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

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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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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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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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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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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

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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

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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

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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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