CONCRETE PRODUCTS Construction and Hardscape Special Thanks: Besser Company extends our sincere thanks to the many people, Contents companies and organizations that provided information and Technical Data* .............................................................. 4 photographs for this project. Loadbearing Masonry .................................................... 6 Every effort was made to provide Standard Units .............................................................. 8 a comprehensive tool for the Special Purpose Units ................................................... 9 promotion of concrete masonry. Please bring any omissions or errors to our attention and every Corner, Floor & Seismic Construction ....... 10 effort will be made to correct them Corner Construction in the next printing. Masonry Floor System Seismic Construction The intent of this brochure Architectural ............................................ 12 is to highlight many of the uses for concrete masonry Split units produced using Besser Scored equipment. Because of space Fluted and Ribbed limitations, not all units or Shadowal possible applications are Stri-Face shown. Additionally, some of Slump the products shown may be Concrete Brick patented, licensed or franchised. Ground Face Please contact Besser Company for additional information. Antiqued Sandblasted/shotblasted Be sure to check your national Glazed and local requirements as Fusion Stone technical data provided is Novabrik™ intended to only serve as a guideline.* Acoustical Hardscape ................................................ 20 Paving Stone Permeable Interlocking Pavement (PICP) Slabs Grass Units Stepping Stones Lawn Edging Fence Units Erosion Control Segmental Retaining Walls The Production of Concrete Products ...... 26 Published by: Besser Company, 801 Johnson Street, Alpena, Michigan 49707 USA Phone: 989.354.4111 Fax: 989.354.3190 besser.com e-mail: [email protected] 2 Production of dense, strong, aesthetically pleasing concrete products is simple using a complete production system supplied and supported by Besser Company. Complete systems are capable of producing a wide range of concrete products, which is critical in today’s competitive marketplace. Besser systems will produce all of the concrete products shown in this book – and more! Concrete Products – The Perfect Building Material Designers from around the the concrete products industry. globe incorporate concrete There are many well-documented products in construction projects benefits of using concrete products. ranging from commercial and These include: aesthetics, strength, educational to residential. Low, durability, fire resistance, thermal mid and high-rise structures insulation, sound absorption and perform equally well using modular dimensioning. As the concrete masonry. The popularity industry has grown, standards of concrete products can be have risen steadily to ensure the attributed to the wide variety of consistent performance of concrete shapes, sizes, textures and colors masonry units. Groups such as the available, all of which will meet American Society for Testing and any design criteria. Materials (ASTM), the National Split, split-fluted, stri-face, Concrete Masonry Association scored and ground face block (NCMA), Interlocking Concrete and concrete brick are just a Pavement Institute (ICPI) and few of the thousands of concrete The Masonry Society (TMS) are products readily available organizations whose mission is to for building construction safeguard the industry. applications. Additionally, Concrete products producers imaginative designs of concrete manufacture consistent, products such as paving stone, dimensionally precise, high strength retaining wall units and slabs units regardless of what type of have emerged as highly desirable concrete units are produced. hardscaping products for use in Producers use specialized industrial, commercial, municipal equipment, locally available and residential construction. aggregate, sand, cement and water Paving stone, retaining wall units to create the world’s most perfect and slabs are integral elements of building material. 3 Technical Data Sound Level Decibels Sound 140 Jet plane takeoff 130 Threshold of discomfort 120 Riveting 110 Thunder-sonic boom 100 Hard rock band 90 Power lawnmower 80 Pneumatic jackhammer 70 Noisy office 60 Average radio 50 Normal conversation 40 Quiet street 30 Quiet conversation 20 Whisper at four feet Relationship Between 10 Normal breathing Sound Transmission Loss Through a Wall & Hearing Condition on Quiet Side* 3 Threshold of audibility Transmission Hearing Condition Rating Loss in Decibels Normal speech can be understood 30 or less quite easily and distinctly through Fair the wall. Sound Loud speech can be understood 30 to 35 fairly well. Normal speech can be Fair Concrete products are especially heard but not easily understood. effective in reducing the transmission Loud speech can be heard, but of unwanted sound because of is not easily intelligible. Normal Good 35 to 40 speech can be heard only faintly, their mass and rigidity. The sound if at all. transmission class (STC) is a single- Loud speech can be faintly heard Very good, recommended figure rating based on tests. The 40 to 45 but not understood. Normal for dividing walls between rating provides an estimate of the speech is inaudible. apartments. performance of the wall in common Very loud sounds, such as Excellent, recommended loud singing, brass musical sound insulation problems. The for band rooms, music instruments, or a radio at full heavier the wall, the greater the 45 or more practice rooms, radio and volume can be heard only faintly sound studios. sound transmission rating. or not at all. *This table is based on the assumption that a noise corresponding to 30 decibels is continuously present on the listening side and that noises passing through the wall are audible despite this noise level. A decibel is roughly equivalent to the smallest change in sound energy that the average ear can detect and 30 decibels corresponds approximately to the average background noise in a quiet apartment. 4 The intrinsic benefits of concrete products make them the perfect building material. Technical data highlights these outstanding qualities. Calculating Estimated Fire Resistance Ratings Equivalent Thickness Concrete Masonry Walls Minimum required equivalent thickness Equivalent thickness is the solid thickness that inches (mm) would be obtained if the same amount of concrete contained in a hollow unit were Aggregate Type 4-Hour 3-Hour 2-Hour 1½-Hour 1-Hour re-cast without core holes. Calcareous or Siliceous Gravel 6.2 (157) 5.3 (135) 4.2 (107) 3.6 (91) 2.8 (71) Calculating Estimated Fire Resistance Example: An 8" hollow masonry wall is constructed of Limestone, Cinders or Slag 5.9 (150) 5.0 (127) 4.0 (102) 3.4 (86) 2.7 (69) expanded slag units reported to be 56%* solid. Expanded Clay, Shale or Slate 5.1 (130) 4.4 (112) 3.6 (91) 3.3 (91) 2.6 (66) What is the estimated fire resistance of the wall? Expanded Slag or Pumice 4.7 (119) 4.0 (102) 3.2 (81) 2.7 (69) 2.1 (53) Eq Thickness = 0.56 x 7.625 = 4.3 inches From table below: The wall has a 2-hour fire resistance rating. R Values * Percentage solid can be calculated average from net 2 2 area or net volume values as determined by ASTM C 140 hr-ft -°F/Btu (m -K/W) “Methods of Testing Concrete Masonry Units.” Cavity wall, Single-Wythe, backup CMU Cavity wall, backup CMU Nominal Reinforcement Single- empty, 2" CMU empty, 2" Density, Width, 48" on center, Wythe, Extruded Polyisocyanurate lb/cubic inches remainder Cells Empty Polystyrene in insulation in cavity, foot (mm) filled with cavity (XPS), 4" 4" CMU veneer insulation CMU veneer Fire 95 6 (140) 2.26 (0.4420) 4.45 (0.2247) 13.64 (0.0733) 18.04 (0.0554) Concrete masonry wall systems are 95 8 (190) 2.42 (0.4137) 5.61 (0.1782) 13.80 (0.0725) 18.20 (0.0550) unsurpassed in functioning as barriers 95 10 (250) 2.45 (0.4086) 6.82 (0.1467) 13.83 (0.0723) 18.23 (0.0549) to contain the spread of fire. Masonry 95 12 (300) 2.47 (0.4056) 7.95 (0.1257) 13.85 (0.0722) 18.25 (0.0548) effectively resists the passage of flames 135 6 (140) 1.89 (0.5291) 2.97 (0.3369) 13.27 (0.0754) 17.67 (0.0566) and hot gases. Fire resistance ratings 135 8 (190) 2.02 (0.4961) 3.71 (0.2699) 13.40 (0.0747) 17.80 (0.0562) are commonly determined from 135 10 (250) 2.07 (0.4830) 4.55 (0.2197) 13.45 (0.0743) 17.85 (0.0560) tables. Data included in these tables 135 12 (300) 2.10 (0.4752) 5.36 (0.1865) 13.48 (0.0742) 17.80 (0.0559) is based on extensive testing of walls. The tables reflect the differences in Needed Discussion/Caveats raw materials and concrete masonry 1. All thermal assumptions on materials and calculation methods consistent unit configuration. Units with greater with information provided in NCMA Thermal Catalog for Concrete Masonry equivalent thickness have greater fire Wall Assemblies, 2nd Edition. resistance rating. 2. Thermal data provided as “R-value (U-factor)”. Units on R-value are (hr·ft2·°F/Btu). Units on U-factor are (Btu/hr·ft2·°F). Thermal 3. Web and face shell dimensions are ASTM C90-15 minimums. Concrete masonry walls provide a. For 6" CMU, face shell thickness is 1", web thickness is 0.75" a wide array of options to increase b. For 8, 10, 12" CMU, face shell thickness is 1.25", web thickness is comfort and insulating value. Changing 0.75" the raw materials used may increase 4. All CMU have three full height webs, resulting in two cores. the performance. Special shapes 5. For ‘Single-Wythe Cells Empty’, there is no cell fill or surface finishes. 6. For ‘Single-Wythe, Reinforcement 48" on center, remainder filled with can enhance the thermal resistance. insulation’, it is assumed that the assembly has vertical reinforcement and Insulating materials and inserts improve grout at 48" on center (no horizontal reinforcement) and ungrouted the insulation and retain the hard, cells are filled with insulation with an R-value of 5.91 (consistent with pour- durable face of the wall that may be built in-place closed cell polyurethane foam).