Forticrete masonry dcm tm

CI/SfB (Ff3)

September 2012

®

The architects’ choice

Simple yet beautiful Dense Concrete Masonry (DCM) Blocks

ECOBLOCK

Product: Splitface Yorkstone & Polished Florentine速 Hamstone Project title:

Tesco Store, Ashley Gateway Retail Park, Widnes

Client: Morbaine Developments Contractor: Britannia Construction Architects: Gordon White & Hood, Leicester

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Front cover: Product: Polished Florentine速 Yorkstone Project title:

Etrop Court, Wythenshawe

Client: St. Modwyn Developments Contractor: Allenbuild Architects: AEW Architects Manchester

Dense Concrete Masonry blocks and the environment pages

4-5

Finishes and profiles

pages

6-9 Colours

pages

10-17 Standard sizes and weights

pages

18-19

Bespoke specials

pages

20-21

Technical specifications page

22

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Dense Concrete Masonry and the environment Forticrete has always set the standards in dense concrete masonry innovation.

From being the first to develop the capability to produce multiple colours and textures, to being the creator of the first polished concrete masonry, it should be no surprise to hear we have, again, pushed back the boundaries to refine our raw material content.

Increasing the quantity of recycled aggregate in many products demonstrates the continued commitment to improving our environmental credentials.

All Forticrete factories operate to the highest standards, whether it is the international Quality Standard BS EN ISO 9001, ISO 14001 for Environmental Management or BES6001 for Responsible Sourcing. This ensures a product of quality with dimensional accuracy and a variety of colour and finishes.

The standard product range is the broadest available enabling you to specify from a selection of combinations in colour, shape and size, including cills, quoins, jambs, lintels and plinths to help create structures which blend in with their surroundings.

Innovative products that don’t cost the earth Together with our commitment to act as a socially responsible corporate citizen, Forticrete views the development of products to specifically benefit the environment as a significant opportunity.

This is key to our company strategy, and also forms an important part of Best Practice exchanges.

There is also increasing recognition of the environmental benefits of many of our established products which allow energy consumption to be reduced.

The benefits of using concrete products in new home building are recognised within the Code for Sustainable Homes and the Green Guide to Specification, where constructions that use both masonry and roof tiles are awarded an A or A+ rating.

We introduced an ‘ECO’ branding scheme for product development some 10 years ago to enable our customers to instantly recognise that our products have high environmental credentials. These products have various benefits over traditional products.

As a consequence of our manufacturing facilities conforming to the quality standard BS EN ISO 9001, environmental management standard BS EN ISO 14001 and the responsible sourcing standard BES 6001, all of our products carry an ‘ECO’ mark.

Where a product has additional benefits which are not recognised by The Green Guide to Specification or has recycled content of over 30%, then we have distinguished them with our ‘ECO-PLUS’ logo to allow their unique qualities to be acknowledged.

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Recycled content of Hess made products Product Range

Colour

Recycled Contents

DCM

Autumn

25

DCM

Bathstone

35

DCM

Damson

25

DCM

Diamond

0

DCM

Flint

35

DCM

Hamstone

35

DCM

Ivory

20

DCM

Limestone

35

DCM

Pewter

25

DCM

Sandstone

35

DCM

Sports Green

35

DCM

Spruce

25

DCM

Straw

35

DCM

Steel Grey

35

DCM

Terracotta

35

DCM

Yorkstone

35

Granito™

Natural and Dark

45

Novastone®

White and Yellow

45

Quailstone™

Yellow and Grey

35

Sparstone™

Red, Yellow and Black

0

Product: Splitface Diamond Project title:

Clapham One, South London

Client: Cathedral Group Contractor: United House Architects: Studio Egret West

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Finishes Shot-blasted finish Provides a weathered appeal

Example: Shot-blasted Sports Green®

Shot-blast masonry adds a natural weathered appeal. With a broad selection of ‘special’ shapes and sizes as standard, Shot-blast offers an almost limitless variety of options.

Fairface finish The original and still the leader in the field

Example: Fairfaced Yorkstone

Fairface masonry offers the benefits of a structural product and finish in one. Its quality finish, dimensional stability, range of subtle, natural colours and economy against competitive materials maintain its position as the leader in its field.

Burnished Venezia finish ™

The subtle beauty of burnished natural aggregates

Example: Burnished Venezia™ Steel Grey

A subtly burnished finish brings out all the deeply embedded beauty of the natural aggregates. For projects where reduced glare is a consideration this finish offers an understated beauty for internal or external walls.

Splitface finish Emulating the rugged appeal of natural hewn stone

Example: Splitface Autumn

6

Cost-effective and offering flexibility, Splitface adds a prestigious appearance to any building, whether creating complete, imposing structures or in combination with other Forticrete products, in feature panels and bands.

Polished Florentine finish ®

Affordable prestige inside or out

Example: Florentine® Straw Polished

www.forticrete.co.uk

Use this to create broad expanses of reflective, decorative walling or in combination with other Forticrete Masonry products to provide impressive highlights.

Granito fine etched finish ™

Combining the sparkle of a granite finish with environmental benefits

Example: Granito™ Dark

Manufactured with a high content of recycled material, Granito allows you to create a stunning façade or alternatively, combines perfectly with other products from the Forticrete masonry range.

Polished Quailstone Florentine finish

™

®

Distinctive and stylish with universal appeal

Examples: Polished Quailstone™ Yellow

Polished Quailstone offers a glossy finish with standout black aggregate. A versatile block suitable for decorative walls, highlights, and reflective surfaces.

Sparstone - in Shot-blasted and Splitface finishes ™

The rugged, weathered appeal of a rural vernacular Examples: Sparstone™ Shot-blasted Red

Novastone fine textured masonry finish ®

A fine textured masonry finish with time-weathered appeal Example: Novastone® White

Novastone is a range of components which will give you that natural, weathered appeal from the day they are laid, enabling brand new buildings to blend into established surroundings with impressive ease.

Sparstone™ Splitfaced Black

Shot-blasted - This has a coarse texture with a natural appeal. Sparstone enables you to successfully replicate the ‘weathered’ vernacular of many rural towns and villages throughout the UK. Splitface - When Sparstone masonry is split, it creates an imposing finish. The natural beauty of the embedded aggregates is enhanced to give your buildings an essentially rugged appeal, enabling them to blend into many local vernaculars with consummate ease.

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Profiles Standard Profile The most popular profile This versatile profile provides a multitude of design possibilities through the range of size and finish options available.

Example: Sandstone Standard in Shot-blasted finish

Ribloc® Profile Bold geometric planes create light and shade Ribloc masonry, with its eight ribbed appeal, creates clean lines and a geometric uniformity which will give an imposing appearance to any building. Its ribs provide controlled weathering characteristics.

Example: Sandstone Ribloc® in Shot-blasted finish

Twinbloc® Profile A ‘stack-bonded’ appearance with structural integrity Twinbloc masonry is the fast, sure, economical way to create the impressive appeal of ‘stack bonding’. Created to standard block proportions, Twinbloc incorporates a carefully gauged central groove to give the appearance of two half blocks when laid and yet, as it is laid stretcher-bond, it provides the inherent strength of any DCM wall removing the need for bedjoint reinforcement to stabilise the wall in the majority of situations.

Example: Sandstone Twinbloc® in Shot-blasted finish

Airbloc® Profile* A discrete ventilation block Innovations in the manufacturing process of our DCM allows us to offer a product that solves the issue of incorporating adequate ventilation into a cavity wall. The purpose made air block is available in all finishes allowing the same external façade to be maintained.

Example: Sandstone Airbloc® in Shot-blasted finish

Profiles

* Bespoke versions available

Finishes

Fairface Shot-blasted Splitface Burnished Venezia

™

Polished Florentine

®

Novastone

®

Sparstone

™

Polished Quailstone

™

Granito

™

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Standard

Ribloc

®

Twinbloc

®

Airbloc

®

Products: Polished Florentine速 & Precast Project title: Welbeck College, Loughbourgh Client: The Ministry of Defence Contractor: Interserve Architect: HLM Architects

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Colours Pewter Recycled Content: 25%

Fairface

*

Steel Grey Recycled Content: 35%

Flint Recycled Content: 35%

Limestone Recycled Content: 35%

Ivory Recycled Content: 20%

Diamond Recycled Content: 0%

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*

Not recommended for large expanses of block work

Shot-blasted

Splitface

Burnished Venezia™

Polished Florentine

ÂŽ

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Colours Bathstone Recycled Content: 35%

Yorkstone Recycled Content: 35%

Hamstone Recycled Content: 35%

Straw Recycled Content: 35%

Sandstone Recycled Content: 35%

Terracotta Recycled Content: 35%

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Fairface

Shot-blasted

Splitface

Burnished Venezia™

Polished Florentine

ÂŽ

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Colours

Shot-blasted

Fairface

Damson Recycled Content: 25%

*

Autumn Recycled Content: 25%

*

Spruce Recycled Content: 25%

Sports Green

*

速

Recycled Content: 35%

*

14

Not recommended for large expanses of block work

Shot-blasted Hamstone with Bullnose columns at Excelsior Academy, Newcastle.

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Splitface

Burnished Venezia™

Polished Florentine

®

Polished Florentine® Yorkstone and Pewter, Easington College, Durham.

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15

Colours

Novastone

®

White Recycled Content: 45%

Buff Novastone® Buff, Apartments, Sunderland, Tyne & Wear.

Recycled Content: 45%

Sparstone Shot-blasted ™

Red Recycled Content: 0%

Yellow Recycled Content: 0%

Black Recycled Content: 0%

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Sparstone Splitface ™

Polished Quailstone Florentine ™

®

Grey Recycled Content: 35%

Yellow Recycled Content: 35%

Granito

™

Natural Recycled Content: 45%

Dark Recycled Content: 45%

Granito™ Natural at Nottingham University.

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Sizes and weights

†

Fairface, Shot-blasted, Polished Florentine , Burnished Venezia Sparstone (shot-blasted only), Novastone , Quailstone and Granito ®

®

™

®

™

®

450mm x 225mm Co-ordinating size - 440mm x 215mm actual face size Nominal thickness (mm)

90mm

100mm H1

D1

Shot-blasted units

215mm F1

SOLID

G1

140mm

19.8

17.9 G16

42.7

28.0 H16

QUOIN

D16

The darker tint areas on the illustrations indicate faces which are Textured as standard. Additional requirements for Texturing should be indicated on the architect’s drawing. The additional finishing process ensures that factory cut faces have an appearance complementary to the other finished faces.

Fairface units ™

23.0

25.2

32.5

BULLNOSE

D1BN

In general, all vertical faces are fairfaced. Tops and bottoms of units are not, except where indicated. Factory cutting creates a different texture from the main faces of the units.

19.6

BULLNOSE QUOIN

D16BN

25.0 H3

HOLLOW*

D3

F3

130º QUOIN SQUINT

14.8 G23

D23

17.4

25.7

19.1 H21

D21

F21

† Please refer to the Forticrete Size and Weights guide for all other options.

CILL

G21

27.7

18.5 H23

15.1

38.1

*Not available in Novastone® and Granito®

Ribloc

®

Nominal thickness (mm)

23.2

17.1

Twinbloc

The range also includes innovations like the bullnose straight or quoin units.

These provide smooth cornered contours which are ideal for educational and healthcare environments and a broad range of cut ‘standards’, with each component cut under tightly controlled factory conditions, making them easier to specify and build. To view the wider range of specials available please refer to our size and weights guide.

®

90mm

100mm D1

100mm

E57

E58

Key:

SOLID

G1

100mm

Typical weight (kg) 19.8

17.9

23.7

18.7

The hatched areas on the illustrations indicate factory cut faces in fairface.

SOLID

D16

Twinbloc® central groove is 10mm wide x 15mm deep to allow for mortar pointing.

25.5

Denotes units over 20kg

To view the wider range of specials available please refer to our size and weights guide.

All Splitface finishes Nominal thickness (mm)

95mm S5

S4

S16*

SOLID

QUOIN

S3

9.2

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18.9

13.7

24.1

* S16 is only available in a cut and bonded unit.

Hi-Light blocks ®

Hi-Light

®

400mm x 200mm Co-ordinating size 390mm x 190mm actual face size

PLUS

ECOBLOCK

Nominal thickness (mm)

90mm

140mm P1

SOLID

K1

190mm

21.8

14.0 K16

The revolutionary Hi-Light block has been designed to provide all the benefits associated with dense masonry, yet is up to 25% lighter than an equivalent solid masonry unit. With a cellular underside but a solid top surface to provide a full bed for mortar, Hi-Light complies with Health and Safety recommendations and provides complete cover under CDM regulations.

P16

QUOIN

®

17.6 HI-LIGHT

450mm x 225mm Co-ordinating size 440mm x 215mm actual face size 90mm

16.7 K3

140mm

11.1

H2

K23

15.6

12.7

19.0

D16HL QUOIN

12.3

18.0 R21

P21

CILL

K21 19.1

11.5

Twinbloc

17.7

25.5

Ribloc

®

Nominal thickness (mm)

17.7

P23

130º QUOIN SQUINT

CELLUAR

D2

R3

P3

HOLLOW

Nominal thickness (mm)

24.6 P2

®

®

90mm K16

E51

E56

SOLID

K1

90mm

17.6

14.0

19.3

13.0

Twinbloc central groove is 10mm wide x 15mm deep to allow for mortar pointing. ®

All Splitface finishes

Ribloc

®

Nominal thickness (mm)

95mm E54

S32

S31

E56

SOLID

S30

95mm

14.9

7.0

7.2

14.3

10.8

19

Now you can build with total design freedom

Bespoke elements

Forticrete delivers an almost limitless capability in high quality detailing.

Forticrete’s production of specialist PreCast elements has developed into a service which offers a virtually limitless capability.

It’s a facility which can produce bespoke detailing in a vast array of designs, either to blend into an Architectural Masonry structure or to create stunning highlights within large expanses of masonry or brickwork. Features such as thresholds, arches, circular columns, corbels, cills, lintels, radius details and unique window surrounds are all achievable.

Polished Precast at Riverside, Hemel Hempstead.

Precast elements at Clearwater Court, Reading.

Forticrete Precast elements are available in colours that are blended to those of the Fairface and Shot-blast Masonry ranges. Additional variations can be created to specification requirements.

High quality bespoke Precast concrete detailing

Fairfaced: Pewter, Steel Grey, Flint, Limestone, Ivory, Bathstone, Yorkstone, Hamstone, Straw, Sandstone, Terracotta, Damson, Autumn, Spruce and Sports Green .

The use of Forticrete Precast elements can help to recreate the impression of past eras and provide finishing touches to any building, to make it stand out from the crowd.

Shot-blasted: Pewter, Steel Grey, Flint, Limestone, Ivory, Diamond, Bathstone, Yorkstone, Hamstone, Straw, Sandstone, Terracotta, Damson, Autumn, Spruce and Sports Green .

A range of standard units is available, to fulfill the needs for the more commonplace copings and airbricks, but bespoke elements can be created, each hand moulded by experienced craftsmen to match your designs and to realise your ideals.

Forticrete Precast elements have a mean compressive strength of 35N/mm2 and a density of 2300 kg/m3.

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®

®

The quality is assured Forticrete’s manufacturing methods and strict adherence to a BSI approved Quality Assurance scheme to BS EN ISO 9001:2000 ensures consistent product quality, whether it’s a bespoke, one-off element or multiple units. What’s more, Forticrete’s manufacturing facilities accommodate flowline production, ensuring that the elements you require are manufactured to the tightest lead times, all with the unmistakable hallmark of Forticrete quality.

Precast Polished Florentine® Autumn Da’wah Academy, Leicester.

Precast Bat Boxes allow bats to create a natural home habitat within the block.

Ideal for new build & conservation work

The bespoke elements you need to deliver polished appeal The ability to provide bespoke elements with a highly polished surface once again sets Forticrete apart in the industry. Whether it’s detailing to complement the Burnished Venezia™ or Polished Florentine® ranges, or individual units to suit your specific designs, the Forticrete service is a unique capability in UK manufacturing.

Precast units can be created to blend with the Burnished Venezia™ and colour ranges, as follows: Burnished Venezia™ Polished Florentine®: Pewter, Steel Grey, Flint, Limestone, Ivory, Diamond, Bathstone, Yorkstone, Hamstone, Straw, Sandstone, Terracotta, Damson, Autumn, Spruce and Sports Green . ®

Additionally, specialist aggregates or colour variations can be provided to meet specific requirements.ww

Elements: All units are made to order.

Reinforcement & fixing: The only reinforcement that is incorporated into Forticrete Precast units is for handling within the factory manufacturing environment. Design for structural reinforcement and specialist fixings should be detailed by the structural engineer carrying out the design for the specific project. The lead times for Polished Precast elements will be reduced considerably if the above information is supplied with the order.

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Technical specifications Dense Concrete Masonry is manufactured from a carefully controlled mixture of aggregates and cement in accordance with BS EN 771-3:2003 ‘Specification for masonry units’ and meets the statutory requirements of the relevant sections of The Building Regulations 2000 and The Building Standards (Scotland) Regulations 1990 (amended 2001).

Mean compressive strength (air dry)

Moisture movement

Solid:

17.5 N/mm

0.45mm/m

Hollow/Cellular:

10.4 N/mm

2 2

Net dry density* 2100 kg/m

3

Water vapour permeability (tabulated from EN 1745): 5/15 µ

*For Gross Dry Densities, please refer to Table 3 in the

Reaction to fire

‘Forticrete Masonry Design Guide’

Euroclass A1

Manufacturing tolerance

Shear bond strength

Please refer to the Masonry Design Guide

(tabulated from EN 998-2:2003 Annex C) 0.15 N/mm2

Category

Configuration

I

to EN 1996-1-1

Thermal properties as CIBSE Guide A table 3.1: Protected:

1.46 W/mK

Exposed:

1.56 W/mK

Durability see table 12: BS 5628- 3:2005

Water absorption <75 g/m2/s0.5

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Solid:

Group 1

Hollow/Cellular:

Group 2

Air permeability Please refer to the Masonry Design Guide.

Product: Splitface Steel Grey and Polished Florentine® Steel Grey Project title:

Sainsbury’s, Newcastle-under-Lyme

Client: J Sainsbury PLC Contractor: Bowmer & Kirkland Architects: Chetwood Architects

Product: Splitface Pewter and Polished Florentine® Pewter Project title:

South Shields Community School, Tyne and Wear

Client: South Tyneside Council Contractor: Carillion Architects: Ryder Architecture

23 www.forticrete.co.uk

HD

Printed in High Definition The latest in print technology

Masonry Sales enquiries: Forticrete Limited, Thornley Station Industrial Estate, Salters Lane, Shotton Colliery, Durham DH6 2QA Tel: 01429 838001 Fax: 01429 836206 E-mail: masonry@forticrete.com

Information on the complete range of Forticrete products can be found at www.forticrete.co.uk he ‘F’ Logo, Forticrete, Florentine, Novastone, Ribloc, Hi-Light, T Twinbloc, Airbloc, Sports Green, Ecoblock, Ecoblock Plus and the E device are registered trademarks of Forticrete Ltd. CRH is a registered trademark of CRH plc.

Venezia, Granito, Quailstone and Sparstone are trademarks of Forticrete Ltd.

Although the instructions contained in this publication and any other information published by Forticrete are believed to be accurate at the date of publication, they are strictly for guidance only and Forticrete accepts no liability in relation to their use or for any losses, howsoever caused. You are responsible for taking all reasonable steps to ensure your use of the goods/products conforms to all applicable health and safety requirements from time to time. If in doubt, please consult appropriately qualified persons. All products sold by Forticrete are sold subject to Forticrete’s Terms and Conditions of Sale, a copy of which is available on request.

­­© Forticrete Ltd. 2012. All rights reserved.

This document does not form part of any contract and Forticrete cannot accept liability for any errors or omissions.

In order to maintain its position as a market leader, Forticrete operates a policy of continuous product development and therefore reserves the right to alter specifications without notice.

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®

The architects choice

EMS 74048

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