INSULFORM POLYSTYRENE PERMANENT CONCRETE INSULATING FORMWORK EPS - TPB
5. CONSTRUCTION SPECIFICATIONS
5.1. Preliminary
Refer to the Conditions of Contract and Preliminary and General clauses which
shall apply
to this section of the works. Allow to co-operate with all other trades.
5.2. Scope
This section of the work consists of the supply of all labour, plant,
materials, propping,
temporary bracing and the like for the erection of all polystyrene blocks as
formwork for
the walls etc as shown on the plans. Horizontal reinforcement must be placed at
the
same time as the blocks are being laid. Vertical reinforcement can be placed
after the
blocks are laid provided wire tying loops are provided for tying the vertical
bars to the
starters and the horizontal bars.
5.3. Blocks
All Insulform polystyrene blocks are injection moulded from fire retardant
polystyrene
beads in accordance with the specification contained in the BASF technical
leaflet TL 423,
January 1993, so as to produce accurate dimensionally stable blocks. The blocks
shall
have a final density between 23 and 26 kg per cubic metre.
Heavy duty thermoplastic bridging shall be polypropylene bonded into each
external skin
of polystyrene.
Allow to cut with a hot wire or saw to all non modular sizes. Support any cut
blocks with
other supports where required to prevent bulging and grout loss.
5.4. Workmanship
Sufficient care shall be taken when handling or transporting EPS blocks that
corners,
rebates, etc are not damaged. Before use, blocks shall be kept dry, free from
contact with
the ground, and completely covered from the weather. Caution must be taken to
ensure
no solvent based products come into contact with polystyrene, as they will
dissolve the
polystyrene in the blocks.
All polystyrene blocks shall be laid by a layer experienced in this type of
work. All walls
shall be true to line, level, and plumb to within the following accuracy.
Deviation from the position shown on the plan. 20mm.
Deviation from vertical within a storey. 10mm per 3m.
Relative displacement between load bearing walls in
adjacent storeys intended to be in vertical alignment. 5mm.
Deviation from line to plan.
(i) Any length up to 10m. 5mm.
(ii) Any length over 10m. 10mm.
Deviation from horizontal.
(i) Any length up to 10m. 5mm.
(ii) Any length over 10m. 10mm.
All blocks shall be accurately bedded into the blocks below and shall butt
accurately up
against each other so that true wall dimensions are achieved. Webs of blocks
must not
be placed over the vertical flue of the blocks below.
Horizontal joints can be glued with a polystyrene contact adhesive on each face
if required
to assist stability against wind or construction loads.
All walls shall be stayed against wind and construction loads.
Where required sills, reveals, and rebates shall be formed to conform to the
details drawn
on the architectural drawings.
5.5. Inspections
The Engineer shall be notified 24 hours before commencement of grout filling,
to enable
inspection of the work to ensure that the work is carried out with the intent
of his design.
5.6. Build-In
Build in all bolts, straps, fixings, switch and power boxes, etc, as shown on
the drawings
or as required by the various trades
Chases, holes, cut outs, and recesses in masonry shall be constructed only as
specified
or approved by the Engineer.
Any fixings to be cast in shall have polystyrene removed so as to give 30mm
concrete
cover around the fixing.
5.7. Concrete Placement
Consolidation of the concrete shall be carried out using mechanical vibration
or rodding
with a 16mm square end reinforcing rod. Place grout into cells as a semi
continuous
operation allowing for consolidation as the work proceeds. Each lift shall be a
maximum
height of 1.2 metres before consolidation of itself and reconsolidating
previously poured
concrete to a depth of 100mm.
All concrete work shall comply with N.Z.S.3109:1997 "Specification for
Concrete
Construction".
5.8. Construction Joints
The preparation of construction joints shall be as specified in
N.Z.S.3109:1997.
Immediately before placing concrete the construction joint shall be made wet
and a 10mm
thick layer of slurry applied to the joint. This slurry can be all cement and
water paste or a
1:1 slurry of cement and concreting sand. Well work the slurry into the
construction joint
before placing the concrete.
5.9. Concrete
All concrete shall be supplied from an approved ready mix concrete plant and
shall comply
with N.Z.S.3104:1991. Grout grade and strength are defined in N.Z.S.3104
and
N.Z.S.3108.
Concrete shall be High Grade Concrete with a minimum compressive strength of
20MPa
at 28 days, having a slump of 100mm. Higher strengths are required for
durability within
500m of a coast line. Concrete shall consist of Portland Cement, sand,
aggregate up to
14mm maximum size, water, and plasticiser/water reducing agent. Super
plasticisers and
expansion additives must not be used.
5.10. Tests and Records
The delivery dockets and other certified records for plant mixed concrete shall
be
forwarded to the Engineer at fortnightly intervals.
The Contractor shall keep an accurate record of the in-place location of all
batches. Tests
on site shall be carried out as per Section 9 of N.Z.S.3109:1997.
5.11. Reinforcement
Bar reinforcement denoted on the drawings with the prefix H shall be deformed
bars of
grade 430, complying with N.Z.S.3402:1989 "Steel Bars For The Reinforcement
Of
Concrete".
Bar reinforcement denoted on the drawings with the prefix D shall be deformed
bars of
grade 300 complying with N.Z.S.3402:1989 "Steel Bars For The Reinforcement
Of
Concrete".
Bar reinforcement denoted on the drawings with the prefix R shall be plain bars
of grade
300 complying with N.Z.S.3402:1989 "Steel Bars For The Reinforcement Of
Concrete".
5.12. Bending and Placing of Reinforcement
Reinforcement shall be cut, bent and placed as indicated on the drawings and
in
conformity with the appropriate sections of N.Z.S.3109:1997. Reinforcement
shall be
secured with wire ties and the cover maintained with plastic or concrete
spacers.
Bars shall be lapped only where detailed, except that bars in foundation and
slab edge
beams may be lapped to suit stock lengths with the proviso that laps shall be
kept to a
minimum and staggered where possible.
Before pouring begins the Engineer is to be notified and reasonable opportunity
given for
him to inspect the reinforcing as fixed.
All reinforcing steel shall be bent to return to all wall, beam, slab or column
junctions,
where not otherwise shown.
5.13. Cleaning
During laying and on completion, clean down all blockwork to remove all
adhesive or
concrete splashes and to leave a first class fair finish to all polystyrene
blockwork exposed
in the finished building. Make good with acrylic cement plaster any damaged
corners or
faces. Remove from the site, all plant and debris pertaining to this trade, all
to the
complete satisfaction of the Engineer.
6. TECHNICAL SPECIFICATIONS
6.1. Manufacture Technical
All INSULFORM blocks are manufactured by injection moulding of building grade
EPS.
Building grade EPS contains a fire retardant additive. The blocks are moulded
to a density
of approximately 23-27kg/m³. Each block contains about 700g of polystyrene
bead. The
heavy duty thermoplastic bridges are 2.0 mm thick bonded into the polystyrene
at the time
of moulding.
? INSULFORM standard block includes bridges bonded into the polystyrene at
the
time of moulding.
? INSULFORM Supablock features bridges inserted on site.
6.2. Series 200
The INSULFORM Series 200 block is designed for single storey and internal load
bearing
walls. It has applications for small retaining walls also.
LENGTH HEIGHT WIDTH CONCRETE PER
BLOCK
CONCRETE WALL
THICKNESS
1000mm 300mm 200mm 0.03m³ 100mm
6.3. Series 250
The INSULFORM Series 250 block is designed for up to three storey external
walls and
internal load bearing walls. Also used for retaining walls to 3m.
LENGTH HEIGHT WIDTH CONCRETE PER
BLOCK
CONCRETE WALL
THICKNESS
1000mm 300mm 250mm 0.045m³ 150mm
6.4. Series 300
The INSULFORM Series 300 block is designed for multi storey external load
bearing and
larger retaining walls.
LENGTH HEIGHT WIDTH CONCRETE PER
BLOCK
CONCRETE WALL
THICKNESS
1000mm 300mm 300mm 0.06m³ 200mm
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Architect
. Specifier 
