ISOTEX, OPERATIVE ASSEMBLY MANUAL - EUROPEAN LEADER FOR OVER 30 YEARS
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OPERATIVE ASSEMBLY MANUAL
ISOTEX,
QUALITY, SAFETY AND
EASY ASSEMBLY
EUROPEAN LEADER
FOR OVER 30 YEARS
THE WOODCRETE INSULATED CONCRETE FORMWORK SYSTEM,
MANUFACTURED MATERIALS – CEMENT, MINERALISED TREATED
WOODCHIPS AND INSULATION PROPERTIES
1976 The Nurnberg
Building
1985 The residential
district of
The Isotex establishment Fidenza (PR)
ISOTEX utilises woodcrete, a specialist
mixture which traces back to as early as
1946, ISOTEX blocks evolved in 1985, with a
2004 The Capo
unique design to eliminate any manufacturing Coda
Cavallo
tolerances, and improve strength within Hotel
the ISOTEX woodcrete shuttering System. Project
ISOTEX blocks are truly contractor and self- (NU)
build friendly, with over 18 different blocks
shapes and sizes available.
2019 Multi-floor
buildings in
Today in 2019, ISOTEX holds a build Bologna
portfolio of over 400,000 Build Examples
across Europe, and worldwide.
CONTENTS
Correct transfer of blocks from the vehicle to the ground..........................................2-3
Block Types and tolerances .....................................................................................4-6
Normal blocks (STD) ...........................................................................................................................................................................................4
Special blocks ......................................................................................................................................................................................................5
Tolerances and cutting of blocks ..................................................................................................................................................................6
Method for requesting/ordering blocks ....................................................................7
Correct laying of blocks ..……………………………………………………………………………. 8-11
Correct laying of the first course ……….................……………………………………………………………………………………………………… 8
Correct laying of subsequent courses .………................…………………………………………………………….………………………………… 9
Procedure for pouring concrete ………..………………………………………….................………………………………………………………….10
Location of correct reinforcement steel bars ……………………………………………..............………….……………………………………11
Construction particulars ……………………………………………………………………..….. 12-18
Corners in HDIII 30/10 blocks with graphite ………………………….................……………………………………………………….……….12
Corners in HDIII 33/13 blocks with graphite …………………………………………………………................………………………………...13
Corners in HDIII 38/17 blocks with graphite ………………………………………………………………………...............……………………14
Corners in HDIII 44/23 blocks with graphite ............................ …………………………………………….....…………...........……………..15
3-4 way junction .……………………………………………………………………………………………………………………………….................….... 16
Door and window lintels …………………………………………………………………………………………………………………................…....... 17
Block cutting for rebates ….............……………………………………...……………………………….………………………………………………… 18
How to create ducts in Isotex walls ……………………………………………...................... 19
Isotex certificates .…………………………………................................................................ 20
CORRECT TRANSFER
OF PACKS FROM THE DELIVERY
VEHICLE TO THE GROUND
Unloading of Isotex Packs: Isotex do NOT use wooden pallets for our deliveries, you simply lift the
Isotex Blocks with the blocks themselves as per below
1. The packs are lifted ‘one at a time’, using equip- 4. Do not stack more than 2 pallets high when on
ment and procedures in full compliance with the ground
current applicable standards on safety 5. Prior to unloading or moving the packs ensure
2. A forklift / tele-handler or alike is required to the plastic straps are in good condition
off-load the blocks 6. We would advise when placing the blocks on
3. Ensure the ground where Isotex Pack’s are the ground to separate the block types for ease
placed is level and firm, and not un-even of build, via the different coloured banding
highlighting different block types
CORRECT POSITION FOR FORKLIFT UNLOADING
PACK OF “HDIII WITH INSULATION” BLOCKS PACK OF “HB/HD WITHOUT INSULATION” BLOCKS
[ pag. 2 ]
CORRECT TRANSFER
OF PACKS FROM THE DELIVERY
VEHICLE TO THE GROUND
[ pag. 3 ]
STANDARD BLOCKS (STD)
Block HB 20 Block HB 25/16 Block HB 30/19
Block HB 44/15 - 2 Block HDIII 30/10 graphite Block HDIII 33/13 graphite
NEW
Block HDIII 38/14 cork Block HDIII 38/17 graphite Block HDIII 44/23 graphite
[ pag. 4 ]
SPECIAL BLOCKS
PASS block of 30 - 33 - 38 - 44 cm Shoulder block of 38 - 44 cm Universal block (UNI)
of 38-44 cm for external corners
Universal block (UNI) of 30-33 cm Block for internal corners Block with angle at will
for external corners and shoulders of 30-33-38-44 cm of 25-30-33-38-44 cm
X
z
Block and beam-hollowcore plank block Wall pillar block of Half block shoulder of 44 cm
x = as required 33 cm section CLS 25x38 cm
y = as required *38 cm section CLS 30x38 cm
z=x+y *44 cm section CLS 33x39 cm
*Possibility of inserting 5 cm insulation
**Possibility of inserting 8 cm insulation
[ pag. 5 ]
BLOCK DIMENSIONS
AND TOLERANCES
Length (b) and width (d) ± 5mm Holes for concrete + 5 mm/ -2 mm
Height (G) ± 2 mm Horizontal webbs (e-f) + 10 mm/ -3 mm
CUTTING OF BLOCKS
The blocks are easily cut using the following devi- a. Hacksaw;
ces which will attach as utensils to the Widia tool: b. Band saw;
c. Electric chain saw;
d. Other appropriate equipment;
e. Circolar saw;
f. Aligator saw.
[ pag. 6 ]
METHOD FOR
REQUESTING MATERIAL
- Applications for material must be forwarded by fax or e-mail at least
21 days before blocks are required onsite.
- Un an articulated lorry carries 52 packs
- A lorry carries 24 packs
BLOCKS WITHIN A PACK
QUANTITY (in m²) OF BLOCKS WITHIN A PACK:
- 1 pack of 20 cm blocks measures 6 m²
- 1 pack of 25 cm blocks measures 5 m²
- 1 pack of 30 cm blocks measures 4 m²
- 1 pack of 33 cm blocks measures 4 m²
- 1 pack of 38 cm blocks measures 3 m²
- 1 pack of 44 cm blocks measures 3 m²
BLOCK PALLETS
PACKS OF BLOCKS ARE SUPPORTED ON:
- PASS blocks (length 45-42-37-31 cm) = green supports
- SPALLA blocks (for doors and windows) = blue supports
- Corner blocks (for corners) = orange support
- STD (standar) blocks - black supports
- STD (standar) blocks of 33 cm = white or white/black supports
[ pag. 7 ]
KEY CRITICAL: INSTALLATION OF
1ST COURSE TO ISOTEX BLOCKS
Isotex unless retaining ground eg: in a basement This is achieved via placing two strips of mor-
scenario, would not require steel reinforcement tar (not a full bed) below the 1st course of Isotex
tying the concrete core to the strip/raft founda- blocks, typically 10/25mm is acceptable. Keeping
tion, unless designed in this way by a structural the 1st course of Isotex blocks in line/level – allow-
engineer. ing these to set for 24 hours before placing subse-
quent courses of Isotex blocks above.
Laying of the 1st course: Isotex blocks is ‘Key Criti-
cal’ to be line and levelled. This allows for 2nd, 3rd,
4th, courses to be ‘dry stacked’ eg NO mortar bed
required thereafter the very 1st course of Isotex.
RAFT FOUNDATION
STRIP FOUNDATION
[ pag. 8 ]CORRECT LAYING OF
SUBSEQUENT COURSES
It is very important to stagger subsequent courses design measurements, is done at the centre of the
by half a block brick bond, using the special pieces wall. The cut is kept in the same position over sub-
in order to obtain the maximum volume to concrete sequent courses to avoid staggering of the pillars
within the forms, as is necessary to achieve the within the blocks, with the consequent reduction
wall’s load bearing capacity. of load bearing and the difficulty of filling the forms
with concrete.
The blocks are always laid with the lunettes facing
upwards, for connection of the reinforcement and The reinforcement steel bars need to be calculat-
the concrete. The parts with insulation towards the ed by the structural engineer.
outside (see the illustration on page 8) and any nec-
essary cut to the block for building the wall to the
CORRECT BORDER DOOR
CORRECT BORDER WINDOW
[ pag. 9 ]PROCEDURE FOR POURING THE CONCRETE Having reached a height of 6 courses, equivalent concrete must have a class of consistency (fluidity) to 1.5 m, complete refilling of the walls with con- of not less than S4 with a class of resistance taken crete is carried out, possibly by bucket or concrete from the calculated requirements and the granu- pump, taking care not to apply excessive pressure lometry of the aggregates (
STEEL REINFORCEMENT
LOCATIONS IN ISOTEX
Location of the individual horizontal bars:
Rest the individual horizontal bars in the webbs
with spacers at every course of blocks. Overlapping
must be 50% greater than that required by current
applicable technical Standards.
Location of the vertical bars:
Position the vertical bar into the central position of
the pillar, aligned with the vertical mark inscribed
on the polystyrene, which operation is carried out
at the same time as pouring the concrete.
Location of the horizontal bars:
In the event that double horizontal bars should be
required, locate the same in the webbs with distan-
cers, fixed to the blocks with screws.
[ pag. 11 ]CORNER DETAIL
HDIII 30/10
In corners with blocks of 30 cm thickness, the the direction of the 30 cm thickness of the cor-
45 cm PASSES are used, which are positioned on nerblock). Before positioning the corner blocks,
the side of the 30 cm corner to carry the 25 cm an aperture must be created in the internal part
module (30+45=75 cm). Subsequently, on both of the block to allow for connection of the hori-
ends of the wall, 50 cm long blocks are laid. zontal reinforcement and the concrete, to the
size of the lunettes of normal blocks.
The corner is positioned in the subsequent
course in order to cross and tie the corner in well, The packs of 45 cm PASS blocks have green
repeating the operation as above (45 cm block in supports.
The reinforcement steel bars
need to be calculated by the
structural engineer.
STD = standard block
C = Corner block
[ pag. 12 ]CORNER DETAIL
HDIII 33/13
In corners with blocks of 33 cm thickness, the 42 the direction of the 33 cm thickness of the corner
cm PASSES are used, which are positioned on the block). Before positioning the corner blocks, an
side of the 33 cm corner to carry the 25 cm module aperture (similar to the size of the lunettes of nor-
(33+42=75 cm). Subsequently, on both directions mal blocks) must be created in the internal part of
of the wall, 50 cm long STD blocks are laid. the block to allow for connection of the horizon-
tal reinforcement and the concrete.
The corner is positioned in the subsequent
The packs of 42 cm PASS blocks have green
course in order to cross and tie the corner in well,
supports.
repeating the operation as above (42 cm block in
The reinforcement steel bars need to be calculated by the structural engineer.
[ pag. 13 ]CORNER DETAIL
HDIII 38/17
In corners with blocks of 38 cm thickness, the 37 be turned over and laid in the opposite sense to the
cm PASSES are used, which are positioned on the course below it. In making corners with 25 cm thick
side of the 38 cm corner to carry the 25 cm module blocks, it is not necessary to use PASS blocks be-
(38+37=75 cm). Subsequently, on both directions of cause the module remains at 25 cm (25+50=75 cm).
the wall, 50 cm long STD blocks are laid.
The packs of 37 cm PASS blocks have green sup-
For the subsequent course, the corner block must ports.
The reinforcement steel bars
need to be calculated by the
structural engineer.
STD = standard block
C = Corner block
[ pag. 14 ]CORNER DETAIL
HDIII 44/23
In corners with blocks of 44 cm thickness, the For the subsequent course, the corner block
31 cm PASSES are used, which are positioned on must be turned over and laid in the opposite
the side of the 44 cm corner to carry the 25 cm sense to the course below it.
module. On the side of the 50 cm corner, after
The packs of 31 cm PASS blocks have green
having placed the 31 cm PASS on the 44 side, con-
supports.
tinue with a 50 cm long block.
The reinforcement steel bars
need to be calculated by the
structural engineer.
STD = standard block
C = Corner block
[ pag. 15 ]3-4 WAY
JUNCTION
For making three or four way junctions, proceed To be avoided on the other hand, as is other-
with laying the internal wall, arriving at abutting wise usual with traditional blocks, are the “ties”
the external wall, creating an aperture at the because, with the ISOTEX system, connection
point of contact with that external wall to permit between the three or four way junctions is made
the lodging and connection of the horizontal rein- with the steel reinforcement bar and the con-
forcement and the concrete. crete.
[ pag. 16 ]DOOR AND
WINDOW LINTELS
The door and window frames are formed by 38 cm) or the laying of 44 cm blocks. In this man-
alternating SHOULDER blocks while laying the ner, thermal bridges are eliminated. The lintel re-
blocks. Door and window lintels are made by cut- inforcement must by indicated by the structure
ting the SHOULDER blocks at the yard (of 30 and designer.
Example HDIII 44/23 with graphite
1 2 3
[ pag. 17 ]BLOCK CUTTING
FOR REBATES
When rebates are required, these can be cut order to avoid possible detachments while cut-
into the SHOULDER blocks after pouring the ting. Proceed in the same manner for rebates in
concrete. Plastic anchors must nevertheless must the lintels above doors and windows.
be inserted (as in the diagram) before the pour in
[ pag. 18 ]HOW TO MAKE CHANNELS
IN ISOTEX WALLS
In order to make channels for plant, it is advised width and depth in order to obtain the required
that, over the 4-5 cm of wood chip cement, a wood dimensions rapidly and precisely.
router tool is used which allows for adjusting the
[ pag. 19 ]ISOTEX
CERTIFICATES
Partial extract of certification in the verbatim version on the site www.blocchiisotex.com
Certificato di conformità
del controllo della produzione in fabbrica
0099/CPR/A87/0390
In conformità al Regolamento sui Prodotti da Costruzione (UE) N. 305/2011 del Parlamento europeo e
del Consiglio, del 9 marzo 2011, l'organismo notificato AENOR (n. 0099) ha rilasciato questo certificato per
ISOTEX S.R.L.
con Sede Legale presso Via D'Este, 5/7-5/8, 42028 - POVIGLIO, ((RE) - Italia)
Prodotto da costruzione Travetti per solai a travetti e blocchi
Norma armonizzata EN 15037-1:2008
Riferimenti In Allegato al Certificato
Stabilimento di produzione Via D'Este, 5/7-5/8. 42028 - POVIGLIO ((RE) - Italia)
Sistema di certificazione Questo certificato attesta che sono state applicate tutte le disposizioni di
cui al sistema 2+ relative alla valutazione e verifica della costanza della
prestazione descritto nell’allegato ZA della norma armonizzata di cui
sopra, e che il controllo di produzione in fabbrica soddisfa tutti i requisiti
prescritti nella norma armonizzata.
Questo certificato rimane valido fino alla sua data di scadenza, a
condizione che non siano cambiati i metodi di prova e requisiti per il
controllo della produzione in fabbrica inclusi nella norma armonizzata per
valutare la prestazione delle caratteristiche dichiarate, e che le condizioni
di produzione non siano cambiate in modo significativo.
Data prima emissione: 2010-12-14
Data ultima emissione: 2018-12-14
Data di scadenza: 2019-12-14
Rafael GARCÍA MEIRO
Direttore Generale
AENOR INTERNACIONAL S.A.U.
Génova, 6. 28004 Madrid. España Organismo Notificato accreditato da ENAC con Accreditamento 01/C-PR356
Tel. 91 432 60 00.- www.aenor.com
AENOR Italia Corso Trapani, 16. 10139 Torino - www.aenoritalia.com
Example of DOP (Protected Designa- Obligatory flooring EC marque dated REI120 - CSTB classification
tion of Origin) 01.01.2011
MANAGEMENT SYSTEM
CERTIFICATE
Certificato no./Certificate No.: Data prima emissione/Initial date: Validità:/Valid:
CERT-04707-99-AQ-BOL-SINCERT 29 luglio 1999 13 luglio 2017 - 13 luglio 2020
Si certifica che il sistema di gestione di/This is to certify that the management system of
ISOTEX S.r.l. - Sede Lega e Operativa
Via D'Este 5/7 - 5/8 - 42028 Poviglio (RE) - Italy ENVIRONMENTAL PRODUCT DECLARATION (EPD) FOR
WOOD CEMENT BLOCKS
È conforme ai requisiti della norma per il Sistema di Gestione Qualità/
has been found to conform to the Quality Management System standard:
ISO 9001:2015
Questa certificazione è valida This certificate is valid
per il seguente campo applicativo: for the following scope:
Produzione e commercializzazione di: Manufacture and trade of wood-chip concrete
blocchi cassero, solai, elementi da shuttering blocks, floor slabs, construction
costruzione e manufatti in genere in legno- elements and artifacts in general (EA: 16, 29)
cemento (EA: 16, 29)
Company: ISOTEX Srl
Via D’Este, 5/7-5/842028 Poviglio (RE)
www.blocchiisotex.com
Programme operator: The International EPD ® System –
c/o EPD International AB
Valhallavägen 81 SE-114 27 Stockholm Sweden
www.environdec.com
PCR: 2012:01 Construction products and construction services version 2.3
Geographical scope: Europe
Luogo e Data/Place and date: Per l'Organismo di Certificazione/ EPD registration number: S-P-01472
Vimercate (MB), 31 luglio 2018 For the Certification Body
DNV GL – Business Assurance
ECO EPD reference number: 00000795
Via Energy Park, 14 - 20871 Vimercate Date of publication: 2018-12-18
(MB) - Italy
Date of validity: 2023-12-18
Zeno Beltrami
Management Representative
La validità del presente Certificato è subordinata al rispetto delle condizioni contenute nel Contratto di Certificazione/
Lack of fulfilment of conditions as set out in the Certification Agreement may render this Certificate invalid.
DNV GL Business Assurance Italia S.r.l., Via Energy Park, 14 - 20871 Vimercate (MB) - Italy. TEL:039 68 99 905. www.dnvgl.it
Certification of quality ISO 9001:2008 Sustainable housing certification EPD - Environmental Product
Declaration
[ pag. 20 ]This Document named “Operational Assembly Manual” is the exclusive property of ISOTEX Srl.
ISOTEX makes the operational assembly manual available to its clients as a useful and important
compendium for the correct laying and use of Blocks and Flooring panels, made up of the ISOTEX®
anti-seismic construction method.
The operational assembly manual contains and illustrates the particulars of applying ISOTEX®
products with related recommendations. The document has been produced by ISOTEX Srl, and
consequently must only and exclusively be used in relation to the ISOTEX® construction method.
The operational assembly manual may not be reproduced and used, as a whole or in part, without
the express previous approval of ISOTEX Srl.
All abuses and/or misappropriation of the operational assembly manual (including attempts to as-
sociate it to a method and/or a product even if only similar to ISOTEX®) will be prosecuted to the
full extent of the law, notwithstanding ISOTEX® declining all responsibilities regarding any dam-
ages or malfunctions deriving from the aforementioned abuses and/or misappropriation.
© 2011 ISOTEX Srl - all rights reserved - reproduction prohibited
ISOTEX® is a registered trade mark
[ pag. 21 ]Maximum seismic safety & living comfort, always.
ISOTEX Srl - Via D’Este, 5/7-5/8 - 42028 Poviglio (RE) - Italy
Tel.: +39 0522 9632 - Fax: +39 0522 965500
info@blocchiisotex.it - www.blocchiisotex.com
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