An AERCON block wall will usually consist of a variety of
AERCON products, integrated together to create a complete wall system that
satisfies the project requirements. The installation process is basically
the same regardless of the individual components. Blocks are typically
installed directly on a foundation system, but can also be installed on
an elevated floor for multi-story construction. In both conditions, the initial bed
joint is a critical element. The base mortar joint must be level and true so that
the construction can proceed with minimal adjustments. In order to provide
adequate thickness for adjustment, the initial bed joint is usually Type M or S
mortar, 3/8 to 1/2 inch in thickness. Head joints in the starter course are
mortared together with AERCON thin bed mortar. When thin bed mortar is used at
a joint, it is to be applied with a trowel having the proper style, teeth and
width to ensure coverage across the entire thickness of each block.
Lay successive courses plumb, level, and true to line,
in running bond with 8-inch lap (6-inch minimum) for standard blocks;
when cored block is used, lap should equal the block thickness, in order to
align the cores at the corners. Use thin bed mortar at all bed joints and
for head joints of flat face blocks. Tongue and groove blocks do not require
mortar at the head joints. Check each block as laid for levelness and plumbness,
making adjustments as required using a rubber mallet, while the mortar is still
soft and plastic.
Thin bed mortar should be applied with a trowel having the proper
style, teeth and width to ensure adequate coverage.
When necessary to accommodate an odd dimension or configuration,
blocks are to be cut with an appropriate hand saw or band saw that is specially
designed for cutting autoclaved aerated concrete (AAC). Consider the layout of the
wall before starting construction and install blocks in a manner that minimizes
cutting. Provide temporary bracing as required.
Cored blocks are used at specified locations to provide a
continuous cell for a threaded rod or a reinforcing bar. If a threaded rod is
used to resist overturning of a shear wall or to resist direct uplift from a
roof, the cell does not require grouting since the rod is strictly a tension
element that can be tightened to achieve tautness for load transfer. If
a reinforcing bar is used, then the cell must be grouted to ensure the rigidity of
the bar during load application and to provide a lap splice when necessary.
A reinforcing bar in a grouted cell can function as a tie-down in
addition to increasing the flexural strength of the wall. A fine aggregate
grout, with good flowability, should be used to fill the cells. The cells
should be wetted prior to filling, and a vibrator should be used
during the filling process. Cored block are installed in the same
manner as standard block. At the base course, if a clean-out or
inspection port is required, the cored block can be cut so that the core
becomes exposed to one side. If necessary, repair mortar can be used to fill
and seal the base course block where it was cut.
Filled U-blocks can be used as bond beam elements and as
lintels. The U-shape is manufactured from standard blocks, which ensures
dimensional and material compatibility with other types of AERCON blocks
and panels. U-blocks are installed using thin bed mortar for the bed joint and
head joints. Typically two reinforcing bars are inserted in the U-shaped cavity,
one above the other (not side-by-side). The U-blocks are then filled with a small
aggregate concrete mix to complete the Ublock installation. Prior to pouring the
concrete, the cavity should be wetted to minimize the absorption of water from
the poured concrete.
Solid, reinforced AERCON lintels are installed in the same
manner as standard blocks – mortaring the bearing bed joints and the head joints
with thin bed mortar. Depending on the height of the opening that the lintel
spans across, a filler piece of block may be required to achieve the desired
bearing elevation; or the blocks that support the lintel can be notched downward if the
coursing results in the bearing elevation being too high. Based on their
internal reinforcing, AERCON lintels are intended to be installed in a
particular orientation and are marked to indicate that orientation. AERCON
lintels are not to be cut unless authorized by an AERCON Representative.
The large size of ValuBlocks enables more wall area to be
installed per block, expediting installation, minimizing the number of blocks
that are handled and minimizing the volume of mortar that is needed. Depending
on the size and weight of the ValuBlocks, a minicrane and special lifting
clamp may be required to lift and set the blocks accurately. Use thin bed
mortar at all bed joints and for head joints of flat face blocks. Tongue and
groove blocks do not require mortar at the head joints. ValuBlocks can be
manufactured with cores and/or radiused edges. When two radiused edge blocks
are installed adjacent to each other, a cell is created, dimensionally
the same as the drilled cores.
Multiple configurations for interfacing reinforcing
bars and tiedowns at the foundation are available. Some are shown in the
Construction Details Section. These include epoxying into the foundation to
ensure accurate placement, casting in a hooked anchor, and using an embedded
composite system.
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