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SmartBlock™Design and Product Manual
October 2002 Edition
| Site Work & Foundations | Building Walls | Interior Finishes | Doors & Windows | Exterior Finishes | Plumbing & Electrical | Product Specifications | Design Details | Support Reports |
PLUMBING & ELECTRICAL
7.1 Introduction to Plumbing and Electrical
Consideration of support services such as plumbing and electrical systems from the preliminary schematics phase through final construction, including regard for ease of installation, cost and future access requirements, can avoid many construction problems. Structural systems can be modified and interior chases and soffits can be incorporated to provide space and access necessary for years of satisfactory service. SmartBlock insulating form concrete walls share the same attributes as other solid masonry wall systems and must incorporate many of the same construction practices.
The following sections contain suggested methods to facilitate the installation of plumbing and electrical systems in SmartBlock insulating form walls. All design parameters must be consistent with applicable codes and regulations for all governing authorities having jurisdiction over the project.
7.2 Plumbing
7.2.1 Direct Embedment
Design parameters for pipes in SmartBlock insulating form concrete walls are similar to the design parameters for pipes in other solid masonry walls. Most building codes prohibit direct embedment of pipes in concrete walls and foundations to avoid damage from expansion and contraction of hot water pipes and from expansion, contraction and settlement of structural systems.
7.2.2 Protection of Pipes
Code compliance through varying methods of protecting piping from the results of expansion, freezing and structural stresses is generally interpretative. Suitability of any particular method should be verified by local building officials during the design phase. Some methods now in use, although legal in some jurisdictions, are not recommended by the manufacturer. Included, by example, would be wrapping pipes in layers of building paper or any other method that would restrict future access to that pipe. Some of these methods may be suitable for commercial applications, but would be inappropriate in residential construction.
7.2.3 Installation Recommendations
The details in this manual should serve most conditions and are configured to show "extreme case" installation requirements. See Chapter 9 for Details 19.0 and 19.0A. "Extreme case" in this instance is considered to be a 4" ABS soil line, running vertical past the floor ledger, assuming 5" across the hub. Note: The use of 4" cast iron soil pipe may require the structural abandonment of an entire vertical cell and specific engineering consideration would be necessary.
To embed pipes in SmartBlock SF10 Series walls, chases should be cut through the foam blocks at the foam bridges. This method maintains the structural integrity of the vertical cell and horizontal bond beam at the floor level. (This wall section should be shored until the concrete is cured.) This location provides maximum concrete retention in the vertical cells and will not affect the location of vertical reinforcing bars. The benefit of this system is that exact pipe location is not necessary at the time of setting the vertical foundation reinforcing, as would be, if an entire vertical cell were eliminated. When using this system for large pipe, a vertical section of foam is removed to house a portion of the pipe. Since floor ledgers are inset into the foam and secured directly to the concrete, vertical pipe runs conflict in this area. Ledgers may be notched at this location, provided structural analysis has been performed as with any alteration of structural support elements. Doubling the anchor bolts at either side of the notch should be sufficient, although confirmation should be sought by the project architect or engineer.
Location of any structural reinforcing or fastening members in relation with the chase shall be verified to meet all structural requirements as to clearances, embedment, continuous application, etc.
Insulation of pipes in exterior walls may be required to protect pipes from freezing. The remaining layer of polystyrene foam at the exterior may be sufficient to prevent freezing in milder climates. Insulation of pipes may also be desired to dampen sound transmission. In most cases, foam insulation fit onto the clearance space of the chase should be sufficient to reduce noise and should not effect free movement of the pipe. These considerations should be addressed with local building officials before application.
Installation of smaller pipes, including copper supply lines, may be channeled directly into the foam. This is accomplished by using a router or heat tool to cut enough foam out providing a channel of sufficient width and depth to house the pipe. When using this system, pipes must be protected from mechanical damage. This may be accomplished by providing a section of metal strap, no less than 1/16" thick, over the channel after the pipe is secured.
7.2.4 Support of Pipes
All pipes shall be supported as required by local codes, considering pipe alignment and the weight of the piping and contents. Since pipes are to be installed after concrete is set, support must be of an approved concrete fastening system.
Drilled concrete screw type anchors are recommended, although any approved concrete fasteners may be used. Power actuated nails are not recommended with SmartBlock SF10 Series forms due to the possibility of firing pins through the foam bridges.
7.3 Electrical
Electrical wiring can easily be placed into walls built with SmartBlock insulating forms. Place deep concrete junction boxes through the wall of the form at desired locations prior to pouring concrete. This will allow for the mechanical attachment of the box to the concrete. Also prior to pouring, run conduit to the primary junction boxes from the future location of the joist bay above. The junction box will also serve as the switch location for the room's "half hot" plug or ceiling mounted fixture. Check with local building department for specific sizes and requirements.
From the junction box, one Romex wire will be used for the switch and "half hot" plug; another for the other electrical outlets required in the room. After the pour, these wires can be placed in chases cut into the wall of the forms from the main junction box. Create a chase for the Romex with a router or heat tool (a heat tool is faster, cleaner and more accurate) making larger cut outs at the desired locations for the outlets. If holding a straight line is difficult with the router or heat tool, snap a chalk line to follow a course.
To protect the Romex from nails or screws, a number of methods may be used. One method is to cover the Romex with a minimum 16 gauge continuous "C" channel pressed flush with the surface of the SmartBlock insulating form. As an alternative, if the foam is cut out to a minimum of 11/2", the Romex can be glued in place with an adhesive or spray foam applied every 24" on center. You can also replace the cut out foam piece over the Romex, pressing or rasping the foam flush with the wall, so the Romex will not back out of the slot. Either method will give a minimum 11/2" protection, after addition of the drywall, to properly protect it from any penetration.
When using SF10 Series forms, locating outlet boxes on the bridges after concrete placement will permit use of a deeper box. If boxes cannot be located on the bridges or if 12VWF Series forms are installed, a shallow outlet will be required. See Detail 20.0 from Chapter 9.
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