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ALe

CSR Building Materials (M) Sdn Bhd

The intelligent building system

Background

200mm

SO-2S0mm

CSR Building Materials (MJ Sdn Bhd is a subsidiary of CSR Limited, Australia's leading rnenufacrurer and supplier of building products with operations throughout Australia, New Zealand and Asia.

CSR Building Materials (M) Sdn Bhd's ALe Division produces ALC (Autoclaved Lightweight Concrete) products such as bloch, reinforced panels, lintels, mortars, tools and accessories for use in housing, commercial and industrial construction.

ALe has been available in Malaysia since the early 90's and has been used in Europe for over 60 years, Today, the product is extensively used throughout the world.

ALe has won wide acceptance as an innovative building material due to its speed of construction, excellent thermal properties and ability to provide for versatility in design.

CSR ALC Blocks

(5R ALe blocks can used for external and internal load-bearing and non load-bearing walls. The blocks are produced with a nominal face dimension of 600mm x 200mm and in a th ickness ra nge of 50- 250mm (2Smm incrE'mentsj. There are 8.33 blocks per squa re meter of wall area.

Due to their dimensional accuracy, the blocks are easily laid in eSR ALC Thin Bed Adhesive with 2-3mm joints. The first course is laid in regular mortar to take out irregularities in the s lab, A DPe is required between the slab and CSR ALe bloch on the ground floor and in wet areas. it is essential that the first course is laid accurately so that speed is achieved in subsequent courses. Subsequent courses are then glued together using thin bed adhesive. This method makes for rapid and easily constructed walls. Wastage is minimized as bloch can be cut to size using a tungsten tip handsaw.

Block Properties

Property Value Units

Length 600 mm
Height 200 or 400 mm
Thickness 50 - 250 mm
Nominal Dry Density 490 kg/m'
Working Density Range 495 - 650 __ kg/m'
Compressive Strength, f'e 2.8 MPa
Minimum Compressive Strength, f'm 2.5 MPa
Modulus of Elasticity, E 1500 MPa
Modulus of Rupture, f'Ul 0.44 MPa
Ultimate Tensile Strenght. f'ml 0.44 MPa Notes:

1 All dlmen"olJs and densit.es are nomfl'lill, for IIcrua! dimeosK,lllal lolt'l'ances. please rei., ro rhe (5R ALe produCf specHiralion,

l. The producr characteriSliCS Il)Ied JJl IlJe "bow cable are based on le!ring carril'd Olff by (SIRO nr Austr.lia and

recognised In M""ys,ra) and SIRJM,

J. 400mm h'9ft bloch "v"llable In lOOmm bloch only on special order. 4, Block Ihlcknesses available in 25mm intTl'ml'nt (rom 50mm [0 250mm,

5. Moaulu! 01 ruprure ,,",,'" [0 rhe rensde w"",gtn In rte~ure 01 a single masonry unit. wnere.!! ultrmare lensile sm>nglh reI"" 10 rhe tensile strffiglh 01 Se\I('fdl masonry u"''' bonded togerher

(SR ALe carries a stock of standard block sizes as shown in the following table. It is recommended that these standard sizes be used whenever possible to facilitate quick deliveries. if non-standard sbes are required, allow additional lime for production and delivery.

CSR ALCStandard Block Size Range

Producl Standard Standard Nominal Block m' per No of

Code Nominal Nominal Thickness ttnm) pallet pieces per

Length tmm; Height tmm) pallet

62100 62125 62150 62200

600 600 600 600

100 125 150 200

21.60 17.28 14.40 10.08

180 144 120 84

200 200 200 200

J

CSR ALC Reinforced Panels

CSR ALC panels are reinforced load bearing panels used for f100~, walls or roofs, Panels (an be used in conjunction with ALC block> to provide a total load bearing system.

CSR ALe panels are supplied in the following thicknesses:

r OOmm. 125mm. lS0mm. r 75 mm & 200mm

Wei g hi : Typically 37 5kg per 6m long panel, 1 SOm m thick.

When used as flooring. the thickness of the slab should be in accordance with CSR ALes recommended designs taking into account the required span and load. TYPical floor panels for housmq are 150mm in thickness with maximum span of 3.7m. Panels lifted Into position one by one using a crane. The panels are butted together, joint reinforcement on spacers are installed and mortar is then poured to form the ring anchor system. Ensure that the reinforcement has adequate cover around it.

Panel Properties

Property VaLue Units

Floor Wal(

- --

Length 0,6 - 6.0 0.6 - 6.0 m
Width or Heigh, ]00 - 600 ]00·600 mm
Thickness 100 - 200 75 - 200 mm
Nominal Dry Density SSO SSO kglm
Working Density Range 780 - 820 780·820 kg/m
Compressive Strength. f'c ].5 3.S MPa
Modulus of Elasticity, E 2190 2190 MPa NDt""

1 All ~Im~nllgnl ~nd dt'nllt,~ ar~ nomlfl I for d(iUdl dll1'Hmllonal loll:fdn~e~ ",~a.~ nff~r 10 I~e (sR ALe produa Spf'(i/l~dllon

Z. Th~ pmdU<1 charaaemu<3 I"ll'd In 'te db01ie lclble ere bifSed on 151ing (amID OUt by GIRO (in AI."rra/'rl dnd m:ogmst'd in M~I~Y'lla) and SIRi'A.

3. Pol nel IhlCknelst'S dV~II.bl~ In 15mm 'nCwmen I ffom 75 mm 10 ZOOmm

4 Pd n ~i I ngll, " nd mdl h dn be var.f'd In,' ernen IS IJf lDmm.

CSR ALC Lintels

CSR ALC limels are 1'Iv1'I1IClbie in a range of sizes to bndqe common Sized openings for doors and windows. Since they are constructed out of the same material as CSR ALC blocks and panels, the wall remains a homogenous unit and surfaces are easily finished.

CSR ALC lintels are designed for a minimum of ZOOmm support at both ends with a maximum span between support, of 3000mm. CSR ALC Technical Department will advise on the appropriate lintel for the required application.

Lintel Properties

Properly Value Units

Nominal Dry Density 600 kg/m
Working Density Range 780 - 820 kg/m
Compressive Strength, f', 5.0 MPa
Modulus of Elasticity, E 2190 MPa Not·es,

I All d,me~I"'nl and denSI!'e, die Mmmdl, for clClUdl dJm~niional IOle",,,, ... ple<o>e ",("." ro the CS~ ALe P'oOO("1 Ipt'(,lir.IJon.

2 I~ pruduo dl~r.m!.'f'lliC5 Ir'tl/d rn lh~ "b(M' rable all' ~ed on 1e\lIng carr/red our by (lIRO (in Auw~rra and '('(ogmsed in Mald)'l~) dnd SIRIM

Mortars, Tools and Ties

CSR ALC provides a range of tools, mortars and ties which have been designed for use with its products.

CSR ALC Ven'cal Wall Panel, consist of re i nfo["[~d 1\ L C. They can be used lor external and Internal load bearing wail,.

1. Infill Walls

CSR ALC blocks have been used successfully in many projects throughout Malaysia. ALC walls can be used for both internal and external infill walls. Typically block thicknesses are 125mm for external walls, 100mm for internal walls and 150mm for party walls or other applications such as plant rooms and machinery rooms. Thicker bloch are available for special applications.

2. Load-bearing Walls

The use of load-bearing design in housing allows for numerous benefits including simple installation, faster speed of construction as well as reduced use and wastage of raw materials at site.

Once the foundation is constructed, load-bearing Willis are installed to support each floor level. CSR ALC lintels are available to bridge over openings and also provide support for floor panels where walls are not available. The flooring system comprises of CSR ALC floor panels.

The sizing and strength requirement of walls should comply with established standards. Guidance is available from CSR ALC Technical Dept.

CSR ALe Floor Panels consist 01 ",inforted ALe.

Thry are r~ady 10 use prefab elements which /

h iNe tu II load -beari n9 (a paclty on del, ve ry

Le~gths up 106m are dva,iabl .. No lormwork Or

bracing ,5 necessary.

(sR ALC Llmel Beam5 cons", of """Iorced /

ALe. 1hey ""ow unInterrupted block-I"I"ng

10 continue over doors and wlndov~

CSR ALC Blocks a re produced to narrow di rnensiona I tolerances & laid with 2·3mm th,.k jotrns, This results in a high quality wall strucune,

3. Flooring Systems

(SR ALl Roof Panels consut of reinlorced ALe They prOVide e>.(ellent t~ ermal Insula! on.

~ SlePl Straps p'O\ild~ support of roof pan~I.' for construct on of roof opi.'nrngs

(SR AL( venicat or Horrloma Wall Pam,l,

A wid" range of render! and lurface treatrnents can be epplied 10 rSR Ale

I ,

CSR ALC reinforced panels can be used as flooring in domestic dwellings or other lightly loaded floors.

The panels are laid on CSR ALe supporting blockwork and the structure is locked together using a ring beam, as oktured (refer to left). This method of construction means that the floor can be laid down in one day, with blockwork walls being erected the next day.

This flooring system has advantages in that it can be very quickly installed, has superior thermal and fire resistance and when used in conjunction with CSR ALC blockwork, will reduce the differential expansion between floor and walls.

Time

- ~Ktr:~~.i:i':~:ri~~:':~. 7D"c IIIl~~,~r~~~~~ S:r:::x. 2~~

4. Thermal Performance

C5R ALe blocks, due to their cellular structure with entrained air spaces, have excellent thermal insulation properties. This IS measured by the "R" value, with a higher value indicating better thermal Insulation.

100 150 200

0.77 1. 1 5 1.54

Compared to traditional building materials, CSR ALC will provide a much cooler house and will reduce alr-condi ioning cost.

A single skin (SR ALC wall is 3 / times more thermally resistant than clay brick construction.

The effectiveness of CSR ALC products In controlling room temperatures was illustrated in tests by the Fraunhofer Institute for Architectural PhYSICS in Germany.

A west facing wall was chosen and painted black to raise Its surface temperature. The outside wall varied hrough a range of 70 C The inside wall temperature remained at a comfortable 20 C with only a 2 C variation.

The test is illustrated diagrammatically.

s. Fire Resistance

Due to its high thermal resistance, CSR ALC walls also have much higher fire resistance compared to other traditional buildrng materials.

A 100mm thick CSR ALe infill wall has a Bomba certified fire-rating of 4-hours compared to 2-hours for most other materials of similar thickness.

This provides a much higher level of safety when used in fire wall applications such as party walls, plant rooms and other high risk areas.

6. Finishes

A range of finishes is available for use on CSR ALe products. All surface treatments should however, be permeable 10 water vapour.

For external applications, CSR AlC External Render is generally applied with a minimum thickness of 1 Omm-12mm. The dimensional accuracy of the CSR ALC products allow a much thinner coating compared to conventional plasters whilst still providing adequate weather resistance. However, the final coating thickness will depend on the overall tolerance of the structural frame.

The rendered walls are normally finished with an acrylic weather-resistent paint.

In addition to cement based renders, many types of acrylic, alkali-resisting paints and commercial coatings or treatments can be used on CSR ALe blocks for external applications,

Internally, a 3-5mm skim coat finished is commonly used. This can then be mated with most common peints.

It IS recommended that fiberglass mesh be used in the render at windows, door openings and high s ress areas. The relevant surface coating manufacturer should be consulted as to the suitability of the product with CSR ALe products.

I

7. Services

CSR ALC blocks allow for quick and efficient installation of services such as wiring and plumbing. These services (an be simply chased Into the Willi using either a hand or electric router, In accordance With good building practice, vertical chases should not be deeper than 'I of the wall thickness and horizontal chases not deeper than I of the wall thickness, After embedment, the chased services can be filled using (SR's patching monaro Fibreglass mesh should be applied in the render over this area.

8. Fixings and Fasteners

The fixing method and fixing(s) used will vary depending on the load and intended use of the fixture. Holes where required for fittings should be dnlled with a normal drill and not with a hammering action. Loose debris should be removed before insertion of the fixinq. CSR does not recommend metal-type anchors.

For further information, please contact CSR ALe office. Alternatively, further details may be obtained by consulung major anchor suppliers such as Hilti, Ramset or Tenn.

Benefits Of Houses & Buildings Constructed Using CSR ALC

Clockwise from:

Above : Marriol HOle!

Right 1 : Palace of )usrice Purrajayil. 2 : Aparlment blocks at PUlrajaya.

3 : Kampung Llndungan.

Kuala Lumpur,

4 : Office blocks ar Purfajaya,

5 : Inli College. Nilal,

Speed of Construction & Savings in Labour costs

Larger and lighter ALe blocks mean faster and higher rate of installation.

ALe Brick

Installation Rate 1 ALC Block = 6 Bricks
20 - 22m2 I worker I day 10m2 I worker I day
Thinner coatings on ALe 3·5mm skim coat internally 25mm plaster
blockwall means faster (50 - 75m2 / worker / day) (20m2 f worker I day)
application time 12 m m render externally 25mm plaster
(Installation rates) (40m2 / worker I day) (20m2 I worker I day) Design savings

Lighter ALC products can reduce foundation and structural cost by as much as 25% in high rise structures.

Thermally Effective

Due to high insulating ability. no additional wall insulation is required. This means a more pleasant living environment with lower cooling costs.

Fire Resistant

CSR ALC 100mm walls achieve a 4-hour fire rating. which is the highest rating possible and is far superior to normal concrete or clay brickwork.

Termite Resistant

Being masonry. CSR ALC does not support termites or any other pests.

Environmentally Friendly

Timber can be minimised in walls, floors and roof construction. allowing its use for higher value added purposes.

The lower consumption of raw materials and energy in the production of ALC results in the conservation of the environment.

Technical Service

CSR ALe's Technica I Department is staffed by quaJ ified engineers who are available to respond 10 enquiries concerning the application and technical properties of CSR ALC products.

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