• Manufactured from Natural Aggregates
• High Strengths 3.6 - 40N/mm2
• High Density - Excellent Sound Reduction
• Available Solid, Cellular, Hollow Forms
• Work face 440mm x 215mm
• Standard Material for Plastering/ Rendering
• Close Texture for Walls built fair or Painted
• Robust all round Masonry Block
• Standards EN 771-3 & associated test standards

Description
A high strength, high density block manufactured using natural aggregate. It has a
strength of 3.6N/mm2 to 40N/mm2. Available in solid, cellular and hollow forms, having a
textured face ideal for plastering, rendering and dry lining. Colour is concrete buff. A close textured (Class 1) ex Gainsborough and close textured (Class 2) ex Syston is available for walling to receive a paint finish or built fair and left.

Manufactured to EN 771-3 & Associated Test Standards.

Applications
Intercrete masonry units are suitable for the following uses:-
Below damp proof course (BS 5628 Pt3:2001).
Soil classifications 1, 2 and 3. Sulphate resistance units also manufactured to BRE Digest 363:1991 (Revised 1996).
Outer and inner leaves of external cavity walls (additional insulation required).
Internal partition walls - load and non-load bearing.
Separating/Party walls (Building Regulations Approved Document E).
Infill units in conjunction with concrete beam floors.
Close Textured for walls built fair or painted.
Retaining walls, reinforced vertically in cores of hollow units.

Format and Size
Available in solid, cellular and hollow format, also reveal units for 50 and 75mm cavity
closing. (Larger sizes to special order)
Facework size is 440 mm x 215 mm.
Tolerance as EN771-3, Table 1, EN772-16 Category D1.
Unit Length and height mm +3 -5
Unit Width average mm +3 -5

Physical Properties
Relationship of density/strength, approx. (Solid units)
EN772-13 Gross Dry Density
3.6 N/mm2 1850 kg/m3 (to special order)
7.3 N/mm2 2000 kg/m3
10.4-17.5 N/mm2 2050 kg/m3
22.5-40 N/mm2 2050 kg/m3 (to special order)

Design Properties

Modulus of Elasticity
Static Modulus of Intercrete Masonry is approximately 3 to 8 kN/mm2.

Thermal Movement
Coefficient of linear expansions of Intercrete is 10x10- 6/0 c

Moisture Movement
As tested to BS EN 772-14 : 2002
Total Movement = 0.38 mm/m Class 1 Aggregate 0.27 mm/m Class 2 Aggregate

Water Absorption by Capillarity
Test method EN 772-11 - No performance determined
Durability against freeze thaw - No performance is determined
Not to be exposed

Shear Bond Strength
Declared Value 0.15N/mm2 BS EN 998-2 Annex C

Water Vapour Permeability
EN1745 : 2002 - Table A.3 Water Vapour diffusion
Coefficients μ 5/15

Thermal Conductivity (Standard Values)
Based on C.I.B.S.E. Guide Book A 1999



Thermal Resistances at 3% Moisture Content 'R' m2 K/W



Sound Insulation
The table below provides design guidance for the estimated sound reduction values of
walls constructed of the Intercrete masonry units. Data is based on mass law. The
frequency range is 100-3150 Hz. The density range for Intercrete material is 1850-2050 kg/m3.


*Also 100mm Solid Units laid flat
NOTE: Sound Reduction of figures RW (dB) include Fair Face, Close Textured and Paint Grade masonry units, based on fully filled ironed jointwork and sealed abutments to soffite and structure, (i.e. no air leakage gaps)

Acoustic Sound Absorption Coefficients
The following data is based on Approved Document A.D. Amending Part E. The Building Regulations 2000.



Separating Walls
Approved Document AD Amending Part E The Building Regulations 2000.
Intercrete Density 1850-2050 kg/m3.

Wall Type 1.1 215mm Wall units laid flat - block density 1850 kg/m3, 110mm coursing, 13mm plaster finish both sides - min mass per unit area including plaster 415/m2
- Intercrete 100mm units comply. (1850 kg/m3)

Wall Type 2.1 Two 100mm wide solid leaves with a minimum 50mm cavity, unit density
1990 kg/m3, 13mm plaster finish on both room sides, 225mm coursing - min mass per
unit area including plaster 415 kg/m3. 100mm Intercrete 7.3, 10.4 - 40N/mm2 units
comply.

Sound Insulation and Acoustic Coefficients
Approved Document Part E. The Building Regulations require that the seperating walls in
new dwellings are subject to pre-completion testing. It shows construction details,
specifically at the junction of structures to restrict flanking sound transmissions. Robust Standard Details have been devised to be used as an alternative to pre-completion
testing to overcome this issue.

Product Range Table
Concrete Density in the range 1850-2050 kg/m3


( ) figures in brackets laid weights including mortar (9.88 units per sq.m). All data based
on equilibrium moisture contents. Reveals to close 50 and 75mm cavity widths are
available. BS EN 1996-1-1 Categorises units according to void percentages. Cellular Units Group 1, Domino & Hollow Units Group 2. Any unit in excess of 20kg reference should be made to H.S.E.
manual handling guidelines

Fire Resistance
Intercrete standard and close textured units are manufactured to Class 2 Aggregates and
are available from our Syston plant. Intercrete standard and close textured Class 1
Aggregate units are available from our Gainsborough Plant. All these products are
classified as noncombustible.

The application of plaster finishes to the wall will in all cases increase the fire resistance period (See Design Guide).

Sitework
See the Interfuse Design and Sitework Guide.

Delivery/Load Data
Prices quoted per 10 units (9.88 per m2).
All prices include mechanical off-loading and apply to full loads. Load sizes may vary
between 15-19 tonnes Rigid, 20-27 Artics.

Mortar Mixes
For masonry units generally a Grade (iii) mortar i.e. cement, lime, sand is recommended. Stronger mortar maybe used to a structural engineers instruction. Plasticisers if used are to
be added in accordance with the manufacturers written instructions. Mortar joint thickness should not exceed 10mm.



Finishes - Internal Plaster
Lightweight plaster. British Gypsums lightweight plaster, Carlite Bonding, 10mm in
thickness as a backing coat. The finishing coat, Carlite Finishing plaster 2-3 mm thickness.
Dense plaster. A backing coat of 1:1:6 cement, lime, sand or 1:5:6 cement, sand, with
added plasticiser with a setting coat of gypsum plaster, e.g. Sirapite or similar applied to
either of the backing coats described.

Finishes - External Rendering
Depending on exposure conditions it may be necessary to treat the surface with a
spatterdash coat of 1:1 cement, sand, followed when dry and hard with a backing coat
10mm thickness of 1:1:6 cement, lime, sand, ruled out, and lightly scratched. A final or subsequent coat of 5 mm thickness using the same mix finished with a wood float.

Ceramic Tiling
In housing where walls are often plastered, ceramic tiling is fixed with proprietary
adhesive. In buildings other than housing, the wall is rendered using a mix of 1:4
cement, sand, ruled out level, and the tiles are fixed using an adhesive.

Paint Finishing Direct
All types of paint finishes are satisfactory. A sealer-treatment is applied and then
undercoats and finishing coats as specified. Emulsion paint provides an economical finish
using a sealer coat, followed by two full undiluted coats, brush applied. masonry with pronounced texture may require a ‘high build’ paint finish to fill the intercises in the face.

Drylining
Drylining with British Gypsums Wallboard fixed by bonding with plaster dabs (adhesive),
screw fixing to metal firrings or nailing to timber battens, alternatively insulated wallboard
may be used.

Cutting, Chasing, Fixing
Cut with bolster. Use of mechanical cutting reduces wastage and must be used for fair
faced work. Clipper saw or Errut block splitters are suitable tools. Chasing for conduit can
be carried out using a kango electric hammer with chasing bit. Disc cutters can also be
used. Chasing dense concrete masonry is laborious and should be avoided where possible.
Fixings are made using shot fired pins and proprietary devise. Joint mortar can be utilised
for minor fixes.

Quality Control
Interfuse Ltd operate a formalised QA system at both Syston and Gainsborough plants.
All masonry units are subject to stringent quality control checks and are tested daily in our own laboratory.

A documented factory production control system is in operation with regular checks made
on raw materials, production and finished units. A stock control system is in operation with written procedures for non-conforming products. All products are produced to the current European Standards.

Marking
Each pack is marked for traceability of product and unit clarification as given on the
delivery ticket.