Silka Calcium Silicate Elements Together, We Can Face Any Construction Challenge

SILKA CALCIUM SILICATE ELEMENTS TOGETHER, WE CAN FACE ANY CONSTRUCTION CHALLENGE

Calcium silicate products are and its own facilities for market with a clear message: Silka the building material of the research and product deve- calcium silicate elements are future. Certainly if they bear lopment. The synergy within an excellent building material the signature of Xella, a firm the concern enables Xella to with a particularly low environ- with more than half a century of convert the requirements in mental load. But exactly how experience behind it. Xella has the building world rapidly and “natural” are Silka elements? a clear mission: to build reliably flexibly to specific, efficient and And how do they relate to by using innovative products and cost-saving building solutions. sustainable building? These services. Craftsmen who give of Better construction with fewer are the important questions their best to achieve guaranteed costs? Xella is ready for that! that will be addressed extensively quality and provide outstanding Many in the building world in this brochure. service. Xella possesses a large know the slogan: “Building? number of production locations With Silka naturally!” A slogan

Greenimmo / FHW Architecten

2 Silka Calcium Silicate Elements Contents

Chapter 1 Introduction 4 1.1 Calcium silicate, environmentally friendly products 4 1.2 Production process 4 1.3 Use of Silka blocks 5 1.4 Silka calcium silicate elements 6 1.5 Clamping devices and dowels 7

Chapter 2 Construction methods 8 2.1 Ordering and delivery procedure 9 2.2 On-site instructions 11 2.3 Materials and tools 12 2.4 Constructing 14 2.4.1 Work sequence 14 2.4.2 Profile adjustment 14 2.4.3 Kicker course construction 14 2.4.4 Distribution plan 14 2.4.5 Setting up the element stacker 14 2.4.6 Thin joint mortar - Silkafix 15 2.4.7 Erecting walls 16 2.4.8 Scaffold work and shoring 16

Chapter 3 Anchoring Silka elements 18 3.1 Wall ties 19 3.1.1 Thin joint mortar coupling strip 19 3.1.2 Wall anchors 19 3.1.3 Cavity wall anchors 20 3.1.4 Railing anchors 20 3.1.5 Fusible anchors 20 3.2 Purlins 21

Chapter 4 Working in summer and winter 22 4.1 Working in summer 23 4.2 Working in winter 23

Chapter 5 Movement joints 24 5.1 Movement joint advice 24 5.2 Movement joints 26 5.3 Controlling movement joints 27 5.4 Finishing movement joints 27

Chapter 6 Connecting inner cavity walls to boundary walls 28 6.1 Partitioning wall 29 6.1.1 Silka elements in inner leaf of cavity walls 29 6.1.2 Silka thin joint mortar blocks in inner leaf of cavity walls 29 6.2 Lintels and frame connections 29

Chapter 7 Wall finishing & projects 30 7.1 Thin plastering 30 7.2 Tile-work 31 7.3 Multi-storey buildings, commercial, office and industrial buildings 31

Chapter 8 Product information Silka calcium silicate elements 32

Silka Calcium Silicate Elements 3 Chapter 1 INTRODUCTION The natural components of Silka elements are sand and lime. Both raw materials are available in an almost unlimited supply. However, the requirements for this type of sand are less stringent than they are for many other applications.

water lime sand mixing

measuring slaking reactor water

autoclave press

hardening mixing moudling

1.1 Calcium silicate 1.2 Production process blocks and elements, environmentally friendly products:

Silka blocks and elements The modern production process means of steam under high consist mainly of sand (93 %) starts with the fully automated pressure, to obtain the end the remaining component measuring and mixing of product. The ‘Silka block’ being lime (7 %). The sand is quicklime, sand and water. This made in this manner does not usually extracted quite close mixture is placed in a reactor, have any of the qualities of the to the production facilities. where the quicklime is turned original raw materials of sand After extraction, redesign and into slaked lime within a few and quicklime, but consists development of the quarried hours.This mixture – now called of grains of sand that have area is undertaken. ‘mortar’– is transported to the been bonded together through press, where it is processed into calcium silicate hydrate bonds. ‘unfired brick’, which is then placed in an autoclave for hardening. This is done by

4 Silka Calcium Silicate Elements 1.3 Use of Silka blocks

Silka blocks can be used blocks, chamfered blocks and moisture regulation thus on a large and varied range elements. Silka elements are contributing to a pleasant living of projects including the subject of this brochure. environment. housebuilding, commercial and Advantages of calcium silicate industrial buildings, renovation are, among others, good and agricultural buildings. sound insulation (due to a Blocks are predominantly high volume weight /mass), used for foundations, cellars, substantial heat accumulation load-bearing and non ability, considerable load- loadbearing internal walls bearing capacity and high fire as well as external walls. resistance. The ‘breathing’ Xella produces a large range qualities of Silka blocks are of Silka products including extremely suited to good

Silka Calcium Silicate Elements 5 1.4 Silka calcium silicate elements

The elements come in various a sand-lime product, with a very thicknesses with a working smooth finish,capable of delive- length of 897 mm and in heights ring significant on site time and of 623 mm and 643 mm. Silka is money savings upon completion. Product Range

Type Dimension Thickness Mortar Weight (kg)* Profiling mm mm consumption 2 per m2 kg/each per m E100 897x623/643 100 1.4 100 / 104 178 T&G

E150 897x623/643 150 2.2 151 / 156 269 T&G

E175 897x623/643 175 2.5 176 / 182 313 T&G

E214 897x623/643 214 3.3 215 / 222 383 T&G

E240 897x623/643 240 3.7 242 / 249 431 T&G

E300 897x623/643 300 4.7 302 / 311 538 T&G

T&G = tongue and groove

* exclusive pallet

General technical data

Unit

Dry density kg/m3 1800

Dimensional tolerances (l x w x h) mm ± 2 mm, ±2 mm, ±1 mm

Masonry group Cat. I ; group 1

Normalized mean compressive strength fb N/mm2 ≥ 20 / ≥ 28

Characteristic compressive strength wall fk* N/mm2 10.2 / 13.6

Thermal conductivity λUi W/m.K 0.91 Specific heat c J/kg.K 1000

Diffusion resistance factor μ 5/25

Coefficient of linear expension α m/m.K 10x10-6

Coefficient of elasticity E N/mm2 10200 / 13600

Reaction to fire A1 (non-flammable)

* fk in accordance to NA to BS EN 1996 - 3: 2006 γ m = 2.3 (material safety factor of Silka elements) not included

6 Silka Calcium Silicate Elements 1.5 Clamping devices and dowels

At the top end of each Silka- element there are 2 holes, every 500 mm, for mechanical lifting and for dowel placement.

Dowels Dowels are used for simplifying the exact placement of the Silka elements and to prevent them from ‘floating’. The dowels are manufactured from recyclable synthetic material (polypropyle- ne); the blue colour is obtained by adding a cadmium-free colouring agent. A maximum of 1.85 dowels (1 per whole element) is needed per m2.

Silka Calcium Silicate Elements 7 Chapter 2 CONSTRUCTION METHODS Silka walls are composed of standard elements and cut-to-size blocks in accordance with the previously approved wall drawings. The kicker course consists of smaller calcium silicate blocks (standard heights 70, 85, 100, 115, 130, 145 and 160 mm or extra insulating thermoblocks). This allows wall parts to be supplied as semi-prefabricated packages (illustration 1).

Walls are constructed using ■■ a small mobile crane With this building method, ■■ a thin layer of plaster; and useful tools; smooth walls can be obtained, ■■ tiling straight onto ■■ “thin joint mortar” of which are extremely well suited the surface. traditional composition. for finishing with:

arch. Hans Kollhoff

8 Silka Calcium Silicate Elements Illustration 1

N x 897 mm + cut block

A = elements. These are in standard formats in the working dimensions of Advantages of building 897x625/645 mm in various thickness dimensions. B = straight fitting pieces, cut to size from the elements, which makes straight with Silka calcium wall endings possible. silicate elements: C = slanting fitting pieces, cut from elements to the desired angles and sizes, mainly for use in apexes of gables D = kicker course blocks. To be used for construction of the first layer of ■■ simple building technique; blocks. This functions as a fitting edge for the elements but also to level out the floors. This layer can also be built using Thermo - kickercourse blocks. ■■ high compressive strength;

■■ fast, rational and non-intensive labour; 2.1 Ordering and delivery procedure ■■ easy build ability with thin joint mortar; The building system is offered These will be quoted separately. and sold by Xella per nett m2 Once the client has placed ■■ thin wall finishing (2–3 mm per thickness. PriceN x 897 calculati mm + cut -block the order. Xella will produce the plaster finish); ons are based on the drawings, working wall drawings of the ■■ all round use; which must at least have a scale elements and cut-to-size blocks

■■ little preparation; of 1:100, supplied by the con- required for the walls, based tractor or architect. Included in on the drawings supplied by ■■ flexible; m2 price: the customer. ■■ no large investments ■■ whole elements and cut in equipment such as blocks delivered on an artic formwork and heavy cranes; vehicle for forklift off-loading; ■■ cutting of the elements; ■■ ‘slimmer’ walls than ■■ working drawings of walls. traditional;

■■ building techniques Not included are prices of ma- versions; terial aids, thin joint mortar and ■■ less building moisture; accessories.

■■ no waste.

Silka Calcium Silicate Elements 9 The working drawings of Illustration 2: wall drawings Xella Fabriek - - - Kruibeeksesteenweg 24 - BURCHT the walls also include the dimensions for the cut-to-size

2650 + blocks (maximum dimensional c b tolerances in height and length a 2500 of cut to size blocks measured c b a 150 + TL kickercourse 20 + across the saw cut: -4 mm to +2 20 / 130 0 TL concrete slab 8000 mm). These working drawings are first presented to the client Quality: CS 20 MarkMerk ThicknessDikte HeightHoogte LenghtLengte NumberAantal Mark MerkThickness DikteHeightHoogteLenghtLengteNumberAantal Place Kimkicker stellen course op on circa 20 mm 20 mortar mm specie ScaleSchaal 1:501:50 623 150 623 897 32 for approval, before cutting can 623 150 623 897 32 ThicknessStootvoegdikte of the vertical 3 jointmm 3 mm a 150 623 800 2 a 150 623 800 2 PiecesStuksOut metres Opp m²m3 m³ b 150 623 445 2 b 150 623 445 2 l ElementsHele elementen 32 3217.88 17.88 2.682.68 c 150 623 352 2 Passtukken 6 1.99 0.30 c 150 623 352 2 Cut elements 6 1.99 0.30 commence. Kimblok 150 130 8000 Subtotaal 38 19.87 2.98 Kicker course 150 130 8000 Subtotal 38 19.87 2.98 Kimmen 1.04 0.16 Kicker course 1.04 0.16 Lateien (Afval) Lintels (waste) Totaal 38 20.91 3.14 Total per wall 38 20.91 3.14 DATUM 18-04-2013 AANTAL WANDCODE DATE 18 04 2013 NUMBER WALLCODE TEKENAAR G DRAUGHTSMAN G PROJEKT 1201036 1 001 Delivery schedule PROJECT 1201036 1 001 Delivery takes place based Xella Fabriek - - - Kruibeeksesteenweg 24 - BURCHT Mark Thickness Height Lenght Number Mark Thickness Height Lenght Number Place kicker course on 20 mm mortar Scale 1:50 623 150 623 897 23 l 150 173 172 2 * Thickness of the vertical joint 3 mm on a schedule. The delivery a 150 623 800 2 m 150 623 755 2 / l Pieces Out metres m3 b 150 623 668 2 l lintel 150 113 1250 1 - v Elements 23 12.85 1.93 c 150 623 625 1 l kicker course 150 130 7090 Cut elements 18 4.24 0.64 d 150 623 445 1 l Subtotal 41 17.09 2.56 is affected by direct contact 175 175 e 150 623 352 1 Kicker course 0.92 0.14 f 150 623 230 1 Lintels (waste) 627 2 g 150 623 219 2 Dilatatie Total per wall 5500 + 5500 + 41 18.02 2.70 between the client and the h 150 623 130 1 k j k DATE 18 04 2013 NUMBER WALLCODE 5165 + 450 c 1250x150x113 f m

115 5050 + 5050 + j 150 623 623 1 l l DRAUGHTSMAN G

k 150 623 314 2 * PROJECT 12010361250 Mark Thickness Height Lenght Number Mark Thickness Height Lenght Number Place kicker course on 20 mm mortar 1 Scale 0021:50 a h m logistics department of the 623 150 623 897 32 Thickness of the vertical joint 3 mm 4250 + a 150 623 800 2 Pieces Out metres m3 b 150 623d 445 2 l e b Elements g 32 17.88 2.68 2200 supplying factory. Wherever c 150 623 352 2 Cut elements 6 1.99 0.30 Mark Thickness Height Lenght Number Mark Thickness Height Lenght Number Place kicker course on 20 mm mortar Scale 1:50 Kicker course 150 130 8000 a g Subtotal b 38 19.87 2.98 623 150 623 897 16 kicker course 150 130 7958 ThicknessKicker course of the vertical joint 3 mm 3000 + TL kickercourse 1.04 0.16 2870 + a 150 623 752 1 Lintels (waste) Pieces Out metres m3 2850 + 20 / 1302850 1250 + TL concrete slab possible, the Silka calcium b 150 623 734 1 Elements 23 12.85 1.93 3500 910 3590 Total per wall 38 20.91 3.14 c 150 623 412 1 l Cut elements 18 4.24 0.64 6750 DATE1250 18 04 2013 NUMBER WALLCODE d 150 623 299 1 8000 SubtotalDRAUGHTSMAN G 41 17.09 2.56 silicate elements are supplied e 150 623 292 1 PROJECTKicker course 1201036 1 0.92 0010.14 f 150 623 144 1 l Lintels (waste) g 150 623 127 1 Total per wall 41 18.02 2.70 h 150 623 777 8 DATE 18 04 2013 NUMBER WALLCODE in full loads. The blocks are j 150 623 777 2 l DRAUGHTSMAN G Quality: CS 20 k 150 451 484 2 * PROJECT 1201036 MarkMerk ThicknessDikte HeightHoogte LenghtLengte NumberAantal MarkMerkThicknessDikte HeightHoogteLenghtLengteNumberAantal Place Kimkicker stellen course op on circa 20 mm 20 mortar mm specie 1 ScaleSchaal 0031:50 623 150 623 897 23 l 150 173 172 2 * 623 150 623 897 23 l 150 173 172 2 * ThicknessStootvoegdikte of the vertical 3 jointmm 3 mm offloaded on site, by a fork-lift a 150 623 800 2 m 150 623 755 2 / Stuks Opp m² m³ a 150 623 800 2 m 150 623 755 2 / l Pieces Out metres m3 b 150 623 668 2 KZ-Latei 150 113 1250 1 - V b 150 623 668 2 l lintel 150 113 1250 1 - v ElementsHele elementen 23 2312.85 12.85 1.93 c 150 623 625 1 Kimblok 150 130 7090 Passtukken 18 4.24 0.64 c 150 623 625 1 l kicker course 150 130 7090 Cut elements 18 4.24 0.64 d 150 623 445 1 Subtotaal 41 17.09 2.56 and should be stored on a level d 150 623 445 1 l Subtotal 41 17.09 2.56 e 150 623 352 1 Kimmen 0.92 0.14 e 150 623 352 1 Kicker course 0.92 0.14 f 150 623 230 1 Lateien (Afval) f 150 623 230 1 Lintels (waste) g 150 623 219 2 Totaal 41 18.02 2.70 g 150 623 219 2 Total per wall 41 18.02 2.70 area and kept safe from rising h 150 623 130 1 DATUM 18-04-2013 AANTAL WANDCODE h 150 623 130 1 DATE 18 04 2013 NUMBER WALLCODE j 150 333 623 1 TEKENAAR G j 150 623 623 1 DRAUGHTSMAN G k 150 333 314 2 * PROJEKT 1201036 1 002 k 150 623 314 2 * PROJECT 1201036 1 002 moisture. Both the elements Mark Thickness Height Lenght Number Mark Thickness Height Lenght Number Place kicker course on 20 mm mortar Scale 1:50 623 150 623 897 32 Thickness of the vertical joint 3 mm a 150 623 800 2 Pieces Out metres m3 and cut-to-size blocks are b 150 623 445 2 l Elements 32 17.88 2.68 c 150 623 352 2 Cut elements 6 1.99 0.30 Xella FabriekMark -Thickness - - KruibeeksesteenwegHeight Lenght 24 - BURCHTNumber Mark Thickness Height Lenght Number Place kicker course on 20 mm mortar Scale 1:50 Kicker course 150 130 8000 Subtotal 38 19.87 2.98 623 150 623 897 16 kicker course 150 130 7958 Thickness of the vertical joint 3 mm Kicker course 1.04 0.16 a 150 623 752 1 Pieces Out metres m3 delivered on pallets and are Lintels (waste) b 150 623 734 1 Elements 23 12.85 1.93 Total per wall 38 20.91 3.14 c 150 623 412 1 l Cut elements 18 4.24 0.64 DATE 18 04 2013 NUMBER WALLCODE d 150 623 299 1 Subtotal 41 17.09 2.56

21 163 833 1503 2174 2844 3514 3514 2844 2174 1503 DRAUGHTSMAN833 163 21 G shrink-wrapped. Each cut- e 150 623 292 1 Kicker course 9430 + 0.92 0.14 PROJECT 1201036 1 001 f 150 623 144 1 l k k Lintels (waste) g 150 623 127 1 Total per wall 41 18.02 2.70 to-size-block is provided with h 150 623 777 8 h a h DATE 18 04 2013 NUMBER WALLCODE j 150 623 777 2 l DRAUGHTSMAN G k 150 451 484 2 * PROJECT 1201036 h e j 1 003 Mark Thickness Height Lenght Number Mark Thickness Height Lenght Number Place kicker course on 20 mm mortar Scale 1:50 an identification mark, which 623 150 623 897 23 l 150 173 172 2 * Thickness of the vertical joint 3 mm 3580 a 150 623 800 2 h b m 150 623 755 j 2 / l Pieces Out metres m3 b 150 623 668 2 l lintel 150 113 1250 1 - v Elements 23 12.85 1.93 c 150 623 625 1 l kicker course 150 130 7090 Cut elements 18 4.24 0.64 corresponds with the marks on h f g h d 150 623 445 1 l Subtotal 41 17.09 2.56 e 150 623 352 1 Kicker course 0.92 0.14 f 150 623 h 230d 1 c Lintelsh (waste) 5850 + TL kickercourse the working drawing. g 150 623 219 2 Total per wall 5720 + 41 18.02 2.70

20 / 130 5700 + h 150 623 130 1 DATE 18 04 2013 TL concrete NUMBERslab WALLCODE j 150 623 623 40001 4000 DRAUGHTSMAN G k 150 623 314 2 * 8000 PROJECT 1201036 1 002

Quality: CS 20

MarkMerk ThicknessDikte HeightHoogte LenghtLengte NumberAantal MarkMerkThicknessDikte HeightHoogteLenghtLengteNumberAantal Place Kimkicker stellen course op on circa 20 mm 20 mortar mm specie ScaleSchaal 1:50 623 150 623 897 16 Kimblok 150 130 7958 623 150 623 897 16 kicker course 150 130 7958 ThicknessStootvoegdikte of the vertical 3 jointmm 3 mm a 150 623 752 1 a 150 623 752 1 PiecesStuksOut metres Opp m²m3 m³ b 150 623 734 1 b 150 623 734 1 ElementsHele elementen 23 1612.85 8.94 1.341.93 c 150 623 412 1 Passtukken 19 4.70 0.70 c 150 623 412 1 l Cut elements 18 4.24 0.64 d 150 623 299 1 Subtotaal 35 13.64 2.05 d 150 623 299 1 Subtotal 41 17.09 2.56 e 150 623 292 1 Kimmen 1.03 0.16 e 150 623 292 1 Kicker course 0.92 0.14 f 150 623 144 1 Lateien (Afval) f 150 623 144 1 l Lintels (waste) g 150 623 127 1 Totaal 35 14.67 2.20 g 150 623 127 1 Total per wall 41 18.02 2.70 h 150 623 777 8 / DATUM 18-04-2013 AANTAL WANDCODE h 150 623 777 8 DATE 18 04 2013 NUMBER WALLCODE j 150 623 777 2 / TEKENAAR G j 150 623 777 2 l DRAUGHTSMAN G k 150 451 484 2 / PROJEKT 1201036 1 003 k 150 451 484 2 * PROJECT 1201036 1 003

10 Silka Calcium Silicate Elements 2.2 On-site Schematic overview of the ordering instructions and delivery procedure

A Xella project supervisor can Offer stage Execution of order give onsite instructions about The builder provides the in- Providing Xella with the order building with the Silka calcium formation of the building pro- either direct or via builders silicate elements. Should ject to be executed in Silka merchant. Builder will pro- instructions be required, the (including the construction vide Xella with 1:100 scale client can get in touch with Xella. drawing on scale 1:100) and drawings for the proposed requests a quotation. Based project. Based on the defi- If parties concerned have no on price calculation, nite work drawings,working experience in using the Silka a quotation is made. drawings of walls are drafted calcium silicate elements, it is and given to the builder and/ of importance that the project or client for approval. Once supervisor has a meeting with approved by the client, the the the contractor and the necessary cut-to-size blocks installers well before the actual and elements are being start of the installation. The in- produced and prepared for structions are given at the start transportation. of the construction process. Topics include working with Delivery at buyer’s material aids, such as element option stacker, installing of elements Delivery of the elements and cut to size pieces. If further and cut-to-size blocks advise is required a Xella project takes place according to a supervisor can visit the site schedule, agreed and set by when the walls are under con- the factory and the client. struction. The project supervisor draws up a report when visiting a site and gives his thoughts about the work methods.

Silka Calcium Silicate Elements 11 2.3 Materials and tools

The following tools and materials are necessary for this method of construction:

A. An element stacker per squad B. Approved clamping device (various models are available). for lifting the Silka elements with a element stacker.

C. Clamping devices for lifting D. A double clamping device for E. Silka thin bed mortar dispen- cut blocks with the element adjusting two elements simul- ser, suitable for the thickness stacker. taneously in an anchorless of the elements used. An cavity wall. even spread of the correct thickness of mortar can only be achieved by using this thin bed mortar dispenserfor bed joints.

F. Silka thin bed mortar scoop, G. A spack knife for removing H. A pallet-truck for manoeu- designed for the thickness excess mortar. vring the pallets of the elements used, which evenly applies the thin joint mortar to the vertical joints of the elements.

The tools and materials A to D can be hired, on a weekly basis, from the supplying factory. The tools and materials can also be bought directly through Xella.

12 Silka Calcium Silicate Elements I. Plastic mortar trough for mixing the thin joint mortar.

The builder will need to provide the following:

■■ a bar or barrel mixer;

■■ small (masonry)tool;

■■ a mobile crane for distribution of the heavy materials and for moving the element stacker;

■■ trestle scaffolding, pallet lifting device etc.;

■■ even offloading area and scaffold parts to enable offloading of silka calcium silicate elements (for prevention of rising moisture).

Silka Calcium Silicate Elements 13 2.4 Constructing

2.4.1 Work sequence Thermo - kickercourse blocks When using the Silka elements, These special insulating kic- the following work sequence kercourse blocks have been de- should be followed: veloped to avoid cold bridging. They offer insulating properties ■■ adjust the necessary corner and loadbearing capacity. uprights; ■■ kicker course construction; 2.4.4 Distribution plan ■■ setting up the It is vital a distribution plan is element stacker; drawn up to allow the system to ■■ mixing the thin joint mortar; maintain its efficiency. The plan ■■ erecting the wall; allows the materials to be cra- ■■ removing excess mortar and ned into an appropriate position repairing any wall damage for efficient construction. with an appropriate filler; ■■ shoring the walls. 2.4.5 Setting up the element stacker 2.4.2 Profile adjustment A number of element stackers Corner uprights are set the are available from 1350 kg to same as for laying traditional just over 2000 kg. The element blocks; the adjusting slats stackers works on high voltage should not interfere with the currant (380V - 16A). element stacker.

2.4.3 Kicker course construction The kicker course is constructed using Silka kicker course blocks, specially designed for this purpose as they are com- pletely flat, level and easily adjustable by means of a line, in a general purpose mortar. The vertical joints are filled with thin joint mortar. The kicker course construction should be comple- tely set before placement of the Silka elements can begin.

14 Silka Calcium Silicate Elements 6.000 6.000

002 005 1,00 m

Pallet Pallet Silka elements with cut with cut E 150 for wall 007 elements elements in two layers for for Silka Silka wall 002 E 100 wall 005 E 100 elements elements for wall 002 for wall 005 for Silka Silka E 150 elements for wall 001 for for wall 004 for in two layers in two elementsE 150 f elementsE

001 Place for setting up Place for setting up crane Wheelbase for crane Wheelbase Specifications: Pallet

2.00 x 2.00 m 2 Pallet with cut 2.00 x 2.00 m with cut wall 001 on top of on top 10.000 elements elements each other for wall 004 for Silka Silka E 150 elements elements ■■ delivery in bags of 25 kg; for wall 001 for in two layers in two E 150 for wall 004 E 150 for 004 004 007 Pallet Pallet Pallet ■■ instructions for use on the

with cut with cut with cut Silka Silka Silka lelements E 100 elements E 100 elements elements in two layers in two elements for lelements for for for wall 006 for for wall 003 for wall 003 wall 006 wall 007 wall 007 E 150 for packaging; 1,00 m

1,00 m ■■ setting time about 4 hours; 003 006

plan for placing the Silka products on the fl oor work sequence: ■■ the special winter thin -wall 001 -wall 002 joint mortar can be used -wall 003 move crane -2 x wall 004 up to about –3 °. (Winter -wall 005 -wall 006 mortar is delivered from -wall 007 about 1 November until 1 April).

2.4.6 Thin joint mortar - Silkafix These are specially developed ■■ Silka elements are Remark: The thin joint mortar water retaining mortars for stacked, as close as must be mixed for about 4 Silka calcium silicate elements possible to the wall minutes allowing the dry mix and blocks, based on traditional to be built, taking to fully bond with the water to method of preparation. A bed of into account possible a soluble and useable mixture. 2–3 mm mortar is required to recommendations by the After 4 minutes a good, smooth, lay the blocks; such a technique flooring manufacturer. workable mass is created and is known as ‘thin joint mortar’ there is no powder left. Service pipes should Silka recommends using only protrude as little as the thin joint mortar, supplied possible (max.100 mm) by the factory (Silkafix) and above the floor. adhering to the instructions on the packaging.

Silka Calcium Silicate Elements 15 2.4.7 Erecting walls 2.4.8 Scaffold work and With a squad consisting of two shoring persons, Silka calcium silicate The Silka walls can immediately elements can be laid mechani- be erected to the full height of cally. One person operates the the wall. Depending on weather elemeny stacker, picking up conditions and the thickness of strategically placed elements the walls, it may be necessary and bringing them to the wall to shore walls. The regulations under construction. The second set by health and safety direc- person sees to the application tives must always be adhered of thin joint mortar to all joints with regard to shoring walls as and ensures that the elements well as scaffolding work. are correctly placed. During and after construction, The application of thin joint the walls must be prevented mortar must take place with the from falling down. Walls falling aid of the mortar dispenser; the over or sliding down could be slide of this dispenser must be caused by wind load (pressure set to size disposing only of a or suction) or because of impact 2 mm mortar bed. The mortar load, which could take place for the vertical joint is applied during, for example, assembly with a scoop, from the bottom to of floor slabs. the top,on the already adjusted Silka elements. For elements Calculations by ‘TGB with a thickness of 300 mm, it is Steenconstructies en proefne- recommended that the mortar mingen’ (according to European is applied by the person opera- Standard) have shown that a ting the crane before he cranes wall with a height of up to 2.70 the next block to the wall. m and a thickness of up to 214 mm should be supported and If necessary, the placement of properly shored every 5.00 m the elements could be tightened until the floor on top of the up with the use of a heavy rub- walls (or roof construction ber hammer to close the ver- respectively) has been placed. tical joint. Excess mortar must be removed with a spack knife after it has slightly hardened.

16 Silka Calcium Silicate Elements Shoring Walls closed tops As a guideline for closed walls up to 2.50 m high and up to and including 214 mm 3m shore thick and closed tops, the above mentioned diagrams If necessary a longer middle can be followed.Remark: shore diagrams are intended for

> 3m shores the inland areas; in blustery areas a shoring distance of 1/3 L of max. 5m L 4.00 m maximum applies. Suitable as shore are: ■■ cross walls with a mini- mum length of 2.00 m, which have been decently anchored to the wall with REMARK: the standard clamping; Do not apply the thin ■■ shoring as shown on the joint mortar with the picture. aid of a trowel under any circumstances.

closed walls

shore (or struts) max. 5m max. 5m 2m

shores

max. 5m max. 5m

shores > 2m max. 2m max. 5m max. 2m

Walls with a height of 2.50 m and thickness up to 214 mm

Silka Calcium Silicate Elements 17 Chapter 3 ANCHORING SILKA ELEMENTS

arch. Jaspers-Eyers

18 Silka Calcium Silicate Elements 3.1 Wall ties

Due to the thin mortar joints (± 2 mm), a complete anchoring programme was developed for Silka calcium silicate elements and Silka small blocks. As a result, working with thin joint mortars has become very easy. The following anchors and ties are used in Silka thin joint masonry:

3.1.1 Thin joint mortar 3.1.2 Wall anchors coupling strip These anchors, also known These are flat, perforated as wall ties, are for rigid and strip anchors for connecting flexible joints between partition adjoining walls in a vertical walls and load-bearing walls. joint. A strip anchor is required Flexible wall anchors can also for each layer. be applied in flexible ceiling Dilatation anchor joints. be applied as a head res- traint in flexible ceiling joints.

Anchors

Dilatation wall anchor Rigid wall anchor Flexible anchor

1 to 2 anchors every 625 to 645 mm, in consultation with the builder

Coupling strip

Coupling strip 300 mm

Silka Calcium Silicate Elements 19 3.1.3 Cavity wall anchors

These anchors have a flat strip on one side. They are placed closed side up, to the rebate, in the mortar.

Cavity tie SS Clip for apply- 130 +/-15 mm ing insulation 160 +/-15 mm LIPCLIP article

3.1.4 Railing anchors 3.1.5 Fusible anchors

Railing anchors were specially developed with a view to the safety regulations. These anchors, which are placed in the bed joints of the inner leaf of the cavity wall, facilitate the placement of a railing by means of scaffolding parts.

Railing Clamp Apply for edge security, Fusible synthetic anchor quantity to the builder’s specification.

Railing thin bed mortar plate Apply for edge security systems. Fusible steel anchor For mounting railing clamp, use 1 plate per clamp. Place in bed joint, between the 2 top layers of elements

20 Silka Calcium Silicate Elements 3.2 Purlins

Purlins can be supported using special purlin anchors, available on the market. These purlin anchors should be mounted on an eaves purlin, against the bevelled wall.

Trimming joist anchor Joist hanger (heavy duty)

Wedge

Silka Calcium Silicate Elements 21 Chapter 4 WORKING IN SUMMER AND WINTER

AIKO - arch. Michiel Verstraete

22 Silka Calcium Silicate Elements 4.2 Working in winter

Using thin joint mortar is considered to be one of the least frost sensitive activities. This means that work does not have to stop immediately if frost is expected. Of course, frozen elements or elements with ice should not be used. Thanks to the fact that thin joint mortar sets very quickly, the newly erected walls are less sensitive to the consequences of frost than walls built with conventional.

However, precautions should be taken to prevent freezing, 4.1 Working in such as: summer ■■ protecting materials and In dry periods, the adhesive equipment by covering it with surfaces of the Silka elements for example a frost protecting must be moistened before cover or by heating and mortar is applied. The mortar storage in frost free sheds; should not be applied in excess ■■ shelter of the building site; of 3 m ahead of the last element ■■ protecting recently built walls placed, in order to prevent the and kicker courses from frost mortar from ‘burning’. The by covering or heating; mortar trough with ready mixed ■■ keeping dowel holes clean thin joint mortar must be kept and water free. out of the full sun, unless the If correct precautions are taken, mortar is well covered. working with Silka calcium silicate elements can continue until the frostdelay comes into effect.

Never scatter salt near calcium silicate. To combat ice and frost, use coarse (breaker) sand.

Silka Calcium Silicate Elements 23 Chapter 5 MOVEMENT JOINTS

5.1 Movement joint advice

It could be necessary to include ■■ wall height; movement joints in the walls, as ■■ wall thickness; Advice on movement joints is Silka walls are subject to shrin- ■■ weakening due to openings; provided by Xella. kage due to loss of moisture. ■■ impediments. The criteria for the advice on movement joints are:

24 Silka Calcium Silicate Elements arch. Blondel As the wall becomes higher Vertical impediments and thicker, it can take more ■■ Slack bending: wall end con- tensile stress/axial tension. If nected to a cross wall (tooth the wall experiences shrinkage structure or vertical joint) and is impeded, this can result slimmer than the width of the in cracks. The impediments are wall under consideration; distinguished as follows: ■■ Stiff bending: wall end con- nected to a cross wall (tooth Horizontal impediments structure or vertical joint) one-sided: wider than the width of the ■■ all non load-bearing walls; wall under consideration; two-sided: ■■ Unimpeded: wall end free. ■■ all load-bearing walls.

Silka Calcium Silicate Elements 25 arch. A2M

5.2 Movement joints

The movement joints indica- can also influence the move- fire-resistant partitioning walls, ted on the working drawings ment in the movement joint. without a finishing plaster. In of Silka elements are related Necessary structural movement this case, it is important to bear to possible size reductions of joints must be indicated by the in mind that the fire resistance calcium silicate due to drying builder on site. Silka elements is demanded for the whole shrinkage. However, shrinkage are not manufactured and wall, which means that also the of calcium silicate is only a few delivered as fair faced masonry. movement joint must be fire tenths of millimetres maximum. Nevertheless, it regularly oc- resistant. For walls on deflecting founda- curs that Silka calcium silicate tions, the deflection of the floor elements are used to build

1000

Dilation

Cross-section A Cross-section B Cross-section C

Cut Do not apply mortar Do not apply mortar Apply mortar

26 Silka Calcium Silicate Elements 5.3 Controlling 5.4 Finishing movement joints movement joints

Movement joints come in “Cold ” movement joints can be two kinds: finished off by directly applying a ■■ “Cold” movement joint with wide fibreglass tape of min. 150 a width of approx. 1 mm, mm, which has been provided without filling. This type with a perforated fibre of 50 mm of joint can only be used in the middle (f.i. Technotape/ in walls on non-deflecting Dilatape or equivalent). foundations and where extra adjustment space is not If the wall areas differ from required (for examples in each other on either side, the party walls between houses). joint must previously be evened out with a thin layer of plaster. This plaster must be hardened

Cold movement joint in out before the self-adhesive loadbearing wall (e.g.house separating wall) fibreglass tape is applied. 0 of 1 mm Filled movement joints can remain visible finishing the layer perforated min. 150 mm fibre of plaster with a casing bead tension distributing layer as a reinforcement in on both sides of the movement the thin plaster joint. It is important that the arch. Christian Farber casing beads are kept at least ■■ Movement joint with a width 3 mm apart and filled with an of approx. 10 mm and filled airtight and flexible seal, which with an elastic and airtight will remain flexible and can be joint sealing. Meant for walls, painted. in which a structural movement joint must be applied “Cold” movement joints in a and walls in which extra wall with a layer of plaster, over adjustment space is required which a nonelastic layer of paint (for example non load- is applied, can be finished off bearing walls and inner leaf with 2 casing beads with 1 to 2 cavity walls in longitudinal mm space, with a hidden outer walls). elastic seal.

Cold movement joint in Airtight 10 mm loadbearing wall flexible (e.g.house separating wall) seal 0 of 1 mm

seal min. 3 mm wide seal 2 x casing beads 2 casing beads

Silka Calcium Silicate Elements 27 Chapter 6 CONNECTING INNER CAVITY WALLS TO BOUNDARY WALLS

In consultation with Xella, The connection possibilities are: TNO Bouw in the Netherlands. working drawings of walls will constructive straight edge The structural engineer involved indicate the method for tooth structure in a certain project remains connecting inner cavity walls flexible seal responsible for the construc- to separating walls. The mechanical qualities of tion. The mechanical qualities shoved vertical joints meet the of a vertical joint with special requirements of the European ties are equal to the mechanical standard. This was tested by qualities of a tooth structure.

28 Silka Calcium Silicate Elements 150 mm 150 mm

vertical joint coupling strip 240 x 20 x 0,75 R.V.S. or an equivalent every insulation panel (PS or PUR) 645 mm break at the cavity wall 150 150

movement joint in cladding (optional)

6.1 Partitioning wall 6.1.2 Silka thin joint mortar blocks in inner leaf of cavity When using the Silka calcium walls silicate elements for party walls For smaller tighter areas and between houses it is highly spaces, inner leaf cavity walls recommended, particularly can also be built with because of the specific thin small blocks. finishing of the walls, to build the inner leaf of the cavity walls with Silka elements as well. 6.2 Lintels and frame connections 6.1.1 Silka elements in inner leaf of cavity walls Preferably door and window Because of their measurements frames should run up to the of 897x623/643 mm, Silka ceiling above. If this is not elements are extremely suit- possible, there are two alterna- assembled lintel able for larger wall surfaces. tives: filling the opening above The inner cavity leafs should door and window frames with or self-supporting synthetic foil be placed simultaneously with a timber panel up to the cei- the party walls. In simultane- ling above or having the lintel length recess size of bearing ous execution of party walls run across the full height. For lintel and inner cavity leafs, complete window and door openings, a shells can be achieved. An ad- lintel should be used above the ded advantage is, that the newly opening in a wall. Due to the built walls are more stable and remaining, 2 mm high, bed joint, therefore, more resistant to it is impossible to add steel bed gusts of wind. joint reinforcements in Silka The minimal bearing of the thin joint mortar systems. The lintel depends of the span and Silka range includes lintels with the type of lintel. Lintel not to be a length up to 1.75 m laid on block gauge. If applying a steel lintel, serration is necessary.

Silka Calcium Silicate Elements 29 Chapter 7 WALL FINISHING & PROJECTS

7.1 Thin plastering

Walls made of Silka can be finished with a skim of plaster either manually, mechanically or by means of spray plaster. Before finishing the wall, uneven joints and possible face damage have to be filled with a suitable filler. Skim plaster can subsequently be applied with adhesive gypsum or spray plaster, according to the supplier’s specification. Although it is also possible to use a plaster that does not require uneven joints and damages to be filled by hand first. Consult the supplier of the finishing material for advice on this. When applying a spray plaster, the total plaster thickness will be about 3 mm.

30 Silka Calcium Silicate Elements Building guidelines for using thin joint mortar systems Criteria for surface assessment of calcium silicate walls built with SILKA products

Assessment aspect Group 1 Group 2 Group Elements Hand size blocks Chamfered blocks Vertical joints (with regard to the permitted joint no requirements no requirements permitted deviation width) ±1 mm at most Bed joints (with regard to the permitted joint width) no requirements no requirements permitted deviation ±1 mm at most Bed joints (longitudinal direction;measured over top no requirements no requirements permitted deviation block) 2 mm/m Levelness: maximum dimensional variation 1 m 2 mm 3 mm 2 mm permitted at distances between measuring 4 m 3 mm 4 mm 3 mm points of: 9 m 5 mm 5 mm 5 mm

Description of groups: Group 1: walls of elements, which can be finished with a plastering system to a maximum thickness of 3 mm. Group 2: walls of (hand size) blocks, which can be finished with a skim plaster as from 3 mm thick. Group 3: walls of chamfered blocks, which will not be finished (one or twosided fair-face work).

Source: BKB (BV Quality declarations Constructions)

7.2 Tile-work 7.3 Multi-storey house building, commercial, Tiles can be applied straight on office and industrial to calcium silicate with a tile ad- building hesive with either a cement-or a synthetic base, in accordance The higher compressive with the directions supplied strength of masonry with Silka by the manufacturer of the tile elements is specifically adapted adhesive. Should the surface for construction of medium high prove to be too uneven, the wall and high buildings up to 10 or will first have to be evened out 12 storeys. with a cement based product. The wall can subsequently be Industrial buildings tiled,using a tile adhesive on There are element stackers either cement or synthetic base. available with a hoisting height Applying tiles to a gypsum wall of 10.5 metres. These machines finish should be avoided under are very useful for building high all circumstances, as this can walls in industrial buildings. lead to damaged tilework.

Aedes sprl

Silka Calcium Silicate Elements 31 Chapter 8 PRODUCT INFORMATION SILKA CALCIUM SILICATE ELEMENTS

Product description Composition Method of manufacture Silka elements are suitable for Raw material: mixture of mainly The mixture is pressed into application in load- and non slaked lime and sand. blocks or elements and after loadbearing inner leaf ca- that hardening takes place by vity walls, party walls or other means of steam under high wall constructions. They are pressure. available in various sizes and requirements.

32 Silka Calcium Silicate Elements Product range Silka elements

Type Dimension Thickness Mortar Weight (kg)* Profiling mm mm consumption in kg/m2 kg/each per m2

E100 897x623/643 100 1.4 100 / 104 178 T&G

E150 897x623/643 150 2.2 151 / 156 269 T&G

E175 897x623/643 175 2.5 176 / 182 313 T&G

E214 897x623/643 214 3.3 215 / 222 383 T&G

E240 897x623/643 240 3.7 242 / 249 431 T&G

E300 897x623/643 300 4.7 302 / 311 538 T&G

T&G = tongue and groove

* exclusive pallet

Shape Kicker course blocks Mechanical characteristics Rectangular elements with la- Blocks for the kicker course are fb in accordance with EN 771-2 byrinth joint. Cut-to-size blocks produced in standard heights and BBA n° 08/4553 are cut to the correct size out of of 70, 85 100, 115, 130, 145 and fb ≥ 20 N/mm² (≥CS20) and elements at the factory. 160 mm. Thermo-kickercourse fb ≥ 28 N/mm² (≥CS28) block are available to avoid Element tolerances: thermal bridges. length, width +/- 2 mm; heigth +/- 1 mm. Appearance Surface structure: smooth. Cut-to-size block tolerances: Colour: white. length and height: from –4 mm to +2 mm.

Silka Calcium Silicate Elements 33 Fire resistance

Silka calcium silicate elements are fireproof. The fire resistance values of a wall with fully filled joints are:

Thickness wall (mm) Fire resistance

100 EI 90*, REI 90*

150 EI 240*, REI 240*

175 EI 240*, REI 240*

200 EI 240*, REI 240*

240 EI 240*, REI 240*

300 EI 240*, REI 240*

* According to NBN EN1996 - 1 - 2 -ANB: 2011 joint horizontally and vertically joined together with thin bed mortar without plaster

Gases, liquids and solid subs- Thermal characteristics Acoustic qualities tances Linear coefficient of expansion: Sound absorption coefficient: Water vapour permeability: 5/25 α = 10 x 10-6 m/m.K α = 0,03 (500 – 1000 Hz). The Thermal conductivity: noise reduction of a wall with λUi = 0.91 W/m.K fully filled joints and finished is: Specific heat c = 1000 J/kg.K

Acoustic properties

Rw Width (mm) Finish Surface weight (1) Single wall Cavity wall construction

no plaster 45 dB (*) 100 180 kg/m² / ≥ 150 kg/m² thin plaster coat both sides 45 dB (*)

no plaster 50 dB (*) 150 270 kg/m² / ≥ 250 kg/m² thin plaster coat both sides 50 dB (*) 69 dB (*)

no plaster 51 dB (*) 175 315 kg/m² / ≥ 250 kg/m² thin plaster coat both sides 52 dB (*)

no plaster 56 dB (*) 214 385 kg/m² / ≥ 250 kg/m² thin plaster coat both sides 56 dB (*)

no plaster 57 dB (**) 240 432 kg/m² / ≥ 250 kg/m² thin plaster coat both sides 57 dB (**)

no plaster 58 dB (*) 300 540 kg/m² / ≥ 250 kg/m² thin plaster coat both sides 58 dB (*)

(*) the dB values are being tested by the Laboratory of acoustics and heat conductivity of the K.U. Leuven. (**) the dB values are guideline values (1) see “acoustic amendments of the structural shell work for terraced houses and appartments by means of cavity walls” TC acoustic, WTCB Files 2012/2

34 Silka Calcium Silicate Elements Application Altiplan architecten E 150 to E 300: inner leaf cavity walls and load-bearing constructions in masonry back-up. E 100: non load-bearing party walls.

Building process Storage: on stable, even and non conteminated surface. Preparation: pre-processing check (by client) of the working wall drawings supplied by Xella. Silka elements, cut-to- size blocks and kicker course blocks, which are too dry for processing, should be moisten- Workability: sawing. The Silka product range from ed one day before use. Xella finds its way to all sectors in the building industry, finding Installation: consult the Silka Prices, delivery and use in dwellings, non-residen- installation guidelines. The ele- guarantees tial buildings and renovation. In this connection, Silka blocks ments are mechanically stac- Silka elements are delivered have the right properties for ked, according to the working under CE certification, Silka use in load-bearing and non load-bearing constructions. In wall drawings, with calcium elements meet the BBA addition to sales and marke- silicate thin joint mortar, bed n° 08/4553 requirements. ting activities. joint thickness 2 mm, butt joint Prices and terms of delivery: Xella supplies technical advice thickness 3 mm. Both perp according to specification on construction and gives information to customers, ends and bed joints must be of Xella. builders, clients, architects fully filled with mortar. Delivery time: standard ele- and advisers. If you have any questions about this brochure Accessories: Silka thin joint ments usually from stock, or the Silka-products and their mortar applicators, mortar cut-to-size blocks according to applications and/or how they can be used in construction, scoops, clamping devices were specification. please contact Xella. developed especially for the Although Xella has devoted the processing of Silka elements. Technical service greatest possible care to the Movement joints: movement ■■ Technical construction content and composition of this brochure, no rights can be joints are indicated on the advices; derived from it by third parties. working wall drawings supplied ■■ Application advices. Always consult the instructions by Xella. for use and the product infor- Finishing: Silka elements are mations that come with the goods. Xella reserves the right used in non-fair faced applica- to modify product specificati- tions and can be prepared for ons at any time without prior notice. wallpapering by applying a thin skim plaster.

Silka Calcium Silicate Elements 35 E-mail: Fax: Telephone: 5SH B75 Coldfield Sutton Canwell Road London Old Priory 7 The nv/sa BE Xella of A branch UK Xella contact: please advise &technical sales For Internet: silka-uk www.xella.co.uk +44 (0) 843 290 9081 290 843 (0) +44 9080 290 843 (0) +44 @ xella.com Silka, Ytong andXellaare registered trademarks oftheXellaGroup. expressed orimplied. that mightinfringeanyexisting patents, norisanywarranty made,either as permission orrecommendation for theuseofanyproduct ina manner No statement madeinthisMaterial Safety Data Sheetshallbeconstrued comply withanydutiesimposedbyStatutory orRegulatory requirements. risks posedintheemployment ofanyproducts are undertaken andto user to ensure thatsuitable andsufficient assessment ofhazards and is intended for general guidance only, anditistheresponsibility ofthe Health andsafety information provided intheMaterial Safety Data Sheet on thebasisthatwe cannot guarantee itsaccuracy orcompleteness. the product decribedonly, andwhichissuppliedto product purchasers information provided inthisMaterial Safety Data Sheetwhichrelates to Disclaimer: Every effort hasbeenmadeto ensure thecorrectness ofthe

03-2016