EZYBLOCK Pty Ltd is one of the many innovative and environmentally friendly building products designed and manufactured by the Ezy Building System group in Australia. Insulated Concrete Form (ICF) walls have a proven track record in Europe, the USA and the UK for many decades now. EZYBLOCK is proudly Australian manufactured and owned and is now readily available across Australia and New Zealand.
Eliminate as many “fat cat” trades on your building project and save real time and money whilst building a far more superior home in terms of energy efficiency. The days of the brick veneer, timber frame and aluminium houses are numbered.
EZYBLOCK is suitable not only in domestic construction but all forms of commercial, industrial and multi-unit construction. EZYBLOCK will not burn down as timber will. No other building product can rival EZYBLOCK for strength.
At a glance: EZYBLOCK
- Fire retardant – moulded from flame retardant materials
- Cost effective – reduced labour and utility costs
- Environmentally friendly – use of timber products greatly reduced
- Energy efficient – provides excellent insulation, reducing heating/cooling costs
- Quickly constructed – experienced crew can quickly erect walls in a day
- Versatile – any standard interior or exterior finish can be applied
- Sound resistant – interior rooms are shielded from outside/adjoining noise sources
- Can be poured 3m high in a single pour with due care
- External Wall
55mm nominal thickness polystyrene inner and outer skins connected with high impact styrene spreaders to provide permanent form-work for concrete core. Overall thickness of wall is 250mm with a concrete core of 140mm. Four complete blocks make up one square metre of wall area.
- All Walls
Polystyrene skins (blocks) lock together at edge, top and bottom to provide leak-proof joints. Spreaders are provided with notches to locate and retain reinforcing. Special brackets are available for 90, 60 and 45 degree corners. Modular block height is 250mm. Standard block length is 1000mm. Slide-in core endstops to sides of openings are available.
Instruction into curved walls provided upon request from our in-house technician. To satisfy the Building Code of Australia and AS3600 'Concrete Structure’ code, all wall cores in both vertical and horizontal directions must be reinforced. Minimum reinforcing requirements to Section 11 AS3600.
- All Walls
Concrete workmanship and materials to comply with AS3600 'Concrete Structures Code'
Concrete grade N20. Maximum aggregate size 10mm or to engineers specification.
Face of joints between new and previously poured concrete to be scabbled clean of all rubbish, latence and materials likely to be deleterious to a sound joint.
Reinforcement to be Grade 500 Mpa deformed bar.
Provide L shaped bars of 500mm leg to all horizontal bars at corners.
Bars must not be displaced to clear services, unless certified by structural engineer.
Bars should be long lengths but may lap spliced to the following: Vertical bars lap 50 bar diameters, Horizontal bars lap 65 bar diameters
- External Finishes
The external finish of EZYBLOCK is a textured or smooth coating of specialised reinforced plaster coating, manufactured and approved as a permanent coating over EPS.
- Internal Finishes
EZYBLOCK can be finished with a textured coating or lined with plasterboard or similar sheet system.
EZYBLOCK is transported in flat panels, and the spreaders in boxes. Fifty seven blocks are stacked on each pallet making transportation very economical. Assembly is made easy by clipping and stacking the formwork together to form an interlocking hollow core form-work ready to be steel reinforced concrete.
EZYBLOCK is D.I.Y. friendly but can be installed by most trades people and contractors within the building industry. As well as providing an installation manual, on site training can be made available to first time users of EZYBLOCK.
- Prop System
Our unique propping and scaffold system is available at a modest cost.
Buildings of Mass Construction
While effective ‘passive design’ cannot be underestimated, ‘getting it right’ will help maximise the benefits of thermal mass design. The ancients were spot on when it came to using strong, thermally efficient building materials. Some of their constructions were in extremely hot areas, such as the middle east, while others were in colder zones. The common factor? The thermal efficiency of their base building block. The same concept applies to EZYBLOCK.
Hot or cold the solid concrete wall goes a long way in keeping a dwelling in human comfort zone. Thermal mass put simply, is the ability of the building material to retain and maintain heat energy when the dwelling is subjected to a temperature difference. Concrete walls and floors have a very high thermal mass.
During hotter periods, a building with a high thermal mass can slow or reduce the transfer of heat through the wall by trapping and storing some of the heat flowing from the exterior. Known as “thermal lag”, the delay is typically around six hours. The maximum external temperatures are usually between noon and 2pm and with the maximum heat flow not occurring till much later, the dwelling has the ability to cool when the process is reversed as the external temperature drops.
Buildings with a high thermal mass will “iron out” and stabilise the temperature variations naturally. While the temperature tends to stay in the ideal human comfort zone, the real benefit is to the environment at large as the dwelling has a reduced need for artificial heating and cooling.
Method of Construction
- Starter bars, when pouring ground floor slabs is one method of starting construction, however it is possible to drill & grout starter bars after pouring the slab. If this later method is adopted place bars @ 375mm cts and 100mm to 150mm deep to engineer’s detail. For the average tiled roof house the use of 12mm deformed bars are required @ 375mm vertical cts and 250mm horizontal cts. Use extra bars @ window & door openings as specified by your structural engineer.
- Wall starter bars are to be placed in centre of wall or 125mm from outside edge of slab. All walls to be located on floor with U channels on inside skin of walls cts. Either drill or plug & fix with ramset or similar. Gun fix with 25mm nails @ 750mm cts.
- Safety caps to be placed on all starter bars until height of wall exceeds height of bars.
- Start to fix blocks with spreaders; eight spreaders to each block.
- Begin installing blocks. Each block is 1000mm long, 250mm wide and 250mm deep. Start laying first blocks at corners. Either mitre or bond corners as per manufacturers instructions. Both methods are simple and all cut blocks can be used in the middle of runs or under window openings.
- After first course of blocks are laid, place 12mm reo bars in centre of block. Use short cable ties every 750mm. Use more ties at corners to hold laps together.
- Use ramset or similar foam plugs at all cuts and mitres as required (foam plug applicator gun & solvent cleaner required to keep gun clean & operational).
- If timber reveals are to be used on windows and doors allow 20mm to 30mm over side of frame (not garage doors).
- Build wall to approximately 1250mm high and then install support system. Fix to slab at wall junctions and adjust leg approx. 1500mm from base of wall with re-usable masonry fixings 6mm x 50mm long ramset a.b.m. anka-screw. Drill 6mm hole in slab at least 60mm deep. Re-use screws after concrete walls are set normally the next day. The anka-screws can be used time and again.
- The vertical wall supports must be fixed @ 1500mm cts and at each wall spreader and each course in holes at relevant centres. Use #8 chipboard screws 30mm to 60mm long depending on type of wall support used.
- Plank out support system with planks that are certified for the span involved. Erect hand rails as required.
- Get the wall supports plumb as possible and check again after wall is full height and as the concrete is pumped. Use a string line from the top of the wall and adjust as required.
- Concrete mix required is 20mpa,10–12mm aggregate and 125mm-150mm slump.
- Concrete must be placed from top of wall. 50% of wall height initially then continue with remaining pumping. Never start to fill walls from corners and always use wall brace at all external “T” intersections (outside).
- Vertical Reo is usually placed down from top of wall at full height or can be placed at 1/3 height mark (easier from top of wall). It is always good practice to have one man on look out for possible problems. With a wooden float, tap the wall to indicate how concrete mix is flowing. It is very, very important that the core mix will flow and does not appear course as this will not do the job.
- Roof fixings using brooker rod ( threaded ) 500mm long x 12mm. Leave protruding 75mm above concrete on centreline of wall @ approx 750mm cts.
- Ezy Building Systems will work in with your workforce to keep them on track.
- All concrete work to be poured on the one day.
- Best to have your slab accurate to + or –2.5mm to achieve best results.
- You are now using the best and simplest method of I.C.F. construction in the world.