Dubai Municipality Standard ‫المواصفـات القيـاسية لبلـدية دبـي‬

DMS 1: Part 5: 2011

Specification for precast concrete blocks

Part 5: Concrete-Polystyrene Sandwich Masonry
blocks

Issue Date Revision Revision Description

Issue for use

14/08/2011 01
This revision superseded DMS 1: Part 5 previous editions which are withdrawn

This document is the property of Dubai Municipality and its issue is controlled. No part of this document should be
reproduced or copied without the prior written permission of Dubai Central Laboratory Department.
 Dubai Municipality Standard ‫المواصفـات القيـاسية لبلـدية دبـي‬
DMS 1: Part 5: 2011

Title of DMS:
Specification for precast concrete blocks - Part 5: Concrete-polystyrene sandwich masonry blocks

Application Number: S-350-11-ICS

Application Date: 27-06-2011

This Dubai Municipality Standard is:

Reviewed by: The Standardization Committee:

Khader Bandali Akkawi Head of Committee

Edwin Tan Palma Member

Sameer Darwish AlPojoq Member & Coordinator

Aslam Riaz Azmi Member

Jasar Mohammed Ismail Member

Approved by: Head of Standardization Group

Authorized by: Head of Research & Standardization Management Office

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 Dubai Municipality Standard ‫المواصفـات القيـاسية لبلـدية دبـي‬
DMS 1: Part 5: 2011

Table of Contents

Page
Foreword iii
1 Scope 1
2 References 1
3 Definitions 1
4 Requirements for materials 2
5 Polystyrene core properties 2
6 Sandwich block properties 3
7 Durability aspect 6
8 Sampling for tests 6
9 Intended use 6
10 Conformity assessment and certification 6
Tables
1 Dimensions of sandwich blocks 4
2 Minimum compressive strength of masonry blocks based on gross area 5
Figures
1 Example of a polystyrene core 2
2 Example of sandwich block 4
Annexes
Annex A: Compressive strength: Rapid testing 7
Annex B: Site application of sandwich blocks 8
Annex C: Materials properties and limits 10

Publications referred to 13

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DMS 1: Part 5: 2011
Foreword

With a view to having a comprehensive set of unified Dubai Municipality Standards which
would be consistent and appropriate to local conditions and yet be at par with International
Standards, the Dubai Central Laboratory Department is formulating standards taking guidance
as much as possible from International and Regional Norms.

This Standard sets the minimum requirements for a new type of precast concrete masonry block
that is introduced in the local market to be used as thermal insulating block. Besides the basic
requirements of the block, this Standard addresses the connectivity and stability requirements of
a wall constructed using this type of block.

This Standard also includes an annex for the site applications of the thermal insulating-blocks.

The DM Standard Specification for precast concrete blocks falls in five parts as follows:

Part 1: Masonry blocks

Part 2: Filler blocks
Part 3: Autoclaved aerated concrete masonry blocks
Part 4: Paving blocks
Part 5: Concrete-polystyrene sandwich masonry blocks

Amendments issued since publication

Amd No. Date Text affected

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DMS 1: Part 5: 2011
1 Scope
This standard specifies minimum performance levels for normal weight and lightweight precast
concrete-polystyrene masonry Sandwich-blocks. Annex B of this Standard addresses the
connectivity and stability requirements of a wall constructed using this type of block.
2 References
This standard incorporates provisions from other references. These references are cited undated
at the appropriate points in the text, but latest edition of these references applies (including
amendments). In case any reference is shown as dated, then that specific edition shall be used.
The titles of these references are listed on the last page.
3 Definitions
3.1 Masonry block
a precast concrete masonry block manufactured from cementitious binder, aggregates and water
and which may contain admixtures and additions and colouring pigments and other materials
incorporated or applied during or subsequent to block manufacture intended for use in the
construction of walls.
3.2 Normalweight concrete
concrete having an oven-dry density greater than 2000 kg/m3 but not exceeding 2600 kg/m3.
3.3 Lightweight concrete
concrete having an oven-dry net density of not more than 2000 kg/m3. It is produced using
lightweight aggregate with full or partial replacement of the lightweight fines with normal
weight sand.
3.4 Expanded polystyrene
rigid cellular plastic material, manufactured by molding beads of expandable polystyrene or one
of its copolymers, with an air filled closed cellular structure.
3.5 Extruded polystyrene
rigid cellular plastics insulation material expanded and extruded with or without a skin, from
polystyrene or one of its copolymers and which has a closed cell structure
3.6 Sandwich-block
a precast concrete block consisting of two outer leaves of concrete sandwiching a polystyrene
core.
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3.7 length
the largest dimension of the horizontal plane of installation.
3.8 width
the smallest dimension of the horizontal plane of installation .
3.9 height
the vertical dimension perpendicular to installation plane.
4 Requirements for materials
4.1 General
Only materials with suitability established in terms of their properties and performance shall be
used in the manufacture of concrete masonry blocks.
These materials shall conform to the requirements shown in Annex C.
Where, by conformity with relevant specifications, the properties and performance of materials
have been demonstrated, further testing need not be performed.
4.2 Asbestos
Asbestos, or materials containing asbestos, shall not be used.
5 Polystyrene core properties
5.1 Size and shape
Polystyrene core of the Sandwich-block shall have the same length and height of the overall
concrete dimensions. Polystyrene core thickness, when measured at any point, shall not be less
than 60 mm.
Polystyrene core shall have a dovetailing shape as shown in Fig. 1. Other shapes can also be
used.

Fig. 1: Example of a polystyrene core

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Polystyrene core shall be either molded or extruded to shape without cutting.
5.2 Apparent density
When tested in accordance with BS EN 1602, the average apparent density shall not be less than
25 kg/m3.
5.3 Thermal conductivity
Thermal conductivity of the polystyrene core shall be declared by the polystyrene manufacturer
according to BS EN ISO 10456 at 35 ºC and 60% relative humidity (RH).
When tested in accordance with BS EN 12667 or ASTM C 518, at 35 ºC & 60% RH,
polystyrene core average thermal conductivity of three specimens shall not exceed the declared
value.
5.4 Reaction to fire
Polystyrene shall be of the flame-retardant type. When tested in accordance with BS EN 11925-
2, the flame spread shall not exceed 150 mm within 60 s. Alternatively, the Oxygen index shall
not be less than 24% by volume when tested in accordance with ASTM D 2863.
6 Sandwich block properties
6.1 Shape
Blocks shall have regular and uniform shape, free of cracks and defects and have rough surfaces
to provide key for plaster.
6.2 Sizes
6.2.1 Dimensions
Sandwich-block overall dimensions shall conform to the requirements of Table 1. If air cavities
exist in any of the two concrete leaves of the Sandwich-block, the shell thickness shall not be
less than 20mm. A sample block is shown in Fig. 2.

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Table 1 - Dimensions of Sandwich-blocks

Sandwich-block sizes
Length (mm) Height (mm) Width (mm)
400 200 200
400 200 250
NOTE Other dimensions can be declared by the manufacturers.

Fig. 2: Example of a Sandwich-block

6.2.2 Tolerances
When measured in the manner described in BS BS EN 772: Part 16, the length, height or width
of each block from the sample shall not deviate by more than ± 3 mm from the declared
dimensions.
6.3 Manufacturing
Sandwich-blocks are manufactured using concrete cast integrally with the dovetailed
polystyrene core placed in the mould and wet concrete poured around it. The concrete is then
compacted and cured. These processes are to be carried out without damage to the polystyrene
core.

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6.4 Chloride and sulfate content
When tested in accordance with BS 1881: Part 124, the acid soluble chloride (Cl) and sulfate
(SO3) content of Sandwich-blocks concrete shall not exceed 0.05% and 0.5% by dry mass of
concrete respectively.
6.5 Compressive strength
When tested in accordance with BS EN 772: Part 1 or by using the rapid compressive strength
method as per "Annex A" of this DMS, the average compressive strength and that of an
individual specimen, based on the gross area, shall not be less than the values given in Table 2:
Table 2 - Minimum compressive strength of masonry blocks based on gross area

Strength N/mm2
Type of masonry blocks
Average Individual
Normalweight concrete 7.5 6
Lightweight concrete 3.2 2.6
NOTE Designers may specify blocks of higher strengths than those given in this Table if required from
design considerations.

Sandwich-blocks shall maintain their integrity during the compressive strength test i.e. failure
pattern during compressive strength test shall not show evidence of separation between the
polystyrene core and the outer concrete leaves. Any evidence of separation noticed before or
during the test shall be considered as not complying with the requirement of this clause.
6.6 Thermal properties
Thermal conductivity of the Sandwich-blocks shall be declared by the block manufacturer
according to BS EN ISO 10456 at 35 ºC and 60% relative humidity (RH).
When tested in accordance with BS EN 12664 or BS EN 12667 or BS EN 1934 or BS EN ISO
8990 or ASTM C 1363, at 35 ºC and 60% RH, Sandwich-block thermal conductivity shall not
exceed the declared value.
As an alternative, thermal conductivity of the Sandwich-blocks shall be calculated according to
BS EN ISO 6946 taking into consideration the block configuration, concrete and polystyrene
thermal conductivities declared by their manufacturers at 35 ºC & 60% RH.

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7 Durability aspect
Under normal exposure conditions of use in Arabian Gulf region environment, precast concrete
blocks will continue to provide satisfactory strength, provided they conform to clause (6.5)
above.
8 Sampling for tests
8.1 For the dimensions and compressive strength the minimum number of test specimens shall
conform to BS EN 771 – 3.
8.2 For other tests, the number of specimens shall be:
- Sandwich-block Concrete Chloride and Sulfate content 1 block
- Sandwich-block thermal conductivity or Concrete As required by the
thermal conductivity testing laboratory
9 Intended use
Sandwich-blocks are intended to be used as thermal insulating blocks for the construction of
infill, non-load bearing, masonry walls in buildings.
Sandwich-blocks shall be used in superstructures only and shall not be used in substructures.
10 Conformity assessment and certification
10.1 Conformity of the product with this standard shall be assessed in accordance with Dubai
Municipality third party product certification system.
10.2 Product delivered to site shall demonstrate compliance with this standard through a
Certificate of Conformity or Mark of Conformity issued by Dubai Municipality.

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Annex A:

Compressive strength: Rapid testing

A.1 Method of testing
Compressive strength test shall be carried in accordance with BS EN 772 – 1 with the following
deviations:
A.1.1 Surface preparation
Rub the bed faces of specimens with a carborundum stone to remove any fins or high spots.
Wipe the bearing surfaces of all the platens clean and remove any loose grit or other material
from the surfaces of the specimen which are to be in contact with the platens.
A.1.2 Conditioning
Specimens shall be stored in the normal laboratory temperature and humidity for at least 16 h
before being used for tests.
A.1.3 Procedure
A.1.3.1Grinding method
Grind the specimen as per the requirement of BS EN 772 – 1
A1.3.2 Use of fiber board
As an alternative to grinding method and capping method as mentioned in BS EN 772 – 1, fiber
boards can be used. Use fiber board (12 ± 1) mm thickness as in parallel contact with the
platens. Place the specimen in the machine between two new pieces of 12 mm thick fiber board.
Ensure that the board overhangs the specimen by a minimum of 5 mm along each edge and the
centre of mass of the specimen coincides with the axis of the machine.

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Annex B:

Site application of Sandwich-blocks

B.1 Site storage
Ultra-Violet light adversely affects the polystyrene properties. Therefore, polystyrene cores
should be stored or kept in closed places unexposed to solar radiation. Also, Sandwich-blocks
need to be protected from exposure to solar radiation during their storage and handling until the
time of erection where the polystyrene is then fully protected.

B.2 Handling
Sandwich-blocks need to be handled with care to avoid damage such as chipping of edges and
corners, splitting between the polystyrene core and the outer concrete layers, …etc.

B.3 Thermal bridging

Mortar joints in masonry walls built with Sandwich-blocks will act as a thermal bridge due to
the high thermal conductivity of the mortar compared to the polystyrene core. To avoid this
thermal bridge, 45 mm wide Polystyrene strips, having a thickness equal to the mortar joints
thickness, shall be included in the horizontal and vertical mortar joints to provide continuity for
the Polystyrene thermal insulation layer.

As an alternative, light weight aggregate concrete mortar with low thermal conductivity can be
used as full bed mortar joints without any polystyrene strips.

Other alternatives can also be used.

B.4 Installation
Care should be taken to align the blocks both horizontally and vertically in a way that the
polystyrene cores of adjacent blocks are not staggered. This is of great importance so as to
avoid forming thermal bridges inside the walls.

B.5 Reinforcement

B.5.1 General
Polystyrene may loose its adhesion with the concrete with time, leaving the two concrete leaves
of the Sandwich-block apart without connectivity. To ensure the connectivity of the two

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concrete leaves together, a suitable method of those mentioned in clause (B.5.2) shall be
applied.

B.5.2 Methods of connection:

- 150 mm wide Alkali resistant fiber mesh reinforcement, or galvanized metal mesh or
ladder type wire mesh reinforcement, embedded in the mortar joints at every third course.

- 150 mm long ties complying with the requirements of BS EN 845: Part 1 shall be placed in
mortar joints at a rate not less than 4.9 ties per one square meter of wall area.

- Other methods for ensuring connectivity may be used.

B.5.3 Column-masonry junctions shall be connected by galvanized wall ties, 2.5 mm x20 mm
x 150 mm, complying with the requirements of BS EN 845: Part 1, at every third course.

B.5.4 If the wall height is more than 3.5 m, galvanized beam-masonry wall ties of 2.5 mm x 20
mm x 75 mm, complying with the requirements of BS EN 845: Part 1, shall be fixed at 1.2 m c/c
approximately.

B.5.5 Concrete stiffeners should be provided around windows and doors openings to allow for
stiffening the wall free ends.

B.6 Condensation
To avoid the condensation problem that is expected to happen in walls built with Sandwich-
blocks, special coatings having very low water-vapor permeability characteristic (i.e.
permeance ≤ 57.5 ng/(Pa.s.m2) [1.0 perm]) shall be applied on the external surface of the walls.

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Annex C
Materials properties and limits
Table C.1 – Normal weight aggregate
Permissible limits
S.No Requirements Test methods Fine Coarse
aggregate aggregate
Physical Properties
1 Water absorption -- Max.2.0 %
ASTM C 127, or
BS EN 1097 Part 6
ASTM C 128, or Max 2.3 % --
BS EN 1097 Part 6
2 Specific gravity (apparent) -- Min. 2.6
ASTM C 127, or
BS EN 1097 Part 6
ASTM C 128, or Min. 2.6 --
BS EN 1097 Part 6
3 Clay lumps and friable particles ASTM C 142 Max. 1% --
4 Material finer than 0.075 mm
 Natural uncrushed ASTM C 117 Max. 3 % Max. 1 %
 Crushed Max. 7 % Max. 1 %
5 Shell content
 Coarser than 10mm BS EN 933 – 7 -- Max. 5 %
 Between 5mm and 10mm -- Max. 15%
6 Particle shape - Flakiness index BS 812: Part 105.1 -- Max. 25 %
7 Particle shape – Elongation index BS 812:Part 105.2 -- Max. 25%
8 Soundness – MgSO4 ( 5 Cycles) ASTM C 88 Max 12% Max 12%
Mechanical Properties
9 Soaked 10% fines value BS EN 1097 Part 2 -- Min. 100 kN
10 Los angeles abrasion ASTM C 13l / C 535 -- Max 30%
Chemical Properties
11 Organic impurities ASTM C 40 Not darker --
than the
standard
solution
12 Acid soluble chlorides (Cl) BS EN 1744 Part 5 0.03% 0.01%
13 Acid soluble sulphates (SO3) BS EN 1744 Part 1 0.3% 0.3%

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Table C.2 – Cementitious Materials

S. No. Constituents Standard specification
ASTM C 150, or
1 Portland cements
BS EN 197
ASTM C 618, or
2 Fly ash
BS EN 450
ASTM C 989, or
3 Ground granulated blastfurrace slag
BS 6699
ASTM C 1240, or
4 Silica fume
BS EN 13263
5 Blended hydraulic cement ASTM C 595
6 Standard performance for hydraulic cement ASTM C 1157

Table C.3 – Water

S. No Concentrations Test method Limit
1 Chloride as Cl ASTM D 512 Max.1000 mg/l
2 Sulphates SO4 ASTM D 516 Max.2000 mg/l
3 Alkali carbonates and bicarbonates ASTM D 513 Max.1000mg/l
4 Total dissolved solids, including 1,2 & 3 above BS 1377: Part 3 Max.2000 mg/l
5 pH ASTM D 1293 7 ≤ pH ≤ 9

Table C.4 – Other materials

S. No. Constituents Standard specification
ASTM C 331, or
1 Lightweight aggregates
BS 13055: Part 1
ASTM C 260, or
2 Admixtures ASTM C 494, or
BS EN 934
Thermal insulation core of the sandwich block shall be made of either expanded
3 polystyrene (EPS) or extruded polystyrene (XPS) that complies with the requirements of
clause (5) of this Specification and shall be certified by Dubai Municipality.

Any other material, not mentioned in this Annex may be used provided that the material
conforms to applicable standard or shall be shown by test or experience that it is not
detrimental to the durability of the concrete masonry units or any material customarily
4 used in masonry manufacturing.
The suitability requirements of the material used shall be given in the manufacturer’s
production control documentation.

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Summary of changes
1. Clause 3 new sub clause 3.7, 3.8, and 3.9 are added
2. Table 1 has been revised
3. Clause 6.2.2 has been revised
4. Table C.3 of Annex C has been revised.

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Publications referred to

ASTM C 40 Standard test method for organic impurities in fine

aggregates for concrete
ASTM C 88 Standard test method for soundness of aggregates by use of
sodium sulfate or magnesium sulfate
ASTM C 117 Standard test method for materials finer than 75-µm (No.
200) sieve in mineral aggregates by washing
ASTM C 127 Standard test method for density, relative density (specific
gravity), and absorption of coarse aggregate
ASTM C 128 Standard test method for density, relative density (specific
gravity), and absorption of fine aggregate
ASTM C 131 Standard test method for resistance to degradation of small-
size coarse aggregate by abrasion and impact in the los
angeles machine
ASTM C 142 Standard test method for clay lumps and friable particles in
aggregates
ASTM C 150 Standard specification for portland cement
ASTM C 260 Standard specification for air-entraining admixtures for
concrete
ASTM C331 Standard specification for lightweight aggregates for
concrete masonry units
ASTM C 494 Standard specification for chemical admixtures for concrete
ASTM C 518 Standard Test Method for Steady-State Thermal Transmission
Properties by Means of the Heat Flow Meter Apparatus
ASTM C 535 Standard test method for resistance to degradation of large-
size coarse aggregate by abrasion and impact in the los
angeles machine
ASTM C 595 Standard specification for blended hydraulic cements
ASTM C 618 Standard specification for coal fly ash and raw or calcined
natural pozzolan for use in concrete
ASTM C 989 Standard specification for slag cement for use in concrete
and mortars
ASTM C 1157 Standard performance specification for hydraulic cement
ASTM C 1240 Standard specification for silica fume used in cementitious
mixtures
ASTM C 1363 Standard test method for the thermal performance of building
assemblies by means of a hot box apparatus
ASTM D 512 Standard Test Methods for Chloride Ion in Water
ASTM D 513 Standard Test Methods for Total and Dissolved Carbon Dioxide
in Water
ASTM D 516 Standard Test Method for Sulfate Ion in Water
ASTM D 1293 Standard Test Methods for pH of Water

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ASTM D 2863 Standard Test Method for Measuring the Minimum Oxygen
Concentration to Support Candle-Like Combustion of Plastics
(Oxygen Index)
BS 812: Part 105.1 Testing aggregates ― Part105: Methods for determination
of particle shape section 105.1 Flakiness index
BS 812: Part 105.2 Testing aggregates ―Part 105.2: Elongation index of coarse
aggregate
BS 1881: Part 124 Method for analysis of hardened concrete
BS 1377: Part 3 Methods of test for soils for civil engineering purposes ―
Part 3: Chemical and electro-chemical tests
BS 6699 Specification for ground granulated blastfurnace slag for
use with portland cement
BS EN 197 Cement ― Part 1: Composition, specifications and
conformity criteria for common cements
BS EN 450 Fly ash for concrete ― Part 1: Definition, specifications and
conformity criteria
BS EN 771: Part 3 Specification for masonry units ― Part 3: Aggregate
concrete masonry units (dense and light-weight aggregates)
BS EN 772: Part 1 Methods of test for masonry units - Part 1: Determination of
Compressive Strength
BS EN 772: Part 16 Methods of test for masonry units Part 16: Determination of
dimensions
BS EN 845: Part 1 Specification for ancillary components for masonry — Part
1: Ties, tension straps, hangers and brackets
BS EN 933: Part 7 Tests for geometrical properties of aggregates - Part 7:
Determination of shell content - percentage of shells in
coarse aggregates
BS EN 934 Admixtures for concrete, mortar and grout
BS EN 1097: Part 2 Tests for mechanical and physical properties of
aggregates ― Part 2: Methods for the determination of
resistance to fragmentation
BS EN 1097: Part 6 Tests for mechanical and physical properties of
aggregates ―Part 6: Determination of particle density and
water absorption
BS EN 1602 Thermal insulation products for building applications –
determination of apparent density
BS EN 1744: Part 1 Tests for chemical properties of aggregates ― Part 1:
Chemical analysis
BS EN 1744: Part 5 Tests for chemical properties of aggregates ― Part 5:
Determination of acid soluble chloride salts
BS EN 1934 Thermal performance of buildings - Determination of thermal
resistance by hot box method using heat flow meter - Masonry
BS EN 11925: Part 2 Reaction to fire tests – Ignitability of building products subjected
to direct impingement of flame – Part 2: Single flame source test
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BS EN 12664 Thermal performance of building materials and products –
Determination of thermal resistance by means of guarded hot
plate and heat flow meter methods – Dry and moist products of
medium and low thermal resistance
BS EN 12667 Thermal performance of building materials and products –
Determination of thermal resistance by means of guarded hot
plate and heat flow meter methods – Products of high and
medium thermal resistance
BS EN 13055: Part 1 Lightweight aggregates― Part 1: Lightweight
aggregates for concrete, mortar and grout
BS EN 13263 Silica fume for concrete
BS EN ISO 6946 Building components and building elements – Thermal
resistance and thermal transmittance – Calculation method
BS EN ISO 8990 Thermal insulation — Determination of steady-state thermal
transmission properties — Calibrated and guarded hot box
BS EN ISO 10456 Building materials and products – Procedures for determining
declared design thermal values

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