Building With Large Clay Blocks

DETAIL Practice

Building with Large Clay Blocks

Details Products Built examples

Theodor H u g ues Klaus G re i l i c h Christi ne Peter

Edition Detail

Authors:

This book is also available i n a German language edition ( ISBN 3-920034-09-0).

Theodor Hugues, Prof. Dr. - l n g . , architect Chair of Design, Construction and Building Materials, Technische Universitat M u nchen Klaus Grei lich, D i pl.- l n g . , architect Christine Peter, D i p l . - l n g . , architect

A CIP catalogue record for this book is avail­ able from the Li brary of Congress, Washing­ ton D.C., USA

Drawings: Editors for Deta i l lna Philipp, Dipl.-lng. Anna Werth, D i p l . - l n g .

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Secretariat: Marga Cervinka Editing and proof-reading: Nicola Kollmann, Dip l.-l ng. Andreas Gabriel, Dipl.-lng., architect Translators (German/English): Gerd H. Soffker, Philip Thrift, Hannover

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A specialist publication from Redaktion DETAIL ISBN 3-7643-7 1 1 1 -0 Printed on acid-free paper produced from chloride-free pulp. All rights reserved, including the copying of extracts, translation, photomechanical repro­ duction and mi crocopy i n g . The transfer of the content, either in whole or in part, to data­ bases and expert systems, and the rendering therein, is prohibited. Layout and production: Peter Gensmantel, Cornelia Kohn, Andrea Linke, Roswitha Siegler Printed by: Wesei-Kommunikation Baden-Baden 1 st edition, 2004 4,000 copies l nstitut fUr l nternationale Architektur­ Dokumentation GmbH & Co. KG Sonnenstr. 1 7, 80331 Munich, Germany Tel : +49 89 38 1 6 20-0 Fax: +49 89 39 86 70 I nternet: www.detai l . de in cooperation with: Ziegelforum e.V. Bavariaring 35 , 80336 M un ich, Germany Tel: +49 89 74 66 1 6-0 Fax +49 89 7 4 66 1 6-30 I nternet: www.ziegel.com e-mail : [email protected] Distribution Partner: Birkhauser- Publ ishers for Architecture P.O. Box 1 33, CH-401 0 Basel , Switzerland Tel: +41 61 205 07 07 Fax: +41 61 205 07 92 email: [email protected] http://www.birkhauser.ch

All the detail drawings are drawn to a scale of 1 : 1 0. The various components have been shown i n a number of variations. They represent typical solutions which must be coordi nated with the respective boundary conditions and requirements, the relevant statutory instruments, standards and manu­ facturers' information val id i n each specific, ind ividual case. Neither the authors nor the publ isher shall be liable for any claims for damages arising from the content of this book. Decisions relating to the construction, con­ struction law and building performance char­ acteristics are based o n the situation in Germany and the D IN standards plus- if already introduced- the EN standards valid i n Germany.

DETAIL

Practice Building with Large Clay Bloc ks

Theodor Hugues Klaus Greilic h Christi ne Peter

Contents 8 11 12 16 20 22 24 26 28 30 32 38 41 42 44 48 50 52 56 62 68 70

I ntroduction House A External wal l , rendered plinth External wal l , concrete p l i nth External wal l, window External wal l , window and c lay hollow pot floor Double-leaf party wall Load bearing and non-loadbearing partitions Clay hol low pot floor Double-leaf party wall and c lay hol low pot floor External wal l and u nused roof space Double-leaf party wall and c lay-tile roof House B Non-insu lated external basement wall External basement wal l with peripheral insulation External basement wal l with c avity i nsulation Masonry external basement wal l External basement wal l made from lig htwei g ht c lay bloc ks Rad iator recess, window with rol ler shutter External wal l and converted roof space Chimney Partition and false wal l concealing servic es

76 78 79 83 91

Princ i p les Clay brick and bloc k formats, dimensional tolerances Masonry bonds Dimensional coord ination Structure and constr uction Plaster/Render on c lay masonry Supplement

96

Clay masonry b u i l d ings - Examples

1 14 115 117 118

Standards, referenc es, assoc i ations Manufacturers Subject index I ndex of persons, picture cred its

73 74

Bauen mit groBformatigen Ziegeln, a book of practical exerc i ses and the forerunne r of this book, ori gi nate d at the suggestion of the Munic h-base d Ziegelforum e .V. The graphic layout and the production of the original e d ition was c arrie d out at the office s of Sc hwe i ge r Wi nsc he rman, also in Munic h . The authors are grateful to the assistance give n by Dr.-lng. Be rnhard Be hringer (str uctures) and Dr.-lng. Pete r Roe ke (plaste r/re nder and masonry tec hnology) .

Building with lar ge c lay bloc ks

In or der to i l l ustrate the problems and relationships, two, basically sim ilar, terrac e house types, A and B, wer e devised . These do not c laim to be spec ial in any way but rather are intended to represent the "standard c ase". The d iffer ences between the two house types lie in the degree to whic h the i nter ior space is used as wel l as the building methods and building mater ials employed . A is a simple house . A has no basement and the roof space is not used as living acc ommodation. The intended high degree of self-build involved is helped by omitting the central heati ng and hot­ water systems, the use of clay hol low pot or timber joist floors, and the use of conventional b u i l d ing elements. The separate electr ic or gas-fired heat­ ers requir ed are placed in front of the wal l .

Cold roof space No basement Raised ground floor H i g h degree of self-build

Longitudinal loadbearing walls Timber stairs Minimal chimney False walls concealing services

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B is a more elaborate design. B has a basement and a roof space for use as living accommod a­ tion. Solid rei nforced conc rete floors and central hot-water heating and hot-water supply systems call for a hi gher stand ard of construction, l i kewise the windows with roller shutters. The use of ex­ perienced contractors is highly advisable. The couple roof is supported on abutments monol ithic with the topmost rei nforced conc rete floor and pro­ vides a roof space free from intermed iate columns. Easy acc ess for handicapped occ upants is guar­ anteed by having the ground floor at th e same level as the surround i n g ground .

Converted roof space Heated and un heated basement Same-level access False walls concealing se rv ices Radiators and chimney Construction by contractors

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House A 12 16 20 22 24 26 28 30 32 38

External wal l , rendered plinth External wal l , concrete plinth External wal l , window External wal l, window and c lay hol low pot floor Double-leaf party wal l Loadbearing and non-load bearing partitions Clay hol low pot floor Double-leaf party wal l and c lay hol low pot floor External wal l and unused roof space Dou ble-leaf party wal l and c lay-tile roof

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Exte rnal wal l, re nde re d p l i nth Ve rtical se ction through fo undation and plinth

D a Use an excavator to dig the tre nche s for fo undatio ns i n stab le subsoils. The width o f the fo undatio n is the refo re dete rm i ne d by the width of the excavato r b ucket and must also be checke d with re spect to the permissible beari ng pre ssure . The nece s­ sary depth to preve nt frost heave ( m i n . 800 mm, in ex­ pose d locatio ns as much as 1 200 mm) can be achieved with a strip fo undatio n of ade quate de pth .

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D b Build a p l i nth wal l on the levelling bed joint on the plain co ncrete (grade C 1 2/1 5) foundation and prote ct this wal l agai nst saturatio n o n both side s . One approach we l l te ste d fo r re nder makes use of a waterproofi ng syste m made from an elastic sealing coat­ ing. Apply a suitable fi l le r to achieve a smooth surface and then paint o n the coat­ ing with a b rush in seve ral layers to achieve a minimum thickness of 2 mm; o n the out­ side apply a coat of p laste r­ ing mix gro up P I l l suitab le for p l i nths. In o rde r to ensure that wate r running down the facade drains c le ar, both wate rproofing and re n de r co ntinue to the outside e d ge of the fo undatio n via a rounde d corne r fil let. The surrounding strip of coarse gravel re duces the amount of wate r splashing up o n to the p l inth. D e Spread a layer of hardcore ove r the excavation betwee n the walls to preve nt capillary action and permanent satu­ ratio n fro m unde rne ath, and to provide re l ief for a te m po ­ rary b uild-up of wate r. This layer should consist of 1 50 mm of coarse -graine d , c le an

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gravel ( D I N 1 81 95}, ideally grad ing curve 1 6/32 , which is readily co m pacte d b ut is sti l l sufficiently pe rmeab le . In o rder to preve nt co ncrete see page whe n casting the ground floor slab, cove r the hardcore with a sheet of 0 . 2 mm po lyethyle ne . D d To protect against mo isture rising through cap il lary actio n , a continuous damp­ proof memb rane (dpm) is re quire d . The dpm and the damp-proof co urse (dpc) i n the wal l must be jo i ne d to gethe r. I n o rde r to minim ise the d iffe re ntial settle ment betwee n wal l and ground floor slab , careful co m pac­ tion of the subso i l and the anti-capillary hardco re is necessary. lt is he l pful to cast the floor slab as late as possib le . The floor water­ proofing, assuming non­ hydrostatic pre ssure and a mode rate load i n g , sho uld consist of o ne layer of b itu­ men fe lt (e . g . G 200 DD with g lass cloth inlay) or o ne laye r of b u i lt-up b itume n fe lt (e . g . V60 S4 with g lass fleece inlay) with 1 00 mm bo nde d laps: laid loose, fully o r partially bo nde d . Bo nd the dpm unde r the floor to the dpc in the wal l with 1 00 mm ove rlapping jo ints. As these are made at d iffe re nt time s , a rob ust dpc using a b itumen fe lt with a metal fo i l inlay (e . g . Cu 0 . 1 D ) i s to be re comme nde d .

Vertical section through foundation

D e If the subso i l around the foundation trench is unsta­ b le, formwork is required on both sides of the strip foun­ dation . Setti ng up the form­ work in turn requires a work­ ing space of 500 mm. I n addition, the sides o f the excavation must be sloped back ( 60°-40° ) to suit the angle of repose of the part ic­ ular soi l .

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D f The masonry p l i nth wal l con­ structed on the foundation must be waterproofed and the waterproofing must be protected agai nst mechani­ cal damage. This can be achieved by means of, for example, corrugated bitu­ men sheeting or synthetic studded sheeting. Backfi l l the foundation trench in layers and com­ pact the backfi l l i ng material inside and outside simu ltane­ ously. O g Build the ground floor slab i nto the masonry p l inth . I n order to accommodate stresses due to d ifferential settlement, the slab must be reinforced, at least around the edges. Covering the anti-capil lary hardcore with polyethylene sheeting i s the simplest approach. However, damage caused by the reinforcement or while casti ng the rein­ forced concrete floor slab is a risk here (see p . 1 2 , b) .

D h One key advantage of the rei nforced concrete ground floor slab is that the junction between the damp- proof membrane (dpm) and the damp-proof course (dpc) is not vulnerable to settlement. The continuous dpc in the wal l at the same leve l , to­ gether with the standard plinth height of approx. 300 mm (DIN 1 8 1 95), deter­ m i nes the position of the ground floor slab above the surrounding ground. Water­ proofing agai nst ingress of moisture from the side "must be desig ned to continue up the wal l for max. 300 mm above ground level in the standard case in order to guarantee suff icient adjust­ ment options i n the ground level. U pon comp l etion , this d i mension should not be less than 1 50 m m . " ( D I N 1 81 95 part 4 )

D i The moisture-resistant render to the plinth continues to the top of the p l i nth. lt is possi­ ble to achieve no d ifference in texture between p l i nth render (P I l l} and lightweight render (P 11) by choosing suitable plastering systems. The dpc continues to the outside edge of the structural masonry. Attach a strip of expanded metal over this problematic interruption in the substrate to provide a background for the render.

13

External wal l , rendered pl inth Vertical section through glazed door

D a Set up the frame to the glazed door on the ground floor slab. Align the frame, wedge it in p lace and fix it to the floor slab with steel fixi ng cramps. Join the floor water­ proofing to the frame. After positioning the frame, add a concrete topping with an approx. 1 0 % fal l to the outside. To prevent satura­ tion, the wood of the frame is wrapped in polyethylene sheeti ng or crepe paper. D b The strip of insulating mate­ rial ( moisture-resistant poly­ styrene, mineral fibre or per­ l ite batts) required at the wal l j unction conti nue unin­ terrupted. Add the thermal insulation after casting the concrete ground floor slab in order to avoid damage to masonry and insulation. The facing of cut c lay blocks creates a uniform substrate for the render.

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D e Place the step ( p recast con­ crete, reconstituted stone or in situ concrete) in front of the door on the compacted backfi lling but separate from the house; better still, on 300-400 mm of properly compacted gravel to pre­ vent frost heave. All surfaces should have a 1 -2 % fal l . D d Supporti ng the open grid flooring on an angle bracket screwed into the step en­ ables the sequence of ope­ rations to be separated. D e Tuck the sheet metal sill over the screed behind the render on both sides, screw it to the galvanised water bar and seal it at that point with a fi l let of sealing com­ pound. D f Fix the galvanise d , close­ mesh open grid flooring by means of spacers and self­ tapping screws, or by means of bolts welded to the flooring. The floor water­ proofing must remain per­ manently bonded to the water bar. Th is robust detail with water bar and single-rebate frame is only possible in a lobby that is not permanently heated.

Vertical section throug h entrance door

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Ext ernal wall , concrete plinth Vertical section through foundation and p l i nth

Da Build the foundation only on virg in subsoil (no fill) and deep enough to prevent frost heave . Set out the external wal l exactly on the strip foundation , which is wider than the wal l and is cast d i rectly against the sides of the trench . Set up the formwork for the con­ crete p l i nth on this. Db Cover the anti-cap i l lary hardcore with an approx. 50 mm layer of bl inding con­ crete (grade C 8/1 0) to pre­ vent seepage of the cement slurry. This also eases the positioning of the reinforce­ ment required for the rein­ forced concrete floor slab. De To prevent damage caused by splashing water, con­ struct the plinth with ade­ quate concrete cover to the rei nforcement and without any construction joints , and compact the concrete care­ fully. Dd A flush finish with the render above is achieved by creat­ ing a chamfer to the top out­ side edge of the concrete by means of a triangu lar fil let ( 1 5 x 1 5 mm) . Separation at this point is necessary owing to the d ifferent deformations. Use a galvanised, better sti l l stai nl ess steel, stop bead at the bottom of the render and fi ll the joi nt between stop bead and concrete with an elastic sealing compound to accommodate the different changes in length due to shri nkage and thermal expansion.

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De As bitumen felt can split when subj ected to bending, employ a bitumen felt with a metal foi l inl ay for the damp­ proof course (dpc) i n the wal l . I nsert approx. 50 mm thick i nsulation (mineral fibre, rigid expanded polystyrene foam) i nto the middle of the wal l to guarantee the neces­ sary thermal i nsulation. Reduce the effect of the thermal bridge - masonry backin g/p l i nth concrete ­ by extending the i nsu lation downwards.

Vertical section through g lazed door

D f The damp-proof course (dpc) in the wal l continues across the door open ing and must be protected for the duration of construction work. Carefu lly bond the exposed edge to the sub­ strate in order to prevent moisture seeping under­ neath . Build in the door threshold on preformed compressible sealing strips glued i n place. O g Lay the stiffer thermal insu­ lation on the more elastic im pact sound insulation and cover this with a separating layer before pouring the scree d . O h Pour the floating screed without any material connec­ tion to the adjoining parts of the construction ; only in this way can the sound insula­ tion qual ities be guaranteed. The perip heral strips of insu­ lation (mi neral fibre, expanded polystyrene foam 8-1 0 mm thick) should extend 20-30 mm above the finished floor leve l . Cut this off flush after layi ng the floor finish.

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External wal l , concrete pl inth Plan on entrance door

D a The " bridge-like" arrange­ ment of the open grid floor­ ing has advantages: the space between the flooring and the door reveal is wide enough to allow easy c lean­ ing, and the door frame does not need to be notched to accommodate the floori ng.

D b After positioning, aligning and fixi ng the door, cast the galvanised water bar into the concrete. Then clean the concrete ground floor slab and remove all loose debris. To im prove adhesion, roughen the surface and wet it; alternatively, apply a bonding coat. Dc The door frame finishes j ust above the screed and is screwed to the continuous water bar. Protect the end grain of the wood and seal the joi nt on all sides with a permanently elastic sealing compoun d .

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Elevation on and vertical section throug h entrance door

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External wal l , wi ndow Horizontal sections throu gh different reveals

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D a The masonry shoulder at doors and windows has a long trad ition . Derived from brick masonry bonds, the depth is 1 1 5 mm ( 1 /2 brick) and the width approx. 60 mm ( 1 /4 brick) . In l i g htwei ght clay block masonry the shoulder can be created with specials or by sawing whole blocks to suit. This somewhat more elab­ orate detail is becomi n g popular a g a i n for practical and other reasons. For instance, it improves thermal insulation and moisture con­ trol aspects, and the joint between window frame and render is set back and thus protecte d . I nstall t h e window frame, primed and given a first coat of paint, on a preformed, compressible and i mpreg­ nated seal ing stri p ; this compensates for irregu lari­ ties as it tries to return to its ori g inal size. Fill the joint between frame and masonry with a moisture-resistant i nsulating material ( e . g . non­ CFC foam) . Sealing the joint on the inside with a mois­ ture-resistant seal ing com­ pound prevents saturation due to condensation water and ensures that the seal ing compound remains fully effective over the long term . Prefabricated sealing gas­ kets are available to ensure airtig htness and moisture tightness between wal l and window; the use of these helps to guarantee a good detai l .

D b The om ission of shoulders at the head and reveals sim­ p l ifies the detail consi dera­ bly. However, many prob­ lems have to be overcome at the resulting "straight" joi nt: - accommodati ng d i men­ sional and flatness toler­ ances ( D I N 1 8202 ) ; - fixing the frame (fixing cramps, screws every approx. 800 mm) ; - accommodating tempera­ ture-related changes in length, deformations and movement without damage; - sealing agai nst wind (from the outside) and water vapour (from the inside) because condensation water can be expected in the joint due to the tempera­ ture d ifference of 1 5-20° ; - protection against rain and driving rain - the most favourable values in terms of moisture control have been measured in the middle of the reveal, the isotherms are d istributed over the entire width of the reveal. D e If the window moves further outwards, it is not j ust the stresses on the components and their joints due to sun, wind and rain which increase. We find with hi gh-qual ity wal l insulating materials in particular that the tempera­ ture in the reveal can drop below the dew point in the winter. The result is conden­ sation water and mould growth. I nsulation across the reveal is advisable. Positioning the window at least 20 mm back from the l i ne of the structural wal l h e l p s t o achieve a decent return for the render.

Vertical section through sill and l i ntel

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D f The l i ntels used here consist of shal low U-shaped clay channels in which the conventional or prestressed reinforcing bars are laid and cast in. In structural engineeri ng terms these bars form the tension tie of the l i ntel . A "compression zone" of masonry shou ld therefore be built over such shal low l i ntels; use lightweight clay blocks of compressive strength class 1 2 . Shal low clay li ntels are available in depths of 7 1 and 1 1 3 mm, and widths of 1 1 5 or 1 75 mm. Without a structural analysis, shal low clay l intels may be used only as single-span beams up to a span of 3. 00 m. Temporary supports during erection are necessary for clear spans exceeding 1 .25 m. PrefabriD e cated conventionally reinforced or prestressed shalIf the desired sill height is low clay l i ntels are covered not a multi p l e of the size of by approvals. blocks being used, saw Sawn make-up blocks are blocks to form appropriate required at the supports for make-up un its. Rustproof masonry reinforce- shallow clay l i ntels, either ment laid as high as possible above or below, in order to match up with the bed joi nts in the spandrel panel helps i n the wal l (every 250 mm) . to prevent cracking.

D d I rrespective of the type of reveal and the position of the window withi n the thickness of the wal l , there is never a masonry shoulder at the s i l l . Fix the standard type of window sill - made from 2 mm sheet aluminium with a fal l of approx. 1 : 1 0 - to the wall with brackets in such a way that the rainwater drip projects approx. 30 mm beyond the render. Attach L- or C-shaped sections to both ends of the aluminium sill for tucki ng behind the render on both sides. Do not remove the factory-applied plastic wrapping around the aluminium sill until all the rendering and painting works have been completed in order to avoid, for examp le, splashes of l i me or cement.

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External wal l, window and clay hol low pot floor Vertical section throug h lintel and floor-wa l l j unction

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Da Clay hol low pot floors can be laid qu ickly without form­ work for self-build projects. Merely the beams require temporary support during erection . The floor un its- the hol low cl ay "pots" - are laid on in situ concrete ribs with pre­ fabricated lattice beams acting as the reinforcement (see p . 28) . Db To al low hei ght adj ustments, but also to avoid excessive bearing pressure at the edge and to prevent the voids of the clay b locks being fi l l ed with concrete, provide a leve l l ing bed of mortar 20 mm thick. De Lay the lattice beams of the ribs with a m i n . 1 00 mm bearin g on the bed of mortar and connect them together by means of an in situ con­ crete ring beam . The i nsula­ tion, about 50 mm thick, between beam and block­ work is best inserted after casting the beam. To create a uniform sub­ strate for the render, saw a large-format clay b lock to suit.

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Dd If shal low clay l intels with d ifferent widths (1 1 5 and 1 75 mm) are being used, the thermal i nsulation can be considerably improved by fitting i nsulation approx. 80 mm thick (mi neral fibre or extruded polystyrene) between the l i ntels. Position the window in l ine with this i nsulation.

Vertical section through li ntel

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D e L i ghtweight clay channels matching the thickness of the wall, 238 mm deep and 240 mm long, serve as per­ manent formwork and pro­ vide a uniform substrate for the render. Position the insu­ lation and the reinforcement, then fi l l the channels with concrete. Th is type of rein­ forced concrete l i ntel can span clear openings up to about 2.75 m.

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D f The use of shal low clay l i n­ tels with d ifferent depths and widths permits the con­ struction of l i ntels with shoul­ der and thermal i nsulation.

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Double-leaf party wal l Vertical section through foundation

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Plan on party wal l-external wal l j unction

D a The sound reduction i ndex (57 dB, D I N 4 1 09) required for the party wall can be achieved with a double-leaf wal l comprising two leaves of 175 mm lightwei ght clay blocks, gross density class 0.8, p l us m i n . 30 mm thick semi-ri gid mineral fibre i nsu­ lating batts . The batts are positioned loose and held in place by the masonry leaves. The sound reduction index can be increased to 67 d B (enhanced requirements, DIN 41 09) and the wal l classed a s a fire compart­ ment wal l (Bavarian Building Code) by using vertically perforated clay blocks with B-type perforations and gross density class > 1 .2 . D b Continuing the damp-proof course (dpc) across the separating joint has no adverse effect on the acous­ tic properties of the wal l . Build the leaves of the party wall i n succession , not simu ltaneously, in order to rule out - as far as possible - acoustic bridges for struc­ ture-borne sound caused by debris and mortar drop­ pings. Separati ng joint b oards with an inorgan ic coating on one side, devel­ oped for dou ble-leaf con­ crete walls, can be used here to help keep the work clean.

D d I n both variations, conti nue the construction of the party wal l as for the external walls and plinths shown on pp. 1 2 and 1 6. D e Shear wal l s do not need to be built into the external wal l s - a butt joi nt is ade­ quate - when other means (e.g. flat anchors cast in) are provided at the j unction to resist the tensi le and com­ pressive forces. O f The separati ng joint, fi lled with elastic insulating mate­ rial , must continue through to the render and be sealed there with an elastic mate­ ria l . Stop beads, fixed with a background to the wal l , are frequently used . The joint itself is then covered with a folded PVC profi le. The solution shown here makes use of two stainless steel stop beads along the sides; the render continues right up to these stop beads. The space between the stop beads is fil led with a closed­ cell foam profile and after su itable treatment the joint is closed off with a perma­ nently elastic sealing com­ pound.

0 The ideal place for the rain­ water down pipe would be directly over the joint. How­ ever, it is d ifficult to fix the p i pe clips securely to the soft joint material - special fixings wou l d be required .

D e The separating joint must continue through the foun­ dation if the en hanced requirements are to be met. To do this, cast the strip foundation i n two halves. Place the separating joint board agai nst the part cast first and cast the other half against the coated side of the board.

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Load bearing and non-load beari ng partitions Vertical sections through foundation

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D a If separate concrete ground floor slabs are used i n each room, this saves concrete and rei nforcement and also enables the use of d ifferent floor constructions . How­ ever, this does subj ect the damp-proof mem brane (dpm) to an increased risk of d ifferential settlement and hence damage.

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Vertical sections throu gh ground floo r slab

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D b The constru ctional advan­ tages of the co nti nuous rein­ forced co ncrete ground floor slab become clear at the partitio ns. No n-lo ad bearin g partitions can be "carried" by a rein­ forced concrete grou nd floor slab if the slab is provided with su itable reinfo rcement to distribute the load .

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De Secure joi nts in the d p m are also necessary below load­ bearing partitio ns. The fou ndation to the par­ titio n , which is not affected by frost heave and can th erefo re be shallower, is co nnected to the d eeper fou nd ation at the externa l wal l either v i a a shou lder or, if the d ifference i n d epth is o n ly smal l , by a slo pi n g (30° , approx. 2 : 1 ) ar�angement.

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Clay ho l low pot floors and non-load bearing partitio ns I sometric view of clay ho l low pot floo r

C lay ho l low pot floo rs con­ sist of beams, or rather ribs, with no n-stru ctu ral clay ho l­ low "pots" in between . The prefabricated ribs must be temporarily su ppo rted dur­ ing erectio n , but further formwork is u nnecessary.

28

The compression zo nes of the ribs, rei nforced as lattice beams, are finished on site with in situ concrete. Spans of 5-7 m are possi ble by using floor u n its of d ifferent depths (between 1 60 and 250 mm) and by varying the spac ing of the ribs (500 o r 625 m m centres) . A n in situ stru ctu ral concrete to pping added o n site improves the load -carrying capacity and sound i nsu latio n .

Vertical sectio ns through partitions

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D a In this detail the partition and the rib are on the same axis.

D b If the partitio ns do not co in­ cide with the ribs, a rein­ forced trimmer formed by a row of concrete-fi l l ed "nega­ tive pots" is required .

29

Dou ble-leaf party wal l and clay hollow pot floo r Vertical sectio n throu g h floor without co ncrete topping

If the structu re is not a mu lti­ ple of the size of the clay ho l low pot floo r u n its, co n­ struct make-u p (end) bays. D a With large ed ge marg ins lay flat "negative pots" and fi l l them with co ncrete to form an ed ge beam (reinforced as requ ired ) . The brick-o n­ end masonry u n its guaran­ tee the function of the sepa­ rating jo int. The beari ng fo r the floor units, a bed of mortar approx. 20 mm thick, should be at least 30 mm deep. D b With small ed ge marg ins between lattice beam, or rather the ri b , and wal l, fi l l the space between the floor u n its and the brick-o n-end masonry u n its with concrete (rei nfo rced as requ ired) to fo rm a ring beam . D e If the ring beam has to co n­ tinue u p to the separating jo int, then it shou ld be cast in two pieces, with the sound i nsu lation being positioned after the first concrete pou r and kept c lean with a poly­ ethylene sheet. The po ly­ ethylene sheet u nd erneath the mortar l evelling bed pre­ vents cement slurry seeping into the separating jo i nt. D d A concrete to pping co nsider­ ably improves the load -car­ rying capacity with regard to imposed loads and light­ wei ght partitio ns, but also the acou stic perfo rmance of the clay ho l low pot floor. I n terrace hou ses - assu m i ng no high demands o n impact and airborne sound insu la­ tion withi n the same resid en­ tial u nit - a carpet with good sou nd insu lation pro perties cou ld well be adequate.

30

Vertical section th rou gh floor with concrete topping

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External wal l and roof space not used as living accommodatio n Vertical sectio n through eaves, purl in roof and clay ho l low pot floo r

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Vertical section throu g h eaves, pu rlin roof and clay ho l low pot floo r

D a The floo r u n its should bear max. 30 mm on the external wall, or rather mortar levelling bed . They are jo ined to gether and to the ribs with an in situ co ncrete ring b eam. D b lt is easy to co nstru ct a ventilated, "co ld" roof space and this presents no pro blems in terms of insu l atio n , mo istu re co ntro l , etc. The roof is simply an "u mbrel la" over a heated, heavyweight structu re. lt is l ittle trou ble to provide the to pmost floor with thermal insu l atio n . This type of floor is airtight and , thanks to its mass, stores heat wel l . Ventilation in shal lowpitched roofs ( < 1 0° ) takes place from eaves to eaves (min. 20 mm net per m) , controlled by wind pressure and wind suctio n. On steeper roofs ventilation at the rid ge or near it (e. g . i n the seco nd row of tiles from the to p) is necessary. As it is not possible to prevent dust and driving snow fro m entering the roof space throu gh the jo ints in the roof covering, this limits the use of the roof space. De Co nnect the eaves pu rl in to the ring beam with ragbolts. Th� ragbolts are inserted into correspond ing pockets which are fi l l ed with concrete after aligning the pu rI in.

D d The thermal insu l ation laid over the clay ho l low pot floor is afterward s covered with a screed , which has joints arou nd the ed ge and every 25-40 m2. The screed serves as a wearing cou rse, prevents d amage caused by any mo istu re present in the roof space and also acts as fire protectio n .

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D e When using interlocking clay roof tiles, check the length of the rafter to ensure that it is su itable fo r the cover length of the particu lar ti les chosen. D f "Negative pots" act as permanent fo rmwork fo r the stiffening transverse ri b . O g Gable wal l s, if not su p po rted by maso n ry piers or crosswalls, must be fixed to the roof stru ctu re ( D I N 1 053) , e . g . by means of galvanised steel flats or ru stproof ragbolts. The jo i nt between the final rafter and the maso nry of the gable must be able to transfer the forces invo l ved . D h After setti ng u p the rafters, finish off the to p of the gable wal l with a screed , flush with the rafters. Cover this with a flashing of, fo r examp le, fu l ly bonded bitumen roofing felt V 1 3 . The 1 0--1 5 mm deep cou nter battens of AW 1 00 p lywood prevent water co llecti ng behind the tiling bat, tens. The cover width of the clay verge ti les must co incide with the width of the bu i ld i n g .

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D a The roofing felt u nder the tiles is a water-repel lent but vapo u r-permeable material which remains stable despite temperature changes, e . g . mesh-rei nforced polyethylene. lt prevents the ingress of d ust, rain and d riving snow. Stretch it taut, secure it with co unter battens and ensure that water can d rain away at the eaves - id eally into the gutter (see p . 36, d ) . D b As on p. 32, flat-pan tiles are used here as wel l . The roof pitch of approx. 3JO chosen for our examp l e is suitab l e for virtually all types of clay roof tile: bullnose tiles as crown or slip ti l i n g , pantiles, interlocking tiles with single or do uble tro ughs, right u p to the ever mo re accurately interlocking varieties. De Determ ine the cross-sectio nal areas of g utters and downpipes based o n the size of the roof area to be d rained . C reate the fal l of the gutter - min. 1 mm/m by bend i n g the g utter b rackets to suit.

D d The roofing felt below the tiles co ntinues over the to p of the maso n ry, to which it is bonded . The thin counter batt ens prevent water collecting behind the ti ling battens.

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D e Use the two-piece bent sheet metal verge whe n , for example, the width of the build i n g is not a multi p l e of the cover width o f the interlo cking clay tiles. Otherwise, special o r cut tiles are necessary. D f Connect t h e masonry gable to the roof structure by means of cast-in ragbolts. Bracing i n the p lane of the roof i s thereby necessary.

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External wal l and roof space not u sed as living accommodatio n Vertical sectio n throu gh eaves, pu rl in roof and timber joist floor

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Da The timber joist floor over the u pper storey represents an inexpensive and , for self­ bu i ld projects, simple form of construction . Virtually any depth of thermal insu lation is possible with loose mate­ rials, and easi ly laid . lt is possible to improve the low heat storage capacity by using heavy loose materials or by laying solid bricks 5070 mm thick below the lo ose materia l . O b The stability of the bu ild i n g in all d irections is guaran­ teed by joining a l l load bear­ ing and shear wal l s to the floors with proper structu ral connections. If ring beams are provided , the walls can be regarded as being su p­ ported on all four sides; the floor joists only need to be held in position in that case . Line the joists pockets in the masonry with a moistu re­ resistant thermal insu lation , at least at the end of the joist, preferably on al l sides, to redu ce the risk of d amage by condensation water. De The airti ght connection between the 0.2 mm poly­ ethylene sheet and the wal l i s achieved with ad hesive and by using a clamping batten pressed onto a pre­ formed compressi b le seal­ ing strip along the wal l . The most secure connection is when the polyethylene sheet is wrapped arou nd a batten and screwed throu g h this into the wal l .

O d G lu e the roofing felt below the tiles to the nai led sheet metal. The perforated sheet metal bent into an i nverted V-shape ensures ventilation below the clay roof tiles. D e Even if the plastering work is carried out before l aying the timber joists, the u neven­ ness of the wal l and the ring beam must be evened out with an ad aptable "system" which closes off the joints airtight. This can be achieved with a batten nailed throu g h a preformed compressi b l e sealing stri p . Fill t h e void between joist and wal l com­ pletely with an u ncompacted mineral fibre material. After fi l l i n g the bays between the joists with a loose insu lati ng material, nail on the actual flooring mate­ rial . The gaps at the ed ges, necessary to al low move­ ment of the flooring, can be covered with a triangu lar fi llet. e

D f C onnect the gable wal l to the roof constru ction in such a way that forces can be transferred .

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Dou ble-leaf party wal l and clay tile roof Vertical sectio n throu gh ring beam and timber jo ist floo r

38

Vertical section th rou gh ring beam and clay ho l low pot floor

D a If th e floo r jo i sts are paral lel with th e wal l , th e slender, tall party wal ls must be secu red with ring beams if th ey are not co nnected to th e braced roof stru ctu re. D b Connect th e u nsu p po rted tops of the walls to the braced roof structure such th at forces can be transferred . Continue th e separating joint th rough to th e roof even in a roof space not u sed as living acco mmodatio n . D e Th e roofing felt h eld by th e cou nter battens - essentially taut but sagging sl ightly due to temperatu re ch anges and extension of th e material - is bond ed to th e mortar level­ ling bed . D d lt is advisable to replace th e tiling battens by galvanised steel angles. A clearance of 1 0-20 mm between the angle and th e to p of th e masonry enables th e roof structu re to defo rm without restraint. Fill the space between the angles with an inco m bu sti ble, vo lu­ metrically stable insu lating material . If th e roof space is to be co nverted into living accommodatio n at a later date, th e separating jo i nt must co ntinue u p to th e roof covering and th e tiling battens must be d ivided .

39

House B 42 44 48 50 52 56 62 68 70

Non-insu lated external basement wal l External basement wal l with perimeter i nsu latio n External basement wal l with cavity i nsu latio n Maso nry external basement wal l External basement wal l made fro m lig htweig ht clay b lo cks Rad iator recess, window with ro ller shutter External wal l and converted roof space C h i mney Partitio n and false wal l co ncealing services

41

No n-insulated external basement wall Vertical sectio n through co ncrete plinth

D a C ast the upper, and rein­ forced, part of the strip fo un­ d ation to gether with the rein­ fo rced concrete basement floor slab in one pour, then strike the outside formwo rk. The depth of the reinfo rced concrete basement floor slab d e pends on the loads from the basement part itions but sho uld be m i n . 1 20 mm in o rder to ensure the neces­ sary co ncrete cover to the reinfo rcement. D b A d amp-proof mem brane (d pm) beneath the screed is not required when the build i n g is fo unded on a quick-d raining subso i l and neither a high- q ual ity floor coverin g nor impact so und i nsulation or thermal insula­ tion is required . However, if a d amp-proof mem brane is not included , a layer of hard­ core to prevent cap i llary action is necessary . An approx. 30 mm bonded cement screed is adequate as the wearing co urse in simple basement rooms.

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D e Basement wal ls constructed i n normal-weight concrete­ even if they are reinfo rced must be waterproofed on the side in contact with the so i l . The type of waterproofing depends on the level of mo isture to be expected on the outsid e . D I N 1 81 95 part 1 tab le 1 categorises types of waterproofing accord i n g to moisture load and so i l type. Moisture in the so il must always be reckoned with . Furthermo re, in cohesive so ils and/o r on slo p i n g sites the presence of water in dro p let/l iquid form is to be expected . This means that waterproofing to protect against non-hyd rostatic pressure must be backed up with a drainage system

which prevents sho rt-term hyd rostatic pressure (see p p . 48 and 52) . Special measures must be taken fo r hyd rostatic pres­ sure on the o utsid e . Fo r moderate loads water­ proofing to the normal-weight co ncrete of the external basement wal l can be achieved i n various ways: e.g. with one layer of bitumen felt, bitumen bui lt-up felt, in each case with a fabric in lay and 1 00 mm laps o n a prim­ ing coat; with b itumi no us coatings in several layers; with two layers of a mineral sealing coati ng with build ing authority approval. Whereas in the case of flexible sheet­ ing good protectio n is required d uring backfil l ing and the upper "exposed " end must be sealed, the mineral coati ngs cannot brid ge over any cracks owing to their inherent brittleness. D d The gro u nd floo r co nstruc­ tion in this example includes thermal insu lation to i nsulate agai nst the unheated base­ ment. Take the presence of heavy co ncentrated loads into account when choosing the insulating material. Place the impact so und i nsulation beneath the thermal i nsula­ tion and around the ed ges without i nterruption - in o rder to prod uce a "floating" floo r constructio n . Conse­ quently, the floor finish must be fully isolated as wel l ; con­ tinuing the ed ge insulating strip up to finished floo r level is advantageous.

Vertical sect io n t h rough co ncrete lightwell

De Lightwells of in situ co ncrete "hang" on t he basement wal l and must b e co nnected to t his - possibly wit h fo lding anchors which are placed i n t he formwork a n d , after strik­ ing t he fo rmwo rk, are ex­ posed again and fo lded o ut into posit io n . Df The base of t he lightwell can be covered with a coarse gravel , which wi l l have to be rep laced from time to t ime­ assuming a q uick-draining subso i l and backfi l l i n g .

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Dg The to p edge of t he lightwell in t hi s example is reduced to match t he size of t he grat ing so t hat any paving or grass can co ntinue right up to the edge of t he frame. Cast t he top edges of t he lightwells later to mat c h t he level of ext ernal works and external doors, also wit h falls if neces­ sary . Dh If t he t hermal insu lat io n is attached to t he u nderside of the ground floor slab, this results in a thermal bri dge to t he external wall. This has to be minimised by including insulat io n wit h i n t he t h ick­ ness of the wal l which ex­ tends down at least to t he underside of the ground floo r slab.

43

External basement wal l with perimeter insu l ation Vertical sectio n throu gh prefabricated p l i nth

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D a The basement wal l can also be waterproofed by using impermeable co ncrete. This type of concrete is achieved with m i n . grade C 25/30 concrete havi ng a l i mited water penetratio n depth (max. 50 mm) , and by ad­ hering to the requ ired water/ cement ratio and grad ing curves. Rei nfo rcement to prevent/limit cracking is essentia l . Carefu l com pac­ tion and su bsequent treat­ ment is requ ired . The mini­ mum thickness is not pre­ scri bed but should not be less than 250 mm. External - perimeter thermal i nsu lation to compo­ nents in contact with the so i l is produ ced from c lose-cel l extrud ed , polystyrene foams or cellu lar g lass , which absorb little o r no mo istu re and are attached to the waterproofed basement wal l with dabs o f , fo r example, bond ing mortar. Cover the i nsu lation with corrugated bitu men sheet­ ing o r studded flexible sheeting to protect it against mechanical d amage du ring backfi l l i n g . D b Fou ndatio ns to small hou ses are often simpl ified and co n­ structed together with the grou nd slab as a raft fou nda­ tio n , which must be pro perly designed and reinforced accord ingly. Thickening of the slab may be necessary u nder heavy load s , e . g . i nd i ­ vidual co lu mns, i ntermed i ate load bearing wall s with larger openings. If the raft fou ndatio n is constructed from imperme­ able concrete l ike the exter­ nal wal l , seal the jo int between the two co ncrete compo nents with a water­ sto p o r water bar.

44

D e A heated basement forming part of the living accommo­ d ation requ ires an acou stic­ a l ly and thermally insu lated , waterproofed floo r slab with a flo ating screed . To prevent satu ration of the impact sou nd insu lation by the co n­ structio n mo istu re i n the concrete floor slab, provide a separating l ayer of, for exam ple, po lyethylene sheeting. D d Protect the transition between basement wal l and external wal l - the p l i nth - agai nst splashing water and mecha­ nical d amage by means of precast co ncrete or natu ral stone panels. Su p port these on cast-in ancho rs. Finish the render at a sto p bead and close off the jo i nt to the pl i nth with a permanently elastic sealing co mpou nd . The external maso nry pro­ jects approx. 90-1 00 mm beyond the concrete wal l . The u nderside o f the perfo­ rations in the clay blocks should be closed off at the proj ectio n . On the insid e , reinfo rce t h e p laster with a textile mesh at the transition between the two materials.

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D e Lay the insulation below the reinfo rced co ncrete base­ ment slab on a fi lter gravel or layer of blinding and cover over with a separati ng layer. C ast the basement slab o n this. A covering o f lean-mix concrete is advisable. When calculating the heat­ ing requirements allow for small heat losses via the thermal bridges at the strip fou ndatio ns u nder the exter­ nal walls and load beari ng wal ls.

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O h D I N 1 81 95 part 4 calls for at least one horizontal d amp­ proof co urse (d pc) i n the internal and external walls. The number of horizontal d amp-proof co urses is left to the d iscretion of the design team. The damp-proof course beneath the masonry of the wall represents a precau­ tionary measure preventing mo isture rising from the co n­ crete below.

D f Co nti nue the mineral sealing coating beneath the external wal l and jo i n it to the flexible sealing coating o n the o ut­ side of the external basement wal l . O g The b u i ld i n g trade is d ivid ed on the best method of con­ structin g a rendered plinth on properly fixed perimeter insulation batts. At least two coats of impermeable render (suitable fo r plinth work) will be necessary on splatterdash and a galvanised back­ gro u nd, add itio nal ly rein­ forced if necessary. Whether the normal rend er thickness of 20 mm is suffi­ cient fo r this type of detail is q uestionable. The render that extends into the gro u nd must be protected against lo ng-term saturatio n . e

45

External basement wal l with perimeter insu lation Horizontal section through prefabricated lightwe l l

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Vertical section throu gh prefabricated lightwel l

D a Fixing a lightwel l to a wal l with perimeter i nsu lation i s not without its pro blems because the insu lation should not be penetrated or, at best, only min imally . I nd ivi­ d ual fixings using heavy-duty anchors and spacers with bu ild ing authority approval are therefo re employed . The approved ed ge d istance between ancho r and window opening must be assured . O b Fu rthermore , the "surface of the wal l " presents pro b lems. Althou gh the render to the plinth can co ntinue down into the lightwell to gether with the backgrou nd , su ch small areas of render com­ plicate the co nstructio n . The area can be rendered before mou nting the lightwe l l .

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External basement wal l with cavity i nsulation Vertical sectio n through co ncrete plinth

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Db Lay the pipes, min. 1 00 mm N B , fo r the perimeter drain­ age o n a gravel bed to a fal l o f 0.5%, better 1 % , and sur­ ro und them with a filter mat in order to keep out the fin­ est so i l particles. In o rder to avoid undermining the fo un­ d ation , do not lay the d rain­ p i pe and the filter bed lower than the underside of the fo undatio n . A d i stance of m i n . 200 mm between the to p of the structural slab and the underside of the d rain­ p i pe is mand ato ry.

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Da The reinforced concrete strip fo undatio n req uires fo rmwo rk to both sides. Cover the anti-cap i l lary hardcore layer, included for add itional security , with a layer of b l ind ing co ncrete, grade C 8/1 0, and then cast the reinfo rced concrete gro u nd slab on to p of that. This forms a good base for worki ng in d ifficu lt, e . g . clayey, subso i ls d uring rai ny periods. Drainage around the perimeter is necessary o n slo ping sites o r i n cohesive so ils.

De The concrete d rainage un its protect the waterproofing against mechanical d amage and ensure that water is d rai ned away fro m the external wal l .

Vertical section through lightwel l and entrance door

D d The detail with moisture­ resistant cavity insulatio n , e . g . polystyrene o r mineral fibre batts, and an i nner l eaf ensures adequate thermal insulation and a good mois­ ture balance in heated base­ ment roo ms. lt is not usual ly necessary to include a vapour barrier o n the inner side of the thermal i nsu latio n . D e The thermal insulation on the underside of the slab over the basement is necessary in this case in order to reduce the thermal brid ge effect of the mono l ithic reinfo rced co ncrete co nstructio n . D f If complicated junctions are to be avo id ed , seal the pro­ jecting basement wal l with a dense, mesh-rei nfo rced screed . Such a detail requires a location protected fro m the weather and preferably roofed over. D g A co ntinuous slot in the base of the lightwel l ensures water can drain away into the quick­ draining backfi l l i n g material.

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Maso n ry external basement wal l Vertical sectio n throu gh rendered p l i nth

D a The wal l s to u nheated base­ ments are bu ilt using verti­ cally perforated clay blo cks, e . g . H lz 1 2- 1 . 2-6 OF, which have a greater compressive strength but, mainly , a higher gross density. As maso n ry basement wal l s can o n ly resist lateral so i l pressure o nce the verti­ cal load of the bu i ld i n g is available, backfi lling is car­ ried out later, e . g . after com­ p leting the stru ctu ral wo rks. A water-repellent basement wal l rend er of grou p P I l l provides the waterproofi n g . A s this rendering is relatively expensive and time-consum­ ing, is also rigid and there­ fo re vu lnerable to cracking, flexible seal ing coatings which can be rendered over may also be u sed . Drainage mats, e . g . corru ­ gated o r studded sheeting, protect against mechanical d amage during backfi l l i n g .

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D b Lay a damp-proof cou rse (d pc) of R 500 b itumen roof­ ing felt, better sti l l Cu 0. 1 D waterproof sheeting ( D I N 1 8 1 95) , o n the strip fou nda­ tio n and bond this to the d amp-proof membrane (d pm) over the rei nfo rced concrete ground slab. Great care must be taken with the jo i nt where the strip founda­ tion projects beyond the basement wal l ; the provision of a rou nd ed fil let and a fal l to the outside is advisable. The dpc beneath the walls should be jo ined to the grou nd slab dpm in o rder to produce an id eal , contro l l ed horizontal waterproofing sys­ tem.

D e The 25 mm mastic asphalt floor finish (surface finished with a smoothing compound) laid o n a special bitu men bu i lt-u p felt satisfies basic requ irements regard i n g ther­ mal i nsu latio n and impact sou nd insu latio n .

Vertical section through prefabricated lightwel l

D d The pl inth render u p to the level of the d amp-proof course has the same com­ position and thickness as that on the external base­ ment wal l . lt is finished flu sh with the render to the masonry above; s l it the joint between the two types of rendering with a trowel. An ang led undercut is reco mmended .

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D e Bu i ld u p the prefabricated lightwel l units o n the backfi ll­ ing separate fro m the house. This arrangement overcomes the need to fix complicated anchors i nto the masonry but does requ ire the backfi ll­ ing to consist of clean, com­ pactable material. lt is essen­ tial to compact the material carefu l ly and pro perly in o rder to reduce settlement of the free-stand ing lightwel l and hence damage to the masonry.

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External basement wal l made fro m lightwei ght clay b lo cks Vertical sectio n throu gh rendered p l i nth

D a Basement walls mad e fro m large lightweig ht clay blocks provide the necessary ther­ mal insu l atio n fo r heated basement roo ms and all the cond itions fo r a comfortable interior climate. A structu ral analysis must be carried o ut befo rehand to ensu re that the wal l thick­ ness co mbined with the ver­ tical load are able to resist the lateral so i l pressure over the depth of the basement. Waterproof the wal l with an elastic coating, e.g. made fro m a bituminous material, which contin ues as a flexi ble sealing coati ng i n the area of the rendered p l i nth. Drain­ age mats guarantee protec­ tio n fo r the waterproofi ng. D b The damp-proof mem brane (d pm) to the ground slab, required to protect against water held or flowi ng in the so i l du e to cap illarity (suc­ tion water, retained water, cap i l lary water), shou ld be secu rely bonded to the d am p-proof course (d pc) beneath the masonry wal l (protectio n against capillary mo istu re) and also the ex­ ternal waterproofi ng.

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D e Lay the peri meter d rainage o n a gravel bed and protect it on all sides with a filter mat agai nst ingress of fine par­ ticles.

Vertical section throu gh prefabricated lightwell

D d A nu m ber of manufactu rers produce prefabricated p las­ tic lightwells fitted with a su itable grati ng. These are ancho red in the maso nry . D e If the reinforced co ncrete floor slab spans over the wi ndow opening, it is not necessary to provide a masonry "compression zo ne" over the shallow clay l i ntels (see p. 2 1 ) . 12 OF Ill

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External basement wal l made from lightweight clay blocks Vertical section thro ugh entrance door

D a The wooden threshold to the door prevents condensation water and the fo rmation of ice in winter; the rebates and seals can continue right aro und the door. However, special precautions for this d etail are necessary, also because it is subjected to high mechanical load s: the cho ice of a su itable species of wood , e . g . oak; the provi­ sio n of fal l s to the o utside; keeping o ut heavy or d riving rain by means of the close­ mesh o pen grid flooring screwed on clear of the wood ; the fo rmation of a water bar with d ri p throat to repel incoming water. Th is latter task is o n ly ful­ filled by the botto mmost board of the o uter leaf to a very l i mited extent. To do this, the entrance door m ust be protected fro m the wind and weather. As mechanical d amage is hardly avo idable, this detai l is not suitable for heavily trafficked areas.

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D b The build i n g of a "naturally" coo l and damp basement fo r storage purposes requires a subso i l in which d rai nage is abso l utely guaranteed . A build-up of water m ust be ruled o ut. An anti-capil lary hardcore layer m i n . 150 mm d eep below the floo r of so l id clay bricks bedded in sand is advisable for extra secu­ rity . The inside of the base­ ment wal l s should be pro­ vid ed with an elastic sealing coati ng painted over with a m ineral whitewash , l ime­ wash or mi neral paint.

Vertical sections throu gh partitio ns

D e The d rawi ng shows the tran­ sition between the storage roo m with its floo r d i rectly o n the ground and the thermal ly and impact-sou nd insu lated floor of the heated basement area. The damp-proof mem­ brane (d pm) u nder the heated area must be fixed to the water bar at the door.

D d Partitio ns in the basement, ju st l ike externa l walls, requ i re protectio n against moistu re rising from below. D e A d pm is not requ ired below partitio ns over basement areas.

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Radiator recess, window with ro l ler shutter Vertical sectio n throu gh clay ro ller shutter box

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D a The ro ller shutter box and the outer leaf co ncealing the floo r slab fo rm a u n ifo rm su bstrate for the render. Such boxes are facto ry-pre­ fabricated , no n-load bearing items which can carry their own wei ght over o penings up to about 5 m wide thanks to their integral reinforcement. They are approx. 300 mm deep and available fo r wal l thicknesses of 300 o r 365 mm. D b The mai ntenance opening cover, made from 1 2-1 5 mm BFU plywood and a layer of thermal insu l atio n , e . g . m i n . 3 0 mm rigid polystyrene foam, is screwed i nto a rebate formed by an alu m i niu m angle. lt is rare fo r any attention to be paid to the detail at the ends of the mai ntenance o pening cover; heat losses and d rau ghts are the resu lt. Co nti nu i n g the angle frame arou nd all fou r sides and jo i n i n g it to the thermally insu lated su p po rts fo r the ro ller shutter box wou ld be necessary.

56

De The 1 75 mm maso n ry leaf behind the rad iator recess enables the rad iato r to be mou nted in the usual way o n cast-in wal l brackets. The i nterru ptio ns to the thermal insu lation simply have to be accepted . D d Fit the thin wi ndow board , e . g . 25 mm natu ral stone, into chases i n the maso nry reveals and su ppo rt it o n brackets every approx. 600 mm. D e Cut an o pening in the masonry fo r the shutter o perating cord if a special brick with a ready-mad e o pening is not being used .

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f The brush o r l i p seals to the o pening for the shutter o per­ ating co rd cannot com­ pletely ru le out heat losses at this po int.

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g A clay ro ller shutter box requ ires a m i n . 80 mm bear­ ing, 1 50 mm on the operat­ ing cord sid e . Cut off the rend er sto p bead at the u nderside of the shutter box to match the clear o pening of the window.

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h Rad iator recesses must be co nstru cted to match the masonry bond of the wal l . Ru nning the p i pes in verti­ cal slots in the external wall and weakening the sides of the recess fo r con necting the rad iato r pipewo rk was fo r a lon g time the standard solutio n . In o rder to meet the enhanced thermal i nsu latio n requ irements of newer leg is­ latio n , insu late the slots at least on the outsid e , prefer­ ably on three sides. Cut the slots fo r co nnecting the rad i­ ator pipework with a masonry saw.

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i Cutting the thermal insu la­ tion to fit exactly in the recess is the standard so lu­ tio n . Heat losses throu gh the no n-i nsu lated sides are igno red ; any condensation water that does occu r here is simply d riven off by the heat from the rad iator. Wood -woo l slabs o r sand­ wich panels with a poly­ styrene core have suffi­ ciently rou gh su rfaces to provide a key for plaster.

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Radiator recess, window with rol ler shutter Vertical section through prefabricated roller shutter box

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Da "Half" roller shutter boxes are available for windows with a masonry shoulder at the window head . A l i ntel flush with the ceil­ ing or a shallow clay l i ntel spans over the opening in the masonry. This deter­ mines the size of the rol led­ up shutter and in turn the hei ght of the window. From the point of view of thermal i nsulation , operating the shutter with a winding mechanism fitted in the reveal or on the wal l is pref­ erab le to the operati ng cord . Db I ncorporating a 300 mm c lay masonry unit (5 OF) in the 365 mm external wal l (6 OF or 1 2 OF un its) but flush on the outside creates a recess in the wal l , 1 35 mm high x 65 mm deep, above the re­ inforced concrete floor. With i nsulation at the back of the recess, this can be used for the radiator p ipework. Con­ nect the p ipes to the rad i ator underneath in the radiator recess. Smooth , fi l l and coat the screed . A structural ana­ lysis is required for this hori­ zontal slot.

De Span over the radiator recess with a shal low clay l inte l . The window board can be corre­ spondingly thinner in this case .

58

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O d The ends of the rol ler shutter box bear m i n . 40 mm on the external wal l . The bond of the masonry above the shallow clay lintel must match the masonry bond of the large clay b locks of the external wal l .

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D e The masonry shoulder en­ ables the guide track for the roller shutter to be fitted vir­ tual ly flush with the render. The bottom end of the track is welded closed and rests on the sheet metal window sill. The U- or L-shaped bent-up ends of the window sill are notched to suit. Precautions to prevent galvanic corrosion are nec­ essary if the metal of the track and the metal of the window sill are different. Slit the joint between rendering and roller shutter track with a trowel , or fi l l the joint with sealing compound. D f Continuous reinforcement in the masonry, at least in the uppermost bed joint, is neces­ sary to minim ise cracki ng.

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Radiator recess, window with roller shutter Vertical section through wi ndow/rol ler shutter element

D a The removable external fascia board of this special construction overcomes the problems of a maintenance cover that does not close tightly. The inside face of the wal l can continue uninter­ rupted . Roller shutter and window are incorporated as a single element from the outside, with a neat transi­ tion to the render. Operating the roller shutter by means of an electric motor is more complicated but does avoid the weak poi nts described earlier. D b Screw the fascia board to the shutter box, e . g . water­ proof-glued grade AW 1 00 plywood , to the frame tucked behind the render. Leave a small gap to highl ight the joint and protect the top of the fascia board with a metal Z-section. D e The rad iator p ipework runs in a slot (parallel with the external wall) in the rein­ forced concrete floor slab. Thermal insulation is not necessary because the existi ng thermal perform­ ance is unaffected and any heat lost from the p ipes sti l l benefits the same residential unit, in this case a terrace house.

60

Horizontal sections throug h roller shutter box, window, rad iator recess

Dd A steel flat bracket fixed to the frame supports the shaft of the roller shutter. De This detail permits the win­ dow element to be fitted flush with the render. How­ ever, it is advisable to inset the window by m i n . 1 0 mm, preferably 20-30 m m , in order to al low for tolerances and to provide some protec­ tion from the weather.

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External wall and converted roof space Vertical section through eaves of couple roof

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D a The rei nforced concrete floor slab can be used as the tie for the rafters and therefore eliminates the need for any columns in the roof space. Fix the eaves purlin with ragbolts every approx. 1 .5-2 .0 m cast i nto pockets in the reinforced concrete abutment mono­ lithic with the slab. Notch the continuation of the raft­ ers to suit or provide counter battens. D b The areas outside the con­ verted roof space are col d . Conti nue the thermal insula­ tion to the roof together with the airtig ht membrane or vapour barrier down the out­ side of the timber stud wal l . Provide thermal insulation on top of the reinforced con­ crete slab. D e Bond the roofing felt below the roof tiles to the eaves flashing. The bottom course of clay roof tiles rests on a strip of bent-up perforated sheet metal fixed to the eaves flashing with clips. The per­ forated sheet metal guaran­ tees ventilation and al lows any moisture to drain away. D d If the roof surface is in the form of a "stiff plate " , the connections to adjoining components around the edges of the roof plate must be capable of transferri ng the forces which occur. The gable wal l is attached to the roof structure. Rag­ bolts fitted carefully into the masonry every approx. 1 .52.0 m are suitable. I n order to prevent corrosion caused by condensation water, it is advisable to select stainless steel fasteners. Insert plywood spacers as necessary.

The junction with the gable wal l may also include a rein­ forced concrete capping beam along the top , unsup­ ported edge of the masonry. As the rei nforced concrete beam is cast in "steps" , which are determined by the masonry bond and the size of the masonry units, spec ial care should be taken to en­ sure that no therma l bridges through the concrete ensue.

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External wal l and converted roof space Vertical section throu gh eaves of couple roof

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Section through verge with parapet

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D a The gutter adjoins the roof covering directly and is joined to the downpipe via a coni­ cal header. The ventilation layers below the roofing felt and above the thermal i nsu­ lation end at the perforated plate through which fresh air can enter. Th is p late is fixed to the tilting board with con­ cealed nails, held in place by a continuous c l i p , and the bottom edge is finished as a rainwater drip. O b The "ventilated" roof, also known as a "cold deck", re­ quires a continuous air i nlet along the eaves (2 %o of the associated sloping roof area, min. 200 cm2/m unobstructed opening) and with this roof pitch an air outlet at the ridge too (0.05 %o of total slop ing roof area) . In this case a vapour bar­ rier is not required, which is difficult to i nstall properly on site anyway. Instead , a "vapour check" is incl uded which only allows as much vapour through as can be carried away by the move­ ment of air in the ventilation layer. Airtightness is absol utely imperative. Use, for exam­ ple, impreg nated paper, crepe paper or polyethylene sheet for the airti ght mem­ brane and vapour check. Care should be taken to ensure that all joints are adequately overlapped or bonded and, above al l , con­ tinuous and tightly sealed junctions with other compo­ nents. Provided the material chosen has a suitable vapour d iffusion resistance , the airtight mem brane can also act as a vapour check.

D e The gable wall is constructed as a parapet projecting wel l above the roof surface and thus accentuating the edge of the roof. Clad the inner face of the parapet with sheet metal. The parapet also has a sheet metal cap p i n g . Lay this on a separating layer bitumen roofing felt, PVC sheet, oiled paper depend­ ing on the metal - and on approx. 25 mm grade AW 1 00 plywood battens fixed with c l i ps. The capping overhangs the render by about 30 mm and the bottom edge finishes with a rai nwater drip. Bend­ ing up the capping a long the outside edge and/or pro­ viding a gentle fal l towards the roof surface avoids satu­ ration of the gable wal l . O d Use sheet metal soakers at the junction between the overlapping plain bullnose tiles and the masonry para­ pet. Fix the sheet metal para­ pet cladding with clips and provide a generous overlap to the soakers. D e After fixi ng the airtight membrane/vapour check, seal the plasterboard cei ling agai nst the gable wal l with a permanently elastic material.

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External wal l and converted roof space Vertical section through eaves of couple roof

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Section through verge with profiled bargeboard

D a A patented rafter abutment made from galvan ised sheet steel and screwed to a cast­ in proprietary channel elimi­ nates the need for a concrete abutment. Side plates hold the rafter i n place. D b Providing full-depth insula­ tion between the rafters in the form of a loose material (e. g . cellulose fibres or per­ lite) requires the construc­ tion of a box. Attach an air­ tight membrane/vapour check to the underside of the rafters and cover this with 19 mm tongue-and­ groove or p lai n-edge floor­ boards. This ensures ther­ mal insulation right down to the eaves. Dwarf walls can be provided as required to close off areas of the roof space. Add itional counter battens only at the rafters reduce the number of per­ forations in the vapour check, compensate for b u i l d ing tolerances and provide space for electric cables. D e Accord ing to the manufac­ turer, the 22 mm bitumen­ impregnated wood fi bre insulating board attached to the top of the rafters can function as a water run-off layer below the roof cover­ ing. The vapour permeabil ity of this material should be such that it is suitable for use with the airtight mem brane/ vapour check. Rule of thumb: the vapour permeabil ity should increase towards the outside. Fire protection require­ ments with respect to the roof structure, e . g . F 308, must be taken i nto account and may require different sizes of loadbearing tim ber members or a fire-retardant lining or cladding.

D d I n roof structures with verti­ cal framing the purlins, kneebraces and posts or common rafters are respon­ sible for transferring the wind loads. The gable wal l is "sus­ pended" from the roof struc­ ture. The junction detail here is no d ifferent to that for a roof p late (see p . 63) . Cast the rei nforced concrete cap­ ping beam on the stepped gable wal l . Thermal i nsula­ tion to the top of the beam is required because owing to the stepped arrangement the concrete extends into the heated area below and wou ld otherwise result in a thermal bridge. The antici­ pated deformation of the rei nforced concrete beam (as a result of the unavoid­ able shrinkage, aggravated by temperature fluctuations) must be taken i nto account when designing this deta i l . The use of a gable wall with­ out a reinforced concrete cap ping beam overcomes this problem (see p . 33) . Whatever the situation, care­ fu l ly fi l l the gap between the wal l and the final rafter fully with insulating material and connect the vapour check at least airti ght.

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D e Cut the outer leaf at the top of the wal l to suit and finish it off with a cement scree d . The "serrated" bargeboard, cut to match the line of the b u l l nose tiles, i s screwed to a batten and that in turn to the overhanging ti ling bat­ tens.

67

Chimney with flue lining Vertical section through rendered chimney stack

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D a The advantageous position near the ridge means that the chimney only needs to conti nue 400 or 500 mm above the ridge capping, depend ing on the appl ic­ able G erman building code. Cast the in situ concrete flaunching on a levelling bed of mortar. The cast-in expan­ sion sleeve a llows for the changes in length of the flue lining, which is insulated and enc losed in masonry.

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D b A rendered chimney stack requires a sufficiently wel l insulated flue. The ch imney stack should be as smooth as possible in order to improve flow char­ acteristics. On the other han d , to protect the render and accommodate move­ ment, a sheet metal capping with a large overhang is desirable. If there is no risk of corro­ sion, this confl ict can be overcome by providing a sheet metal capping of, for examp le, stainless steel . Connect the capping to the expansion sleeve with a welted joint. The rai nwater drip around the edge of the capping stands wel l clear of the render. D e If joints fi lled with perma­ nently elastic material are deemed undesirab le, the only option is to accept the risks and fit a capping strip flashing behind the render. Separate the render and the sheet metal with a 2-3 mm wide slit. Sheet metal flash ings in facing masonry are fitted into raked-out joi nts, fixed with c l i ps and sealed.

Prefabricated chimney Vertical section throug h chimney stack with facing brickwork

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D d The chimney here consist of lightweight concrete flue blocks around a thermally insulated flue lining of refrac­ tory clay. The min. 1 1 5 mm facing masonry of frost-resistant clay bricks - VMz or VHLz is seated on a built-in pre­ cast concrete element and must be built and pointed particularly carefully. Per­ pends left open act as in lets and outlets to the ventilation cavity. D e Place the prefabricated flaunching on a bed of mor­ tar, rake out the joint min. 20 mm deep and fill it with a permanently elastic material to secure the joint against driving rain . If the flaunching oversai ls the masonry, this protects the joint to some extent.

69

Partition with services concealed behind false wall Vertical section through san itary fittings

D a False walls for conceal ing services are desirable owi ng to the rational installation. There is no need to mod ify the masonry in anyway. In those cases in which the sound insu lation to the wal l , particu larly a party wall , i s adversely affected by pipe­ work, a false wal l i nstallation is i n d ispensable. The system shown here makes use of prefabricated instal lation elements made from polymer concrete for the respective sanitary fit­ tings .

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D e The junction between the flexible floating screed and the ri gid false wal l must allow for movement. Include a seal ing strip with a loop, ' conti nue this up the wal l and ' bond it to the wal l . Seal the =;: -itjoint between floor and wal l !I I with a permanently elastic ,-� material . I il I il As neither a shower nor a I il floor outlet are intended , this c bathroom is classed as a h area (but not a flooded wet �>�<� -; , : <,>', <<<<, >:, :> �, ->> :-"/:'/>>',->>', , ->� / ; , , , / / / , , / / " , . , " , ; , , , , , , / , , , / / / area) and does not requ ire Ll waterproofing beneath the floor covering and screed. lt is usually sufficient to lay the ceramic floor tiles in a water­ proof tile adhesive with nar­ row joints.

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The following section deals with the most important pri nciples for building with large clay blocks: - Clay block formats and d i mensional tolerances - Clay block types and mortar - Masonry bonds - Di mensional coordination The essay "Masonry of large clay blocks - structure and construction" by Dr.-lng. Bernhard Behringer clearly i l lus­ trates the i nteraction of the components to form a complete structure. The report "Plaster/Render on c lay masonry" by Dr.-lng. Peter Roeke explains the basic rules for applying plaster/ render to clay masonry by way of the behaviour of the wal l and its "cladd ing". Just how building with large clay blocks is affected by the Energieeinsparverordnung (EnEV - Energy Economy Act) wh ich has rep laced the 1 995 Warmeschutzverordnung (WSchVO - Thermal I nsu lation Act) - is not consi dered in this publication. The new Act is a com prehensive document wh ich has repercussions for building design and b u i l d ing services: the heat gains and/or losses associated with ori­ entation and fenestration , airtightness, thermal bridges and also the heating systems.

73

Clay brick and block formats , di mensional tolerances

The various sizes of clay bricks and blocks are de­ rived from a basic module, the thin format designated by the format code OF. Th is allows d ifferent brick/block formats to be com bined in a masonry construction . Larger formats made up of this format are easi ly imag­ ined, whereby the un its - as in the masonry construction - are assembled with joi nts. Clay bricks/blocks without conventional perpend mor­ tar are given the nearest for­ mat code ( D I N 1 05) . When desi gnating large ver­ tically perforated clay blocks it is necessary to specify the thickness of the masonry in order to d istinguish the blocks exactly. For example: clay blocks with the code 6 OF are avai lable for vari­ ous wal l thicknesses and course heights; clay blocks with the code 1 2 OF can be manufactured for 240 mm and 365 mm walls. In these cases the webs and fins separating the perforations or special perpend arrange­ ments are designed for a particular wal l thickness.

74

The dimensions g iven for the clay masonry un its are refer­ ence sizes. D I N 1 05 permits d imensional deviations from the reference sizes: min imum sizes and maximum sizes. So the actual d imensions of a c lay masonry unit 240 mm long may vary between 230 and 245 mm; for a 300 mm unit a length of 290-308 mm is permissible; for a 365 mm unit, 355-373 mm. However, on the building site it is im portant that the del iveries for a certain struc­ ture a l l lie with in a certain tolerance: the d imensional deviation is ± 1 0 mm for 240 mm units, and ± 1 2 mm for 300 and 365 mm units. The deviations for the height of a unit are stricter: 233-243 mm for a reference hei ght of 238 mm, and a d imensional deviaton of ± 6 mm.

Clay block formats , d i mensional tolerances

Lightweight vertically perfo­ rated clay masonry un its are clay bricks and blocks per­ forated perpendicular to the bed joint ( D I N 1 05 part 2 ) . The d ifference between these and vertically perfor­ ated clay masonry un its type Hlz is their low gross den­ sity, which may not exceed 1 000 kg/m3. They are avai la­ ble as type HLzA with type A perforations ( 1 5-50% of bed face area, each single open­ ing :s:: 2.5 cm2) , as type HLzB with type B perforations (as type A but with size of open­ ings specified ) , or as type H LzC with type C perfora­ tions (closed on five sides, total cross-section of perfo­ rations max. 50% , each sin­ gle open ing :s:: 1 6 cm2, size of opening specified) . Light­ weight vertically perforated clay masonry units type W (HLzW) of hei ght 238 m m have type B perforations and must also comply with requirements regard ing gross density and the number of rows of perforations in the direction of the wal l thick­ ness. New developments outside the D I N standard are covered by building authority ap provals.

Lightweight vertically perfor­ ated c lay masonry units are available with d ifferent per­ forations and perpends. Here are a number of examples of clay blocks of format code 1 2 OF for 365 mm external wal l s : D a Block with grip (thumb) openings for masonry with mortar to the perpends. D b Block with mortar slot for two methods of laying: laid indi­ vidually with mortar to the perpends but the slot l eft empty, or laid in rows brick to brick and the slot fi lled with mortar. D e Block with grip (thumb) openings for interlocki ng perpends without mortar. D d Toothed block for multiple interlocki ng perpends (no mortar) or as a gauged block for thin-bed mortar joints . The method of layi ng the blocks without mortar to the perpends reduces the work­ load during layi ng and the amount of mortar req uired, and also improves the ther­ mal insulation value of a plain external wal l . However, deviations in the sizes of the individual units cannot be compensated for in the mor­ tar joints like with conven­ tional masonry. At corners and junctions with other wal l s the perpends sti l l have to be filled with mortar; and at door and wi ndow reveals mortar joints or make-up units are necessary.

Mortar for masonry work is a mixture of sand and binder (lime or cement) p lus admix­ tures and additives which alter the properties of the mortar by physical or chemi­ cal means ( D I N 1 053) . Normal-weight mortar is either m ixed on site or sup­ plied ready mixed ( D I N 4226 part 1 ). We d istinguish between mortar groups MG I , 11 a, 11 b and I l l , and each group has to com ply with certain conditions ( D I N 1 053) . Li ghtweight mortar is sup­ plied ready mixed or as pre­ mixed dry mortar. Due to its lower oven-dry bulk density and the use of a lig htwei ght mi neral ag gregate, this type of mortar improves the ther­ mal insulation properties of sing le-leaf external walls. We d isti nguish between groups LM 2 1 and LM 36 ( D I N 4226) . Thi n-bed mortar is a fine­ grain premixed dry mortar ( D I N 4226) . lt must be used with a bed joint thickness of 1 -3 mm. lt is classed as a mortar group MG I l l .

75

Masonry bonds

Walls are built accord i n g to the followin g b aslc princi­ p ies - the b ondlng rules ( O I N 1 053) : - U n its in on e course sha l l be of equal h eight, the bed JOints shall b e continuous . - The perpend s and wal l . JOi nts of succe sslve courses must b e offset . This offset ­ the bon d i n d imension ­ must be 0 . x unit height but not le ss than 45 mm ( e . g . 95 m m for a unit 238 mm high) . Large clay blocks are u:�ally offset by half the len g . of the block. Crosswal ls - tc l u d i n g shear walls - do no necessarily have to be bonded ·In - a b utt JOint .1s ade q uate when . other m eans are provided to resist tens·IOn and compresSlon, e . g . fl at anchors b u i lt in. Simpl e masonrY b onds are used for la rge clay bl ocks, . which usually m atch the thickness of th e wal l . For exampie, stretch bond for parti­ tions 1 1 5 ' 1 5 and 240 mm thick, hea d er bond for external walls 365 mm thick.

�

·

�

76

For estimatin g purposes , th e . approXl mate work 'lng times are as follows: per sq uare metre of 1 1 5 mm partition: OF 1 .5 hours 2 OF 0.9 hours 6 OF 0.3 hours per square m etre of 240 mm ' P art1' t1on: O F 2 . 1 hours 1 .5 hours 2 OF 1 2 O F 1 ·2 hours

�

per square etre of 365 mm external wa O F 3 .3 hours 2 OF 2 . 1 hours 1 2 O F 1 .4 hours

Masonry bonds

D a

1 1 5 mm wal l

stretcher bond with DF units D b 1 1 5 mm wal l stretcher bond with 6 DF units

D c

240 mm wall header bond with DF u nits

0 d

240 mm wal l stretcher bond with 1 2 DF u n its

D e

365 mm wal l E n g l i s h b o n d with DF u n its

Stretchers are masonry units l a i d with their longitu d i nal, i . e . stretcher, faces parallel with the line of the masonry. Headers, however, are laid perpendicular to the l i ne of the masonry. The outward appearance of both bonds is therefore simi lar, i . e . successive courses offset. But the appearance of this b lockwork masonry is different from the fami l iar brickwork bonds - i n t h i s case English bond - characterised by their regular alternation between stretchers and headers .

D f

365 mm wal l header bond with 1 2 DF units

77

D i mensional coordination

Masonry dimensions are based on the "octametric" system: the 1 1 5 mm u n it plus 1 0 mm joint form the basi c module of 1 25 mm. By adding or su btracting joints we arrive at the three basic d i mensions: External dimension A = n x 1 25 - 1 0 mm Open ing dimension 6 n x 1 25 + 1 0 mm Projection d imension V = V = n x 1 25 mm =

78

D i mensional coordination also applies to clay masonry un its laid without mortar to the perpends. In this case the perpends are taken to be 3 mm wide and the u n its 247 mm long. Smaller un its, ends and junctions are cut to suit. Even though these days cutting and sawing on site can be carried out accu­ rately and efficiently, wast­ age due to cutting should be avoided when structures are designed accord ing to the masonry dimensions of the "octametric" system . lt should be remembered that stand­ ard windows and doors are also desig ned to fit the "octametric" system.

Masonry of large clay blocks - structure and construction Dr.- l n g . Bernhard Behringer

1.

Three-dimensional construction Buildi ngs, with their load-carrying and bracing elements , are loadbearing structures whose stabil ity must be guaran­ teed. That concerns both the individual loadbearing ele­ ments and the overall three-d imensional construction of the loadbeari ng structure. The primary load beari ng elements (apart from roof struc­ ture and foundations) are the walls and the floors. In the construction an individual wal l acts together with other wal l s with w h i c h it is d i rectly connected or coupled v i a floor plates or capping/ring beam systems. 1.1 Walls Masonry wal l s forming part of the load-carrying construc­ tion (" loadbearing wal ls") usually assume two different structural functions: Load-carrying : - vertical dead and imposed loads from floors, other walls, roof - horizontal loads perpendicu lar to the wal l due to wind or soil pressure Braci n g : - horizontal loads paral lel to the wal l due to floors, capping/ ring beams, crosswalls Walls without such functions are designated "non-load­ beari ng". 1 .2 Floors, capping/ri ng beam systems The primary structural function of the floor is always to the transfer the load per u nit area to the loadbearing elements (walls/beams/columns) . In addition , floors also act as hori­ zontal restraints for the walls; when designed as shear­ resistant p lates they form, together with the shear walls, a construction braced in all directions.

If a floor element is not designed to act as a p late (e.g. timber joist floor, clay hol low pot floor without concrete top­ ping) , the function of the three-d imensional coupling of the walls is ach ieved with capping and ring beam systems. Capping beams are components su bjected to bending which provide restrai nt transverse to the p lane of the wal l , i . e . resist forces d u e t o wind or soil pressure. R i n g beams accommodate axial forces (tension or compression) , i . e . "anchor" together, for example, t h e walls - normally pro­ vided with capping beams - transverse to the beam . Capping and ring beams - normally of reinforced concrete - can be om itted in certain circumstances (max. 2 proper storeys, length < 1 8.00 m, window/door openings < 60% of wal l length, or if wi dth of opening > 2/3 x storey height, then < 40% of wal l length ) . In these cases the floor beams (every 2.00 m) must be suitably anchore d . 1 .3 Simplified structural analysis D I N 1 053 prescribes cond itions which, if comp l ied with, enable a wal l to be designed using a simplified structural analysis with simpler stress verification. In addition , for sim­ ple types of b u i l d i n g , l i ke the terrace houses considered i n this book, the stabil ity is also g uaranteed for : - max. 2 storeys with storey hei ght up to 2 . 75 m - load beari ng walls: d = 365 or 240 mm for internal and external wal l s - non-load bearing walls: d = 1 1 5 mm - u pper floors of concrete, tim ber joists or c lay hol low pots, max. span 4.20 m - normal i mposed loads for residential use (max. 5.0 kN/m2) - proportion of windows < 60%, for windows > 1 .80 m wide < 40% I n these cases the only structural analysis requ i red for all load beari ng masonry walls is to show that the actual com­ pressive stress cr = N/A is less than the permissible com­ pressive stress. N is the vertical compressive force due to the self-wei g ht of the wal l plus the floor and roof loads carried by the wal l . A is the cross-sectional area o f the wal l o n which this com­ pressive force acts. The permissible stress is the "basic permissible stress" cr0, which is merely dependent on the type of clay masonry u nit being used (masonry u n it strength) and the mortar (mortar group ) .

79

Structure and construction contd .

1 .4 Detailed structural analysis Exceptions or special cases in which the geometric framework cond itions given in 1 .3 above are not com p l ied with are dealt with i n section 2 below. I n these cases the components covered by the simp l ified stress verification accord ing to D I N 1 053 part 1 must be checked for various other effects. One primary parameter for assessing the stresses in a wal l is its "slenderness", i . e . the ratio of buckl i n g length hk to wal l thickness d . The buckling length of a wal l is the clear storey hei ght m ulti plied by a factor p which takes into account the lateral restrai nt and the type of connection to the floors. The factor p l ies between 1 .0 (wall held on two sides, no restraint due to rei nforced concrete floors) and 0.35 (wall held on four sides, spacing of lateral restraints max. 2 .00 m) . The value h/d may not exceed 25. The basic permissi ble stress cr 0 must be reduced by a factor k, which in turn depends on the coefficients k, and k 2 or k3 . The reduction factors take i nto account the length of the wal l (k1 = 1 .0-0. 8) , the slenderness (k 1 .0-0) and the 2 effects of floor deflection (angle of rotation at supports) for floor spans between 4 . 20 and 6.00 m (k3 1 .0-0.7) . The background to these coefficients wi l l not be explained i n detail here ; the reader is referred to D l N 1 053 part 1 (7 . 2 ) . =

=

2 Special situations ("d isruptions" , special cases) A detailed structural analysis for the simple houses con­ sidered here i ncludes the roof structure , floors, concrete components and foundations (structure/subsoil i nteractio n ) . The masonry walls c a n generally be assessed accord ing to 1 .3 above. Special situations may make it necessary to per­ form calculations accord ing to 1 .4 , or the construction may require special consi deration. 2.1 "Disruptions" to the overal l construction The overal l loadbearing structure, the walls and floors, is weakened if the connections between the elements are "disrupted". We d isti nguish between two main cases :

a The lack of a connection between wal l and floor, e . g . at large floor openings in areas with galleries or stairs, where rooms (and hence walls) are two storeys h i g h . b The floors do not act as plates ( e . g . tim ber joist floors, clay hol low pot floors without concrete topping) . 2.2 " Disruptions" to the masonry wall The stability of a loadbearing wal l element can be impaired if local " d isru ptions" impair the restraint with i n the overall construction or reduce the thickness of wal l : a Openings in the wal l (wi ndows, doors) i nterrupt the wal l plate effect locally a n d t h e sections of wal l between the win­ dows represent "unsupported edges" without lateral restrai nt. The slenderness of the wall i ncreases, the load­ carrying capacity decreases. b Horizontal chases in the wall red uce the structural ly effec­ tive cross-section ; vertical chases or recesses can , beyond a certain depth , weaken the wal l so severely that the slen­ derness increases because at these poi nts an " unsup­ ported edge" must be al lowed for. However, chases up to a certain depth (depending on length) are permitted which do not have to be consi dered in the structural analysis . We dis­ ti nguish here between the way in which the chases are pro­ duced (milled or chisel led) . D I N 1 053 tab l e 1 0 contains more detailed information . 2.3 Special case "col umn" Masonry columns are usually constructed using small masonry units (i.e. bricks) . They represent a special situa­ tion in two respects: a The lateral restraint to this "short wal l " is missing on both sides, so columns are always held only on two sides ( i . e . the ends) . Column cross-sections < 0 . 1 0 m 2 may carry only 80% of their permissible design loa d , those < 0.04 m2 are not permissible as loadbearing elements. b Columns are generally positioned at points where loads from floors or wal l s above concentrate. The load-carrying capacity with respect to these i ncreased loads must be proved .

80

Structure and construction contd.

2.4 Special case "basement wal l " (in contact with t h e soil) Masonry external basement wal l s have to resist the soil pressure of the backfi lled excavation . This horizontal load is much greater than the horizontal load due to wind. The soil pressure causes the wal l to bend, which i n turn sets up ten­ sile and compressive stresses. As it is not permissible to design masonry for tensile stresses , it is necessary to can­ cel out the tension by means of appropriate compressive stresses (minimum vertical load ! ) . On the other han d , the vertical load should not be so high that the compressive stresses due to bending can no longer be resisted (maxi­ mum vertical load ! ) . An accurate structural analysis is not requ i red when it can be guaranteed that the vertical load lies between these minimum and maximum figures (see 3.4 below) .

3 Measures to al low for "d isruptions" and special cases The "d isruptions" described i n 2 . 1 above generally call for additional constructional measures to be taken. In some cir­ cumstances, however, an accurate structural analysis may show that the stabil ity is sti l l guaranteed and ad d itional measures are su perfl uous.

3.1 "Disruptions" t o the overall construction, t h e walls and floors a The lack of horizontal restrai nt to the wal l provided by the floor ( e . g . at large floor openings, galleries, stairs) is solved in constructional terms by providing a capping beam at the level of the floor and parallel to the open i n g . However, this is not necessary when the two-storey wal l at this point can be shown to be structural ly adeq uate. Th is is possible when appropriate lateral restraint from crosswal l s ("wall held on three sides") is avai lable. b Floors that are not designed as p l ates ( e . g . timber joist floors, clay hollow pot floors without concrete top ping) can provide horizontal restrai nt for walls if su itably anchored (see 1 . 2 above) . However, i n terms of the construction it is better to include capping/ring beam systems, i . e . restrain­ ing and cou p l i ng the wal l s at floor level by way of concrete components. In certain cases cappi ng/ring beam systems can be provided in the form of reinforced masonry.

Capp i n g and ring beams: The width is governed by the thickness of the wal l minus any i nsulation necessary. The depth is equal to a course of masonry. Capping and ring beams must be reinforced . Rei nforced masonry : Rei nforc ing bars in the bed joi nts must be protected agai nst corrosion (galvanise d , coated) or of stain less steel . R i n g beams i n the form of rei nforced masonry are only per­ missible with corresponding perforations in the units (pro­ portion of perforations < 35%, webs and fins not offset with respect to each other) . This requi rement is not met by large aerated clay bricks. Rei nforced masonry is therefore to be regarded as a special solution hardly used in practice and not advisable for the simple build ings considered here .

3.2 " D isruptions" t o the masonry wal l a Openings in the wal l (windows, doors) are to be spanned over with clay or concrete l i ntels, or by the rei nforced con­ crete floor slab (beam with i n depth of slab ) . Critical points here could be the supports (end of wal l or column) because the concentration of load here results in higher stresses and the wal l is restrained on only two or three sides, which calls for a buckl ing analysis (see 1 .4 above) . Clay l i ntels: Clay l i ntels are prefabricated tension chords for a load­ bearing element consisting of l i ntel plus masonry or con­ crete compression zone. The load-carrying capacity of clay l i ntels is generally defi ned in tabl es specifying width , depth and span . The maximum perm issible span of clay l i ntels is

3 .00 m .

Concrete l i ntels : Lintels not monol ith ic with the reinforced concrete floor slab should have dimensions l i ke those of capping and ring beams. With h 240 m m , spans of approx. 3.00-4 .00 m are possible, depending on vertical loa d . I n the case of a mon­ olithic l i ntel/floor slab, the depth of the l i ntel should be cho­ sen sensi bly: e . g . slab depth 1 60 mm + masonry course 250 mm = 41 0 m m . Spans of 5. 00-6.00 m are therefore possible, depending on vertical load. =

81

Structure and construction contd .

Rei nforced concrete floor slab: Suitably reinforced , a beam can be produced within the depth of a reinforced concrete floor slab, which can then span over an open i n g without the need for a l inte l . The spans possible depend on the depth of the floor slab, the d i rection in which the slab spans, and the vertical load . Deflection is critical for beams within the depth of the slab carrying vertical wal l loads because cracks ensue i n the masonry above. Without vertical wal l loads, spans of 3 .004.00 m are possible. b Horizontal chases with d imensions exceed i n g those g iven i n D I N 1 053 table 1 0 must be checked structurally. The analysis should take account of the eccentric ity e. Addi­ tional bending stresses occur due to the moment M n x e . The method of analysis is dealt with i n 3.4 below. =

3.3

Special case "col umn" Special constructional solutions may be necessary for very slender columns or those carrying heavy loads. If the permissi ble stress is exceeded for a g iven column size, it may prove prudent to use masonry units with a h i gher strength and/or a h i gher grade of mortar. The use of rein­ forced concrete columns or even steel stanchions is some­ times unavoidable. 3.4 Special case " basement wal l " ( i n contact with the soil) lt is not necessary to check a masonry external basement wal l in contact with the soil for compression (vertical load) and bending (soil pressure) if various cond itions (vertical load/geometry) are com p l ied with. Geometric cond itions: - max. 2 . 60 m clear basement storey hei ght - max. 2 . 50 m depth of ground surcharge The surcharge due to imposed loads may not exceed 5.0 kN/m2 • The minimum and maximum vertical loads are as follows: Wall thickness 240 mm 300 mm 365 mm

M i n . vertical load 7.50 kN/m 5.00 kN/m 4.00 kN/m

The maximum vertical load is such that the resultin g com­ pressive stress does not exceed 45% of the permissible compressive strength of the masonry.

82

Thanks to the self-weight of the floor slab over the base­ ment and the wal l to the ground floor above, the necessary m i n i mum vertical load is normally reached in the house types considered here with 365 mm external walls. At worst, the only problems occur at open ings in the floor slab at ground floor level ( e . g . stairs) or in areas without an external wall at ground floor leve l . Analyses may be requ i red in such cases, maybe also constructional measures (e. g . capping beam or reinforced masonry) i n certain circumstances. The maximum vertical load is normally never reached in these house types, even with low-strength masonry in the base­ ment wal l . If t h e above conditions are not com p l ied with, i t is neces­ sary to carry out a more accurate analysis of the stresses for the superim position of the compressive stress due to the vertical load cr0 N/A on the bending stresses (tensile and compressive) crP = +1-M/W. The tensile stresses due to bend­ ing must be cancel led out by the compressive stresses due to vertical load i n g . The same method of analysis should be used for an eccentric compressive load, as mentioned in 3 . 2 b above. =

Plaster/Render on clay masonry Dr.- l n g . Peter Roeke

1.

3.

Preamble Plaster and render are used to protect the building fabric and also for decorative purposes. That the latter is particularly sign ificant can be seen from the many different surface textures and colours that are possible. However, this aspect is also documented in prac­ tice by the many complaints concerni n g the appearance of plastered or rendered surfaces. That shows just how much significance is attri b uted to the visual appearance of p laster and render.

Types of plaster/render The standard defines plaster and render as wal l/soffit fin­ ishes produced from mixes and coating materials. Plaster and render are applied i n a certain thickness i n o n e or more coats. T h e p laster/render achieves its final properties after sol id ifying on the building and i n conjunc­ tion with this. We d istinguish between the fol lowing types of plaster/ render accordi n g to their constituents:

I n terms of appearance, the main complai nts are:

Plaster/Render with mineral b i n ders The m ixes from which this type of plaster/render is pro­ duced are a mixture of b i nder, aggregate and water. And recently in particu lar, add itives and admixtures have been added to i nfluence the properties of the p laster/render and the workabil ity of the mix.

-

cracks spal l i n g colour variations (streaks or blemishes) different textures i n the finish coat uneven surfaces, offsets uneven edges at b u i l d i n g corners and wal l openings inaccurate junctions with other components

Careful selection and han d l i n g of the mix, observing a l l the recommendations associated with this technology and tak­ ing care with details can help to avoid such defects. These pages are intended to provide g u i dance.

2. Standards Plasteri ng and rendering is these days covered by D I N 1 8550 parts 1 to 4. D I N 1 8550 part 1 - Plaster; terminology and requ i rements D I N 1 8550 part 2 - Plaster; p l asters made of mortars containing mineral binders; application D I N 1 8550 part 3 - Renderi n g ; renderin g systems for thermal insulation pur­ poses made of mortars consisting of mi neral binders and expanded polystyrene ( EPS) as aggregate D I N 1 8550 part 4 - Plasters and renderi n g ; l i g htwei g ht p lasters and render­ ing; execution D I N 1 8558 - Synthetic resin plasters; termi nology, requirements, application

3.1

The standard d istinguishes between additives and admix­ tures: •

Additives

These affect the properties of the plaster/render by way of chemical and/or physical actions. (Air entrai ners, waterproofers, retarders , accelerators, stabi­ l i sers for increasing the water-retention capacity and addi­ tives to i mprove the adhesion between mix and substrate. ) •

Admixtures

Adm ixtures in the mean ing of the standard are finely d istrib­ uted substances which also affect the properties of the mortar but whose volume, i n contrast to add itives, general ly has to be taken into account. ( F i l lers, e . g . stone d ust, to improve workabil ity; pigments to provide colour.) The standard d isti nguishes between the following types of p laster/render in terms of the tasks to be fulfi lled: - plaster/render that satisfies general requirements - plaster/render that satisfies add itional requirements • water-retardant plaster/render • water-repel lent p laster/render • render with enhanced strength • plaster with enhanced abrasion resistance • plaster for walls and ceilings in wet areas - plaster/render for special purposes • thermal insulation p laster/render • plaster/render providing fire protection • plaster/render with enhanced radiation absorption

83

Plaster/Render on clay masonry contd .

3.2

Plasters/Renders with organic b i nders These are p lasters/renders contai n i n g synthetic resins and produce a coating with an appearance resemb l i n g that of plaster/render. If these types are applied to a m ineral undercoat, this must be given a coat of primer fi rst. (For further details of synthetic res i n plaster/render see D I N 1 8558 . ) The binders i n synthetic resin plaster/render are synthetic resins. The other constituents, l ike sand and fil lers, are the same as those for mi neral plaster/render.

4. Plaster/Render The standard disting uishes between m ixes and coating materials.

4.1 M ixes The standard classifies mixes in five groups P I to P V. Mix groups Mix group 1 1

These types of p laster/render are primarily used for :

PI

- the finish coat on m ineral undercoats or other mi neral substrates - the final coat over thermal i nsulation composite systems

PII

3.3

Silicate plasters/renders These types are related to synthetic res i n p laster/render. However, the binder is different - in this case consisti ng of potassium water g lass with a d ispersion add itive for stabili­ sation. The water vapour permeabil ity of sil icate plaster/render is hi gher than that of synthetic resin p laster/render. This characteristic makes this type of p laster/render suita­ ble for historical b u i l d ings, for i nstance, and, if i ncombusti­ bil ity has been verified, as the final coat over thermal i nsula­ tion composite systems. This type of plaster/render cannot be used on substrates of wood , wood-based products or plastics.

P ill

P IV PV

Type of binder

non-hydraulic l i mes21 , semi-hydraulic limes, hydraulic l imes

h i ghly hydraulic limes, p laster b i nder and masonry cement, l ime-cement mixes

cements

calcined gypsum with and without b u i l d i n g l i me

anhydrite binder with and without building lime

1 For further subd ivision of mix groups, see DIN 1 8550 part 2, 1 985 edition, table 3 .

2 A l i mited amount of cement may be added .

Mixes consist of one or more b i nders , aggregates and water , possibly also with add itives and/or admixtures. The grain size of the majority of the aggregate l ies between 0 . 25 and 4 m m . In finish coats the proportion of grains > 4 mm can domi nate. The grain size has a great influence on the shrinkage behaviour of the p laster/render. The smaller the size of aggregate, the greater is the tendency to shrink. Mixes made from calcined gypsum and anhydrite binder mostly contain no aggregates. M ixes are also d isti ngu ished according to their state and p lace of production. •

State :

green (sti l l workable) hardened (solid ified)

•

84

Place of production: in situ (constituents mixed together on the building site) ready mixed (constituents mixed together in a factory)

Plaster/Render on clay masonry contd.

5.

6.3

Coating materials These consists of organic binders and aggregates or fil lers and are used for producing synthetic resin p laster/ render. The grain size of the majority of the aggregate is > 0.25 mm.

Thermal insulation p laster/render This type of plaster/render was specially developed to provide good thermal insu lation and exhi bits a bulk density considerably lower than that of l i g htweight plaster/render. Characteristic values for thermal conductivity � = 0.07 W/mK are possible with thermal i nsulation plaster/render. These types are manufactured as premixed dry materials. Thermal i nsulation plaster/render with a m ineral bi nder and expanded polystyrene (EPS) as the aggregate are currently covered by D I N 1 8550 part 3 . The compressive strength of the hardened m i x must l i e between 0 . 8 N/mm2 a n d 3 . 0 N/mm2 . Besi des polystyrene as an aggregate, covered in the aforementioned standard , mineral aggregates ( e . g . perlite and cellu lar g lass pellets) are being i ncreasingly employed. However, these do not generally achieve the aforementioned characteristic val ues for thermal conductivity.

These materials are produced i n a factory.

6. Disti nguishing plaster/render accord ing to its appl ication

6.1 Plaster/render for g eneral req uirements (normal-weight plaster/render) This type of plaster/render is covered by D I N 1 8550 parts 1 and 2 .

6. 2

Lightweight plaster/render Th is type of p laster/render is l i ke a normal-wei ght type with a mineral binder. However, in contrast to these they have a limited bulk density. The lower b u l k density is achieved by means of mineral and/or organic ag gregates with a porous microstructure. D I N 1 8550 part 4 includes su itable provisions for app ly­ ing l i g htweight p laster/render. Lightweight plaster/render and the associated finish coats must be manufactured i n the form of premixed dry materials. Compressive strength of l i g htwei ght plaster/render (mix group P I l l ) : between 2 . 5 and 5 . 0 N/mm2 Bulk d ensity of lightwe ig ht plaster/render: between 600 and 1 300 kg/m3 If a l i g htweight p laster/render comp l ies with the req u i re­ ments of mix group P 11, the compressive strength of the fin­ ish coat should be in accordance with the req u i rements for group P I c or P 11. Owi ng to its deformation behaviour, l i g htwei ght p laster/ render is particularly suitable for masonry comprising ther­ mally insulatin g , porous, l i g htweig ht vertically perforated clay masonry u n its. Lightweight p laster/render is not a thermal i nsu lating mate­ rial in itself. An organic finish coat, e . g . synthetic resin render, should not be applied to a l i g htweight render.

6.4 Renovation plaster/render This type of p laster/render exh i bits a h i g h porosity and water vapour permeabil ity. The capil larity is considerably lower. Renovation p laster/render is used on damp masonry and/ or masonry containing salts. The high vol ume of entrained air allows the salts to crystal l ise with in the p laster/render. I n t h i s way the salts are retai ned withi n the material a n d d o not reach the surface. The high water vapour permeabil ity is useful for al lowing the masonry to dry out.

7. Plastering/Renderi ng systems These systems are defined by the standard as all the coats of a plastered/rendered wal l/soffit finish in conjunction with the substrate. Even single-coat plasteri ng/rendering can be classed as a system . The system , i n its entirety, must comply with the particular requ i rements of the specification . Compatib i l ity betwee n the properties of the various coats i n a system is essential. The same is true for the compatib­ i l ity between plaster/render and su bstrate . The substrate must be prepared if necessary. Apart from leg itimate exceptions, e . g . render to basement walls and p l i nths, the strength of the finish coat for p laster/ render with a mi neral binder should be less than or equal to that of the undercoat. This principle also applies to the compatibil ity between undercoat and substrate .

85

Plaster/Render on clay masonry contd .

8. Applications 8.1 Render 8.1 . 1 General Basically, for render we d istinguish between the fol lowing : • wal l render above the p l i nth • basement wal l render ( i n contact with the soi l) • pl inth render • soffit render (underside of slabs in contact with the out­ side air) 8 . 1 .2 Wall render above the p l i nth The render must be resistant to the effects of the weather, moisture, temperature changes, wi n d , etc. In terms of protection from the rai n , 0 IN 41 08 part 3 specifies the exposure groups and the resu lting requ i re­ ments. 8 . 1 .3 Basement wal l render ( i n contact with the soi l ) I n areas in contact with t h e s o i l t h i s render forms a sub­ strate for the waterproofing. M ixes with hydrau lic b inders must be used for this type of render, which must also exh i b it a compressive strength of at least 1 0 N/mm2. If mix group P I l l is employe d , it is not necessary to verify the compressive strength. If masonry un its of compressive strength 6 N/mm2 or less are used for the basement wal l , the compressive strength of the mix shou l d not be significantly higher than 1 0 N/mm2, but may be less (� 5 N/mm2) . 8.1 .4 Plinth render This type of render must be sufficiently hard . it may absorb only small amounts of water and must be resistant to the effects of moisture and frost. Render made from m ixes with m ineral b i n ders must exhibit a compressive strength of at least 1 0 N/mm2. it is not necessary to verify the compressive strength when using render accord ing to the following tab le. If masonry un its of compressive strength 6 N/mm2 or less are used for the wal l , the compressive strength may be lower (but at least 5 N/mm2) . However, the requirements for water­ repellent render systems must be complied with .

86

Plinth render M ix group or coating material type for undercoat

finish coat1l

add itive

P ill

Pill

none

-

Pill

-

P ill

P Org 1

P Org 1 2l

l l Finish coats can be finished with or without some form of surface decoration (e. g . on surfaces to be coate d ) .

2l O n l y on a concrete substrate with a closed microstructure.

8.2 Plaster Plaster must comply with the normal requirements, e . g . suitable a s a substrate for paint a n d wal l paper. The compressive strength must be at least 1 .0 N/mm2. it is not necessary to verify the compressive strength when using the p lasteri ng systems classed accord ing to the req u i rements or applications of D I N 1 8550 part 1 .

9. Th ickness of p laster/render A minimum thickness must be mai ntained in order to fulfi l physical and other requ i rements. However, there is also an upper l i m it to the thickness. The standard prescri bes the fol lowin g average thick­ nesses for general requ i rements: Render:

20 mm (permissible m i n . thickness 1 5 mm) Plaster:

1 5 mm (permissible m i n . thickness 1 0 mm) single-coat plaster made from premixed d ry materials : 1 0 mm (perm issi ble m i n . thickness 5 mm) The permissi b l e m i n imum thickness must be confined to isolated patches. In the case of add itional req uirements, the thickness should be chosen to meet those req uirements. Single-coat water-repellent render made from premixed d ry materials: average thickness 1 5 mm ( m i n . thickness 1 0 mm).

Plaster/Render on clay masonry contd.

As a rule, the average thickness of l i g htwei ght render when used as an u n dercoat should be 1 5 mm. Here agai n , the minimum thickness must b e confined to isolated patches. The minimum thickness of thermal insu lation p laster/ render is given as 20 m m . However, in order to ach ieve a better thermal insu lation effect, it is usually thicker. Plaster/Render should be appl ied to achieve a consistent thickness. 1 0. Su bstrate A suitable su bstrate is a vital cond ition for durable p laster/ render free from defects. The properties of the substrate have a considerable influ­ ence on the adhesion of the p laster/render. A detailed examination of the substrate is therefore espe­ cially important and must be carried out by the plastering/ rendering contractor. Any objections must be recorded i n writi n g . Any work necessary t o rectify defects i n t h e substrate are the responsibil ity of the client ( D I N 1 96 1 : Contract proce­ dures for building works, part B: general conditions of con­ tract for the execution of b u i l d i n g works - c l . 4 para. 3 ) . Conditions for a suitable substrate:

- The substrate must be dry, free from d ust, clean, firm and capable of supporting the p laster/render. - Visi ble deposits that could damage the plaster/render shou l d be rectified; lime bloom and m i n imal efflorescence do not represent any p roblems. - The d i mensions of the substrate must be such that the p laster/render can be applied with a consistent thickness. - When used as a substrate for p laster/render, masonry must comply with the sti pulations in D I N 1 053: • all joints must be fi lled with mortar, • if perpends without mortar are used , these must be filled on the faces with a su itable mortar on both sides of the wal l if they are wider than 5 mm, • the prescri bed bonding d imension must be maintained, • defects, unfi lled slots and the exposed header faces of dog-tooth courses must be filled with mortar. The necessary mortar work should be carried out as the masonry is b u i lt. If the mortar is applied subsequently, a waiti ng time of at least four weeks is requ ired before apply­ ing the plaster/render.

11. I nterdependence of p laster/render and substrate The p lastering/rendering system chosen must be suitable for the type of substrate available. The first move i n select­ i n g a plaster/render is to make sure that it is suitable for the substrate . The choice of p lastering/rendering system depends on : - the suction rate of the substrate, - the loads to be expected during usage, - the properties of the masonry, and other factors. 1 2. Prepari ng the substrate Preparation of the substrate i nc l udes all those measures that are necessary in order to g uarantee a permanent bond between plaster/render and su bstrate. After exam i n i n g the substrate, the ensu ing preparatory work should be carried out: - H i gh ly absorbent substrates may need to be pre-wetted (observe instructions of mix suppl ier) . Other measures may also be necessary (high suction primer, prim i n g , full­ coverage spatterdas h ) . I n every case , follow the i nstruc­ tions of the mix manufacturer. - M ixes suitable for h i ghly absorbent masonry are avai lable. I n these the water-retention capacity of the undercoat is matched to the suction rate. - On a low-absorption substrate, blobs of spatterdash (not ful l coverage) are preferred in order to improve the adhe­ sion of the plaster/render. Adequate adhesion can also be achieved by other measures such as bonding coats or primers. - If the substrate consists of different materials with different suction rates, a ful l-coverage spatterdash is necessary in order to achieve a un iform suction rate. - If the substrate i nc l udes components made from materials that are unsu itable for use as a plastering/rendering sub­ strate, some form of background must be provided. - If stresses in the plaster/render are to be expected due to the type of construction or details, the p laster/render should be reinforced. - Wood-wool slabs should be covered with spatterdash. Reinforce the plaster/render in such areas. - Always follow the i nstructions of the mix manufacturer and the relevant techn ical information with respect to the sub­ strate.

87

Plaster/Render on clay masonry contd .

1 3. Examining the substrate - Visual inspection for: • cracks • moisture • dust and loose fragments on the surface • coatings or foreign matter on the surface • efflorescence • damage • protrud i ng mortar • excessive unevenness • perpends and bed joi nts not fully filled (primarily substrates for render) • excessively wide perpends without mortar • correctness of bonding d imension • strength (scratch test) - Wetti ng test with water for : • suction rate of substrate • d ifferent suction rates on varying substrates, if neces­ sary also for different clay masonry u n its • excessive moisture (no d i scoloration) • release agents etc. on , for examp l e , concrete compo­ nents, wood-wool slabs - Measurement for: • unevenness of wal l surface (straightedge, plumb line, etc . ) • surface temperature a n d air temperature 1 4. Applying the p laster/render - The deformations specific to the material of the substrate shou l d be completed before starting to apply the p laster/ render. - When using spatterdash, this must be sufficiently firm. - The su bstrate must be free from frost (not below +5°C) . - Owing to the constituents (e.g. add itives) in premixed dry materials, the properties of the plaster/render are not usually identifiable for the user. Good contact with the customer service department of the manufacturer of the premixed p laster/render is therefore h i ghly advisable. - The undercoat for render, especially when spatterdash is not being used, should be applied i n two operations. The fi rst (dubbing-out) coat should even out any irregu larities (approx. 7- 1 0 mm) . Only after this coat is stiff (after wait­ ing at least three hours or longer, depend i n g on the suc­ tion rate of the substrate) should the second undercoat be applied. The finish coat can be applied after the standard waiting time (1 day/mm thickness) . The leading mix manu­ facturers point out i n thei r techn ical information that the mix requ ires sufficient water in order to cure properly. With a th i n coat or excessively fast d ryi n g , the finished surface of the plaster/render should be wetted at least once. - If the finish coat is to be painted , then this shou l d not be carried out on the "green" p laster/render. The paint must 88

exhibit an adequate water vapour permeabil ity. The sub­ strate ( i . e . finish coat) must be suitable for painting and the paint must be compati b l e with the p laster/render. 1 5. Recommendations for obtaining p laster/render free from defects 1 5. 1 Shrinkage The setti ng process of the p laster/render is accom panied by shri nkage . Every type o f plaster/render - also those types with a small grain size to achieve good machine worka b i l ity ­ produced from the ready-mixed varieties avai lable today is subjected to shrinkage processes to some degree - large or small - after application. These shrinkage processes cause stresses i n the p laster/ render and, consequently, deformations. If the shri nkage stresses can be transferred to the substrate, the plaster/ render generally remains free from cracks. Essential for this is a good bond between plaster/render and substrate. If this bond is not achieved, the stresses cannot be relieved and the p laster/render cracks in areas where an adequate bond is lacki n g . The tensile stresses resulting from the shrinkage are greater than the tensile strength of the p laster/render. Continuous support for the p laster/render is therefore necessary over the entire surface of the substrate. If, for example, there are voids in the p laster/render over joints, there is no adhesion and the plaster/render cracks at those positions; the crack wi l l follow the l i ne of the joint. The cause of the cracking is therefore not the clay masonry itself but rather the plaster/render in conjunction with inadeq uate ad hesion at the joi nt. So the joint determines the course of the crack. For this reason it is absolutely essential to fi l l completely a l l the joi nts in the masonry.

Plaster/Render on clay masonry contd.

However, cracks over the joints can have other causes. If the mortar in the joints of the masonry has a lower suc­ tion rate than that of the clay masonry u n its , the p laster/ render over the surface of the clay masonry units will set earl ier and the tensile stresses due to shrinkage cause cracks at the joi nts because there the p laster/render is sti l l wetter and hence softer. T h i s problem c a n be remed ied b y wetting t h e surface o f t h e clay masonry units, following the instructions of the mix manufacturer. The magnitude of the d ifferent effects also depends on the thickness of the p laster/render, and the spacing of the joi nts also p lays its part. If the p laster/render is too th i n , the influence of the joi nts is more noticeable. The thickness of the plaster/render also affects its strength. If the plaster/render does not adhere wel l to the surface of the clay masonry u n its, e . g . because the properties of p laster/render and clay masonry are not i deally compati b l e , i t becomes detached due t o t h e stresses; a network of cracks is the result. I nadequate adhesion between finish coat and undercoat due to, for example, poor workmansh i p , can also cause the two coats to separate. If, for example, the surface of the undercoat is not rou g hened or, during hot weather, the sur­ face is not wetted , an i nadequate bond can be the out­ come. This also happens when the finish coat is stronger than the undercoat. The contractor wou l d be wel l advised to keep to the tried­ and-tested rule of decreasing the strength from inside to outside and to ignore what has been said recently about the opposite being better! However, the p laster/render should not be too thick because otherwise excessive stresses occur i n the surface of the plaster/render, which in turn lead to cracks. The shrinkage stresses at the surface can no longer be ade­ quately rel ieved because the distance of the surface from the substrate is too large and the stresses cannot be prop­ erly transferred to the su bstrate. Shrinkage is affected or increased by : : • a high proportion of b inder • a too rap i d water loss • too much water in the p laster/render • the grad i n g curve of the ag gregate

1 5. 2 Loads on the p laster/render In most cases of damage, moisture in one form or another is at least partly to blame. The constituents of the mix also play an important role with respect to the take-u p and release of water through capil lary action. The greater the effects of moisture, the greater is the stress on the plaster/render. Cracks which are frequently no cause for complaint become defects later due to the effects of water. Th is situa­ tion can often be seen primarily on the side exposed to the prevailing wi n d . 16 Patterns of damage - A network of fine, i rreg ular cracks not penetrating the full thickness Cause: • • •

too much bi nder in the mix impurities i n the aggregate plaster/render rubbed too early, too long and too vigorously

Shrinkage cracks: •

a too rap i d water loss (due to sunshine, high temperature or d raug hts)

Network of wider cracks:

( i nadeq uate ad hesion to substrate) • too much b i nder in the mix (cracks penetrate full coat thickness) • a too rap i d water loss Hairline cracks not penetrating deep into the plaster/render: •

•

these cracks are caused by rubbing the surface of the p laster/render where the surface is rich in binder and water fi ne-grain ag gregate with a smooth surface to the plaster/ render

Cracks following the line of the masonry joints:

I n this situation the stresses in the plaster/render over the joints are d ifferent to those over the masonry units them­ selves (capil lary water absorption of masonry units and joint mortar is different and results in different drying cond itions) .

89

Plaster/Render on clay masonry contd .

Cause: •

• •

mortar remains damp for longer when the masonry un its have a h i gher suction rate than the mortar defective substrate (joi nts not filled completely) perpends closed off only on the i n ner and outer faces (thermal bridge with formation of condensation water)

Plaster/Render separates like "puff pastry" • • •

excess water in the mix has frozen before it could escape mix was not yet strong enough frost progresses from outside to inside and the freezi ng water causes the mix to become detached in layers

Low mix strength •

•

too l ittle b i nder, too rap i d loss of moisture, poor grad ing of aggregate coat too dense when using P I (lime m ix) (P I requ i res a regular supply of moisture to reach its strength)

Plaster/Render detaches from substrate

(with good bond between finish coat and undercoat) inadequate bond when the surface absorbs too l ittle water - the binder paste is not absorbed to a sufficient extent (bond i ng forces are i neffective) • excessively absorbent substrate (spatterdash recom­ mended as regu lating i ntermediate layer) • absorbent clay masonry u n its should be pre-wetted d u r­ ing hot weather • p laster/render is not compatible with substrate (regu lated by means of high suction primer) •

Inadequate adhesion between finish coat and undercoat •

•

•

undercoat was not pre-wetted (during hot weather) , undercoat not roughened finish coat stronger than undercoat (dense coats transfer add itional stresses as they dry out) temperature grad ient - in thi n p laster/render especially ­ due to direct sunli ght (low heat d issi pation inwards , par­ ticularly in thermal i nsu lation masonry)

90

Supplement, August 2003

A masonry structure made from large l i g htwei ght vertically perforated clay blocks is much more effi­ cient in terms of thermal insu lation ( i n accordance with today's req uirements) than the masonry struc­ tures of the past built from (smal l-format) clay bricks. This development has brought about a change in the gross density and the strength. I n combination with other materials (principally con­ crete) , careful design is necessary plus compre­ hensive foresi ght i n weighing up the possible risks: Stresses due to deformations caused by thermal processes (hot - col d , sun - shade, day ­ night, summer - winter . . . ) moisture-related processes (water - vapour, rain - snow - ice, moisture due to construction and usage and the associated shrinkage and swell­ ing) material-related and chemical processes •

•

•

Estimates or calcu lations of deformations together with the structural engineer are i nvaluable. In doing so, the loads from outside (orientation with i nci­ dence of solar rad i ation, preva i l i n g wind side . . . ) are to be included in the catalogue of risks to the same extent as the loads from the structure itself: its size and usage, the type of loadbearing structure and the materials used in its construction. Likewise, also any protective arrangements such as roof overhangs, canopies , balconies . . . right up to pro­ jections, re-entrant corners and shoulders. What are the consequences for this book? The detail drawings are "compati ble" with each other but remain as typical, partial i nformation . Thei r fea­ sibi lity and compati b i l ity must be carefully checked in each individual case because integrating these into the design of each new, d ifferent structure could necessitate fundamental changes.

Designers wishing to create d urable structures must be prepared to learn from recent experiences in order to avoid vulnerable situations (see Schaden­

freies Bauen mit Mauerwerk, Katalog von Riss­

schaden und Maf3nahmen zu deren Vermeidung,

Prof. P. Schubert; Masonry Construction Manual, Pfeifer et al . , p. 1 06) . Differential deformations

As differential deformations represent a key prob­ lem, the primary parameters of wal l materials are l i sted below (characteristic values but also ranges which indicate someth ing of the d iversity and scat­ ter of the materia l ) . Th is will enable a rou g h esti­ mate of d ifferential tem perature or moisture defor­ mations to be made and hence the compati b i l ity or i ncompati b i l ity between materials. Supports for reinforced concrete floor slabs

Deformations in rei nforced concrete floor slabs cause stresses in the external masonry; these can be superimposed on and increase other deforma­ tions. If temperature-related deformations can be ruled out thanks to adequate and properly installed thermal insulation , deformations due to the loads plus shrinkage and creep of the concrete are the principal causes : ·

Deflection of the slab and l ifting of the slab at the supports due to the rotation of the edges of the slab, aggravated by the excessive slenderness of the slab and a low vertical load at the supports. The result is horizontal cracks at the supports or in the u nderlying courses. The corners of roof slabs without any vertical load are particularly at risk due to the " d ishing" effect.

Deformation parameters for shrinkage, creep and temperature changes to D I N 1 059 table 2

Type of masonry unit

Clay

Calcium sil icate Lightweight concrete Concrete Aerated concrete

Final moisture expansion shrinkage, chem. swel ling

Char. value mm/m 0

-0.2 - 0 .4 -0.2 -0.2

Final creep coefficient

Range mm/m

Char. value

Range

-0. 1 t o -0. 3 -0. 2 to -0. 5 -0. 1 t o -0.3 +0. 1 t o -0.3

1 .0

1 .5 2.0

0.5 to 1 . 5

+0.3 to -0.2

1 .0 1 .5

shortening (shrinkage) : - s i g n ; len gthening (chemical swelling) : + sign

1 .0 to 2 . 0 1 . 5 to 2 . 5 1 .0 to 2 . 5

Coeff. o f thermal expansion

Char. value 1 0 -6/K 6 8 1 0 (8*) 10 8

Range 1 0 -6/K

5 to 7

7 8 8 7

to to to to

9 12 12 9

* for lightwei ght concrete with expanded clay as principal aggregate

91

Supplement, Aug ust 2003

•

•

Shortening of the slab and " p u l l i n g " the masonry units at the support. The res u lt is horizontal cracks at the support but also downward diago­ nal cracks i n internal crosswalls at the supports or horizontal cracks in the middle of the wal l . Eccentric load transfer at the support - also a conseq uence of the aforementioned deforma­ tions. The result can be cracks on the outside of the wal l or also cracks beneath the support on the i nside due to excessive edge beari ng pressure.

Countermeasures •

Concrete technology and workmansh i p : the use of low-shrinkage concrete with a low water/ cement ratio (beware of uncontrolled addition of concrete additives ) , careful curing (striking the formwork later, protecting concrete surfaces against sunshine and wi nd by coveri ng keeping moist, sprinkl ing with water . . . ).

· A sufficient slab depth: DIN 1 8530 specifies maxi­ mum slenderness ratios for roof slabs (generally without vertical loads) ; it is also possible to replace the lack of vertical load by i ncorporati ng a vertical tie to the slab below. •

•

le> 'r-

[> [> f-.-...

b ,---, r /l<

/ / "/ / <. ,.- // /

�'

l___j

/ /"' / // / /

Reduce the shortening due to shrinkage , espe­ cially that of the roof slab, by l imiting the length of the slab or incorporating contraction joints. Include a bed of h i gh-strength mortar or a sepa­ rating layer between the concrete slab and the masonry at the supports.

A sufficiently wide bearing for slabs with larger spans: D a: I ncorporate compressible strips on the inside of the support to centre the load transfer and avoid damage due to the beari ng pressure on the edge D b : Reduce the thickness of the fac ing leaf (brick slips instead of half-brick units) or bed the concrete in a suitably prepared clay channel b lock.

I

•

Capping and ring beams

The shrinkage of ring beams, capping beams and other concrete and reinforced concrete compo­ nents with i n the masonry can lead to damage if these processes are not considered when design­ ing the detai l s . Concrete components which are not absolutely essential should therefore be omitted.

92

k> [> [> �

n LJ

b

I

Supplement, August 2003

Securing unsupported edges of masonry and the stability of the building can be achieved by provid­ ing structural connections to appropriately braced components, l ike roof or floor plates. Openings in walls

I n masonry structures wel l-known patterns of cracks can occur, e . g . in spandrel panels, which usually run d iagonally downwards from the corners of openings. To avoid these, the drawings else­ where in this book show "anti-crack rei nforcement" in the spandrel panels. Th is "anti-crack reinforce­ ment" , which merely l imits the width and d i stribu­ tion of cracks, should comprise steel bars pro­ tected agai nst corrosion, better sti l l , specially designed brickwork rei nforc ing elements of stain­ less steel - such reinforcing elements have nodes and cannot be p u ll ed out. The reinforcement should extend i nto the masonry adjoi n i n g , for example, an opening by about 600-800 m m .

At larger openings the reinforcement should be i ncorporated as "high" as possible, i . e . in the top­ most bed joi nt. lt is also possible to incorporate the approx. 5 mm reinforcing elements in l i g htwei g ht mortar because this is not classed as rei nforced masonry ( D I N 1 053 part 3) . Chases and recesses

These can severely weaken the load-carrying capacity of the homogeneous masonry due to the change i n the cross-sectional area, the flexural stiff­ ness and the eccentricity of the remaining area. Chases and recesses made in the finished masonry can lead to considerable damage because they are often cut unsupervised and in particularly sensi­ tive areas without consultation . In external walls they also form undesi rable thermal bri dges. In other words, chases and recesses must be prop­ erly planned and integrated into the structure

Chases and recesses not requiring a structural analysis in load bearing walls to D I N 1 053 table 1 0 Vertical chases a n d recesses i n a masonry bond Wal l thickness (mm)

Chase wi dth (mm)

Residual wal l thk. (mm)

240

max. 385

min. 1 1 5

max. 385

m i n . 240

1 15

365

Edge d i stance m i n . 2 x chase width but at least 240 mm

Distance between chases and recesses to be at least equal to m i n imum chase wi dth .

The total width of chases per 2.00 m of wall len gth may not exceed the maximum chase width.

Chases and recesses cut subsequently ( length of chase u n l i m ited) Wall thickness (mm)

Horizontal and d iagonal

115 240 365

Vertical chases and recesses

depth (mm)

depth (mm)

width of single chase

max. 1 5

max. 30

max . 1 50

max. 20

max. 1 0

max. 30

max. 1 00

max. 200

Edge distance of chases and recesses from openings to be at least 1 1 5 m m .

Horizontal and d iagonal chases are o n l y permissible w h e n a t least 0.40 m above or below t h e structural floor slab

and only on one side of a wal l . When using tools with which the cutting depth can be set accurately, the depth may be i ncreased by 1 0 mm and walls at least 240 mm thick may have chases cut on both s i des max. 1 0 mm

deep. Chases max. 80 mm deep and max. 1 20 mm wide that extend no more than 1 .00 m above the floor may be

cut in walls at least 240 m m thick.

93

C l ay masonry b u i l d i n g s Exam p l e s

Clay masonry buildings - examples 97

Hou s i n g complex i n M u n i c h Christoph Wallner, M u n i c h

98

Semi-detached h o u s e i n M u n i c h Andreas M e e k and Brig itte Puis, M u n i c h

1 00

Houses in M u n i c h Thomas M . Hammer a n d Doris Schmi d-Hammer, M u n i c h

1 02

House in Hal lertau Waiter Stolz, Rose nheim

1 04

1 06

Studio house in Eichstatt

D i ezin ger & Kramer, Eichstatt

Housing development in Neu-Uim G .A.S.-Sahner, Stuttgart

1 08

Hous i n g complex in Waldkraiburg Andreas Meek, M u n i c h

1 10

Hou s i n g complex in Ludwi gsburg Hartwig N . Schneider with Gabriele Mayer, Stuttgart

96

Clay masonry buildi ngs Exam ples

Housing complex in M u nich

la

aa Ground floor plan Section Detail Scale 1 :20 •

Christoph Wal l ner, Munich Situated to the north of Munich in a residential district with detached and terraced houses, this brightly painted oblong building immed iately catches the eye . The complex, containing four apartments, is located on a corner plot with apple trees and is not out of scale with its surroundings. The flat sides of the box are broken up by openings for logg ias at ground floor level and a spacious staircase to the apartments on the first floor. The wal l s are sol id with a thermal i nsulation composite system . The windows are emphasised

Scale 1 :400

by their dark wooden frames fl ush with the wal l . The c l ient, a ski lled pai nter hi mself, also had a hand in deciding on the final colour scheme. The entire external skin was first given two coats of an opaque yel low silicone resin pai nt. The final coat of outdoor glaze with a terracotta shade was applied with brushes and sponges i n delicate wi ping movements. From outside, the building looks as though it has been coloured with a pigment ClJ DETAIL 1 2/2003

97

Clay masonry build ings Examp les

Semi-detached house i n M u nich

� I D

. __2

C_ aa

Andreas Meek and Brig itte Puis, Munich At first sight this small sem i-detached house seems to represent the arche­ typal housing development unit a d is­ tinct, compact envelope with a steep p itched roof and eaves and verge vir­ tually flush with the walls, standing out peacefully from the surrounding, i nho­ mogeneous built environment. Th is is hel ped by restricti ng the number of d if­ ferent building materials. Only upon closer inspection do we appreciate the sensitive treatment of the everyday ar­ chitectural language. Simplicity is the basic concept behind this building. I n­ stead of the conventional Velux-type roof windows, conspicuous boxes with straightforward top-hung opening l ights penetrate the roof surface. Un­ treated mahogany windows fit flush with the external wal l but sti l l seem to protrude just a l ittle from the facade. The omission of g lazing beads and the way the panes of g lass are g lued flush into their frames allow the windows to appear as flat elements without any depth. Only the entrance doors set back into the facade create a distinct accent and correspond to our idea of the customary "hole in the wall" so typical of masonry facades. The 240 mm clay masonry is covered completely on the outside with a ther­ mal insu lation composite syste m ; the smooth surface of the render has been given no further treatment. No coats of paint conceal the irregularities of the ind ividual stages of the work or sub­ sequent maki ng good. The surface ap­ pears animated and can already tell its own story. The render on the gable ter­ mi nates elegantly in classical style at the del icate, zigzag line of the clay bullnose roof tiles. ClJ DETA I L 1 /2 2002 98

Ground floor plan Section scale 1 :400 Section through facade scale 1 : 1 0 •

2 3 4 5 6 7 8

M i neral render, finished directly o n the underside of the clay roof tiles Render background: 30 mm wood-wool slabs 80 m m rigid polystyrene foam U ntreated mahogany window Balustrade, welded 30 x 8 mm steel flats, galvanised and coated U ntreated mahogany entrance door In situ concrete step 60 m m rigid cel lular glass insu lation

Clay masonry buildi ngs Examples

Houses i n Mu nich

aa

Thomas M. H ammer and Doris Schmid-Hammer, Munich The governing idea for the design of this pair of houses was independent yet joint l ifestyles. The loose coupling of the houses gives each of the clients - two brothers - space to enjoy his own l ifestyle. Two different envelopes were created , li nked by a tal l wal l on the road side. The entrance and garage doors along this facade are protected by a continuous canopy, signifying the access zone. The per­ sonal lifestyles of the brothers are primarily evident in the d ifferent i nterior layouts. One of the houses is partly in ti mber and takes account of the needs of a communal l ifestyle. Here, the open-plan living room/kitchen forms the communal, communications hub of the house , although each occupant is provided with living and working areas, all the same size. The external wal l of the other house, which is parallel to the road , is of 365 mm l i ghtweight clay masonry with a white render finish . The spacious open-plan living and dining area for the family occupies virtually the whole of the ground floor. The various private rooms are located on the upper floor and under the roof; these serve as bedrooms, studies or children's rooms depending on the size of the fam ily. Despite the compactness of this build­ ing, skilful design has resulted i n an in­ teresti ng interior layout with d iverse in­ ternal and external views. The i ngen­ ious use of natural l i ghting underli nes and rounds off this effect. QJ in DETA I L Single Family Houses

1 00

a

a

Sections Ground floor plan scale 1 :400 Details scale 1 :20 •

Standing seam roof covering of sheet titanium-zinc 2 layers of bitumen roofing felt 24 mm rough-sawn tongue and g roove boards 1 00 mm ventilation cavity between 1 00 x 1 00 mm rafters 1 9 mm bitumen-impregnated softboard 220 mm cellu lose insulation between 1 20 x 220 mm purl ins 24 mm open boarding 2x 10 mm p lasterboard with vapour barrier between 2 365 mm clay masonry Hlz 1 2- 1 ,0- 1 2 OF units 3 Basement wall: cement render on bonding coat cellu lar glass insu lation waterproofing 4 Sol i d wood lining, 50 mm larch

101

Clay masonry buildi ngs Examples

House in Hallertau

Waiter Stolz, Rosenheim

The plot is located in a new residential development with a variety of detached homes on the outskirts of this l ittle town in Bavaria. The house and garage are positioned at the top end of this gently sloping site. Together with the wal l in between , they form a boundary on the road side and enclose the west-facing garden with its view towards the town in the valley. The north elevation of the main buildi n g has very few openings but includes a g lazed porch, which acts as a climate buffer and lobby for the entrance.

L._

aa

1 02

Careful choice of materials and simple, precise detai ling have resulted in a building that relates to both contemporary architecture and regional building traditions. The wal ls are of 365 mm lightweight clay masonry with a finish of three-coat lime render pai nted sienna red . The natural-colour concrete roof tiles termi nate at the eaves and verges without an overhang , simply with sheet metal flashings. Q:l DETA I L 1 /1 999

15

16

Ground floor plan Section scale 1 : 250 Section Verge detail scale 1 :20 •

•

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Roof construction: natural-colour concrete roof tiles battens and counter battens roofing felt, open to d iffusion 22 + 40 mm wood fibre insulation 80 x 1 76 m m rafters with 1 00 + 60 mm thermal insulation between vapour barrier 1 6 m m spruce boards 240 x 300 mm rei nforced concrete ring beam Lightweight clay toothed blocks, 8-0,8- 1 2 OF 3-coat l i me render Heat-absorbing g lass (2 panes of toughened safety glass) Perforated sheet titanium-zinc 60 x 1 60 mm wall plate Steel angle, 90 x 90 x 7 mm both sides of rafter 8 mm toughened safety glass 25 x 25 x 3 mm stai nless steel angle Wood/Aluminium window Louvre blind Prefabricated clay lintel Drainage channel 24 mm veneer plywood Titanium-zinc verge flashing Clay channel

1 03

Clay masonry buildi ngs Exam ples

Studio house in Eichstatt

Diezinger

&

Kramer, Eichstatt

On the edge of the old quarter of the town, a compact, rendered studio house has been erected to replace a ruined artisan's house dating from the 1 6th century while retaining the con­ tours of the old building. With its dis­ tinct, modern stance, the new house is not intimidated by the confines of its surroundi ngs and introduces a striking urban highl ight. The diagonal entrance elevation, like the old building, and the freely arranged open ings animate the envelope with its rigid contours. The white, brightly lit i nterior contrasts with the rendered external walls with their coat of dark grey paint. This two-storey house has a total of about 75 m2 of floor space. The ground floor has a small display area and a larger room for receptions and similar events (but also suitable as guest accommoda­ tion) . U pstairs is the scul ptor's studio. The bathroom, in red-painted wood , is a stark contrast to the white of the rest of the interior surfaces. The two levels are l inked by the small display area next to the entrance, extending right up to the underside of the roof. Passers­ by can see into this area throug h the "disp lay window" which is finished flush with the render and conti nues around the corner of the building. Despite its small size, the display area forms a l i nk between interior and exter­ ior, and acts as a foca l point for the internal layout. All the fixed l i ghts are positioned flush with the render. There are no frames around the panes of glass; the glass is held in p lace by clips between the panes. The top-hung Velux-type roof windows open outwards. QJ DETA I L 7/8 2002

1 04

I/ I I I I

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a

I I

I

J! I 11

I I

I

n

l

u

a

Sections Plans scale 1 : 200 Section scale 1 :20 •

2

3 4 5 6 7 8

Wal l constructio n : 2 5 mm painted mineral render 365 m m vertically perforated clay masonry galvanised rei nforcement to top 3 courses 2x 0 8 mm bars per bed joint 1 5 mm lime-gypsum plaster Floor construction: 60 m m end-grain wood-block flooring 1 0 mm hot-rolled asphalt 45 mm cement screed on PE sheeting 20 mm impact sound insulation on PE sheeting 220 m m reinforced concrete floor slab 50 mm mineral fibre thermal insulation to side of 1 40 mm reinforced concrete beam Clay channel l i ntel on galvanised steel angles, 200 x 200 x 1 6 mm Wooden window with single glazing 36 mm white-faced p lywood Glazing clip between panes Double g lazi n g : 6 mm float glass + 1 6 mm cavity + 8 mm toughened safety glass, edge seal enamelled for UV protection

1 05

Clay masonry build ings Examples

Housing development in Neu-Uim

G. A S.-Sahner, Stuttgart Georg Sahner Not far from the town of Neu-Uim, adjoining an area of farmlan d , there is a small residential district with a core of 20 system houses. With their asso­ ciated storage sheds, the small en­ trance yards to these L-plan houses form an im portant private area. At first sight it is not obvious that all the houses here have an identical ground floor lay­ out and belong to the same system . The picture is too d iverse - d u e t o the different roof shapes but, principally, the various grouping options. The basic idea is to build houses with a modular

1 06

aa

structure. Starting with a minimum unit size, which encompasses two rooms, the stairs and the central util ities b lock with kitchen, bathroom and WC, the houses can be extended by adding in­ d ividual rooms. The largest variation has seven rooms spread over three floors. The sizes of the rooms and the layouts are similar so that hig hly diverse occu­ pancies are possible. Further varia­ tions are possible by including base­ ments and attach ing different roof modules.

The concept also allows for the use of the most d iverse building materials i n order to suit the local suppl iers and availabil ity of materials. The grou p of houses i n Neu-Uim was built using c lay masonry. CO DETA I L 4/2001

Ground floor scale 1 :250 Section scale 1 : 20

2 3

4 5

•

Section

Roof construction: 1 8 x 76 mm corrugated aluminium sheeting 50 x 40 mm battens and counter battens roofing felt 24 mm roug h-sawn spruce boards 80 x 220 mm spruce rafters 200 mm mineral fibre insu lation between rafters vapour barrier 48 x 28 mm spruce battens 1 2 . 5 m p lasterboard 3-ply core plywood, 25 mm spruce U p per floor construction: carpet or PVC floor covering 50 mm screed on polyethylene separating layer 50 mm thermal and impact sound insulation 200 mm precast concrete flooring units 365 mm gauged clay masonry units (/.A 0 . 1 1 W/mK) Ground floor construction without basement: carpet or PVC floor covering 50 mm screed on polyethylene separating layer 50 mm thermal and impact sound insu lation waterproofing 200 mm i n situ concrete ground slab polyethylene separating layer 80 mm perimeter insu lation =

1 07

Clay masonry buildi ngs Exam ples

Housing complex i n Waldkraiburg

Andreas Meek, Munich Th is complex is the fi rst phase of what is intended to be a larger develop­ ment. Situated alongside a busy road, it is desi gned to act as a noise barrier for the plots further from the road. Access is via two staircases and there are 1 1 apartments p l us a cafe. The eight maisonettes are arranged in two groups of four on two levels, mean ing that the entrances are at ground floor level and second floor leve l . On the road side the anc i l l ary rooms serve as a buffer for the living accommodation and bedrooms, which face away from

1 08

the road. Every apartment has its own garden or rooftop terrace. The arrangement of the access to the maisonette entrances at ground floor level nearest to the road helps to pre­ serve privacy: a paved pathway be­ tween grassed areas leads to the two steps up to a covered landing in front of the entrance door. From here we pass through a lobby, which projects from the main line of the facade, into the hallway which leads to the various rooms. Access to the upper floor is via a single fl ight of stairs.

The entrances to the upper maison­ ettes are situated along the covered wal kway, with only a narrow opening on the side fac ing the road. Th is open­ ing allows the afternoon sun to shine through on to the larch wood benches next to the doors. These extend the private sphere and encourage social contact between the tenants. ()) DETA I L 4/1 997

Ground floor scale 1 : 200

•

1 st floor

Horizontal section scale 1 : 20

Vertical section

•

Wall construction: 1 5 mm plaster 240 mm vertically perforated clay masonry 40 mm m i neral wool thermal insulation between counter battens 50 mm battens/ventilation cavity 8 mm fibre cement sheets 2 Double glazing in wooden frames, outer pane of wired glass

3

4 5

6 7 8 9

Bench of 40 x 40 mm larch wood strips on T 50 steel section brackets welded to end plates Wooden double-skin door, painted Rooftop terrace/covered walkway construction 300 x 300 x 50 mm paving flags in 50 m m chippings waterproofin g on separating layer 1 60 (80) mm thermal insulation vapour barrier reinforced concrete slab Precast concrete coping Rendered vertically perforated clay masonry, 240 mm Roller shutter box Linoleum floor covering on floating screed

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1 09

Clay masonry buildings Examp les

Housing complex in Ludwigsburg

Hartwig N. Schneider with Gabriele Mayer, Stuttgart These 60 publ icly assisted rented apartments for d ifferent occupancies ­ sing les, single-parent fam i l ies, couples and fami l ies - were erected in a q uiet urban location between the city centre and the suburbs, among low-density developments from the 1 950s. Clearly arranged around three semi-private courtyards, this development comple­ ments the open design of the surround­ ings while providing a high density (plot ratio 1 . 2) through a d ifferentiated concept of accommodation and open spaces. All the apartments, with one, two and three rooms (plus bathroom and kitchen) , sometimes on two floors, are wel l l it from two sides. The living rooms lead on to logg ias with sliding windows i n the rendered facades. Sliding glass shutters with an enam­ el led inside face provide privacy for the bedrooms. The tree- l i ned court­ yards face the road and are accessed from there via open staircases; covered passageways link them to the gardens on the south side. Located beneath the courtyards are two natural ly venti lated underground parking areas. The envelope was built in lightweight clay masonry and finished with pig­ mented mineral render, the surface of wh ich changes with the weather. To contrast with this some parts of the facade make use of untreated timber cladding. _On the south elevation slid­ ing wooden shutters and narrow balco­ nies of coloured precast concrete ele­ ments define the appearance. Wooden windows with heat-absorbing glass were installed but in some more exposed areas wood/aluminium windows were C::O DETA I L 1 /1 999 employe d .

110

al

7

d Section Plans scale 1 :500 Section through west elevation Horizontal section through sliding glazing and render scale 1 :20 •

2

3 4 5 6 7 8 9 10

8 mm toughened safety glass, inside face enamelled Wall construction: 20 mm mineral render 300 mm Hlz lightweight clay masonry 1 5 mm p laster 300 mm lig htweight clay channel 1 00 x 50 x 5 mm aluminium channel Wood/Aluminium window Reconstituted stone window board 8 mm toughened safety glass 60 x 20 x 3 mm steel hollow section, galvanised Loadbeari ng thermal insulation element Floor construction: 5 mm floor covering 0.2 mm polyethylene separating layer 20 mm impact sound insu lation 60 mm thermal insulation 1 80 mm reinforced concrete floor slab

111

Clay masonry build ings Examples

2 3 4

5

6 7 8 9 10 Horizontal section scale 1 :20

•

Vertical section

4

112

Wall construction: 15 m m p laster 240 mm Hlz clay masonry 80 mm m i neral wool protective covering (non-woven fabric) 58 mm prefabricated cedar wood cladding 1 40 x 30 mm timber closing piece Fixed cedar wood cladding Cedar wood sliding shutter Parapet claddi n g , 1 4 mm wood-cement fibreboard U p per track for sliding shutters Lower track Balustrade of galvanised, colour-coated steel sections Precast concrete element, coloured 220 x 48 mm timber closing piece

Appendix Contents

Appendix 1 14 115 117 118

Standards, references, associations Manufacturers Subject i ndex I ndex of persons, picture credits

113

Appendix Standards, references, associations

The brick and b lock formats used in this book, their designations and the statutory instruments mentioned correspond to G erman standard s .

Standards

DIN

1 05 :

References

Clay bricks

DIN

1 045 :

Structural use of concrete

DIN

1 053:

Masonry

Masonry Construction Manual G u nter Pfeifer, Rolf Ramcke, Joachim Achtziger, Konrad Zilch 2001

D I N 4095 : Planning, design and installation of drainage systems protecting structures against water i n the ground D I N 4 1 08 : Thermal i nsu lation and energy economy in build ings DIN 4 1 09: Sound insulation in buil dings DIN

4226:

Aggregates for concrete

D I N 1 8 1 95 : Waterproofing of build ings and structures D I N 1 8530: Solid structural decks for roofs DIN

1 8550:

Plaster

Der Mauerziegel Franz Hart, Ernst Bogen berger 1 964

Trade associations

Bayerischer Ziegelindustrie-Verband e.V. Bavariaring 35 D-80336 Miinchen

+49 (0) 8 9 74661 6-0 Tel : Fax: +49 (0) 89 7 4661 6-30 [email protected] www.ziegel.com Fachverband Ziegelindustrie Sudwest e.V. Friedrich-Ebert-Str. 1 1 - 1 3 lnd ustriehaus D-67433 Neustadt a. d . Weinstrasse

Baukonstruktion fUr Architekten Franz Hart 1 959

Die Kunst der Wi:il bung Franz Hart 1 965

Rissschaden an Mauerwerk Werner Pfefferkorn 1 994

Schadenfreies Bauen mit Mauerwerk Peter Schubert 2002

Information supplied by the clay i n dustry: Ziegel lexikon 1 999

Aussenputz auf Ziegelmauerwerk 2002

Tel : +49 (0) 6321 852-0 Fax: +49 (0) 6321 852-290 vse@verband-stei ne-erden.de www.verband-steine-erden .de Fachverband Ziegel industrie Nord e.V. Bahnhofsplatz 2a D-261 22 Oldenburg

+49 (0) 4 4 1 2 1 0260 Tel : Fax: +49 (0) 441 2 1 02620 [email protected] www.ziegel-industrie.de Fachverband Ziegelindustrie Nordwest e.V. Am Zehnthof 1 97-203 D-45307 Essen

+49 (0) 2 0 1 5921 306 Tel : Fax: +49 (0) 201 5921 359 [email protected] www.zieg el-zentrum.de Bundesverband der Deutschen Ziegelindustrie e.V. Schaumburg-Lippe-StraBe 4 D-531 1 3 Bonn

+49 (0) 228 91 493-0 Tel: Fax: +49 (0) 228 91 493-28 [email protected] www.ziegel . de Massiv mein Haus e.V. Falkensteinstr. 9 D-8631 6 Friedberg

Tel: +49 (0) 821 7849773 Fax: +49 (0) 82 1 784447 [email protected] www. massiv-mein-haus.de

114

Appendix G erman manufacturers/associations arranged accord ing to postcode

Otto Bergmann GmbH Heinrich-Spier-Str. 1 1 (Werk 2)

Ziegelwerk Friedland GmbH HeimkehrerstraBe 1 2

07607 Eisenberg/Thiiringen

32839 Steinheim-Bergheim

37133 Friedland

Tel: +49 (0) 36691 7 1 - 1 00 Fax: +49 (0) 36691 7 1 -1 1 5 i nfo@wzi .de

Tel: Fax:

Wienerberger Werk Eisenberg Jenaer StraBe 56

Wienerberger Werk Zwickau BOrgerschachtstraBe 6a 08056 Zwickau

Tel : +49 (0) 375 27535-0 Fax: +49 (0) 375 27535-99 [email protected] Wienerberger Werk Hainichen Frankenberger StraBe 60 09661 Hainichen

Tel: +49 (0) 37207 45-0 Fax: +49 (0) 37207 45-29 i nfo@wzi .de Wienerberger Lager BrOck Paui-Ruoff-StraBe 2 1 481 1 Briick

Tel : +49 (0) 33844 6 1 0 Fax: +49 (0) 33844 6 1 1 25 info@wzi . de Wienerberger Werk Bad Freienwalde Eberswalder StraBe 1 07 1 6259 Bad Freienwalde

Tel : +49 (0) 3344 41 7-0 Fax: +49 (0) 3344 41 7-1 1 9 i [email protected] Wienerberger Werk Gransee Strelitzer StraBe 1 6775 Gransee

Tel : +49 (0) 3306 7983-0 Fax: +49 (0) 3306 7983-83 [email protected] Wienerberger Werk Jeddeloh Jeddeloher Damm 26 26188 Edewecht

OT Jeddeloh 1 Tel: +49 (0) 4405 7020 Fax: +49 (0) 4405 8496 i [email protected] Wienerberger Werk Sittensen 27419 Sittensen OT Tiste

+49 (0) 4282 2041 Tel : Fax: +49 (0) 4282 2044 i nfo@wzi . de Wienerberger Ziegelindustrie GmbH Olden burger AI lee 26 30659 Hannover-Lahe

Tel: +49 (0) 5 1 1 61 070-0 Fax: +49 (0) 51 1 61 4403 i [email protected] Ton- und Ziegelwerke Werner Florke KG N iedermehner Str. 36 32351 Stemwede

Tel : Fax:

+49 (0) 5773 202 +49 (0) 5773 3 1 7

Otto Bergmann GmbH I m Roten Lith 3 (Werk 1 ) 32689 Kalletai-Hohenhausen

Tel : +49 (0) 5264 6482-0 Fax: +49 (0) 5264 6482-64 l nfo@Bergmann-Zieg el.de

+49 (0) 5233 9558-0 +49 (0) 5233 9558-28

Aug ust LOcking GmbH & Co. KG Postfach 2409 33050 Paderborn

Tel : +49 (0) 5251 1 340-0 Fax: +49 (0) 5251 1 340-20 [email protected] Pasel & Lohmann GmbH Salzkottener Str. 35/36 33178 Borchen-Aifen

Tel : +49 (0) 5258 6001 Fax: +49 (0) 5258 6588 [email protected] Wienerberger Werk Rietberg 33397 Rietberg OT Westerwiehe

Tel : +49 (0) 5244 9039-0 Fax: +49 (0) 5244 9039-1 7 i [email protected] Aug ust LOcking GmbH & Co. KG E g gestr. 2 344 1 4 Warburg-Bonenburg

Tel : Fax:

+49 (0) 5642 6007-0 +49 (0) 5642 6007-22

Wienerberger Lager Volkmarsen Steinweg 65 34471 Volkmarsen

+49 (0) 5693 9896-0 Tel : Fax: +49 (0) 5693 6350 [email protected] Heinrich Abhau GmbH Lispenhauser StraBe 1 361 99 Rotenburg a. d. Fulda

Tel: Fax:

+49 (0) 6623 9248-0 +49 (0) 6623 9248-2 1

J u l ius Zan ge GmbH & Co.KG Schlitzer StraBe 40 36272 Niederaula

Tel : +49 (0) 6625 91 51 -0 Fax: +49 (0) 6625 9 1 5 1 -79 [email protected] Ziegelwerk Schenklengsfeld GmbH & Co. Baukeramik KG Ring bergstraBe 1 0 36277 Schenklengsfeld

Tel : Fax:

+49 (0) 6629 332 +49 (0) 6629 7861

Wienerberger Werk Wefensleb.en Zechenhauser Weg 39365 Wefensleben

+49 (0) 3 9400 961 2-0 Tel : Fax: +49 (0) 3 9400 2081 [email protected] Wienerberger Lager Lauterbach Ziegelei 1 36367 Wartenberg/Angersbach

Tel: +49 (0) 6641 9644-0 Fax: +49 (0) 6641 9644-1 1 [email protected]

Tel: +49 (0) 5504 8080 Fax: +49 (0) 5504 80827 friedland-zieg el@t-on line.de Wilhelm Alten Ziegelei Ziegelweg 1 37586 Dassei-Wellersen

Tel: +49 (0) 5562 252 Fax: +49 (0) 5562 66 1 0 [email protected] Ziegelwerk Buch GmbH HansastraBe 1 37671 Hi:ixter

Tel: +49 (0) 527 1 2248 Fax: +49 (0) 527 1 381 84 [email protected] Janinhoff GmbH & Co. KG ThierstraBe 1 30 48163 M unster

+49 (0) 2 5 1 981 680 Tel : Fax: +49 (0) 251 981 6830 [email protected] Wienerberger Werk Buldern R6dder 59 48249 Diilmen-Buldern

Tel : +49 (0) 2590 9455-0 Fax: +49 (0) 2590 41 85 i [email protected] Eifeler Ziegel- und Klinkerwerke Peter Koos GmbH & Co. KG

54675 Utscheid- Neuhaus

Tel : Fax:

+49 (0) 6522 7 1 7 +49 (0) 6575 1 300

Adolf HOning GmbH & Co. KG HauptstraBe 1 59399 Olfen

Tel: +49 (0) 2595 9642-0 Fax: +49 (0) 2595 9642-22 [email protected] J UWO-Porotonwerke Ernst Jungk & Sohn GmbH Ziegelh OttenstraBe 42 55597 Wi:illstein

Tel: +49 (0) 6703 91 0-0 Fax: +49 (0) 6073 91 0-1 59 [email protected] Keraform Spezialziegel Hamburger StraBe 97 61 1 1 8 Bad Vilbel

Adolf Zeller GmbH & Co. Poroton-Ziegelwerke KG Markerstr. 44 63755 Alzenau

Tel : +49 (0) 6023 97760 Fax: +49 (0) 6023 301 57 [email protected] Ziegelwerk U . GrOn Hahner StraBe 80 64354 Reinheim

+49 (0) 61 62 341 5 Tel: Fax: +49 (0) 61 62 331 6 [email protected] Trost Mauerziegel An der 83 69254 Malsch

Tel: +49 (0) 7253 208-0 Fax: +49 (0) 7253 208- 1 6 i [email protected] Hess Ziegelwerke AmeisenbOhl 40 71 332 Waiblingen

+49 (0) 7 1 5 1 5 1 034 Tel: Fax: +49 (0) 7 1 51 1 8949 [email protected] Neuschwander GmbH Nei ppergerstraBe 4 1 74336 Brackenheim

+49 (0) 7 1 35 961 09-0 Tel: Fax: +49 (0) 7 1 35 961 09-3 [email protected] Ziegelwerk Schmid Erligheimer StraBe 45 74357 Bi:innigheim

+49 (0) 7 1 43 8744-0 Tel : Fax: +49 (0) 7 1 43 8744-50 [email protected] Wienerberger Werk MOhlacker ZiegeleistraBe 1 2 7541 7 Miihlacker

Tel : +49 (0) 7041 8706-0 Fax: +49 (0) 7041 8706-55 i [email protected] Ceraline GmbH Weisweiler StraBe 6 79771 Klettgau-Erzingen

+49 (0) 7742 9240-0 Tel: Fax: +49 (0) 7742 9240-40 [email protected] Ziegelsysteme Michael Kel lerer ZiegeleistraBe 1 3

+49 (0) 61 01 5448-48 Tel: Fax: +49 (0) 6 1 01 5448-40 i [email protected]

82282 Oberweikertshofen

Ziegelwerk Franz Wenzel Offenbacher LandstraBe 1 05 6351 2 Hainburg

Ziegelwerke Leipfinger-Bader KG Puttenhausen (Werk 2) AuBere Freisinger Str. 31

Tel : +49 (0) 6 1 82 9506-0 Fax: +49 (0) 6 1 82 9506-20 [email protected]

Tel: Fax:

Tel: Fax:

+49 (0) 8 1 45 923-0 +49 (0) 8 1 45 5422

84048 Mainburg

+49 (0) 8751 9021 +49 (0) 8751 4571

Schlagmann Baustoffwerke Grafentraubach 505 84082 Laberweinting

Tel: +49 (0) 8772 9686-0 Fax: +49 (0) 8772 9686-1 0 [email protected]

115

Appendix German manufacturers/associations arranged accord ing to postcode

Erlus Baustoffe AG Hauptstr. 1 06 84088 Neufahrn/NB

Tel: Fax:

+49 (0) 8773 1 8-0 +49 (0) 8773 1 8-1 1 3

GIMA Girnghuber GmbH & Co. KG Ludwi g-G irnghuber-Str. 1 84163 Marklkofen

Tel : Fax:

+49 (0) 8732 24-0 +49 (0) 8732 24-200

Schlagmann Baustoffwerke Lanhofen 1 00 84367 Tann

Tel : +49 (0) 8572 1 7-0 Fax: +49 (0) 8572 81 1 4 [email protected] Schlagmann Baustoffwerke Lengdorfer StraBe 4 84424 1sen

Tel: +49 (0) 8083 5399-0 Fax: +49 (0) 8083 1 563 [email protected] Ziegelwerk Aubenham Adam Holzner KG Aubenham 3 84564 Oberbergkirchen

Tel: Fax:

+49 (0) 8637 841 +49 (0) 8637 454

Ziegelwerke Lei pfinger-Bader KG Vatersdorf 1 0 (Werk 1 ) 847 1 2 Buch a. Erlbach

Tel: +49 (0) 8762 733-0 Fax: +49 (0) 8762 733-1 1 0 [email protected] Zieg elwerk Gerhard Turber Riedenburger Str. 25 85104 Pforring

Tel: Fax:

+49 (0) 8403 9294-0 +49 (0) 8403 9294-25

Ziegelwerk l g naz Schiele Wittenfelder StraBe 1 5 851 1 1 Adelschlag

Ziegelwerk Franz X. Hanrieder OHG Kratzerimbach 3

THERMOPOR Ziegei-Kontor Ulm GmbH O l gastraBe 94

85406 Zolling

89073 Ulm

Te l : Fax:

Tel: Fax:

+49 (0) 8 1 67 950233 +49 (0) 8 1 67 931 7

Hiirl Ziegei-Technik ZiegeleistraBe 24 86368 Gersthofen

+49 (0) 821 4789-0 Tel : Fax: +49 (0) 821 4789-299 l [email protected] Schlagmann Baustoffwerke ZiegeleistraBe 3 1 86551 Aichach

Tel: +49 (0) 81 68 9062-0 Fax: +49 (0) 81 68 9062-23 i [email protected] Ziegelwerk Anton Hanrieder OHG Harland 1 9 1 /2 85406 Zolling

Tel : +49 (0) 81 67 950284 Fax: +49 (0) 8 1 67 9036 [email protected]

Ziegelwerk Gundelfingen GmbH AuBere Haunsheimer Str. 2

Ziegelwerk Waldsassen AG HART-KERAMIK Am Bergwerk 1 2

86633 Neuburg-Ried

89584 Ehingen

Ziegelwerk Englert GmbH Krautheimer StraBe 8

Tel : Fax:

Tel: +49 (0) 7391 5008-0 Fax: +49 (0) 7391 5008-33 [email protected]

Tel: Fax:

+49 (0) 8431 83 1 9 +49 (0) 8431 4 1 1 28

Creaton AG D i l l i nger Str. 60 86637 Wertingen

Tel : Fax

+49 (0) 8272 86-0 +49 (0) 8272 86-500

Rapis-Ziegel Markt Wald GmbH Lechfelder Str. 20

Tel: Fax:

+49 (0) 9073 9599-0 +49 (0) 9073 9599-60

Walther Dachziegel GmbH Lohmuhle 3-5 90579 Langenzenn

Tel: Fax:

+49 (0) 9 1 01 708-0 +49 (0) 91 01 708-38

Wienerberger Werk Spardorf Buckenhofer StraBe 1

86830 Schwabmiinchen

91 080 Spardorf

Tel: +49 (0) 8232 4074 Fax: +49 (0) 8232 3321 [email protected]

Tel: +49 (0) 9 1 3 1 509-0 Fax: +49 (0) 9 1 3 1 509-50 i [email protected]

Ziegelwerk Klosterbeuren Ludwig Leinsing GmbH & Co. ZiegeleistraBe 1 2 87727 Babenhausen

Tel: +49 (0) 8333 9222-0 Fax: +49 (0) 8333 4405 [email protected]

+49 (0) 7564 308-0 Tel: Fax: +49 (0) 7564 308-90 [email protected] Georg Rimmele KG J.G. Scheerle KG Pfullendorfer StraBe 1 Q-1 2 885 1 2 Mengen

Tel: Fax:

+49 (0) 7572 8275 +49 (0) 7572 6764

Ott Ziegel Pfu llendorf GmbH & Co. KG Oberlinger StraBe 70 88630 Pfullendorf

Tel : +49 (0) 7552 921 6-0 Fax: +49 (0) 7552 921 6-22 uni [email protected] Ziegelwerk Ott ZiegeleistraBe 20 88662 Uberlingen-Deisendorf

Tel: Fax:

1 16

95652 Waldsassen

+49 (0) 9632 848-0 Tel: Fax: +49 (0) 9632 848-48 i [email protected]

Georg Rimmele KG Riedlinger StraBe 49

Hiirl & Hartmann Ziegeltechnik GmbH Pellheimer Str. 1 7

85395 Wolfersdorf

89297 Bellenberg

Tel: +49 (0) 7306 9650-0 Fax: +49 (0) 7306 9650-77 [email protected]

Ziegelwerk Stengel GmbH l ngolstadter Str. 1 01

8841 0 Bad Wurzach-Arnach

Ziegelwerk-Deckensysteme Wiihrl GmbH Berghaselbach 5

Ziegelwerk Waldsassen AG HART-KERAM I K Mitterte icherstraBe 6

89423 Gundelfingen

Ziegelwerk Arnach J. Schmid GmbH & Co. KG ZiegeleistraBe 1

Tel : +49 (0) 8 1 3 1 555-0 Fax: +49 (0) 8 1 3 1 555-222 info@hoerl-hartmann . de

Ziegelwerk Bellenberg Wiest GmbH & Co. KG Tiefenbacher Str. 1

95490 Mistelgau

+49 (0) 9279 998-0 Tel: Fax: +49 (0) 9279 998-66 [email protected]

Tel : +49 (0) 8251 888 1 -0 Fax: +49 (0) 8251 8881 - 1 0 [email protected]

Tel: +49 (0) 8424 8922-0 Fax: +49 (0) 8424 8922-22 i [email protected]

85221 Dachau

+49 (0) 731 966940 +49 (0) 731 63053

Dehn-Ziegel GmbH & Co. KG Culmer StraBe 1 4

+49 (0) 755 1 622 1 4 +49 (0) 755 1 4947

Dehn-Ziegel GmbH & Co. KG Am Hutsberg 1 9 1 4 1 3 Neustadt a. d. Aisch

Tel: +49 (0) 9 1 6 1 8998-0 Fax: +49 (0) 9 1 6 1 8998-22 dehn-ziegei-NEA@t-on line.de Ansbacher Ziegelei NaglerstraBe 40 91 522 Ansbach

Tel: +49 (0) 981 96955-0 Fax: +49 (0) 981 96955- 1 5 [email protected] Schlagmann Baustoffwerke ZiegeleistraBe 5 92444 Rotz

Tel: +49 (0) 9976 2001 1 -0 Fax: +49 (0) 9976 2001 1 -504 [email protected] Ziegelwerk Sittling Kiiglmaier OHG Sittl ing 23 1 /2 93333 Neustadt a. d. Donau

Tel : Fax:

+49 (0) 9445 2834 +49 (0) 9445 2598

Jungmeier GmbH & Co. KG Landshuter Str. 1 30 94315 Straubing

Tel: Fax:

+49 (0) 9421 5007-0 +49 (0) 9421 5007-400

95706 Schirnding

Tel: Fax:

+49 (0) 9233 771 4-0 +49 (0) 9233 771 4-1 4

97509 Zeilitzheim

+49 (0) 9381 2433 +49 (0) 9381 4740

Wienerberger Werk Bad Neustadt BesengaustraBe 1 9 976 1 6 Bad Neustadt

+49 (0) 9771 6 1 340 Tel: Fax: +49 (0) 9771 2952 info@wzi . de ZU Bayerische Ziegelunion Zur Ziegelei 1 6 97753 Karlsstadt-Wiesenfeld

Tel : +49 (0) 9359 971 0-0 Fax: +49 (0) 9359 971 01 8 [email protected] Wienerberger Werk Erfurt-G ispersleben Zur Alten Ziegelei 99091 Erfurt-Gispersleben

Tel : +49 (0) 361 7401 8-0 Fax: +49 (0) 361 7 401 8-99 i [email protected] Wienerberger Werk Bol lstedt Am Silberrasenweg 1 99998 Bollstedt

Tel : +49 (0) 3601 8816-0 Fax: +49 (0) 3601 881 6-1 4 i nfo@wzi .de

Appendix Subject index

Subject index

Additives

75, 83, 84, 88, 92

Admixtures

75, 83, 84

Airtight membrane

62, 63, 65, 67

Airtightness

20, 64, 72

13 Background for plaster/render 4 1 , 42, 43, 44, 45, Basement wall 48, 50, 5 1 , 52, 54, 81 , 82, 85, 86, 1 0 1 Basement wall render 50, 86 Bitumen felt

Glazed door

1 4, 1 5

Grip (thumb) openings

75 25, 50, 75, 9 1

Gross density Ground floor slab

1 3, 1 4, 1 8, 25, 26, 43

76, 77

Header bond Interlocking perpends

1 6, 45, 48

Lig htweight mortar

76, 87, 88 76

Lightwei g ht plaster/render

Bonding rules Buckling

80, 81 75, 85

Bulk density Bullnose tiles Butt joint

34, 62, 65

75, 93

63, 67, 81 , 82

Chases

56, 80, 82, 93

Chimney

68, 69

Chimney stack Clay channel

67, 69 2 1 , 23, 91 , 1 03, 1 05 , 1 1 1

Clay hol low pot floor Coating materials

30, 33, 79

59, 81 , 82, 1 03, 1 05 8, 44, 45, 78, 79, 80, 93

Compressive strength Concrete l i ntel

2 1 , 75

Make-up unit

20, 73, 76, 77

Masonry bonds Maximum vertical load Minimal chimney

8 1 , 82 8

Minimum vertical load

81 , 82

80, 82

Non-loadbearing wall

2 1 , 50, 82, 85

Normal-wei ght mortar

9 42, 82, 83, 88, 89, 91 , 92, 93 91

79 75

33, 76, 78, 80, 92 92, 93 1 3, 1 6, 1 7, 25, 45, 50, 5 1 , 52

Damp-proof membrane 1 3, 1 6, 42, 5 1 , 53, 55 Dimensional coordination 78 "Disruptions" 80 1 4 , 1 5, 1 6, 1 7 , 1 8, 20, 43, 47, 54, Door

78

"octametric" system

22, 44, 56, 74, 75,

Openings

79, 80, 81 , 83, 93, 97, 1 02, 1 04

55, 75, 78, 79, 80, 81 , 97, 98, 1 00, 1 08, 1 09 42, 48, 50, 52, 54, 1 03 30, 3 1 , 32, 33, 34, 35,

62, 63, 64, 66, 98, 1 02 End-grain wood-block flooring 1 05 54, 1 08 Entrance door 1 0, 1 1 , 1 2 , 1 6,

1 1 , 22 , 23, 25, 28, 36, 39, 70 Perimeter insulation 41 , 44, 45, 46, 47, 1 07

Shoulder

2 1 , 20, 23, 27, 58, 59, 90

Shrinkage

1 6, 67, 85, 88, 89, 91 , 92

Slenderness Sound insulation ·

84 80, 91 , 92 1 7 , 29, 31 ' 42, 44, 50, 70, 1 05, 1 1 1 87, 88, 90

Spatterdash Stab i lity

36, 79, 80, 81 , 93 1 6, 25, 45, 57 76, 77

Stretcher bond Strip foundation

1 3, 1 2 , 1 6, 24, 42, 45, 48, 50 24, 30, 32, 33, 35, 39, 63, 67,

73, 74, 78, 79, 80, 81 , 85, 86, 90, 91 , 93, 1 06 Swelling 91 83, 84, 85 Synthetic resin plaster 85 1 6, 43, 45,

Thermal bridge

49, 63, 67, 73, 90, 93 Thermal insulation

1 4, 1 6, 1 7 , 20, 22, 23,

62, 65 , 67, 73, 75, 83, 84, 85, 87, 90, 91 , 97, 98, 1 03, 1 05, 1 09, 1 1 1 Thermal insulation plaster/render 83, 85, 87 86 Thickness of plaster/render

Pl inth Plinth render Purl in roof

1 1 , 1 2 , 1 3 , 1 6, 25, 40, 44, 45, 46, 50, 5 1 , 52, 85, 86 1 3 , 5 1 , 86 30, 31 , 32, 33, 34

Rad iator recess

4 1 , 55, 57, 56, 58, 59 44

Raft foundation Rai nwater drip

2 1 , 65, 69

Reinforced masonry Render

Thin-bed mortar Three-dimensional construction Timber joist floor Tolerances Toothed block

75 79

34, 35, 36, 37, 79, 80, 81 20, 6 1 , 67, 72, 73, 75, 1 03

Undercoat

84, 85, 87, 88, 89, 90

4 1 , 55, 56, 57, 58, 59, 80, 93

48, 50 81 , 82, 93

Vapour barrier

48, 62, 64, 1 03, 1 07 , 1 09

Vapour check Ventilation

64, 65, 67 32, 37, 63, 65, 69, 1 0 1 , 1 09

Verge

33, 35, 63, 65, 98, 1 02, 1 03

1 1 , 1 2 , 1 3, 1 4 , 1 6, 20, 2 1 , 22, 24, 45,

47, 50, 5 1 , 52, 56, 57, 59, 60, 6 1 , 63, 65, 68, 69, 73, 83, 84, 85, 86, 87, 88, 89, 90, 98, 1 00, 1 01 ' 1 03 , 1 04, 1 05 , 1 09, 1 1 0, 1 1 1

33, 67, 83 34 69, 68 74, 75

Rendering system

83, 85, 87

1 2 , 1 4 , 1 6, 27

Renovation plaster

85 1 8, 20, 2 1 , 56, 58, 75 22, 30, 33, 36, 37,

Reveal 75

2 1 , 22, 23, 53, 58, 59 25, 37, 76, 79

84, 85, 86, 87, 88, 89, 90, 1 0 1 , 1 05, 1 07 , 1 09, 1 1 1 ' 1 1 2 1 3 , 86 Plastering system

Reinforced concrete ground slab

33, 37, 63, 65, 67

Shallow clay lintel Shear wall

33, 37, 42, 43, 44, 48, 50, 52, 56, 57, 58, 60,

1 3, 1 6, Reinforced concrete floor slab 53, 60, 63, 81 ' 82, 91 ' 1 05, 1 1 1

Gable wall Gauged block

1 7, 45, 65, 92, 1 07, 1 09, 1 1 1

1 2 , 1 3 , 37, 45, 57, 63, 65, 73, 83,

Plaster

48, 55, 57, 58, 59, 60, 62 , 64, 75, 76, 79, 82,

8, 9, 41 , 69, 70 83, 84, 85, 86, 88, 89, 90

1 4, 1 7 , 1 9 , 33, 42, 44, 48, 58, 63, 67, 7 1 , 1 05, 1 07, 1 09

Party wall

Recess

93, 98, 1 00, 1 04

Screed

Synthetic resin render

1 8, 20, 23, 25, 27, 30, 32, 34, 4 1 , 43, 44, 45,

Frost heave

33, 35, 37, 39, 50, 62, 65 , 1 01 , 1 03, 1 07

1 1 ' 24, 26, 27, 29,

Partition

Drainage

Flue l ining

33, 34, 38, 40, 62, 63, 66

Structure

3 1 , 4 1 , 42 , 53, 55, 68, 76 Damp-proof course

Format code

33, 35, 37, 63, 7 1 , 98, 1 02, 1 03

Stop bead

22

Crosswall Curing

False wall

Roof tile Roofing felt

Silicate p laster/render

83, 84, 85

Column

Finish coat Fire protection Flat-pan tiles

8, 9, 1 1 , 30, 32,

Separating layer

perforated clay masonry 75, 85 Lightwell 4 1 , 43, 46, 47, 49, 5 1 , 53 2 1 , 20, 22, 23, 53, 58, Lintel

25, 76

Capping beam

External wall

62, 67

Roof space

1 3 , 83, 85, 87

Lightwei g ht vertically

Load bearing wall

Eaves

58, 59, 60, 6 1 , 1 09 Roof plate

1 2 , 1 6, 42

Bonding dimension

Cracks Creep

9, 41 ' 55, 56, 57,

75

Bl inding

Couple roof

Roller shutter

1 2, 1 3, 1 6, 42, 48, 54

Hard core

79, 81

Ring beam system

Ring beam

39, 79, 81 , 92, 1 03

Waterproofi ng Window

1 2 , 1 3, 1 4 , 42, 48, 50, 52, 70, 86, 1 01 , 1 07, 1 09 9, 1 1 , 20, 2 1 , 22, 4 1 , 47, 53, 55,

56, 57, 58, 59, 60, 61 , 75, 78, 79, 80, 81 , 97, 98, 1 03, 1 04 , 1 05, 1 1 0, 1 1 1 Window board Window sill Wood-wool slab

56, 58, 1 1 1 21 , 59 57, 87, 88, 98

117

Appendix I n d ex of person s , p i cture cred its

Picture credits

Index of persons page 97

page 1 06

pages 7, 1 08

Housing complex in Munich

Housing development in Neu-Uim

Franz Wimmer, M u n i c h

Architect:

Cl ient:

Christof Wallner, Munich Associates: Bettina Gbrgner, Corinna M u l l er Structural e n g i n eer: Joachim Eiermann , M u n i c h p a g e 98 Semi-detached house in Munich Cli ent: Brig itte Puis, M u n i c h Architects: And reas Meek, Munich Brig itte Puis, M u nich Detailed desi g n : Stephan Kbppel, M u n i c h Structural e n g i neers: Hans-Ludwig Hausdorfer, Markt Schwaben

N UWOG/Helmut M i l d ner, Neu-Uim Architect: G .A.S.-Sahner, Stuttgart Georg Sahner Structural e n g i n eers: l n g . Buro Mul ler, Kirch berg/l ller page 1 08

Doris Schmid-Hammer, M u n i c h Associates: Timo Jeskanen, Manfred Weihermann Structural engi neers:

Andreas Meek, M u n i c h Associates:

House in Hallertau Architect: Waiter Stolz, Rosenheim Associates: Georg Treng ler Elisabeth Mehrl (colour scheme) Structural e n g i n eers: Bauer l n genieure, Landshut page 1 04

Studio house in Eichstatt Client: Mr and Mrs Lan g , Eichstatt Architects:

Diezinger & Kramer, Eichstatt

1 18

page 1 04

Andreas Gabriel , M u n i c h

pages 1 06, 1 07

Peter Bonfi g , M u n i c h

Egbert Ackerman n ,

p a g e 1 09

Christoph Engler

Edwi n Kunz, Berg

Structural eng i neer: Franz Mitter-Man g , U nterreit page 1 1 0

Woh n u ngsbau Ludwi gsburg G m b H Architect: Hartwig N. Schneider with Gabriele Mayer, Stuttgart Project architects: Andreas Gabriel, l n go Pelchen Associates: Franz Lutz

Behringer und Muller, M u n i c h page 1 02

Gerhard Sc hlbtzer, Bamberg

page 1 05

Housing complex in Ludwigsburg

Thomas Hammer and

Job Roman, M u n i c h

p a g e 1 03

Stefan M u l ler-Nauman n , M u n i c h

Client:

Architects:

H e n n i n g Koepke, M u n i c h

p a g e 1 02

Housing complex in Waldkrai burg

page 1 00

Norbert und Klaus Weigl

M i chael Heinrich, M u n i c h

pages 1 00, 1 0 1

Architect:

Houses in Munich Clients:

pages 95, 97, 9 8 , 9 9

I n dex of persons The names are listed after specifying the respective architect.

pages 1 1 0 , 1 1 1

Christian Kan dzia, Essl i n gen page 1 1 2

Roland Halbe/Contur, Colog ne Photographs not specifically credited were taken by the architects, provided by the manufacturer, or suppl ied from the DETA I L archives.

ISBN 3 - 7 6 4 3 - 7 1 1 1 - 0

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�

L 7 OO

9

1 1 1 11111 1 111 1 1 1 1 1 7 8 3 7 6 4

3 7 1 1 1 1