Frequently Asked Questions

Engineering.
Technical Support & Instruction.
Quotes or Estimates.
Construction.
Polypropylene Ties/Bridges.
Superform Sides.
Stacks Flat.
Positive Fixing.
Bracing System.
Concrete.
Insulation.
Fire Resistance.
Weight Factor.
Environmental.
Foundations.
Cladding.

Engineering.

The SUPERFORM Big Block manual has been formatted to assist designers in correct specification of reinforcing and includes a Bracing Unit (BU) Chart (Earthquake Resistance). NOTE: This does not replace the requirement for an engineer's certificate. The majority of consulting engineers and architects are aware of EPS Blocks, currently we are introducing them to the SUPERFORM Big Block. Please contact your representative to ensure your engineer is included.

Technical Support & Instruction.

Construction is an important and crucial area. SUPERFORM Building Systems Ltd, has free on site technical instruction and training for first time users.. We also have a detailed Technical Manual which is available upon request, one important factor is the temporary bracing of the walls before placing of the concrete, we have a specialized system called the EZI-BRACE for this purpose. We also offer and supply solutions for all types of construction areas, such as: curved walls, inter-tenancy (STC sound rated), retaining walls, multi story developments and swimming pools.

Quotes or Estimates.

Free comprehensive quotes are available off the Full Working Drawings, each quote will detail all areas, allowing for the Blocks, Polystyrene and Timber Stopends along with H3 Timber Inserts. We can also supply a Fabrication quotation (Labor to construct) from one of our registered fabricators. Therefore reducing the chance of cost over runs due to variations not allowed for. Free comprehensive estimates are available off the Scalable Concept Drawings, each estimate offers the same details as above. The objective is to alleviate the assumption that this building system is very expensive.

Construction.

Expedient (Fast) Construction leads to major labor cost savings and holding cost savings. Another very important factor for new buildings, no internal strapping (and placing of insulation) is required, just simply screw, fix (and glue if you want) the internal lining (ie. plasterboard 9.5mm) to the face of the SUPERFORM Big Block. Licensed Fabricators are available to erect the blocks for you this ensuring that the work is carried out correctly, with resultant time saving on the project.

Polypropylene Ties/Bridges.

The SUPERFORM ties are designed for strength, mechanical fixing, non corrosive, non thermal bridging, UV resistant and practical. The preceding attributes of the ties, which come in three sizes (200,250,300 Series) forming 100mm, 150mm or 200mm solid reinforced concrete walls, allow the efficient and fast construction of these true solid walls. With the practical nature of the Tie System wider ties are easily obtainable allowing thicker walls, columns etc. where specific designs require (ie. Multi Level Buildings). Each block holds 10 and when fabricated correctly all the ties line up vertically thus enhancing the ease of mechanical fastening to the wall.

Superform Sides.

Manufactured from a high density fire retardant expanded polystyrene (29 kg/m3 Density) with Dove Tail Grooves every 50mm, allowing ease of inserting stopends while importantly allowing the concrete to key positively to each side. Each side is 1500 x 300 x 50mm and has positive interlocking (Clips together with no side way sliding possible) this eliminates extra gluing.

Stacks Flat.

The kitset properties of the SUPERFORM polystyrene Big Block allows stacking flat, 30 sides to 1.4 cubic metre (30 Blocks). This equals large savings in cartage.

Positive Fixing.

With our special polyproplene tie and the distinctive groove showing each tie's placement simple and positive mechanical fixing is attained through only 10mm of polystyrene. This enables the screw fix of internal linings, avoiding the reliance on glues only. When FRR (Fire Resistant Rating) walls are constructed mechanical fix of plasterboard is Required, Why?, The plasterboard is the first line of defense against fire, and glues are not relied on. Curved walls are easier lined when positive fixing is available.

Bracing System.

Our galvanized specific EZI Bracing System is very simple to erect, is adjustable, so the walls after pouring of the concrete can be adjusted and straightened if necessary, and after 7 days the removal is simple and efficient. A further unique modification allows the system to also double as a scaffold system, eliminating excessive ladders or trestles being hired and getting in the way. Note backfilling should be done 28 days after pour. Due to the positive fixing, the cumbersome and freight expensive corner blocks are not required. As the practical and simple use of the SUPERFORM EZI Brace System allows easy creation of corners whether they are designed at angles of 45, 90, 135 (or other) degrees, as well as forming Tee Junctions. An inexpensive hire rate is available and will be included on request

Concrete.

We recommend the use of a quality 20 mpa, 100 slump, 13mm aggregate be used. A big advantage that is not normally recognized is that the concrete is allowed to Hydrate (Cure) in ideal conditions. Due to the Polystyrene sides of the Superform Big Block, as moisture is retained for full potential, the chemical reaction of the cement mix, will generate heat up to approximately 15 degrees (C), this basically allows steam curing, to optimum strength. In fact tests have revealed after 28 days a 40 mpa (double concrete strength) is commonly achieved.

Insulation.

In NZ we experience variation in weather, some places described as "Four seasons in one day". Therefore achieving a constant temperature is not an easy or cheap task. With the SUPERFORM Polystyrene Big Block a minimum of R2.7 is accomplished (and that's just the Polystyrene) which is nearly five times greater than 190 series Concrete block (before any Lining and Cladding of the interior and exterior). The Double Continuous Thermal Envelope (The Polystyrene Sides), with a Solid Concrete Core creates a Thermal Mass true efficiency, for low cost heating and ventilation. This Thermal Insulation not only keeps out the Cold of the day and night, but also that annoying and uncomfortable Heat. Sound travels in waves, until it is broken partly by the EPS and Lining, then it comes upon the Solid Concrete Core of the SUPERFORM Big Blocks System. The SUPERFORM Big Block Building System gives high STC Rating (Sound Transmission Class). Up to STC. 62 is obtainable with linings (dependant on concrete core). Please note that the higher the STC the Better the Rating. A STC.55 is required by regulation between units (ie. Motels, Apartments and Flats). Test results are available on request to substantiate the STC ratings.

Fire Resistance.

An extensive test performed by BRANZ saw a result of 335 minutes (over 5.1/2 hours) before they needed to switch off the furnace with no failure. This has enabled a proven 240/240/240 FRR with our 250 series with only 9.5 Standard plasterboard lining both sides (ie. Inter-Tenancy walls) while also allowing the simple installation of services (ie Power points, Switches and Plumbing). On the boundary a SUPERFORM Big Block Wall with 9.5mm plasterboard internally and Rockcote's Plaster System on the exterior also returns a 240/240/240 FRR. Unlike metal or polystyrene our special uPVC ties allow no transfer of heat or fire.

Weight Factor.

Our 250 series is normally comparable as an alternative to a 190 series concrete block, being popular as it eliminates the requirement of strapping and insulation or other equivalent methods. A new bonus that has come to hand is our 250 series is up to 15% Lighter while still offering that superior strength, of solid concrete construction, than the comparable 200 series concrete block. This is truly a bonus in engineering requirements and can figure to impressive saving especially in high rise/multi-story developments.

Environmental.

No CFC's are created or used in the manufacture of SUPERFORM Big Blocks or ties and with the SUPERFORM Big Blocks the requirement to heat is substantially reduced, therefore reducing this depletion of both the ozone and natural resources. With SUPERFORM Big Blocks the use of timber is only a few meter's compared to a few logs. Polystyrene uses substantially less energy to produce compared to milling, transportation etc.

Foundations.

Builders have learnt that the use of the SUPERFORM Big Block is very fast and efficient. Eliminating the time and labour intensive practice of boxing then stripping of Formwork and without the normal waste and replacement of timber boxing. With the added advantage of insulated foundations especially a prerequisite when using underfloor heating.

Cladding.

Though any form of BRANZ appraised cladding can be applied (ie. Schist, Stone, Brick, Cedar, corrogated colour steel etc.) The majority of buildings use plastering. SUPERFORM Big Block Building Systems have closely observed the application of plaster and is confident with the development of modified plastering systems and highly recommend the use of such BRANZ Appraised Systems which offer a substantial degree of crack resistance and longevity. Rockcote NZ Ltd. has shown they are the market leaders in this field of expertise and have BRANZ appraised and specific systems that are unsurpassed on today's market. Their use of quality texture architectural coatings is innovative, while giving the client a guaranteed low maintenance finish unrivalled in the market place.