STEPOC

T H E R E A L A LT E R N AT I V E TO SHUTTERED CONCRETE

www.andertonconcrete.co.uk

STEPOC
THE FASTER, MORE ECONOMICAL WAY TO BUILD WALLS WITH EXCEPTIONAL STRENGTH STEPOC SYSTEM
Stepoc is a system of highly-engineered and dimensionally co-ordinated building modules which are designed to readily accept horizontal reinforcement for use where structural performance is the prime consideration.

Multi-Storey Development, Kenyon Street, Birmingham

Stepocs unique design enables horizontal reinforcement to be placed adjacent to either block face, or both if required, to ensure that maximum strength is achieved just where its needed. Stepoc is bonded with concrete, which is poured down through the inter connected cavities in the blocks. The blocks unique design creates a cascade or waterfall effect which ensures a smooth filling of the poured concrete, forcing out air and eliminating segregation, to create walls which have immense compressive and lateral strength. Stepoc enables the fast construction of single skin retaining walls up to 3.8 metres high, subject to a design carried out by a structural engineer. At less than 20kg all units are well within the HSE guidelines for a single man repetitive lift. Stepoc is proven in use on applications the length and breadth of the UK.

Stepoc combines the ease of blockwork construction with the versatility of in-situ concrete, and yet is faster to apply than both, making it an ideal component for:
Retaining walls Sheer wall Laterally-loaded panels Blast panels Bund walls Basement walls Swimming pools and any applications that require higher compressive or lateral loads than those achievable with standard masonry. The Stepoc system is available in three widths of 200mm, 256mm and 325mm and each comprises a range of units allowing the construction of terminal ends and corners while still achieving the correct bond. Built dry, with no mortar joint, and requiring no special on-site skills or techniques, the blocks are laid to a running bond, using a combination of half or third and full lengths. Specific data sheets are available to illustrate the construction of ends, corners and other required details.
Brick Clad STEPOC for Wilmott Dixon Homes

WORKING WITH STEPOC

Travel Lodge, London Euston

STEPOC - THE REAL ALTERNATIVE TO SHUTTERED CONCRETE

SETTING OUT
Where the length of a wall is not to a Stepoc module, Full Length Blocks will not be able to be used for the entire length of the wall. Setting Out should therefore commence from ends of walls and/or movement joints, working towards central positions where some cutting of the units may be necessary. (A butt joint at this position is acceptable.) At openings, Full, Third or Half Length Plain Ends may be used and cut to suit. As an alternative, temporary formwork may be used. Check vertical faces for plumb on completion of alternate courses. It is recommended that the first course be laid in mortar to ensure the wall is level before proceeding with the remainder of the courses.

POUR HEIGHTS
Movement joints are recommended at centres of 10m subject to engineers approval. Where a continuous run of masonry includes a corner the measurement between movement joints should be taken around the corner and not measured from the corners. Data Sheets are available on request or alternatively please contact the Technical Department. There is a maximum height for each pour so that stability is not lost in the dry laid blocks as they are filled. Lower heights for each pour can also be used. The maximum heights are: 200 Stepoc - 8 Courses 256 Stepoc - 10 Courses 325 Stepoc - 10 Courses = 1.9m = 2.25m = 2.25m

If multiple concrete pours are required, the concrete of the previous pour should finish 50-75mm from the top of the course of Stepoc, with the vertical bars projecting the equivalent of a splice, length taken from the engineers schedule. This is to ensure a proper key between consecutive pours.

Kings School, Rochester

CONCRETE PRODUCTS LTD

WORKING WITH STEPOC

CONCRETE MIX
The concrete should possess the characteristic strength specified by the structural engineer who has carried out the design of the wall, but not less than 35N/mm2, and in accordance with BS EN 206 Part 1:2000.
Block type Concrete Infill

200mm 256mm 325mm

0.12m3 per m2 0.15m3 per m2 0.19m3 per m2

The concrete should be designed to be suitable for the specific means of delivery, possessing a slump of no less than 150mm. The maximum aggregate size should not exceed 10mm and the mix should contain no less than 300kg of OPC per cubic metre of fresh concrete. Filling is best accomplished by a concrete pump or skip with a 75mm nozzle, and the design of the concrete should take this into account. Mechanical vibration must not be used. The use of water reducing agents is acceptable to lower cement content in the mix design.

REINFORCEMENT DETAILING & DESIGN

For standard cantilever retaining walls only the general principle within BS 5628 Part 2 allows the height of the wall to be based on 18 times the effective depth. The charts below show the position of the vertical steel on the retained face for each width of Stepoc. 200mm Stepoc 256mm Stepoc
v v

325mm Stepoc
v

151.5 100

162.5 96.5

225

200 256
d = 100 + (
h/2) + ( v/2)

d 325
v/2)

225

228

d = 151.5 + (

h/2) + (

d = 228 + (

h/2) + (

v/2)

Vertical bar spacings for 200, 256 and 325 STEPOC are based on multiples of 200, 133 and 162.5mm respectively. Horizontal bar spacings are based on multiples of 225mm for all three units.

RADIUS WALLS
The flexibility of STEPOC allows radius walls to be constructed using either standard or third/ half length units. Data Sheets are available on request or alternatively contact the Technical Department.

Monk Garron Wine Cellar utilising 256mm STEPOC

STRUCTURAL STRENGTH
These charts are intended to display the range of strengths attainable when Stepoc walls are designed in accordance with BS 5628 Code of Practice for Use of Masonry The design loads referred to are at ultimate limit state, i.e. factored. For unreinforced Stepoc, a partial safety factor of 3.5 for material strength should be used. For reinforced Stepoc, the partial factor of safety should be taken as 2.3 and 1.15 for steel in accordance with part 2 of the masonry code and Andertons quality control procedures.
200mm Stepoc
120

256mm Stepoc
120

100

100

80 80
ULS Bending moment (kNm) ULS Bending moment (kNm)

60

60

40

40 20

20

20

20

100

200

300

400

500

600

700

800

900

1000

1100

0 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200
Area of bending steel (sq.mm/m)

Area of bending steel (sq.mm/m)

Area of reinforcement (mm/m2) for various bar diameters and centres. BAR DIAMETER (mm) BAR CENTRES

Area of reinforcement (mm/m2) for various bar diameters and centres. BAR DIAMETER (mm) BAR CENTRES

10 200 393

12 566

16 1006

20 1571

25 2455

10 133 266 591 295

12 851 425

16 1512 756

20 2363 1181

325mm Stepoc
250

CHARACTERISTIC COMPRESSIVE STRENGTH f(k)

200

200 256

14N/mm2 18N/mm2 18N/mm2

ULS Bending moment (kNm)

150

325

100

50

These calculations demonstrate the ULS bending capacity of the section only. Shear and serviceability limit state checks will be required for a complete structural design of the section.These calculations are for indication purposes only and should not be used as part of the final structural design. A full design check should be undertaken by the designer in accordance with BS 5628: part 2: 2005 Structural use of Reinforced and Pre-stressed Masonry, accounting for ultimate and serviceability limit states as required.
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000
Area of bending steel (sq.mm/m)

The charts below each graph indicate possible bar centres for each block. Reinforcement may not be required at every centre spacing but will be specified by the Structural Engineer.

Area of reinforcement (mm/m2) for various bar diameters and centres. BAR DIAMETER (mm) BAR CENTRES

10 162 325 485 242

12 699 348

16 1242 619

20 1940 969

25 3031 1511
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S P E C I F I C AT I O N
TYPE 200

STEPOC

COMPOSITION AND MANUFACTURE

Stepoc blocks are manufactured to BS EN 15435 2008 using aggregates which satisfy BS EN 12620 and cement to BS EN 197-1.

400

200 35

130

200

DIMENSIONS
Stepoc blocks are available in three standard sizes:

72.5 35

165

35 82.5

35

157.5

400 x 200 x 225mm standard

200 x 200 x 225mm 1/2 length

400 x 200 x 225mm 400 x 256 x 225mm 325 x 325 x 225mm

TYPE 256

400

133

TYPICAL UNIT WEIGHTS

256

(Applies to standard units)

184

256mm = 19.8kg 325mm = 19.8kg

40

227

40

93

40

93

400 x 256 x 225mm standard

133 x 256 x 225 1/3 length

MANUFACTURING TOLERANCES
TYPE 325 Height: +2, -2 Length: +2, -2 Width: +2, -2 Fire Resistance Minimum fire resistance: 2 hours. For specific applications refer to BS 8110 Part 1 1997. Resistance to Frost Damage The Stepoc system is resistant to the freeze-thaw conditions that are likely to occur below a damp proof course. Resistance to Sulphate Attack Stepoc has adequate resistance to Class 3 sulphate ground conditions.
325 162

35

325

290

35

255

10

35

127

36

117

10

325 x 325 x 225mm standard

162 x 325 x 225mm 1/2 length

DELIVERY AND OFFLOADING

Stepoc blocks are supplied on pallets for offloading by forklift truck or crane. Blocks should be stored on dry, firm, level ground with protection from rain and snow. If blocks are accidentally wetted, provision should be made for free circulation of air round the stack so that the units may dry out prior to being used. Blocks should not be stacked directly on sulphatebearing ground, clinker or ashes, unless precautions are taken to prevent chemicals being drawn into them by rising moisture, nor should they be stacked on newly-cast slabs until the concrete is fully matured. Mechanical handling should not be used after the blocks have been offloaded from the wooden pallet.

Designed & Produced by Wodehouse Direct 0161 875 2486

A:
CONCRETE PRODUCTS LTD

Units 1 & 2 Cosgrove Business Park Soot Hill, Anderton Northwich, Cheshire CW9 6AA

T: F: E: W:

01606 535300 01606 75905 civils@andertonconcrete.co.uk www.andertonconcrete.co.uk

35 8

255

35

36

200mm = 17.5kg

10

220

184

36

35

130