1.1. This instruction has been developed in compliance with the requirements of regulatory documents of the Republic of Uzbekistan and can be used as a guide to the use of polystyrene concrete as thermal insulation for the facade of enclosing external walls and foundations.
1.2. Polystyrene concrete products for building construction are manufactured by NORTEC COMPANY LLC and comply with the requirements of the O`zMSt 338:2024 standard "Thermal insulation products made of polystyrene concrete. Technical conditions" and the GOST 33929-2016 standard.
1.3. JV OOO NORTEC COMPANY can produce polystyrene concrete products in densities from D400 to D500.
1.4. Users of polystyrene concrete products should be guided by the provisions of this instruction when designing and installing polystyrene concrete parallelepiped blocks (hereinafter referred to as PCPB).
1.5. PCPB products for foundation insulation are manufactured with a material density ranging from 400 to 500 kg/m³, i.e. grades D300-D500. At the same time, the grades or classes of concrete for compressive strength are B1 – B1.5.
INSTRUCTIONS
FOR DESIGNING AND INSTALLING BUILDING STRUCTURES USING INSULATION BLOCKS MADE OF POLYSTYRENE CONCRETE FOR INSULATION AND WATERPROOFING OF THE FOUNDATION
1. General Provision
1.6. For PCPB for foundation insulation, the recommended density is within D400-D500, the compressive strength within B1 - B1.5 depends on the specific purpose depending on the design solution of the application area. It should be noted that with a decrease in the density of polystyrene concrete, its soundproofing, heat-insulating and waterproofing properties increase. In this regard, when making a design solution, the values of density and strength should be specified. Depending on the customer's wishes, PCPB can be reinforced with a light wire mesh, which improves safety for transportation, installation and finishing without damage (chipping or breaking).
1.7. PCPB are mainly used for external walls and partitions, but can also be used for insulation and waterproofing of foundations.
1.8. It is also permissible to insulate the facade side of brick, cinder block and concrete walls or concrete columns and beams without vapor barrier using PCPB blocks.
1.9. The polystyrene concrete material has a high resistance to moisture absorption, tests showed that when in an aquatic environment, the blocks absorbed water along the perimeter from the surface to a depth of 6 cm in the body of polystyrene concrete for three months.
1.10. When constructing buildings using PCPB produced by NORTEC COMPANY LLC, horizontal and vertical surfaces of the bases (foundations, walls, columns) must be level and clean. In this connection, the surface of the base elements must be pre-prepared.
1.11. Laying polystyrene concrete products for insulation and waterproofing of the foundation is carried out using polyurethane foam. In case of using cement-sand mortar of grade not lower than 100, it is recommended to use a special additive to concrete, popularly called liquid glass. The thickness of horizontal and vertical masonry joints when using cement glue varies within 5-7 mm. It should be taken into account that when using cement glue for mounting slabs or blocks with a thickness of horizontal and vertical masonry joints more than 7 mm, microcracks may form along the contour of the blocks, due to the release moisture of the mounting glue. When insulating a foundation with increased moisture characteristics of the soil, it is recommended to use a special waterproofing material, such as a profiled membrane, 0.45 mm thick, which is attached to the surface of polystyrene concrete with special plastic mushroom-shaped anchors.
1.12. When using BPBP for insulation and waterproofing of the foundation, it is necessary to use a block thickness of 12.5 cm to 19 cm.
1.7. PCPB are mainly used for external walls and partitions, but can also be used for insulation and waterproofing of foundations.
1.8. It is also permissible to insulate the facade side of brick, cinder block and concrete walls or concrete columns and beams without vapor barrier using PCPB blocks.
1.9. The polystyrene concrete material has a high resistance to moisture absorption, tests showed that when in an aquatic environment, the blocks absorbed water along the perimeter from the surface to a depth of 6 cm in the body of polystyrene concrete for three months.
1.10. When constructing buildings using PCPB produced by NORTEC COMPANY LLC, horizontal and vertical surfaces of the bases (foundations, walls, columns) must be level and clean. In this connection, the surface of the base elements must be pre-prepared.
1.11. Laying polystyrene concrete products for insulation and waterproofing of the foundation is carried out using polyurethane foam. In case of using cement-sand mortar of grade not lower than 100, it is recommended to use a special additive to concrete, popularly called liquid glass. The thickness of horizontal and vertical masonry joints when using cement glue varies within 5-7 mm. It should be taken into account that when using cement glue for mounting slabs or blocks with a thickness of horizontal and vertical masonry joints more than 7 mm, microcracks may form along the contour of the blocks, due to the release moisture of the mounting glue. When insulating a foundation with increased moisture characteristics of the soil, it is recommended to use a special waterproofing material, such as a profiled membrane, 0.45 mm thick, which is attached to the surface of polystyrene concrete with special plastic mushroom-shaped anchors.
1.12. When using BPBP for insulation and waterproofing of the foundation, it is necessary to use a block thickness of 12.5 cm to 19 cm.
2. Information on Application
2.1. PCPB are generally used not only for partitions, but also for thermal insulation of external walls, columns, beams, anti-seismic belts, attic and basement floors of buildings of various purposes with dry, normal and wet operating conditions.
2.2. The advantage of polystyrene concrete products is high thermal insulation, sound insulation and waterproofing capacity, light weight and improved physical and mechanical characteristics that meet the requirements of standards for use in construction, which is stipulated in the standard O`zMSt 338:2024 "Thermal insulation products made of polystyrene concrete. Technical conditions" and the standard GOST 33929-2016, which is considered in conjunction with this instruction.
2.3. Polystyrene concrete has the necessary resistance to microtoxins, is resistant to the formation of fungal mold and is not damaged by rodents.
2.4. The general appearance of the PCPB products is shown in Fig. 1.
2.2. The advantage of polystyrene concrete products is high thermal insulation, sound insulation and waterproofing capacity, light weight and improved physical and mechanical characteristics that meet the requirements of standards for use in construction, which is stipulated in the standard O`zMSt 338:2024 "Thermal insulation products made of polystyrene concrete. Technical conditions" and the standard GOST 33929-2016, which is considered in conjunction with this instruction.
2.3. Polystyrene concrete has the necessary resistance to microtoxins, is resistant to the formation of fungal mold and is not damaged by rodents.
2.4. The general appearance of the PCPB products is shown in Fig. 1.
3. Shapes & Sizes of Products
Name of Product: Polystyrene concrete thermal insulation tiles Density D 300 - D500, B0,75 – B1,5; F150
Dimensions of blocks with permissible deviations, in mm:
Length: 600±7
Width: 400±7
Thickness: 60±5
Number of blocks in 1 м², Pcs.: 4.16
Dimensions of blocks with permissible deviations, in mm:
Length: 600±7
Width: 400±7
Thickness: 60±5
Number of blocks in 1 м², Pcs.: 4.16
Name of Product: Polystyrene concrete parallelepiped blocks for external self-supporting walls from D 450 до D600; B1, 5 - B1,5; F150
Dimensions of blocks with permissible deviations, in mm:
Length: 600±5
Width: 400±5
Thickness: 125±3
Number of blocks in 1 м², Pcs.: 4.16
Dimensions of blocks with permissible deviations, in mm:
Length: 600±5
Width: 400±5
Thickness: 125±3
Number of blocks in 1 м², Pcs.: 4.16
4. ACCESSORIES AND INSTALLATION TOOLS
For installation and insulation of structural elements in a set with PCPB SP OOO NORTEC COMPANY recommends using the following materials and tools:
- galvanized wires with a cross-section of 2 to 6 mm according to GOST 3282-74;
- composite polymer reinforcement for reinforcing concrete structures according to GOST 31938-2011;
- cement adhesive and plaster compositions;
- waterproofing compositions for application to the surfaces of masonry joints;
- construction mounting foams;
- hacksaw with a wide blade and large teeth;
- electric drill with an attachment for mixing mixtures;
- attachment to an electric drill for making holes;
- cord-chipping device (15 m) with a plumb line;
- level 1500 mm, rule 2000 mm;
- rubber hammer;
- metal shears;
- plastic container for making mortar;
- box for putty mixture;
- trowel-spatula, wide spatula, spatula for internal corners, spatula for external corners, notched spatula for applying glue to ceramic tiles and decorative facings;
- hand grinding device;
- wide brush, roller;
- construction gun for shooting embedded parts to columns and beams;
- mushroom-shaped plastic anchors;
- profiled membranes.
- galvanized wires with a cross-section of 2 to 6 mm according to GOST 3282-74;
- composite polymer reinforcement for reinforcing concrete structures according to GOST 31938-2011;
- cement adhesive and plaster compositions;
- waterproofing compositions for application to the surfaces of masonry joints;
- construction mounting foams;
- hacksaw with a wide blade and large teeth;
- electric drill with an attachment for mixing mixtures;
- attachment to an electric drill for making holes;
- cord-chipping device (15 m) with a plumb line;
- level 1500 mm, rule 2000 mm;
- rubber hammer;
- metal shears;
- plastic container for making mortar;
- box for putty mixture;
- trowel-spatula, wide spatula, spatula for internal corners, spatula for external corners, notched spatula for applying glue to ceramic tiles and decorative facings;
- hand grinding device;
- wide brush, roller;
- construction gun for shooting embedded parts to columns and beams;
- mushroom-shaped plastic anchors;
- profiled membranes.
5. installation technology
5.1. In order to enhance the load-bearing capacity of the masonry made of polystyrene concrete products, it is recommended to lay the foundation of the first row on a shelf of a metal corner attached to the wall with a thickness of up to 5 mm and a shelf size of up to 6 cm, or on a concrete shelf in the presence of a special concrete ledge. The horizontal evenness of the masonry depends on the quality of the masonry of the first row, when insulating the facade wall, since the base of the first row must be sufficiently even. It is recommended to apply a cement-sand mortar of grade not lower than 100 (with a cement and sand ratio of 1:3) over uneven surfaces, and if the surface unevenness is greater than 30 mm, a mortar with mesh reinforcement is applied.
5.2. It is recommended to use plastic mushroom-shaped anchors up to 20 cm long for fastening slabs to the foundation surface, as well as for fastening the profiled membrane to the surface of the polystyrene concrete wall.
5.3. The front surfaces of walls made of polystyrene concrete slabs or blocks must have a finishing coating in the form of cement mortar plaster, decorative plaster or other product, as well as facings made of stone materials in those places of the foundation that protrude from the ground surface or, as they say, from the zero point. The use of polystyrene concrete products without facings is not recommended due to the low resistance of polystyrene foam granules to solar ultraviolet rays. The facings and stones used for external finishing must meet frost resistance requirements.
5.4. When plastering the surface of walls made of polystyrene concrete slabs or blocks, it is recommended to prime the surface of the base with an acrylic base before applying the plaster. Acrylic primers are universal, quick-drying and increase adhesion. In the case of using cement and lime-cement plasters, it is permissible to apply a mineral primer or splash. In the case of using splash, plastering work should be started no earlier than 24 hours after its application.
5.5. Plaster mortar on cement or lime-cement binder can be applied both in one layer and layer by layer. When installing a multi-layer plaster coating, each layer must be applied after the previous one has set.
5.6. Reinforcing (plaster) meshes or waterproofing profiled membranes are mounted with an overlap of at least 100 mm. The mesh installation starts from the ceiling, securing the upper edge of the sheet along the entire length using fasteners, then install the fasteners in a checkerboard pattern over the entire surface of the wall. Between the mesh and the wall, it is necessary to provide a gap of 5-10 mm, depending on the thickness of the plaster mortar layer when plastering the surface of the polystyrene concrete insulation. And when installing a profiled membrane on the surface of a polystyrene concrete wall, work begins from the bottom. At the joints horizontally and vertically, the sheets should overlap each other with an overlap of 100-150 mm.
5.2. It is recommended to use plastic mushroom-shaped anchors up to 20 cm long for fastening slabs to the foundation surface, as well as for fastening the profiled membrane to the surface of the polystyrene concrete wall.
5.3. The front surfaces of walls made of polystyrene concrete slabs or blocks must have a finishing coating in the form of cement mortar plaster, decorative plaster or other product, as well as facings made of stone materials in those places of the foundation that protrude from the ground surface or, as they say, from the zero point. The use of polystyrene concrete products without facings is not recommended due to the low resistance of polystyrene foam granules to solar ultraviolet rays. The facings and stones used for external finishing must meet frost resistance requirements.
5.4. When plastering the surface of walls made of polystyrene concrete slabs or blocks, it is recommended to prime the surface of the base with an acrylic base before applying the plaster. Acrylic primers are universal, quick-drying and increase adhesion. In the case of using cement and lime-cement plasters, it is permissible to apply a mineral primer or splash. In the case of using splash, plastering work should be started no earlier than 24 hours after its application.
5.5. Plaster mortar on cement or lime-cement binder can be applied both in one layer and layer by layer. When installing a multi-layer plaster coating, each layer must be applied after the previous one has set.
5.6. Reinforcing (plaster) meshes or waterproofing profiled membranes are mounted with an overlap of at least 100 mm. The mesh installation starts from the ceiling, securing the upper edge of the sheet along the entire length using fasteners, then install the fasteners in a checkerboard pattern over the entire surface of the wall. Between the mesh and the wall, it is necessary to provide a gap of 5-10 mm, depending on the thickness of the plaster mortar layer when plastering the surface of the polystyrene concrete insulation. And when installing a profiled membrane on the surface of a polystyrene concrete wall, work begins from the bottom. At the joints horizontally and vertically, the sheets should overlap each other with an overlap of 100-150 mm.
6. basic safety rules for work
6.1. When performing work on the installation of structures using PCPB, only persons who have undergone training in safety precautions, industrial sanitation, and are trained in installation techniques must be allowed.
6.2. It is recommended that work on the installation of structures using PCPB be carried out by specialized teams with experience in installing such structures and equipped with special tools and special clothing. And the tools, equipment, tooling and devices used in the performance of work for the installation of structures must meet the safety conditions for the performance of construction and installation work.
6.3. When facing the walls of buildings to a height of up to 0.7 m from the working platform and the distance from its level behind the wall being erected to the ground surface (ceiling) is more than 1.3 m, it is necessary to use collective protection equipment (fencing or catching devices) or safety belts.
6.2. It is recommended that work on the installation of structures using PCPB be carried out by specialized teams with experience in installing such structures and equipped with special tools and special clothing. And the tools, equipment, tooling and devices used in the performance of work for the installation of structures must meet the safety conditions for the performance of construction and installation work.
6.3. When facing the walls of buildings to a height of up to 0.7 m from the working platform and the distance from its level behind the wall being erected to the ground surface (ceiling) is more than 1.3 m, it is necessary to use collective protection equipment (fencing or catching devices) or safety belts.
7. basic rules for technical operation of structures
7.1. During the operation of partition structures made of BPBPG, BPBP, there is a need to hang various objects on them. Depending on the weight of the objects to be hung, various fasteners are used. According to the tests carried out on BPBPG and BPBP of medium density grades D450 and D500 after removing them from the molding casting molds on the 4th day, it was demonstrated that when installing an 8 cm dowel and screw into the body of the blocks, one screw was able to hold a weight of 50 kg without any shrinkage of the dowel in the body of the block.
8. normative references
1. KMK 2.01.03-19. Construction in seismic zones.
2. KMK 2.03.01-96. Concrete and reinforced concrete structures.
3. KMK 2.03.07-98. Stone and reinforced stone structures.
4. KMK 3.01.02-00. Safety in construction.
5. KMK 3.03.01-98. Non-load-bearing and enclosing structures.
6. KMK 3.03.06-99. Preparation and use of construction mortars.
7. SHNK 4.02.08-04. Brick and block structures.
8. SHNK 4.02.15-04. Finishing works.
9. SHNK. 4.02.61-07. Plastering works. Repair and construction works
10. SHNK 2.01.02-04. Fire safety of buildings and structures.
11. KMK 2.01.07-96. Loads and impacts.
12. SHNK 2.08.01-19. Residential buildings.
13. KMK 2.08.02-09. Public buildings and structures.
14. SHNK 4.02.58-07. Roofs, roofing. Repair and construction work.
15. SHNK 4.02.26-07. Thermal insulation work.
2. KMK 2.03.01-96. Concrete and reinforced concrete structures.
3. KMK 2.03.07-98. Stone and reinforced stone structures.
4. KMK 3.01.02-00. Safety in construction.
5. KMK 3.03.01-98. Non-load-bearing and enclosing structures.
6. KMK 3.03.06-99. Preparation and use of construction mortars.
7. SHNK 4.02.08-04. Brick and block structures.
8. SHNK 4.02.15-04. Finishing works.
9. SHNK. 4.02.61-07. Plastering works. Repair and construction works
10. SHNK 2.01.02-04. Fire safety of buildings and structures.
11. KMK 2.01.07-96. Loads and impacts.
12. SHNK 2.08.01-19. Residential buildings.
13. KMK 2.08.02-09. Public buildings and structures.
14. SHNK 4.02.58-07. Roofs, roofing. Repair and construction work.
15. SHNK 4.02.26-07. Thermal insulation work.