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T H E R E A L A LT E R N AT I V E TO SHUTTERED CONCRETE
www.andertonconcrete.co.uk
STEPOC
THE FASTER, MORE ECONOMICAL WAY TO BUILD WALLS WITH EXCEPTIONAL STRENGTH STEPOC SYSTEM
Stepoc is a system of highly-engineered and dimensionally co-ordinated building modules which are designed to readily accept horizontal reinforcement for use where structural performance is the prime consideration.
Stepocs unique design enables horizontal reinforcement to be placed adjacent to either block face, or both if required, to ensure that maximum strength is achieved just where its needed. Stepoc is bonded with concrete, which is poured down through the inter connected cavities in the blocks. The blocks unique design creates a cascade or waterfall effect which ensures a smooth filling of the poured concrete, forcing out air and eliminating segregation, to create walls which have immense compressive and lateral strength. Stepoc enables the fast construction of single skin retaining walls up to 3.8 metres high, subject to a design carried out by a structural engineer. At less than 20kg all units are well within the HSE guidelines for a single man repetitive lift. Stepoc is proven in use on applications the length and breadth of the UK.
Stepoc combines the ease of blockwork construction with the versatility of in-situ concrete, and yet is faster to apply than both, making it an ideal component for:
Retaining walls Sheer wall Laterally-loaded panels Blast panels Bund walls Basement walls Swimming pools and any applications that require higher compressive or lateral loads than those achievable with standard masonry. The Stepoc system is available in three widths of 200mm, 256mm and 325mm and each comprises a range of units allowing the construction of terminal ends and corners while still achieving the correct bond. Built dry, with no mortar joint, and requiring no special on-site skills or techniques, the blocks are laid to a running bond, using a combination of half or third and full lengths. Specific data sheets are available to illustrate the construction of ends, corners and other required details.
Brick Clad STEPOC for Wilmott Dixon Homes
SETTING OUT
Where the length of a wall is not to a Stepoc module, Full Length Blocks will not be able to be used for the entire length of the wall. Setting Out should therefore commence from ends of walls and/or movement joints, working towards central positions where some cutting of the units may be necessary. (A butt joint at this position is acceptable.) At openings, Full, Third or Half Length Plain Ends may be used and cut to suit. As an alternative, temporary formwork may be used. Check vertical faces for plumb on completion of alternate courses. It is recommended that the first course be laid in mortar to ensure the wall is level before proceeding with the remainder of the courses.
POUR HEIGHTS
Movement joints are recommended at centres of 10m subject to engineers approval. Where a continuous run of masonry includes a corner the measurement between movement joints should be taken around the corner and not measured from the corners. Data Sheets are available on request or alternatively please contact the Technical Department. There is a maximum height for each pour so that stability is not lost in the dry laid blocks as they are filled. Lower heights for each pour can also be used. The maximum heights are: 200 Stepoc - 8 Courses 256 Stepoc - 10 Courses 325 Stepoc - 10 Courses = 1.9m = 2.25m = 2.25m
If multiple concrete pours are required, the concrete of the previous pour should finish 50-75mm from the top of the course of Stepoc, with the vertical bars projecting the equivalent of a splice, length taken from the engineers schedule. This is to ensure a proper key between consecutive pours.
CONCRETE MIX
The concrete should possess the characteristic strength specified by the structural engineer who has carried out the design of the wall, but not less than 35N/mm2, and in accordance with BS EN 206 Part 1:2000.
Block type Concrete Infill
The concrete should be designed to be suitable for the specific means of delivery, possessing a slump of no less than 150mm. The maximum aggregate size should not exceed 10mm and the mix should contain no less than 300kg of OPC per cubic metre of fresh concrete. Filling is best accomplished by a concrete pump or skip with a 75mm nozzle, and the design of the concrete should take this into account. Mechanical vibration must not be used. The use of water reducing agents is acceptable to lower cement content in the mix design.
325mm Stepoc
v
151.5 100
162.5 96.5
225
200 256
d = 100 + (
h/2) + ( v/2)
d 325
v/2)
225
228
d = 151.5 + (
h/2) + (
d = 228 + (
h/2) + (
v/2)
Vertical bar spacings for 200, 256 and 325 STEPOC are based on multiples of 200, 133 and 162.5mm respectively. Horizontal bar spacings are based on multiples of 225mm for all three units.
RADIUS WALLS
The flexibility of STEPOC allows radius walls to be constructed using either standard or third/ half length units. Data Sheets are available on request or alternatively contact the Technical Department.
STRUCTURAL STRENGTH
These charts are intended to display the range of strengths attainable when Stepoc walls are designed in accordance with BS 5628 Code of Practice for Use of Masonry The design loads referred to are at ultimate limit state, i.e. factored. For unreinforced Stepoc, a partial safety factor of 3.5 for material strength should be used. For reinforced Stepoc, the partial factor of safety should be taken as 2.3 and 1.15 for steel in accordance with part 2 of the masonry code and Andertons quality control procedures.
200mm Stepoc
120
256mm Stepoc
120
100
100
80 80
ULS Bending moment (kNm) ULS Bending moment (kNm)
60
60
40
40 20
20
20
20
100
200
300
400
500
600
700
800
900
1000
1100
0 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200
Area of bending steel (sq.mm/m)
Area of reinforcement (mm/m2) for various bar diameters and centres. BAR DIAMETER (mm) BAR CENTRES
Area of reinforcement (mm/m2) for various bar diameters and centres. BAR DIAMETER (mm) BAR CENTRES
10 200 393
12 566
16 1006
20 1571
25 2455
12 851 425
16 1512 756
20 2363 1181
325mm Stepoc
250
200 256
150
325
100
50
These calculations demonstrate the ULS bending capacity of the section only. Shear and serviceability limit state checks will be required for a complete structural design of the section.These calculations are for indication purposes only and should not be used as part of the final structural design. A full design check should be undertaken by the designer in accordance with BS 5628: part 2: 2005 Structural use of Reinforced and Pre-stressed Masonry, accounting for ultimate and serviceability limit states as required.
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000
Area of bending steel (sq.mm/m)
The charts below each graph indicate possible bar centres for each block. Reinforcement may not be required at every centre spacing but will be specified by the Structural Engineer.
Area of reinforcement (mm/m2) for various bar diameters and centres. BAR DIAMETER (mm) BAR CENTRES
12 699 348
16 1242 619
20 1940 969
25 3031 1511
CONCRETE PRODUCTS LTD
S P E C I F I C AT I O N
TYPE 200
STEPOC
400
200 35
130
200
DIMENSIONS
Stepoc blocks are available in three standard sizes:
72.5 35
165
35 82.5
35
157.5
TYPE 256
400
133
184
40
227
40
93
40
93
MANUFACTURING TOLERANCES
TYPE 325 Height: +2, -2 Length: +2, -2 Width: +2, -2 Fire Resistance Minimum fire resistance: 2 hours. For specific applications refer to BS 8110 Part 1 1997. Resistance to Frost Damage The Stepoc system is resistant to the freeze-thaw conditions that are likely to occur below a damp proof course. Resistance to Sulphate Attack Stepoc has adequate resistance to Class 3 sulphate ground conditions.
325 162
35
325
290
35
255
10
35
127
36
117
10
A:
CONCRETE PRODUCTS LTD
Units 1 & 2 Cosgrove Business Park Soot Hill, Anderton Northwich, Cheshire CW9 6AA
T: F: E: W:
35 8
255
35
36
200mm = 17.5kg
10
220
184
36
35
130