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Cement |
Pyrotherm
Introducing The New High Performance
CMU:
In today's competitive environment, doing more with fewer
resources is the universal management mandate. With new, revolutionary
High Performance Concrete Masonry Units (HPCMUs), you can reduce costs
and add value through all phases of design, construction and occupancy.
Whether you are an architect, structural engineer, masonry contractor,
building owner or tenant, HPCMUs provide a compelling alternative to other
construction systems - from heavy or lightweight CMU to wood, metal or
tilt-wall.
HPCMUs are designed to reduce structural/underpinning costs and increase
jobsite productivity, while providing superior performance and ongoing
energy savings.
The High Performance initiative links specifiers. block producers, contractors,
builders and tenants in a "value chain" of quality - delivering
up-front construction efficiencies, flexibility for future retrofits and
operating cost benefits that will last the life of the building.
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Features top
It Isn't High-Performance Unless
It's 100% PyroTherm Aggregate Inside!
Produced to exacting specifications in a strictly controlled manufacturing
process, strong PyroTherm aggregate is the essential ingredient that separates
High Performance CMUs from all others.
PyroTherm is created by firing a special blend of aggregate particles
in a rotary kiln at temperatures of up to 2000°F. During the process,
the unique blend of shale or clay particles is permanently converted to
a porous, glass-like aggregate with excellent strength and thermal stability.
The result is a pure noncombustible, nondegradable, "optimum density"
aggregate that infuses superior energy efficiency, fire resistance and
sound insulation performance features into every High Performance CMU
you specify.
Feature By Feature, It Pays To Check
Before You Spec!
When you specify HPCMUs, you can be confident that you are selecting a
wall system that will exceed performance standards other wall systems
only attempt to meet.
PyroTherm™ - The Cornerstone
Of Value
Possessed with outstanding physical properties, PyroTherm aggregate contains
the optimum blend for non-gap graded materials. The well-graded properties
of pure, low-density PyroTherm aggregate allows for a remarkably even
distribution of the aggregate in the mix - endowing each HPCMU with maximum
strength to transfer loads properly throughout the unit.
The result is an "optimum-density" unity - utilizing low-density
aggregate, yet outperforming the weight requirements of ASTM-C90 lightweight
units. The reduced weight of HPCMUs delivers increased productivity and
reduces wear and tear on masons, crews and equipment.
An HPCMU is a well-proportioned, highly durable construction product with
significantly reduces thermal conductivity characteristics that provides
all the safety, security and comfort offered by standards ASTM LWCMUs.
Plus...a host of exciting performance and efficiency characteristics far
exceeding those of tilt-wall, wood frame, metal frame, steel or other
CMU wall systems.
Better Fire Ratings
Fire walls in units using HPCMUs will outperform wood and sheetrock fire
wall systems - even ASTM-LWCMUs. Plus, a certified HPCMU using 100% PyroTherm
aggregate is a passive, noncumbustible unit that will not function as
a source of fuel. In fact, HPCMUs well exceed Universal Building Code
(UBC) and UL equivalent thickness requirements for firewall period ratings.
When you specify HPCMUs, you insure an extra margin of safety that can
save lives and dollars.
NOTICE: Adding sand, gravel or other fillers to PyroTherm aggregate will
reduce the thermal stability and fire resistance qualities of CMUs.
Superior Noise Reduction
The sound-absorbing properties and rigid mass of HPCMU walls using 100%
PyroTherm aggregate reduces reflected noise. This can be important in
noise-filled rooms. An Noise Reduction Coefficients (NRC) of 0.50 is typical,
creating a quieter, more peaceful living or working environment.
Approximate Noise Reduction Coefficients (NRC)
Unparalleled Structural Integrity
PyroTherm has a coefficient of linear expansion significantly
lower than heavyweight aggregate. PyroTherm possesses much greater thermal
stability than other aggregates. Unlike sheetrock, the HPCMU wall can
withstand extreme 2000°F heat and the thermal shock of high pressure
fire hose spray without cracking, or "caving in".
Time and time again, HPCMU walls will remain intact, ready for re-use
after a fire. (See ASTM-E119, "Standard Test Methods For Fire Testing
Of Building Construction And Materials.")
Improved Aesthetics By Reduced Chipping
The discovery of a chipped-up wall in your project
can be disappointing. What can you do, now that the CMU is installed?
HPCMUs possess improved capability to flex prior to fracture. This greater
tensile strain capacity means that units will be less subject to chipping.
The high tensile/weight ratio also produces a strong wall system that
reduces dead load design requirements. Designers committed to the total
quality "look" will appreciate these added benefits.
Superior Insulating Power
At a time when the need for highly insulative wall
systems has never been greater, "optimum-density" HPCMUs with
low-density PyroTherm aggregate outperform other systems because of a
powerful combination of R-value bolstered by superior heat capacity expresses
as HC. In fact, the HPCMU outperforms other systems due to its thermal
mass.
Low Sound Transmission
Sound is a vibration in an elastic medium. The rigid,
uniform mass of the HPCMU wall minimizes vibration and contributes to
very low transmission of unwanted exterior sounds through to the quiet
side of the wall. The Sound Transmission Class of a solid HPCMU wall without
doors or windows can be as high as 50 decibels, meaning a 100-decibel
rock band next door can sound like a normal conversation to those listening
on the other side of the wall.
Unsurpassed Strength
An optimum-density mix with improved particle interlock
and superior cement paste distribution using PyroTherm will result in
a remarkably high strength/weight ratio. Testing performed by NCMA has
shown that HPCMUs exceed ASTM minimum strength specifications by 65% to
250%.
While the HPCMU must have a minimum net compressive strength of 3000 PSI,
higher strengths can be specified. Expect higher strength and less weight
than the current ASTM LWCMU on the market today!
Nothing "Walls In" Energy Costs Like HPCMUs
Source: Energy Advantages of Concrete Masonry, Florida Concrete
& Products Association, Orlando, FL.
Reduced Thermal Bridging
Metal frame wall systems are notorious thermal conductors
that allows "thermal bridging," or the funneling of outside
temperatures through the studs, effectively overpowering their R-Values.
The result is higher energy costs and uncomfortable hotspots.
Not so with an HPCMU. The thermal mass
of an "optimum-density" HPCMU allows the wall to act as a "storage
unit" that collects heat slowly and evenly to retard the migration
of heat to the cool side - stopping temperature fluctuations and keeping
energy bills down.
The Dee Brown Companies were formed during the past
40 years with a goal to provide our client with the highest quality
masonry product, on time, and within the client's budget. We have provided
this work on projects such as the Lew Sterrett Justice Center - Dallas,
Texas; The Meyerson Symphony Center - Dallas, Texas; Burlington Northern
Railroad - Fort Worth, Texas; Brooke Army Medical Center - San Antonio,
Texas; World Savings Corporate Offices - San Antonio, Texas.
"As a member of the ASTM-C15 Committee,
I understand the High Performance CMU exceeds all existing ASTM standards,
yet will weigh less than the existing CMU units. The lighter weight,
along with a more uniform edge and texture, will increase the mason's
productivity, thus allowing for a better quality product. We are encouraging
the specification of High Performance CMUs, and we are excited about
using this high quality product to enhance the value and quality of
the masonry wall system we install."
- Robert V. "Buddie" Barnes
Jr., President & CEO, Masonry Technology Inc.
D and H Masonry was established in 1985 in
Houston, Texas, and is committed to supplying the construction industry
with the highest quality masonry jobs possible. We have successfully
completed numerous schools for Fort Bend and Houston Independent School
Districts as well as the recently completed Museum of Fine Arts Junior
School and Administration Building.
"We support the use of High Performance
Concrete Masonry Units on the jobs we do. We expect better productivity
and less chipping due to the lighter weight and higher compressive strength
of each unit. As part of the total masonry system that includes quality
masonry performed by D and H Masonry, the addition of yet another quality
component only results in a winning combination!"
- David Knight, Owner and Mel Oller, Chief Estimator,
D and H Masonry
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Productivity
top
It Isn't High-Performance Unless It's 100% PyroTherm
Aggregate Inside!
Produced to exacting specifications in a strictly controlled manufacturing
process, strong PyroTherm aggregate is the essential ingredient that separates
High Performance CMUs from all others.
PyroTherm is created by firing a special blend of aggregate particles
in a rotary kiln at temperatures of up to 2000°F. During the process,
the unique blend of shale or clay particles is permanently converted to
a porous, glass-like aggregate with excellent strength and thermal stability.
The result is a pure noncombustible, nondegradable, "optimum density"
aggregate that infuses superior energy efficiency, fire resistance and
sound insulation performance features into every High Performance CMU
you specify.
Feature By Feature, It Pays To Check
Before You Spec!
When you specify HPCMUs, you can be confident that you are selecting a
wall system that will exceed performance standards other wall systems
only attempt to meet.
PyroTherm™ - The Cornerstone
Of Value
Possessed with outstanding physical properties, PyroTherm aggregate contains
the optimum blend for non-gap graded materials. The well-graded properties
of pure, low-density PyroTherm aggregate allows for a remarkably even
distribution of the aggregate in the mix - endowing each HPCMU with maximum
strength to transfer loads properly throughout the unit.
The result is an "optimum-density" unity - utilizing low-density
aggregate, yet outperforming the weight requirements of ASTM-C90 lightweight
units. The reduced weight of HPCMUs delivers increased productivity and
reduces wear and tear on masons, crews and equipment.
An HPCMU is a well-proportioned, highly durable construction product with
significantly reduces thermal conductivity characteristics that provides
all the safety, security and comfort offered by standards ASTM LWCMUs.
Plus...a host of exciting performance and efficiency characteristics far
exceeding those of tilt-wall, wood frame, metal frame, steel or other
CMU wall systems.
Better Fire Ratings
Fire walls in units using HPCMUs will outperform wood and sheetrock fire
wall systems - even ASTM-LWCMUs. Plus, a certified HPCMU using 100% PyroTherm
aggregate is a passive, noncumbustible unit that will not function as
a source of fuel. In fact, HPCMUs well exceed Universal Building Code
(UBC) and UL equivalent thickness requirements for firewall period ratings.
When you specify HPCMUs, you insure an extra margin of safety that can
save lives and dollars.
NOTICE: Adding sand, gravel or other fillers to
PyroTherm aggregate will reduce the thermal stability and fire resistance
qualities of CMUs.
Superior Noise Reduction
The sound-absorbing properties and rigid mass of HPCMU walls using 100%
PyroTherm aggregate reduces reflected noise. This can be important in
noise-filled rooms. An Noise Reduction Coefficients (NRC) of 0.50 is typical,
creating a quieter, more peaceful living or working environment.
Approximate Noise Reduction Coefficients (NRC)
Unparalleled Structural Integrity
PyroTherm has a coefficient of linear expansion significantly lower than
heavyweight aggregate. PyroTherm possesses much greater thermal stability
than other aggregates. Unlike sheetrock, the HPCMU wall can withstand extreme
2000°F heat and the thermal shock of high pressure fire hose spray without
cracking, or "caving in".
Time and time again, HPCMU walls will remain intact, ready for re-use after
a fire. (See ASTM-E119, "Standard Test Methods For Fire Testing Of
Building Construction And Materials.")
Improved Aesthetics By Reduced
Chipping
The discovery of a chipped-up wall in your project can be disappointing.
What can you do, now that the CMU is installed? HPCMUs possess improved
capability to flex prior to fracture. This greater tensile strain capacity
means that units will be less subject to chipping. The high tensile/weight
ratio also produces a strong wall system that reduces dead load design requirements.
Designers committed to the total quality "look" will appreciate
these added benefits.
Superior Insulating Power
At a time when the need for highly insulative wall systems has never been
greater, "optimum-density" HPCMUs with low-density PyroTherm aggregate
outperform other systems because of a powerful combination of R-value bolstered
by superior heat capacity expresses as HC. In fact, the HPCMU outperforms
other systems due to its thermal mass.
Low Sound Transmission
Sound is a vibration in an elastic medium. The rigid, uniform mass of
the HPCMU wall minimizes vibration and contributes to very low transmission
of unwanted exterior sounds through to the quiet side of the wall. The
Sound Transmission Class of a solid HPCMU wall without doors or windows
can be as high as 50 decibels, meaning a 100-decibel rock band next door
can sound like a normal conversation to those listening on the other side
of the wall.
Unsurpassed Strength
An optimum-density mix with improved particle interlock and superior cement
paste distribution using PyroTherm will result in a remarkably high strength/weight
ratio. Testing performed by NCMA has shown that HPCMUs exceed ASTM
minimum strength specifications by 65% to 250%.
While the HPCMU must have a minimum net compressive strength of 3000
PSI, higher strengths can be specified. Expect higher strength and
less weight than the current ASTM LWCMU on the market today!
Nothing "Walls In" Energy
Costs Like HPCMUs
Source: Energy Advantages of Concrete Masonry, Florida Concrete
& Products Association, Orlando, FL.
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TEAM-WIDE
BENEFITS top
Architect/Structural Engineer: $21,000
reduction in labor/material costs for substructure/underpinnings vs. ASTM
LWCMU.
Masonry Contractor: Increased Productivity
& Labor savings - 8.2 Days Earlier Completion Rate vs. ASTM LWCMU.
Retail Tenant: $110,500 Annual Energy Savings
vs. Tilt-Wall
$17,500 Annual Energy Savings vs. ASTM LWCMU.
Plus... Revenue bonus for store's
first year of operation: Eight extra selling days due to earlier completion
date using HPCMUs vs. ASTM LWCMUs ($160,000 in incremental revenue, based
on $20,000 projected daily sales).
HPCMU Savings Breakdown:
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HPCMU
vs
ASTM LWCMU |
HPCMU
vs
Tilt-Wall |
| Total 3-Year Savings: |
$ 70,650 |
$294,750 |
| Total 5-Year Savings: |
$104,650 |
$515,750 |
* All costs used in this study were determined by
Construction Technology Consultants, Lee Walden, P.E. using City of Houston
labor and electricity rates.
NOTE: This is an estimation of potential costs in regard to the
performance of the wall systems shown and is presented to illustrate how
the exterior envelope construction and materials used can impact an overall
energy design. The actual energy costs for a building is a complex evaluation
performed by a qualified energy design engineer, taking into consideration
a multitude of possible design situations to meet or excess the requirements
of Model Energy codes. |
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Technical
Data top
Guide Specifications For High Performance
Concrete Masonry Units (HPCMUs) Using 100% PyroTherm™
Provide concrete masonry units meeting the certification requirements
of 100% PyroTherm™ High Performance Concrete Masonry Units. Minimum
net compressive strength at 28 days shall not be less than 3000 PSI (20.8
MPa) as an average of three units, with no individual unit less than 2700
PSI (18.6 MPa) net compressive strength when tested in accordance with
ASTM C90-93 and C140-91.
NOTE: In addition to normal low pressure steam curing, HPCMUs shall be
allowed to air cure in the manufacturers yard and/or job site a minimum
of 10 days from time of removal from kiln. Minimum net compressive strength
when tested ten days or less from time of removal from kiln shall be at
least 2700 PSI (18.6 MPa) net compressive strength as an average of three
units, with no individual unit less than 2500 PSI (17.2 MPa) net compressive
strength prior to placement in wall.
In addition to the manufacturing requirements of certified HPCMU, the
unit shall conform to the requirements of ASTM Designation C90-93 for
Load Bearing Concrete Masonry Units or ASTM Specification C 129-93 Non-Load
Bearing Concrete Masonry Units. The stricter requirements of PyroTherm
HPCMU criteria shall prevail over any lesser requirement of ASTM C90-93
or C129-93.
Weight Requirements
The normal dry (received) weights of various sizes of two core HPCMUs
shall not exceed the weight shown in the table below when tested in accordance
with ASTM C140. Weights given are for minimum face shell and web thickness
allowed ASTM C90. If units are manufactured using "optimized webs"
or thicker face shells than required by ASTM C90 an adjustment in maximum
block weight will be allowed based on the units calculated volume.
Nominal
Size |
US
(inches) |
4x8x16" |
6x8x16" |
8x8x16" |
10x8x16" |
12x8x16" |
Normal
Weight |
US
(pounds) |
16 |
19 |
25 |
30 |
35 |
Nominal
Size |
Metric
(mm) |
102x203
x406 |
152x203
x406 |
203x203
x406 |
254x203
x406 |
305x203
x406 |
Normal
Weight |
Metric
(kg) |
7.3 |
8.7 |
11.4 |
13.6 |
15.9 |
Performance Requirements
- Fire Ratings: The Certified
HPCMU producer shall furnish, if required, certification from an independent
laboratory confirming that all 8" or larger masonry units meet
all of the UL 618 and/or local building code requirements for two hours
or better, referencing ASTM E119 for full scale fire testing.
- Thermal Resistance: The
Certified HPCMU producer shall furnish certification from an independent
laboratory confirming by test conducted by ASTM C177, "Test Methods
for Steady-State Thermal Transmission Properties by Means of the Guarded
Hot Plate", that the thermal resistance (R-Value) of an 8"
HPCMU shall be a minimum of 2.30 (BTU/F° * ft©ò * h).
- Certification of Testing:
The Certified HPCMU producer shall submit certifications of compliance
with ASTM C90, C331 and, if required, UL 618, 60 days prior to job site
delivery. In addition to the forgoing, the laboratory test report shall
also certify that the units meet the strength and weight requirements
of PyroTherm™ HPCMU. Field sampling of concrete masonry units shall
be conducted during construction by an independent laboratory according
to the requirement of ASTM C140.
Concrete Purity Assurance
The use of cinder bottom ash or similar waste products is prohibited.
Blending of limestone chips, cinders, unexpanded slag, calcareous and/or
siliceous gravel, or any other deleterious substance is also prohibited.
Units shall not be comprised with organic impurities, since these contribute
to rusting, popouts or staining. No combustible materials of any kind
may be used in the concrete of PyroTherm™ HPCMU.
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