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TABLE OF CONTENTS

S. # CONTENTS PAGE NO.

1. Introduction 1
1.1 What is Siporex? 1
1.2 About our plant 2
1.3 Codes & Standards 3
2. Manufacturing 4
2.1 Manufacturing Process 5
2.2 Quality Control 6
2.3 Material Identification & Markings 7
2.4 Handling, Shipping & Storage 8
3. Properties & Benefits of Using Siporex 9
3.1 Benefits of Using Siporex 10
3.2 Properties of Siporex 11
4. Range of Products 17
4.1 Wall Panels 17
4.2 Lintels 20
4.3 Floor & Roof Slabs 22
4.4 Siporex Blocks 24
5. Design 27
5.1 General 27
5.2 Design Principle 30
5.3 Structural System 30
6. Erection 32
6.1 Guidelines for Estimating Erection Cost 32
6.2 Hand tools & Equipments 33
6.3 Erection Procedure 35
6.4 Repair of Siporex Panels 37
6.3 Illustrations Showing Erection Stages 38
7. Typical Connection Details 40
8. Electro-Mechanical 44
8.1 Chases & Penetrations 44
8.2 Electro-Mechanical 45
8.3 Plumbing 46
9. Finishes 47
10. Fixings to Siporex 50
11. Siporex Glue 51
12. Serpo Gesol 52
13. List of Projects 53
SIPOReX
AAC BUILDING SYSTEM

1. INTRODUCTION

1.1 WHAT IS SIPOREX?

S IP O R E X i s li g h tw e ig h t A u t o c la v e d A e r a t ed C o n cr e t e ( A A C) w h ic h i s a l s o
c a ll e d c e ll u la r c o n cr e t e .

S IP O R E X i s c o mp l e te l y c u re d m i x o f c a lc a re ou s m a t e ri a ls s u ch a s
c e me n t a n d s il ic e o u s f i n e m a t e ri a ls s u ch a s q u a r t z s a nd w it h
t h e ad d i ti o n of w a te r a n d a l u mi n u m p ow d e r a c t in g a s f o a m i n g
a g e n t to f o r m a h o m o g en o u s c e ll u la r s t ru c t u re k n o wn a s
C a lc iu m S i l i c a t e H yd r a t e .

S IP O R E X i s a h i g h q u a l it y s t r u c t u ra l m a t e ri a l , l o a d - b e a ri n g a n d e x t re m e ly
w e ll i n su l a ti n g m a t e ri a l d u e t o n u m e r ou s t in y n on - c o n n e ct in g
a i r b u b b le s w h ic h g i v e s S i p o re x i t s i n c re d i b ly d i v e rs e q u a l it ie s .
T h e h i g h p r e s su r e s t e a m- c u ri n g i n a u t o c la v e s a c h ie v e s a
p h y si ca l ly a n d c he m i ca l ly s t a b le p r od u c t w it h an a ve r a g e
d e n s it y b e i n g a p p ro x im a t e l y o n e f o u r t h o f n o r ma l c o n c r e t e .

S IP O R E X i s p r o d u ce d a s b l o ck s a n d p r e c a st r e in f o rc e d u n i ts , i .e . , w a ll
p a n e l s, l in t e ls an d f l oo r / ro of s la b s f o rm i n g a co m p l e te b u i ld i n g
system.

S IP O R E X h a s b ee n u s e d o n l a rge s ca l e p r o j e ct s s u ch a s h o u s in g s ,
s ch o o l s, h o s p it a ls , c o mm e r c ia l , i n d u st ri a l a n d g o v e rn m e n t
p r o j e ct s u n d e r a l l c li ma t ic c o n d it io n s s in c e t h e e a r l y n i n e t e en
t h ir t ie s w o rl d w id e .

S IP O R E X i s d e f i n it e ly o ne of th e m a j o r a c h ie ve m e n t s i n t h e f i e ld of
c o n st ru c t io n . It i s a r e v o lu t io n a r y m a t e r ia l t h a t o f f e r s a u n i q ue
c o mb i n a ti o n of s t re n g th , l ig h t we i g h t, t he r m a l i n su l a ti o n , s o u nd
a b s o rp t io n , u n su r p a s se d f i re r e s is t a n ce a n d u np r e c e d en t e d
buildability.

S IP O R E X i s a n a tu r a l a n d n o n -t o x ic c o n st ru c t io n m a te r i a l, s a ve s e n e r g y ,
a n d i s f r ie n d l y t o t h e e n v i ro n m e n t .

S IP O R E X a s a b u i ld i n g s ys t e m, m e e t s a ll t h e r e q u ir e m e n t s o f o u r mo d e r n
a g e t h ro ug h o u t th e w o rl d . It s p r o p e r t i e s e n s u re a b u i ld i n g
m a t e ri a l t h a t o ut p e rf o r m s a l l o t h e rs . In v ie w o f t h e r a p i d
d e v e lo p m e n t a n d i n cr e a s in g d e m a n d , we c a n c l a im w it h c e rt a in
j u st if i ca t io n t h a t S i po r e x i s t h e id e a l c h o ic e f o r b u i ld i n g
c o n s t ru c t io n .

1
SIPOReX
AAC BUILDING SYSTEM

1. INTRODUCTION

1.2 About Our Plant

Industrial production of this versatile building After more than thirty years and having used by
material was started in 1929 and it has been several thousands of projects, LCC Siporex
produced and used for building construction became the leading supplier of this truly
ever since. First in Europe and now world- amazing material not only within the kingdom
wide. but also to GCC countries, Yemen, Jordan,
Here in the Kingdom of Saudi Arabia, LCC Sudan, Ethiopia and as far away as Djibouti,
Siporex Company was established in 1977 Taiwan and Japan.
and has been producing Siporex AAC material Builders, engineers, architects and contractors
at our plant in the Second Industrial Estate, not only appreciate the excellent properties of
AlKharj Road. With our continued expansion of Siporex, but also energy-saving and pollution-
additional manufacturing plant to sustain the free techniques used in its production. In fact,
growing demand, our current total production Siporex manufacturing process produces neither
capacity has intensified to about 350,000 cubic polluting waste gases nor dangerous residues
meters of Siporex AAC products per year. and there is no waste of costly raw materials.

Siporex manufacturing plant in Riyadh, Saudi Arabia

2
SIPOReX
AAC BUILDING SYSTEM

1. INTRODUCTION

1.3 CODES & STANDARDS

Various international codes and standards had been developed to provide engineers and designers
with provisions for the analysis and design of AAC factory-produced reinforced panels and blocks
based on various research studies and experiences on its use. These include guidelines or
recommended practice addressing the materials, manufacture and structural design of AAC including
design considerations such as erection and construction details incorporating the use of AAC products
in conventional construction. Some of these Codes & Standards are listed below:

CODE OR DE SIG NA TIO N


D E S C R I P T IO N
STANDARD NO.
G u i d e f o r D e si g n a n d C o n st ru c t io n w it h A u t o c la v e d
AC I A C I 5 2 3 . 4 R- 0 9
A e r a t e d C o n cr e t e P a ne l s
S t a n da r d P r a c t ic e f o r A u t o c l a ve d A e r a t ed C o n cr e t e
AS T M C 1 5 5 5 -0 3 A
Ma s o n ry
S t a n da r d S p e c if i ca t i o n f o r P r e c a s t A u t oc la v e d
AS T M C 1 3 8 6 -9 8
A e r a t e d C o n c r e t e W a l l C o n s t ru c t io n U n it s
S t a n da r d S p e c if i ca t io n f o r R e inf o r c e d Au t o c la v e d
AS T M C 1452-00
A e r a t e d C o n cr e t e E l e me n t s
D E UT C H DIN 4165 A u t o c la v e d Ae r a t e d C on c re t e B l o ck s
NO R M
D E UT C H DIN 4223 A e r a t e d C o n c r e t e; R e inf o r ce d U n it s
NO R M
BR IT IS H B S 8 1 10 – Pa r t
A u t o c la v e d Ae r a t e d C on c re t e
S T AN D AR D 2 , S e c t io n S i x
BR IT IS H BS EN 771-
A u t o c la v e d Ae r a t e d C on c re t e Ma s o n ry U n i t s
S T AN D AR D 4 : 2 0 03
BR IT IS H BS EN D e t e rm in a t i o n o f t h e D ry D e n s it y o f A u to c la v e d
S T AN D AR D 6 7 8 : 19 9 4 A e r a t e d C o n cr e t e
BR IT IS H BS EN D e t e rm in a t i o n o f t h e c o mp r e ss iv e S t r e ng t h of
S T AN D AR D 6 7 9 : 19 9 4 A u t o c la v e d Ae r a t e d C on c re t e
BR IT IS H BS EN D e t e rm in a t i o n o f t h e D ry in g S h r in k a g e of
S T AN D AR D 6 8 0 : 19 9 4 A u t o c la v e d Ae r a t e d C on c re t e
BR IT IS H BS EN
Me t h o d o f te s t f o r Ma s o n r y U n it s
S T AN D AR D 7 7 2 - 1 0 : 19 9 9
BR IT IS H BS EN D e t e rm in a t i o n o f F le x u ra l S t r e n g t h o f A u t o cl a ve d
S T AN D AR D 1 3 5 1 :1 9 97 A e r a t e d C o n cr e t e
BR IT IS H BS EN D e t e rm in a t i o n o f Mo i st u r e C o n t e n t o f A ut o c la v e d
S T AN D AR D 1 3 5 3 :1 9 97 A e r a t e d C o n cr e t e
S AS O S A S O 15 7 9 P r e c a s t A u t o c la v e d A e r a t ed C o n cr e t e
S W E D I S H B U I L D I NG C O D E A u t o c la v e d Ae r a t e d C on c re t e P r o d u c t s
D e si g n P r o ce d u r e f o r S i p o re x R o of , F l o o r, W a l l
COUNCIL OF AMERICAN
P a n e l s , Ma s o n ry B l o ck s a n d L i n t e ls o f Au t o c la v e d
B U IL D I NG O F F I C I AL S
L i g h tw e ig h t C e ll u la r C o n c re t e (R e p o rt # N E R- 2 9 7 )
R IL E M A u t o c la v e d Ae r a t e d C on c re t e

3
SIPOReX
AAC BUILDING SYSTEM

2. MANUFACTURING

2.1 Manufacturing Process

Siporex is produced by a highly complex and advanced manufacturing process in our factory under the
careful control of chemists and engineers. Siporex is made either as steel reinforced panels using
moulds 6 meters long, 1.5 meters wide and 600 mm deep or as non-reinforced blocks using moulds 6
meters long, 1.5 (or 1.2) meters wide and 600 mm deep. A schematic diagram of manufacturing
process is shown on fig. 1.

The basic raw materials are sand, water, aluminum


powder and cement. The sand is ground to required
fineness in a ball mill before mixing with other raw
materials with water to form slurry to which a trace of
aluminum powder is added as expanding agent.
All Siporex panels are reinforced with steel. Steel coils are
straightened, cut and spot-welded into mats, where
crossbars provide anchorage to the longitudinal
reinforcements. Siporex blocks are not reinforced.

After dipping the welded mats in a homogenized anti-


corrosion mix for rust protection, they are dried and
assembled into cages and set accurately in the moulds
before the slurry is poured in.
Regulated amount of aluminum powder gives accurate
control of density of the final product. Moulds are only
partly filled with slurry which then expands in a controlled
reaction to fill the moulds.

When the mass is sufficiently hard, the moulds are


stripped and the cake is wire-cut to close tolerances into
panels and blocks using high-precision cutting technology.
These are then steam cured under high pressure in
autoclaves for up to 15 hours. This completes the
chemical process, resulting in a unique crystal structure of
calcium silicate hydrate and ensuring a stable and inert
product giving AAC outstanding qualities not found in
other products.

After cooling to ambient temperature, the panels are


demoulded and milled to required profile as necessary. All
Siporex panels are singled out for proper marking, and if
required, dry cut and stacked for further handling and
storage. The blocks are demoulded, strapped, marked
and stored on wooden pallets.
The finished goods inspection programme ensures the
products quality. The material is now ready for loading
and delivery.

4
SIPOReX
AAC BUILDING SYSTEM

2. MANUFACTURING

Fig. 1 Siporex Production Process

5
SIPOReX
AAC BUILDING SYSTEM

2. MANUFACTURING

2.2 Quality Control:

The manufacturing of Aerated Lightweight


Concrete as blocks and reinforced panels (Roof
slabs, Wall panels & Lintels) by LCC Siporex
implements and maintains a Quality
Management System which fulfills the
requirements of ISO 9001:2008. It is the policy
of LCC Siporex to provide quality products or
services that always meet or exceed the
expectation of the customer from inquiry to final
delivery of the materials / services.

ISO Certification

For final products, compressive test,


shrinkage and dry densities are carried out
on a daily basis. A load test for crack and
rupture is performed on a load testing
machine for slabs to ensure product quality of
reinforced panels.

Siporex Chemical Laboratory

Quality Control and Quality Assurance at


LCC Siporex encompass both raw materials
and finished products. Raw materials
certificates are obtained from suppliers of
cement, aluminum powder and reinforcement
steel. In-house quality assurance is made for
silica sand, cement, gypsum, Magnesite,
lime, steel protection coating, aluminum
powder and process water.
Compressive Strength Test

6
SIPOReX
AAC BUILDING SYSTEM

2. MANUFACTURING

2.3 Material Identification & Markings:

Siporex Blocks:
After autoclaving, Siporex blocks are ready for
packing and distribution. Blocks are strapped in
bundles and marked with a stamp denoting
block dimension, density type and batch
number. Bundles of blocks are arrange in
stacks laid on wooden pallets and sent to
storage or distribution.

Reinforced panels:
Reinforced panels are marked after autoclaving
and demoulding, with stamp code containing
information about the type of product, density,
permissible load, dimensions, batch number
and order number. An arrow indicating the top
side of the panels will be marked at one end of
the floor/roof slabs and lintels.

The following abbreviations are used for the


Typical Markings on Block Stack types of product:
WV – Vertical wall panels
WH – Horizontal wall panels
WP – Partition wall panels
WF – Fluted wall panels
RS – Roof slabs
FS – Floor slabs
LW – Panel-type lintels
LA – Arch-type lintels
LB – Box-type lintels
B – Blocks

Density 5 – denotes nominal dry density of


550 kg/m3 for both blocks and reinforced
panels.
Density 4 – denotes nominal dry density of
450 kg/m3 for Hordi blocks.
Typical Markings on Panels

Permissible load – Indicates service load


in kg/m2 for walls and slabs or kg/lm in
case of lintels.

7
SIPOReX
AAC BUILDING SYSTEM

2. MANUFACTURING

2.4 Handling, Shipping and Storage:

Siporex products are designed to resist normal handling and transport. Siporex blocks should be
handled by forklifts and/or cranes with appropriate straps to avoid damage to the material.

Siporex materials are shipped by trucks or flat-bed trailers and can be transported by road, train and by
sea for international projects.

They have unlimited storage stability, provided that they are not exposed to extreme conditions. They
must be supported by properly placed bearers and stored in such a way that they cannot absorb water
from the ground or be splashed with sea water. Siporex is an inorganic material and is not affected by
termites and other insects.

Siporex Blocks: Reinforced panels:


Bundles of blocks (60 cm high) are stored on On the ground, the stacks of reinforced panels
wooden pallets. Each pallet can be stored with shall be supported by wooden planks, one on
up to 3 bundles of blocks (180 cm high). At the each end, placed approximately one fourth of
storage area, the floor should be level to avoid the length from the ends.
tilting of stocks. Stocks of blocks can easily In transporting, the stacks are tied by strapping
withstand 3 pallets with 3 bundles each of at both ends, protected with plastic angles.
Siporex blocks.

8
SIPOReX
AAC BUILDING SYSTEM

3. PROPERTIES & BENEFITS OF USING SIPOREX

3.1 Benefits of Using Siporex:

The manufacturing process as well as the basic ingredients used provides Siporex its unique
properties and benefits not found in other traditional building materials and will radically change
the construction practices in this industry.

3.1.1 Lightweight
Siporex weighs less than a quarter compared to conventional
concrete. Due to the lightweight property of Siporex, the
foundation loads are greatly reduced resulting to big savings
in the overall construction cost especially at areas having
poor soil bearing capacity. Its light weight also means
significant advantage in transportation cost.

3.1.2 Energy Efficient


Siporex ensures pleasantly healthy and comfortable room
temperature without the need for additional insulation. Its
thermal insulation and heat retention offer a good protection
against rapid cooling or heating up too much. This means
lower power consumption in environmental management
system.

3.1.3 Dimensional Accuracy


The production process guarantees the accurate dimensions
of the panels and blocks that comprise the building system.
This allows for a straight and plumbed walls resulting in less
on-site trimmings and reduces the quantity of mortar and
finishing materials required. The dimensional tolerance is
±3mm for thickness & width and ±5mm for length.

3.1.4 Workability
Siporex products can be sawn, cut, slot, drilled, chased and
nailed with ordinary woodworking tools which makes them
easier to install than other building materials. This also
simplifies the installation of electro-mechanical services and
other utilities, which means more cost savings.

3.1.5 Resistance to Fire


Siporex is totally inorganic and does not contain any
combustible materials, which means it is resistant to fire. A 15
cm thick panel will resist fire for seven life-saving hours.
Siporex is ideal for firewall application and as protection for
structural steel construction.

9
SIPOReX
AAC BUILDING SYSTEM

3. PROPERTIES & BENEFITS OF USING SIPOREX

3.1 Benefits of Using Siporex :

3.1.6 Acoustic Insulation


Siporex meets the appropriate standards for sound insulation
in house building, which means quieter and more comfortable
interior. In industrial construction, Siporex minimizes industrial
noise pollution. The sound absorption of untreated Siporex
surface is better than that of dense concrete.

3.1.7 Non-toxic
Siporex itself is ecologically harmless, since it neither
contains gases nor fibers, it is neither dangerous to ground-
water nor does it releases any radioactive radiation. No
pollutants or toxic by-products are produced in the
manufacturing process or even when subjected to fire.

3.1.8 Durability
Siporex products do not contain any organic matter subject to
deterioration and will not degrade even under severe weather
conditions. Structures built several decades ago are still in
active use today.

3.1.9 Quake Resistant


The low mass of Siporex results to reduced total dead load of
the building and consequently reducing the applied seismic
forces to its structure. Structures built in earthquake zones
such as Japan & Mexico have shown good resistance to
seismic forces in actual practice.

3.1.10 Speedy Construction


Siporex has all the advantages of a precast system, i.e.
eliminates shuttering, wet construction, curing, on-site testing
& quality control resulting to reduced overall construction time
and cost. It also requires minimal supervision and
construction staff.

3.1.11 Pest Resistant


Siporex provides airtight interior, does not contain any
organic ingredient and makes your home uninviting to pest,
insects or rodents.

10
SIPOReX
AAC BUILDING SYSTEM

3. PROPERTIES & BENEFITS OF USING SIPOREX

3.2 Properties of Siporex :

3.2.1 Weight
Siporex products are supplied with nominal dry density of Siporex products is 550 kg per cubic meter
and weigh less than a quarter compared to conventional concrete. Other densities such as 450 or 600
kg per cubic meter can also be produced upon request. Due to its light weight, the number of trailers
required to transport Siporex materials is much less than those required to transport conventional
precast panels and handling at site can be carried out with ease.

3.2.2 Compressive Strength


Siporex is solid and has a high compressive strength in relation to its weight, which in the aspect of
application is very sufficient to take building loads. Siporex achieves its final strength during the
autoclaving process. Following are the minimum characteristic strength of Siporex material
corresponding to cube specimen and having nominal dry density of 550 kg/m3:
Compressive strength = 35 kg/cm2
Tensile strength = 20 to 40% of compressive strength
Shear strength = 20 to 30% of compressive strength
Modulus of elasticity = 16,000 kg/cm2

3.2.3 Thermal Conductivity


The thermal conductivity (“k” value) for completely dry Siporex is 0.144 W/mºC. The air bubbles trapped
in Siporex are giving10 times better insulation properties compared with conventional dense concrete.
This is reflected in considerable savings of electricity consumption and improved indoor comfort. A
special independent study conducted by the Research Institute of the King Fahd University of
Petroleum and Minerals confirmed that 63% energy cost saving is achieved when using Siporex
material based on a model 2-storey house with 525 m2 gross floor areas.
Other savings are also achieved by replacing a 30-35 cm thick sandwich wall by a single 20 cm thick
Siporex wall. This will reduce the size of R.C. beams, columns and foundations and will give more living
space. Siporex construction system is not only ideal for exterior and interior walls, but also for floor and
roofs. All these result in a low average thermal conductivity value for whole building surface.
Siporex is the only structural material classified by the Saudi Electricity Company as an insulation
material. Siporex qualities not only exceed their rival construction material but far more superior. Fig. 3
shows the superiority of Siporex over other conventional material.

1.6
1.4 1.355
1.2 1.097 1.129
1
0.8
THERMAL CONDUCTIVITY
("K" VALUE") 0.6 0.55
0.4
0.2 0.144
0
SIPOREX CLAY CONCRETE SANDLIME PREFAB
BRICKS BLOCKS BRICKS CONC.

11
SIPOReX
AAC BUILDING SYSTEM

3. PROPERTIES & BENEFITS OF USING SIPOREX

3.2 Properties of Siporex :

3.2.4 Fire Resistance


Siporex has remarkable fire resistance
properties and is non-combustible. Heat
migration takes place at a slow rate due to its
low thermal conductivity, giving Siporex
excellent fire resistance. Water in crystalline
form within the material acts as a heat sink
and the porous structure allows steam to
escape without causing surface spalling. The
temperature of Siporex is lower in Siporex
compared to dense concrete, not only on the
non-exposed side but also on the side
exposed to heat. This fact is vital as it affects
the protection of the reinforcing steel in
structural units.
Due to its excellent fire resistance and very positive practical experience obtained, Siporex panels and
blocks had been widely gaining popularity in worldwide construction. In many cases of building fires, the
structural parts of Siporex were able to continue to serve with minor repairs, which considerably
reduced the cost of damage caused by the fire.
The following table shows the unsurpassed average fire-ratings of various thicknesses of Siporex walls:

Thickness (cm) 10 15 20 25
Fire ratings (hrs) 4 7 7+ 8

3.2.5 Thermal Expansion


The thermal expansion of Siporex is of the order of 8x10-6/°C. Expansion coefficient of regular concrete
varies between about 4 to 14x10-6/°C depending on the type of aggregate and curing procedure.

3.2.6 Moisture Content


Siporex products have a moisture content of 25 to 40% of its weight when the material is delivered. As
with all concrete products, Siporex will dry out until it reaches equilibrium with the moisture content of
the surrounding air. In this state, it reaches a moisture content of 2% to 6% within one year from
erection.
As with all other concrete finishes, slabs and walls should receive protection against water penetration,
For external walls, this can be a single decorative coating.

3.2.7 Shrinkage
Loss of moisture in AAC results in drying shrinkage. It is determined according to European Standard
as the relative length change for specimens at specified moisture contents of 30% and 6% by mass
respectively. The average shrinkage for AAC is 200x10-6 as compared to 500x10-6 for ordinary
concrete. The lower shrinkage for AAC is attributed mainly to the high pressure steam curing
(autoclaving) that the fresh material is subjected to during production.

12
SIPOReX
AAC BUILDING SYSTEM

3. PROPERTIES & BENEFITS OF USING SIPOREX

3.2 Properties of Siporex :

3.2.8 Acoustic Properties


The Sound Transmission Class (STC) rating is a single number guide used to rate acoustic barriers
according to their effectiveness in reducing sound transmission. Sound reduction is the ratio of sound
energy at its source to that at any other location expressed as decibels (dB). It is important to note that
the scale of decibel is logarithmic, i.e. an increase of 10 dB means a reduction of sound to one-tenth,
20 db a reduction to one-hundredth etc. Figure 4 shows some STC ratings of a few wall constructions
consisting of Siporex material.

The unique structure of Siporex also provides superior sound absorption better than normal concrete
and is more apparent at higher frequencies. This property reduces the echo effect (i.e. reflecting sound)
in empty rooms.

2x200mm thick Siporex wall panels with 50 mm gap and 2mm


Serpospack on exposed faces 57

200mm thk Siporex wall panel with 3mm Serpocoat externally,


40mm thk fiberglass and 12.5mm gypsum board on 50mm steel stud 55

200mm thk Siporex wall panel with 3mm Serpocoat externally


and12.5mm gypsum board on 50mm steel stud 53

250mm thk Siporex wall panel without finishes 49

200mm thk Siporex wall panel with 3mm Serpo externally and 2mm
Serpospack internally 48

150mm thk Siporex wall panel without finishes 43

100mm thk Siporex wall panel without finishes 39

Sound Transmission Class 35 40 45 50 55 60

Figure 4. Sound Transmission Class of some few Siporex wall constructions.

3.2.9 Specific Heat


At normal equilibrium moisture content, the specific heat is 1.0 – 1.1 kJ/kg°C or about 0.24 – 0.26
kcal/kg°C.

3.2.10 Melting Point


Siporex starts to sinter at about 1,000°C and melts at about 1,100 to 1,200°C. Certain physical
transformation occurs at these conditions, therefore, Siporex is not suitable for construction which are
going to be exposed to high temperature, e.g. kilns, stoves, chimneys, etc.

13
SIPOReX
AAC BUILDING SYSTEM

3. PROPERTIES & BENEFITS OF USING SIPOREX

3.2 Properties of Siporex :

3.2.11 Environmental Exposure of Siporex


Like any other cementitious materials, Siporex is deteriorated by strong acids. Acid salt solutions such
as chlorides or sulphates may also degrade Siporex in long term. However, Siporex is normally
unaffected by alkaline solutions.
The vital components of Siporex are water insoluble. However, like most concrete building materials,
Siporex contains small amount of water soluble salt which have no influence on the strength and
resistance. Under severe conditions, they can appear on the surface as efflorescence. The formation of
efflorescence is mainly a matter of repeated wetting in combination of very bad drying conditions. Under
normal drying conditions, it hardly ever occurs.

3.2.12 Airtightness
Even with normal construction procedures, Siporex buildings have excellent airtightness qualities. Test
on AAC buildings measured 1 to 2.5 air changes per hour at a reference pressure of 50 Pa. This
compares favorably well with other types of construction, such as concrete block, where normally the
average air change rate at 50 Pa is about 7. (Ref. NPCA , June 26, 2000)

3.2.13 Colour, Texture


Siporex is grayish white with even
surface.
The pores present in Siporex
material can be divided according
to size into micropores (< 0.1
mm) and macropores (0.1 to 1.0
mm). Of the total porosity or
pores volume, approximately
35% is micropores and the
remainder 65% is macropores.
At the wire cut surface, the pores
are not visible. Milling of the
jointing surface after the steam
curing makes the pores visible.

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SIPOReX
AAC BUILDING SYSTEM

3. PROPERTIES & BENEFITS OF USING SIPOREX

3.2 Properties of Siporex :

3.2.14 Reinforcing Steel Properties


Steel reinforcement to be used in Siporex reinforced products shall satisfy the physical requirements of
ASTM A615, A82 or A185. Siporex panels are supplied with corrosion protected steel mats. These
mats are dipped in homogenized anti-corrosion mix and allowed to dry under high temperature. The
dipping/drying process is duplicated to ensure a double protection against harsh weather condition.
The minimum aerated concrete cover to the longitudinal reinforcement, “d”, is 12.5 mm for roof slabs /
floor slabs and 25 mm for wall panels. Increased cover for greater fire resistance or allowances for
chases can be arranged upon request.

Cross Section of panel / slab showing Bar position for possible reinforcing
standard rebar position and spacing configuration

No. of Bars
2 AG
3 ADG
4 ACEG
5 ABDFG
6 ABCEFG
7 ABCDEFG

The number and diameter of bars varies, depending on the panel / slab design. Details of reinforcement
can be obtained from our technical department on request.

Positioning of anchorage reinforcements (Cross bars) at panel end

Positions Slab Length


1+2 < 3000 mm
1+2+3 ≥ 3000 mm but < 5000 mm
1+2+3+4 500 mm and over

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SIPOReX
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3. PROPERTIES & BENEFITS OF USING SIPOREX

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SIPOReX
AAC BUILDING SYSTEM

4. RANGE OF PRODUCTS

4.1 Wall Panels :

4.1.1 Vertical Wall Panels (WV)


WV are reinforced units, for load bearing
applications as either external or internal walls
in a wide variety of low and medium rise
buildings. They can also be used as non-load
bearing cladding for steel or concrete framed
structures. They may have single mat or double
mat reinforcements depending on the structural
requirements.

4.1.2 Horizontal Wall Panels (WH)


Similar to WV, they are also reinforced units
with either single or double mat reinforcements,
but are used in horizontal positions. Applications
include: low parapet, boundary walls, wall
claddings to steel or concrete framed structures
and for filling of space between lintels and
ceiling. Tongue and groove joints are usually
provided for multi-layered WH construction for
ease of on-site assembly.

4.1.3 Fluted Wall Panels (WF)


Wall panels are also available with fluted
surface as an added feature. They make very
attractive features in building facades used
either in small areas such as under window
openings or as an all-over treatment. Fluted wall
panels are also favorite features for boundary
walls. Flutes are available in depths of 25 mm or
less.

4.1.4 Partition Wall Panels (WP)


These are normally used as non-load bearing
internal partitions with thickness ranging from 10
to 15 cm thick depending on the height of wall.
The flexibility in the design of partition wall
panels means it can be provided with central
groove to accept grouting or with standard
tongue and groove, increasing their ease of on-
site assembly. They are simply fixed using steel
angles or by grouting where possible inside
framed structures or concrete-shell buildings.

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AAC BUILDING SYSTEM

4. RANGE OF PRODUCTS

4.1.5 Permissible Compressive Stress on Vertical Wall Panels (WV)

Permissible Compressive Stress (kg/cm2) at the following Wall


Wall Height
Thicknesses (mm)
(m)
100 150 200 250
2.50 5.3 6.5 6.8 6.9
2.75 4.7 6.3 6.7 6.9
3.00 4.0 6.1 6.6 6.8
3.75 1.2 5.3 6.3 6.6
4.00 - 4.9 6.1 6.6
4.50 - 4.0 5.8 6.4
5.00 - 2.9 5.3 6.1
5.50 - 1.6 4.7 5.8
6.00 - - 4.0 5.5

Above values were calculated based on the allowable compressive stress in low density concrete load-
bearing walls as stipulated in ACI 523.2R-96 (Guide for Precast Cellular Concrete Floor, Roof and Wall
Units), Chapter 4.3.2.
Non load-bearing partitions or curtain walls should be limited to a height/thickness (h/t) ratio of not
greater than 48.

4.1.6 Maximum Length of WV & WH with Various Design Lateral Loads using Siporex Standard
Reinforcements

Thickness Maximum Length of Wall Panels at the following


(mm) Design Wind Load (kg/m2)
80 120 160 200
75 250 cm - - -
100 400 cm 375 cm 325 cm 275 cm
125 500 cm 475 cm 450 cm 400 cm
150 600 cm 575 cm 550 cm 500 cm
175 600 cm 600 cm 600 cm 575 cm
200 600 cm 600 cm 600 cm 600 cm
225 600 cm 600 cm 600 cm 600 cm
250 600 cm 600 cm 600 cm 600 cm

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AAC BUILDING SYSTEM

4. RANGE OF PRODUCTS

4.1.6 Millings for Wall Panels

Wall panels are milled along their edges to suit various construction conditions and appearance using
standard profiles. They may be chamfered or fluted on one or both faces. Following are various shapes
of wall panel millings:

Central Groove – Applicable for WV, groove


to be filled with cement-sand grout (1:3),
providing rigid connection between panels as
well as connection to the foundation through
steel anchorage and next upper floor through
steel dowel bars and ring beams.

Tongue & Groove – Applicable for WV,


usually for non-load bearing external cladding
or internal partitions where central groove for
grouting is not applicable. Also commonly used
for boundary walls using WH fixed at the ends
to the supporting columns.

Fluted Surface – Can be applied for both WV


& WH in combination with Central Groove or
Tongue & Groove for architectural purposes.
Depth of flute can be 25 mm or less. Standard
distance between flutes is 100 mm center to
center.

Plain Corners – Used in combination with


Central Groove or Tongue & Groove where
plain wall surface is required. Fiberglass tape
fixed with our special adhesive, Gesol, along
the joints will be necessary prior to application
of wall finishes.

Chamfered Corners (one or both faces)–


Also used in combination with Central Groove
or Tongue & Groove where joints between
panels are required to be visible, forming V-
grooved joints. This is appropriate for Siporex
wall panels used as claddings to a framed
structure.
Fiberglass tape will not be necessary where
chamfered corners or V-grooved joints are
provided.

NOTE: ALL DIMENSIONS INDICATED ABOVE ARE IN mm.

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SIPOReX
AAC BUILDING SYSTEM

4. RANGE OF PRODUCTS

4.2 Lintels :

4.2.1 Panel Type Lintels (LW)


Lintels are used as load-bearing members over
window and door openings for external or
internal walls, eliminating the need for
shuttering and in-situ concrete. They are
bedded with special Siporex glue onto wall
panels adjacent to the opening of reduced
height. The maximum obtainable lengths (free
spans) in meters for lintels of various design
loads and thicknesses are shown in table of
Section 4.2.4. LW’s usually have standard
height of 60 cm.

4.2.2 Arch Type Lintels (LA)


Arch type lintels are also load-bearing members
but with added architectural features that can be
designed with various shape and sizes of
arches applicable for openings at external
facades or internal walls. Reinforcement mats
are specially arranged to facilitate fabrication
and avoid exposure after cutting the required
shape. Arches can be designed with single
panel where height of arch does not exceed 30
cm or multi layers of panels for high arches.

4.2.3 Box Type Lintels (LB)


Box type lintels are designed with special steel
reinforcement arrangement to be used where
lintel depth is limited. They are suitable for block
wall construction, produced with depth equal to
the height of Siporex blocks for ease of
construction. This eliminates shuttering and
cast-in-situ works as well as avoids thermal
bridges caused by the use of traditional
concrete lintels. The maximum obtainable
lengths (free spans) in meters for Box type
lintels of various design loads and thicknesses
are shown in table of Section 4.2.5.

The minimum permissible end bearings for all types of lintels are as follows:
for L ≤ 2400 mm 200 mm each end
for L > 2400 mm 300 mm each end
Due to the special reinforcement arrangement, lintels must never be cut.

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SIPOReX
AAC BUILDING SYSTEM

4. RANGE OF PRODUCTS

4.2.4 Maximum Clear Span of Panel Type Lintels with Various Design Loads
(Height = 60 cm)

Thickness of Panel Type Lintel (mm)


Design Load 100 150 200 250
500 kg/m 250 cm 450 cm 540 cm 540 cm
1000 kg/m 200 cm 325 cm 400 cm 450 cm
1500 kg/m 100 cm 275 cm 325 cm 375 cm

4.2.5 Maximum Clear Span of Box Type Lintels with Various Design Loads
(Height = 25 cm)

Thickness of Box Type Lintel (mm)


Design Load 100 150 200 250
500 kg/m 200 cm 350 cm 360 cm 360 cm
1000 kg/m 150 cm 250 cm 260 cm 265 cm
1500 kg/m 75 cm 200 cm 210 cm 210 cm

Other heights and spans of lintels can be designed by our technical department depending on their
particular condition and considering the clear span of openings as well as design loads. Since Siporex
lintels are constructed with the same materials as the wall panels or Siporex masonry blocks, the
surfaces are easily finished and the possibility of cracks due to different thermal expansion is
eliminated.

Various actual applications of Siporex lintels


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SIPOReX
AAC BUILDING SYSTEM

4. RANGE OF PRODUCTS

4.3 Floor & Roof Slabs (FS & RS)

4.3.1 Product and Application


Siporex floor/roof slabs are reinforced aerated The excellent thermal insulation of Siporex slabs
concrete products which are produced in ensures pleasantly healthy and balanced
accordance with international standards. internal temperature.
Siporex slabs attain their design strengths The units are milled along their edges to provide
during the high-pressure steam curing process tongue & groove and grouting notch on top. The
in the autoclaves. Thus, after delivery, slabs can bottom longitudinal edges are preferred to have
be erected immediately within a very short corner chamfers giving an attractive V-shaped
period and ready for occupancy use. joints pattern on the ceiling.
Installation can be done with minimal number of Siporex slabs are also produced in various
erection crew, light equipments and will not thickness and spans depending on the required
require highly skilled workers. Shuttering works load-bearing capacities. The table shown on
are eliminated, and finishing works can Section 4.3.3 gives a guide to the permissible
commence directly, saving time and overall spans of slabs with different design loads of
costs. various slab thicknesses.
Siporex slabs can be used both in flat roof areas FS & RS can be used in all types of buildings,
or sloped roof. They can also be installed with e.g. housings, industrial, commercial &
cantilevered ends, produced with special educational buildings.
reinforcements.

4.3.2 Millings for Floor & Roof Slabs

Typical Section of Siporex Slab Construction

Milling of floor/roof slabs

Note: Dimensions shown are in millimeters.

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SIPOReX
AAC BUILDING SYSTEM

4. RANGE OF PRODUCTS

4.3.3 Permissible Spans of Various Slab Thickness and Design Loads

Design imposed Permissible Spans with the following Thicknesses (mm)


DL + LL
100 150 200 250
(kg/m2)
110 kg/m2 4250 6000 6000 6000
160 kg/m2 4000 5750 6000 6000
210 kg/m2 3500 5500 6000 6000
250 kg/m2 3500 5250 6000 6000
300 kg/m2 3250 5000 6000 6000
350 kg/m2 3000 4750 6000 6000
400 kg/m2 2750 4500 5750 6000
500 kg/m2 2500 4000 5250 5750

Above design loads are in addition to the self-weight of the Siporex slabs. Siporex slabs are reinforced
with double steel welded mats and anti-corrosion coated in Siporex factory. Quantity and sizes are in
accordance with Siporex steel reinforcement tables.
The minimum required end-bearing supports are 75 mm for masonry & concrete supports and 50 mm
for steel beam supports.

Various applications and construction of Siporex floor/roof slabs

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SIPOReX
AAC BUILDING SYSTEM

4. RANGE OF PRODUCTS

4.4 Siporex Blocks (B)


4.4.1 Product Application & Characteristic Data
Siporex solid blocks are used as load-bearing and non load-
bearing walls and as thermally insulating roof tiles in addition to
being used as Hordi blocks or infills for ribbed slabs. They are
produced with very precise dimensions with slim tolerance of
±3mm for thickness and width, therefore they are able to be laid
by thin-bed mortar (Siporex glue) with a maximum of 3mm thick
mortar joint. This results to a high quality wall structure with
uniform thermal insulation and fast installation.

4.4.2 Masonry Blocks Dimensions


For the past decades, LCC Siporex had been supplying AAC blocks with a standard face size of 25 cm
high x 60 cm long only in various thicknesses. However, due to the increasing demand and growing
popularity of the use of AAC blocks, LCC Siporex have started the production of new dimensions of
blocks in line with the continued expansion of additional manufacturing plant to sustain the market
requirements. Siporex blocks are now produced at the following standard sizes:
Standard face size: 25 cm high x 60 cm long: Thickness: 10, 15, 20, 25 and 30 cm
Standard face size: 20 cm high x 60 cm long: Thickness: 10, 15, 20, 30 and 40 cm
Above standard sizes with nominal dry density of 550 kg/m3 are usually available in our stocks. It is
possible to produce other dimensions on request, but should be referred to our Sales or Technical
departments for verification.

4.4.4 Hordi Blocks


Hordi blocks or infill blocks for ribbed slabs can
be produced in various dimensions to form
lightweight infill between in-situ reinforced
concrete ribs designed to span in one or both
directions. Due to their excellent bondage to in-
situ concrete, Siporex Hordi blocks are easily
arranged to form permanent part of the slab,
providing excellent thermal insulation as well as
fire resistance material. Hordi blocks are
produced with density of 450 kg/m3 according to
the following dimensions:

Length : 60 cm
Width : 37/38 cm or 40 cm
Thickness : 20, 25, 30, 35 cm

Other sizes may be produced upon request only.


Hordi blocks are not available in stock and are
manufactured against order only. Hordi blocks application

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SIPOReX
AAC BUILDING SYSTEM

4. RANGE OF PRODUCTS

4.4.3 Thermal Insulating Tiles


Roof insulation of existing conventional roof can still be improved with the use of Siporex thermal
insulating tiles available at the following dimensions:
4.4.3.1) 60 x 60 x 7.5 cm
4.4.3.2) 60 x 25 x 7.5 cm
4.4.3.3) 60 x 25 x 5 cm
Other dimensions can be produced upon request.

4.4.5 Packing Data for Siporex Blocks


Siporex blocks are delivered ready for use and packed in easily
transportable wooden pallets. The pallets should be unloaded at the site
by construction-site cranes, forklifts or other suitable hoisting
equipments. For ease in unloading of materials, it is suggested to order
Siporex blocks in whole bundle or pallet volume to avoid handling loose
quantities. Following table is an easy reference in making order of some
standard sizes of Siporex blocks in bundles or pallets.

No. of No. of
No. of No. of
Blocks Bundle m3 per m3 per
Block Dimensions Blocks Blocks
per per Bundle Pallet
per m3 per m2
Bundle Pallet
10 x 25 x 60 cm 66.66 6.67 75 2 1.125 2.25
15 x 25 x 60 cm 44.44 6.67 50 3 1.125 3.375
20 x 25 x 60 cm 33.33 6.67 35 3 1.05 3.15
25 x 25 x 60 cm 26.66 6.67 30 3 1.125 3.375
30 x 25 x 60 cm 22.22 6.67 25 3 1.125 3.375

10 x 20 x 60 cm 83.33 8.33 72 3 0.864 2.592


15 x 20 x 60 cm 55.55 8.33 48 3 0.864 2.592
20 x 20 x 60 cm 41.67 8.33 36 3 0.864 2.592
30 x 20 x 60 cm 27.78 8.33 24 3 0.864 2.592
40 x 20 x 60 cm 20.83 8.33 18 3 0.864 2.592

SIPOREX ROOF TILES:


5 x 25 x 60 cm 133.33 6.67 150 2 1.125 2.25
7.5 x 25 x 60 cm 88.89 6.67 100 2 1.125 2.25
7.5 x 60 x 60 cm 37.04 2.78 40 3 1.08 3.24

SIPOREX HORDI BLOCKS:


20 x 37/38 x 60 cm 22.22 4.44 21 3 0.945 2.835
20 x 40 x 60 cm 20.83 4.17 18 3 0.864 2.592
25 x 37/38 x 60 cm 17.78 4.44 18 3 1.013 3.038
30 x 37/38 x 60 cm 14.81 4.44 15 3 1.013 3.038
30 x 40 x 60 cm 13.89 4.17 12 3 0.864 2.592
35 x 37/38 x 60 cm 12.70 4.44 12 3 0.945 2.835

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SIPOReX
AAC BUILDING SYSTEM

4. RANGE OF PRODUCTS

4.4.6 Block Laying

The first course should be laid on cement-mortar bed of thickness about 1 to 3 cm depending on the
evenness of the base and should maintain a correct level for fast installation progress in the following
courses. It is recommended to spray the mortar face of the block before installation to keep damp at
erection time especially during the hot seasons. After installation, spray with water twice a day for 3
consecutive days for curing of the mortar.
Three types of Mortars can be applied on the succeeding courses:
4.4.6.1) Siporex Glue (for thin joints):
Pre-mixed mortar – only water is to be added. Thickness of glue should not exceed 3 mm in
horizontal and vertical joints in order to achieve the ideal consumption rate as follows:
· 7 kg/m2 for Siporex blocks 25 cm thick
· 6 kg/m2 for Siporex blocks 20 cm thick
· 5 kg/m2 for Siporex blocks 15 cm thick
4.4.6.2) Ordinary Mortar with Gesol
1:6 Cement : Sand (by volume) respectively in addition to water (with 10% of Gesol). The
erection can be carried out normally as for conventional blocks. (Gesol is a liquid material used
as bonding agent and retardant for the mortar especially during hot weather. Gesol is available
at Siporex factory in 3 kg and 25 kg plastic containers).

4.4.6.3) Ordinary Mortar with Lime:


1:1:10 Cement : Lime : Sand (by volume)

4.4.7 Plastering of Siporex Block Wall

Before plastering, dirt and loose particles should be removed from walls. Spray walls with water and
follow one of the two methods mentioned below:
4.4.7.1) Traditional Plastering:
Similar to plastering of conventional block walls with the following mix:
· Splattering (3mm): Use 1 cement : 3 sand mixed with solution of water and Gesol (20% of
the volume). Spray with water twice a day.
· Ordinary Plastering Mortar: (1 – 1.5 cm thick, apply 24 hours after the splattering)
Use 1 cement : 6 sand mixed with solution of water and Gesol (10% of volume).

4.4.7.2) Plastering with Pre-mixed Mortar (Serpo Prime)


Water is added to the pre-mixed plaster supplied in bags of 25 and 50 kgs. Surfaces should be
thoroughly cleaned and wetted without any splattering. Apply plaster directly with a thickness
ranging between 0.5 to 1 cm
In both above methods, walls should be watered twice a day after plastering for three consecutive days.

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SIPOReX
AAC BUILDING SYSTEM

4. RANGE OF PRODUCTS

4.4.8 Cladding with Marble or Artificial Stone

Marble or artificial stones are fixed using hooks and screws. It is necessary to use screws with plastic
plugs like Fisher and Hilti anchors in addition to several other types specially made for use in cellular
concrete. Refer to figure 7.9 on page 43 showing the typical section of wall with stone cladding.

4.4.9 Bolts and Fixings

Various type of bolts and fixings applicable for both Siporex blocks walls and reinforced panels are
discussed in section 10. These types of fixings are used in installation of doors and windows, as well as
wall accessories with weights not exceeding the allowable loads of the type of fixing used. Through-bolts
should be used in case of heavy fixtures such as water tanks and hanging lavatories (please refer to fig.
7.7 & 7.8 on page 43).

27
SIPOReX
AAC BUILDING SYSTEM

5. DESIGN

5.1 General

With its innovative physical


properties, Siporex system
offers design and
engineering flexibility for a
variety of construction
applications ranging from
single and multi-family
residential to commercial
buildings, as well as
warehousing, schools and
government facilities.

Siporex system consists of various product types: wall panels, floor/roof slabs and lintels
which can be combined to form a load-bearing structure. By using this system, costly labour
and material intensive in-situ concrete structures of columns, beams, floor and roof slabs can
be eliminated. This fact makes it particularly suited for the construction of buildings up to six
storeys.

The width of the units in the Siporex system is in accordance with the international modular
standard of 60 cm. Thickness and length of the units can be selected to suit requirements of
each particular project. Therefore the Siporex system offers high degree of flexibility which
can easily be adapted to various design requirements. Figure 5.1 shows how the component
parts of the Siporex system fits together to form complete structure.

LCC Siporex offers services


including technical viability
studies of client’s projects to
Siporex system, quotations,
as well as recommendations
on how Siporex can be
adapted to the original design
of your structure that will fit
your project-specific needs.
Figure 5.2 shows a sample
Siporex shop drawing based
on customer’s architectural
drawing.

28
SIPOReX
AAC BUILDING SYSTEM

5. DESIGN

FIG. 5.1 Component parts of Siporex System


29
SIPOReX
AAC BUILDING SYSTEM

5. DESIGN

FIG. 5.2 Sample Siporex shop drawings developed from client’s architectural plans
30
SIPOReX
AAC BUILDING SYSTEM

5. DESIGN

5.2 Design Principle


Much of the company’s work entails the conversion of client’s original designs from other materials to
Siporex system, generally resulting in cost and energy savings. But the best and most economical use
of Siporex is produced by designing in the material from onset.

Optimum results and savings can be obtained through careful design work and meticulous planning
before and during execution. Before commencing the architectural design for a project, the following
guidelines should be noted:

1. The maximum span of Siporex panels is 6.00 meters. This means that the maximum clear
span between the load bearing walls should not exceed 5.85 meters considering 7.5 cm end
bearing of floor/roof slabs. The distance between the non-load bearing walls is immaterial. If
the clear span is more than 5.85 meters, then steel or concrete beams supported on steel or
concrete columns should be used to support the roof slabs.
2. Upper walls are recommended to be aligned with walls of the lower floor. Walls at upper floor
supported directly on Siporex slabs are not allowed. When unsupported walls cannot be
avoided, intermediate steel beam can be used or convert the wall to non-load bearing
lightweight dry wall partition, in order to achieve maximum economy.
3. The foundation should be made high enough such that the external wall panels will not absorb
moisture from the ground.
4. Width of door/window openings are recommended to be limited to the allowable spans shown
in Sections 4.2.4 & 4.2.5 in order to utilize Siporex lintels and avoid the use of in-situ concrete
lintels.

5.3 Structural System


Siporex buildings are designed based on box system principle. Siporex load-bearing walls act as
shear walls resisting lateral forces due to wind or seismic loads. The wall panels have grooves along
their edges which form joints when erected. These joints receive steel tie bars from the footing and at
the top connecting the lower wall with the one above. As they penetrate the ring beam, a strong
connection will be provided between the vertical and horizontal structures. These joints (3.3 x 5 cm)
are grouted and they are able to transfer shear forces from one panel to the other.
The roof and floor slabs have tongue and groove as well as notch at the top to be reinforced with 8mm
diameter bar between spans and grouted with cement-sand mortar (1:3) consequently eliminating
differential deflection. Due to the ring and bond beams around the building, all slabs form membrane
acting as laterally stiff diaphragms which can transfer lateral forces to the bearing walls .
These constitute the diaphragm action of the Siporex structural system. Lateral forces are distributed
in proportion to the moment of inertia of the walls, that is, proportional to their stiffness. Based on
actual experiences of actual occurrences in different countries, It has been noted that Siporex
buildings are very resistant to earthquake forces.

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SIPOReX
AAC BUILDING SYSTEM

6. ERECTION

6.1 Guidelines for Estimating Erection Cost of Siporex Elements


6.1.1 Erection Manpower
4 man-hours per cubic meter of Siporex panels for residential construction is a good average figure.
The figures cover erection of the superstructure on the prepared foundation base (level tolerance ±1
cm) and include grouting of wall and roof joints as well as repair works to make the surface ready for
application of finishes. The figures also include casting the normal ring beam behind the rebated wall
panel upstand.

A typical erection crew with crane & operator consists


of the following:
1 – crane helper
2 – erectors
1 – panel preparation man
2 – assistant erectors for general site works,
grouting, repair works, dowel drilling, etc.
Note that one crane can serve 2 crews at a time.

6.1.2 Type of Crane & Crane Hours


Mobile telescopic crane 10 to 40 ton range depending on the reach is normally needed. A single crane
with operator can serve two erection crews at the same time. Crane usage will be about 0.33 hours per
cubic meter of Siporex elements considering two crews or 0.66 hours per cubic meter for one crew.

6.1.3 Cost of Auxiliary Materials and Consumables:


SR 30 to 40 per cubic meter of Siporex elements. The figure includes cost of Siporex glue, sand-
cement grout, concrete and reinforcements for ring beams, plastic wedges, nails and dowel bars. Cost
of large beams/columns requiring form works shall be calculated separately. Major steel fixings and
steel beams are not included.
Note: Above data should be considered as general guidelines only. They are not substitute for careful
evaluation of actual requirements of each project and a detailed bill of quantities. The data
supplied are based on LCC’s own experience and are correct to the best of our knowledge.
However, no guarantee of any kind can be given as individual projects vary a great deal.

List of Auxiliary Materials: Approximate Consumption:


· Siporex glue for bedding and minor repairs . . . . . . . . . . . . . 10 kg per cubic meter of Siporex
· Sand-cement grout to fill joints between wall panels . . . . . . 45 kg per cubic meter of Siporex
· Fiberglass tape for joints . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 lm per sq. m. of Siporex wall
· Gesol (Adhesive liquid) for fixing fiberglass tape . . . . . . . . . 1 kg per 18 lm of fiberglass tape
· Dowels, Ø5.5mm x 250mm long, stitches to connect walls . 2 pcs per wall panel
· Plastic wedges – to support wall panels temporarily . . . . . . 2 pcs per wall panel - reusable
· Galv. nails: 100mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 pcs per cubic meter of wall
· Galv. nails: 125mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 pcs per cubic meter of slab
· Siporex Sand paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 lm per 200 cu. meter of Siporex
· Masonry nails, 50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 box per average villa
· Reinforcements for ring beam . . . . . . . . . . . . . . . . . . . . . . . . 1 kg per cubic meter of Siporex
· Concrete for ring beams. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 m3 per 20 m3 of Siporex slab

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AAC BUILDING SYSTEM

6. ERECTION

6.2 Hand Tools and Equipments


6.2.1 Siporex erection tools
The following tools are provided by LCC Siporex free of charge on return-basis against a refundable
deposit as an extension of services to customers. They are to be returned to the Siporex factory upon
completion of the erection works to serve other Siporex customers.

Roof slab grab; width of slab = 600 mm.

Lifting grab for horizontal wall panels and lintels.

Lifting hook for vertical wall panels.

Lifting sling for slabs (7.8 m long and 2 tons capacity).

Wall braces to temporarily support vertical wall panels.

Cramp for closing joints between floor/roof slabs

Lever for raising partition walls against the ceiling.

33
SIPOReX
AAC BUILDING SYSTEM

6. ERECTION

6.2.2 Other hand tools and equipments


The following tools (not provided by LCC Siporex) are also required in addition to the special erection
tools during the installation of Siporex elements.

Grinding board

Plane for chamfering sharp edges.

Siporex Saw with special blade for aerated concrete


(available for sale at Siporex factory).

Hack Saw Blade for cutting steel reinforcement.

Electric circular saw with metal blade.

Electric grooving machine for making grooves on


panels.

34
SIPOReX
AAC BUILDING SYSTEM

6. ERECTION

6.3 Erection Procedure

6.3.1 R.C. foundation should be cast with a smooth


and leveled surface. This saves a lot of work
in leveling the tops of wall panels later.

6.3.2 Layout of wall panels should be marked on


the foundation using chalk lines and ensuring
that any overhang has been allowed for on
the periphery of the foundation.

6.3.3 Steel dowels connecting the wall panels to the


foundation are either placed in their positions
before casting the foundation or placed in a
drilled hole of 4 cm in diameter in the
foundation and then grouted. Another
alternative is to make a hole of 8 mm diameter
and fix the steel dowels using Hilti C10 epoxy
or equivalent. These dowels are placed at
each wall panel joint as indicated on Siporex
shop drawings.

6.3.4 Nylon offset lines should be used to ensure


outside line of panels is maintained.

6.3.5 Aluminum straight edge should be set to line


and level to inside face of the wall.

6.3.6 The longest elevation with least number of


openings at the farthest reach should be
selected for initial installation. This is to
maintain sight lines between operator and
erector and ensures correct signals can be
given to the crane operator.

6.3.7 Siporex glue mortar is used as a bed for the


wall panels. Wedges are used for temporary
support of wall panels and allow fine
adjustment for plumb.
6.3.8 Corner elements are erected first and carefully
positioned. Succeeding panels are erected as
per mark numbers shown on Siporex shop
drawings.

35
SIPOReX
AAC BUILDING SYSTEM

6. ERECTION

6.3.9 Working with a fixed straight edge for


alignment, the wall panels are lifted by a lifting
hook, placed in position and checked for
plumb. The top edges are also aligned and
are steadied by temporary wall braces at
every 3rd or 4th panel. Dowels of Ø5 mm x 250
mm long are used as stitches to connect the
top joints between the panels.

6.3.10 The tightly fixed together wall panels are


grouted by thoroughly wetting the grooves
with water and then pouring in fluid cement-
sand grout (1:3) and then positioning steel
dowels for the next storey panels. Note that
Siporex products should always be well
wetted with water before applying any other
materials (e,g, glue, grout, plaster,…etc.)

6.3.11 Lintels are placed on top of windows and door


openings using a lintel grab. They are
supported on and connected to the wall
panels adjacent to the openings. Steel dowels
are drilled and grouted on top of the lintel
prior to installation of vertical panels above.

6.3.12 Floor and roof slabs are lifted with a grab and
carefully positioned with specified end
bearings on leveled wall panels. Minimum 50
mm side bearing is required on walls parallel
to the span. Tongue and groove joint faces
provide firm connection between the units
which ensures the stability of the building.

6.3.13 The notches formed between the floor or roof


slabs are concreted along with the ring/bond
beams after placing all the connecting and
continuity steel bars. Refer to the figure
showing the different details for continuity
steel bars.

6.3.14 Any damages are repaired and any spaces


between the panels are filled flush with
Siporex glue. After repair and setting of the
mortar, the repaired areas and joints are
rubbed down with sand paper to give smooth
surfaces.

36
SIPOReX
AAC BUILDING SYSTEM

6. ERECTION

6.4 Repair of Siporex Panels

6.4.1 Guidelines
Damage to Siporex panels may be repaired at site subject to certain limitations. Siporex units
which are structurally defective and unfit for the purpose for which they are designed must not
be repaired but should be rejected and replaced with sound units.

Broken floor/roof slabs must be rejected. A broken floor/roof slab is a unit which due to fracture
on its lower face (tension side) or through breakage and/ or fracturing of the bearing faces at
the ends is no longer able to fulfill its structural functions for which it has been designed.

Slabs with transverse cracks which extend through the thickness of the slab should be
rejected. Slabs with hair-line cracks which do not penetrate to the tensile reinforcement will
normally be suitable for use.

Damage which exposes extensive parts of the reinforcement should not be repaired. Panels
with major damage to the bearing surface which exposes the cross bars on the tensile steel
should not normally be repaired.

Spalling or peeling-off of fragments to face of panel can be repaired if maximum length of


repair is 30 cm and depth is less than ¼ of the total panel thickness. Spalling to edge of panel
can be repaired if maximum dimension of repair is 30 cm and maximum width is 20 cm.

6.4.2 Repairing Instruction


Siporex panels should be free from defects which would impair their strength and structural
integrity. Slight damages are normal and can be repaired as per the following instructions:
6.4.2.1 Clean the defective surfaces thoroughly with a stiff brush and remove all dirt and
loose material. Wet thoroughly with water using s large brush. If a large piece has
broken-off and the broken-off section is available undamaged, the piece can be
glued on by applying Gesol to both surfaces and pressing the broken-off section into
the unit to fit.

6.4.2.2 Place a suitable amount of Siporex glue in a bucket. Add clean potable water with
10% Gesol and mix thoroughly with a mason’s spoon till a soft putty consistency is
achieved. Do not mix more mortar than can be consumed before the mortar starts to
set. Do not add water when mortar starts to set in order to restore workable
consistency.

6.4.2.3 Deep repairs shall be reinforced with galvanized cut nails before Siporex glue is
applied. Apply Siporex glue to the damaged area with a mason’s spoon. During
application, use slightly more material than is needed to fill the damaged area.

6.4.2.4 After application, leave the material untouched till the mortar starts to harden slightly.
Then level with a wood float. If necessary apply a small amount of water to the
surface during leveling. Level by moving the wood float towards the Siporex material.

37
SIPOReX
AAC BUILDING SYSTEM

6. ERECTION

6.5 Illustrations Showing Erection Stages

A) Starter bars are laid in position. B) Siporex glue is applied for bedding.

C) Corner panels are placed in position. D) Succeeding panels are erected.

E) Provide temporary wall bracings. F) Top joints are stitched and grooves are
grouted.

38
SIPOReX
AAC BUILDING SYSTEM

6. ERECTION

6.5 Illustrations Showing Erection Stages

G) Lintels are laid above openings. Dowel H) Siporex glue is used as leveling bed at top.
bars are provided for next level. Dowel bars are positioned for next level.

I) Floor/roof panels are laid. J) Provide steel reinforcement for ring beams

K) Continuity bars between spans are laid. F) Cast concrete along grooves and ring
beams. Proceed with next upper level.
39
SIPOReX
AAC BUILDING SYSTEM

7. TYPICAL CONNECTION DETAILS

7.1) Parapet connection 7.2) Roof slabs connection

7.3) External wall & slab connection 7.4) Internal wall & slab connection

7.5) External wall & foundation connection 7.6) Internal wall & foundation connection

40
SIPOReX
AAC BUILDING SYSTEM

7. TYPICAL CONNECTION DETAILS

7.7) Siporex wall cladding, fixed to R.C. main frame (External wall)

7.8) Siporex wall cladding, fixed to R.C. main frame (Internal partition)
41
SIPOReX
AAC BUILDING SYSTEM

7. TYPICAL CONNECTION DETAILS

Alternative 2: Slab supported on steel beam web

Alternative 1: Slab on top of steel beam

Alternative 3: Slab inserted between flanges

7.9) Siporex slabs supported on steel beams

7.10) Siporex external wall cladding, fixed to steel main frame

42
SIPOReX
AAC BUILDING SYSTEM

7. TYPICAL CONNECTION DETAILS

7.11) Water heater fixing detail 7.12) Lavatory fixing detail

7.13) Marble / artificial stone fixing 7.14) Wooden / aluminum door & windows

43
SIPOReX
AAC BUILDING SYSTEM

8. Electro-Mechanical

8.1 Chases and Penetrations

Small conduits can be chased


easily into Siporex wall panels,
but cutting of steel bars should be
avoided. (refer to Section 3.2.13
for locations of steel bars). For
large conduits requiring the
cutting of the entire width of the
wall panel, the cut portion should
be filled with concrete and
reinforced with steel mesh at both
faces.

Large cut-outs and pipe-runs passing through the Panel board recesses can be provided neatly
floor / roof slabs can be accommodated during and economically by using a lining panel to
design stage to avoid unplanned cuttings. Panels avoid large recesses in the wall as shown on the
with large cut-outs will have reinforcement above section.
specially designed around these cut-outs.

44
SIPOReX
AAC BUILDING SYSTEM

8. Electro-Mechanical

8.2 Typical Section Showing Electrical Installations in Siporex Building

45
SIPOReX
AAC BUILDING SYSTEM

8. Electro-Mechanical

8.3 Typical Section Showing Plumbing Installations in Siporex Building

46
SIPOReX
AAC BUILDING SYSTEM

9. FINISHES

Various types of finishes used in conventional concrete construction are also applicable to Siporex
system. Before applying finishes, damages should be repaired and chases or openings should be
made good with Siporex glue mortar. Deep holes and chases can be dubbed with ordinary cement-
sand mortar (1:6) to within 5 mm from the surface and finished with Siporex glue.
A comprehensive range of finishing products suitable for use on Siporex surfaces such as internal /
external walls and ceiling can be supplied by Saudi Serpo Company. Saudi Serpo products are
available in wide range of colors to choose from. Samples are shown below.

9.1 Internal Walls

Joints between wall panels should be taped with


fiberglass tape. Serpospack thin wall plaster applied
in two coats gives a very smooth surface as a base
for painting or wall papering. Where required, the
second coat may be applied with a textured finish.

9.2 External Walls

Similarly, joints between wall panels should be taped


with fiberglass tape unless if the joints are V-
grooved. Where Siporex panels have V-grooved
joints, two coats of Serpocoat textured finish are
recommended. Where Siporex have plain joints, one
coat of SerpoHard or SerpoFill followed by Serpo
Primer are recommended before applying the finish
coat of Serpo Décor Textured paints.

9.3 Ceiling

Siporex slabs make attractive ceiling with the visible


V-grooved lines. Serpospack applied in two coats
will give a very smooth base for painting. Where
required, the second coat may be applied with a
texture finish. Suspended ceiling systems can also
be used which are normal for bathroom areas to
conceal waste pipe runs.

47
SIPOReX
AAC BUILDING SYSTEM

9. FINISHES

9.4 Floors

Compared to cast-in-situ concrete floors, Siporex


floor slabs provide a completely dry smooth floor
construction on which decorative floor finishes of
tiles, parquet, linoleum and other required finishes
are readily applied.

9.5 Roofs

Above sections shows the suggested arrangements of finishes on top of Siporex roof slabs (Accessible
& Non-accessible roofs).

48
SIPOReX
AAC BUILDING SYSTEM

9. FINISHES

49
SIPOReX
AAC BUILDING SYSTEM

10. FIXINGS TO SIPOREX

Special types of commercially available fixings can be used with Siporex structures. In fixing built-in
units and other items; galvanized nails, bolt fastenings and wall plugs are used. Ordinary wire nails
should not be used since their anchoring ability to Siporex is low. The type of anchoring method to be
used depends on the holding capacity required. The manufacturer’s recommendations should be
consulted as to the maximum loads suitable for use with their products. Some of the types of fixings
and anchors suitable for use with Siporex AAC materials are as follows:

10.1 Galvanized Cut Nails


Galvanized Cut Nails comes in different lengths and are
available at our Siporex Factory. Cut nails are hammered
directly into Siporex walls and do not need to be pre-drilled
They can be used to fasten light to moderate weight items
to Siporex.

10.2 Hilti HGN Anchors


HGN Gas Concrete Anchors, manufactured by Hilti
Company is a Cadmium-free Polyamide anchor specially
suitable for AAC concrete base. Available in various sizes,
it provides high pressure per unit of area, as well as good
resistance to turning in the hole due to its large fins.
Technical data regarding the recommended tensile / shear
loads for Siporex base are shown on the table below.

10.3 Fischer Anchors


Also available with plastic plugs suitable for light to
medium weight fixings in aerated concrete. Technical data
regarding the recommended tensile / shear loads for
Siporex base are shown on the table below.

10.4 Permissible Loads of some Suitable Fixings to Siporex


Type Designation Permissible Tension Permissible Shear
Cut nails 100 mm long 10 kg 25 kg
125 mm long 12 kg 35 kg
150 mm long 18 kg 40 kg
Hilti HGN 8 30 kg 35 kg
HGN 10 50 kg 60 kg
HGN 12 65 kg 70 kg
HGN 14 80 kg 80 kg
Fisher S 10 18 kg 40 kg
S 10 H 90 40 kg 80 kg
S14 50 kg 100 kg
S 16 60 kg 120 kg
50
SIPOReX
AAC BUILDING SYSTEM

11. SIPOREX GLUE

Description
Siporex glue is an adhesive mortar for quick and secure laying of Siporex blocks with a thin joint and for
providing a leveling bed for the erection of Siporex wall panels and slabs. It is in powder form consisting
of white cement, limestone and special additives that improve workability and adhesion.

Properties

Setting time after mixing: 20 to 30 minutes depending on weather conditions

Coverage: For blocks face size of 25 x 60 cm: 35 kg per m3 of


Siporex blocks with 3 mm thick joints.

For blocks face size of 20 x 60 cm: 45 kg per m3 of


Siporex blocks with 3 mm thick joints.

Adhesive strength after setting: Not less than 4 kg/cm2


Preparation
Prepare Siporex glue mix in a clean trough with 5 liters of clean water per bag. Mix thoroughly until a
homogenous creamy paste is obtained. Preferably use a high shear mixer on a drilling machine to
obtain a uniform mix. During the hot season and when the blocks have been lying under the sun,
replace the mixing water with a mix of 5 parts of water to 1 part of Gesol, a retardant to prevent too
rapid setting under hot or dry conditions.

Packaging and Storage


Siporex glue is available in 25 kg paper bags. It should be stored in a dry place protected against rain
and moisture from the ground. The shelf life is approximately 3 to 6 months if unopened and when
stored in a dry place.

51
SIPOReX
AAC BUILDING SYSTEM

12. SERPO GESOL

Description
Serpo Gesol is a highly concentrated, non-toxic, non-flammable copolymer which serves as a bonding
agent in mortar and plaster mixes or as a primer sealer for these substrates. Serpo Gesol has excellent
adhesive and cohesive strength.

Technical Data:
Solids: 55 ± 1%
Viscosity (20 °C): 1500 mpa. s.
Mechanical stability: Excellent
Density: 1.05 g/cm3
Color: White
Application:
Serpo Gesol is used in the following applications:
· To prevent too rapid setting in lime/cement materials and improve curing under hot and dry
conditions.
· To seal and prepare substrates with a strong absorbent background, particularly in hot climatic
regions.
· As a primer to improve adhesion.
· As a bonding agent for screeds, leveling compounds, repair mortars, plasters and renders. To
boost adhesion, compressive and flexural strength, abrasion resistance, etc.

Instructions on usage:
· Substrates must be sound, clean, free from oil
and loose materials.
· Moisten porous subfloors until saturated before
applying SerpoGesol.
· As a bonding agent (Mixing with cementitious
products):
Use a mixture of 1 : 5 to 15 (by volume) of Serpo
Gesol and water.

52
SIPOReX
AAC BUILDING SYSTEM

13. SIPOREX PROJECTS

LIST OF SOME SIPOREX PROJECTS


S. # Client / Contractor Name of Project Location Year

01 Panda Stores 2 Storey Dormitory Riyadh 1981


Royal Commission for Contract No. 113-C02 EPC 419
02 Jubail 1982
Jubail & Yanbu Dwelling Units
Royal Commission for Contract NO. 801-C06 E.P.P.C.
03 Jubail 1982
Jubail & Yanbu
04 Saudi Ceramic Dormitories & Ancillary Bldgs. Riyadh 1982
Jeddah &
05 SCECO Substations 1982
Taif
AlJubail Petrochemical
06 27 Housing Units Jubail 1983
Co. (KEMYA)
07 Essam Economic Co. Clinic & Residential Complex Jubail 1983
Gustav Epple &
08 SCECO – Central PP 8 Power Station Riyadh 1983
Pollenisky & Zoelner
Baker Trading &
09 AMG (GAMA) 80 Units Compound Riyadh 1983
Contracting
Saudi Petrochemical Co.
10 E.P.C. Contract for 100 Houses Jubail 1984
(SADAF)
11 AMAL Est. Saudi Diesel Compound AlKhobar 1984
12 Sirafi / Carlson Gr. Inc. University Staff Housing Ph.II Riyadh 1984
13 BETA Company Microwave Station Around Riyadh 1984
14 Brown Bovery & CIE AG 7 SCECO Substations Riyadh 1984
15 Hanshin Const. Co. Human Resources Dev. Institute Jubail 1985
Saudi Mcinerney Const.
16 Kanoo Housing Complex Jubail 1985
Co. Ltd.
17 Poong Lim Saudi Arabia National Methanol Housing Jubail 1985
JV SAAD Polensky & Jamjoom Commercial Center
18 Jeddah 1985
Zoellner / Gustav Epple
Societe Auxillaire D’ent.,
19 AlQatif Housing Project AlQatif 1986
Dammam
20 Skanska Gen. Contr. Red Sea Hospital Jeddah 1986
21 Skanska Gen. Contr. Bisha Hospital Bisha 1986

53
SIPOReX
AAC BUILDING SYSTEM

13. SIPOREX PROJECTS

S. # Client / Contractor Name of Project Location Year

22 Arabuilt Co. Ltd. KSU Housing Proj. Ph.II Riyadh 1986


23 Saudi Petrochemical Co. 136 Housing Units Jubail 1987
24 Haifco Bitas, Makkah Juffali Commercial Bldg Makkah 1987
25 A. A. AlTazi Corp. Aziziyah Beach Housing AlKhobar 1988
26 Sheikh AbdulAziz AlHamdan Commercial Complex Roof Riyadh 1988
AlHamdan, Riyadh Covering
27 Jarir Furniture 8 Villa Compound Riyadh 1988
Meto Bau / AG. Jed. Substation at AlZahir, Sisha, Makkah Makkah &
28 Steidle S.A. & Moll & Jubail, Kubais & Power Plant 110 Makkah / 1989
Arabia Ltd. KV Extn. Taif
29 Ghassan A. AlKhalid Co. Various Houses, Chalets & Schools Kuwait 1990
30 Asahi Glass Co., Japan Siporex Wall Panels Japan 1990
31 ElEkam Gen. Contr. Girls School at Ajman U.A.E. 1990
32 AlMulla Est. Abjar Hotel at Dubai U.A.E. 1990
33 SASCO Roadside Rest Areas Diff. sites 1990
34 Prince Khalid Bin Faisal Abha Exhibition Center Abha 1990
King Fahad Medical City (Interstitial
35 Hyundai, Riyadh Riyadh 1990
Floors)
36 A.K. Group School Building Dhahran 1991
37 Basem AlKhateeb Special Forces Accom. Riyadh 1991
38 A. Azhar Corp. Makkah Kindergarten Makkah 1991
39 Faraj AlQahtani Est. Faisal Islamic Bank Villas Jubail 1991
40 GAMA Services GAMA Compound Jeddah 1991
41 Projects & Trading Co. ABV MODA Resi. Camp Jeddah 1991
AlTarifi General Safwa
42 Hospital Project for Ministry of Health 1991
Contracting AlLaith
43 A.K. Group Aziziyah Housing 208 Villas AlKhobar 1992
44 AlShaden Cont. Est. AlHasawi Housing Compound AlKhobar 1992
45 AKC Contracting Khalifa Oly. Stadium Qatar 1992
46 Arch. Saleh Qadah AlMeftaha Village Abha 1992

54
SIPOReX
AAC BUILDING SYSTEM

13. SIPOREX PROJECTS

S. # Client / Contractor Name of Project Location Year

47 Saudi Shinwha Co. Sharq Exp. Factory Jubail 1992


48 AlWaad Co. 8 Villa Compound Jubail 1992
49 Ghassan A. AlKhalid Different Chalets Kuwait 1992
ABV Rock Group / SSSP Residential Compound 120
50 Madinah 1992
Arabian Gulf Co. Units
ABV Rock Group / Haif SSSP Residential Compound 110
51 Abha 1993
Est. Units
ABV Rock Group / SSSP Residential Compound 110
52 Buraidah 1993
United Const. & Trdg Co. Units
AlWasat Trading & AlSulayyel Housing Compound
53 AlSulayyel 1993
Contracting Co.
54 Kimma Construction Yanpet Housing Project 200 Villas Yanbu 1993
55 Ibn Zumaie Const./Maint. AlKaki Compound Jeddah 1993
56 AlBustan Company AlHada Dev. Project 20 Villas AlKhobar 1993
57 AlBustan Company Stemco Cmpd. 8 Villa AlKhobar 1993
58 Senam United Mod. Co. 20 Villa Compound Jubail 1993
59 ABV Rock Group ABV Compound Jeddah 1993
60 Ghassan A. AlKhalid Different Chalets Kuwait 1993
61 A.K. Group AlGossaibi Accommodation Dammam 1993
Saudi Constructioneers GOSI Housing Project 36 Units Jubail 1993
62
Est.
63 UGETCO/Kuwait Hotels Dubaiya 30 Chalets Kuwait 1993
N A Z C O (Najeeb
64 SAFCO Housing Project Jubail 1993
AlZamil Group)
65 Nasser A. AlTuraiki 6 Villas Compound Dammam 1993
66 Nesma & AlFadl Cont. Co. Hadeed Housing Project Jubail 1993
Dammam
67 Abdullah AlMubarak Est. Municipalities 1993
& Dhahran
68 A.K. Group Base Commander Residential Dhahran 1994
69 UGETCO Different Villas / Chalets Kuwait 1994
70 Saudi German Hospital Hospital Extension Jeddah 1994

55
SIPOReX
AAC BUILDING SYSTEM

13. SIPOREX PROJECTS

S. # Client / Contractor Name of Project Location Year

Tabuk Gardens Village –


71 A. K. Group Tabuk 1994
60 villas
72 Saudi Archirodon Ltd. Compound Extension Jeddah 1994
73 Armetal Labor Camp Riyadh 1994
74 AlMutabagani Health Serv Housing Compound 10 Villas Taif 1994
75 Hanil Development Co. Housing Compound AlJouf 1994
76 Moll Arabia Ltd. SCECO Substations Jeddah 1994
77 Saudi Wiemer & Trachte Hofuf Cement Factory Hofuf 1994
78 AlAjdal Trading Est. Sipenny’s Labor Camp Dubai-UAE 1994
79 Abdullah AlMubarak Est. Municipality Jubail 1994
80 AlGhurery Co. Manarat AlSharkia Schools Dammam 1994
81 Sata Engineering Blocks Taiwan 1994
82 Eng’r. AlBassam AlBassam’s Compound Riyadh 1994
83 Arabian Fal Co. Ibn Sina Housing Project Jubail 1994
84 Saudi Real Estate Co. D.Q. Housing Project Riyadh 1994
M.S. AlSuwaidi Cont. Yanpet Housing Project Phase II 300
85 Yanbu 1994
Est. Villas
86 Bin Ayed Est. Panda No. 8 Renovation Riyadh 1995
87 AlOthman Agri. Prod. Various Projects Hofuf 1995

88 AlAjdal Trading Est. Cold Store Building Dubai 1995


89 AlThinayyan Dev. Co. Petrolube Factory Offices Riyadh 1995
90 UGETCO Ministry of Interior Extn. Kuwait 1995
91 AlAjdal Trading Est. 92 Buildings Extension AbuDhabi 1995
92 AlAjdal Trading Est. American Hospital Dubai 1995
92 AlSarif Corporation AlWazir Center Riyadh 1995
93 AMERAB-ECO- Tawam 89 Villas & B. Walls AbuDhabi 1995
94 AlFanar Co. Iskan AlAam Substation Makkah 1995
95 Assad Said Corp. Office for Power Plant 9 Riyadh 1995
96 AlKhozaim Construction AlWalaan Showroom Riyadh 1995
97 AlMobti for Trad. & Cont. 273 Villas Compound Djibouti 1996

56
SIPOReX
AAC BUILDING SYSTEM

13. SIPOREX PROJECTS

S. # Client / Contractor Name of Project Location Year

98 Arabian Turkish Cont. Co. AlMatroud Staff Accommodation Sihat 1996


99 Teamwork S.A. Ltd. Al Hayat Pharma. Plant Riyadh 1996
100 Shamsa Trading Est. 5 Buildings AlKharj 1996
101 ElSeif Eng. Cont. Est. PP 8 Phase II, Ext. II Riyadh 1996
102 Riyadh AlHuda Schools School Complex Jubail 1996
103 Delta Est. Office & Accommodations Riyadh 1996
104 ABV Rock Group KB. Boundary Walls Abha 1996
105 AlToukhi Co. Ind & Trad. AlBayaah Substation Madina 1996
106 Saudi Binladin Group Aqaba Substation Jordan 1996
107 Giant Crete Bldg. Mat. Wall Claddings Taiwan 1996
108 Moll Arabia Ltd. Faysaliyah New Substation Jeddah 1996
109 A.K. Group R.S.L.F. Housing Tabuk 1996
110 AlMasarah Cont, Est Yanpet Housing Phase 2 Ext. Yanbu 1996
111 A. K. Group Commanders Office 4 Bldgs. Taif 1996
112 A. K. Group Emarah Palace Complex Kharkhair 1996
113 Saudi Binladin Group Power Plant (PP 9) Riyadh 1996
114 AlKhulaifi Business Group 16 Villa Complex Qatar 1996
115 Amana Steel Hangers U.A.E. 1996
116 A. K. Group S S O C Compound Taif 1996
117 Ret Ser Yanbu Cement Factory Yanbu 1996
118 Saudi Build Barracks Gurrayat 1997
119 International Center Co. YCC – 40 Villas Yanbu 1997
120 C C C (ARAMCO) Residential & Industrial Compound Shaybah 1997
General Presidency for Different
121 16 Colleges Buildings 1997
Girls Education Locations
122 Developed Building Co. 180 Villas (Roof Slabs) Qatar 1997
123 Giant Crete Bldg. Mat’ls. Wall Claddings Taiwan 1997
124 Dr. Khalid Idress Hospital Hospital Extension Jeddah 1997
125 Ibrahim AlSheikh Est. Central Electrical Bldg. Ext. Jeddah 1997
126 Tawam Gen. Cont. Co. Coast Guard Institute Project AbuDhabi 1997

57
SIPOReX
AAC BUILDING SYSTEM

13. SIPOREX PROJECTS

S. # Client / Contractor Name of Project Location Year

127 Mr. Yaqub AlGhoul Chalets & Hotel Gizan 1998


128 AlSwayeh Co. Hyatt Regency Hotel Riyadh 1998
129 John Shenton Architects Princess Donnas Palace Ren. Riyadh 1998
130 Pax Kent Tea factory Jabel Ali 1998
131 Mannai Engineering Co. Intercontinental Hotel AlAhsa 1998
132 Tawam General Cont. Co. AlDukkan Project Diff. sites 1998
133 AlOthman Est. Wall Claddings for 2 Buildings AlAhsa 1998
134 Developed Building Co. 5 Villas Qatar 1998
135 Pax Kent Unilever Gulf Project Dubai 1998
136 Pax Kent GAC Distribution Center Dubai 1998
137 Assad Said Corporation Offices for SSOC AlKhaj 1998
138 Oasis Co. Gymnasium Alkhobar 1998
139 Montajat Co. Veterinary Pharma Plant Dammam 1999
Boyot Makkah for
140 Holy Quran School Project Makkah 1999
Trading
141 AlJassim Trading Group Fujairah Womens College Fujairah 1999
142 Ibrahim AlKhalaf AlRuwad School Riyadh 1999
143 Zaas Office Bldg – Min. of Interior Riyadh 1999
144 Arch Center Hail Trade Center Hail 1999
145 Developed Building Co. Landmark Shopping Mall Proj. Qatar 1999
146 AbdulLateef Jameel Co. Toyota, Buraidah Center Buraidah 1999
147 REDICO Tabuk Gardens Village – 2A Tabuk 2000
Shoaiba Power Plant / Substation at Shoaiba &
148 Moll Arabia 2000
Jamiaa Jeddah
149 Fahad Bin Saad Co. Green Beach Fam. Fun Park Riyadh 2000
150 Modern Building Co. Star Markets Yanbu 2000
151 Saqr AlBar AlAhmar Bachelor Compound Jeddah 2000
152 Developed Bldg. Co. Al Ittihad & Al Rayyan Stadiums Qatar 2001
153 Al Kayid Co. Recreation center Al Jouf 2001
155 Bin Jarallah Group Housing Compound Najran 2001

58
SIPOReX
AAC BUILDING SYSTEM

13. SIPOREX PROJECTS

S. # Client / Contractor Name of Project Location Year

156 Obaid Al Maary Makkah Girls School Makkah 2001


157 Saudi Wiemer & Tracte Al Rushaid Village 2 Alkhobar 2001
158 Al Qasabi Cont. Hand Ball Hall Qassim 2001

159 Saudi Teryadh Hand Ball Hall Sanabis 2001


160 Developed Bldg. Co. Giant Stores Qatar 2001
161 Al Afras Cont. Office Compound Makkah 2001
162 Saudi Binladin Group King Abdullah Multi-storey Hotel Madinah 2001
163 Al Maawdah const. Building extension Bahrain 2002
164 Nasser Al Hajri Yanpet Hsng Proj.-Ph.3 Yanbu 2002
165 REDICO CFS Expansion K. Mushayt 2002
Dammam
166 KAMCO Madinah Printing Press 2002
& Riyadh
167 Rakan Trading R.C. Four Schools Yanbu 2002
Modern Villas Real
168 Housing Compound Riyadh 2002
Estate
169 Riman Trading School Building Riyadh 2002
170 Al Thobaiti Co. SWCC Clinic & Mosque AlKhobar 2002
171 Al Fasla Est. Al Thakafa School Riyadh 2002
172 Al Someie Real Estate Housing Compound Riyadh 2002
Wadi
173 Al Najdain for Contg. Moda Accommodation 2002
Dawasir
174 Arabian Bemco Substation Taif 2003
175 Abdullatif AlIssa Group Al Issa Compound Riyadh 2003
176 Green Top Contg. Qatif & Dammam BSP Qatif/Dam 2003
177 Al Marasem Contg. Residential Compound Shouaiba 2003
178 Bin Jarallah Group Gizan Housing Gizan 2003
179 Al Marasem Cont. Housing Compound Tufail 2003
180 Al Mashrab Co. Abha University Abha 2004
181 Rezaik Al Gedrawi Charity Housing Skaka 2004
182 Rezaik Al Gedrawi Charity Housing Qurayyat 2004
183 Saudi Archirodon Steam Power Plant Housing Shoaiba 2004

59
SIPOReX
AAC BUILDING SYSTEM

13. SIPOREX PROJECTS

S. # Client / Contractor Name of Project Location Year

184 Al Ali Engineering 108 Villas Qatar 2004


185 Al Ali Engineering Villaggio Qatar 2004
2,500 villas - Developmental Housing
186 King Abdullah Foundation Diff.sites 2004-2006
Project
187 Contraco 380/110kV Substation Jeddah 2004
188 Al Fawzani Housing Compound – Clinic Jubail 2004
189 Arabian Bemco Cont. Substation Khaybar 2004
190 Al Marasem Medical Clinic Tufail 2004
191 EMECO Al Amar Gold Mine – Housing Quayyiah 2004
192 Al Fanar Co. 110 kV Zahra Substation Makkah 2005
193 Al Ma’awdah Const. 10 Villas for E.Alwan Bahrain 2005
194 Al Ali Engineering 30 Villas Qatar 2005
195 Al Othman Agri. NADA Accommodation Bldgs Hofuf 2005
196 Contraco Al Rabwa Substation Jeddah 2005
197 Saudi Archirodon Office Building Jeddah 2005
198 Biad Development Co. 110/13.8kV Substation Jeddah 2005
Mohd. Mousa Shahada
199 Al Jouf Municipality Al Jouf 2005
Est.
200 Al Yasser Gen. Cont. Jubail Municipality Jubail 2006
201 Wadi Maramer School Buildings Jizan 2006
202 Abdulaziz Trading Est. Hill View Real Estate-Phase I Ethiopia 2006
203 Philipp Holzman New Surgery Hospital Ext. Riyadh 2006
204 Al Rashid Abetong 10 units Building Extensions Riyadh 2006
205 Rezaik Al Gedrawi Admin. Buildings – 3 Bldgs. Al Jouf 2006
206 Al Ali Engineering 84 Villas Qatar 2006
207 Assad Said Corporation ASC Housing Compound Jubail 2006
208 Imar Development Co. Al Tilal Project Madinah 2006
209 Al Ma’awdah Const. 25 Villas Bahrain 2006
210 Haif Contracting Gazadco Shrimp Farm Jizan 2006
211 Assad Said Corporation Substations AbuHadriya 2007
& Shoaiba

60
SIPOReX
AAC BUILDING SYSTEM

13. SIPOREX PROJECTS

S. # Client / Contractor Name of Project Location Year


.

212 Saudi Binladin Group Al Haram Shopping Center Madinah 2007


213 Royal Defense Command Renovation-Apartment Bldgs Jeddah 2007
214 Al Ali Engineering The Pearl Qatar Qatar 2007
215 Al Ali Engineering 58 Villas Qatar 2007
216 Al Gosaibi Labour Camp Jubail 2007
217 Makkah Co. Supply of Blocks Kuwait/Iraq 2007
218 Erfan Hospital Hospital Extension Jeddah 2007
219 Al Mabda Rezayat Housing Compound Jubail 2007
220 Project Building Est. Al-Mouwasat Hosp. FF Ext. Jubail 2007
221 Saudi Binladin Group Dar Al-Qibla Complex Madinah 2007
Khurais/
222 MEEDCO Substations 2007
Shedgum
223 Sinoma Hofuf Cement Factory Hofuf 2007
224 Al-Fanar Co. 380/110 kV Substation Thuwal 2007
225 Al-Marasem Co. Charity Housing Diff. sites 2007
226 Al-Rashid Co. Al-Rashid Mall Extension AlKhobar 2007
227 Al-Othman Agri. Prod. Housing Compound Hofuf 2008
228 Danash Co. Al Jouf Cement Factory – Housing Turaif 2008
229 S.M.A. Proj. & Devt. Co. Khartoum College of Med. Science Sudan 2008
230 Framing Co. Developmental Housing Project Qurrayat 2008
231 Rezaik Gedrawi Developmental Housing Project Aflaj/Rafha 2008
232 Contraco South Aziziah Substation Makkah 2008
233 AlFanar Co. 380 kV Switching Station Rabigh 2008
234 Contraco 380/132 kV Substation Shuqaiq 2008
235 Saudi Binladin Group “KAUST” Central Services Building Thuwal 2008
236 Sulaiman A Al Rajhi SOHAR Project Qassim 2008
237 Saudi Al Terais Co. Al Kudmi Substation Jizan 2008
238 Al Muhaidib Co. Royal Commission Housing (240 villas) Yanbu 2008
239 Philipp Holzmann Co. Madareem Crown Hotel Riyadh 2008
240 Saudi Archirodon Ltd. Housing Project Jeddah 2008

61
SIPOReX
AAC BUILDING SYSTEM

13. SIPOREX PROJECTS

S. # Client / Contractor Name of Project Location Year


.

241 Azmeel Contg. Royal Commission Housing (329 villas) Jubail 2009
242 Redico Royal Commission Housing (405 villas) Jubail 2009
Quwaizah,
243 Contraco Substations Teiam, 2009
Thuwal
244 Saudi Archirodon RSF Expt. Camp Jeddah 2009
245 Sahel Areej Trading Secondary School Jizan 2009
246 Al Ali Engineering Cont. Labour Accommodation Qatar 2009
247 Al Marasem Co. Housing Project Umluj 2009
248 Al Mabani Gen. Cont. Power Plant Project (PP10) Riyadh 2009
249 Al Refaie Co. SWCC Housing Project 5 sites 2009
250 Al Fanar Co. Substation – Jizan Economic City Jizan 2010
251 National Prawn Co. Accommodation Buildings Ghallah 2010
252 Al Ali Engineering Cont. Shopping Complex Qatar 2010
253 Al Saad Gen. Contg. Qassim Power Plant Qassim 2010
254 Al Fawzani SWCC – Housing Project Diff. Loc. 2010
255 Assad Said Corp. Princess Noura University Substation Riyadh 2010
256 Azmeel Contracting Royal Commission Housing (491 villas) Jubail 2011
257 Royal Air Force Housing Project Qahma 2011
258 King Saud University 460 Villa Extensions Riyadh 2011
259 BEMCO PP10 – Turbine Building Riyadh 2011
260 SCECO 5 Substations Diff. Loc. 2011
261 Nesma Co. Olaya Towers Riyadh 2011
262 Drake & Scull Jawhara Tower Jeddah 2011
263 AlMa’awdah Const. Different Tower Projects Bahrain 2011
264 D.C.C. Burj Rafal Riyadh 2012
265 Al Fanar Co. New Haramain Hi-Speed Railway S/S 6 sites 2012
266 Gulf Elite Co. Shaybah RIC Expansion Project Shaybah 2012
267 Azmeel Corporation Royal Commission Housing, Ph.8, C13 Jubail 2012
268 Azmeel Corporation GOSI Housing Project Jubail 2012

62
SIPOReX
AAC BUILDING SYSTEM

13. SIPOREX PROJECTS

S. # Client / Contractor Name of Project Location Year


.

269 Huta Marine Housing Compound Rabigh 2012


270 Al-Fanar Co. Qurayyah Substation Qurayyah 2012
271 Al-Toukhi Co. Makkah North Substation Makkah 2012
272 Al-Arrab / CCC Ras Al-Khair Substation Ras Al-Khair 2012
273 REDCO Qatar Airways Housing Qatar 2012
274 Rezaik Al-Gedrawi King Abdullah Housing Project Najran 2012
275 Al Marasem King Abdullah Housing Project Wadi Hayat 2012
276 Al-Hokair Co. Hotel Jizan 2012
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297

63