3.0 TOOLS, EQUIPMENT AND CONSUMABLES

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1 3.0 TOOLS, EQUIPMENT AND CONSUMABLES 3.1 Tools Suggested useful specialist tools for project ELECTRIC HOT KNIFE We have found this tool an easy way to cut POLYWALL Blocks to size and form cut-outs in the blocks for plumbing and electrical services etc. Makes no mess and is simple to use. Try IRONCORE TRANSFORMERS PTY LTD (03) IMPACT DRIVER - Battery operated makes drilling and driving the screws in easier. SABRE SAW - use for preparing opening cut-outs ROUTER - An alternative to the electric knife for grooving out the blocks for cables and pipes. BRACING Refer to manufacturer s detail April 12 Page 9 of 23

2 VARIOUS HAND SAWS For cutting blocks and bridges to shape. POWER SAW - useful for cutting long straight grooves or cuts OTHER ITEMS Rebar cutter & bender use to cut and bend 12 mm end bar Concrete trowels, buckets etc. Builders level, squares, plumb bob, string lines, chalk lines, etc April 12 Page 10 of 23

3 3.2 Consumables for Project POLYURETHANE EXPANDING FOAM This low-expanding foam is an excellent product used to glue the forms together, glue the forms to the footing or slab, fill small holes, hold anchor bolts and utility penetration pipes in place, install electrical wire and boxes, plumbing, etc. FASTENERS:- SCREWS AND BOLTS #8 x 40 hex head washer faced ZP self-tapping screws 12mm x 80 hex head dyna bolts 10 mm x 250 coach bolts with nut and washers (1 shown reworked) Ramset nails for fixing starter channel. METAL COMPONENTS Metal angles and hoop iron REINFORCING RODS Per engineering specifications. TIES Use plastic or wire ties to hold reinforcing rods to bridges etc. TIMBER Plywood x 19mm thick doors and window openings Plywood x 6 + mm thick whaling plates and fixing points F7 pine - 45x 90 lengths doors and window openings OTHER ITEMS Adhesive tapes & plastic tapes as required April 12 Page 11 of 23

4 3.3 Quantity Survey The following information is given as a guide to estimate material required for a standard building project and would be subject to changes as required by the consulting engineer. POLYWALL Blocks: 1 block measures 1200 long x 300 high x 60 mm thick = 0.36 M 2 of face area Thus approximate 3 blocks per 1M 2 per side or 6 per 1M 2 of wall less windows and doors. Note: Bridges are supplied in sufficient numbers for the blocks. Recycling of POLYSTYRENE OFF-CUTS. As the building of walls progresses some unwanted off cuts of blocks and connecting bridges will be accumulated. Any clean (uncontaminated by other building products) off-cuts should be placed in the special bags provided by Polyfoam. This product may be returned for recycling. Reinforcement steel reinforcement bars 12 mm dia. Rebars are normally required as follows but subject to the engineer s specifications. Horizontally at 400 mm centres plus extras as lintels over doors and windows. Vertically at 400 mm centres plus extras next to door and window openings. Concrete. One square metre (1M 2 ) of wall requires the following amount of concrete. Allow extra for start-up, wastage and clearing. 250 wall 120 concrete 1M 2 of wall requires 0.12 M 3 of concrete 270 wall 150 concrete 1M 2 of wall requires 0.15 M 3 of concrete. 320 wall 200 concrete 1M 2 of wall requires 0.20 M 3 of concrete Or 250 wall 120concrete 1M 3 fills approximately 8.5 M 2 of wall. 270 wall 150 concrete 1M 3 fills approximately 6.5 M 2 of wall. 320 wall 200 concrete 1M 3 fills approximately 5.0 M 2 of wall. Consumables. Product Starting Channel (Code 209) Screws #8 x 40 hex wf ZP screws 12 mm 80 dyna bolts Expanding Foam Timber 90 x 45 Plywood 20 mm Plywood 6 mm Rebar - Reinforcing rods 12 dia Ties wire Support bolts for whaling plates Quantity required 1 per metre length of wall (inner wall use only) 10 per metre length of wall 1 per metre length of wall 2 canisters per 250 M 2 of wall per storey For Bracing, shuttering and whaling plates etc. Can be re-used. 4 Kg/M 2 of wall. Stock item as required As required April 12 Page 12 of 23

5 4.0 USING THE POLYWALL SYSTEM i A well planned and set out construction becomes a well-built home. Squareness and accuracy of dimensions are important. 4.1 Setting out the site. Slab or Strip Footings Construction. This information is provided as a guide to construction of POLYWALL and is always to be over ridden by the consulting engineer s instructions and specifications or government regulations. Position of Reinforcing Bars Fix vertical Rebars at 400 centres, minimum of 400 high. Refer to engineer s specifications. Check for flatness of the floor with a level. Set out of building dimensions. Set out the building using a chalk line. Snap chalk line to the inner room dimensions. Mark doorways and windows on the concrete as an aid to construction. Fix starting channel Fix starting channel to the concrete so that the shorter inner leg of the channel lies along the chalk line. Pack if necessary to maintain level. April 12 Page 13 of 23

6 Corners Place minimum of 1 metre per side of starting channel on the outside wall to support corner as shown. This supports the corner and is used with corner bracing. 4.2 Assembling the POLYWALL Build POLYWALL Beginning at a corner, construct one layer of blocks using starter bridges, lay the horizontal Rebars at first connecting bridges and fix to vertical Rebars and bridges. Set second row with 600mm offset. Continue to build one wall to four blocks high placing vertical and horizontal Rebars at the specified spacing. i When placing the rebar vertical and horizontal take care to not have Rebar passing through areas such as doors, windows and penetrations though the wall. April 12 Page 14 of 23

7 Use POLYWALL Corners Code 203 (Page 16) or Corners Site Construction To form a corner from standard blocks cut back the inside block as follows:- POLYWALL mm POLYWALL mm POLYWALL mm Second Wall Blocks Preparation To form a corner from standard blocks cut back the inside block as follows:- POLYWALL mm POLYWALL mm POLYWALL mm Building from the Corner. Add horizontal and vertical Rebars. Tie all Rebars to the connecting bridges and to the cross bars. Bend bars around the corners for extra strength. April 12 Page 15 of 23

8 Corner Construction Continue building the corner cutting the inner block as shown. Place corner bracing at level 4. Check for vertical position. i When placing the horizontal rebar bend around corner to lock corner. Corners Bracing When constructing corners from standard blocks use corner bracing as shown. The inner and outer braces are held together with 12mm threaded rods. Use the adjustable props to maintain the corner vertical. After the pour, remove the nuts from the through bolts leaving the rod in the concrete, cut off excess material. Corner Construction using POLYWALL Corners As an alternative to the onsite construction of corners, use the preformed POLYWALL Corner (Code 203). Available in left and right hand. NB - For 250mm walls only. April 12 Page 16 of 23