VIII. Installation

A. General Page VIII-2

B. Installation of Floor and Roof Panels Page VIII-4

C. Installation of Non-Load Bearing Wall Panels Page VIII-5

D. Installation of Load Bearing Vertical Wall Panels Page VIII-6

E. Installation of Blocks and Lintels Page VIII-7

A sufficient storage area must be provided, allowing material to be stored off of the groundand room for crane accessibility.

RequirementsAll work shall adhere to the fol-lowing documents:

• ASTM

• AERCON shop drawings and details

• Specifications

• Construction and Erection guidelines

• Safety requirements

Prerequisites for ErectionTo insure an economic andeffective erection of AERCONproducts, the prerequisites listedbelow must be followed:• The structural foundation

and any frames for supportof AERCON systems mustbe accurate with regard todimensions, levelness andelevations. Any supportframes must be true andplumb. All field require-ments shall correspond tothe shop drawings. Theerection crew must verifythe existing site conditionsprior to the start of erection.

• The accessibility of the con-struction site for the deliv-ery of material and for theerection crane must beguaranteed during allweather conditions. Theerection crane must be ableto reach within the perime-ter of the building for erect-ing panels.

• A sufficient storage areamust be provided. All mate-rial must be elevated abovethe ground. The materialshall be accessible for thecrane to reach the entirebuilding perimeter.

• The delivery and responsi-bility of the scaffolding forthe project must be coordi-nated prior to mobilizationof the crane and material.

• Appropriate electricalservice and potable watermust be available at the site.

• Review all codes, specifica-tions and manufacturer’serection requirements priorto commencement of theproject.

• All work shall be erected asindicated on the shop draw-ings and per the manufac-turer’s recommendations.

A. General

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All items presented in Sub-Section A are applicable.

AERCON floor and roof panelscan be erected or placed onAERCON, conventional con-crete, steel or masonry con-struction. All bearing surfacesmust be in accordance with theproject documents, and theminimum bearing requirementsas shown on the AERCON shopdrawings must be attained forthese panels.

During the erection of the firstpanel, position the panel precise-ly so as not to misalign all follow-ing panels. Indicate each panellocation on the support structureprior to placement to assist withfinal positioning. “Warped” posi-tions of floor and roof panelsmust be prevented at all times.

For large building areas, indi-vidual pallets of panels may beloaded on the floor and roofdeck for ease of erection. Verifythe capacity of the structure tosupport the pallets. Providetemporary shoring as required.

All floor and roof anchors notedon the project documents mustbe installed.

When erecting sloped roofpanels, secure the first panel toprevent sliding during erection.Prior to filling the joints andpouring the perimeter bondbeam, ensure the panels aresnug together.

Prior to filling the joints withgrout, remove all deleteriousmaterial from joints using com-pressed air. The joint reinforce-ment as indicated on the rein-forcement drawing must be

placed and secured prior to fillingthe joints. Moisten all joints priorto filling. Verify all joint reinforce-ment is fully covered by grout.

Clean the panel surface of anyloose material after joints andbond beam have set.

See Structural Design andConstruction Details Sectionsfor floor and roof panel details.

B. Installation of Floor and Roof Panels

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06/03 / VIII-4

AERCON floor and roof panels are installed using a crane and clamp.

All items presented in Sub-Section A are applicable.

AERCON non-load bearing wallpanels are attached to loadbearing construction such asconcrete or steel and can beoriented vertically or horizon-tally. The exterior supportcolumns must be plumb andtrue for proper erection of wallpanels. All wall anchor acces-

sories must be installed prior tothe erection of the wall panels.The base mortar joint must belevel and true prior to place-ment of the first panel.Immediately after placing thepanel, attach the wall anchor tothe superstructure and thepanel with the appropriate fas-teners as noted on the shopdrawings. The back face ofthe panel must be flush with

the face of the superstructure.Any gaps must be filled solidwith non-shrink grout.

The joint width indicated on theshop drawings shall be main-tained throughout the project.

Notching of the panel for erec-tion, due to the interferencefrom the wall anchor acces-sories, shall be accomplishedby recommended tools.

Use extreme care so as not todamage the bearing areas ofthe panel and the wall anchorconnection areas. All wallanchor fasteners must main-tain a minimum edge distanceof 2 1/2".

If the wall panels have a non-tongue and groove profile, thepanels must be mortaredtogether with AERCON mortar.

C. Installation of Non-Load Bearing Wall Panels

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VIII - Installation

Horizontal non-load bearingwall panels attached to a loadbearing superstructure; inthis case steel.

VIII - Installation

All items presented in Sub-Section A are applicable.

AERCON load bearing verticalwall panels are used to supportfloor and roof systems in singlestory or multi-story construc-tion. These panels can be usedfor exterior and interior walls.

The panels are erected utilizinga crane and lifting clamp andare placed in a mortar bed joint.

All vertical joints are mortaredtogether with AERCON thinbed mortar.

The panel erection should startfrom a designated corner of thebuilding. Provide temporarybracing as required to preventany incidental movements untilthe mortar has set.

See the Construction DetailsSection for panel details.

S e e i n f o r m a t i o n o nS u r f a c e Treatment forexpansion joint details, in theArchitectural Design Section.

D. Installation of Load Bearing Vertical Wall Panels

06/03 / VIII-6

Load bearing vertical wall panels are used to support floor and roof systemsin single story or multi-story construction.

An AERCON block wall will usu-ally consist of a variety of AERCON products, integratedtogether to create a completewall system that satisfies theproject requirements. Theinstallation process is basicallythe same regardless of the indi-vidual components. Blocks aretypically installed directly on afoundation system, but can alsobe installed on an elevated floorfor multi-story construction. Inboth conditions, the initial bedjoint is a critical element. Thebase mortar joint must be leveland true so that the constructioncan proceed with minimaladjustments. In order to provideadequate thickness for adjust-ment, the initial bed joint is usu-ally Type M or S mortar, 3/8 to1/2 inch in thickness. Headjoints in the starter course aremortared together with AERCONthin bed mortar. When thin bedmortar is used at a joint, it is tobe applied with a trowel havingthe proper style, teeth and widthto ensure coverage across theentire thickness of each block.

Lay successive courses plumb,level, and true to line, in runningbond with 8-inch lap (6-inchminimum) for standard blocks;

when cored block is used, lapshould equal the block thick-ness, in order to align the coresat the corners. Use thin bedmortar at all bed joints and forhead joints of flat face blocks.Tongue and groove blocks donot require mortar at the headjoints. Check each block as laidfor levelness and plumbness,making adjustments as requiredusing a rubber mallet, while themortar is still soft and plastic.

When necessary to accommo-date an odd dimension or con-figuration, blocks are to be cutwith an appropriate hand saw orband saw that is specially

designed for cutting autoclavedaerated concrete (AAC).Consider the layout of the wallbefore starting construction andinstall blocks in a manner thatminimizes cutting. Provide tem-porary bracing as required.

Cored blocks are used at speci-fied locations to provide a con-tinuous cell for a threaded rod ora reinforcing bar. If a threadedrod is used to resist overturningof a shear wall or to resist directuplift from a roof, the cell doesnot require grouting since therod is strictly a tension elementthat can be tightened to achievetautness for load transfer. If a

E. Installation of Blocks and Lintels

06/03 / VIII-7

VIII - Installation

Thin bed mortar should be applied with a trowel having the proper style,teeth and width to ensure adequate coverage.

Handling of AERCON PanelsAERCON panels must behandled carefully during trans-portation, storage and erection.As with any material, exercisecare to minimize damage andrepairs.

AERCON products must alwaysbe stored above the ground onwood blocking or pallets toprevent any discoloration anddamage to the panels due tocontact with the soil.

For unloading and erectingAERCON panels, appropriatelifting equipment must be used.

Pre-Erection Requirementsfor the Erection CompanyThe construction site must beprepared in accordance withthe applicable safety require-ments. All scaffolding andsafety equipment as requiredby OSHA shall be utilized.

If any panel is damaged suchthat the stability or integrity ofthe panel is compromised,then that panel shall be reject-ed and replaced with a newpanel in accordance with thespecifications.

The quantity, type, StrengthClass and dimensions of the

panels must be verified withthe shop drawings and siteconditions prior to erection.

RepairsAny minor damage to an AERCON panel which occursduring transportation or erectionand does not affect the overallstability or integrity of the build-ing can be repaired with AER-CON repair mortar in accor-dance with the manufacturer’srecommendations.

Field ModificationsErect the AERCON panels asdelivered to the job site. As anexception, the panels may becut as shown on AERCON shopdrawings or under certaincircumstances as directed by

an AERCON Representative.Field drilling of holes up to 4"in diameter is acceptable.However, the hole locationsand drilling procedure must notaffect the strength or stabilityof the panel. If holes that arerequired are not shown onAERCON shop drawings, anAERCON Representative shouldbe contacted prior to drilling.

All field modifications may beaccomplished using a drill,handsaw, c i rcu lar saw orrouter. The use of hammersand chisels is not acceptable.

Cold Weather ProtectionJoint repairs and patching ofpanels are not allowed if thepanel temperature is below 32°F.

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VIII - Installation

As with any material, exercise care to minimize damage and repairs.

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reinforcing bar is used, then thecell must be grouted to ensurethe rigidity of the bar during loadapplication and to provide a lapsplice when necessary. A rein-forcing bar in a grouted cell canfunction as a tie-down in addi-tion to increasing the flexuralstrength of the wall. A fineaggregate grout, with goodflowability, should be used to fillthe cells. The cells should bewetted prior to filling, and avibrator should be used duringthe filling process. Cored blockare installed in the same manneras standard block. At the basecourse, if a clean-out or inspec-tion port is required, the coredblock can be cut so that the corebecomes exposed to one side.If necessary, repair mortar canbe used to fill and seal the basecourse block where it was cut.

Filled U-blocks can be used asbond beam elements and as lin-tels. The U-shape is manufac-tured from standard blocks,which ensures dimensional andmaterial compatibility with othertypes of AERCON blocks andpanels. U-blocks are installedusing thin bed mortar for thebed joint and head joints.Typically two reinforcing bars

are inserted in the U-shapedcavity, one above the other (notside-by-side). The U-blocks arethen filled with a small aggregateconcrete mix to complete the U-block installation. Prior to pour-ing the concrete, the cavityshould be wetted to minimizethe absorption of water from thepoured concrete.

Solid, reinforced AERCON lintelsare installed in the same manneras standard blocks – mortaringthe bearing bed joints and thehead joints with thin bed mortar.Depending on the height of theopening that the lintel spansacross, a filler piece of blockmay be required to achieve thedesired bearing elevation; or theblocks that support the lintel canbe notched downward if thecoursing results in the bearingelevation being too high. Basedon their internal reinforcing,AERCON lintels are intended tobe installed in a particular orien-tation and are marked to indicatethat orientation. AERCON lintelsare not to be cut unlessauthorized by an AERCONRepresentative.

The large size of ValuBlocksenables more wall area to be

installed per block, expeditinginstallation, minimizing thenumber of blocks that are han-dled and minimizing the volumeof mortar that is needed.Depending on the size andweight of the ValuBlocks, a mini-crane and special lifting clampmay be required to lift and setthe blocks accurately. Use thinbed mortar at all bed joints andfor head joints of flat faceblocks. Tongue and grooveblocks do not require mortar atthe head joints. ValuBlocks canbe manufactured with coresand/or radiused edges. Whentwo radiused edge blocks areinstalled adjacent to each other,a cell is created, dimensionallythe same as the drilled cores.

Multiple configurations for inter-facing reinforcing bars and tie-downs at the foundation areavailable. Some are shown inthe Construction Details Section.These include epoxying into thefoundation to ensure accurateplacement, casting in a hookedanchor, and using an embeddedcomposite system.