ACOTEC PRECAST WALL PANELS

Used Commercially Worldwide ICC-ACOTEC

Europe, Middle-East & Asia Precast Wall Panels
Asia Europe & Middle-East
Sri Lanka Germany
Japan United Kingdom
Singapore Spain
South Korea Ireland
China Portugal
India Saudi Arabia
Indonesia
Philippines
Taiwan
Thailand

International Construction Consortium Pvt Ltd

Address #57, S. De. S. Jayasinghe Mawatha, Kohuwala, Nugegoda, Sri Lanka

Technical & Installation Manual

Telephone +94 114 645 454 / Fax +94 114 645 422
Website www.icc-construct.com
Contents

1. Product description 1
2. Raw materials for manufacturing of ICC- ACOTEC wall panels 1
3. Production process 2
4. Panel dimensions 3
5. Physical properties of the ICC-ACOTEC wall panel 4
6. ICC-ACOTEC wall panel application 5
7. Accessories and material for erection 6
8. Typical ICC – ACOTEC wall Panel layout and connection details 7
9. Required site conditions before mobilization/ installation 10
10. Installation guideline of ICC-ACOTEC wall panels 11
11. Special details 21

List of Tables

Table 1: Material specification 1

Table 2: ICC-ACOTEC wall panel dimensions with maximum tolerances 3
Table 3: ICC-ACOTEC wall panel properties 4
Table 4: List of accessories 6
Table 5: Tools required for the erection process 11

List of Figures

Figure 1 : Production process 2

Figure 2 : ICC-ACOTEC panel cross sections 3
Figure 3 : Types of internal partitioning 5
Figure 4 : ICC-ACOTEC Panel layout 7
Figure 5 : Top connection 7
Figure 6 : Top connection (front elevation) 8
Figure 7 : Bottom connection (front elevation) 8
Figure 8 : Panel to panel connection 9
Figure 9 : Panel to column connection 9
Figure 10 : ICC-ACOTEC 90o connection 21
Figure 11 : ICC-ACOTEC ‘T’ connection 21
Figure 12 : Door connection 22
Figure 13 : Lintel connection 22
Figure 14 : Electrical & plumbing connection 23
Figure 15 : Horizontal cross section 24
Figure 16 : Vertical cross section 24

Revision 02 : 15th march 2018

 1. Product description
The ICC-ACOTEC non- load bearing precast wall panels are manufactured with Grade 30
 concrete through an extrusion process. The sides of the panels are finished with tongue and
groove to facilitate the assembly of panels. the panels are manufactured in three
thicknesses 75mm,100mm and 140mm.Width of the panel is 600 mm.


2.Raw materials for manufacturing of ICC- ACOTEC wall panels

 Raw materials for the manufacturing process of ICC-ACOTEC wall panels are summarized in
the table below. Each material shall comply with their respective standards.

 Table 1: Material specifications

Material Standard/ specification

Ordinary Portland Cement SLS 107:2015
BS EN 197 – 1:2011



Figure15 : Horizontal cross section

Fine aggregates BS 410 : 1986

 Coarse aggregates BS 410 : 1986

Admixtures EN 934-2




Water BS 3148 : 1980
Figure16 : Vertical cross section

Page 24 Page 1
 • Filling of concrete shall be done prior to installation
• Installation shall be done after 24 hrs. of filling the chip concrete.
• Cut and remove a portion of minimum width 300 mm either side of wall panel for the
3. Production process door frame installation.
The following production process is maintained in the manufacture ICC-ACOTEC wall panels • The cutting has to be done from the highest point of the door frame to the soffit.
using the specified materials in table 1. • Insert the cut portion of a wall panel in the horizontal direction as shown.
• Fill the gap with construction grout
• The lintel shall be fixed after 24 hrs at erection of side panel

11.4 Electrical and plumbing provisions

• Hollow cores can be used for plumbing & conduits.
• The ICC-ACOTEC panel can be cut or drilled as required
• Electrical conduits can be easily placed by cutting the wall panels using a concrete cutter
To insert the conduits depth of the cut should not exceed 50% of the panel thickness.
Mixing of Primary Secodary • Conduits can be placed in any direction.
Extruding Packing • Distribution board can also be fixed in the 100mm and 140mm thickness panels as shown below.
concrete curing curing
• MEP work should commence after 7 days of panel installation
DB Box DB Box
ICC-ACOTEC PANEL ICC-ACOTEC PANEL







Figure 1: Production process

• Mixing of concrete : Raw materials summarized in table 1

are mixed as per the approved mix design

• Extruding: The mixed concrete shall be poured into the extruder of the
ACOTEC plant where the hollow cores are formed

• Primary curing: once the panels are cast each of them

will be stacked on steel pallets covered with tarpaulin for 24 hrs. 

• Packing : After completing its primary curing stage all panels will be
uncovered and bundled 

• Secondary Curing: The bundles are then air cured for 18 days. 

Figure 14 : Electrical & plumbing connection

Page 2 Page 23
 4. Panel dimensions
11.3 Door and Window openings with lintels 
w  
 
t
 l





 





Figure 12 : Door connection
Groove Wt

 


 
50mm 50mm Tongue
St


Figure 2: ICC-ACOTEC panel cross sections
250mm 250mm
Table 2: ICC-ACOTEC wall panel dimension with maximum tolerances
300mm 300mm

t=Thickness (mm) l=Length (mm) w=Width (mm)

75±3 2700 600±5

100±3 3300 600±5


140±3 3300 600±5

Panel Thickness (mm) St=Shell Thickness(mm) Wt=Web Thickness

75 Minimum 12 Minimum 20
100 Minimum 15 Minimum 20
 140 Minimum 20 Minimum 20
Figure 13 : Lintel connection change diagram with R/F bars and insert a new one with concrete gap. ICC-ACOTEC manufacturing process has the facility of producing panels
Or otherwise we can keep the RF one as an option. of varying Lenghts according to the customer requirements within
the range of 2100mm to 3300mm
Note: The hollow cores of side wall panels and lintel panel adjacent to the door frame
should be filled with chip concrete.
Page 22 Page 3
 11. Special Details
5. Physical properties of the ICC-ACOTEC wall panel 11.1 Installing two panels at an angle

90o angle X
X T- connection
ICC Acotec Panel
Table 3: ICC-ACOTEC wall panel properties

ICC Acotec Panel

ICC-ACOTEC wall panel thickness (mm)
Parameter 75 100 140 Crack control tape

Weight 110 kg/m2 124 kg/m2 164 kg/m2 Insitu Concrete

Crack control tape
Bulk density 1200 kg/m 3
1200 kg/m 3
1150 kg/m 3 Insitu Concrete Crack control tape
X X
Concrete cube 30 N/mm 2
30 N/mm 2
30 N/mm2 X X
strength (28 days)

ICC Acotec Panel ICC Acotec Panel

Panel Strength >5.0 N/mm2 >5.0 N/mm2 >5.0 N/mm2 X = 100mm or 140mm X = 100mm or 140mm

Fire resistance * 120 mins >130 mins >130 mins Figure 10 : ICC-ACOTEC 90o connection Figure 11 : ICC-ACOTEC ‘T’ connection

Sound insulation * 41 dB 43dB >43 dB

11.2 Crack repairing procedure
Thermal resistance * 0.4 m2 K/W >0.4 m2 K/W >0.4 m2 K/W
• Due to various reasons, hair line cracks may appear at few locations of installed wall area at joints.
• Since cracks are hair line nature, most of the time it can be visible only after skim coat. So make sure to
keep the skim coated wall for sufficient period (at least 02 weeks) to observe the cracks.
*According to international references. • Such observe cracks should be repaired as follows.

1. Identify the crack formed area

2. Grind the area of the appeared crack to a width of 50mm at 25mm offsets both sides to a
depth of 1-1.5 mm with grinder machine.
3. Clean the respective area with brush to make sure it is free from the dust and debris.
4. Apply the crack bridging wall primer (CIC-Dulux) one layer on the same area by 50mm roller brush.
5. Rest the treated area for 24 hours to settle the crack wall bridging primer.
6. Prepare the mix of Glidden precoat (CIC-Dulux) and Crack bridging wall primer (1Kg: 35ml)
and apply on the respective area.
7. Level and smoothen the treated area.
Note : Painting to be proceeded only after rectifying the visible cracks.
Complete all the vibration induced site works before final painting.

Page 4 Page 21
 10.2.16 Applying crack control tape

Non water proofing areas

6. ICC-ACOTEC wall panel application
• Firstly identify the joints to be treated with crack control tape. • Used for internal non-load bearing wall partitions
• Grind the joint area with grinder machine to create even surface. • ICC-ACOTEC walls can be used as single walls, double walls or double wall with cavity
• Clean the respective area to make sure that it is free from the
• dust and debris.   
• Inspect carefully the fiber tape applying area to ensure
• it is free from cracks and damages.
• Apply the 1st layer of crack bridging wall primer (CIC-Dulux) on grinded
area by 50mm roller brush.
• Afterwards apply the crack control tape on center of the joint with symmetrical offsets.
• Finally apply the 2nd layer of crack bridging wall primer (CIC-Dulux) on the applied crack control tape
and ensure the quality of joint.

Water proofing areas (bath room & pantry)

• Firstly identify the joints to be treated with crack control tape.
• Grind the joint area with grinder machine to create even surface.
• Clean the respective area to make sure that it is free from the dust and debris.
  
• Inspect carefully the crack control tape applying area to ensure it is free from cracks and damages.
• Apply the 1st layer of crack bridging wall primer (CIC-Dulux) on grinded area by 50mm roller brush.
• Afterwards apply the crack control tape on center of the joint with symmetrical offsets.
  
• Finally apply the 2nd layer of crack bridging wall primer (CIC-Dulux) on the stuck crack control tape and
ensure the quality of joint.     Figure 3: Types of internal partitioning

• Additional tape should be installed with similar procedure for following areas.
• When having double walls, it is preferred to adopt a staggered pattern.
- At lintel joints - Last panel of the wall - Column, Wall joint
• For wet area erection at places such as bathrooms, water proofing application followed by wall
Note: Apply crack control tape after placing of plumbing & service lines. plastering is necessary
• All the other areas shall be finished with 3mm skim coat without any wall plaster.
10.2.17 Skim coat application

Application limitations

• The maximum length of the wall which can be erected without a cross wall or a vertical
stiffener is 6m.
• Maximum height of ICC-ACOTEC wall panel is 3.3 m.
• Maximum span of an ICC-ACOTEC lintel is 2.4m.Any span exceeding 2.4m needs structural
engineers recommendations
• Skim coat shall be applied only after site rectification are completed.

No plastering required, just a thin layer of skim coat (3-5mm)

Page 20 Page 5
 7. Accessories and material for erection
10.2.14 Placing the next ICC-ACOTEC panel
Table 4: List of accessories

Accessory Description Image

Steel U bracket The steel brackets shallbe used to
stabilize the wall panel in vertical
direction. Material : Zinc coated
mild steel [1mm thick]

Polyurethane PU foam is used to obtain flexible

Foam top joint in order to
facilitate un due movements and
settlements.

Crack control Crack control tape is used to

tape prevent crack development • Apply ICC-ACOTEC grout on tounged end of the erected panel and the grooved end of this panel.
between panels • Place the panel as already described steps.

Construction Non shrink grout for joint gap

grout filling between structural
elements and acotec panels

10.2.15 Final finishing

ICC-ACOTEC Specially formulated non shrink

grout grout to fill gaps between panels
(Flow cable 50, Cement & Clean
Water are used as raw materials)

Crack bridging Crack bridging wall primer is

wall primer used when applying the crack
(CIC-Dulux) control tape.

Glidden pre-coat Glidden pre-coat is used only in • One the Panels are joined the surplus grout is removed from the joints immediately after installation.
(CIC-Dulux) the crack repairing process if • 24 hours after installation, remove the wooden wedges & fill any gaps with relevant filling material.
required • Recommend to sand the joint with sand paper to get even surface.
• Joint treatment to prevent shrinkages between panels to be done after 2-3 weeks of installation.

Page 6 Page 19
 10.2.12 Placing of the corner panel and fixing 8. Typical ICC – ACOTEC wall Panel layout and connection details

RC Beam Steel U Bracket

Non Shrinkage PU Foam

grout

Wall Height
RC Column (2.7m, 3m, 3.3m)
• Cut the side of panel to open the first hole
• Chip the concrete column of panel- column inter face
• Drill the column at 3 location (Bottom, Middle & Top) and fill with ICC ACOTEC grout and RC Slab
insert the dowel bars (see 8.1.4)
• Once the gluing material is applied lift the Panel to the upright position using the lifting machine. Construction
• Place the panel next to the RC column. grout
• Using the installation steel bar adjust the Panel position until it makes contact with RC column•
• Make sure the bottom & the top of the Panel are in contact with the guide boards. Width of the panel 600mm
1: 5 Cement Sand Mortar
• lift the panel using the installation tool until the top joint gap reduces to 10-15mm. Figure 4 : ICC Acotec Panel layout
• Once the panel is lifted nail the U bracket to the top beam.
• By using wooden wedges at the top and bottom, fix the panel & release the installation steel bar 8.1 Connection Details
• Minimum allowable width of the cut panel is 200mm 8.1.1 Top Connection-(At beam or slab soffit)

10.2.13 Finishing of joints





• Fill joint gap at the bottom with 1:5 cement sand mortar.
• Fill the joint gap at the top with PU foam.
• Fill the joint gap at the column face with construction grout.

• Keep the installed panel for 7 days undistured for joint hardening.

Figure 5 : Top connection

Page 18 Page 7
 
10.2.9 Applying ICC-ACOTEC grout








Figure 6 : Top Connection (front elevation)
Note:
• Steel U bracket will be fixed at top of the panel. Sequence of bracketed panels • Bring the ICC-ACOTEC panel as close as possible to the bottom guide board using
are 1st,03rd, 05th, 7th etc. the lifting machine.
• There are three different sizes of U brackets for three types of panels • Apply construction grout at the surface of RC column and top of slab
• Allowable thickness of the jont is 10-15mm • Apply ICC-ACOTEC grout on the side of the panel.

8.1.2 Bottom Connection-(On slab top)

10.2.10 Fixing of the steel U bracket









• Insert the U bracket through the last hollowcore and make sure it is firmly inserted
Figure 7 : Bottom Connection (front elevation)

• Steel U bracket will be fixed at bottom of the panel. Sequence of bracketed panels
are 1st,03rd, 05th, 7th etc.h
• There are three different sizes of U brackets for three types of panels
• Allowable thickness of the joint is 15-20mm

Page 8 Page 17
 10.2.7 Fixing guide boards before installation
8.1.3 Panel To Panel Connection

 



• Fix the guide boards to the ceiling and the floor, along the guide lines using props.


10.2.8 Mixing the ICC-ACOTEC grout
Figure 8 : Panel to panel connection
Raw materials
• Cement – 01 Kg Note: The tongue and groove creates a mechanical connection between the erected panels &
• Clean Water – 500ml maximum allowable width of the joint is 5mm.
• Flow cable 50 – 05 g

8.1.4 Panel To Column Connection

Procedure
• Select a clean and suitable bucket for preparing the grout.  
• Firstly pour clean water (only 60%) into the selected bucket 
• Secondly add 1Kg of cement (portion by portion in 3 steps) in to the mixing bucket and use
• the grout mixer to mix it firmly (2-3min.) until all cement powder has been dissolved.
• Afterwards pour the flowcable 50 (5g) to the mixture & mix using the grout mixer firmly
• (2-3min.) 
• Next get the mixture checked by the QA officer to ensure the quality.

• Once approved by the QA officer use it at the panel joint within 30 mins. 
• Finally maintain the workability by adding the rest 40% of water.
Figure 9 : Panel to column connection
Ref: Technical data sheet for Flowcable 50. Note: Maximum allowable width of the joint is 10mm.

Safety Fact: Use personal protective equipments(PPE) during mixing

process (eg: hand gloves & eye protectors)
Page 16 Page 9
 Option - 03

9. Required site conditions before mobilization/installation

• One panel can be easily moved using an ACOTEC trolley.
• Always move the panel in vertical position.
• Maintain balance to avoid any damage to the front & the rear corners.
• Option 3 is the most convenient method since it’s faster and causes less handling damage
• The area should be clean and free of debris
• Rectification of structural and architectural misalignments of elements Safety Fact: Take the necessary safety precautions during & after unstrapping the stacked panels
• Conforming the position of electrical conduits which may affect the panel erection
• The structural floor shall be levelled
• In wet areas ledges are to be placed for the required height
10.2.6 Marking guide lines before installation

• Identify the location where the panels are to be installed.

• Mark the guide lines using carbon threads in specified locations.

Page 10 Page 15
 10.2.5 Moving an individual panel within the floor 10. Installation Guide line of ICC-ACOTEC wall panels
Option - 01
10.1 Required tools for installation
Table 5: Tools required for the erection process

Tools Image Tools Image

Nail gun Mixing drill

PU foam gun Lever

• Individual ICC-ACOTEC Panels can also be moved manually.

• Insert a short steel tube / bar (500mm long) into the 2nd hollowcore to act as a handle. Concrete cutter Buckets
• The steel tube / bar is not continuous therefore should be inserted from both ends.
• Panels should always be moved in their vertical position as shown in the above picture

PU foam Scraper
Option - 02

Trolley Masonry trowel

Drilling machine Lifting bar

Lifting belts Spirit level

• Panels can be easily moved using the lifting machine.

Angle grinder Timber wedge
• Transfer one panel on to the lifting machine from the stack(manually using handle as above).
• Maintain the position as shown in the figure.

Page 14 Page 11
 10.2 Installation process 10.2.3 Unloading and stacking at work site

10.2.1 Loading to the vehicle

• Use a forklift / crane to unload

• The unloading platform should be leveled
• Check if the panels are perfectly strapped together. • Make sure to unload on top of square wooden logs
• Make sure the uniform timber beams are underneath the panel stacks. • Panels cannot be exposed to rain (keep in a shelter / cover with tarpaulin)
• Always stack the panels in the vertical position. • Do not load more than two stacks of panels on top of each other.
• Use forklift or crane to load panels on to the vehicle. • keep a gap between each Panel stack for air circulation & to gain easy access for lifting
• Do not load more than two stacks of panels on top of each other.
• Timber supports must be vertically in line. Safety Fact: Be aware of any contacts of the edges of the stacked Panels
• Panels have to be properly fastened before transportation. when loading & unloading
• Make sure to put uniform timber beams between the panel stacks to avoid colliding
during transportation.
10.2.4 Lifting panels to specified floor
• Make sure the bed of the truck has a flat surface.
10.2.2 Transportation

• Make sure to wrap the belt around the panel stack firmly at strap locations.
• Use a forklift or crane.
• Maintain the vertical stacked position of the panels
• Stack the panels in the pattern shown above
• Unload the panel stacks on top of uniform timber beams
• Remember to tighten the loaded panels with the loading ropes to avoid any panel movements.
• Place the panel stack on a rigid bottom frome when lifting
• Cover the panels with tarpaulins. (Do not expose to rain)
Safety Fact 1 : Please use caution during crane movement to avoid any injury
Safety Fact: Prevent ICC-ACOTEC panels tipping over to provide Safety Fact 2 : Do not lift panels without the rigid bottom frame
maximum safety during transportation

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