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Celcon House, Ightham, Sevenoaks, Kent TN15 9HZ. Tel: 01732 886333 Fax: 01732 886810 Technical Advice: 01732 880580 Sales Office: 01732 886444 www.hhcelcon.co.uk

H+H UK LTD

Millfields Road, Ettingshall, Wolverhampton WV4 6JP. Tel: 01375 656210 Technical Advice: 0870 2421489 Sales Office: 0845 606 2468 www.topblock.co.uk

Tarmac Topblock Limited

Stewartby, Bedfordshire MK43 9LZ. Tel: 08705 258258 Fax: 01234 762040 Technical Advice: 08705 626500 Sales Office: 08705 626500 www.thermalite.co.uk

Hanson Building Products

Derrylin, Co. Fermanagh, BT92 9AU N.Ireland Tel: 028677 48866 Fax: 028677 42309 Technical Advice: 028677 48866 Sales Office: 028677 48866 www.quinn-group.com

Quinn Group

CI/SfB

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November 2003

THIN
JOINT MASONRY
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Building with Aircrete

Thin joint masonry Getting started

CALA HOMES
Housebuilder CALA Homes have radically reduced build times following adoption of the thin joint system on many of its developments, often using large format blocks as a way of further increasing the speed of laying. This allowed the inner leaf to be completed in a fraction of the time associated with traditional forms of construction.

Thin joint masonry is an innovative construction method for use with Aircrete blockwork that allows build times to be significantly improved and offers many other practical and commercial benefits.

The build method

The use of a 2-3mm mortar joint with lightweight Aircrete means greater wall heights can be achieved in a day often more than doubling productivity. Using a familiar build process, it can be easily and reliably installed by existing trades with only little additional training. Thin joint Aircrete masonry does, quite simply, utilise a much thinner mortar joint than with traditional blockwork. These mortars, supplied dry to standard formulations, are mixed with water on site and applied using a scoop or sledge 'applicator'. This ensures an accurate and consistent depth of mortar the key to thin joint construction. The mortar cures rapidly, achieving full bond strength within 1-2 hours, eliminating the problem of 'floating' and permitting far more courses to be laid per day. Thin joint combines reduced build times with the greater flexibility of Aircrete masonry construction ease of handling, working and finishing. It can yield significant cost savings, allows improved build quality, has lower wastage and provides solutions that comply with the requirements of current Building Regulations.

CALA have found that the time taken to seal the roof on large detached houses has reduced to just five days giving access to finishing trades some four weeks earlier than when using conventional build methods and resulting in a total construction time of only 12 weeks. This rapid technique can be achieved using a masonry inner leaf whilst in practice allowing a very tolerant, versatile method of building.

This brochure sets out the basic principles of thin joint construction and summarises the best practice methodology agreed by the Aircrete industry.
For further information and specific technical or design queries, please refer to individual member companies.

...a proven process

Thin joint masonry speeds up progress on site.

A proven process

Independent tests have shown that using this method a team of skilled tradesmen with no prior 'thin joint' experience can build the inner leaf of a detached, 4-bedroomed, 2-storey house in just five to six days. This removes brickwork or external cladding from the critical path and permits access to finishing trades far sooner in the build schedule. Thin joint masonry is a truly innovative build method that adds significantly to the ease and speed of construction without the requirement for specialised skills.

Inner leaf blockwork to wall plate in just a few days First fix finishing trades on site within days Hugely versatile and practical Nationally available Method easily learned by range of trades Potentially better quality construction Excellent acoustic and thermal insulation Simple solutions to the Building Regulations Resists fire, frost, moisture and sulfate attack Waste reduction of mortar and blocks Reduced construction times Environmentally friendly materials

An ideal choice for house building. A simple method which ensures consistent build quality.

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Making the most of thin joint

LYTHAM ST. ANNES
The improved completion times resulting from earlier access for finishing trades when using thin joint Aircrete masonry can be even greater when used on medium-rise buildings, such as this 5-storey apartment building at Lytham St. Annes on Lancashires Fylde coast.

Real commercial benefits

In addition to the faster build times achieved using thin joint Aircrete masonry, productivity is improved through better utilisation of both first and second fix trades, whilst earlier completion and handover has obvious implications for the release of capital tied up in each project. The storage of bulk materials on site is reduced, with consequent transport savings. There is lower wastage of mortar and blocks and, with brickwork off the critical path, the complete build process is at less risk from problems caused by poor weather avoiding delays to the program. Technically, thin joint Aircrete is an excellent choice too, providing a range of solutions to meet the requirements of the Building Regulations. The reduced area of mortar joints further enhances Aircretes natural insulation properties and this provides potential for a more airtight structure, reducing the heat losses caused by uncontrolled ventilation. Aircrete's inert, micro-cellular composition is highly resistant to fire, sulfate attack, frost and the passage of moisture.
Working with Aircrete blocks

This brick-clad development by Gleeson Homes comprised sixteen seafront apartments, each finished out to a high standard, which meant the earlier commencement had a significant impact on the overall build time. Despite its light weight, Aircrete is a strong and durable masonry unit, with compressive strengths that exceed the requirements for medium-rise buildings such as this. Thin joint Aircrete is a proven method of construction, widely used in Europe and with full Agrment certification, that extends the already impressive list of benefits enjoyed by this innovative material.

Aircrete is a light weight masonry material that is easy to handle, cut and work with. The available block sizes minimise the amount of cutting needed, however some site cutting will be necessary, in which case Aircrete can be easily cut using a handsaw. Alternatively, an electric handsaw, circular saw or band saw may be a more effective method, particularly on larger projects where there may be repetitive cutting.
Thin joint tools and mortar

Best practice is for the user to purchase complementary products from the same manufacturer. Joints should be fully filled and it is a matter of personal choice as to the type of tools used.

What Aircrete blocks can you use?

...faster build times

Planning for faster build times is crucial at the design stage.

Aircrete masonry, for thin joint construction, is manufactured to exact tolerances. There is a wide range of sizes available from the leading manufacturers which are suitable for internal and external cavity wall or solid wall construction. Many manufacturers also produce 'large format' Aircrete blocks that are up to twice the size of a standard block. Aircrete's light weight means that even these larger units weigh less than 20kg, and so meet the repetitive handling requirements of the Health and Safety Executive. The use of large format blocks with thin joint construction can yield very rapid build times. Please refer to manufacturers' literature for futher details of the sizes available.
Planning for faster build times

To get the most from thin joint masonry, it is important to plan the project carefully scheduling labour, site management and the supply of materials to account for the faster stages of completion. The site should be kept level and clear wherever possible to facilitate rapid completion and aid the delivery and storage of materials required by following trades. Early completion of the outer shell will change or accelerate the traditional linear process of construction from trade to trade, and this will require anticipation and planning. If the roof is to be installed after only a few days, materials such as lintels, floor joists and roof trusses need to be on site almost from the outset. The result will be a build programme up to 50% quicker than using conventional build methods.

Thinner mortar joints speed drying and build time.

Easy cutting and handling speed up progress.

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Getting started
SOHAM, CAMBRIDGESHIRE
Newmarket developer, Braeburn Homes had always embraced the use of innovative build methods and materials, recognising the commercial benefits and flexibility they sometimes offer over more traditional methods. They were looking for a build process that would provide speed of construction and thermal performance for a small development of 4-bedroomed houses in Soham, Cambridgeshire.

Preparing the base course

Thin joint Aircrete masonry is suited to both solid wall and cavity wall construction. In both cases, blockwork is typically constructed by working from the inside of the building, directly off the ground floor and first floors. Generally, the substructure walls are completed to dpc level in conventional masonry. The base course of blocks is laid using a conventional sand:cement mortar incorporating the dpc. This enables any irregularities in the substructure to be accommodated, as it is essential that the first course is laid level and plumb. Care taken at this stage will enable smooth progress for the rest of the build. The perpends (perps) should be formed using thin joint mortar to aid stability of the base course and maintain the bonding for the subsequent blockwork. The base course should be allowed to become stable before the subsequent thin joint blockwork is commenced.
Preparing to use thin joint mortar

Thin joint mortar is a finely ground blend of sand and cement, supplied pre-mixed in 25kg bags. The dry mix should be added to a measured volume of clean water (typically 5.0 - 6.0 litres) in a round container and mixed using an electric paddle. The consumption of thin joint mortar will depend upon the face size and thickness of the blocks being used. Once mixed, the mortar is workable for up to four hours with occasional remixing with the paddle, although no additional water should be used. For optimum results, the mortar should be stored dry following the recommendations of the manufacturer. The manufacturer will also give advice on working in cold weather.

At the time of their product search, the directors happened to see a video on thin joint Aircrete construction, in which the speed of construction and great versatility of the build method were demonstrated. They arranged for a trial wall to be built and, suitably impressed, changed the specification on the Soham project and started to build. Braeburn believe the Aircrete system saved them money as well as time, and were particularly pleased with the thermal performance they have since used thin joint on further projects.

Applying the mortar

...a practical solution

The mortar remains workable for several hours.

Prior to application, care should be taken to remove any loose surface material using a stiff brush. Thin joint mortar is applied using a notched scoop or sledge, which is drawn across the bed face to ensure the correct depth and spread. Thin joint mortar should maintain a consistent joint thickness of between 2 3mm. Once applied, the mortar bed will remain workable for up to 5 10 minutes. Blocks should be laid by pushing firmly against the mortared face of the preceding block whilst lowering onto the horizontal bed. A rubber mallet may be used to assist levelling, reduce the mortar thickness and ensure joints are fully filled. Once laid, setting takes place within a further ten minutes enabling storey height lifts to be built without compression of the mortar joints. To increase laying speed, mortar can be applied to several perpend joints in one operation by placing blocks 'on end' on a flat surface.
Outer skin cavity wall

Although the outer leaf of a cavity wall is normally built following completion of the thin joint inner leaf, the external skin should be built up to dpc before commencing the thin jointed blockwork. This allows the setting out of the window and door openings with outer masonry and the gauging of lintel heights, etc.

The notched scoop ensures a consistent joint thickness of 2 3mm.

The sledge one of a range of tools available to suit each application.

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Building with thin joint blockwork

WHITSTABLE, KENT
Denne Group, a leading edge developer, used the thin joint mortar system together with large format Aircrete blocks on a 29-unit development for Swale Housing Association as part of their Masterplan system. Masterplan is an approach to building thats designed to eliminate the typical, but avoidable delays inherent using traditional methods. By adopting new techniques, new technology and new processes the aim is to improve efficiency, save time and costs and achieve a better build quality and consistency.

Cavity walls

The outer leaf is normally constructed after the Aircrete inner leaf has been completed. This has the added advantage of allowing partial insulation to be retained against the inner wall using clips on the wall ties. It also reduces risk of mortar snots and minimises the likelihood of bridging and moisture ingress. Ties should conform to BS 1243, DD140-2 or have a British Board of Agrment certificate. Those designed for conventional mortar are not normally suitable for use with the thin joint method. Helical, or other suitable ties are recommended; these being driven, or face fixed, into the face of the blockwork as the brickwork proceeds. These are nominally spaced at 900mm centres horizontally and at 450mm centres staggered vertically, depending upon site exposure conditions. Additional ties will be required around openings and movement joints as is conventional practice.
Cavity trays

Best practice is to use a Type C tray which is built into the outer leaf as the wall progresses and leans against the outer face of the inner leaf.
Partition walls

On this particular project the Denne Group employed a team of apprentices from South Kent College who had just completed a short training course on thin joint construction. Thin joint is an accurate, high quality method yet is a skill that is quickly and easily learned or can be adopted intuitively by existing trades. In the longer term this will help reduce some of the problems of skills shortages in the industry as well as promoting a faster and more reliable form of construction.

Aircrete blocks are ideal for partition walls, both loadbearing and non-loadbearing. Research suggests that homeowners strongly prefer 'solid' walls when given the choice and Aircrete not only provides excellent resistance to the passage of sound but is fire resistant too. Junctions with the inner leaf need not be bonded in, a tied junction is normally sufficient, unless the partition is designed to buttress the inner leaf. Alternatively, the junction may be formed as a movement joint.
Window openings

Blockwork can be taken up in full block heights to form window openings, using cut blocks to sill level as necessary. Reveals may be formed by cutting a block slip to the required cavity thickness and mortaring it in position. The type of cavity closer needed will depend on the detail used, in some cases additional insulation may be required. Lintel bearings are normally cut in position, as the blockwork will usually be coursed to floor joist height.

Improved thermal insulation

...a versatile option

Thin mortar joints improve thermal insulation.

The insulating performance of conventional mortar is significantly inferior to that of Aircrete and, under current Building Regulations, the heat loss through mortar joints has to be considered when calculating U-values for walls. These losses are much reduced with the smaller volumes of mortar used in thin joint construction, whilst the greater potential for fully filled joints achieved by this method improves the airtightness of the building. So, whilst Aircrete used with conventional mortar has comparatively superior performance to other constructions, its use with thin joint mortar can further reduce heat losses by up to 10% in cavity walls. Due to the numerous detailing options for solid and cavity walls, insulation and internal finishes, it is not possible to give definitive performance data within this Guide. Specifiers should refer to the comprehensive technical data available from individual manufacturers at the addresses given on the back cover.
Improved sound insulation

The micro-cellular composition of Aircrete makes it a very efficient sound insulator in relation to its density. The British Board of Agrment has assessed field test data for separating walls constructed from Aircrete. As a result, they have stated that if built correctly and in accordance with the details of the relevant BBA certificate, Aircrete separating walls can meet the requirements of Approved Document E when constructed with thin joint mortar. Aircrete cavity wall solutions are also included in the Robust Standard Details construction document. Independent testing has shown that Aircrete partition walls built using thin joint mortar provide the level of acoustic performance needed for internal walls between certain rooms, as required by Approved Document E. Specific data and detailing options for separating walls and partitions can be obtained from individual manufacturers in relation to their own products.

Cavity trays are built into the outer leaf.

Suitable for a range of applications.

External cavity wall External solid wall

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Building with thin joint blockwork

RIDGEWAY HIGH SCHOOL
When time is of the essence, it is imperative that the build method used is predictable and reliable - just the job for thin joint Aircrete. Such was the case for the new 1.5m Learning Centre at Ridgeway School in Birkenhead, which had a construction window of just 9 months before the centre opened to students.

Structural stability of walls

The structural performance of thin jointed blockwork is greater than that of blockwork built with conventional mortar joints, taking into account both compressive and flexural strengths. Guidance on this may be found in BRE Digest 432 and the Draft for Development of Eurocode EC6 (ENV1996-1-1). The combination of the quick setting time of thin joint mortars and the large format blocks means that storey height lifts can be completed in one day. However, as with all masonry, it is good practice to temporarily prop walls that may be vulnerable during periods of adverse weather. This is particularly the case with long runs of blockwork, often at upper levels, which are not supported by internal partitions until the roof has been installed. Temporary propping of the wall should be considered at the design stage. Propping can consist of the use of scaffold boards fixed at the head of the wall and propped off the floor.
Scaffolding

Contractors Lockwoods Construction had worked with Aircrete for several years and knew that when used with the thin joint mortar system a watertight envelope could quickly be achieved, allowing finishing trades to begin work internally far sooner than would otherwise be possible. Work commenced using Aircrete blocks and thin joint mortar in conjunction with a steel frame construction. This took the outer skin off the critical path, gaining valuable additional weeks for the build programme, which was successfully completed and fitted out in time for the new school term.

Blockwork is laid from the inside of the building using the ground and intermediate floors as the working platform. To reach the higher levels, hop ups or bandstands and boards are necessary. An independent external scaffold is required to provide access and allow the intermediate floors and the roof to be installed. The scaffold may be either a traditional tube and clip or quick staging type. The quick staging types tend to be more flexible in use than traditional scaffolds. Scaffolding should be set out to take account of the outer leaf being built at a later date.
Movement joints

Consideration for movement should be given at the design stage and provision made for movement joints in all walls exceeding 6m in length. These should be designed at 6m centres, with the first no less than 3m from edge restraints or external corners. These joints are formed in the normal manner but require restraint ties across the joint that are compatible with a 2-3mm mortar joint. An alternative solution is to use a suitable reinforcement material, such as stainless steel or nylon mesh reinforcement, which is compatible with thin joint mortars. These materials are used in areas subject to high loading or stress, such as above and below openings. To distribute the stress in such situations it is recommended that they extend into adjacent blockwork 600mm horizontally and 430mm above and below each opening. In large panels of blockwork these materials may be used more frequently.

Joists

...a practical solution

Proprietary combination or boxed lintels are all suitable.

It is recommended that timber joists be built into the inner leaf, cutting and bedding blocks to fit in between, and sealing edges to prevent air leakage. Floor joists spanning onto party walls should be supported in hangers. Where joist hangers are used they should be notched into the block course above, or be of a proprietary type suited to the thinner joint. The decking should then be laid as soon as possible to provide a safe working platform.
Lintels

Lintels should be used and bedded into position using a traditional mortar to compensate for any irregularities in the dimensional tolerances of the lintel. Proprietary combination or box lintels are both suitable for use in thin jointed blockwork. Consideration should be given to temporary propping of the outer leaf of combination lintels until the mortar has set.
Internal finishes

A range of easy-to-use materials are available to complement Aircrete thin joint masonry.

Thin joint Aircrete masonry provides a highly accurate form of construction, leaving a smooth, flat internal surface that lends itself to traditional as well as innovative finishing techniques. For example, spray plaster or render can be applied direct to the blockwork with a total thickness of 3mm 4mm, greatly reducing the internal finishing time. Traditional plaster or dry-lining techniques may be used, whilst tiles can be bonded directly onto the blockwork surface.
External finishes

When using Aircrete as the inner leaf of a cavity wall construction, traditional outer leaf materials may be used. Alternatively, solid wall construction allows for rendering, tile hanging, timber cladding, insulated panels or various other board finishes onto battens fixed directly to the blockwork. Refer to individual Aircrete or cladding manufacturers for detailed design recommendations. For further guidance on internal or external finishes the individual manufacturers technical literature should be referred to.

The smoother surfaces help achieve faster finishing.

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