The Formblock Technical Manual 2010

FORMBLOCK MASONRY CODE - STANDARDS Applicable to FORMBLOCK All components and installation shall comply with the Building Code of Australia (BCA) and the relevant Australian Standards, including AS 3700 and the Standards referred to therein. Unless noted otherwise, masonry units shall comply with AS 4455 and the following requirements: 1. Dimensional Category 4 2. General purpose salt attack resistance grade protected 3. Minimum characteristic compressive strength 15 MPA 4. Units shall have a maximum permeability of 2mm / minute, and efflorescence potential of Nil or slight, and a characteristic modulus of rupture of 0.8 MPA 5. Colour and texture of Units as specified by Architect. All grout used for core filling to be 25 MPA with a slump spread of 550 mm Prop walls where necessary to ensure stability. Retaining walls are to be cured for a minimum of one week prior to being back filled. Walls to remain propped during Backfilling. Waterproofing of walls to Architects specification. All reinforcing is to be centrally located unless otherwise noted by the Engineer. All reinforcement to be in accordance with the Engineers design and specification Project Conditions 1. Protection of Formblock : During construction, cover tops of walls, projections, columns and sills with waterproof sheeting at the end of the days work. Cover partially completed masonry when construction is not in progress. Extend cover a minimum of 600mm down all faces and hold cover securely in place. 2. Do not apply uniform floor and roof loads for at least 12 hours and concentrated loads for at least 3 days after building masonry walls or columns. Such loads shall be suitably propped to minimize load on masonry until grout has fully cured as determined by the Engineer. 3. Stain Prevention : Immediately remove grout seepage and other materials from the face of walls and columns to prevent staining. i. Protect base of walls from rain-splashed mud by spreading coverings on ground and over wall face surfaces. ii. Protect walls, columns, sills, ledges and projections from debris dropping into cavity prior to core filling. iii. Protect surfaces of window and doors as well as similar products from damage resulting from grout fill. iv. Turn scaffold boards near the masonry face on edge at the end of each day to prevent rain from splashing dirt onto completed masonry. Formblock Masonry Units: (FMUs) All Formblock Masonry Units are to be manufactured only by Manufacturers under License to Formblock. Strict quality control guidelines for block size, tolerances and characteristics are to be strictly adhered to. Any defective masonry units delivered to site are to be set aside and returned to the Manufacturer. Shapes: Formblock Units provide for 6 shapes :i. Standard block 400mm x 200mm x 200mm nominal ii. Half block 200mm x 200mm x 200mm nominal iii. End block 400mm x 200mm x 200mm nominal iv Left hand block 400mm x 200mm x 200mm nominal v. Right hand block 400mm x 200mm x 200mm nominal vi. Uni-block 400mm x 200mm x 200mm nominal

Execution Examine conditions with Installer present, for compliance with requirements for installation tolerances and other conditions affecting performance of work. i. For the record, prepare written report, endorsed by Installer, listing conditions detrimental to performance of work. ii. Verify that foundations are within tolerances specified. iii. Verify that reinforcing dowels are properly placed to suit Formblock masonry units. iv. Layout walls in advance for accurate spacing of surface bond patterns with accurate locations of openings. Movement-type joints, returns and offsets. Avoid using less-than-half-size units, particularly at corners, jambs and where possible, at other locations. v. Stopping and resuming work: Stop work by raking back units in each course from those in course below: do not tooth. vi. Form up and grout fill spaces between masonry and built-in items unless otherwise indicated on Architects detailing. vii. Inspectors: Owner will engage qualified independent Inspectors to perform inspections and prepare reports. Allow Inspectors access to scaffolding and work areas, as needed to perform inspections. viii. Place grout fill only after inspectors have verified compliance of grout spaces and grades, sizes, and location of reinforcement. ix. Testing Agency: Owner will engage a qualified independent Testing and Inspection Agency to perform field tests and inspections and prepare test reports. Payment of these services will be made by the Owner. Retesting of materials failing to comply will be done at the Contractors expense. x. Testing Frequency: One set of tests for each 460 sq. mtr. of wall or portion thereof. xi. Formblock Masonry Unit Test: For each type of unit provided, per AS 3600 - 2001. Source documentation from manufacturer as a minimum. xii. Grout Test (Compressive Strength): For each mix provided, per AS 3600 2001 xiii. Pargeting and below ground Membranes: External masonry walls below ground level shall be protected from rising damp causing stain and dampness to the wall. Only industry approved methods of pargeting or membrane applications shall be used.

Waterproofing Any single skin concrete masonry unit regardless of grout fill is not waterproof. Many options are available for waterproofing external walls such as: a. Cavity wall b. Externally applied membrane. c. Combination of a. and b. Additives that are mixed into the grout fill and block composition are only beneficial as a second line of defense to water penetration. As there are numerous products on the market for such additives and external membranes that vary in colour range and textures it is considered the responsibility of the Architect, Contractor or Specifier to determine which method of weatherproofing, suitable to the on-site project conditions, that should be used. Particular attention is required around openings to ensure that water penetration is prevented from getting into the joint between the masonry and the insert, e.g. Window frames, door frame. Issues for consideration:(i) Weatherproofing should be durable. (ii) Rebates in the form of treated timber or concrete are used. (iii) Water that penetrates through to the weather stop should be capable of draining away. (iv) Pressure equalization at the base of joinery should be provided. Coordination of Trades The General Contractor should note that it is necessary to coordinate all trades that require in-wall product such as electrical conduit, plumbing and the like prior to core filling the wall.

Introduction:Formblock is a fast, easy to install, dry stack, concrete block wall system that can provide significant savings in labour and construction times over traditional masonry block work. The system can also reduce costs associated with lintels, bond-beams, scaffold and plant hire, mortar mixes, waste and clean up costs. Overall, Formblock is a faster, more effective walling system. Formblock walls are laid in a conventional stretcher bond pattern using a specially designed plastic bridge which helps locate the position of each block and holds the horizontal and vertical steel reinforcing bars in the correct position, ensuring correct cover is always maintained. In addition, vertical bars do not need to be tied to the starter bars, as the bridge locates them within a minimum allowable distance of each other. See BRANZ test reports ST0597-2 and 3. It is important to understand that Formblock is a masonry unit not dissimilar to conventional masonry however it does not require mortar between the blocks. Until it is reinforced and core-filled it is not considered a structural element and therefore, like its conventional counterpart, it requires engineering computations if it is to be used in load-bearing or retaining capacity. The Formblock building system is the subject of intellectual property owned by Global Ryder Holdings Pty Ltd including patents, design rights, trademarks and copyright property worldwide.
Standard Right hand

200 Series Formblock shapes:As the Formblock profile differs from standard masonry, in particular when using corner blocks and the Uni-Block, the reinforcement placement will differ from the standard 400mm grid set-out.

Half

Uni-block

400mm nominal
16" nominal

200mm nominal

8" nominal

Left hand

End block

Step By Step Procedure: Footing Set-up

Preferably the footing, or slab, needs to be as level as possible before commencing the block laying, as conventional block work can compensate for any imperfections through the number of courses in the wall and by providing a near as possible level base it makes the initial base course of Formblock much easier to lay level and plumb. Each Formblock measures 400mm x 200mm x 200mm nominal making it very easy to set out on the construction site. Step 1. Lay the first course of Formblocks on a bed of conventional mortar ensuring that the side face of the block is plumb and the top face level. Spend a little extra time on the first course to achieve this result. Each corner will consist of left hand and right hand corner blocks.

Step 2. Insert the plastic Form Bridges across the ends of the blocks. There are two types of plastic Form Bridge, the standard bridge black and the corner bridge red.

Step 3. As with all block laying, ensure that all blocks are plumb and level

The standard bridges, when inserted, have up-stands that form a key for the next course, whilst the corner bridges sit flush with the top of the block. This allows the course above, which has a center web, to lay directly across the bridge without obstruction The plastic bridge also ensures that the vertical reinforcement splice bars do not have to be tied to starter bars as they are spaced within the minimum distance of each other. See Auckland University test results page 3 Executive Summary and BRANZ test results
Step 4. Lay the required horizontal or lateral steel into the plastic Form Bridge. There are three lateral steel placement locations and one centre hole for the vertical steel within the bridge. The structural engineer with specify the size and location of all reinforcing and nominate its position within the wall. The reinforcement steel simply clips into the bridge and at the same time allows the blocks align to with each other and will add strength to the wall even before the wall is filled with concrete grout.

41 mm

300mm 100mm

200mm

multiples of 200mm

300mm 100mm

200mm

multiples of 200mm

STARTER BAR LAYOUT

Step 5. Lay the next course of Formblocks in a stretcher bond pattern on top of the previous course. Repeat steps two to five. To level or straighten a Formblock wall, use a string line and set it about 25mm above the last course along one face of the wall. If there are any blocks leaning off this line, insert a plastic wedge between the courses of blocks to adjust the block back to the line. (Breakaway wedges are found in the center of each bridge).

Step 6. Once the wall is set at the required height, check that the wall is plumb and in alignment. Brace the wall adequately to ensure stability as determined by the engineer or general contractor. Insert the vertical steel reinforcing into the required chambers and in accordance with the structural engineers specification. Ensure that the vertical steel is fully inserted to the depth required by the engineer. An indication that this has been achieved is by bouncing the steel off the concrete footing or slab resulting in a pinging sound, alternatively by measurement of steel to wall height. The wall can now be core-filled.

Cut Blocks When reducing wall dimensions, simply cut the required block to length and bond as illustrated. Place the plastic bridges into the insets of the block wherever possible to help the bonding. The steel reinforcement is then placed into the locators provided in the bridges, locking the blocks in place laterally. Note: Always place a cut Formblock in the middle of the wall never use a cut Formblock as the last block. Box and brace over this area. If the cut block only has one center web left, inspect the block to make sure that the remaining web is in good condition.

400

cut to size

400

400

400

95

nominal 95

As shown in the BRANZ test result ST0597-2, the full width of the Formblock can be used in calculations less any external chamfers as shown in this drawing.

Core-filling Formblocks So as to reduce the risk of hydrostatic pressure, pour slowly and carefully over steel and/or the center web of the block to slow the flow of grout. The wall will automatically fill diagonally as shown in the diagram. Allow grout to fill to the top block before moving the pump nozzle. Then slowly move the nozzle along the wall allowing remaining parts of the wall to diagonally fill. There will be no need to vibrate. Gently rod as you go, to settle the pour and to eliminate voids within the wall. When rodding do not remove rod in one motion, rod as you gently remove.

A:

B:

C:

D:

Concrete Core-fill Core-filling Formblocks requires a flowable grout with a maximum aggregate or stone of 6 to 8mm and needs to be sufficiently fluid so as to fill all the voids. It will then bond together the adjacent masonry units, to bond steel reinforcement into the cores, and to unify the wall into a single monolithic structure. See Auckland University test results page 5. Use conventional core-fill mix common to the area with the following requirements:a. b. Mix strength to structural engineers specification i.e.: 20 MPA Plasticiser as specified by engineer to achieve continuous smooth flow and spread. DO NOT keep adding water to achieve required spread. Spread to be 600mm and maintained during the pour. The initial spread test is to be done on site prior to pour and check spread midway through each pour. Maximum aggregate size to be 6 to 8mm for 200 and 150 block series

c.

d.

Concrete core-fill As weather conditions effect the life span of concrete before it begins to set, consideration must be given to the mix to ensure that the plasticity and fluency of the core-fill is constant. It is recommended that the blocks walls are thoroughly watered down prior to core-filling, along with the concrete pump and hoses. There is no need to use mechanical vibrators. Its only necessary to gently rod the mix whilst pouring to ensure that the core-fill flows adequately into all voids within the blocks. A slow bleed will be seen between the blocks as the wall fills. Testing has shown that Formblocks can be poured at a height of 3 meter. However, all care must be taken when doing so. Blocks must be inspected for damage/cracks, prior to laying and brace the wall adequately. We recommend pouring at the industry standard.

Using Formblock in columns and piers

9 400 300 100100 300 400 sealant backing rod neoprene gasket
100 100 300 100

9 400 300 100100 300 400 sealant backing rod neoprene gasket
200 100

400

300

200

300

400

400

300

100

200 100

expansion joint

9 400 300 100100 300 400 sealant backing rod neoprene gasket
100 100 300 100 4" 8" 4"

expansion joint

PIER TYPE 1 2nd course

neoprene gasket backing rod sealant

PIER TYPE 2 2nd course

neoprene gasket backing rod sealant

PIER TYPE 3 2nd course

100 200 100

CORNER 2nd course

9 400 300 100100 300 400 sealant backing rod neoprene gasket
200 100

400

300

200

300

400

400

300

100

200 100

PIER TYPE 1 1st course 100 400

neoprene gasket backing rod sealant 100

100

PIER TYPE 2 1st course 100 300

300 100

neoprene gasket backing rod sealant

PIER TYPE 3 1st course

100 200 100

CORNER 1st course

300 100

200

100

100 300

fig.1
uni-block

400
300

200

300
uni-block 300

300

100

400

100
100 300 100

400

backing rod neoprene gasket

fig. 2
400 400

100

400

100 300

neoprene gasket COLUMN TYPE 2 1st course backing rod EXPANSION JOINT sealant

COLUMN TYPE 1 1st course

400

sealant

uni-block

COLUMN TYPE 2 2nd course 100 300 300 100

400 300 100 9 100 300

200

300

200

Cut open end to uni-block and partial open end as per fig. 2

200

300

COLUMN TYPE 1 2nd course

200

Cut open end to uni-block and partial open end as per fig.1

400

uni-block

400

400

400

400

300 100

400

300 100

Concrete slab as per Engineers design.

200 200

Concrete slab as per Engineers design.

Invert lintel blocks to enable horizontal steel to be positioned at bottom

Reinforce and core fill to Engineers detail.

800 800

150mm wide formply fixed to timber head HEAD DETAIL

150mm wide formply fixed to timber head

HEAD DETAIL
1300 window opening varies

1300 window opening varies

3000

3000

200 x 50mm timber boxing to support lintel,braced as required.

Remove boxing and secure timber window bucks.

200 x 50mm timber boxing to support lintel,braced as required.

SILL DETAIL
cut block to suit sill height

SILL DETAIL
cut block to suit sill height

cut blocks to suit sill height

2200

Reinforce and core fill to Engineers detail.

900

2200 900

SECTION WINDOW DETAIL OPTION - 1 Condition where only the sill requires cutting

SECTION WINDOW DETAIL OPTION - 1

ELEVATION WINDOW DETAIL OPTION - 1

OPTION - 1 LINTEL PROCEEDURE

Concrete slab as per Engineers design.

200 200

Concrete slab as per Engineers design.

Use 1/2 block turned end up where lintel requires cutting.

At each end use standard block cut in half to allow for steel and core fill to flow through

Use 1/2 block turned end up where lintel requires cutting. This condition would apply where window head is not on block coursing.

600

600

Reinforce and core fill to Engineers detail. 225mm wide formply fixed to timber head

150mm wide formply fixed to timber head

125

HEAD DETAIL
1375 window opening varies

125

HEAD DETAIL
1375 window opening varies

3000

3000

200 x 50mm timber boxing to support lintel,braced as required.

Remove boxing and secure timber window bucks.

200 x 50mm timber boxing to support lintel,braced as required.

SILL DETAIL
cut block to suit sill height

SILL DETAIL
cut block to suit sill height

cut blocks to suit sill height

2300

2300

Reinforce and core fill to Engineers detail.

900

900

7'-7"

SECTION WINDOW DETAIL OPTION - 2 Condition where both sill and head require cutting

SECTION WINDOW DETAIL OPTION - 2

ELEVATION WINDOW DETAIL OPTION - 2

OPTION - 2 LINTEL PROCEEDURE

SUMMARY OF FORMBLOCK INTERNATIONAL TEST REPORTS:

FULL DETAIL COPIES OF THESE REPORTS ARE AVAILABLE UPON REQUEST OR FROM WEB SITE www.formblock.net
Auckland University Test Results In plane shear It was noted that NZ4230:2004; BS 5628-2:2004; AS3700:2001; and US masonry standard MSJC (2005), testing indicated that the Formblock wall system exhibited excellent displacement ductility capacity, substantially in excess of the maximum value of = 4 that is stipulated in NZS 4230:2004. No significant slip was observed in the non-contact lap splices at the base of the wall, and the use of Form-fill concrete was found to ensure masonry compression strengths well in excess of the values specified in NZS 4230:2004. Overall the Formblock concrete masonry system performed in a manner compliant with NZS 4230:2004, BS5628-2:2005; AS3700:2001 and US masonry standard MSJC (2005) . BRANZ Test Result ST0597-2 It is considered acceptable to assume that the outside edge of the horizontal contact area ( i.e. 88mm from the center of the block see drawing on following page ) may be taken as the outer edge of the compression stress block and the depth of the stress block may be calculated using normal reinforced concrete masonry ultimate limit state design principles, where the compressive strength of the masonry is assumed it be 15MPa since there is no mortar present to limit the design stress, as in NZS 4230:2004. BRANZ Test Result ST0597-3 Non-contact splice bars between vertical bars and the corresponding starter bars are acceptable with Formblock walls, given that they are constrained within the plastic bridges used to maintain alignment of the blocks. 12mm starter bars must lap the main vertical steel over a minimum length of 400mm. For walls that span vertically under face loading, the horizontal bars must be placed alternately on either side of the vertical bars to maintain the vertical bar at a position near the center of the wall. Because the walls are dry stacked, there are no mortar droppings and because the bars are non-contact spliced, there is no need to provide cleanout/access ports at the bottom of the walls. CSIRO Fire Test Performance observed in respect of the following AS1530:Part 4-1997 criteria: Formblock 200mm wall Structural adequacy Integrity Insulation - No failure - No failure - No failure 240 minutes 240 minutes 240 minutes

Performance observed in respect of the following AS1530:Part 4-1997 criteria: Formblock 150mm wall Structural adequacy - No failure 241 minutes Integrity - No failure 241 minutes Insulation 112 minutes

CSIRO Sound Test The measurement was performed in compliance with the requirements of AS1191-2002 and recorded a STC rating of 52 for the 150mm corefill Formblock wall.

Exploded view of Formblock during construction

Grout fill All cores

Horizontal and Vertical steel laid to Engineers requirements

Vertical reinforcing to lap along side of starter bars

.

No need to tie starter bars as testing showed that as long as they are inside the Plastic bridge then they are within allowable distance there will be no slip.

Lap to Engineers Specification

No need for Cleanout blocks

Vertical starter bars formed into footing

Formblock wall poured and lifted, demonstrating the ductility of the system.

This demonstration panel is one of 6 built in Florida showing how a 1.5tonne panel can hang from a Formblock lintel. The sides of the display are cut to show how well the grout penetrates throughout the wall.

Formblock used as lintels above door and window openings. This eliminates expensive boxing and poured columns and beams.

Formblock maintains a spotless work site.

Formblock used in Uptown Motorcity as supporting columns and piers. By using Formblock, the builder - Al Futtaim Carillion - was able to reduce their expensive on site labour from some 500 men to only 50 and also bought the site to completion well ahead of schedule.

Formblock was able to be laid to suit the unique architectural circular design for Uptown Motorcity.

Formblock Training Site in Dubai

Training labourers ready for Uptown Motorcity site, UAE Using the Formblock system, enabled the developer to reduce onsite labour from 500 men to 50

Formblock Training Site in Dubai

Formblock On Uptown Motorcity Site in Dubai

Formblock in civil contracts

Formblock used as a services culvert for a prison in New Zealand

Formblock supporting the M7 freeway Sydney, Australia. The walls are 200mm Formblock, retaining full 12 meters.

The trompe loeil was a pleasant addition to the walls but was not part of the contract.

More Formblock completed apartment buildings