Design & Specifications

1. MATERIALS

2. CONCRETE PROPERTIES

3. GENERAL SPECIFICATIONS

SECTION 7 450 – INSULATED CONCRETE PANEL SYSTEM

PART 1 - GENERAL

1.1 RELATED DOCUMENTS
    A. Contract Drawings and general provisions of the Construction Contract, including CONTRACT CLAUSES and CONDITIONS, and other Division I Contract Specification Sections apply to work of this Section.
1.2 SUMMARY
    A. The scope of these works shall include the design, fabrication, supply, and installation of insulated concrete panel system as indicated in these specifications and as noted below.
    1. Engineering design of SOLEID insulated concrete panel building system including the preparation of fixing details, shop and erection drawings.
    2. The fabrication, surface finishing, packaging and delivery of insulated concrete panel materials to the job site.
    3. The installation and erection of SOLEID insulated concrete panel building system under supervision of manufacturer’s qualified technical staff.
    B. The extent and location of insulated concrete panel building enclosure are as indicated on the Contract Drawings and as noted below.
    1. Insulated concrete paneling system to the new building enclosures as shown on the drawings
    2. Factory made corner and special pieces as required to complement standard straight panels
    3. Wall/roof closure panels as required to suit design and field conditions
    4. Factory made custom trim, lintels and accessories as required
    C. The intent of these specifications and drawings is to establish a quality and performance level for design, material, finishing, durability, and workmanship.
1.3 SUBMITTALS
    A. For insulated concrete panels, submit the following in accordance with the general contract provisions.
    1. Product data for each prime material used in fabrication. SOLEID brochures and catalog information shall be submitted to describe in detail the insulated concrete panels to be furnished.
    2. Shop drawings for each type and size of fabricated unit, at 1:50 scale for plans, elevations, and sections; and ½ size for details of support, framing, and interface with other work. Shop drawings must clearly indicate the geometric layout of the main structural enclosure as well as the secondary support members. They shall comprise layout plans, sections, anchor and connection details, as well as all other relevant fixing details between wall and roof panels and adjacent components.
1.4 QUALITY ASSURANCE
    A. The panels and supports shall be the design of a manufacturer who is regularly engaged in the fabrication of an insulated concrete panel system. All materials shall be new, unused, and free from defects.
    B. The following standards and criteria (of most recent issue) shall be used where applicable in the structural design of the building covered by these specifications:
    1. ANSI standards for cementitious backer units (CBU), A118.9-1990
    2. Underwriters' Laboratory standards as required for any fire-rated assemblies.
    3. American Society for Testing and Materials (ASTM) standards for masonry, cements, aggregates, mortars, grouts, admixtures, reinforcements, accessories etc that are applicable to this section.
    4. “Steel Construction Manual” – American Institute of Steel Construction
    5. “Cold Formed Steel Design Manual”- American Iron and Steel Institute
    6. “Code for Welding in Building Construction” – American Welding Society
    C. The design, fabrication, surface finishing & building frame erection shall be in accordance with ISO 9001, Quality System procedures.
1.5 DELIVERY, STORAGE, AND HANDLING
    A. Comply with design criteria for packaging, handling, protection, storage, and delivery of all wall panel and cladding components.
    B. Delivery: Deliver panel materials to project site in manufacturer's containers, bundles, pallets or other standard packaging devices, fully identified with name, type, grade, color and size.
    C. Storage: Store panels and accessories on platforms and protect from weather, soiling, moisture and damage. Panels are to be handled and not dumped during delivery and installation to minimize damage. Store cementitious ingredients in dry, weather tight enclosure and protect against contamination and warehouse set. Stockpile and handle aggregates to prevent contamination from foreign materials.
    D. Co-ordination: Co-ordinate work of this section with interfacing and adjoining work of all other trades.
    E. Protection:
    1. Protection of Work: During erection, if rain is imminent, cover top of walls with heavy waterproof sheeting at end of each day's work. Cover partially completed structures when work is not in progress.
    2. Uniform Loads: Do not apply uniform wall or roof loading for at least 12 hours after erecting insulated concrete panel system.

PART 2 - PRODUCTS

2.1 INSULATED CONCRETE PANELS (ICP)
    A. The insulated concrete panels covered by this specification shall be an integrated assembly of synthetic polystyrene insulation foam between fiber-reinforced cement board sheets. The overall system shall be concrete type construction, interconnected face sheets with unfinished exposed surfaces.
    B. The typical insulated concrete panel sizes shall be in 600mm modular widths in lengths standard size of 3.0M. Overall nominal thickness shall be 150mm for typical wall panels, roof panels to be 200mm thick or as otherwise required per structural performance.
    1. Overall panel weight: 87 kg/M2 (150mm thickness)
    2. Polystyrene foam density: 40 kg/M3
    3. Thermal U-value: 0.25 W/MK at 150mm thick in accordance with ASTM C-236 (ASHRAE winter design) with 15 Mph wind outside, still air inside.
    4. Jointing system: tongue & groove, with reinforcing dowels and setting grout, square ends
    5. Performance Characteristics:
    a. Water Resistance: non-penetrable per AEST (Australian Standard)
    b. Fire Resistance: 3-hours per CSIRO (Australian Standard)
    c. Compressive strength (composite panel) > 3.5Mpa
    d. Airborne Sound Transmission loss > 54dB per ASTM E90
    6. Overall strength: maximum deflection of L/180 at 1000 N/M2 pressure per ASTM E72
    a. Axial panel load bearing: 122kN per panel
    b. Bending: 5 kN/M
    c. Anchor Pullout test: 4.35 kN
    d. Anchor Shear test: 7.4 kN
    C. Support anchors shall include stainless steel rivets, corrosion resistant power nails and bolts in conjunction with assorted clip angles and hold-down channels.
    D. Corners, lintels and special panels shall be factory fabricated using the basic panel components to match colors, modular dimensions and panel joints. Polymer coated glass fiber reinforcing mesh and tapes for joints and plastering lath.
2.2 MATERIALS
    A. Materials shall conform to the requirements specified for the particular item, and where these requirements are not specified in detail the material shall be as recommended by the manufacturer and designed for the intended use. All materials shall be subject to the approval of the Project Director prior to the fabrication of the insulated concrete panel materials.
    1. External panel layer shall be rigid board composed of fiber-reinforced cement and calcium
    silicate, 6.0mm thick, natural gray color.
    2. Internal panel layer shall be composed of same sheet material as the external layer with a smooth exposed surface for skim plaster & paint finish.
    3. The external and internal layers shall be bonded together by a solid lightweight core of Portland cement and expanded polystyrene bead aggregate, continuously poured in place and cured into a rigid board form, free from air pockets, bubbles or blistering. Foam insulation shall be 95% closed cell structure with the following properties.
    a. Minimum density of 40 kg/M3 as determined by ASTM D 1622-75
    b. Minimum tensile strength of 350 N/M2 as determined by ASTM C 297-76
    c. Minimum compressive strength of 0.34 MPa as determined by ASTM C 365-76
    B. Certificate of compliance for all approved materials used in fabrication of the insulated concrete panels shall be submitted. A method of fabrication statement shall also be submitted for approval.
2.3 SUPPORT SYSTEM COMPONENTS
    A. Fasteners
    Insulated concrete panels shall be secured to supporting frame structure by means of concealed clip angles and mating brackets. Clip angles and brackets shall be fixed to the panels and support frame by self-tapping sheet metal screws, Hilti power nails and/or rivets. All attachment devices and related fasteners shall be of stainless steel or equal corrosion resistant materials.
    B. Support Frame and Secondary Structure
    1. Supporting frame members shall consist of steel ‘I’ beam sections and rectangular hollow tubes conforming to ASTM A53, BS EN 1387 steel, or as specified in the design. Tubes shall be closed at both ends and fixed to primary structural elements via steel angles welded in place. The supports shall transmit both compressive and tensile forces of the panels as required.
    2. Supports and angles shall be included as a secondary structure for connection of the roof decking materials. Component members for the secondary system shall be manufactured from appropriate ‘I, C, or U’ profiles of formed steel or box sections (tubes).
    3. Flashing & closure elements shall be roll formed of galvanized sheet material, into ribbed profiles using required materials gauges for structural stability.
    4. All flashings, perimeter edge trim, gutters, closures, etc shall be provided as needed to ensure the finished building enclosure will be air & dust-tight. Trim pieces and flashings shall be factory formed from galvanized steel sheet of suitable gauge.
    5. All welding shall conform to ANSI/AWS D1.1 standards.
    C. Related components
    1. All related components including profiled joint stripping, neoprene sheet, foam cell closures, sealants, etc shall be provided as required to insure a weather tight installation for the composite building panel system.
    2. Stainless Steel: AISI Type 302/304, with polished No. 4 finish, 0.86-mm minimum thickness.
2.4 GROUT MATERIALS
    A. The following raw materials for grout and mortar setting mixes shall be as follows:
    1. Portland Cement: ASTM C-150, Type I. Provide natural color gray cement as required to produce the required mortar or grout mix.
    2. Aggregates: ASTM C-144, except for joints less than 6mm (1/4") use aggregate grades with 100% passing the No. 16 sieve.
    3. Water: Clean, free of deleterious materials that would impair strength or bond.
    4. Elastisizer: An approved proprietary mortar additive which improves workability, elasticity, adhesion and strength.

PART 3 - EXECUTION

3.1 DESIGN REQUIREMENTS
    A. The insulated concrete panel system shall be in compliance with building design codes, or equivalent internationally approved standard. All loading criteria shall be clearly stated and all load cases and load combinations must comply with ANSI-ASCE 6-95, or equivalent internationally approved standard.
    B. The basic design loads shall include live, wind, and seismic, in addition to dead load. All other design loads, whether they are static, dynamic or kinetic in nature, shall be considered as auxiliary loads.
    C. The Contractor shall ensure that the building frame supporting structure can safely accommodate all loads, reactions and moments induced by the insulated concrete panels and super-imposed equipment loads according to the design analysis.
3.2 FABRICATION
    A. The manufacturer shall provide all panel members, anchor bolts, bearing plates and accessories necessary for a complete building installation. Each panel shall be clearly marked in accordance with all shop and erection drawings for ease of identification and installation. The wall panel system shall be manufactured in accordance with the requirements of BS EN ISO 9001:1994 or the approved equivalent.
3.3 INSTALLATION
    A. Install insulated concrete panels as indicated, including materials, accessories, and devices which have been shipped disassembled, in compliance with manufacturer's/fabricator's instructions. Set plumb and level, true to line and location. Reinstall elements of steel support or accessory units, which have been disassembled for shipment/handling/installation. B. All installation works shall be carried out by a qualified erection company with extensive experience in installation of such insulated concrete panel system.
    C. Bonding Slurry
    A bonding slurry for joints between insulated concrete panels shall consist of the following components & mix design.
    1. 1-part fine washed sand by volume
    2. 6-parts Portland Type GP cement by volume
    3. Sufficient water to form a slurry of workable consistency
    Mixing should be performed either by hand, using a clean container and mixing tool or in a cement mixer by adding sand and cement to water, whilst mixing continuously to ensure a smooth, homogenous consistency that is free of lumps. The volume of mix made at any one time shall not exceed amount required to lay the quantity of wall panels within 45-60 minutes from initial mixing time and is dependent on climatic conditions.
    D. Mortar Bed
    The mortar bed mix for setting insulated concrete panels onto concrete foundations shall consist of the following components & mix design.
    1. 3-parts blended washed sand by volume
    2. 1-part Portland Type GP cement by volume
    3. 1-part water/elastisizer mix (more may be added during mixing to achieve optimal consistency).
    Mixing should be performed in a cement mixer free of fresh or loose mortar residues by adding aggregates to the water/elastisizer mix (initially proportioned as one part by volume), whilst mixing continuously to ensure a smooth, homogenous consistency that is free of lumps. All components shall be measured by means of calibrated containers. Water/elastisizer mix may be added in the specified proportions to impart a consistency such that it may be loosely shaped by hand into ball form leaving hands moist but not wet. The volume of mix made at any one time shall not exceed amount required to lay the quantity of wall panels within 45-60 minutes from initial mixing time and is dependent on climatic conditions.
    E. Joint Grout
    Grout fill for dowel & reinforcement joints between insulated concrete panels shall be a drybagged proprietary brand, fine aggregate/cement/admixtures type grout with high-flow and shrinkage properties, non-staining in the course of its application and of a compressive strength in excess of 20Mpa. Mixing shall be in accordance with the Manufacturer’s instructions.
3.4 CONSTRUCTION TOLERANCES:
    A. Variation from Plumb
    For vertical lines and surfaces of walls, do not exceed 6mm in 3 meters or 10mm in a story height not to exceed 6 meters, nor 13mm in 12 meters or more. For external corners, expansion joints, control joints and other conspicuous lines, do not exceed 6mm in any story or 6 meters maximum nor 13mm in 12 meters or more.
    B. Variation from Level
    For lines of exposed lintels, sills, parapets, horizontal grooves and other conspicuous lines, do not exceed 6mm in any bay or 6-M maximum, nor 20mm in 12 M or more.
    C. Variation of Linear Building Line
    For position shown in plan and related portion of columns, walls and partitions, do not exceed 13mm in any bay or 6 meters maximum, nor 20mm in 12 meters or more.
    D. Variation in Cross-Sectional Dimensions
    For columns and thickness of walls, from dimensions shown, do not exceed 6mm.
3.5 REPAIR, POINTING AND CLEANING
    A. Loose or broken panels:
    Repair or replace panels which are loose, chipped, broken, stained or otherwise damaged, or if panels do not match adjoining surfaces, adjust and install in fresh mortar or grout, pointed to eliminate evidence of replacement.
    B. Pointing:
    Point-up all joints at corners, openings and adjacent work to provide a neat, uniform appearance, properly prepared for application of caulking, sealant compounds, painting primers or under layers, finishing materials and textures.
    C. Cleaning:
    Clean exposed panel finishes by dry brushing at the end of each day's work and after final pointing to remove mortar spots and droppings.
    Clean overall panel finish surfaces not less than 6 days after completion of work, using clean water & stiff-bristle brushes. Do not use wire brushes, acid type cleaning agents or other cleaning compounds with caustic or harsh fillers. Installer shall advise Contractor of proper procedures to protect insulated concrete panel work from deterioration, discoloration or damage during construction and until acceptance of the work.
END OF SECTION 07 450