not immediately after casting the ring-beams and slab joints, then keeping the concrete damped is a must as per specifications.

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Erection
7.3 Cutting and Repairing
Generally, when cutting of a slab is required, it is already done in the factory in accordance with the parts list for the specific delivery order. Sometimes, it is required to cut a slab in other dimensions in site after delivery. Then a grinder machine is the suitable tool for this job. Also holes are allowed of maximum 20 cm to cut slabs as shown in figures. If other cutting shapes in different dimensions is required, contact ACICO technical office. For repairing damaged slabs, a special ready-mix repair mortar is produced by ACICO plant to be used for repairing. Instructions and applications are illustrated on the repair mortar bags. But never repair cracked or damaged slab whenever structural risk is there.

20

20

40

Max. width to cut round or square openings is 20 cm.

variable Length

When placing the opening in the Slabs-Joints, the width is 40 cm.

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Details
Supports

7.5

7.5

7.5

7.5

Masonry support

Concret beam support

Steel beam support

Ring Beam On load bearing masonry

2 12 ACICO closure block 2 12

Erection bar 8mm spacing 1.5m

10

25
External wall

20
Internal wall

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Details
Ring beam on concrete structure
2 12 2 12

Erection bar 8mm spacing 1.5m

10
External wall

5
Internal wall

Supports parallel to the slab-span

7.5

10

ACICO roof slabs with concrete cover

U shaped bar

Steel Mesh 6mm @ 20 cm c/c

U shaped bar 4

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Details
Roof coverings and parapet details
Anchor Bars for ParapetColumns Styropor Strip Th. Min. 3 cm Membrane Tiles in Mortar and Sand Foam Concrete

Joint Bar 8 mm Ring Beam 2 12 mm

Infill Blockwork

Parapet with ACICO blocks or panels

3 cm Space to avoid them exp. pressure Slope cut ACICO block Membrane Tiles in Mortar and Sand Screed Foam Concrete

Joint Bar Ring Beam

ACICO Bearing Masonry

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Details
Sloped Roof Supported on internal Bearing Masonry, and anchored by Ring beam.

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Details
Finishing of Ceilings

A- Nonvisible Joints

Finishing by ACICO ready mix plaster and paint. (The slab-joints are covered with fiber or wire mesh strips.)

B- Visible Joints

Finishing by fine course-rendereing. (Edges chamfered before slabs erection)

C- False Ceilings

Fixing of Hanger for false ceilings.

a- By threaded bolt with Washer and Nut. (Hole by Drill) b- By fischer plug perm. load 30 kg. (Hole by Hammer and Bolt.) c- By galvanized wires

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Details
Installation of Conduits and AC. - Ducts For finishing by plaster:

8
Conduits are fixed before foam concrete. (Holes for light points by drill.)

Light Point

For false ceiling:

Conduits are fixed by cleat (clip) and ACICO nail.

Fixing AC-ducts:
By threaded bolts. (Holes by drill.)

Or by Fischer plug GB 10. (Plug-holes by hammering and bolts.) perm. load 30 kg/plug.

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Details
ACICO Loft Slabs

Precast Slabs without shuttering etc.

Concrete skeleton

Concrete slabs

False ceiling Room for AC Equipments etc. ACICO Partitions ACICO Lintel ACICO Lintel ACICO slabs th. 10 or 12.5 cm supported on int. walls.

Window

Door

BATHROOM ACICO infill blockwork

Wall tiles fixed by cement glue directly on ACICO walls. For connection of water proofing use thinner block in the first course.

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Details
Steel Hanger for openning 62.5 cm

8
Flat steel 80 x 5 mm 62.5 cm L 100 x 7 mm 20

Steel Hanger for opennings 125 cm

20 L

23

125 cm

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Properties and Advantages

9. Properties and Advantages

ACICO Autoclaved Aerated Concrete (AAC) embodies advantages and positive properties which can otherwise be attained only by a combinations of various materials. It is a solid building material, mainly produced with the same raw materials as for concrete, but excluding gravels, (only sand and binders). Therefore ACICO products have approx. the same lifespan as for concrete. The material doesnt release any toxic gases or other substances. ACICO roof slabs is a product of the whole ACICO construction system of blocks, panels, slabs, lintels etc. In comparison to typical concrete roof construction, ACICO roof slabs have advantages as: The slabs are precast. So there is no need for reinforcing and shuttering works or curing time. Immediately after erection, the roof is ready to resist the exposed loads. The light weight property helps in decreasing other structural elements cross sections. The thermal insulation is 12-times higher than concrete. (ACICO l = 0.14 W/(mk) concrete l 1.75 W/(mk) i.e usually no need for more thermal insulating layers in roof finishings. For slab producing only sand and binders are required, i.e. reducing local gravel consumption. Less manpower and time.

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Properties and Advantages

9.1 Thermal Insulation
Due to the air entrained in the AAC, the ACICO building material achieve extremely favorable insulation properties, resulting in low k values. The material has well-balanced heat storage capacity to achieve a pleasant healthy living climate.

Strength Thermal Thickness Resistivity category Conductivity cm 1/8 l W/mK m2 K/W G.B. 3.3 0.14 G.B. 4.4 0.16 10 12.5 15 17.5 20 25 30 10 12.5 15 17.5 20 25 30 0.71 0.89 1.07 1.25 1.43 1.79 2.14 0.63 0.78 0.94 1.09 1.25 1.56 1.88

Heat Transmission Coefficient k W / (m2.K) 1.13 0.94 0.80 0.70 0.62 0.51 0.43 1.25 1.05 0.90 0.79 0.70 0.58 0.49

Some typical roof details to achieve the regulations of the Ministry of Electricity and Water K 0.4 w/ (m2 k) or u 0.07 Btu/ ft2 h F
Tiles in Mortar and sand screeds and membrane Membrane Screed

Foam concrete average 10 cm. ACICO Roof Slabs GB 3.3 20 cm

Foam concrete average 10 cm. ACICO Roof Slabs GB 3.3 20 cm

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Properties and Advantages

9.2 Heat Storage and Cooling
In addition to thermal insulation, the heat storage capacity and the cooling behavior of a building material are of importance for the interior environment. Covering a building (external walls and roof slabs) completely by ACICO products completely will be the basis for most favorable condition.

9.4 Sound Insulation

The solid ACICO building material attains good sound-proofing values by itself. In combination with more courses of other materials, as usual roof constructions, the sound damping factor will be increased. Approximate sound damping factors for ACICO roof constructions are:

60 dB
Tiles in Mortar and sand screeds and membrane

9.3 Diffusion Behavior

Among the mineral solid building materials, ACICO aerated concrete has one of the lowest water vapor diffusion resistances. For example, some values of water-vapor diffusion resistances are: Air Hebal Concrete Glass = 1 = 5-10 = 50=100 =

Foam concrete average 10 cm. ACICO Roof Slabs GB 3.3 20 cm

Remark: As lower the diffusion resistancesvalue as better the interior climate.

50 dB
Membrane Screed

Foam concrete average 10 cm. ACICO Roof Slabs GB 3.3 20 cm

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Properties and Advantages

9.5 Fire Resistance
All ACICO materials are incombustible and highly fire resistant. As per German code DIN 4102, building materials are defined according to their fire resistance in minutes. For example, the classification F60 means minimum 60 minutes fire resistance. But for reinforced material mainly the covering of the steel bars give the required fire resistance. The fire resistance for ACICO roof slabs as per DIN 4102 is following.

A/ Without Plaster
For F30, For F60, For F90, For F120, u = 10 mm u = 20 mm u = 30 mm u = 40 mm

th
u

B/ With Plaster

For F30, For F60, For F90, For F120,

u = 10 mm u = 22 mm u = 34 mm u = 42 mm*

th u
* In this case Plaster with Wire Mesh Note: The reinforcement for concrete slabs need more covering, because in case of fire, ACICO material has better fire resistance than concret.

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