Block layout 2 - Advantage Glass Block Inc.
Transcription
Block layout 2 - Advantage Glass Block Inc.
Advantage/Mulia Glass Blocks Introduction Glass blocks are a timeless building material, yet over the past 50 years they’ve gone in and out of fashion depending on the trends of architectural design. Since the 1980s there has been a steady increase in the use of glass block in commercial and residential construction. Invented in Europe in the early 1900s as thin blocks of glass supported by a grid, glass blocks fell out of favour for a while before resurfacing in the 1950s as a decorative building material. But it was a short-lived love affair as 1960s architecture began to stress the minimalist look. Then two trends combined to bring glass block back into demand. During the 1970s there was a move away from the sparse look in architecture, and in the early 1980s a trend for the feel of the 1950s began. Glass blocks are not only decorative - they also have several functional advantages that make them attractive. Lots of natural light will filter through a glass block window, while at the same time, the patterns on the glass blocks create varying degrees of privacy. They have the insulating value of a 12” thick concrete wall or an insulation R value of 2.0 (similar to a thermal pane double-glazed window). Due to the large enclosed air space, condensation problems normally experienced on conventional windows are not seen on glass blocks (if installed correctly). Glass blocks provide acoustical benefits by reducing outside noise. They also provide a degree of security unavailable from an ordinary flat-glass window, while eliminating the need for expensive window coverings, which only reduce light transmission. Page 1 Until recently, glass blocks remained in the realm of architecture. In the past, an architecturally designed home with a glass block panel was a magnificent sight. But as installation techniques become easier, more homeowners are looking to glass blocks for their own home improvement projects. Homeowners are discovering the benefits of glass block panels for windows, walls, dividers and even furniture. In Europe, as much as 40% of all glass blocks sold are used by the do-it-yourselfer. Designing with Glass Blocks Mulia glass blocks are made from two sections of pressed glass, which are then fused together to create a partial vacuum inside the unit, with the pattern on the inside face. If privacy is the main concern, the wall or window should be built of blocks that will distort any images. The busier the pattern, the greater the distortion. There might be a trade-off between your need for privacy and your desire for natural light, but keep in mind that even a clear block in combination with the mortar grid will provide some distortion of image. To help keep the trade-off to a minimum, you might want to design a glass block wall using a combination of patterned and clear blocks. The clear blocks could be grouped in areas where you want to retain the view or let in the most amount of natural light. In replacing an existing window with glass blocks, you are not limited by the size of the opening. Combinations of different block sizes can be used to retrofit openings where standard multiples of blocks will not work, or where a more interesting design concept can be made while greatly reducing material costs. Two examples are shown here to illustrate the possibilities. In new construction, however, the size of the blocks can be considered in the preliminary design stages, to allow you the broadest choice of pattern and size. See sketches on next page: Page 2 This example shows 2 panels, each 36” X 36” — one using a combination of sizes and the other using all the same size of block. These two panels are identical in size yet one contains 36 blocks while the other contains 25 blocks (in a symmetrical combination). Cost per individual block is identical in this case yielding an approximate 30% saving on material and labour with the 25-block option. Why Architects Use Glass Block Architects have always had a strong attraction to glass. It’s a versatile material — hard while also being translucent or transparent. Glass blocks offer the architect the excitement of glass, while offering many of the advantages of masonry material. Glass blocks are an important element in current design trends and their qualities make them welcome in any renovation, new home design or commercial application. Few construction materials offer all the benefits associated with glass blocks — natural light, openness, strength, attractiveness, coupled with a high degree of privacy and security, and reduced sound transmission. With glass blocks, you can build an expanse of wall with only a thin mortar line between the rows of blocks. No other visually distracting construction material is necessary (within size limits). Page 3 The maximum exterior panel area is 144 sq.ft. with the width no longer that 25 ft. and a maximum height of 20 ft. Interior panels can be a maximum of 250 sq.ft. These calculations are based on the used of 3-7/8 thick blocks. If you use 3-1/8 thick blocks, the maximum exterior area you can cover with a single panel is 85 sq.ft. The maximum interior area is 150 sq.ft., again with a height of no more than 20 ft. If your opening is larger than these sizes, a series of panels is necessary with each panel supported by a structural frame and expansion joints. Maximum Panel Dimensions thick series thin series area (sq. ft.) area (sq. ft.) Channel-type restraint 144 85 Panel anchors 144 85 Channels or panel anchors w/intermediate stiffeners 250 150 Channel-type restraint 250 150 Panel anchors 250 150 Perimeter Support Method interior interior Curved walls are one of the most beautiful applications of glass blocks. A curved wall can round out to catch more light, dip back to the wall line again, go straight for a bit, then curve out once more. There is no end to the variety of design offered. Whether they are clear for maximum visibility or textured to provide privacy, glass blocks will always create a feeling of openness. There are many interesting applications for glass blocks. For example, if you would like an island in your kitchen, but a solid island would appear too heavy, make the base from glass blocks Page 4 to lighten the appearance. Or you may want a bar in a recreation room but again a regular bar would appear too massive. The base can be created from glass blocks while the bar top can be supported by wood columns at either end. Shower installations can surround the entire enclosure or be as simple as light panels inserted anywhere in the drywall. Glass blocks offer a degree of security that is not offered by an ordinary glass window. Since the blocks are 3” to 4” inches thick, they offer protection against forcible entry or breakage. Basement windows are particularly attractive to intruders because they are small, at ground level and are usually in a spot that will prevent detection of the intruder. Sidelights next to the front entrance are a favorite of intruders as well, since it is simply a matter of breaking the glass and reaching in to unlock a deadbolt to gain access. Replace basement windows and sidelights with glass blocks and you restrict access to your house without sacrificing any natural light transmission. Working with Glass Block Glass blocks are not load-bearing and must be used in conjunction with a steel lintel (angle iron) or a wood header. This is no different from typical construction details for a conventional window installation. The panel must be independent of the main structure. There must be a cushion between the panel and the surrounding construction material. Yet the blocks are still tied to the surrounding structure. Glass blocks are treated somewhat like bricks with the panel being built from the bottom up, block by block. It is true that a glass block project is only as good as the craftsmanship employed, but there are no great secrets to masonry work. Page 5 With the use of spacers, you can keep the mortar joints even and prevent bulges in the rows of blocks. So the only remaining trick to the masonry work is preparing and handling the mortar. Mortar is the adhesive that will hold your glass blocks together and give your project its strength. The quality and durability of your glass block panel will depend on the quality of the mortar you prepare. A mortar that is too runny or too dry won’t work. You should mix to a consistency of peanut butter in order to achieve a durable bond with optimal holding power. One bag of our pre-mixed glass block mortar (20 kg) will lay approximately 25-3” blocks or 20-4” blocks. Our pre-mix mortar incorporates latex acrylic polymers to increase water resistance. Using Installation Accessories: Spacers, Anchors, Expansion, Reinforcing Kreuz plastic spacers — called a laying cross — were originally invented in Austria. The crosses at each end of the spacer sit on either side of the glass block providing horizontal rigidity while the bridge sits down in the vertical mortar bed. The tabs at the outside of the spacers keep the wall plumb as it goes up. These tabs snap off when twisted to allow easy striking of the mortar joint. The main body of the spacer remains embedded in the mortar, providing uniform quarter-inch horizontal and vertical joint spacing. The support provided by these spacers allows construction of large spans within a single day with no need to wait for mortar to harden. Glass Block Spacer (specify thickness 3” or 4”) Page 6 These versatile plastic spacers are a key “enabling technology” which ensures that consistent mortar lines are within the reach of anyone who wants to produce a glass block project. A glass block panel cannot support any structural weight other than its own. That means you can not tear down a load-bearing wall inside your house and replace it with a glass block wall — unless you provide an integrated supporting structure. This also means that no lintels or structural pieces of any kind that support weight can rest on top of the glass block panel. Lintels must be supported by other structural members. An expansion joint is placed between the glass block and lintel, acting as a cushion in the case of any lintel deflection. As mentioned earlier, panels must be independent of the main structure. This means the panel cannot be mortared directly to the building for fear of cracking during the differential expansion and contraction of the surrounding materials. The panel is therefore surrounded by an expansion joint at both jambs and at the head position. There are three methods of providing panel support: chase construction, channel construction and panel anchors. In chase construction, the edges of the glass block panel are built so that they fit into a wide groove or channel formed directly into concrete jambs. The second method of securing a glass block panel is channel construction. In this system, the glass block panel sits in a metal channel that is fastened to the jambs and head of the opening. With the panel anchoring method, two-foot-long, hot-dipped, galvanized steel panel anchors are secured into the mortar joint above the first course and then at 16”-24” intervals thereafter, with the last anchor placed directly below the top block. A 16” length of anchor is buried in the mortar, the other 8” is bent and fastened directly to the jambs and/or head (depending on application). This method allows for full view of the glass blocks around the edges of the panel since the block edges are not buried in a channel support. Page 7 Below: Chase and Channel Construction Photo above: Panel Anchor Page 8 It may appear contradictory when to say that a panel must be independent from the main structure, and then explain how to secure a panel. However, in each of these anchoring cases, the panel is separated from the main structure by means of an expansion strip that is usually a compressed polyfoam material. The panel anchor must not come into contact with the glass block (because of the different expansion rates), so make sure the anchor is buried in the middle of the mortar bed. To install four-foot hot-dipped galvanized steel ladder reinforcing, place the lower half of the mortar bed, press the reinforcing into place, then cover the reinforcing with the top half of the mortar bed and trowel smooth. Keep the metal ladder in the middle of the mortar bed to avoid contact with the glass blocks. Overlap the steel ladder reinforcing by a minimun of 6” to maintain continuous reinforcing without bridging the expansion material. Page 9 Three Spacers in One Each glass block installation will generally require the use of all the three possible spacer variations: “Regular”, “T” and “L” spacers. To create “T” and “L” spacers, simply cut off the indicated parts of a “regular” spacer. Regular Use wherever 4 blocks meet. Do not remove end caps until installation is completed. L Remove end cap and two legs (shown dotted) from each end of a regular spacer to form an “L” spacer. Use for corners against sill, jamb and header. T Remove one half of end cap and upper extension of vertical leg from each end of spacer (shown dotted). Use for blocks placed against jamb, sill and header. Page 10 Spacer Application Guide: Bears weight so mortar does not float. How the Glass Block Spacer Works Tabs hold face of blocks aligned and flush Does not obstruct panel anchors or re-inforcing Maintains perfect horizontal and vertical joint Glass block is held secure during installation End caps simply twist off after installation Tools and Accessories Required: • Glass blocks (choose either 3 1/8” or 3 7/8” width). To determine the number of blocks required, divide each of the opening dimensions (horizontal and vertical) by the nominal size of the block used (i.e. 8”). Multiply the number of horizontal blocks by the number of vertical blocks to determine the total number of blocks required. (opening should always be a multiple of the nominal block size + 1/4” – i.e. 10 blocks = 80 1/4”) • Glass block spacers (specify correct size to fit block thickness). To calculate quantity of spacers required, multiply number of horizontal glass blocks plus one by the number of vertical glass blocks plus one (i.e. 2 X 2 blocks requires 9 spacers, see diagram on page 9). • Panel Anchors • Expansion Strips • Panel Reinforcement • Glass Block Mortar • Screws (3/4” or 1” long) and Plugs (if required). • Mortar Trowel, Brick Jointer, Level, Plumb Line, Sponge. • Caulking Gun with Silicone Sealant Page 11 Canada Classified UL® Glass Block Installation Material Plastic mortar joint spacers classified by Underwriters Laboratories Inc. R18127. Preparation • After preparing the work site, first install panel anchors to tie the panel into the jambs of the opening. Anchors will be embedded in mortar during installation of block. Bend the anchor into a “L” shape with an 8” vertical leg and a 16” horizontal leg. Attach vertical leg to the jamb with appropriate fasteners. Additional panel anchors must be placed after every third 6” block or after every second 8” or 12” block. • Install expansion strips, trim strips to proper width and attach to head and jambs. • Prepare “T” and “L” spacers by removing legs from regular spacers. Installation Note: Don’t place mortar between glass blocks and expansion strips. Laying the First Course • Apply mortar to the prepared sill. • Place an “L” spacer in the corner, seating it squarely against the jamb and the sill. • Seat the first block into the corner, resting it on the mortar. Add a “T” spacer under the corner of the block that is not already supported by the “L” spacer. Place the spacer under the block against the sill and seat the block into position. • Place a regular spacer on the free upper corner of the block. • Apply mortar to the vertical side of a second block and put that block into position, using spacers to maintain joint spacing. Seat block horizontally and vertically. • Repeat process to end of first course of blocks • Inspect work periodically to check accuracy, level and plumb. Make any necessary corrections before proceeding. Page 12 Continue the Installation • Clear mortar from the legs of the spacers to ensure an accurate mortar joint. • Install block as described for beginning course. • At courses requiring panel anchors, embed anchor into centre of mortar bed. • Panels over 25 square feet require panel reinforcing to be used, with panel anchors. Embed re-inforcing strips in mortar as each course is finished. Overlap re-inforcing strips by 6” when joining pieces. • At head (top course), place spacers before inserting block. No mortar is used between the header and the block. Use expansion material between block and head. Finishing and Clean-Up • After mortar has begun to set (thumbprint-hard), twist off spacer end caps and discard. Strike joint with brick jointer to a concave smooth finish. • Before mortar has dried, remove excess with a damp sponge or cloth. Rinse cloth often with clean clear water. Film and residue on the block faces can be removed later with a dry cloth. • Use silicone caulk/sealant around the perimeter of your installation. Page 13 Expansion Joints A straight exterior panel that is larger than 144 sq.ft. (13.4 sq.metres) must be built from a series of smaller panels. These smaller panels are fastened together by a series of supports and expansion joints. Although there are various ways of creating expansion joints, each joint contains compressed polyfoam to absorb movement in the panels. To join the two panels, visible or hidden attachments may be used. As shown in Diagram A, a stiffener is used that is visible on one side. The stiffener provides the necessary rigidity to support the large panels being joined. The expansion material is located between the stiffener and the block wall to provide a cushion for movement. For a continuous wall of glass blocks without any visible supports on either side, the steel plate shown in Diagram B is the answer. The steel plate acts as a double jamb and serves to separate the panels into two individual framed panels. ULC Fire Ratings If constructed properly (that is, by using adequate steel reinforcment) glass blocks have a fire rating of 45 minutes, which allows them to be used in areas where ordinary flat-glass windows cannot. Maximum allowable size in a masonry opening is 120 square feet. Maximum allowable opening in drywall is 94 square feet. Neither dimension should exceed 10 feet. Glass blocks are rated by ULC for a 45-minute fire rating which will actually allow a 1-hour fire separation if the materials surrounding the glass block are 1-hour fire rated. Fire-rated glass blocks must be installed according to the following diagram in order to qualify for ULC approval. This requires anchors and steel reinforcing above the first horizontal course, and at every second course thereafter, and with the last anchor and reinforcing placed directly below the top block. Panel anchors must also be used from the head down at 16” intervals. Page 14 The steel plate provides rigidity while expansion material covers both sides of the plate to allow movement. Both the steel plate and the polyfoam expansion material are less wide than the block to allow room for caulking. Where steel plates are used, panel height would be limited to 10 ft. (3 metres). In Diagrams C and D, the expansion joint is more visible. It can be incorporated into the glass block panel as a design element. These configurations use two Uchannels to hold the glass block. The U-channels are either joined together by a mullion (C), or simply connected back to back (D). A B C D Right column: Four Different Types of Expansion Joints: A, B, C, D. Page 15 Fire-Rated Panel Anchor Construction: Lintel or Header Expansion Strip Fire-Rated Caulking Panel Anchor Expansion Strip Panel Re-inforcing Panel Anchors Two Bolts or Screws per Anchor Glass Block Mortar Wall framing shown here for illustrative purposes only. Wall framing can be concrete, masonry, wood, steel, fire-rated drywall or any other structural surround. Asphalt Emulsion Page 16 Curved Walls Curved walls have their own special requirements for expansion joints. Regardless of size, an intermediate expansion joint must be placed in the wall every time a curve changes direction or where a curved section meets a straight wall. The radius of the curve is also restricted. See the following table for radius options available with different sizes of glass blocks. Special tapered spacers accommodate these radius options. These spacers can also be opened up slightly to accommodate minor adjustments to the radius options listed. Mortar Joint Thickness Nominal Block Size & Actual Inside Radius (in inches) D E al Ve rt H ic or al iz on ta l 4 in ch bl oc k 6 in ch bl oc k 8 in ch bl oc k 12 in ch bl oc N k o. of bl oc A ks ng in le 90 in ˚a de rc gr Pr ee od s uc tC od e th id si In O ut si de de w oc k Bl C Ve rt ic A B B: 3 1/8” 5/8” 1/8” 1/4” 19 1/2” 29 5/8” 39 7/8” – 8 11.25˚ ABK-RO1 5/8” 1/4” 1/4” 25 1/8” 37 7/8” 50 1/2” – 10 3/8” 1/8” 1/4” 39 3/8” 59 3/4” 80 1/8” – 16 3/8” 1/4” 1/4” 76 1/8” 114 3/8” 152 1/2” – 30 3.0˚ ABK-RO4 9.0˚ ABK RO2 5.625˚ ABK-RO3 3 7/8” 5/8” 1/8” 1/4” 24 1/2” 37 1/4” 49 7/8” 75 1/4” 10 9.0˚ ABK RO5 5/8” 1/4” 1/4” 30 1/4” 45 1/2” 60 3/4” 91 1/4” 12 7.5˚ ABK-RO6 3/8” 1/8” 1/4” 49 3/8” 74 3/4” 100 1/4” 151 1/8” 20 4.5˚ ABK-RO7 3/8” 1/4” 1/4” 101 5/8” 152 1/2” 203 3/8” 305 1/4” 40 2.25˚ ABK-RO8 4 22.5˚ ABK-ALB 3 7/8” 3/8” 3/16” 1/4” Allbend® Page 17 Page 18 90 Degree Corner Options Here are four methods to get you around corners: Diagram A shows two glass block panels formed into a 90∫ angle by the use of a wood post or steel tubing. The post or tube is covered from floor to ceiling with a steel or aluminum angle. The flanges of the angle must be long enough to overlap the glass block panels on both sides by 1 inch. Expansion joint material is placed between the glass block and the post or tubing. The inside corner is covered with a steel or aluminum “T”. Two of the ”T” flanges cover the corner while the third flange fits into one of the expansion joints. Again, the inside corner flanges must cover the glass block face on each side by 1 inch. Expansion material is stuffed into the edge of each flange, then a bead of caulking is run between the flange and the glass block to seal each joint. Diagram B shows a variation of the above corner-making method. In this version, the steel tubing or wood post is left visible without any aluminum angle attached. The posts act as Diagram A jambs. An expansion strip is placed between the glass block panel with panel anchors to tie the glass block panel to the post. Then a bead of caulking is run between the post and panel to seal the joint. Diagram B Page 19 Diagram C shows a stepped corner. The first diagram showed a post covered with a steel or aluminum angle. In the steppedcorner method, the post is eliminated and the angle is reversed. With the angle secured to floor and ceiling, channels are attached to each side of the angle and the channel method of securing glass block panels is followed. Diagram C The most pleasing 90 degree corner is that made with a special corner block which offers a smooth seamless appearance without the interference of contrasting materials (Diagram D). The limitations of this block, however, are that it is available only in wave design. Diagram D Page 20 Specialty Blocks End blocks in both 8 X 8 X 3 1/8” and 8 X 8 X 3 7/8” are now available with rounded finished ends. This allows construction of walls with exposed vertical or horizontal edges, with a totally finished appearance (wave pattern only). As mentioned above, there is also a 90 degree corner block in wave pattern, intended to help create a seamless corner. It will accomodate either the thick or thin block series. Pre-Cast Panel System Entire glass blocks panels can be pre-assembled in our factory, based on the number of modules needed to complete a project. We can work with you if you require design assistance or prepare panels from your plans or drawings. Our panels are normally manageable by one or two people who will then do the final erection at the work site. Even curved or serpentine walls can be pre-constructed. Replacement or infill panels for any size window or wall opening can also be pre-fabricated. Just call or fax us with the measurements and we will create drawings showing the different possible combinations of blocks required to fill the opening. The drawings will show the correct positions for wall panel anchors, horizontal joint reinforcing, spacers and expansion material. The locations are important due to the need to tie the blocks to the surrounding structure, yet still allow for expansion and contraction. The finest materials go into our special mortar mix such as latex and acrylic bonding agents for superior thermal shock and water resistance. The final installation time is reduced dramatically over laying loose block, yielding great savings on labour costs while providing a superior quality finished appearance. Smaller panels of up to 15 sq.ft. can be produced using a clear construction-strength silicone which allows a seamless appearance. Page 21 Typical Physical Properties of Glass Blocks: Available Patterns: Wave Page 22 Ocean View Quadra Diamond Page 23 Bromo Ice Wave Finishing End (8X8X4) and (8X8X3) Page 24 View (Clear) Pristal Matrix Page 25 Product Order Index UPC Ctn UPC Each SKU# Style Size 619284288020 619284088026 7902 Wave 8X8X3 10 300 619284268121 619284068127 7912 Wave 6X8X3 10 400 619284266226 619284066222 7922 Wave 6X6X3 10 480 619284248321 619284048327 7932 Wave 4X8X3 10 600 619284288822 619284088828 7902-EB Wave End Thin 8X8X3 10 300 619284288426 619284088422 Wave 8X8X4 8 240 619284288938 619284088934 9802-AB Wave 90 angle 8X8X4 4 240 619284288945 619284088941 9802-EB Wave End Thick 8X8X4 8 240 619284279035 619284079031 7903 Pristal 8X8X3 10 300 619284279134 619284079130 7913 Pristal 6X8X3 10 400 619284279233 619284079239 7923 Pristal 6X6X3 10 480 619284279332 619284079338 7933 Pristal 4X8X3 10 600 619284298036 619284098032 9803 Pristal 8X8X4 8 240 619284298012 619284098018 9801 Quadra 8X8X4 8 240 619284298524 619284098520 9852 Ice 8X8X4 8 240 619284279004 619284079000 7900 View (Clear) 8X8X3 10 300 619284279103 619284079109 7910 View (Clear) 6X8X3 10 400 619284298005 619284098001 9800 View (Clear) 8X8X4 8 240 619284279042 619284079048 7904 Bubbles 8X8X3 10 300 619284279059 619284079055 7905 Ocean View 8X8X3 10 300 619284279219 619284079215 7921 Diamond 8X8X3 10 300 619284279530 619284079536 7953 Bromo 8X8X3 10 300 619284298081 619284098087 9808 Matrix 8X8X4 8 240 9802 Page 26 Ctn Qty Skid Qty Accessories: Item Description Drawing Panel Anchors Panel Anchors 1 3/4”W X 24”L Hot-Dipped Galvanized Steel UPC Code # Number of _____? Units per Weight per carton (lb.) SKU # 40 50 16 ABK-PA1 20 Bundles 50 26 ABK-PR3 25 20 8 ABK-SO1 25 20 8 ABK-SO2 4 Pallets 70 3,080 lb GBM-20 16 50 3 ABK-EX2 107 02550 10001 4 Steel Ladder Hot-Dipped Galvanized Steel Ladder 1 5/8”W X 48”L UPC Code # 1 07 02550 10009 0 1/4” Spacers Thinline 3 1/8” UPC Code # 1 07 02550 31221 9 1/4’ Spacer for Glass Block Thinline 3 1/8” Standard 3 7/8” UPC Code # 1 07 02550 71221 7 1/4’ Spacer for Glass Block Standard 3 7/8” Mortar Mix Glass Block Latex Modified Mortar Mix (20 kg. per bag) UPC Code # 7-73727-0714-7 Expansion Strips Expansion Strips White Closed-cell Polyfoam 2 1/4”W X 24”L X 3/8” Thick UPC Code # 107 02550 10103 5 Page 27 Glass Block Installation Gallery: Page 28 Page 29 Page 30 Page 31 Page 32 Page 33 Page 34