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THE BASICS
Disclaimer
The figures and photos in this manual are for illustration purposes only and are not intended to reflect conditions on your construction site, OSHA regulations, or requirements of local jurisdictions.
Change History
Version 1.0 1.1 Date January, 2007 August, 2007 Author L. LaManna; C. Thoen C. Thoen Description Original Additions, corrections
APEX CONSTRUCTION SYSTEMS, INC. Building with the APEX Block Interlocking System The Basics
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TABLE OF CONTENTS
1. WHY BUILD WITH APEX BLOCK? .............................................................................. 1
1.1. 1.2. 1.3. Advantages over Traditional ICF .................................................................................................. 1 Advantages over Masonry Block................................................................................................... 1 Excellent Test Values .................................................................................................................... 2
4.10. Rebar Specifications .................................................................................................................... 25 4.11. Preparing the Rebar ..................................................................................................................... 25 4.12. Placing the Rebar ......................................................................................................................... 25 4.13. Stabilizing the Blocks Prior to Grouting...................................................................................... 26 4.14. Adding Ledgers ........................................................................................................................... 27 4.14.1 Ledgers for Floors ......................................................................................................... 29 4.14.2 Installing Wood Flooring .............................................................................................. 31 4.14.3 Ledgers for Flat Roofs ................................................................................................... 31 4.15. Accounting for Plumbing ............................................................................................................ 32 4.16. Insert Vertical Rebar .................................................................................................................... 34 4.17. Preparing to Pour the Grout ......................................................................................................... 34 4.18. Pouring the Grout ........................................................................................................................ 35 4.19. Adding Wall Top Plates .............................................................................................................. 36 4.20. Wrapping Windows ..................................................................................................................... 38 4.21. Installing Electrical ...................................................................................................................... 38 4.22. Removing Bracing ....................................................................................................................... 40 4.23. Exterior Finishes .......................................................................................................................... 41 4.23.1 4.23.2 Stucco ............................................................................................................................ 41 Rock or Brick Veneer .................................................................................................... 42
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TABLE OF CONTENTS
4.24. Interior Finishes ........................................................................................................................... 42 4.24.1 4.24.2 Dry Wall ........................................................................................................................ 42 Plaster ............................................................................................................................ 42
LIST OF FIGURES
FIGURE 1: APEX BLOCK TONGUE-AND-GROOVE SHAPING ........................................................................ 1 FIGURE 2: APEX BLOCK ISOMETRIC VIEW ................................................................................................. 3 FIGURE 3: APEX BLOCK PLAN VIEW .......................................................................................................... 3 FIGURE 4: APEX BLOCK EDGE VIEW ......................................................................................................... 3 FIGURE 5: APEX BLOCK SIDE VIEW .......................................................................................................... 3 FIGURE 6: REBAR PLACEMENT IN FOUNDATION ............................................................................................. 5 FIGURE 7: FOAM ADHESIVE LABEL DETAILS ................................................................................................. 7 FIGURE 8: FIRST COURSE OF BLOCKS ............................................................................................................. 8 FIGURE 9: FIRST COURSE OF BLOCKS, VERTICAL AND HORIZONTAL ............................................................... 8 FIGURE 10: REBAR BENT TO MEET GROUT CHANNELS .................................................................................. 8 FIGURE 11: WALL WITH SHIMS IN PLACE ....................................................................................................... 9 FIGURE 12: BLOCKS MODIFIED FOR CORNER ................................................................................................10 FIGURE 13: CORNER BLOCKS TOGETHER .......................................................................................................10 FIGURE 14: DETAILS OF CORNER CAVITY .....................................................................................................10 FIGURE 15: HORIZONTAL REBAR BENT AT CORNER ......................................................................................11 FIGURE 16: CREATING A CORNER ..................................................................................................................11 FIGURE 17: INSTALLING METAL STAPLES .....................................................................................................12 FIGURE 18: CORNER WITH STAPLES ..............................................................................................................12 FIGURE 19: WALL WITH STAGGERED SEAMS.................................................................................................13 FIGURE 20: VERTICAL REBAR PLACEMENT AT OPENING ...............................................................................14 FIGURE 21: WINDOW OPENING UNDER CONSTRUCTION ...............................................................................15 FIGURE 22: CREATING A GROOVE IN THE END OF A BLOCK ..........................................................................15 FIGURE 23: 2X6 LUMBER EMBEDDED AT OPENING .......................................................................................16 FIGURE 24: COUNTERSINKING LAG BOLTS INTO BUCKING............................................................................16 FIGURE 25: SMOOTHING BLOCKS, BOTTOM OF OPENING ...............................................................................17 FIGURE 26: BLOCK MODIFIED FOR LINTELOVER OPENING ............................................................................17 FIGURE 27: BOXED SUPPORT OF BLOCKS OVER LINTELS...............................................................................18 FIGURE 28: ADDITIONAL REBAR OVER OPENING ..........................................................................................18 FIGURE 29: BOND BEAM DETAILS .................................................................................................................19 FIGURE 30: SUPPORTED OPENING..................................................................................................................19 FIGURE 31: BRACING WALLS INTERIOR AND EXTERIOR .............................................................................19 FIGURE 32: PREPARING A BRACING BOARD ...................................................................................................20 FIGURE 33: BRACING STRIP GLUED TO WALL ...............................................................................................20 FIGURE 34: CORNER BRACED PRIOR TO POUR...............................................................................................21 FIGURE 35: FOUNDATION FOR CURVED WALL ..............................................................................................21 FIGURE 36: CUTTING A BLOCK FOR A RADIUS ...............................................................................................22
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TABLE OF CONTENTS
FIGURE 37: BLOCKS CUT FOR CURVED WALL ...............................................................................................23 FIGURE 38: CURVED WALL, FIRST COURSE OF BLOCKS INSIDE VIEW ........................................................23 FIGURE 39: CURVED WALL, FIRST COURSE OF BLOCKS OUTSIDE VIEW ....................................................23 FIGURE 40: COMPLETED CURVED WALL .......................................................................................................24 FIGURE 41: INTERSECTION OF CURVED WALL TO STRAIGHT WALL ..............................................................24 FIGURE 42: DETAIL OF REBAR PLACEMENT INTERSECTION OF CURVED AND STRAIGHT WALLS ...............25 FIGURE 43: PLACING HORIZONTAL REBAR....................................................................................................26 FIGURE 44: REINFORCEMENT OF MODIFIED BLOCKS OVER DOORWAY .........................................................27 FIGURE 45: LEDGER PREP - HOLES FOR JBOLTS .........................................................................................27 FIGURE 46: LEDGER PREP J BOLTS WITH PLYWOOD SQUARES IN PLACE ................................................28 FIGURE 47: LEDGER PREP J BOLTS WITH PLYWOOD REMOVED, AFTER GROUT POUR.............................28 FIGURE 48: WOOD LEDGER INSTALLATION ....................................................................................................29 FIGURE 49: LEDGER INSTALLED ....................................................................................................................29 FIGURE 50: JOISTS INSTALLED ON LEDGER ....................................................................................................29 FIGURE 51: EXTERIOR WALL WITH FLOOR JOIST AND LEDGER .....................................................................30 FIGURE 52: INTERIOR WALLS WITH LEDGERS AND FLOOR JOISTS .................................................................31 FIGURE 53: LEDGER FOR FLAT ROOF ............................................................................................................32 FIGURE 54: PREPARING THE BLOCKS FOR PLUMBING ....................................................................................33 FIGURE 55: PLUMBING PIPES INSTALLED IN WALL........................................................................................33 FIGURE 56: EXTERNAL PLUMBING FIXTURE IN WALL ...................................................................................34 FIGURE 57: POURING THE FIRST LIFT OF GROUT ...........................................................................................35 FIGURE 58: WALL PLUG AFTER POURING GROUT..........................................................................................36 FIGURE 59: TOP PLATE INSTALLATION ..........................................................................................................37 FIGURE 60: INSTALLED TOP PLATE ................................................................................................................37 FIGURE 61: GABLE END DETAIL ....................................................................................................................38 FIGURE 62: TRUSS CONNECTION AT WALL ...................................................................................................38 FIGURE 63: PREPARING FOR ELECTRICAL ......................................................................................................39 FIGURE 64: CUTTING GROOVES FOR ELECTRICAL WIRING............................................................................39 FIGURE 65: WALL WITH GROOVES AND CAVITY FOR ELECTRICAL ...............................................................40 FIGURE 66: ELECTRICAL BOXES AND WIRING IN PLACE ................................................................................40 FIGURE 67: ELECTRICAL UTILITIES INSTALLED .............................................................................................40 FIGURE 68: SMOOTHING THE EXTERIOR SURFACE OF THE WALL ..................................................................41 FIGURE 69: CONNECTING APEX BLOCK INTERIOR WALLS .......................................................................43 FIGURE 70: INSTALLING A NAILER FOR INTERIOR FIXTURES .........................................................................44
LIST OF TABLES
TABLE 1 FOUNDATION REQUIREMENTS .......................................................................................................... 4 TABLE 2 TOOLS FOR WORKING WITH APEX BLOCK ................................................................................... 5 TABLE 3 STANDARD RADIUS CHART..............................................................................................................22
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Figure 1: APEX Block Tongue-and-Groove Shaping Easy handling: Improved size and reduced weight ease handling and assembly, Less gluing: The APEX Block Interlocking System significantly reduces the use of glue to keep the blocks in place, saving effort, time, and materials. Ideal reinforced grid spacing: In APEX Block, the reinforced, 6-inch diameter concrete grout channels are placed at 16-inch-on-center intervals, the standard framing spacing in the U.S. Optimum use of concrete: Improved design of reinforcement channels eliminates overuse of concrete while optimizing strength. Consistent size, shape, and weight: Advanced production techniques and strict quality control mean that APEX blocks have a consistent size, shapes, and weight. You can count on APEX blocks to meet specs and to fit together snugly, for easy stacking.
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Level and plumb before grouting: Youll keep the walls level and plumb as you stack the blocks, using small amounts of foam glue to help keep them stable and occasionally using shims to ensure the blocks are level and plumb.
1.3. Excellent Test Values
In independent testing, APEX Block achieves excellent thermal insulation, acoustical insulation and fire resistance values. Thermal Value Insulation: Structures built with APEX Block has proven to save owners and occupants up to 50% on their energy bills. Our initial R-Value test results on our block alone were astounding. We are currently awaiting our latest Thermal Value test results for ASTM C1363 which will provide us with an R-Value rating for a finished APEX Block wall assembly. We expect to have these results by January 08. Sound Insulation: Our acoustical-insulation test results of -55.5 db, per ASTM E90/C634, is an excellent rating that is praised by our customers and occupants. Fire Resistance: Per ASTM E84 test results, APEX Block was given a 3-hour fire resistance rating. (The actual results for this test was 3 hours 53 minutes.) Refer to Appendix A for detailed test results.
2.
APEX Blocks are made of a mixture of recycled expanded polystyrene (EPS), cement, water, and bonding agents. As shown in Figures 1, 2, and 3, our blocks have a precision tongue-and-groove design to allow for a more secure placement of the blocks. The 6 inch diameter, round grout channels are placed 16 inches on center (16 OC) and run horizontally and vertically through each block. Each block is one solid piece, the grout channels pass through the middle of the block, not at a seam, creating secure pathways for the grout.
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AWS-10 Standard APEX Block 48" H x 16" W x 10" D , approx. 55 lbs. Channel spacing for inner reinforced concrete grid is set on the industry standard of 16 inch OC (vertically and horizontally). Red fill shown here represents channel for reinforced concrete pour.
Figure 2: APEX Block Isometric View Figure 3: APEX Block Plan View
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ASTM A615 Grade 60 deformed steel reinforcement bars are used Rebar spaced 16 in. on center, to match grout channels in blocks Openings are specified Two pieces of rebar are placed on either side of any opening, as shown in Figure 6. Rebar extends at least 24 inches above the foundation
Vertical rebar must be minimum No. 4 and must comply with Section 1907 of the IBC. If the construction is based on the IRC, reinforcing steel must comply with IRC Section R611.6.2. If slightly out of position, bend to re-position per Figure 10. Be sure that you know where all planned openings are in relation to the foundation, and mark them on the slab or stem wall as needed. If rebar is missing, drill through the slab with a roto-hammer and epoxy a piece of rebar in place Foundation rebar must extend into the wall panel a minimum of 24 inches or a distance determined in accordance with IBC Section 1901.2 (normally 22 times the diameter of the rebar as mandated by code) whichever is greater. If rebar is too short, drill through the slab with a roto-hammer and epoxy a
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NOTE: You can use APEX Block for a below-grade wall. In this case, be sure to install appropriate waterproofing on the exterior below-grade surface of the blocks.
Skilsaw
Make precise cuts in APEX Block. Cut lumber for framing and bracing.
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Use Cut round holes in blocks Cut or shape blocks by hand Make rough cuts in APEX Block. Scribe areas where small openings are needed, such as holes for electrical boxes Gouge out scribed areas Cut rebar to length Smooth the surface of blocks
Description 4-in. and 6-in. round hole-saw blades Stiff saw blade, 36 inches long with 3-4 teeth per inch
Metal wheel on Skilsaw, hack saw, or rebar cutter Custom made; weld a 6x8-in piece of open diamond-grid grating to a frame and handle.
Staples
Tie blocks together at corners Tack blocks to the foundation and repair small breaks in the blocks.
Custom made; 1/8-in.-thick steel, 1-in.wide; right-angle bends on each end, points on tips, as shown in Figure 17. Glue gun, low-expansion, high-yield foam adhesive, and cleaner of the same general type as shown here.
Glue gun, glue canisters, and gun cleaner canisters. See NOTE below.
Concrete scraper
Scrape off excess grout, flatten top surfaces of wall, clean up slab, scrape off glue 14-in. blade
Lumber
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IMPORTANT:
Use only foam adhesive that has been designed for use with Insulated Concrete Forms (ICF). Figure 7 shows close-ups of the labeling on a canister of the correct type of foam adhesive.
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Figure 8: First Course of Blocks As shown in Figure 9, you can place the blocks horizontally, vertically, or in combination, keeping the vertical grout channels aligned with the rebar.
Figure 9: First course of blocks, vertical and horizontal 2. If necessary, bend the rebar to align with the grout channels, as shown in Figure 10.
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3. Place the next block beside the first, ensuring that the rebar fits into the grout channels and that the tongue-and-grove shaping on the two blocks is snug. 4. Continue placing blocks along the wall, ensuring that the blocks are square, straight, and plumb. 5. Use wood shims to level or plumb APEX Blocks, as shown in Figure 11.
Figure 11: Wall with Shims in Place a. Gently tip up the block and place the shim. b. Do not drive the shim into the joint; this will only crush the block as opposed to raising it. c. Leave the shims in place until 48 hrs after you have poured the grout. d. Cut off or pull out the shims. 6. Account for any doors or windows as you place the blocks. a. Build around openings by cutting or shaping the APEX Blocks to the right length. b. Fill any gaps between blocks with low-expansion high-strength foam adhesive, so the block cant tip or move. c. Allow the glue to dry for 30 minutes before stacking another course of blocks on top. NOTE: If necessary, you can cut openings out of the APEX Block wall after youve built the wall (but before youve placed the rebar or poured the grout). This might be necessary, for example, if a window has been missed during layout or has been moved after the plans were completed. However, try to avoid cutting parts of a wall away after construction, as this wastes time, materials, and money.
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2. Bend a piece of rebar at least 48-inches long at a right angle at the mid-point and place one end in the horizontal grout channel of the first block. 3. As you place the next block (around the corner) slide the bent rebar into the horizontal grout channel in that block. Figure 15 and Figure 16 show the resulting corner.
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NOTE: The string shown in this figure is a line level to ensure that the wall is straight.
Figure 16: Creating a Corner You can also construct a corner by mitering the corner and hollowing out a cavity between the two blocks. If you choose this method, you must be sure that there is a grout cell in the corner, where the diagonal cut of the two blocks meet. However, APEX recommends that you use the method described in Section 4.2, as this creates a much stronger corner. NOTE: If you forget to place rebar in a corner as you lay the blocks, you can use your Sawzall to cut a groove into the APEX Blocks, reaching into the grout channel, to place the rebar after the corner is constructed. 4. Secure the corner blocks with staples on the outside of the corner. Figure 17 illustrates the placement of staples at corners, and Figure 18 illustrates the resulting corner.
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Figure 18: Corner with Staples 5. Before pouring the grout, brace the corner as described in Section 4.8, Bracing the Walls. NOTE: Be sure to place horizontal rebar as you work along the wall, and before you build the next corner. Otherwise, the next corner will cap off that length of the wall, and youll have no easy way to insert the rebar.
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Figure 19: Wall with Staggered Seams Whether you align the seams or not, KEEP THE GROUT CHANNELS LINED UP. Use your Sawzall to cut the blocks to the correct length as needed. Maintain a consistent tongue-and-groove pattern throughout the wall, with the groove end of each new block installed at the tongue end of the previous block. Maintain a smooth, level surface on the inside of the wall. Although APEX blocks are very consistent in size, they may not always be perfect. Place the blocks so that any variance in width appears on the outside of the wall. You can use your rasp to smooth the outside surface of the blocks before applying an exterior finish. After you shim and level your blocks, apply small amounts of foam adhesive between the blocks to tack them in place. This will help keep them square, straight and plumb, and will keep them from shifting before or during the grout pour. NOTE: If you forget to place straight horizontal rebar into any course of a wall until after the wall is completed, you can cut a small hole in one end block and thread the rebar into the horizontal grout channel.
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Figure 21: Window Opening Under Construction NOTE: You may need to shorten some of the blocks to make them the correct length around the opening. If you do, be sure to keep the grout channels aligned. For windows, follow these steps: 1. Stack the blocks to account for the window, ensuring that the grout channels are aligned on each side of the opening, and over the opening (as though the opening were not there). 2. As shown in Figure 22, make a groove on the ends of the blocks on the inside of the opening, at the sides and on the top (not along the bottom of the opening).
Figure 22: Creating a Groove in the End of a Block 3. Inset 2x6 lumber in the grooves on each side of the opening, as shown in Figure 23.
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Figure 23: 2x6 Lumber Embedded at Opening 4. Lead in the bucking on the sides of the opening, using 6-inch hardened-steel lag bolts. a. Drill a pilot hole for each lag bolt b. Drill a countersink hole, so the lag bolts can be inserted flush with the bucking. c. Insert the lag bolts.
Figure 24: Countersinking Lag Bolts into Bucking 5. As shown in Figure 25, use your rasp to smooth any rough spots after cutting the tongue off the blocks at the bottom of the opening. This will provide a flat surface for your window framing.
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Figure 26: Block Modified for Lintelover Opening 2. To reinforce the bottom of the blocks forming the lintel over an opening, build a boxed support as shown in Figure 27. This will provide support for the blocks when the grout is poured, and provide a solid bottom for the grout channel.
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Figure 27: Boxed Support of Blocks over Lintels NOTE: If necessary, you can remove ALL of the APEX material from the center of the blocks when creating a bond beam, leaving only the two side walls. Make sure that you brace these portions of the wall using one or more of the methods described in Section 4.8.
3. Place additional rebar in the grout channel for the header, as required by engineering specs. Figure 28 shows rebar placement in a lintel over a door.
Figure 28: Additional Rebar Over Opening The photos in Figure 28 show a skeleton view of the extra rebar needed in all lintels as it would be placed through blocks over an opening. One block is missing here, so you can see how you would overlap the rebar and how you would place multiple pieces of rebar to reinforce the span. If the height of the opening causes the lintel to fall in the middle of the block, create the opening for the additional concrete and rebar in the upper half of the block, as shown in Figure 29.
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Figure 29: Lintel Details 4. Create adequate support for the opening prior to grouting, using vertical and horizontal bracing as needed, as shown in Figure 30.
Figure 30: Supported Opening Create a reinforced lintel over any span greater than 8 feet long. Refer to Section 4.13 for instructions on reinforcing blocks that you have modified for long spans.
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To brace parts of the wall that have no existing exposed lumber, you can glue a strip of lumber to the wall to seat a bracing board. Follow these steps: 1. Hammer three nails through a short piece of 2x4 lumber at the bottom, middle, and top, so that the nails extend through the board. 2. Apply adhesive foam to the board, as shown in Figure 32.
Figure 32: Preparing a Bracing Board 3. Press that lumber directly to the surface of the blocks. 4. Place your brace against that wood strip.
Figure 33: Bracing Strip Glued to Wall Figure 34 shows a corner fully braced prior to pouring the grout.
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Figure 35: Foundation for Curved Wall Follow these steps to create a curved wall: 1. Set the blocks on the vertical. 2. Cut angles from the tongue edges of blocks, per the standard radius chart in Table 3. Youll lose most, if not all, of the tongue-and-groove shaping on the inside edges of the block.
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10'-0"
0.62
Figure 37 shows block cut and ready for use in a curved wall.
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Figure 37: Blocks Cut for Curved Wall NOTE: Use your rasp to smooth the outside surface of the curved wall, where the blocks meet. Figure 38 shows the first course of blocks in a curved wall, from inside the structure.
Figure 38: Curved Wall, First Course of Blocks Inside View Figure 39 shows the same wall from the outside, with a straight wall extending to the right side of the curved wall.
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Figure 40 shows a completed curved wall, with two rows of blocks, prior to grouting.
Figure 40: Completed Curved Wall 3. As with any corner, bend the rebar to match the curve and thread it into the grout channel as you add blocks to the wall. Figure 41 shows the intersection of a curved wall and a straight wall.
Figure 41: Intersection of Curved Wall to Straight Wall Figure 42 shows a detail of rebar placement at the intersection of a straight wall to a curved wall.
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Figure 42: Detail of Rebar Placement Intersection of Curved and Straight Walls
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Theres usually no need to tie the rebar the vertical rebar can fall as it does; the horizontal rebar can rest on the bottom of the horizontal cells. However, if required by code or engineering specs, you can easily tie the rebar so that it remains in the center of each grout channel: lay another piece of rebar along the top of the row of blocks prior to pouring the grout, and use wire to tie the vertical rebar to the rebar along the top. Ensure that vertical rebar is 2 inches shorter than the very top of the wall (so that none extends beyond blocks at the top). Ensure that there is a 2-foot overlap for any splice. Lap splices for reinforcement must comply with IBC Section 1923 or IRC Section R611.7.1. NOTE: Remember that if you are placing rebar and you have not reached final wall height, then the rebar must extend a minimum of 24 inches above the current course of blocks. Figure 43 shows a builder placing horizontal rebar in a section of a wall.
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6. Use this wire to secure a small piece of rebar on each side of the reinforcement, by twisting the wire to hold the rebar in place, as shown in Figure 44.
Figure 45: Ledger Prep - Holes for Jbolts 2. Place J bolts (sized per engineering specs) in the holes, extending into the grout channel. 3. Cut multiple 6x6-in squares of plywood. 4. Drill holes (matching the size of the J bolts) in the center of each square of plywood. 5. Use nails to tack the squares of plywood onto the wall, with the bolt protruding through the center hole. 6. Use foam adhesive around all four sides to keep the squares of plywood in place during the pour.
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7. Place a nut on the bolt to keep it level and ensure that it wont fall into the grout channel during the pour. These secured squares of plywood will seal the hole so that grout does not escape during the pour. Figure 46 shows the J bolts for the ledger, prior to the pour.
Figure 46: Ledger Prep J Bolts with Plywood Squares in Place 8. About 30 minutes after the pour, check the position of the J bolts to be sure they are straight and at the correct depth. Reposition, if needed, before the grout sets completely. You can remove the plywood after the grout has set up, as shown in Figure 47.
Figure 47: Ledger Prep J Bolts with Plywood Removed, after Grout Pour 9. Drill holes through lengths of lumber, matching the size and locations of the J bolts. 10. Install the lumber on the J bolts and secure with washers and nuts. Figure 48 illustrates ledger installation.
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Figure 48: Wood Ledger Installation 11. Attach hangers for floor joists or trusses, as shown in Figure 49.
Figure 49: Ledger Installed 12. Install the joists or trusses in the hangers, as shown in Figure 50.
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Add ledgers for floors as you place the first course of APEX Blocks. Figure 51 illustrates an exterior wall with a ledger and floor joist.
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Figure 54: Preparing the Blocks for Plumbing 3. Install the copper or plastic piping, as shown in Figure 55.
Figure 55: Plumbing Pipes Installed in Wall 4. Depending on the location of the pipe stubs, you may need to drill through the block to place external plumbing fixtures. 5. Use a wooden or pre-cast concrete block embedded in the wall to stabilize the pipe and reduce the risk of water penetration at the opening, as shown in Figure 56.
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puddles at the bottom of the wall will be displaced by the grout flowing through the wall channels.
IMPORTANT: Before you start filling the wall grout channels, fill all window sills (bottoms of openings). This is important, since the area under the windows is not easily reached by the grout being poured from above the window.
Toe in a 2x10 piece of lumber to keep this grout from coming up through the cells when you pour the rest of the grout. Follow these steps to fill all the channels in the blocks completely with grout: 1. Use your 4-in. hole saw to cut holes in the blocks about half-way up the wall. 2. Starting at one corner of the building, fill the grout cells through the holes, as shown in Figure 57. Fill to this half-way point for the length of the wall.
NOTE: In Figure 57, the builder has tacked the pieces of APEX material cut out of the wall to the wall next to the holes. Hell use these pieces of material to plug the holes after pouring the lift of grout. 3. After pouring the first lift, plug the holes in the walls. Do this by replacing the round pieces of APEX material cut out of the wall, tacking them in place with foam adhesive, and securing them with a metal staple, as shown in Figure 58.
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Figure 58: Wall Plug after Pouring Grout 4. Go back to your starting point and finish filling the cells from openings in the top of the blocks. 5. Scrape off the excess grout along the top of the wall using a 2x4 piece of lumber, or a trowel, making sure that the excess falls to the outside of the structure as much as possible, to reduce cleanup later. 6. When youve finished pouring the grout, clean any grout off the slab before it sets up. 7. After about 30 minutes, place J bolts for roof trusses, per engineering specs. 8. The grout will set up in 48 hours and reach full strength in about 28 days.
IMPORTANT:
Verify that concrete has completely filled all of the block cores. Push a 0.25-in.-diameter, smooth steel rod (or your key-hole saw) through the APEX Block material into the grout channels. Wet concrete on the rod when you pull it out will confirm that the grout channel has been filled completely.
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Figure 59: Top Plate Installation Follow these steps to install a top plate: 1. About 30 minutes after youve poured the grout, place J bolts into the wet grout at regular intervals per engineering specs, with the threaded end extending at least 3 inches above the top edge of the wall. 2. After the grout has set, drill holes in 2x10 pieces of pressure-treated lumber to coincide with the locations of the J bolts. 3. Install the lumber top plate over the J bolts and secure with nuts, as shown in Figure 60.
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Figure 61 and Figure 62 show details of connecting roof trusses to top plates on walls of APEX Block.
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can use your key hole saw.) Figure 63 illustrates routing or cutting cavities for electrical conduit and boxes.
Figure 63: Preparing for Electrical Figure 64 shows a builder preparing a wall for installation of wiring and junction boxes.
Figure 64: Cutting Grooves for Electrical Wiring Be sure to place your junction boxes in parts of the APEX Block that are solid foam. Junction boxes are more than 2 inches deep, and the APEX Block material over a grout channel is just 2 inches deep. So, if you try to place a J box over a grout channel, the grout will keep the box from setting flush with the surface of the wall. Some permitting offices may require conduit for electrical wiring. In this case, simply cut the grooves wide enough to accept the conduit. Figure 65 shows a wall with grooves and a cavity cut for electrical wiring and a double-gang junction box.
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Figure 66: Electrical Boxes and Wiring in Place Figure 67 is a larger view of the same wall with the boxes and wiring in place.
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For any span 6 feet long or longer, (large windows, garage doors) keep bracing up for a minimum of 4 days.
Figure 68: Smoothing the Exterior Surface of the Wall 2. Apply a waterproofing sealant. You must install water-proofing materials in accordance with the manufacturers instructions and per local building codes.
4.23.1 STUCCO
Stucco is a good exterior finish for APEX Block construction, because it is much easier to apply to APEX Block than to a wood-framed structure. Youll apply the stucco directly to the wall, without any chicken wire, lathing, or other special construction. Your time and costs will be reduced significantly, because there is much less labor and material involved. Follow these general steps to apply a stucco exterior finish, ensuring that you comply with the product manufacturers instructions: 1. Wearing a dust mask and safety glasses, use your rasp to smooth any uneven surfaces on the exterior walls. 2. Apply a waterproofing sealant. 3. Apply a smooth base coat of stucco and allow it to dry. 4. Apply the finish coat of stucco, texturing as desired.
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4.24.2 PLASTER
Apply plaster directly to the surface of the blocks, in accordance with the manufacturers installation instructions.
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28 psi
40.1 psi
Fire resistance ASTM E84-05 Comparable to UBC 8-1, 1997 UL 723 ANSI/NFPA 255 Smoke development Sound transmission ASTM E90 ASTM E1289 ASTMC634 Thermal resistance ASTM C1363 ASTM C518 Recycled content
Smoke developed: 50 Coefficient dimensionless: 2.82-106 Loss dB: 55.5 Mean from six test runs in three test sets
Recycled expanded polystyrene foam bead, measured at time of block manufacture Tests or Analysis Walls were loaded laterally at the top corner while a specified eccentric axial compression load was applied simultaneously at the top to failure. As above
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INDEX
A
APEX, 1 APEX Block test results, 1 APEX Block dimensions, 3 edge view, 3 flame-spread rating, 2 grout channels in, 2 quality control, 1 R-value, 2 specifications, 2 test results, 2 tongue-and-groove shaping, 1, 2 APEX Block Interlocking System advantages of, 1
G
Grout completely filling grout channels, 36 first lift, 35 pouring, 35 preparing to pour, 34 second lift, 36 specifications, 34 Grouting preparation, 26
H
Headers, reinforced, 17
I
Installing electrical, 38 exterior finishes, 41 interior fixtures, 43 ledgers, 27 ledgers for flat roofs, 31 ledgers for floor, 29 plumbing, 32 top plates, 36 wood flooring, 31 Interior finishes, 42 dry wall, 42 plaster, 42 Interior fixtures, 43 Interior walls installing, 42 metal stud, 42 of APEX Block, 43 wood frame, 42
B
Bond beams, 17 Bracing walls before pouring the grout, 19 removing the bracing, 40
C
Corners constructing, 9 Curved walls, 21 rebar in, 23 Cutting blocks for curved walls, 22
D
Dry wall as interior finish, 42
E
Electrical utilities installing, 38 Exterior finishes, 41 stucco, 41 Ledgers for flat roofs, 31 for floors, 29 installing, 27
F
First course of blocks, 7 Flame-spread rating, 2 Flat roofs ledgers for, 31 Floors ledgers for, 29 Openings bond beams over, 14 creating, 14 supporting, 14
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P
Planning your project, 4 Plaster as interior finish, 42 Plumbing installing, 32 Pouring the grout, 35 Preparing to pour grout, 34
first course, 7 grout channel alignment, 13 seam alignment, 13 smooth interior surface, 13 Staples, 12 at corners, 12 at openings, 14 Stucco as exterior finish, 41
R
Rebar at top of wall, 26 height above foundation, 4 in curved walls, 23 in grout channels, 25, 26 marking locations of, 34 placement, 14 placing in grout channels, 25 spacing in foundation, 4 specifications, 4, 25 splicing, 26 tying, 26 Rock veneer as exterior finish, 42 R-value of APEX Block, 2
T
Test results, 2, 1 Tools concrete scraper, 6 electric chain saw, 5 for working with APEX Block, 5 glue and glue gun, 6 rasp, 6 Sawzall, 5 staples, 6 Top plates, 36
W
Walls adding courses of blocks, 13 bracing, 19 curved, 21 first course of blocks, 7 Windows bucking out, 15 wrapping, 38 Wood flooring installing, 31 Wrapping windows, 38
S
Second course of blocks, 13 Shims to level the blocks, 9 Specifications APEX Block, 2 grout, 34 Stabilizing the blocks, 26 Stacking the blocks
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