autoclaved aerated concrete products 3 · 6.2 hand tools & equipments 33 - 35 6.3 erection...

Autoclaved Aerated Concrete Products

TECHNICAL GUIDE

3

I N D E X

A A C B U I L D I N G S Y S T E M T E C H N I C A L G U I D E

The Head Office of the Company is in Riyadh.

Production facilities are located at the Industrial City II on Al Kharj Road.

Lightweight Construction Company (LCC-Siporex)

Is originally the sole manufacturer and supplier of

lightweight Autoclaved Aerated Concrete (AAC)

to the Saudi Arabian Construction industry.

The company is wholly owned by Saudi nationals.

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I N D E X

A A C B U I L D I N G S Y S T E M T E C H N I C A L G U I D E

S. N. CONTENTS PAGE NO.

1. Introduction 3 1.1 What is Siporex? 3 1.2 About our plant 4 1.3 Codes & Standards 5

2. Manufacturing 6 2.1 Manufacturing Process 6 - 7 2.2 Quality Control 8 2.3 Material Identification & Markings 9 2.4 Handling, Shipping & Storage 10

3. Properties & Benefits of Using Siporex 11

3.1 Benefits of Using Siporex 11 - 12 3.2 Properties of Siporex 13 - 17

4. Range of Products 19 4.1 Wall Panels 19 - 21

4.2 Lintels 22 - 23 4.3 Floor & Roof Slabs 24 - 25 4.4 Siporex Blocks 26 - 29

5. Design 30 5.1 General 30 - 31

5.2 Design Principle 32 5.3 Structural System 32

6. Erection 33 6.1 Guidelines for Estimating Erection Cost 33 6.2 Hand tools & Equipments 33 - 35

6.3 Erection Procedure 36 - 37 6.4 Repair of Siporex Panels 38

6.3 Illustrations Showing Erection Stages 39 - 40 7. Typical Connection Details 41 - 44

8. Electro-Mechanical 45 8.1 Chases & Penetrations 45 8.2 Electrical Installations 46 8.3 Plumbing Installations 46

9. Finishes 47 - 48

10. Fixings to Siporex 49 11. Siporex Glue 50 12. Siporex Gesol 51 13. List of Some Projects 52

1. Introduction

A A C B U I L D I N G S Y S T E M T E C H N I C A L G U I D E 3

1.1 What is Siporex?

SIPOREX is lightweight Autoclaved Aerated Concrete (AAC) which is also called cellular concrete.

SIPOREX is completely cured mix of calcareous materials such as cement and siliceous fine materials such as quartz sand with the addition of water and aluminum powder acting as foaming agent to form a homogenous cellular structure known as Calcium Silicate Hydrate.

SIPOREX is a high quality structural material, load-bearing and extremely well insulating material due to numerous tiny non-connecting air bubbles which gives Siporex its incredibly diverse qualities. The high pressure steam-curing in autoclaves achieves a physically and chemically stable product with an average density being approximately one fourth of normal concrete.

SIPOREX is produced as blocks and precast reinforced units, i.e., wall panels, lintels and floor/roof slabs forming a complete building system.

SIPOREX has been used on large scale projects such as housings, schools, hospitals, commercial, industrial and government projects under all climatic conditions since the early nineteen thirties worldwide.

SIPOREX is definitely one of the major achievements in the field of construction. It is a revolutionary material that offers a unique combination of strength, lightweight, thermal insulation, sound absorption, unsurpassed fire resistance and unprecedented buildability.

SIPOREX is a natural and non-toxic construction material, saves energy, and is friendly to the environment.

As a building system, SIPOREX meets all the requirements of our modern age throughout the world. Its properties ensure a building material that outperforms all others. In view of the rapid development and increasing demand, we can claim with certain justification that SIPOREX is the ideal choice for building construction.


1. Introduction

1.2 About Our Plant

Industrial production of this versatile building material was started in 1929 and it has been produced and used for building construction ever since. First in Europe and now world-wide.

Here in the Kingdom of Saudi Arabia, LCC Siporex Company was established in 1976 and has been producing Siporex AAC material at our plant in the Second Industrial Estate, AlKharj Road.

With our continued expansion of additional manufacturing plant to sustain the growing demand, our current total production capacity has intensified to about 350,000 cubic meters of Siporex AAC products per year.

Builders, engineers, architects and contractors not only appreciate the excellent properties of Siporex, but also energy-saving and pollution-free techniques used in its production.

In fact, Siporex manufacturing process produces neither polluting waste gases nor dangerous residues and there is no waste of costly raw materials.

Siporex manufacturing plant in Riyadh, Saudi Arabia

After more than forty years and having used by several thousands of projects, LCC Siporex became the leading supplier of this truly amazing material not only within the kingdom but also to GCC countries, Yemen, Jordan, Sudan, Ethiopia and as far away as Djibouti, Taiwan and Japan.


1. Introduction

1.3 Codes & Standards

Various international codes and standards had been developed to provide engineers and designers with provisions for the analysis and design of AAC factory-produced reinforced panels and blocks based on various research studies and experiences on its use.

These include guidelines or recommended practice addressing the materials, manufacture and structural design of AAC including design considerations such as erection and construction details incorporating the use of AAC products in conventional construction. Some of these Codes & Standards are listed below:

CODE OR STANDARD DESIGNATION NO. DESCRIPTION

ACI ACI 523.4R-09 Guide for Design and Construction with Autoclaved Aerated Concrete Panels

ASTM C1555-03A Standard Practice for Autoclaved Aerated Concrete Masonry

ASTM C1386-98 Standard Specification for Precast Autoclaved Aerated Concrete Wall Construction Units

ASTM C 1452-00 Standard Specification for Reinforced Autoclaved Aerated Concrete Elements

DEUTCH NORM DIN 4165 Autoclaved Aerated Concrete Blocks

DEUTCH NORM DIN 4223 Aerated Concrete; Reinforced Units

BRITISH STANDARD BS 8110 – Part 2, Section Six Autoclaved Aerated Concrete

BRITISH STANDARD BS EN 771-4:2003 Autoclaved Aerated Concrete Masonry Units

BRITISH STANDARD BS EN 678:1994 Determination of the Dry Density of Autoclaved Aerated Concrete

BRITISH STANDARD BS EN 679 :1994

Determination of the compressive Strength of Autoclaved Aerated Concrete

BRITISH STANDARD

BS EN 680: 1994

Determination of the Drying Shrinkage of Autoclaved Aerated Concrete

BRITISH STANDARD BS EN

772-10:1999 Method of test for Masonry Units

BRITISH STANDARD BS EN 1351:1997

Determination of Flexural Strength of Autoclaved Aerated Concrete

BRITISH STANDARD BS EN 1353:1997

Determination of Moisture Content of Autoclaved Aerated Concrete

SASO SASO 1579 Precast Autoclaved Aerated Concrete

SWEDISH BUILDING CODE Autoclaved Aerated Concrete Products

COUNCIL OF AMERICAN BUILDING OFFICIALS

Design Procedure for Siporex Roof, Floor, Wall Panels, Masonry Blocks and Lintels of Autoclaved Lightweight Cellular Concrete(Report # NER-297)

RILEM Autoclaved Aerated Concrete


2. Manufacturing

2.1 Manufacturing Process

Siporex is produced by a highly complex and advanced manufacturing process in our factory under the careful control of chemists and engineers. Siporex is made either as steel reinforced panels using moulds 6 meters long, 1.5 meters wide and 600 mm deep or as non-reinforced blocks using moulds 6 meters long, 1.5 (or 1.2) meters wide and 600 mm deep. A schematic diagram of manufacturing process is shown on fig. 1.

The basic raw materials are sand, water, aluminum powder and cement. The sand is ground to required fineness in a ball mill before mixing with other raw materials with water to form slurry to which a trace of aluminum powder is added as expanding agent.

Regulated amount of aluminum powder gives accurate control of density of the final product. Moulds are only partly filled with slurry which then expands in a controlled reaction to fill the moulds.

When the mass is sufficiently hard, the moulds are stripped and the cake is wire-cut to close tolerances into panels and blocks using high-precision cutting technology. These are then steam cured under high pressure in autoclaves for up to 15 hours.

After cooling to ambient temperature, the panels are demoulded and milled to required profile as necessary. All Siporex panels are singled out for proper marking, and if required, dry cut and stacked for further handling and storage. The blocks are demoulded, strapped, marked and stored on wooden pallets.

All Siporex panels are reinforced with steel. Steel coils are straightened, cut and spot-welded into mats, where crossbars provide anchorage to the longitudinal reinforcements. Siporex blocks are not reinforced.

After dipping the welded mats in a homogenized anti-corrosion mix for rust protection, they are dried and assembled into cages and set accurately in the moulds before the slurry is poured in.

This completes the chemical process, resulting in a unique crystal structure of calcium silicate hydrate and ensuring a stable and inert product giving AAC outstanding qualities not found in other products.

The finished goods inspection programme ensures the products quality. The material is now ready for loading and delivery.


2. Manufacturing

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Fig. 1 Siporex Production Process


2. Manufacturing

ISO Certification

2.2 Quality Control

The manufacturing of Aerated Lightweight Concrete as blocks and reinforced panels (Roof slabs, Wall Panels & Lintels) by LCC implements and maintains a Quality Management Siporex System which fulfills the requirements of ISO 9001:2015.

It is the policy of LCC Siporex to provide quality products or services that always meet or exceed the expectation of the customer from inquiry to final delivery of the materials / services.

Siporex Chemical Laboratory

Quality Control and Quality Assurance at LCC Siporex encompass both raw materials and finished products. Raw materials certificates are obtained from suppliers of cement, aluminum powder and reinforcement steel.

In-house quality assurance is made for silica sand, cement, gypsum, Magnesite, lime, steel protection coating, aluminum powder and process water.

For final products, compressive test, shrinkage and dry densities are carried out on a daily basis.

A load test for crack and rupture is performed on a load testing machine for slabs to ensure product quality of reinforced panels.

Compressive Strength Test


2. Manufacturing

2.3 Material Identification & Markings

Siporex Blocks:

After autoclaving, Siporex blocks are ready for packing and distribution.

Blocks are strapped in bundles and marked with a stamp denoting block dimension, density type and batch number.

Bundles of blocks are arranged in stacks laid on wooden pallets and sent to storage or distribution.

Reinforced Panels:

Reinforced panels are marked after autoclaving and demoulding, with stamp code containing information about the type of product, density, permissible load, dimensions, batch number and order number.

An arrow indicating the top side of the panels will be marked at one end of the floor/roof slabs and lintels.

Typical Markings on Block Stack

The following abbreviations are used for the types of product:

WV – Vertical wall panels

WH – Horizontal wall panels

WP – Partition wall panels

WF – Fluted wall panels

RS – Roof slabs

FS – Floor slabs LW – Panel-type lintels

LA – Arch-type lintels

LB – Box-type lintels

B – Blocks

Density 5 – denotes nominal dry density of 550 kg/m3 for both blocks and reinforced panels. Density 4 – denotes nominal dry density of 450 kg/m3 for Hordi blocks. Permissible load – Indicates service load in kg/m2 for walls and slabs or kg/lm in case of lintels.


2. Manufacturing

2.4 Handling, Shipping and Storage

Siporex products are designed to resist normal handling and transport. Siporex blocks should be handled by forklifts and/or cranes with appropriate straps to avoid damage to the material.

Siporex materials are shipped by trucks or flat-bed trailers and can be transported by road, train and by sea for international projects.

They have unlimited storage stability, provided that they are not exposed to extreme conditions. They must be supported by properly placed bearers and stored in such a way that they cannot absorb water from the ground or be splashed with sea water. Siporex is an inorganic material and is not affected by termites and other insects.

Siporex Blocks

Bundles of blocks (60 cm high) are stored on wooden pallets.

Each pallet can be stored with up to 3 bundles of blocks (180 cm high).

At the storage area, the floor should be level to avoid tilting of stocks.

Stocks of blocks can easily withstand 3 pallets with 3 bundles each of Siporex blocks.

Reinforced Panels

On the ground, the stacks of reinforced panels shall be supported by wooden planks, one on each end, placed approximately one fourth of the length from the ends.

In transporting, the stacks are tied by strapping at both ends, protected with plastic angles.


3. Properties & Benefits of Using Siporex

3.1 Benefits of Using Siporex

The manufacturing process as well as the basic ingredients used provides Siporex its unique properties and benefits not found in other traditional building materials and will radically change the construction practices in this industry.

Lightweight Siporex weighs less than a quarter compared to conventional concrete. Due to the lightweight property of Siporex, the foundation loads are greatly reduced resulting to big savings in the overall construction cost especially at areas having poor soil bearing capacity. Its light weight also means significant advantage in transportation cost.

Energy Efficient Siporex ensures pleasantly healthy and comfortable room temperature without the need for additional insulation. Its thermal insulation and heat retention offer a good protection against rapid cooling or heating up too much. This means lower power consumption in environmental management system.

Dimensional Accuracy The production process guarantees the accurate dimensions of the panels and blocks that comprise the building system. This allows for a straight and plumbed walls resulting in less on-site trimmings and reduces the quantity of mortar and finishing materials required. The dimensional tolerance is ±3mm for thickness & width and ±5mm for length.

Workability Siporex products can be sawn, cut, slot, drilled, chased and nailed with ordinary woodworking tools which makes them easier to install than other building materials. This also simplifies the installation of electro-mechanical services and other utilities, which means more cost savings.

Resistance to Fire Siporex is totally inorganic and does not contain any combustible materials, which means it is resistant to fire. A 15 cm thick panel will resist fire for seven life-saving hours. Siporex is ideal for firewall application and as protection for structural steel construction.



Acoustic Insulation

Siporex meets the appropriate standards for sound insulation in house building, which means quieter and more comfortable interior. In industrial construction, Siporex minimizes industrial noise pollution. The sound absorption of untreated Siporex surface is better than that of dense concrete.

Non-toxic

Siporex itself is ecologically harmless, since it neither contains gases nor fibers, it is neither dangerous to ground- water nor does it releases any radioactive radiation. No pollutants or toxic by-products are produced in the manufacturing process or even when subjected to fire.

Durability

Siporex products do not contain any organic matter subject to deterioration and will not degrade even under severe weather conditions. Structures built several decades ago are still in active use today.

Quake Resistant

The low mass of Siporex results to reduced total dead load of the building and consequently reducing the applied seismic forces to its structure. Structures built in earthquake zones such as Japan & Mexico have shown good resistance to seismic forces in actual practice.

Speedy Construction

Siporex has all the advantages of a precast system, i.e. eliminates shuttering, wet construction, curing, on-site testing & quality control resulting to reduced overall construction time and cost. It also requires minimal supervision and construction staff.

Pest Resistant

Siporex provides airtight interior, does not contain any organic ingredient and makes your home uninviting to pest, insects or rodents.

3.1 Benefits of Using Siporex



3.2 Properties of Siporex

3.2.1 Weight Siporex products are supplied with nominal dry density of Siporex products is 550 kg per cubic meter and weigh less than a quarter compared to conventional concrete. Other densities such as 450 or 600 kg per cubic meter can also be produced upon request. Due to its light weight, the number of trailers required to transport Siporex materials is much less than those required to transport conventional precast panels and handling at site can be carried out with ease.

3.2.2 Compressive Strength Siporex is solid and has a high compressive strength in relation to its

weight, which in the aspect of application is very sufficient to take building loads. Siporex achieves its final strength during the autoclaving process. Following are the minimum characteristic strength of Siporex material corresponding to cube specimen and having nominal dry density

of 550 kg/m3:

Compressive strength = 35 kg/cm2

Tensile strength = 20 to 40% of compressive strength Shear strength = 20 to 30% of compressive strength

Modulus of elasticity = 16,000 kg/cm2

3.2.3 Thermal Conductivity

The thermal conductivity (“k” value) for completely dry Siporex is 0.144 W/mºC. The air bubbles trapped in Siporex are giving10 times better insulation properties compared with conventional dense concrete. This is reflected in considerable savings of electricity consumption and improved indoor comfort. A special independent study conducted by the Research Institute of the King Fahd University of Petroleum and Minerals confirmed that 63% energy cost saving is achieved when using Siporex material based on a model 2-storey house with 525 m2 gross floor areas.

Other savings are also achieved by replacing a 30-35 cm thick sandwich wall by a single 20 cm thick Siporex wall. This will reduce the size of R.C. beams, columns and foundations and will give more living space. Siporex construction system is not only ideal for exterior and interior walls, but also for floor and roofs. All these result in a low average thermal conductivity value for whole building surface.

Siporex is the only structural material classified by the Saudi Electricity Company as an insulation material. Siporex qualities not only exceed their rival construction material but far more superior.

Fig. 3 Shows the superiority of Siporex over other conventional material.

0.144 0.55

1.097 1.1291.355

SIPOREX CLAY BRICKS CONCRETE BLOCKS

SANDLIME BRICKS

PREFAB CONC.

THERMALCONDUCTIVITY ("K"VALUE")



3.2.4 Fire Resistance Siporex has remarkable fire

resistance properties and is non-combustible. Heat migration takes place at a slow rate due to its low thermal conductivity, giving Siporex excellent fire resistance. Water in crystalline form within the material acts as a heat sink and the porous structure allows steam to escape without causing surface spalling.

3.2.5 Thermal Expansion The thermal expansion of Siporex is of the order of 8x10-6/°C. Expansion

coefficient of regular concrete varies between about 4 to 14x10-6/°C depending on the type of aggregate and curing procedure.

3.2.6 Moisture Content Siporex products have a moisture content of 25 to 40% of its weight when

the material is delivered. As with all concrete products, Siporex will dry out until it reaches equilibrium with the moisture content of the surrounding air. In this state, it reaches a moisture content of 2% to 6% within one year from erection.

As with all other concrete finishes, slabs and walls should receive protection against water penetration, for external walls, this can be a single decorative coating.

3.2.7 Shrinkage Loss of moisture in AAC results in drying shrinkage. It is determined

according to European Standard as the relative length change for specimens at specified moisture contents of 30% and 6% by mass respectively. The average shrinkage for AAC is 200x10-6 as compared to 500x10-6 for ordinary concrete. The lower shrinkage for AAC is attributed mainly to the high pressure steam curing (autoclaving) that the fresh material is subjected to during production.


Due to its excellent fire resistance and very positive practical experience obtained, Siporex panels and blocks had been widely gaining popularity in worldwide construction. In many cases of building fires, the structural parts of Siporex were able to continue to serve with minor repairs, which considerably reduced the cost of damage caused by the fire.

The following table shows the unsurpassed average fire-ratings of various thicknesses of Siporex walls:

Thickness (cm) 10 15 20 25

Fire ratings (hrs) 4 7 7+ 8

The temperature of Siporex is lower in Siporex compared to dense concrete, not only on the non-exposed side but also on the side exposed to heat. This fact is vital as it affects the protection of the reinforcing steel in structural units.



3.2.8 Acoustic Properties

The Sound Transmission Class (STC) rating is a single number guide used to rate acoustic barriers according to their effectiveness in reducing sound transmission. Sound reduction is the ratio of sound energy at its source to that at any other location expressed as decibels (dB). It is important to note that the scale of decibel is logarithmic, i.e. an increase of 10 dB means a reduction of sound to one-tenth, 20 db a reduction to one-hundredth etc. Figure 4 shows some STC ratings of a few wall constructions consisting of Siporex material.

Figure 4. Sound Transmission Class of some few Siporex wall constructions.

The unique structure of Siporex also provides superior sound absorption better than normal concrete and is more apparent at higher frequencies. This property reduces the echo effect (i.e. reflecting sound) in empty rooms.

3.2.9 Specific Heat At normal equilibrium moisture content, the specific heat is 1.0 – 1.1 kJ/kg°C

or about 0.24 – 0.26 kcal/kg°C.

3.2.10 Melting Point Siporex starts to sinter at about 1,000°C and melts at about 1,100 to 1,200°C.

Certain physical transformation occurs at these conditions, therefore, Siporex is not suitable for construction which are going to be exposed to high temperature, e.g. kilns, stoves, chimneys, etc.


39

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48

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35 40 45 50 55 60

100mm thk Siporex wall panel without finishes


200mm thk Siporex wall panel with 3mm Serpoexternally and 2mm Serpospack internally


200mm thk Siporex wall panel with 3mmSerpocoat externally and12.5mm gypsum board

on 50mm steel stud

200mm thk Siporex wall panel with 3mmSerpocoat externally, 40mm thk fiberglass and

12.5mm gypsum board on 50mm steel stud

2x200mm thick Siporex wall panels with 50 mmgap and 2mm Serpospack on exposed faces

Sound Transmission…



3.2.11 Environmental Exposure of Siporex

Like any other cementitious materials, Siporex is deteriorated by strong acids. Acid salt solutions such as chlorides or sulphates may also degrade Siporex in long term. However, Siporex is normally unaffected by alkaline solutions.

The vital components of Siporex are water insoluble. However, like most concrete building materials, Siporex contains small amount of water soluble salt which have no influence on the strength and resistance. Under severe conditions, they can appear on the surface as efflorescence. The formation of efflorescence is mainly a matter of repeated wetting in combination of very bad drying conditions. Under normal drying conditions, it hardly ever occurs.

3.2.12 Airtightness

Even with normal construction procedures, Siporex buildings have excellent airtightness qualities. Test on AAC buildings measured 1 to 2.5 air changes per hour at a reference pressure of 50 Pa.

This compares favorably well with other types of construction, such as concrete block, where normally the average air change rate at 50 Pa is about 7. (Ref. NPCA , June 26, 2000)

3.2.13 Colour, Texture

Siporex is grayish white with even surface.


The pores present in Siporex material can be divided according to size into micropores (< 0.1 mm) and macropores (0.1 to 1.0 mm). Of the total porosity or pores volume, approximately 35% is micropores and the remainder 65% is macropores.

At the wire cut surface, the pores are not visible. Milling of the jointing surface after the steam curing makes the pores visible.



3.2.14 Reinforcing Steel Properties

Steel reinforcement to be used in Siporex reinforced products shall satisfy the physical requirements of ASTM A615, A82 or A185. Siporex panels are supplied with corrosion protected steel mats. These mats are dipped in homogenized anti-corrosion mix and allowed to dry under high temperature. The dipping/drying process is duplicated to ensure a double protection against harsh weather condition.

The minimum aerated concrete cover to the longitudinal reinforcement, “d”, is 12.5 mm for roof slabs / floor slabs and 25 mm for wall panels. Increased cover for greater fire resistance or allowances for chases can be arranged upon request.


Bar position for possible reinforcing configuration

Cross Section of panel / slab showing standard rebar position and spacing

No. of Bars 2 A G 3 A D G 4 A C E G 5 A B D F G 6 A B C E F G 7 A B C D E F G

The number and diameter of bars varies, depending on the panel / slab design. Details of reinforcement can be obtained from our technical department on request.

Positioning of anchorage reinforcements (Cross bars) at panel end

Positions Slab Length 1 + 2 < 3000 mm

1 + 2 + 3 ≥ 3000 mm but < 5000 mm 1 + 2 + 3 + 4 500 mm and over



Lightweight…


4. Range of Products

4.1 Wall Panels

4.1.1 Vertical Wall Panels (WV)

WV are reinforced units, for load bearing applications as either external or internal walls in a wide variety of low and medium rise buildings. They can also be used as non-load bearing cladding for steel or concrete framed structures. They may have single mat or double mat reinforcements depending on the structural requirements.

4.1.2 Horizontal Wall Panels (WH)

Similar to WV, they are also reinforced units with either single or double mat reinforcements, but are used in horizontal positions. Applications include: low parapet, boundary walls, wall claddings to steel or concrete framed structures and for filling of space between lintels and ceiling. Tongue and groove joints are usually provided for multi-layered WH construction for ease of on-site assembly.

4.1.3 Fluted Wall Panels (WF)

Wall panels are also available with fluted surface as an added feature. They make very attractive features in building facades used either in small areas such as under window openings or as an all-over treatment. Fluted wall panels are also favorite features for boundary walls. Flutes are available in depths of 25 mm or less.

4.1.4 Partition Wall Panels (WP)

These are normally used as non-load bearing internal partitions with thickness ranging from 10 to 15 cm thick depending on the height of wall. The flexibility in the design of partition wall panels means it can be provided with central groove to accept grouting or with standard tongue and groove, increasing their ease of on-site assembly. They are simply fixed using steel angles or by grouting where possible inside framed structures or concrete-shell buildings.



4.1.5 Permissible Compressive Stress on Vertical Wall Panels (WV)

Above values were calculated based on the allowable compressive stress in low density concrete load-bearing walls as stipulated in ACI 523.2R-96 (Guide for Precast Cellular Concrete Floor, Roof and Wall Units), Section 4.3.3.

Non load-bearing partitions or curtain walls should be limited to a height/thickness (h/t) ratio of not greater than 48.

4.1.6 Maximum Length of WV & WH with Various Design Lateral Loads using Siporex Standard Reinforcements

Wall Height (m)

Permissible Compressive Stress (kg/cm2) at the following Wall

Thicknesses (mm) 100 150 200 250

2.50 5.3 6.5 6.8 6.9 2.75 4.7 6.3 6.7 6.9 3.00 4.0 6.1 6.6 6.8 3.75 1.2 5.3 6.3 6.6 4.00 - 4.9 6.1 6.6 4.50 - 4.0 5.8 6.4 5.00 - 2.9 5.3 6.1 5.50 - 1.6 4.7 5.8 6.00 - - 4.0 5.5

Thickness (mm)

Maximum Length of Wall Panels at the following Design Wind

Load (kg/m2)

80 120 160 200

75 250 cm - - - 100 400 cm 375 cm 325 cm 275 cm 125 500 cm 475 cm 450 cm 400 cm 150 600 cm 575 cm 550 cm 500 cm 175 600 cm 600 cm 600 cm 575 cm 200 600 cm 600 cm 600 cm 600 cm 225 600 cm 600 cm 600 cm 600 cm 250 600 cm 600 cm 600 cm 600 cm



4.1.7 Millings for Wall Panels

Central Groove Applicable for WV, groove to be filled with cement-sand grout (1:3), providing rigid connection between panels as well as connection to the foundation through steel anchorage and next upper floor through steel dowel bars and ring beams. Tongue & Groove Applicable for WV, usually for non-load bearing external cladding or internal partitions where central groove for grouting is not applicable. Also commonly used for boundary walls using WH fixed at the ends to the supporting columns. Fluted Surface Can be applied for both WV & WH in combination with Central Groove or Tongue & Groove for architectural purposes. Depth of flute can be 25 mm or less. Standard distance between flutes is 100 mm center to center. Plain Corners Used in combination with Central Groove or Tongue & Groove where plain wall surface is required. Fiberglass tape fixed with our special adhesive, Gesol, along the joints will be necessary prior to application of wall finishes. Chamfered Corners (one or both faces) Also used in combination with Central Groove or Tongue & Groove where joints between panels are required to be visible, forming V-grooved joints. This is appropriate for Siporex wall panels used as claddings to a framed structure.

Fiberglass tape will not be necessary where chamfered corners or V-grooved joints are provided.



4.2 Lintels

4.2.2 Arch Type Lintels (LA) Arch type lintels are also load-bearing

members but with added architectural features that can be designed with various shape and sizes of arches applicable for openings at external facades or internal walls. Reinforcement mats are specially arranged to facilitate fabrication and avoid exposure after cutting the required shape. Arches can be designed with single panel where height of arch does not exceed 30 cm or multi layers of panels for high arches.

4.2.1 Panel Type Lintels (LW) Lintels are used as load-bearing

members over window and door openings for external or internal walls, eliminating the need for shuttering and in-situ concrete. They are bedded with special Siporex Glue onto wall panels adjacent to the opening of reduced height. The maximum obtainable lengths (free spans) in meters for lintels of various design loads and thicknesses are shown in table of Section 4.2.4. LW’s usually have standard height of 60 cm.

4.2.3 Box Type Lintels (LB) Box type lintels are designed with

special steel reinforcement arrangement to be used where lintel depth is limited. They are suitable for block wall construction, produced with depth equal to the height of Siporex blocks for ease of construction. This eliminates shuttering and cast-in-situ works as well as avoids thermal bridges caused by the use of traditional concrete lintels.

The maximum obtainable lengths (free spans) in meters for Box type lintels of various design loads and thicknesses are shown in table of Section 4.2.5.

The minimum permissible end bearings for all types of lintels are as follows:

for L ≤ 2400 mm 200 mm each end for L > 2400 mm 300 mm each end

Due to the special reinforcement arrangement, lintels must never be cut.



4.2.4 Maximum Clear Span of Panel Type Lintels with Various Design Loads (Height = 60 cm)

4.2.5 Maximum Clear Span of Box Type Lintels with Various Design Loads (Height = 25 cm)

Other heights and spans of lintels can be designed by our technical department depending on their particular condition and considering the clear span of openings as well as design loads.

Since Siporex lintels are constructed with the same materials as the wall panels or Siporex masonry blocks, the surfaces are easily finished and the possibility of cracks due to different thermal expansion is eliminated.

Various actual applications of Siporex lintels

Design Load Thickness of Panel Type Lintel (mm)

100 150 200 250

500 kg/m 250 cm 450 cm 540 cm 540 cm

1000 kg/m 200 cm 325 cm 400 cm 450 cm

1500 kg/m 100 cm 275 cm 325 cm 375 cm

Design Load Thickness of Box Type Lintel (mm)

100 150 200 250 500 kg/m 200 cm 350 cm 360 cm 360 cm

1000 kg/m 150 cm 250 cm 260 cm 265 cm

1500 kg/m 75 cm 200 cm 210 cm 210 cm



4.3 Floor & Roof Slabs (FS & RS)

4.3.1 Product and Application

Siporex floor/roof slabs are reinforced aerated concrete products which are produced in accordance with international standards. Siporex slabs attain their design strengths during the high-pressure steam curing process in the autoclaves. Thus, after delivery, slabs can be erected immediately within a very short period and ready for occupancy use.

Installation can be done with minimal number of erection crew, light equipments and will not require highly skilled workers. Shuttering works are eliminated, and finishing works can commence directly, saving time and overall costs.

Siporex slabs can be used both in flat roof areas or sloped roof. They can also be installed with cantilevered ends, produced with special reinforcements. The excellent thermal insulation of Siporex slabs ensures pleasantly healthy and balanced internal temperature.

The units are milled along their edges to provide tongue & groove and grouting notch on top. The bottom longitudinal edges are preferred to have corner chamfers giving an attractive V-shaped joints pattern on the ceiling. Siporex slabs are also produced in various thickness and spans depending on the required load-bearing capacities. The table shown on Section 4.3.3 gives a guide to the permissible spans of slabs with different design loads of various slab thicknesses.

FS & RS can be used in all types of buildings, e.g. housings, industrial, commercial & educational buildings.

4.3.2 Millings for Floor & Roof Slabs

Typical Section of Siporex Slab Construction

Milling of floor/roof slabs

Note: Dimensions shown are in millimeters.



4.3.3 Permissible Spans of Various Slab Thickness and Design Loads

Above design loads are in addition to the self-weight of the Siporex slabs. Siporex slabs are reinforced with double steel welded mats and anti-corrosion coated in Siporex factory. Quantity and sizes are in accordance with Siporex steel reinforcement tables.

The minimum required end-bearing supports are 75 mm for masonry & concrete supports and 50 mm for steel beam supports.

Design imposed DL + LL (kg/m2)

Permissible Spans with the following Thicknesses (mm)

100 150 200 250 110 kg/m2 4250 6000 6000 6000 160 kg/m2 4000 5750 6000 6000 210 kg/m2 3500 5500 6000 6000 250 kg/m2 3500 5250 6000 6000 300 kg/m2 3250 5000 6000 6000 350 kg/m2 3000 4750 6000 6000 400 kg/m2 2750 4500 5750 6000 500 kg/m2 2500 4000 5250 5750

Various applications and construction of Siporex floor/roof slabs



4.4 Siporex Blocks (B)

4.4.1 Product Application & Characteristic Data

Siporex solid blocks are used as load-bearing and non load-bearing walls and as thermally insulating roof tiles in addition to being used as Hordi blocks or infills for ribbed slabs.

4.4.2 Masonry Blocks Dimensions

For the past decades, LCC Siporex had been supplying AAC blocks with a standard face size of 25 cm high x 60 cm long only in various thicknesses. However, due to the increasing demand and growing popularity of the use of AAC blocks, LCC Siporex have started the production of new dimensions of blocks in line with the continued expansion of additional manufacturing plant to sustain the market requirements. Siporex blocks are now produced at the following standard sizes:

Standard face size: 25 cm high x 60 cm long: Thickness: 10, 15, 20, 25 and 30 cm

Standard face size: 20 cm high x 60 cm long: Thickness: 10, 15, 20, 30 and 40 cm

Above standard sizes with nominal dry density of 550 kg/m3 are usually available in our stocks. It is possible to produce other dimensions on request, but should be referred to our Sales or Technical departments for verification.

4.4.3 Hordi Blocks

Hordi blocks or infill blocks for ribbed slabs can be produced in various dimensions to form lightweight infill between in-situ reinforced concrete ribs designed to span in one or both directions. Due to their excellent bondage to in-situ concrete, Siporex Hordi blocks are easily arranged to form permanent part of the slab, providing excellent thermal insulation as well as fire resistance material. Hordi blocks are produced with density of 450 kg/m3 according to the following dimensions:

Length : 60 cm Width : 37/38 cm or 40 cm Thickness : 20, 25, 30, 35 cm

Other sizes may be produced upon request only. Hordi blocks are not available in stock and are manufactured against order only.

They are produced with very precise dimensions with slim tolerance of ±3mm for thickness and width, therefore they are able to be laid by thin-bed mortar (Siporex glue) with a maximum of 3mm thick mortar joint. This results to a high quality wall structure with uniform thermal insulation and fast installation.

Hordi Blocks Application



4.4.4 Thermal Insulating Tiles

Roof insulation of existing conventional roof can still be improved with the use of Siporex thermal insulating tiles available at the following dimensions:

Other dimensions can be produced upon request.

4.4.5 Packing Data for Siporex Blocks

Siporex blocks are delivered ready for use and packed in easily transportable wooden pallets. The pallets should be unloaded at the site by construction-site cranes, forklifts or other suitable hoisting equipments.

For ease in unloading of materials, it is suggested to order Siporex blocks in whole bundle or pallet volume to avoid handling loose quantities.

60 x 60 x 7.5 cm

60 x 25 x 7.5 cm

60 x 25 x 5 cm

Block Dimensions No. of Blocks per m3

No. of Blocks per m2

No. of Blocks

per Bundle No. of Bundle

Per Pallet m3 per Bundle

m3 per Pallet

10 x 25 x 60 cm 66.66 6.67 75 2 1.125 2.25 15 x 25 x 60 cm 44.44 6.67 50 3 1.125 3.375 20 x 25 x 60 cm 33.33 6.67 35 3 1.05 3.15 25 x 25 x 60 cm 26.66 6.67 30 3 1.125 3.375 30 x 25 x 60 cm 22.22 6.67 25 3 1.125 3.375

10 x 20 x 60 cm 83.33 8.33 72 3 0.864 2.592 15 x 20 x 60 cm 55.55 8.33 48 3 0.864 2.592 20 x 20 x 60 cm 41.67 8.33 36 3 0.864 2.592 30 x 20 x 60 cm 27.78 8.33 24 3 0.864 2.592 40 x 20 x 60 cm 20.83 8.33 18 3 0.864 2.592

SIPOREX ROOF TILES

5 x 25 x 60 cm 133.33 6.67 150 2 1.125 2.25 7.5 x 25 x 60 cm 88.89 6.67 100 2 1.125 2.25 7.5 x 60 x 60 cm 37.04 2.78 40 3 1.08 3.24

SIPOREX HORDI BLOCKS

20 x 37/38 x 60 cm 22.22 4.44 21 3 0.945 2.835 20 x 40 x 60 cm 20.83 4.17 18 3 0.864 2.592 25 x 37/38 x 60 cm 17.78 4.44 18 3 1.013 3.038 30 x 37/38 x 60 cm 14.81 4.44 15 3 1.013 3.038 30 x 40 x 60 cm 13.89 4.17 12 3 0.864 2.592 35 x 37/38 x 60 cm 12.70 4.44 12 3 0.945 2.835

Following table is an easy reference in making order of some standard sizes of Siporex blocks in bundles or pallets.



4.4.6 Block Laying

The first course should be laid on cement-mortar bed of thickness about 1 to 3 cm depending on the evenness of the base and should maintain a correct level for fast installation progress in the following courses.

It is recommended to spray the mortar face of the block before installation to keep damp at erection time especially during the hot seasons.

After installation, spray with water twice a day for 3 consecutive days for curing of the mortar.

Three types of Mortars can be applied on the succeeding courses:

4.4.6.1 Glue for Siporex (for thin joints)

Pre-mixed mortar – only water is to be added. Thickness of glue should not exceed 3 mm in horizontal and vertical joints in order to achieve the ideal consumption rate of 50-60 kg of glue for every cubic meter of block.

4.4.6.2 Ordinary Mortar with Gesol

1:6 Cement : Sand (by volume) respectively in addition to water (with 10% of Gesol). The erection can be carried out normally as for conventional blocks. (Gesol is a liquid material used as bonding agent and retardant for the mortar especially during hot weather. Gesol is available at Siporex factory in 25 kg plastic containers).

4.4.6.3 Ordinary Mortar with Lime:

1:1:10 Cement : Lime : Sand (by volume)

4.4.7 Plastering of Siporex Block Wall

Before plastering, dirt and loose particles should be removed from walls. Spray walls with water and follow one of the two methods mentioned below:

4.4.7.1 Traditional Plastering:

Similar to plastering of conventional block walls with the following mix:

• Splattering (3mm): Use 1 cement : 3 sand mixed with solution of water and Gesol (20% of the volume). Spray with water twice a day.

• Ordinary Plastering Mortar: (1 – 1.5 cm thick, apply 24 hours after the splattering)

Use 1 cement : 6 sand mixed with solution of water and Gesol (10% of volume).

4.4.7.2 Plastering with Pre-mixed Mortar

Water is added to the pre-mixed plaster supplied in bags of 25 and 50 kgs. Surfaces should be thoroughly cleaned and wetted without any splattering. Apply plaster directly with a thickness ranging between 0.5 to 1 cm

In both above methods, walls should be watered twice a day after plastering for three consecutive days.



4.4.8 Cladding with Marble or Artificial Stone

Marble or artificial stones are fixed using hooks and screws. It is necessary to use screws with plastic plugs like Fisher and Hilti anchors in addition to several other types specially made for use in cellular concrete.

Refer to figure 7.13 on Page 45 showing the typical section of wall with stone cladding.

4.4.9 Bolts and Fixings

Various type of bolts and fixings applicable for both Siporex blocks walls and reinforced panels are discussed in Section 10. These types of fixings are used in installation of doors and windows, as well as wall accessories with weights not exceeding the allowable loads of the type of fixing used. Through-bolts should be used in case of heavy fixtures such as water heaters and hanging lavatories (please refer to Fig. 7.11 & 7.12 on Page 45).

Siporex Blocks Construction


5. Design

5.1 General With its innovative physical properties, Siporex system offers design and engineering flexibility for a variety of construction applications ranging from single and multi-family residential to commercial buildings, as well as warehousing, schools and government facilities.

Siporex system consists of various product types: wall panels, floor/roof slabs and lintels which can be combined to form a load-bearing structure.

By using this system, costly labour and material intensive in-situ concrete structures of columns, beams, floor and roof slabs can be eliminated.

This fact makes it particularly suited for the construction of buildings up to six storeys.

The width of the units in the Siporex system is in accordance with the international modular standard of 60 cm. Thickness and length of the units can be selected to suit requirements of each particular project.

Therefore, the Siporex system offers high degree of flexibility which can easily be adapted to various design requirements. Figure 5.1 on next page shows how the component parts of the Siporex system fits together to form complete structure.

LCC Siporex offers services including technical viability studies of client’s projects to Siporex system, quotations, as well as recommendations on how Siporex can be adapted to the original design of your structure that will fit your project-specific needs.

Figure 5.2 on page 32, shows a sample Siporex shop drawing based on customer’s architectural drawing.


5. Design

FIG. 5.1 Component Parts of Siporex System


5. Design

FIG. 5.2 Sample Siporex shop drawings developed from client’s architectural plans


5. Design

Much of the company’s work entails the conversion of client’s original designs from other materials to Siporex system, generally resulting in cost and energy savings. But the best and most economical use of Siporex is produced by designing in the material from onset.

Optimum results and savings can be obtained through careful design work and meticulous planning before and during execution. Before commencing the architectural design for a project, the following guidelines should be noted:

1. The maximum span of Siporex panels is 6.00 meters. This means that the maximum clear span between the load bearing walls should not exceed 5.85 meters considering 7.5 cm end bearing of floor/roof slabs. The distance between the non-load bearing walls is immaterial. If the clear span is more than 5.85 meters, then steel or concrete beams supported on steel or concrete columns should be used to support the roof slabs.

2. Upper walls are recommended to be aligned with walls of the lower floor. Walls at upper floor supported directly on Siporex slabs are not allowed. When unsupported walls cannot be avoided, intermediate steel beam can be used or convert the wall to non-load bearing lightweight dry wall partition, in order to achieve maximum economy.

3. The foundation should be made high enough such that the external wall panels will not absorb moisture from the ground.

4. Width of door/window openings are recommended to be limited to the allowable spans shown in Sections 4.2.4 & 4.2.5 in order to utilize Siporex lintels and avoid the use of in-situ concrete lintels.

Siporex buildings are designed based on box system principle. Siporex load-bearing walls act as shear walls resisting lateral forces due to wind or seismic loads. The wall panels have grooves along their edges which form joints when erected. These joints receive steel tie bars from the footing and at the top connecting the lower wall with the one above. As they penetrate the ring beam, a strong connection will be provided between the vertical and horizontal structures. These joints (3.3 x 5 cm) are grouted and they are able to transfer shear forces from one panel to the other.

The roof and floor slabs have tongue and groove as well as notch at the top to be reinforced with 8mm diameter bar between spans and grouted with cement-sand mortar (1:3) consequently eliminating differential deflection. Due to the ring and bond beams around the building, all slabs form membrane acting as laterally stiff diaphragms which can transfer lateral forces to the bearing walls .

These constitute the diaphragm action of the Siporex structural system. Lateral forces are distributed in proportion to the moment of inertia of the walls, that is, proportional to their stiffness. Based on actual experiences of actual occurrences in different countries, It has been noted that Siporex buildings are very resistant to earthquake forces.

5.2 Design Principle

5.3 Structural System


6. Erection

6.1 Guidelines for Estimating Erection Cost of Siporex Elements

6.1.1 Erection Manpower

Four (4) man-hours per cubic meter of Siporex panels for residential construction is a good average figure. The figures cover erection of the superstructure on the prepared foundation base (level tolerance ±1 cm) and include grouting of wall and roof joints as well as repair works to make the surface ready for application of finishes. The figures also include casting the normal ring beam behind the rebated wall panel upstand.

6.1.2 Type of Crane & Crane Hours Mobile telescopic crane 10 to 40 ton range depending on the reach is

normally needed. A single crane with operator can serve two erection crews at the same time. Crane usage will be about 0.33 hours per cubic meter of Siporex elements considering two crews or 0.66 hours per cubic meter for one crew.

6.1.3 Cost of Auxiliary Materials and Consumables SR 30 to 40 per cubic meter of Siporex elements. The figure includes cost of

Siporex glue, sand-cement grout, concrete and reinforcements for ring beams, plastic wedges, nails and dowel bars. Cost of large beams/columns requiring form works shall be calculated separately. Major steel fixings and steel beams are not included. Note:

Above data should be considered as general guidelines only. They are not substitute for careful evaluation of actual requirements of each project and a detailed bill of quantities. The data supplied are based on LCC’s own experience and are correct to the best of our knowledge. However, no guarantee of any kind can be given as individual projects vary a great deal.

A typical erection crew with crane & operator consists of the following:

1 – crane helper 2 – erectors 1 – panel preparation man 2 – assistant erectors for general

site works, grouting, repair works, dowel drilling, etc.

Note that one crane can serve 2 crews at a time.

List of Auxiliary Materials Approximate Consumption Siporex glue for bedding and minor repairs 10 kg per cubic meter of Siporex Sand-cement grout to fill joints between wall

panels

45 kg per cubic meter of Siporex

Fiberglass tape for joints 3.5 lm per sq. m. of Siporex wall Gesol (Adhesive liquid) for fixing fiberglass tape 1 kg per 18 lm of fiberglass tape Dowels, Ø5.5mm x 250mm long, stitches to

connect walls 2 pcs per wall panel

Plastic wedges – to support wall panels temporarily

2 pcs per wall panel - reusable

Galv. nails: 100mm 4 pcs per cubic meter of wall Galv. nails: 125mm 2 pcs per cubic meter of slab Siporex Sand paper 1 lm per 200 cu. meter of Siporex Masonry nails, 50 mm 1 box per average villa Reinforcements for ring beam 1 kg per cubic meter of Siporex Concrete for ring beams 1 m3 per 20 m3 of Siporex slab


6. Erection

Lever for raising partition walls against the ceiling.

Cramp for closing joints between floor/roof slabs

Wall Braces to temporarily support vertical wall panels

Lifting Sling for slabs (7.8 m long and 2 tons capacity)

Lifting Hook for vertical wall panels

Lifting Grab for horizontal wall panels and lintels

Roof Slab Grab width of slab = 600 mm

6.2 Hand Tools and Equipment

6.2.1 Siporex Erection Tools

The following tools are provided by LCC Siporex free of charge on return-basis against a refundable deposit as an extension of services to customers. They are to be returned to the Siporex factory upon completion of the erection works to serve other Siporex customers.


6. Erection

Electric Grooving Machine for making grooves on panels.

Electric Circular Saw with metal blade

Hack Saw Blade for cutting steel reinforcement

Siporex Saw with special blade for aerated concrete (available for sale at Siporex factory)

Plane for chamfering sharp edges

Grinding board

The following tools (not provided by LCC Siporex) are also required in addition to the special erection tools during the installation of Siporex elements.

6.2.2 Other Hand Tools and Equipment


6. Erection

6.3 Erection Procedure

6.3.1 R.C. foundation should be cast with a smooth and leveled surface. This saves a lot of work in leveling the tops of wall panels later.

6.3.2 Layout of wall panels should be marked on the foundation using chalk lines and ensuring that any overhang has been allowed for on the periphery of the foundation.

6.3.3 Steel dowels connecting the wall panels to the foundation are either placed in their positions before casting the foundation or placed in a drilled hole of 4 cm in diameter in the foundation and then grouted.

6.3.4 Nylon offset lines should be used to ensure outside line of panels is maintained.

6.3.5 Aluminum straight edge should be set to line and level to inside face of the wall.

6.3.6 The longest elevation with least number of openings at the farthest reach should be selected for initial installation. This is to maintain sight lines between operator and erector and ensures correct signals can be given to the crane operator.

6.3.7 Siporex glue mortar is used as a bed for the wall panels. Wedges are used for temporary support of wall panels and allow fine adjustment for plumb.

Another alternative is to make a hole of 8 mm diameter and fix the steel dowels using Hilti C10 epoxy or equivalent. These dowels are placed at each wall panel joint as indicated on Siporex shop drawings.

6.3.8 Corner elements are erected first and carefully positioned. Succeeding panels are erected as per mark numbers shown on Siporex shop drawings.


6. Erection

6.3.9 Working with a fixed straight edge for alignment, the wall panels are lifted by a lifting hook, placed in position and checked for plumb. The top edges are also aligned and are steadied by temporary wall braces at every 3rd or 4th panel. Dowels of Ø5 mm x 250 mm long are used as stitches to connect the top joints between the panels.

6.3.10 The tightly fixed together wall panels are grouted by thoroughly wetting the grooves with water and then pouring in fluid cement-sand grout (1:3) and then positioning steel dowels for the next storey panels.

6.3.12 Floor and roof slabs are lifted with a grab and carefully positioned with specified end bearings on leveled wall panels. Minimum 50 mm side bearing is required on walls parallel to the span. Tongue and groove joint faces provide firm connection between the units which ensures the stability of the building.

Note that Siporex products should always be well wetted with water before applying any other materials (e,g, glue, grout, plaster,…etc.)

6.3.11 Lintels are placed on top of windows and door openings using a lintel grab. They are supported on and connected to the wall panels adjacent to the openings. Steel dowels are drilled and grouted on top of the lintel prior to installation of vertical panels above.

6.3.13 The notches formed between the floor or roof slabs are concreted along with the ring/bond beams after placing all the connecting and continuity steel bars. Refer to the figure showing the different details for continuity steel bars.

6.3.14 Any damages are repaired and any spaces between the panels are filled flush with Siporex glue. After repair and setting of the mortar, the repaired areas and joints are rubbed down with sand paper to give smooth surfaces.


6. Erection

6.4.1 Guidelines

Damage to Siporex panels may be repaired at site subject to certain limitations. Siporex units which are structurally defective and unfit for the purpose for which they are designed must not be repaired but should be rejected and replaced with sound units.

Broken floor/roof slabs must be rejected. A broken floor/roof slab is a unit which due to fracture on its lower face (tension side) or through breakage and/ or fracturing of the bearing faces at the ends is no longer able to fulfill its structural functions for which it has been designed.

Slabs with transverse cracks which extend through the thickness of the slab should be rejected. Slabs with hair-line cracks which do not penetrate to the tensile reinforcement will normally be suitable for use.

Damage which exposes extensive parts of the reinforcement should not be repaired. Panels with major damage to the bearing surface which exposes the cross bars on the tensile steel should not normally be repaired.

Spalling or peeling-off of fragments to face of panel can be repaired if maximum length of repair is 30 cm and depth is less than ¼ of the total panel thickness. Spalling to edge of panel can be repaired if maximum dimension of repair is 30 cm and maximum width is 20 cm.

6.4.2 Repairing Instruction

Siporex panels should be free from defects which would impair their strength and structural integrity. Slight damages are normal and can be repaired as per the following instructions:

6.4.2.1 Clean the defective surfaces thoroughly with a stiff brush and remove all dirt and loose material. Wet thoroughly with water using a large brush. If a large piece has broken-off and the broken-off section is available undamaged, the piece can be glued on by applying Gesol to both surfaces and pressing the broken-off section into the unit to fit.

6.4.2.2 Place a suitable amount of Siporex glue in a bucket. Add clean

potable water with 10% Gesol and mix thoroughly with a mason’s spoon till a soft putty consistency is achieved. Do not mix more mortar than can be consumed before the mortar starts to set. Do not add water when mortar starts to set in order to restore workable consistency.

6.4.2.3 Deep repairs shall be reinforced with galvanized cut nails before

Siporex glue is applied. Apply Siporex glue to the damaged area with a mason’s spoon. During application, use slightly more material than is needed to fill the damaged area.

6.4.2.4 After application, leave the material untouched till the mortar starts

to harden slightly. Then level with a wood float. If necessary, apply a small amount of water to the surface during leveling. Level by moving the wood float towards the Siporex material.

6.4 Repair of Siporex Panels


6. Erection

A) Starter bars are laid in position.

B) Siporex glue is applied for bedding.

F) Top joints are stitched and grooves are grouted.

D) Succeeding panels are erected.

E) Provide temporary wall bracings.

C) Corner panels are placed in position.

6.5 Illustrations Showing Erection Stages


6. Erection

6.5 Illustrations Showing Erection Stages

G) Lintels are laid above openings. Dowel bars are provided for next level.

H) Siporex glue is used as leveling bed at top. Dowel bars are positioned for next level.

I) Floor/roof panels are laid. J) Provide steel reinforcement for

ring beams

K) Continuity bars between spans are laid.

L) Cast concrete along grooves and ring beams. Proceed with next upper level.


6. Erection

7.1 Parapet connection 7.2 Roof slabs connection

7.3 External wall & slab connection

7.4 Internal wall & slab connection

7.5 External wall & foundation connection

7.6 Internal wall & foundation connection


6. Erection

7.7 Siporex wall cladding, fixed to R.C. main frame (External wall)

7.8 Siporex wall cladding, fixed to R.C. main frame (Internal partition)


6. Erection

Alternative 1: Slab on top of steel beam

7.9 Siporex slabs supported on steel beams

Alternative 2: Slab supported on steel beam web

Alternative 3: Slab inserted between flanges

7.10 Siporex external wall cladding, fixed to steel main frame


6. Erection

7.11 Water heater fixing detail 7.12 Lavatory fixing detail

7.13 Marble / artificial stone fixing

7.14 Wooden / aluminum door & windows


6. Erection

8.1 Chases and Penetrations

Small conduits can be chased easily into Siporex wall panels, but cutting of steel bars should be avoided. (refer to Section 3.2.14 for locations of steel bars). For large conduits requiring the cutting of the entire width of the wall panel, the cut portion should be filled with concrete and reinforced with steel mesh at both faces.

Large cut-outs and pipe-runs passing through the floor / roof slabs can be accommodated during design stage to avoid unplanned cuttings. Panels with large cut-outs will have reinforcement specially designed around these cut-outs.

Panel board recesses can be provided neatly and economically by using a lining panel to avoid large recesses in the wall as shown on the above section.


6. Erection

8.2 Typical Section Showing Electrical Installations in Siporex Building


6. Erection

8.3 Typical Section Showing Plumbing Installations in Siporex Building


6. Erection

Various types of finishes used in conventional concrete construction are also applicable to Siporex system. Before applying finishes, damages should be repaired and chases or openings should be made good with Siporex glue mortar. Deep holes and chases can be dubbed with ordinary cement-sand mortar (1:6) to within 5 mm from the surface and finished with Siporex glue.

Finishes for Siporex

9.1 Internal Walls Joints between wall panels should be taped with fiberglass

tape. A thin wall putty to be applied in two coats gives a very smooth surface as a base for painting or wall papering. Where required, the second coat may be applied with a textured finish.

9.2 External Walls

Similarly, joints between wall panels should be taped with fiberglass tape unless if the joints are V-grooved. Where Siporex panels have V-grooved joints, two coats of textured finish are recommended. Where Siporex have plain joints, different finishing types can be applied.

9.3 Ceiling

Siporex slabs make attractive ceiling with the visible V-grooved lines. A putty applied in two coats will give a very smooth base for painting. Where required, the second coat may be applied with a texture finish.

9.4 Floors

Compared to cast-in-situ concrete floors, Siporex floor slabs provide a completely dry smooth floor construction on which decorative floor finishes of tiles, parquet, linoleum and other required finishes are readily applied.

9.5 Roofs

Above sections shows the suggested arrangements of finishes on top of Siporex roof slabs (Accessible & Non-accessible roofs).


6. Erection


6. Erection

Special types of commercially available fixings can be used with Siporex structures.

In fixing built-in units and other items; galvanized nails, bolt fastenings and wall plugs are used. Ordinary wire nails should not be used since their anchoring ability to Siporex is low. The type of anchoring method to be used depends on the holding capacity required. The manufacturer’s recommendations should be consulted as to the maximum loads suitable for use with their products. Some of the types of fixings and anchors suitable for use with Siporex AAC materials are as follows :

10.1 Galvanized Cut Nails

Galvanized Cut Nails comes in different lengths and are available at our Siporex Factory.

Cut nails are hammered directly into Siporex walls and do not need to be pre-drilled They can be used to fasten light to moderate weight items to Siporex.

10.2 Hilti HGN Anchors

HGN Gas Concrete Anchors, manufactured by Hilti Company is a Cadmium-free Polyamide anchor specially suitable for AAC concrete base. Available in various sizes, it provides high pressure per unit of area, as well as good resistance to turning in the hole due to its large fins.

Technical data regarding the recommended tensile / shear loads for Siporex base are shown on the table below.

10.3 Fischer Anchors

Also available with plastic plugs suitable for light to medium weight fixings in aerated concrete.

Technical data regarding the recommended tensile / shear loads for Siporex base are shown on the table on section 10.4.

10.4 Permissible Loads of some Suitable Fixings to Siporex

Type Designation Permissible Tension Permissible Shear

Cut nails 100 mm long 10 kg 25 kg 125 mm long 12 kg 35 kg 150 mm long 18 kg 40 kg

Hilti HGN 8 30 kg 35 kg HGN 10 50 kg 60 kg HGN 12 65 kg 70 kg HGN 14 80 kg 80 kg

Fisher S 10 18 kg 40 kg

S 10 H 90 40 kg 80 kg S14 50 kg 100 kg S 16 60 kg 120 kg


6. Erection

Description

Siporex Glue is an adhesive mortar for quick and secure laying of Siporex blocks with a thin joint and for providing a leveling bed for the erection of Siporex wall panels and slabs.

It is in powder form consisting of white cement, limestone and special additives that improve workability and adhesion.

Properties

Setting time after mixing : 20 to 30 minutes depending on weather conditions

Coverage : For blocks face size of 25 x 60 cm: 50 kg per m3 of Siporex blocks with 3 mm thick joints.

For blocks face size of 20 x 60 cm: 60 kg per m3 of Siporex blocks with 3 mm thick joints.

Adhesive strength after setting : Not less than 4 kg/cm2

Packaging and Storage

Siporex glue is available in 25 kg paper bags. It should be stored in a dry place protected against rain and moisture from the ground. The shelf life is approximately 3 to 6 months if unopened and when stored in a dry place.

Preparation

Prepare the glue mix in a clean trough with 5 liters of clean water per bag.

Mix thoroughly until a homogenous creamy paste is obtained.

Preferably use a high shear mixer on a drilling machine to obtain a uniform mix.

During the hot season and when the blocks have been lying under the sun, replace the mixing water with a mix of 5 parts of water to 1 part of Gesol, a retardant to prevent too rapid setting under hot or dry conditions.


6. Erection

Description

Gesol is a highly concentrated, non-toxic, non-flammable copolymer which serves as a bonding agent in mortar and plaster mixes or as a primer sealer for these substrates.

Gesol has excellent adhesive and cohesive strength.

Instructions on usage:

Substrates must be sound, clean, free from oil and loose materials.

Moisten porous subfloors until saturated before applying Gesol.

As a bonding agent (Mixing with cementitious products):

Use a mixture of 1 : 5 to 15 (by volume) of Gesol and water.

Application:

Gesol is used in the following applications:

To prevent too rapid setting in lime/cement materials and improve curing under hot and dry conditions.

To seal and prepare substrates with a strong absorbent background, particularly in hot climatic regions.

As a primer to improve adhesion.

As a bonding agent for screeds, leveling compounds, repair mortars, plasters and renders. To boost adhesion, compressive and flexural strength, abrasion resistance, etc.

Technical Data: Solids 55 ± 1% Viscosity (20 °C) 1500 mpa. s. Mechanical stability Excellent Density 1.05 g/cm

3 Color White


6. Erection

LIST OF SOME SIPOREXT PROJECTS

SN. CLIENT / CONTRACTOR NAME OF PROJECT LOCATION YEAR 01 Panda Stores 2 Storey Dormitory Riyadh 1981 02 Royal Commission for Jubail &

Yanbu Contract No. 113-C02 EPC 419 Dwelling Units Jubail 1982 03 Royal Commission for Jubail &

Yanbu Contract NO. 801-C06 E.P.P.C. Jubail 1982 04 Saudi Ceramic Dormitories & Ancillary Bldgs. Riyadh 1982 05 S C E C O Substations Jeddah & Taif 1982 06 AlJubail Petrochemical Co. (KEMYA) 27 Housing Units Jubail 1983 07 Essam Economic Co. Clinic & Residential Complex Jubail 1983 08 Gustav Epple & Pollenisky & Zoelner SCECO – Central PP 8 Power Station Riyadh 1983 09 Baker Trading & Contracting AMG (GAMA) 80 Units Compound Riyadh 1983 10 Saudi Petrochemical Co. (SADAF) E.P.C. Contract for 100 Houses Jubail 1984 11 AMAL Est. Saudi Diesel Compound AlKhobar 1984 12 Sirafi / Carlson Gr. Inc. University Staff Housing Ph.II Riyadh 1984 13 BETA Company Microwave Station Around Riyadh 1984 14 Brown Bovery & CIE AG 7 SCECO Substations Riyadh 1984 15 Hanshin Const. Co. Human Resources Dev. Institute Jubail 1985 16 Saudi Mcinerney Const. Co. Ltd. Kanoo Housing Complex Jubail 1985 17 Poong Lim Saudi Arabia National Methanol Housing Jubail 1985 18 JV SAAD Polensky & Zoellner /

Gustav Epple Jamjoom Commercial Center Jeddah 1985 19 Societe Auxillaire D’ent., Dammam AlQatif Housing Project AlQatif 1986 20 Skanska Gen. Contr. Red Sea Hospital Jeddah 1986 21 Skanska Gen. Contr. Bisha Hospital Bisha 1986 22 Arabuilt Co. Ltd. KSU Housing Proj. Ph.II Riyadh 1986 23 Saudi Petrochemical Co. 136 Housing Units Jubail 1987 24 Haifco Bitas, Makkah Juffali Commercial Bldg Makkah 1987 25 A. A. AlTazi Corp. Aziziyah Beach Housing AlKhobar 1988 26 Sheikh AbdulAziz AlHamdan, Riyadh AlHamdan Commercial Complex Roof Covering Riyadh 1988 27 Jarir Furniture 8 Villa Compound Riyadh 1988 28 Meto Bau / AG. Jed. Steidle S.A. &

Moll Arabia Ltd. Substation at AlZahir, Sisha, Makkah & Jubail, Kubais & Power Plant 110 KV Extn.

Makkah & Makkah / Taif 1989

29 Ghassan A. AlKhalid Co. Various Houses, Chalets & Schools Kuwait 1990 30 Asahi Glass Co., Japan Siporex Wall Panels Japan 1990 31 ElEkam Gen. Contr. Girls School at Ajman U.A.E. 1990 32 AlMulla Est. Abjar Hotel at Dubai U.A.E. 1990 33 S A S C O Roadside Rest Areas Diff. sites 1990 34 Prince Khalid Bin Faisal Abha Exhibition Center Abha 1990 35 Hyundai, Riyadh King Fahad Medical City (Interstitial Floors) Riyadh 1990 36 A.K. Group School Building Dhahran 1991 37 Basem AlKhateeb Special Forces Accom. Riyadh 1991 38 A. Azhar Corp. Makkah Kindergarten Makkah 1991 39 Faraj AlQahtani Est. Faisal Islamic Bank Villas Jubail 1991 40 GAMA Services GAMA Compound Jeddah 1991 41 Projects & Trading Co. ABV MODA Resi. Camp Jeddah 1991 42 AlTarifi General Contracting Hospital Project for Ministry of Health Safwa AlLaith 1991 43 A.K. Group Aziziyah Housing 208 Villas AlKhobar 1992 44 AlShaden Cont. Est. AlHasawi Housing Compound AlKhobar 1992 45 AKC Contracting Khalifa Oly. Stadium Qatar 1992 46 Arch. Saleh Qadah AlMeftaha Village Abha 1992 47 Saudi Shinwha Co. Sharq Exp. Factory Jubail 1992 48 AlWaad Co. 8 Villa Compound Jubail 1992 49 Ghassan A. AlKhalid Different Chalets Kuwait 1992 50 ABV Rock Group / Arabian Gulf Co. SSSP Residential Compound 120 Units Madinah 1992 51 ABV Rock Group / Haif Est. SSSP Residential Compound 110 Units Abha 1993 52 ABV Rock Group / United Const. &

Trdg Co. SSSP Residential Compound 110 Units Buraidah 1993 53 AlWasat Trading & Contracting Co. AlSulayyel Housing Compound AlSulayyel 1993 54 Kimma Construction Yanpet Housing Project 200 Villas Yanbu 1993 55 Ibn Zumaie Const./Maint. AlKaki Compound Jeddah 1993 56 AlBustan Company AlHada Dev. Project 20 Villas AlKhobar 1993 57 AlBustan Company Stemco Cmpd. 8 Villa AlKhobar 1993 58 Senam United Mod. Co. 20 Villa Compound Jubail 1993 59 ABV Rock Group ABV Compound Jeddah 1993 60 Ghassan A. AlKhalid Different Chalets Kuwait 1993 61 A.K. Group AlGossaibi Accommodation Dammam 1993 62 Saudi Constructioneers Est. GOSI Housing Project 36 Units Jubail 1993


6. Erection

SN. CLIENT / CONTRACTOR NAME OF PROJECT LOCATION YEAR 63 UGETCO/Kuwait Hotels Dubaiya 30 Chalets Kuwait 1993 64 N A Z C O (Najeeb AlZamil Group) SAFCO Housing Project Jubail 1993 65 Nasser A. AlTuraiki 6 Villas Compound Dammam 1993 66 Nesma & AlFadl Cont. Co. Hadeed Housing Project Jubail 1993 67 Abdullah AlMubarak Est. Municipalities Dammam &

Dhahran 1993 68 A.K. Group Base Commander Residential Dhahran 1994 69 U G E T C O Different Villas / Chalets Kuwait 1994 70 Saudi German Hospital Hospital Extension Jeddah 1994 71 A. K. Group Tabuk Gardens Village – 60 villas Tabuk 1994 72 Saudi Archirodon Ltd. Compound Extension Jeddah 1994 73 Armetal Labor Camp Riyadh 1994 74 AlMutabagani Health Serv Housing Compound 10 Villas Taif 1994 75 Hanil Development Co. Housing Compound AlJouf 1994 76 Moll Arabia Ltd. SCECO Substations Jeddah 1994 77 Saudi Wiemer & Trachte Hofuf Cement Factory Hofuf 1994 78 AlAjdal Trading Est. Sipenny’s Labor Camp Dubai-UAE 1994 79 Abdullah AlMubarak Est. Municipality Jubail 1994 80 AlGhurery Co. Manarat AlSharkia Schools Dammam 1994 81 Sata Engineering Blocks Taiwan 1994 82 Eng’r. AlBassam AlBassam’s Compound Riyadh 1994 83 Arabian Fal Co. Ibn Sina Housing Project Jubail 1994 84 Saudi Real Estate Co. D.Q. Housing Project Riyadh 1994 85 M.S. AlSuwaidi Cont. Est. Yanpet Housing Project Phase II 300 Villas Yanbu 1994 86 Bin Ayed Est. Panda No. 8 Renovation Riyadh 1995 87 AlOthman Agri. Prod. Various Projects Hofuf 1995 88 AlAjdal Trading Est. Cold Store Building Dubai 1995 89 AlThinayyan Dev. Co. Petrolube Factory Offices Riyadh 1995 90 U G E T C O Ministry of Interior Extn. Kuwait 1995 91 AlAjdal Trading Est. 92 Buildings Extension AbuDhabi 1995 92 AlAjdal Trading Est. American Hospital Dubai 1995 93 AlSarif Corporation AlWazir Center Riyadh 1995 94 AMERAB-ECO- Tawam 89 Villas & B. Walls AbuDhabi 1995 95 AlFanar Co. Iskan AlAam Substation Makkah 1995 96 Assad Said Corp. Office for Power Plant 9 Riyadh 1995 97 AlKhozaim Construction AlWalaan Showroom Riyadh 1995 98 AlMobti for Trad. & Cont. 273 Villas Compound Djibouti 1996 99 Arabian Turkish Cont. Co. AlMatroud Staff Accommodation Sihat 1996

100 Teamwork S.A. Ltd. Al Hayat Pharma. Plant Riyadh 1996 101 Shamsa Trading Est. 5 Buildings AlKharj 1996 102 ElSeif Eng. Cont. Est. PP 8 Phase II, Ext. II Riyadh 1996 103 Riyadh AlHuda Schools School Complex Jubail 1996 104 Delta Est. Office & Accommodations Riyadh 1996 105 ABV Rock Group KB. Boundary Walls Abha 1996 106 AlToukhi Co. Ind & Trad. AlBayaah Substation Madina 1996 107 Saudi Binladin Group Aqaba Substation Jordan 1996 108 Giant Crete Bldg. Mat. Wall Claddings Taiwan 1996 109 Moll Arabia Ltd. Faysaliyah New Substation Jeddah 1996 110 A.K. Group R.S.L.F. Housing Tabuk 1996 111 AlMasarah Cont, Est Yanpet Housing Phase 2 Ext. Yanbu 1996 112 A. K. Group Commanders Office 4 Bldgs. Taif 1996 113 A. K. Group Emarah Palace Complex Kharkhair 1996 114 Saudi Binladin Group Power Plant (PP 9) Riyadh 1996 115 AlKhulaifi Business Group 16 Villa Complex Qatar 1996 116 Amana Steel Hangers U.A.E. 1996 117 A. K. Group S S O C Compound Taif 1996 118 Ret Ser Yanbu Cement Factory Yanbu 1996 119 Saudi Build Barracks Gurrayat 1997 120 International Center Co. YCC – 40 Villas Yanbu 1997 121 C C C (ARAMCO) Residential & Industrial Compound Shaybah 1997 122 General Presidency for Girls

Education 16 Colleges Buildings Different Locations 1997 123 Developed Building Co. 180 Villas (Roof Slabs) Qatar 1997 124 Giant Crete Bldg. Mat’ls. Wall Claddings Taiwan 1997 125 Dr. Khalid Idress Hospital Hospital Extension Jeddah 1997 126 Ibrahim AlSheikh Est. Central Electrical Bldg. Ext. Jeddah 1997 127 Tawam Gen. Cont. Co. Coast Guard Institute Project AbuDhabi 1997


6. Erection

SN. CLIENT / CONTRACTOR NAME OF PROJECT LOCATION YEAR 128 Mr. Yaqub AlGhoul Chalets & Hotel Gizan 1998 129 AlSwayeh Co. Hyatt Regency Hotel Riyadh 1998 130 John Shenton Architects Princess Donnas Palace Ren. Riyadh 1998 131 Pax Kent Tea factory Jabel Ali 1998 132 Mannai Engineering Co. Intercontinental Hotel AlAhsa 1998 133 Tawam General Cont. Co. AlDukkan Project Diff. sites 1998 134 AlOthman Est. Wall Claddings for 2 Buildings AlAhsa 1998 135 Developed Building Co. 5 Villas Qatar 1998 136 Pax Kent Unilever Gulf Project Dubai 1998 137 Pax Kent GAC Distribution Center Dubai 1998 138 Assad Said Corporation Offices for SSOC AlKhaj 1998 139 Oasis Co. Gymnasium Alkhobar 1998 140 Montajat Co. Veterinary Pharma Plant Dammam 1999 141 Boyot Makkah for Trading Holy Quran School Project Makkah 1999 142 AlJassim Trading Group Fujairah Womens College Fujairah 1999 143 Ibrahim AlKhalaf AlRuwad School Riyadh 1999 144 Zaas Office Bldg – Min. of Interior Riyadh 1999 145 Arch Center Hail Trade Center Hail 1999 146 Developed Building Co. Landmark Shopping Mall Proj. Qatar 1999 147 AbdulLateef Jameel Co. Toyota, Buraidah Center Buraidah 1999 148 REDICO Tabuk Gardens Village – 2A Tabuk 2000 149 Moll Arabia Shoaiba Power Plant / Substation at Jamiaa Shoaiba & Jeddah 2000 150 Fahad Bin Saad Co. Green Beach Fam. Fun Park Riyadh 2000 151 Modern Building Co. Star Markets Yanbu 2000 152 Saqr AlBar AlAhmar Bachelor Compound Jeddah 2000 153 Developed Bldg. Co. Al Ittihad & Al Rayyan Stadiums Qatar 2001 154 Al Kayid Co. Recreation center Al Jouf 2001 155 Bin Jarallah Group Housing Compound Najran 2001 156 Obaid Al Maary Makkah Girls School Makkah 2001 157 Saudi Wiemer & Tracte Al Rushaid Village 2 Alkhobar 2001 158 Al Qasabi Cont. Hand Ball Hall Qassim 2001 159 Saudi Teryadh Hand Ball Hall Sanabis 2001 160 Developed Bldg. Co. Giant Stores Qatar 2001 161 Al Afras Cont. Office Compound Makkah 2001 162 Saudi Binladin Group King Abdullah Multi-storey Hotel Madinah 2001 163 Al Maawdah const. Building extension Bahrain 2002 164 Nasser Al Hajri Yanpet Hsng Proj.-Ph.3 Yanbu 2002 165 REDICO CFS Expansion K. Mushayt 2002 166 KAMCO Madinah Printing Press Dammam & Riyadh 2002 167 Rakan Trading R.C. Four Schools Yanbu 2002 168 Modern Villas Real Estate Housing Compound Riyadh 2002 169 Riman Trading School Building Riyadh 2002 170 Al Thobaiti Co. SWCC Clinic & Mosque AlKhobar 2002 171 Al Fasla Est. Al Thakafa School Riyadh 2002 172 Al Someie Real Estate Housing Compound Riyadh 2002 173 Al Najdain for Contg. Moda Accommodation Wadi Dawasir 2002 174 Arabian Bemco Substation Taif 2003 175 Abdullatif AlIssa Group Al Issa Compound Riyadh 2003 176 Green Top Contg. Qatif & Dammam BSP Qatif/Dam 2003 177 Al Marasem Contg. Residential Compound Shouaiba 2003 178 Bin Jarallah Group Gizan Housing Gizan 2003 179 Al Marasem Cont. Housing Compound Tufail 2003 180 Al Mashrab Co. King Khaled University Abha 2004 181 Rezaik Al Gedrawi Charity Housing Skaka 2004 182 Rezaik Al Gedrawi Charity Housing Qurayyat 2004 183 Saudi Archirodon Steam Power Plant Housing Shoaiba 2004 184 Al Ali Engineering 108 Villas Qatar 2004 185 Al Ali Engineering Villaggio Qatar 2004 186 King Abdullah Foundation 2,500 villas - Developmental Housing Project Diff. sites 2004-

2006 187 Contraco 380/110kV Substation Jeddah 2004 188 Al Fawzani Housing Compound – Clinic Jubail 2004 189 Arabian Bemco Cont. Substation Khaybar 2004 190 Al Marasem Medical Clinic Tufail 2004 191 EMECO Al Amar Gold Mine – Housing Quayyiah 2004 192 Al Fanar Co. 110 kV Zahra Substation Makkah 2005


6. Erection

SN. CLIENT / CONTRACTOR NAME OF PROJECT LOCATION YEAR 193 Al Ma’awdah Const. 10 Villas for E.Alwan Bahrain 2005 194 Al Ali Engineering 30 Villas Qatar 2005 195 Al Othman Agri. NADA Accommodation Bldgs Hofuf 2005 196 Contraco Al Rabwa Substation Jeddah 2005 197 Saudi Archirodon Office Building Jeddah 2005 198 Biad Development Co. 110/13.8kV Substation Jeddah 2005 199 Mohd. Mousa Shahada Est. Al Jouf Municipality Al Jouf 2005 200 Al Yasser Gen. Cont. Jubail Municipality Jubail 2006 201 Wadi Maramer School Buildings Jizan 2006 202 Abdulaziz Trading Est. Hill View Real Estate-Phase I Ethiopia 2006 203 Philipp Holzman New Surgery Hospital Ext. Riyadh 2006 204 Al Rashid Abetong 10 units Building Extensions Riyadh 2006 205 Rezaik Al Gedrawi Admin. Buildings – 3 Bldgs. Al Jouf 2006 206 Al Ali Engineering 84 Villas Qatar 2006 207 Assad Said Corporation ASC Housing Compound Jubail 2006 208 Imar Development Co. Al Tilal Project Madinah 2006 209 Al Ma’awdah Const. 25 Villas Bahrain 2006 210 Haif Contracting Gazadco Shrimp Farm Jizan 2006 211 Assad Said Corporation Substations Abu Hadriya & Shoaiba 2007 212 Saudi Binladin Group Al Haram Shopping Center Madinah 2007 213 Royal Defense Command Renovation-Apartment Bldgs Jeddah 2007 214 Al Ali Engineering The Pearl Qatar Qatar 2007 215 Al Ali Engineering 58 Villas Qatar 2007 216 Al Gosaibi Labour Camp Jubail 2007 217 Makkah Co. Supply of Blocks Kuwait/Iraq 2007 218 Erfan Hospital Hospital Extension Jeddah 2007 219 Al Mabda Rezayat Housing Compound Jubail 2007 220 Project Building Est. Al-Mouwasat Hosp. FF Ext. Jubail 2007 221 Saudi Binladin Group Dar Al-Qibla Complex Madinah 2007 222 MEEDCO Substations Khurais/Shedgum 2007 223 Sinoma Hofuf Cement Factory Hofuf 2007 224 Al-Fanar Co. 380/110 kV Substation Thuwal 2007 225 Al-Marasem Co. Charity Housing Diff. sites 2007 226 Al-Rashid Co. Al-Rashid Mall Extension AlKhobar 2007 227 Al-Othman Agri. Prod. Housing Compound Hofuf 2008 228 Danash Co. Al Jouf Cement Factory – Housing Turaif 2008 229 Al Toukhi Co. Al Dhahiya Substation Dammam 2008 230 Framing Co. Developmental Housing Project Qurrayat 2008 231 Rezaik Gedrawi Developmental Housing Project Aflaj/Rafha 2008 232 Contraco South Aziziah Substation Makkah 2008 233 AlFanar Co. 380 kV Switching Station Rabigh 2008 234 Contraco 380/132 kV Substation Shuqaiq 2008 235 Saudi Binladin Group “KAUST” Central Services Building Thuwal 2008 236 Sulaiman A Al Rajhi SOHAR Project Qassim 2008 237 Saudi Al Terais Co. Al Kudmi Substation Jizan 2008 238 Al Muhaidib Co. Royal Commission Housing (240 villas) Yanbu 2008 239 Philipp Holzmann Co. Madareem Crown Hotel Riyadh 2008 240 Saudi Archirodon Ltd. Housing Project Jeddah 2008 241 Azmeel Contg. Royal Commission Housing (329 villas) Jubail 2009 242 Redico Royal Commission Housing (405 villas) Jubail 2009 243 Contraco Substations Quwaizah, Teiam,

Thuwal 2009 244 Saudi Archirodon RSF Expt. Camp Jeddah 2009 245 Sahel Areej Trading Secondary School Jizan 2009 246 Al Ali Engineering Cont. Labour Accommodation Qatar 2009 247 Al Marasem Co. Housing Project Umluj 2009 248 Al Mabani Gen. Cont. Power Plant Project (PP10) Riyadh 2009 249 Al Refaie Co. SWCC Housing Project 5 sites 2009 250 Al Fanar Co. Substation – Jizan Economic City Jizan 2010 251 National Prawn Co. Accommodation Buildings Ghallah 2010 252 Al Ali Engineering Cont. Shopping Complex Qatar 2010 253 Al Saad Gen. Contg. Qassim Power Plant Qassim 2010 254 Al Fawzani SWCC – Housing Project Diff. Loc. 2010 255 Assad Said Corp. Princess Noura University Substation Riyadh 2010 256 Azmeel Contracting Royal Commission Housing (491 villas) Jubail 2011 257 Royal Air Force Housing Project Qahma 2011 258 King Saud University 460 Villa Extensions Riyadh 2011


6. Erection

SN. CLIENT / CONTRACTOR NAME OF PROJECT LOCATION YEAR 259 BEMCO PP10 – Turbine Building Riyadh 2011 260 SCECO 5 Substations Diff. Loc. 2011 261 Nesma Co. Olaya Towers Riyadh 2011 262 Drake & Scull Jawhara Tower Jeddah 2011 263 AlMa’awdah Const. Different Tower Projects Bahrain 2011 264 D.C.C. Burj Rafal Riyadh 2012 265 Al Fanar Co. New Haramain Hi-Speed Railway S/S 6 sites 2012 266 Azmeel Corporation Royal Commission Housing, Ph.8, C13 Jubail 2012 267 Azmeel Corporation GOSI Housing Project Jubail 2012 268 Al-Fanar Co. Qurayyah Substation Qurayyah 2012 269 Gulf Elite Co. Shaybah RIC Expansion Project Shaybah 2013 270 Huta Marine Housing Compound Rabigh 2013 271 Go Green International Schools & Malls Qatar 2013 272 Saudi Archirodon RSF Houses Jeddah 2013 273 MARCO & GS Imam University Buildings Riyadh 2013 274 Different Contractors Girls Technical Colleges Diff. locations 2013 275 Ansaq Co. Al Hajj Ministry – 5 buildings Mina 2013 276 Military Hospital Labour Housing Riyadh 2013 277 Enteria Arabia Special Forces Security Buildings Riyadh 2014 278 Ewaan Real Estate Al-Fareeda Housing Jeddah 2014 279 Al Haramain Est. Shops Arafat 2014 280 Saudi Gap Staff Accommodation Jubail 2014 281 Saudi Oger Different projects Diff. locations 2014 282 Rowwad Al-Maseel Housing Compound Riyadh 2014 283 Al-Fanar SWCC Yanbu-3 S/S & Power Plant Yanbu 2014 284 Ewaan Real Estate Limas Housing Project Jubail 2015 285 Monsha’at Al Mostaqbal MODA Project Rania/Hareeq 2015 286 Go Green International Indoor Arena Qatar 2015 287 Go Green International LuLu Hypermarket Qatar 2015 288 National Aquaculture Co. Farm 205 & 206 Accommodations Al Leith 2015 289 Go Green International Staff and Labor Accommodations Qatar 2015 290 Saudi Archirodon Al Salama Compound Jeddah 2015 291 MOBCO Ready-Built Factory Buildings Riyadh 2016 292 Al-Kifah for Contracting Defense Force Project, Phase 1 Jubail 2016 293 Retail Real Estate Co. Majma’ah Mall Majma’ah 2016 294 Go Green International Beach Compound Qatar 2016 295 Maher Hassan Al Magamsi Tamr Factory Jeddah 2016 296 Go Green International GWC Logostics Qatar 2016 297 Unicorp PP-12, Warehouse Durma 2016 298 Al-Hussan Const. School Extension Jubail 2016 299 Sinohydro Corp. Shaybah Residential Building Shaybah 2016 300 Go Green International Doha Oasis Qatar 2016 301 Ishada Contracting Sugar Refinery Jeddah 2016 302 Distinguished Brothers Karan Hotel Waad Al Shammal 2017 303 Azmeel Contracting Co. Aramco – South Dhahran Home Ownership Prog. Dhahran 2017 304 MODON Ready-Built Factories 32 diff. Places 2017 305 Al Raidah Co. Sandex Warehouses Riyadh/Jeddah 2017 306 Fast Contracting Jeddah Airport Jeddah 2017 307 Al Rajhi Saudi Group Labour Accommodations Jeddah 2017 308 Waleed Abu-Shawish Arabian Oud Warehouse Riyadh 2018 309 Engineering Union Est. Charity Housing Umluj/Jizan 2018 310 Prime Technical Masic - RBF Jeddah 2018 311 Al Bawani Contg. Co. Sharma Complex Sharma 2018 312 Tareg Al-Jaafari Contg. Worker’s Camp Dammam 2018 313 Delta Star Contg. Takmeel Warehouse Haradth 2018 314 Sadel Construction Deriyah Farm Riyadh 2018 315 MODON 1200 Ready-Built Factories 32 diff. places 2019 316 Ministry of Housing 192 Villas Al-Ahsa 2019 317 Ministry of Housing 959 Villas Dammam 2019

Riyadh (Head Office)

Tel. +966 11 498 1800 Fax +966 11 498 2072

Email: [email protected]

Jeddah Branch

Mob. +966 55 565 1925

Al Khobar Branch

Mob. +966 50 496 6911

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