Topcrete - JPA TL
CI/SfBFf2November 1997TopcreteDense aggregate concrete blocks3
TopblockTopcreteTopcretedense aggregate concrete blockshis brochure describesAll three types are available inRegular blocks are all available in‘Topcrete’ dense aggregateStandard grade and Paint Quality,face sizes of 440mm long 215mmconcrete blocks manufactured inwhilst solid units are also availablehigh and in thicknesses from 75 tothe UK by Tarmac Topblock.as SPW (Special Party Wall).215mm. A range of blocks with faceStandard grade units are suitable forsizes of 390 190mm can berender or plaster finishes whilst themanufactured to order.TThe physical characteristics ofTopcrete blocks make themparticularly suitable for a widerange of applications in bothloadbearing and non-loadbearingconstructions where good soundinsulation, durability and all roundstrength are required.Topcrete blocks are made in allthree types defined in BS 6073:‘Precast concrete masonry units’ as:finer surface texture of PaintQuality units is ideal for wallsintended to receive a direct paintSPW blocks are available 440mmlong 65mm high 195mm thick.finish. SPW units are intended forSpecial Topcrete blocks arethe construction of solid slendermade for coursing and forparty walls.forming reveals.Topcrete blocks are available in Coursing bricks are availablecompressive strengths of 3.5, 7.0,solid, Standard grade or Paint10.0, 15.0, 20.0 and 24.0N/mm2.Quality in strengths of 7.0N/mm2, solidand measure 215 65 100mm. Reveal blocks are available solid,Standard grade or Paint Quality, cellular (voids closed at one end)in strengths to match the hollow (voids open both ends)appropriate regular blocks.Intended to allow reveals to beconstructed without cutting, theyare L shaped and available inthicknesses of 100 or 140mm withcavity returns of 40 or 65mm.Topcrete blocks are also availablein a range of colours: see the‘Topblock Fair Face’ brochurefor details.2
TopblockToAuthorityApplicationQualityTopcrete blocks are suitable for –pcreteTopcrete products areBSI Kitemarked to BS 6073and are manufactured underWalls and partitions above ground:Standard grade & SPW for finishingwith render, cladding, plaster or drylining.a Quality Assurance SchemePaint Quality for direct decoration.complying with BS EN ISO9002. They conform to the‘Special Category ofWalls below ground:Standard grade & SPW for internal andManufacturing Control’external use including sulphate soilrequirements specified inconditions.BS 5628: Part 1.Beam and block flooring:IBS 6073Pts. 1 & 2RMintermediate floors in housing.FIREGSTStandard grade for ground floors andEREDCertificate No.F.M. 948Civil engineering:Standard grade for earth retaining andsound absorption purposes.St. James’ Park, Newcastle United Football Club – utilising Topcrete3
TopblockTopcreteTechnical DescriptionTopcrete blocks are available inHollow and cellular blocks providesolid, hollow and cellular formats.a good strength-to-weight ratioHollow units have voids open bothmaking them suitable for manyends, whilst cellular units havewalling situations.voids closed at one end.Material propertiesStandardgradePaint QualitySpecial PartyWall (SPW)7.0, 10.0, 15.0,20.03.5, 7.07.0, 10.024.03.5, 7.0–1900 – 20001800 – 19002000 – 21001.060.931.200.015 – 0.040.02 – 0.0450.03Vapour resistivity (MNs/gm)100 – 150100 – 150100 – 150Thermal movement (m/K)10 x 10-610 x 10-610 x 10-61.01.01.0Average compressive strength (N/mm2)– Solid block– Cellular & hollowNominal dry density, (kg/m3)Thermal conductivity at 3% moisture content (W/mK)Drying shrinkage to BS 6073: Part 1 (%)Specific heat capacity (kJ/kgK)Unit sizes & weights (face size 440 215mm)Unit weights 8.2––––––11.7–Block thickness (mm)Standard gradeSolidPaint QualitySolidSPWSolidNotes *SPW blocks have a face dimension of 440 x 65mmUnit weights, which are given for design purposes, are approximate only and based on 3% moisture content.Tolerance to BS 6073: Length 3/-5mm, Height 3/-5mm, Thickness 2/-2mm.The availability of Cellular and Hollow Paint Quality blocks should be checked with a Regional Sales Office.4
TopblockTopcreLaid weightsLaid weights including mortar (kg/m2)Wall �––––400–Standard gradeSolidPaint QualitySolidSPWSolidNotes Laid weights are approximate and taken at installed equilibrium moisture content.Unit sizes and weights of reveal blocksUnit weight (kg)Block Thickness (mm) Cavity return (mm)100 40100 65140 40140 65Full length 440mm19.920.927.228.2Half length215mm10.611.614.115.2Notes *Reveal blocks are available in higher strengths if requiredReveal blocks start the runningHalf lengthbond in each course and areCavity returnsupplied in pairs: each block is215mm high and a pair willprovide 450mm of wall height.Full lengthThicknessFull & half length reveal blocks5te
TopblockTopcretePerformanceFire resistance of wallsFireTopcrete blocks are non-Minimum thickness (mm)without finishcombustible and conform to class Orating for the surface spread ofFire resistanceflame. The fire resistance values1 hour2 hours4 hours6 hoursSolid blocksshown are in accordance withBS 5628: Part 3 or based on fireLoadbearing single leaf90100(150)(150)tests carried out in accordanceNon-loadbearing single leaf75100 (75)150 (140)200 (150)100100––140 (100)140 (100)150–with BS 476. The tabulated valuesare applicable to Standard gradeCellular & hollow blocksand Paint Quality blocks of anyLoadbearing single leafstrength. The application ofNon-loadbearing single leaffinishes will generally improvethe fire resistance. Further detailsDouble-leaf collar jointed with solid blocksare available.(tied together with metal tiesunless al mm*The thermal performance of eachNotes size and type of Topcrete block isshown according to its thermal Figures in brackets in Solid Blocks section denote the fire resistance ofTopcrete blocks utilising Class 1 Limestone aggregates duringmanufacture. These are available from certain factories only, andshould be specified when their use is essential in meeting the requiredfire resistance.* Blocks tied together with BRC Bricktie CF140.resistance (measured in m2K/W).These values should be used whencalculating the U-value ofThermal resistance valueswalls built with TopcreteThermal resistance (m2K/W)blocks. For convenience theU-values of a range ofBlock thickness (mm)100140150190200215typical wall constructionsStandard grade– solid0.090.130.140.180.190.20– cellular0.150.20––––– hollow–––0.23–0.25– solid0.110.150.160.200.220.23– cellular0.170.21––––– hollow–––0.25–0.27are featured in the Designsection of this brochureunder ‘External walls’.Paint QualityNotes All thermal resistance values are based on 3% standard moisture content. The valuesfor cellular and hollow blocks have been calculated in accordance with the CombinedMethod given in the CIBSE Guide A3 ‘Thermal properties of building structures’6
TopblAcousticockTopcreteSound reduction valuesAn assessment of the soundWeighted sound reduction index, Rw (dB)insulation performance of TopcreteFinishwalls is given in decibels in termsNo finishLightweightplasterDenseplasterDryliningof the weighted sound reductionSingle leaf wallindex, Rw. The index covers the75mm solid4446474790mm solid46474848Durability100mm solid47484948Topcrete blocks laid with a suitable140mm solid505152515628: Part 3 are durable in150mm solid51525252external and internal walls above190mm solid53545454215mm solid54555555blockwork in exposed and100mm cellular45464746aggressive conditions may be140mm cellularor hollow46515251‘Topblock Design Guide’. When215mm hollow50535453designed and laid in accordanceNotesfrequency range of 100 to 3150Hz.mortar in accordance with BSand below ground. More detailedadvice on the use of Topcretefound in a separate brochure, thewith the relevant codes of practiceTopcrete blockwork will have a Finishes to walls are assumed to be applied to both faces.The performance values of walls with finishes is applicble to Standard gradeand Paint Quality blocks. The performance of walls with no finish assumes theuse of Paint Quality blocks.normal service life equivalent tothe life of the building.Resistance tomoistureMoisture in Topcrete block wallsdoes not adversely affect theirstrength. Provision must be madeagainst water penetration of thewall and against rising damp asrequired by Building Regulationsand Standards.Alpha (UK) Ltd, Milton Keynes – utilising Topcrete7
TopblockTopcreteDesignFull design details for the completeIn a single leaf wall the minimumFor further advice on this subject,range of Topblock products can bethickness of Topcrete, with orincluding a more extensive rangefound in the ‘Topblock Designwithout rendering may beof U-values, refer to the ‘TopblockGuide’. The following points applyselected from BS 5628: Part 3.Design Guide’.specifically to the Topcrete range.Thermal insulationData on insulation material isTopcrete can be used in manyExternal wallsIn cavity walls Topcrete may beused for either leaf, normally with aways to meet the thermalinsulation requirements ofbuilding regulations.minimum leaf thickness of 90mm.Illustrated opposite are several ofWhen used for the outer leaf,ways of achieving wall U-values ofTopcrete should be rendered or0.45W/m2K or better. The U-valuesclad. When the cavity is not to beapply to solid and cellular blocks.filled with insulation a clear cavityof nominal 50mm width should bemaintained, excluding the thicknessof any insulation.MAFF Headquarters, York – utilising Topcrete8correct at time of publication butmay be subject to change. Pleasecontact manufacturers for details.
TopblockTopcreteBrickwork outer leaf(or rendered Topcrete)Full cavity fill –Insulationbrickwork outer leaf insulation 100mm Topcrete surface finish100mmTopcreteU-Values (W/m2K) Surface finishi.e. Paint Quality BlocksDenseplasterLightweightplasterDryliningon dabs65mm CrownDritherm batts0.430.430.420.4065mm Rockwoolcavity wall batts0.450.450.440.420.450.450.440.42No finish70mm blownmineral woolλ 0.039SurfacefinishFull cavity fillBrickwork outer leaf(or rendered Topcrete)Partial cavity fill –Insulationbrickwork outer leaf cavity insulation 100mm Topcrete surface finish100mmTopcreteU-Values (W/m2K) Surface finishi.e. Paint Quality BlocksDenseplaster29mm CelotexCW20000.440.430.42*0.4440mmWallmate CW0.450.450.440.42No finishNotes Lightweight Drylining onplasterdabsSurfacefinish*25mm of Celotex requiredPartial cavity fill50mm residual cavityBrickwork outer leaf(or rendered Topcrete)Clear cavity –100mmTopcretebrickwork outer leaf cavity 100mm Topcrete surface finishU-Values(W/m2K)40mm Gyproc Thermal BoardSuper (R 1.73)0.4150mm Gyproc Thermal BoardPlus (R 1.56)0.44Insulateddry liningClear cavityProfiled steel cladding –Steel claddingsteel cladding insulation 100mm Topcrete surface finishInsulationSurfacefinishU-Values (W/m2K)100mmthickness140mmthickness33mm CelotexCW20000.42*0.4550mmWallmate CW0.400.4060mmRockwool HP0.440.43Block thicknessNotes Profiled steelcladding*29mm of Celotex required100mm Topcrete9
TopblockTopcreteDPCThermal bridgingApproved Document L requiresSealBrickworkouter leafprovision be made to reducethermal bridging around windows,Framedoors and other wall openings. OneInsulationway of achieving this is to close theTopcretecavity with blockwork and aninsulated DPC or similar.SurfacefinishBlockwork provides a substantialRecessed frameInternalwindow boardbackground to which door andwindow frames can be fixed. TheDPCSealdimensions of the blockwork returnshould be assessed taking intoBrickworkouter leafFrameaccount the required cavity width,any insulating material and anallowance for the thickness of theDPC and any mortar. FurtherInsulationTopcreteguidance can be found in BREInformation Paper IP 12/94.Surfacefinish215mmFlush frameInternalwindow boardThe use of Topcrete reveal blockscan assist with accurate closingof the cavity.Internal wallsTopcrete may be used for singleleaf or cavity internal walls with orwithout finishes depending uponthe application.For partitions in dwellings Topcretemay be used to provide soundinsulation as well as a suitablebackground for finishes andfor fixings.For commercial and industrialapplications Topcrete may be usedto provide sound insulation, fireresistance and resistance to impactdamage. Topcrete Paint Quality isParty wallsThe Building Regulations requiredomestic party walls to resist thetransmission of airborne sound.To meet that requirement thefollowing Topcrete wallspecifications may be used. A 215mm solid wall consisting of100mm Topcrete Standard solidblocks laid flat and finished with215mmsolid walleither 13mm plaster or 12.5mmdrylining on both room faces.195mm A 195mm solid wall consisting of195mm Topcrete SPW blocks, andfinished with either 13mm plasteror 12.5mm drylining on bothroom faces.suitable for direct decoration.195mmsolid wall10
TopblockTopcrete Two leaves of 100mm TopcreteScreedStandard solid blocks with a50mm cavity using butterfly typewall ties, and finished with 13mmplaster on both room ncrete slab250mmHardcore withsand blindingTopcreteStandard blockTopcrete blocks below DPCBelow DPC250mmcavity wall50mmminimum cavityBeam and blockflooringTopcrete blocks may be used toconstruct internal and externalTopcrete blocks may be usedwalls below ground. These blocksas infill units in beam and blockare suitable for use in sulphate soilflooring for ground andTest evidence to support the useconditions class 1 to 3, as definedintermediate floors in housing.of Topcrete cellular blocks with ain BRE Digest 363 (according to75mm cavity, and Topcrete solidresearch conducted by theblocks with a drylined finish isConcrete Block Association).available on request.When tested under transverse loadthe blocks will support a point loadof 3.5KN over a 420mm clear span.For further advice on this subject,The Approved Document shouldand on durability refer to thebe consulted for full compliance‘Topblock Design Guide’.details including associated flankingConcretefloor beamwall construction. Unless theScreedconstruction is strictly inaccordance with the abovespecification, it is recommendedBuilding Regulation approval beobtained before work commences.Topcrete flooring blockTimber battensPlasterboardTypical Topcrete beam &block intermediate floor11
TopbFor this application TopcreteStandard 7.0N/mm2 strength solidblocks may be used. Alternatively,Topcrete Cellular Blocks(7.0N/mm2) may be consideredalthough it is recommended thatsolid blocks be used at the floorperimeter to provide a solid bearingfor any walls supported by the floor.lockToProvision formovementpcflat tieto alternatecoursesMovement joints should beretejoint fillerprovided in accordance withBS 5628: Part 3 generally atintervals of 7 - 8m. Movementjoints are not usually necessaryto internal walls in dwellings. Toareas of concentrated stress, suchThe use of beam and block flooringas above and below openings,systems for intermediate floors inconsideration should be givensingle occupancy dwellingsto the introduction of bed jointprovides enhanced sound insulationreinforcement. Further guidancebetween floors and permits acan be obtained fromflexible blockwork partition layoutBS 5628: Part 3 and the ‘Topblockat upper floor level. The use ofDesign Guide’.Sealant asrequiredTypical movement jointblockwork for upper floor partitionswill assist in reducing airbornesound transmission between rooms.MortarAdvice on the specification ofThe mortar type should be selectedFor reinforced blockworkTopcrete blocks in separatingtaking into account durability,applications and high strengthfloors between dwellings isstructural strength and provisionloadbearing walls, stronger mortaravailable on request.for movement.mixes may be required and expertFor work above ground level DPC,Civil engineeringmortar designation (iii) willTopcrete cellular blocks laid flat,ground level mortar designation (iii)with voids exposed, may be usedor (ii) may be used in accordanceto line road underpasses for soundwith BS 5628: Part 3.advice should be sought.normally be satisfactory. Belowinsulation control andaesthetic purposes.Suggested mortar mixesWhen used to form permeableMortar designation inaccordance withBS 5628: Part 3Locationbacking to earth retaining structureshollow blocks should be specified.Above ground –internal orexternal wallsBelow groundNotes Mortar type by volume(iii)*1:1:5-6 cement: lime: sand1:4-5 masonry cement: sand1:5-6 cement: sand withapproved plasticizer(iii)as above(ii)**1:1/2:4-41/2 cement: lime: sand1:21/2-31/2 masonry cement: sand1:3-4 cement: sandwith approved plasticizerSand should comply with BS 1200Sulphate resisting cement may be used below ground inappropriate sulphate levels as specified by the designer12
TopbFinishesWhen used externally TopcretelockTopcreteSpecificationcan be finished withweatherboarding, tile hangingor render: internally TopcreteBlockwork to:(state location)Blocks to BS 6073: Pts 1 & 2Topcrete dense aggregatecan be plastered or drylined.Topcrete Paint Quality blocksare suitable for direct painting.concrete blocksHandlingThe repetitive one-personManufacturer:Tarmac Topblock LimitedType:*Solid *Cellular *HollowGrade:*Standard grade *Paint Qualityhandling of heavy weights hasbeen identified as posing a riskof injury (see Health and SafetyExecutive Construction sheet37). Some constructions mayrequire the use of blocks*SPWexceeding 20kg in weight;appropriate handling methodsshould always be specified Average compressive strength:when such blocks are used.*3.5N/mm2 *7.0N/mm2 *10.0N/mm2*15.0N/mm2 *20.0N/mm2 *24.0N/mm2For further advice on thissubject refer to the ‘TopblockDesign Guide’.Shape and dimensions:Regular block:440mm long 215mm high mm thickParty wall block:440mm long 65mm high 195mm thickCoursing brick:215mm long 65mm high 100mm thickReveal block:440mm or 215mm long *100mm or*140mm thick 215mm high with acavity return of *40mm or *65mm.* delete as applicable Not all strengths are available in all grades: please refer to material properties table.13
TopblockTopcreteSiteworkDelivery and storageLayingTopcrete products are packed inDetailed requirements for layingbanded or fork-lift packs, andblocks are given in BS 5628: Part 3delivered by crane off-load vehicles.and BS 8000: Part 3. The principleTopcrete Coursing bricks to formPacks can be shrink-wrapped orpoints are:small areas of walling, such as Set out the blockwork to maintainbeam filling between joists orpalletised to facilitate site handlingif required; specify specialrequirements when ordering.Topcrete blocks should be stored onfirm, level ground, clear of standingwater, and be protected bywaterproof sheeting against Provide a full block bearinga regular bond pattern, with aminimum bond of 1/4 of a block. Lay cellular blocks with the closedavailable on request.Whilst Topcrete blocks can becut with a hammer and bolster,mechanical cutting with a hydraulicof mortar.be observed:cross joints as work proceeds. Hollow blocks may only beshell bedded with the Remove all excess mortar andtool joints as work proceeds. Ensure proper curing of themortar by protecting new wallingagainst rapid drying, keep the wallis recommended. When blocks aremoistened with damp hessianwet cut they should be allowed toand/or polythene sheeting indry before being built into the wall.windy or hot weather.of 140mm thickness and aboveinclude a small proportion of blockswith pre-formed slots to facilitatethe cutting of half-length units.The use of coursing bricks andreveal blocks can greatly reduceworkmanship required forthe following guideline
BS 6073 Pts. 1 & 2 Application St. James’ Park, Newcastle United Football Club – utilising Topcrete T opblock T opcr ete Topcrete blocks are suitable for – Walls and partitions above ground: Standard grade & SPW for finishing with render, cladding, plaster or drylining.
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