SECTION 04240 ACCOA
Master Specifications
SECTION 03440
AUTOCLAVED AERATED CONCRETE PANELS
PART 1. GENERAL
1.01 DESCRIPTION
The work under this section includes all labor, materials, equipment and services including Special Engineering Design necessary to complete the autoclaved aerated concrete panel work as shown on the Drawings and specified herein. Work includes building chases and routing coordination with construction activities specified in other sections. This section includes design, fabrication, transportation and erection of structural AAC floor, wall and roof reinforced panels and connections.
1.02 RELATED WORK
A. Section 03100 – Concrete Form Work
B. Section 03210 – Concrete Reinforcement
C. Section 04240 – AAC Units
D. Section 04241 – AAC Partitions
E. Section 07840 – Fire stopping
F. Section 08110 – Steel Doors & Frames
G. Section 08520 – Windows
H. Section 09900 – Painting & Special Coatings
I. Division 16 – Electrical
1.03 QUALITY ASSURANCE
A. ACI 530-95: Building Code Requirements for Masonry Structures
B. ACI 530.1-95: Specifications for Masonry Structures
C. ACI 318
D. ASTM C1386-98
E. ASTM E119 – Fire Resistance
F. ASTM C1452-00 Standard Specification for Reinforced AAC Elements
G. Single Source Responsibility: Obtain the AAC wall, floor and roof panels and AAC units and partitions (specified in other sections) and accessory components from one source, from a single manufacturer.
H. ANSI/UL 263 Fire Test of Building Components
I. ASTM E90/ASTM E 492 Sound Transmission (STC), Impact Sound Transmission (IIC)
1.04 SUBMITTALS
A. Shop Drawings signed and sealed by a Professional Engineer registered in the appropriate state, whose specialization is structural design.
1. Indicate sizes, sections, dimension of units, arrangement of joints, joint sealant details, reinforcement design, manufacturer fabrication, and installation and erection details. Include location of openings fabricated in units.
2. Identify reinforced AAC panels with mark used on shop drawings. Identifying marks shall be located on surfaces not visible in installed configuration.
3. Indicate strength category and dry density.
B. Certification: Provide certification signed by an authorized officer of the manufacturer that the products comply with the specified strength requirements.
C. Design calculations: Submit design calculations signed and sealed by a Professional Engineer registered in the appropriate state, who specializes in structural design.
1.05 DELIVERY, STORAGE AND HANDLING
A. AAC panels shall be stored on pallets.
B. Cover open panels with 4 mil visqueen. Keep units dry. Re-cover units during inclement weather and non-work hours.
C. Protect AAC panels from oil and chemical staining.
1.06 PROJECT CONDITIONS
A. Environmental requirements: AAC panels should be stored in stabilized lay down area, out of standing water or mud, within the confines of the project and crane accessible.
B. Spread panel mortar on horizontal and vertical AAC panels and set panels within 60 seconds of spreading mortar.
C. Finishes shall be applied only with a moisture reading no greater than 15%.
D. Heat panel mortar, when required, to produce temperatures between 40° F and 110° F at time of mixing. Maintain temperature above 40° F until placed.
E. Protect in-place panels from rain and snow by covering with weather resistant membrane for 24 hours.
F. Protect AAC in-place construction from direct exposure to wind and sun when ambient air temperature is 100° F or greater to maintain panel mortar life and panel to panel connection.
1.07 SEQUENCING/SCHEDULING
A. Loading AAC panels after completion shall only be done after the units have properly set as follows:
1. Uniform floor or roof loads: 12 hours minimum.
2. Concentrated loads: 72 hours minimum.
B. Schedule, sequence and coordinate with work in other Sections for chases or routing areas required in AAC walls for electrical, plumbing and other items. Request relevant construction contractor or sub-contractors to mark actual routing and chase locations with required depth.
C. Pre-installation / pre-construction conferences:
1. Prior to reinforced AAC panel installation, a pre-installation/pre-construction conference will be held to review work to be accomplished.
2. Attendees: Contractor, reinforced AAC panel manufacturer’s representative, panel installer, steel and concrete subcontractor, window subcontractor, flashing and sheet metal subcontractor, electrical subcontractor, plumbing subcontractor and other subcontractors involved with reinforced AAC panels and adjacent construction installation.
3. Verify submittals have been reviewed.
4. Reinforced AAC panel manufacturer/subcontractor shall review changes to previously reviewed penetration details.
5. Record minutes of meeting; distribute to attending parties and Architect within seven (7) working days of meeting.
PART 2. PRODUCTS
2.01 MANUFACTURERS
A. Acceptable Manufacturers: ACCOA - Aerated Concrete Corporation of America, 3351 West Orange Blossom Trail, Apopka, Florida 32712.
Telephone No.: 407-884-0051. Toll Free No.: 1-888-901-ACCO (2226).
Fax: 407-884-5111.
B. Other manufacturers meeting the requirements of the specifications.
2.02 MATERIALS
A. Autoclaved Aerated Concrete (AAC) panels: AAC panels shall have a minimum net area compressive strength of 580 psi and a minimum dry density of 31 (or greater) pcf.
1. Size:
Nominal dimensions:
a. Wall panels, reinforced: 6”, 8", 9.5”, 12” thickness by 24" width and
20'-0" maximum length.
b. Floor panels, reinforced: 6”, 8”, 9.5”, 12” thickness by 24" width and 20'-0" maximum length.
c. Roof panels, reinforced: 6”, 8”, 9.5”, 12” thickness by 24" width and 20'-0" maximum length.
2. Lintel Units:
a. Solid reinforced units: Same width as walls by 8" nominal height x 96" nominal length.
b. “U-shaped” lintel units: Same width as walls by 8" nominal height x 24" nominal length.
B. Fire Resistance: Wall assemblies shall meet ANSI/UL 263 (ASTM-E 119).
C. Mortar materials: (For thick bed leveling)
1. Portland Cements: ASTM C150, Type 1
2. Sand Aggregate: ASTM C144; use sand from same source for entire project.
3. Water: Potable
4. Hydrated Lime: ASTM C207 Type S
5. Masonry Cement: ASTM C91
D. Masonry Accessories:
1. All masonry reinforcement, anchors, ties and metal embedded in masonry shall be galvanized in accordance with ASTM A 153, Class B-2, Hot-Dip (1.50 oz. per sq. ft.).
E. Brick or CMU Veneer Ties
1. AAC Wall Back-up
a) DUR-O-WAL Inc. D/A 5213 or equal.
b) Anchor fasteners: Fischer Fasteners # S1OH8ORT
c) Hilti or equal
2. Space all horizontal wall reinforcing as required by design, vertically. Space all masonry veneer ties as required by design.
F. Miscellaneous Accessories & Finishes
1. Reinforcing Bars:
Deformed steel, ASTM A615, Grade 60 of the sizes shown.
2. Individual Wire Ties for Masonry:
Fabricate from 3/16" cold drawn steel wire, ASTM A82, unless otherwise indicated, in the length required for proper embedment in wythes of AAC.
3. Anchors and Ties:
Provide straps, bars, bolts and rods fabricated from not less than 16 gauge sheet metal unless otherwise indicated.
4. Flashing for Masonry:
Provide concealed flashings, shown to be built into masonry, as follows:
Provide W.R. Grace’s Ice and Water Shield or similar system.
5. Interior Plaster and chase fill material: Coronado Paint/Granosite System, Elite Cement Products, Syder Oxydro, Tri Arch, or equal as required.
6. Coronado Paint, Granosite System Cement Plaster (stucco), Elite Cement Products, Syder Oxydro, Tri Arch or equal and chase fill material.
7. Backer rods and sealant: Specified in Division 7; Sealant.
8. Fire rated insulation for penetrations of rated walls: Specified in Division 7; Fire-stopping.
G. Mortar and Grout Mixes
1. Mortar:
Except as otherwise specified, mortar shall be ASTM C270, Type S for leveling courses and cell fill. Mortar shall be accurately measured by VOLUME (Proportion method). Mortar for walls and partitions of concrete block shall be one of the two following mixes, at the Contractor’s option:
1 part Portland Cement
½ part Portland Cement
½ part Lime Putty or
1 part Masonry Cement
4 parts Sand
4 parts Sand
2. Mortar and Grout Mixes:
Do not use calcium chloride in mortar or grout.
3. Grout: ASTM C476.
4. Lintels: Fill with 3,000 psi concrete
I. Key joint and ring beam reinforcement: ASTM A615-95b, Grade 60; deformed type for #3 and larger bars; actual sizes indicated on Contract Drawings.
J. Anchors: Recommended by reinforced AAC panel manufacturer.
K. Joint sealant, acceptable product as specified.
L. Headers and frames required to install reinforced AAC panels at openings: Designed and detailed by Project Engineer of Record.
M. Coatings: acceptable product: Coronado Paint, Granosite Systems, Elite Cement Products or equal.
N. Mortar materials, acceptable product: ACCOA Thick & Thin Bed Mortar.
PART 3. EXECUTION
3.01 PREPARATION
A. Protection:
1. Keep panels dry during erection by covering at end of each work period with non-staining waterproof membrane covering.
2. Protect partially completed panels not being worked on from the elements until construction can continue.
3. Covering: Overhang at least 2'0" on each side of wall; anchor on each side of wall.
4. Protect finished, exposed work from stains.
5. Take particular care to keep AAC panels clean.
6. Brace panels during construction to protect from wind damage.
3.02 INSTALLATION
A. Workmanship:
1. Erect AAC panels plumb, level and true to line for range.
2. Cut AAC panels with manufacturers recommended hand-type saw or electric band saw specially designed for cutting AAC products. Lay out panels to minimize cutting.
B. Provisions for other work:
1. Make provisions (chases and routing) for work to be installed under other sections that are required to be coordinated as work progresses. Exercise care not to disturb other materials from position.
2. Coordinate with SEQUENCING AND SCHEDULING article for required routing and chases.
3. Fill in interior spaces around built-in items with fine grout or interior plaster.
4. Fill in exterior spaces around built-in items with fine grout or stucco.
5. Fill hollow metal frames in AAC walls with grout as wall is constructed. Rake back ½" joint between hollow metal frame and adjacent AAC unit to receive sealant at butt type frames. (Back priming of hollow metal frames with a bituminous coating as specified in the Hollow Metal Doors and Frame Section.)
C. Mortar Joints:
1. Spread panel bond material on vertical or horizontal joints prior to erection.
2. Take particular care to avoid spreading mortar on exposed face of AAC panels. Only normal mortar droppings will be accepted on face of AAC panels; remove only after mortar has dried enough not to smear.
D. Flexible flashing:
1. Clean AAC panel surfaces smooth. Maintain free from projections capable of puncturing flashing material.
2. Follow requirements indicated in Flexible Flashing Section.
E. Joint treatment: Remove excess extruded mortar immediately after setting each AAC panel. The tooling of joints is not required. Trowel joints flush with face of unit.
F. Control joints:
1. Make joint ½" wide, unless indicated otherwise, rake out control joints to full depth of unit while mortar is still plastic.
2. Provide joints at 40'-0" O.C. unless otherwise indicated.
3. Leave joint open and clean for caulking in accordance with Joint Sealants Section.
G. Tolerances:
1. Maximum variation from plumb: ¼" in 10'-0"; not exceeding ½" in 20'-0".
2. Maximum variation from level: ¼" in 20'-0"; not exceeding ½" in 40'-0" or more.
3. Maximum variation in linear building line from location indicated: ¼" in 20'-0".
H. Intersecting Walls:
If carried up separately, block vertical joint with 8" maximum offsets and provide rigid steel anchors spaced not more than 4'-0" o.c. vertically or omit blocking and provide rigid steel anchors at not more than 2'-0" o.c. vertically. Form anchors of galvanized steel not less than 1-½" x ¼" x 2'-0" long with end turned up not less than 2" or with cross pins.
I. Non-bearing walls shall be anchored to structural supports using approved anchors at 16 inches on centers of vertical or horizontal dimension, unless otherwise indicated.
J. Mortar Bedding Where Required:
1. Use Type S Mortar throughout.
2. Batch Control:
Measure and batch materials either by volume or weight, such that the required proportions for mortar can be accurately controlled and maintained.
K. Floor and roof panels: Fill joints between reinforced AAC panels using reinforcing bars and grout as specified above. Lap reinforcing bars not less than 25 bar diameters. Mix and place grout in accord with manufacturer’s printed instructions. Feather-out grout at joint irregularities.
L. Leave floor panels ready for floor fill specified in **Cast-in-Place Concrete**Gypsum Underlayment**Section.
M. Leave wall panels ready for finish specified in Related Sections Paragraph above.
3.03 CLEANING AND PATCHING
A. Keep AAC panel work free of mortar droppings as work progresses and at completion of work rub AAC unit to remove excess mortar.
B. Patch AAC panels with excessive spalls or chips.
END OF SECTION 03440