TechnicalInformationfor Planning andConstruction

ACICOManualfor ACICORoof SlabsA technical information manual of the ACICO plant in Kuwait published by ACICO, Kuwait and ACICO International GmbH & Co. Emmering-Füstenfeldbruck.

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.

Building withCommon Sense

Building on solid foundations

SAUDI AERATED CONCRETE INDUSTRIES CO. LTD. (ZAMIL-ACICO)Phone: 03-3580506 - Fax: 03-3580507 - Universal Access Number: 920025655

www.saudiacico.com

2

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

3

1Background

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 it’s 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.

The Kuwait plant is an independent, self- reliant 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.

4

ACICO Aerated Concrete:

2ACICO aerated concrete consists of the same raw material as natural stone but has these significant advantages.

• ACICOaeratedconcreteismadeofquartzsand, lime, cement and water - raw materials that are easily and naturally available

• the patented production process takesrelatively little energy since ACICO aerated concrete is steam cured at only 180˚C

• During the production process a naturalelement – 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 ACICOaerated concrete, give this construction material its exceptional physical characteristics and its combination of properties that make it superior to any natural stone:

• highthermalinsulation• balancedheatstorage• goodvapordiffusioncharacteristics• lightweight,largevolume• easy,rationalworkability• goodacousticproperties• non-combustible• impervioustoinsects• weather-resistant• long-lasting• environmentallycompatible• virtuallymaintenancefree

Better than natural stone.

5

2ACICO Aerated Concrete:

6

Production

3

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 180˚C. After steam curing the construction material and products are ready for delivery to sites.

The production of ACICO aerated concrete:

7

Production

3Raw Materials

Sand Grinding Mill

ReinforcingCutting to Length

SandGround

CementLimeMesh and Basket Welding

Immersion

Corrosion protection

Assembly

Casting

Expanding

Cutting

Steam Curing

Storage/ConstructionSite

Metering WaterExpanding

Agent

Mixing

8

ACICO Roof Slabs: Product and Application

44.1 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 loadbearing 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.

Nonvisible Joint Visible Joint Chamfered by Chamfer plain before erection

th.

L

WLength: Up to 600 cmWidth: 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.

4.2 Shapes and Formats

9

4ACICO Roof Slabs: Product and Application

4.3 Product Characteristics Data

Strength category GB 3.3 GB 4.4 Units

Breaking strength (Test blocks) 3.5 5.0 N/mm2

Dry density max. 600 700 Kg/m3

Thermal conductivity 0.14 0.16 W/(mK)

Design value for dead load incl. reinforcement and joint concrete 720 840 kg/m2

Elastic modulus 2000 2250 N/mm2

Thermal expansion coefficient 8 8 10-6/K

Shrinkage -0.2 -0.2 mm/m

Quality Control Room

10

Planning

5Dimensioning 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)

11

Strength Max dry density Design value Thickness Self load category Kg/m3 kN/m3 mm kN/m2

6Design 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 compressivestrength 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

G.B. 3.3 600 7.2 100 0.72 125 0.90 150 1.08 175 1.26 200 1.44 250 1.80 300 2.16

G.B. 4.4 700 8.4 100 0.84 125 1.05 150 1.26 175 1.47 200 1.68 250 2.10 300 2.52

12

Design Criteria

66.3 Max. Spans and Moments

Roof Slabs GB 3.3

Roof Slabs GB 4.4

SlabThick-ness

mm

M max. IMPOSED LOAD (KN/m2) Self

load

kN/m2

1٫00 1٫50 2٫00 2٫50 3٫00 3٫50 4٫00 4٫50 5٫00 5٫25 5٫50 5٫75 6٫00

kNm/m MAX. SPANS (m)

100 2٫54 3٫27 3٫02 2٫73 2٫51 2٫34 2٫19 2٫07 1٫99 1٫90 0٫72125 4٫17 4٫09 3٫7 3٫39 3٫13 2٫92 2٫75 2٫61 2٫49 2٫38 0٫90150 6٫18 4٫91 4٫38 4٫01 3٫72 3٫48 3٫29 3٫12 3٫03 2٫90 1٫08175 8٫64 5٫54 5٫01 4٫61 4٫29 4٫03 3٫81 3٫63 3٫50 3٫35 1٫26200 11٫46 6٫00 5٫58 5٫16 4٫82 4٫54 4٫31 4٫10 4٫00 3٫80 3٫70 3٫64 3٫58 3٫52 1٫44250 18٫42 6٫00 6٫00 6٫00 5٫85 5٫54 5٫27 5٫04 4٫83 4٫56 4٫56 4٫49 4٫41 4٫34 1٫80300 26٫94 6٫00 6٫00 6٫00 6٫00 6٫00 6٫00 5٫92 5٫65 5٫48 5٫38 5٫30 5٫21 5٫13 2٫16

SlabThick-ness

mm

M max. IMPOSED LOAD (KN/m2) Self

load

kN/m2

1٫00 1٫50 2٫00 2٫50 3٫00 3٫50 4٫00 4٫50 5٫00 5٫25 5٫50 5٫75 6٫00

kNm/m MAX. SPANS (m)100 3.62 3.50 3.50 3.19 2.95 2.75 2.58 2.45 0.84

125 5.96 4.48 4.32 3.95 3.66 3.43 3.24 3.7 2.94 2.81 0٫90

150 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 6٫00 6٫00 6٫00 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 6٫00 6٫00 6٫00 6٫00 6٫00 6٫00 6.00 5.90 5.90 5.90 5.90 5.90 5.90 2.52

13

6Design 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.

6.5 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.

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 aboveACICOslabsfordisceffect.

Typical ReinforcementMain-Bars and Cross Bars

14

Erection

77.1 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 ø8 mm for joints and ø12 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.

15

7Erection

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 isrequired, 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.

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

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

≤ 20

≤ 20 ≤ 40

varia

ble

Leng

th

16

Details

8Supports

Ring Beam

On load bearing masonry2 ø 12 2 ø 12

ACICOclosureblock

Erectionbarø 8mmspacing1.5m

≥10

≥25

External wall

≥5

≥20

Internal wall

≥7.5

Masonry support Concret beam support

≥5

Steel beam support

≥7.5 ≥7.5 ≥7.5 ≥5

17

8Details

Ring beam on concrete structure

2 ø 12 2 ø 12

Erection bar ø 8mm spacing 1.5m

≥10≥5

Internal wallExternal wall

Supports parallel to the slab-span

7.5 ≥10 ≥2 ≥2 ≥5 ≥2

ACICO roof slabs with concrete coverU shaped bar Steel Mesh ø 6mm @ 20 cm c/c U shaped bar

≥4

18

Details

8Roof coverings and parapet details

Anchor Barsfor Parapet-Columns

Styropor Strip Th. Min. 3 cmMembraneTiles in Mortar and SandFoam Concrete

InfillBlockwork

Joint Barø 8 mm

RingBeam2 ø 12 mm

ParapetwithACICOblocksor panels

Joint Bar

Ring Beam

ACICOBearingMasonry

3 cm Space to avoid them exp. pressureSlope cut ACICO blockMembraneTiles in Mortar and SandScreedFoam Concrete

19

8Details

Sloped RoofSupported on internal Bearing Masonry, and anchored by Ring beam.

20

Details

8Finishing of Ceilings

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

B- Visible JointsFinishing by fine course-rendereing.(Edges chamfered before slabs erection)

C- False CeilingsFixing of Hanger forfalse 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

21

8Details

Installation of Conduits and AC. - Ducts

For finishing by plaster:Conduits are fixed before foam concrete.(Holes for light points by drill.)

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.

Light Point

22

Details

8ACICO Loft SlabsPrecast Slabs without shuttering etc.

Concrete skeleton

Concrete slabs

ACICO Lintel

Window

ACICO infillblockwork

For connection ofwater proofinguse thinnerblock in thefirst course.

Wall tiles fixedby cement glue directly on ACICO walls.

Door

ACICOLintel

ACICOPartitions

Falseceiling

BATHROOM

ACICO slabs th. 10 or 12.5 cmsupported on int. walls.

Room for AC Equipments etc.

23

8Details

Steel Hanger for openning ≤ 62.5 cm

Steel Hanger for opennings ≤ 125 cmFl

at s

teel

80 x

5 m

m

20≤

62.5

cm

2020

L 10

0 x

7 m

m

≤ 12

5 cm

L

24

Properties and Advantages

99. 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 doesn’t 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:

• Theslabsareprecast.Sothereisnoneedfor reinforcing and shuttering works or curing time.

• Immediately after erection, the roof isready to resist the exposed loads.

• The light weight property helps indecreasing other structural elements’ cross sections.

• Thethermal insulation is12-timeshigherthan 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.

• Forslabproducingonlysandandbindersare required, i.e. reducing local gravel consumption.

• Lessmanpowerandtime.

25

9Properties 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 Heat category Conductivity cm 1/8 Transmission l W/mK m2 K/W Coefficient k W / (m2.K)

G.B. 3.3 0.14 10 0.71 1.13 12.5 0.89 0.94 15 1.07 0.80 17.5 1.25 0.70 20 1.43 0.62 25 1.79 0.51 30 2.14 0.43

G.B. 4.4 0.16 10 0.63 1.25 12.5 0.78 1.05 15 0.94 0.90 17.5 1.09 0.79 20 1.25 0.70 25 1.56 0.58 30 1.88 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˚ FTiles in Mortar and sand

screeds and membrane

ACICO Roof Slabs GB 3.3 ≥ 20 cm

Foam concrete average 10 cm.

ACICO Roof Slabs GB 3.3 ≥ 20 cm

MembraneScreed

Foam concrete average 10 cm.

26

≥ 60 dB

≥ 50 dB

Properties and Advantages

99.2 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.

9.3 DiffusionBehavior

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 diffusionresistances’are:

Air = 1

Hebal = 5-10

Concrete = 50=100

Glass = ∞

Remark: As lower the diffusion resistances-value as better the interior climate.

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:

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

Tiles in Mortar and sand screeds and membrane

MembraneScreed

27

9Properties 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

B/ With Plaster

th

th

u

u

For F30, u = 10 mmFor F60, u = 20 mmFor F90, u = 30 mmFor F120, u = 40 mm

For F30, u = 10 mmFor F60, u = 22 mmFor F90, u = 34 mmFor F120, u = 42 mm*

* 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.

ACICO Factories, Branch Offices,Sales Organizations and Licensees

International:

Argentina Japan

Australia Korea

Austria Saudi Arabia

Belgium Kuwait

Brazil Malaysia

Bulgaria Mexico

Czech Republic Netherlands

CIS Rumania

Cuba Slovakian Republic

France Spain

Germany Switzerland

Greece Taiwan

Indonesia Thailand

Italy Turkey

United States of America

Our Branches

28