TECHNICAL MANUAL. INSTALLATION : Fire Tested FRL Systems. MgSO4 Sulphate Board NO METAL CORROSIVE CHLORIDE

Transcription

1 FIRECRUNCH INSTALLATION MANUAL: FIRE TRESTED FRL SYSTEMS (09_2018) TECHNICAL MANUAL INSTALLATION : Fire Tested FRL Systems FireCrunch Fire MANUAL SEPT 2018 NATA FIRECRUNCH IS AN AUSTRALIAN FIRE TEST BUILDING CLADDING AND FLOORING PRODUCT UNDER THE NATA ACCREDITED TEST AUTHORITY SYSTEMS FIRE TESTED BY CSIRO AS/ (COMMONWEALTH SCIENTIFIC AND INDUSTRIAL RESEARCH ORGANISATION. NATA IS THE AUSTRALIAN INTERNATIONAL MEMBER OF ILAC ILAC IS THE INTERNATIONAL LABORATORY ASSOCIATION CO-OPERATION COMPLYING WITH ISO / IEC AND OTHER INTERNATIONALLY RECOGNIZED STANDARDS IN 160 MEMBER COUNTRIES. INTERNATIONAL SALES EXPORT ENQUIRIES TO: sales@ FIRE TESTED BY NATA / CSIRO & OTHERS

2 CONTENTS FireCrunch OVERVIEW... 3 Key Features... 3 Product Applications... 3 Environmental Properties... 3 Fire Protection... 3 AUSTRALIAN CERTIFICATION... 4 FIRE PROPERTIES... 4 AUSTRALIAN TESTS... 4 AUSTRALIAN & NEW ZEALAND STANDARDS... 5 INTERNATIONAL STANDARDS... 5 FIRE RATED WALLS - STEEL FRAME FIRE RATED FIRE SEPARATION WALL FRL 120/120/ Boundary Walls and bushfire building and Roof Fixings and Method... Installation & Fixing Notes - Overview... 6 General Installation Internal & External Firewalls... 9 Internal (Non Load Bearing) Fire Wall - FRL -/120/120 - Installation... Single layer vertical installation... Single layer horizontal installation External (Load Bearing) Fire Wall - FRL 90/90/90 - Installation 92mm steel frame... Single layer vertical installation Single layer horizontal installation Single layer horizontal installation: 76mm steel frame External (Load Bearing) Fire Wall FRL 60/60/60 - Installation 92mm steel frame Single layer vertical installation Single layer horizontal installation Single layer horizontal installation : 76mm steel frame _001_FireCrunch_Fire_Manual_ FIRE RATED WALLS - TIMBER FRAME Installation & Fixing Notes - Overview General Installation Internal & External Firewalls Internal (Non Load Bearing) Fire Wall - FRL -/60/60 - Installation...15 Single layer vertical installation Single layer horizontal installation FIRE RATED DOUBLE STUD PARTY WALL SYSTEM : TIMBER FRAME FRL 60/60/60 and 90/90/ FIRE RATED DOUBLE STUD PARTY WALL SYSTEM : STEEL and TIMBER FRAMING FRL 60/60/60 and 90/90/ FIRE SEPARATION WALL TIMBER FRAMING Installation - Overview Steel Frame FRL 60/60/60 and 90/90/90 - Installation Timber Frame FRL 60/60/60 and 90/90/90 - Installation FIRE RATED CEILINGS & FLOORS STEEL Frame CEILING FLOOR GENERAL INFORMATION Storage & Handling Occupational Health & Safety What tools do I need? Cutting & Machining GENERAL FIXING & INSTALLATION PLASTER JOINT CLADDING INSTALLERS PLASTER SETTING JOINTS:SUMMARY INSTALLATION INSTALLERS : STEEL FRAMED FIRE WALL FRL 60/60/60 and SINGLE FRAME TIMBER FIRE WALL FRL 60/60/ SUMMARY INSTALLATION: DOUBLE TIMBER FRAME FIRE WALL (INTERNAL &EXTERNAL FIRE SEPARATION WALLS) SUMMARY INSTALLATION: STEEL Framed FIRE WALL FRL 90/90/90 and Steel FIRE WALLS FRL../120/

3 F Y FRIENDLY LENVIRONMENTAL V I FireCrunch Is a newly developed and extensively tested modern building board used in construction. It is made from a mixture of non organic minerals, bonders and fibre mesh composites. FireCrunch contains no formaldehyde, no asbestos and no toxic chemicals and most important no steel corrosive magnesium chloride as do most MgO products from China FireCrunch uses magnesium sulphate and eliminates any steel corrosion. Australian NON ASBESTOS test certification by Clear safe NSW a NATA accredited testing laboratory to Australian Standards AS/4964. See Certification this web site KEY FEATURES ( Mg ) The fine, densely bonded, 1.15 g/cm3 mineral fibre structure of FireCrunch ensures excellent machining and working properties using normal woodworking equipment or hand tools. In addition, the smooth face surface provides an ideal base for paint finishing with most industrial and domestic coatings. The back surface of FireCrunch is characterised by a coarse, wire screen texture which makes it ideal for rendering and tiling (although tile fixings can be applied to either side). FireCrunch is available in a range of accurately dimensioned sheet sizes and in thicknesses of 10mm interior exterior cladding boards available with square edge and tapered (recessed) edge for plaster set on long sides. 19mm and 20mm flooring and decking substrate interior / exterior use is available in TG size 2700 x 600. Whilst all FireCrunch in any thickness is (CSIRO Fire Tested) Non Combustible.(Ask for test certificate) Only 10mm and above is "system Fire tested" ( CSIRO) in FRL from 30/30/30 to 90/90/90 and NCC solutions for FRL 120/120/120 and above. FireCrunch is Certified and assessed for use in fire penetration walls (Snap Fire Systems) assessed by the CSIRO for use with FireCrunch 10mm sheets to FRL.../90/90 PRODUCT APPLICATIONS FireCrunch has a very wide range of uses for residential, commercial and industrial buildings, schools, hospitals, Government & social housing, utility buildings etc. The board has additional applications in fire safety, electrical switchboard backing blocks, electrical wiring channels and internal electrical risers in multi-story and commercial buildings. Fire tests by CSIRO cover FireCrunch single 10mm sheets using Snap Fire Collars and wall penetration protection for to FRL.../90/90 and beyond. (See web site www. for the full plans and instructional installations for building classification BCA classes 1 to 10.) Internal applications: internal walls, ceilings, floor sub base, tile backer, counter tops, kitchen furniture, built in wardrobes, hot areas and Fire surrounds Wet area applications: bathrooms, shower recess, kitchen - suitable for any wet areas or humidity prone areas. FireCrunch is mould resistant and once sealed correctly, will not degrade in standing water or flood conditions it remains inert and can simply be dried, re plaster set and repainted. Exterior applications: weatherboarding, soffits, lining or decking (meets AS/NZS 3959 BAL Fire Zone Regulation). Can be painted, papered, tiled, rendered or veneered. ENVIRONMENTAL PROPERTIES During the manufacturing process, in carbonation, FireCrunch draws back 90% of the Co2 created and makes it a virtually carbon neutral product generating 90% less Co2 than cement and plaster board products while eliminating the destruction of millions of oxygen producing, life sustaining trees. FIRECRUNCH IS 100% RECYCLABLE. and 45% waste MgO recovery. FireCrunch (10mm, and 19mm) has been tested to ensure the highest fire protection offered and all in one board without compromising on quality or price. FireCrunch provides solutions in single and double stud fire separation wall systems without the use of complex expensive shaft liner methods. The primary FRL tests in 30/30/30 to 90/90/90 tests have been have been fire tested in systems, by the CSIRO. see CERTIFICATION web site. Acoustic third party tests certified to Rw62 show Rw62 plus ctr NET 52 and above A double frame party wall alternative is also available from FireCrunch FRL 90/90/90 timber framing The very high Fire Resistance Level (FRL) for FireCrunch means it can be used in all BAL areas including FZ in Bush Fire Areas under AS/NZS (See separate Bush fire manual web site) Load Bearing Timber Frame FRL 90/90/90 Steel Frame FRL 90/90/90 tests have been fire tested in systems, assessed and certified by the CSIRO. see Accreditation web site. AS/ Acoustic third party tests certified to Rw62 plus ctr net 52 and above. A double stud party wall alternative is also available from FireCrunch. The very high Fire Resistance Level (FRL) for FireCrunch means it can be used in all BAL areas including FZ in Bush Fire Areas under AS/NZS and the superior 1.5 AS/ FRL 90/90/90 CSIRO D.T.S./ BCA TESTING Load Bearing Timber Frame FRL 90/90/90 Steel Frame FRL 120/120/120 CSIRO TESTED FIRE TESTED BY CSIRO / BCA & OTHERS NATA FIRE PROTECTION FireCrunch (10mm ) has been tested to ensure the highest fire protection offered and all in one board without compromising on quality or price. FireCrunch provides solutions in single and double stud fire separation wall systems without the use of complex expensive shaft liner methods. The primary FRL tests in 30/30/30 to 90/90/90 tests have been have been fire tested in systems, assessed by the CSIRO. see Accreditation web site. Acoustic third party tests certified to Rw62 etc..show Rw52 net ctr. A double stud party wall alternative is also available from FireCrunch. The very high Fire Resistance Level (FRL 90/90/90 ) for FireCrunch means it can be used in all BAL areas including FZ in Bush Fire Areas under AS/NZS ( AS /14) Load Bearing Timber Frame FRL 90/90/90 Load Bearing Steel Frame FRL 120/120/120 Y 3

4 AUSTRALIAN CERTIFICATION FireCrunch is certified and complies with the Building Code of Australia (BCA): 1. BCA Volume One 2014: C1.8 Lightweight Construction, C1.10 Fire hazard properties and C1.12 non-combustible components, including state variations for NSW. 2. BCA Volume Two 2014: Part , Fibre Cement Planks and Weatherboard Cladding. 3. BCA Volume Two 2014: Part , Fibre Cements Sheet Wall Cladding. 4. BCA Volume Two 2014: Part , Eaves and Soffit Linings. 5. BCA Volume Two 2014: Part 3.7.1, Fire separation for FRL, including state variations for SA. 6. BCA Volume Two 2014: Part 3.7.4, Bushfire areas to Part and , including state variations NSW, QLD, SA and TAS. 7. BCA Volume Two 2014: Part 3.8.6, Sound Insulation, including state and territory for NT. For more information on FireCrunch certification go to the company website: FIRE PROPERTIES FireCrunch is totally fire resistant. It will not burn in a fire. FireCrunch complies with the Building Code of Australia (BCA) Material Group Number Classification and Deemed to Satisfy Provisions, as determined by AS/NZS 3837, AS/NZS 3959, AS/1530.4/2014 FRL TO 60/60/60 and 90/90/90 (Fire Tested and Scientific Assessment by CSIRO) The FireCrunch building product has been fire tested by the CSIRO to the Certification level standards of AS/NZS 3837 (Group 1 - Non Combustible material). FireCrunch (min. 10mm thickness) is certified for Bushfire Attack Levels (BAL) low, 12.5,19, 29, 40 and FZ (Flame Zone over 50Kw m2 irradiation, 1200ºc) regulation areas and meets the AS 3959 requirements, when used to protect timber - framing, under AS/NZ 3837 Group 1 materials and AS and AS1530.4, and meets AS/3959 and AS/ DEC 2017 Horizontal and vertical element FURNACE TESTS 1000 degc BCA COMPLIANCE time and temperature curve meeting AS/ NZS AND and AS/ AUSTRALIAN TESTS CSIRO carried out Non Combustible material tests on FireCrunch for AS/NZS 3837:1998 in 2009 (Report number FNK6016). AS/ NON COMBUSTIBLE MATERIALS TEST ( CSIRO) AS/NZS 3837:1998 Method of test for heat and smoke release rates for materials and calorimeter (Cone calorimeter test) - Walls & Ceilings. AS/NZS / CSIRO FIRE REPORT 24/08/2015 NO 2674 REPORT NO FSV 1708 Compliance ISO/IEC/17025 CSIRO FIRE REPORT 21ST SEPT 2015 NO 2707 REPORT NO FSV 1711 Compliance ISO/IEC/ Methods for fire tests on building materials, components and structures,part 4: Fire-resistance test of elements of construction covering fire resistance. NATA AS/NZS Applicable and covered under (AS /14) Bushfire Attack Levels (BAL) from BAL 12.5 to BAL 40 and Flame Zone (FZ) - over 50Kw m2 irradiation, 1200ºC SIMULATED REAL TIME LIVE BUSH FIRE TEST CSIRO FEBRUARY 2012 MOGO NSW J LEONARD CSIRO PROJECT LEADER REPORT TEST DATE 15/02/2012 REF EP12179/FILE FE 2508 REPORT DATE JULY 2012 Specimen (10mm) FireCrunch MBE All FireCrunch CSIRO fire tests under AS/ were exposed in the 1000 deg c furnace in "mandatory vertical orientation". Failure to orient the sheets vertical and to the exact fixing process with support elements specified as shown in the FireCrunch fire manuals will void the FCA Warranties. Test Results Ignition No combustion at 1100ºC Flame prpropagation No flame out at 1100ºC Heat release Nominal Smoke release 1.5MJ/m 2 4

5 AUSTRALIAN AND NEW ZEALAND STANDARDS NATA AS/ /2014 CSIRO FIRE TEST REPORTS 24/08/2015 NO 2674 REPORT NO FSV 1708 Compliance ISO/IEC/ /09/2015 NO 2707 REPORT NO FSV 1711 Compliance ISO/IEC/17025 AS/NZS Method of test for heat and smoke release rates for materials and products using an oxygen consumption calorimeter (Cone calorimeter test) - Walls & Ceilings (AS/NZS 3837) complies with Group 1 specification A 2.4 BCA) Properties are determined as follows: (a) Rate of heat release, by measurement of the oxygen consumption, as determined by the oxygen concentration and the flow rate in the exhaust product stream. (b) Effective heat of combustion from a concomitant measurement of specimen mass loss rate, in combination with the heat release rate. (c) Smoke release, by obscuration of light by the combustion product stream. (d) Ignitability, as a measurement of time from initial exposure to time of sustained flaming. ( No Flaming recorded) AS/NZS Methods for fire tests exclusively for materials and elements of construction in bushfire-prone areas, namely: AS Tests on elements of construction for buildings exposed to simulated bushfire attack; Part Radiant heat and small flaming source, which covers BAL12.5 to BAL 40 ; AS Tests on elements of construction for buildings exposed to simulated bushfire attack. Part 8.2: Large flaming sources, which covers BAL FZ. ISO Reaction to fire tests for floor coverings (Floor radiant panel test) The main outcome from the test is a material s critical radiant flux. The critical radiant flux is an indication of the amount of heat flux that needs to be applied to a material, to cause a small flame to ignite the material. The higher the material s critical radiant flux, the better performing a material is. AS Construction of buildings in bush-fire prone areas The objective of this Standard is to prescribe particular construction details for buildings to reduce the risk of ignition from a bush fire. Properties are determined as follows: (a) potential for ignition caused by burning embers, radiant heat or flame generated by a bush fire; and (b) intensity of the bush fire attack on the building. BUSH FIRE ATTACK LEVELS (BAL) AND CORRESPONDING SECTIONS FOR SPECIFIC CONSTRUCTION REQUIREMENTS Bush fire Attack Level (BAL) BAL-LOW BAL-12.5 BAL-19 BAL-29 BAL-40 BAL-FZ Description of predicted bush fire attack and levels of exposure There is insufficient risk to warrant specific construction requirements Ember attack Increasing levels of ember attack and burning debris ignited by wind borne embers together with increasing heat flux Increasing levels of ember attack and burning debris ignited by wind borne embers together with increasing heat flux Increasing levels of ember attack and burning debris ignited by wind borne embers together with increasing heat flux with the increased likelihood of exposure to flames Direct exposure to flames from fire front in addition to heat flux and ember attack INTERNATIONAL STANDARDS FireCrunch has a class A fire rating internationally relates to AS/ European Standards UNI EN ISO 1182 (non-combustible) European Standards UNI EN ISO 1716 (heat resistance) European Standards UNI EN ISO (smoke and flame) United States & Canada US ASTM E136 (non-combustible) British Standard 476 part (non-combustible) (ILAC) THE INTERNATIONAL LABORATORY ACCREDITATION ASSOCIATION has world wide complying laboratory testing with world wide membership over 100 countries In Australia NATA is complying member and in China The Chinese National Academy of Science (CNAS) testing approved by either of these 2 entities meets the equal Australian standard and can be certified as such in Australia or china IMPORTANT NOTE TO ABOVE **** AS ALL STRUCTURAL LOAD BEARING REQUIREMENTS VARY CONSIDERABLY THE FIRE TESTS ARE RELATED TO FIGURE 2 AND 3 ie STRUCTURAL INTEGRITY 90MINS AND INSULATION 90MINS. THE REQUIRMENT IN LOAD BEARING MUST BE DETERMINED BY A STRUCTURAL ENGINEER RELATIVE TO THE INDIVIDUAL LOAD BEARING SPECIFICATION REQUIRED AND APPROPRIATE SPECIFICATION IN STEEL OR TIMBER TO SUPPORT THE LOADING REQUIREMENT IN ADEQUACY ( THE FIRST FIGURE 90 MINUTES) 2 LAYERS OF 10mm FCA ARE REQUIRED FOR FRL.../120/120 5

6 NATA FIRE RATED WALL - LOAD BEARING COLD FORMED SECTION - STEEL FRAME CONSTRUCTION FIXING NOTES Steel framed walls, floors and ceilings are to be constructed strictly in accordance with AS/NZS 4600 (Cold Formed Steel Structures), the Building Code of Australia and all relevant Standards. Fasten to the studs, joists and rafters min 15mm from the edge and 50mm from the corner of boards and staggered each side at a maximum of 200mm centres. Fasteners should be recommended corrosion proof,ribbed head bugle screws and finish with the head just below the surface of the FireCrunch boards. The boards are strong but care should be taken not to damage the core or face. All external wall must be surface sealed with approved MgO sealer primers to front face only and both side and top edges back left unsealed,see recommended products products web site before, or immediately after installation. Cavity of 90mm and 20 Ga min (1.15 BMT) galvanised steel frame filled with 90mm min R 2.5 glass wool batts for single and double steel frames for FRL 90/90/90 with mineral wool batts and Glass wool R2.5 batts for single and double framing timber walls. see recommended products web site Movement or control joints should be provided where the FireCrunch abuts dissimilar materials, where the construction changes within the plane of the wall, and at not more than 5 metre centres. External joints are to be filled with an expandable fire sealant strip. Tested and approved product information is available on our support website (AS/NZS APPROVED ) For FRL 90/90/90 steel stud walls are to have a minimum cavity of 90mm, minimum 20ga (min 1.15 BMT) galvanised steel and external walls are to be filled with mineral wool or rockwool batts. (as per FRL required see detailed notes this site, relevant FRL pages ). Suitable fire resistant vapour/ moisture barriers must be used for all externals walls. FIRE RATED WALL - LOAD BEARING Use min R2.5 mineral or rockwool batt FRL 90/90/90 STEEL FRAME 10mm FireCrunch internal lining proved FRL 90/90/90 from both sides INDICATIVE CONSTRUCTION DIAGRAM As every building is different the following diagram is provided as an indicative guide to the use of FireCrunch in fire rated area situations. Architects, designers and contractors should consult FireCrunch Australia if additional assistance is required. FRL 90/90/90/ and over ( ask us) Gun in recommended fire sealant see web site frecrunch.com.au/recommendedproducts/ AS ,Gun down 3mm thick beads on stud face and comb down face before applying the next board and fxing with min 4mm wide are joint and gun sealant into minimum 4mm gap and tool down 2/3mm for shadow line panel, texture paint or full cover render finish. RECOMMENDED PRODUCTS 90mm 20ga (1.15 BMT) steel frame Non Load bearing wall Use 0.75 BMT,for load bearing min 1.15 BMT OR CHECK STRUCTURAL ENGINEER Products recommended for use with FireCrunch are continually being added as we test the compatibility of application product and systems. The latest products that have been tested and approved for use on the FireCrunch product can be viewed on the FireCrunch support site under recommended products. more than mm from the top and pest protection is provided. NOTE: FireCrunch is of no interest to termites Minimum 10mm FireCrunch external lining 6

7 NATA FIRE RATED FIRE SEPARATION WALL FRL 120/120/120 STEEL FRAMED CONSTRUCTION 1.15 BMT USE 90mm HD ROCKWOOL FIRE BATT Offset joints 50mm (Inner and outer board Joint on Stud Face) FRL 120/120/120 (NCC) INDICATIVE CONSTRUCTION DIAGRAM FRL 120/120/120 NCC ALTERNATIVE Solution 90mm ROCKWOOL HD FIRE BATT. Screw at 200mm centres 12mm from EDGE. STEEL FRAME FRL RATED INTERNAL/EXTERNAL WALLS 50mm Offset are joints to provide solid 20mm barrier, do not tight butt the boards, create 4mm expansion joint on each board (EXTERIOR ONLY) and gun in sealant. If plaster joint required Internally use ONLY recommended products plaster set compounds per instructions web site FCA (TE) recessed edge board butt joint, do not gun are sealant into internal joints. Gun Fire sealant down the stud face joints only 3mm beads. 90mm steel framed wall min 20GA (1.15 BMT) FireCrunch external lining Use corrosion Proof screws (See data Sheet) Minimum 50mm offset joints with 2 LAYERS 10mm FireCrunch USE TE (Recessed edge) for plaster set of interior cladding Use SQ edge or CE edge for exteriors. This is a NCC "Alternative" solution and should be discussed with your fire consultant and Fire Certifier or surveyor first. 7

8 BOUNDARY WALLS STEEL AND TIMBER FRAMING FIRE RATED BOUNDARY WALLS, LOAD AND NON LOAD BEARING, FOR BOUNDARY WALLS FRL 60/60/60**** to FRL 90/90/90**** AS ) BCA, CSIRO, NATA, FIRE, ON ASBESTOS AND NON NATA TESTED. (CSIRO CERTIFICATES WEB SITE) FIXING NOTES Movement or expansion control joints should be provided where the FireCrunch abuts dissimilar materials, where the construction changes within the plane of the wall, and at not more than 5 metre centres. TIMBER FRAMES External joints are to be filled and backing studs facings applied with recommended fire sealant AS Tested and approved product information is available on our support website NCC). (NCC) ALTERNATE TESTED SYSTEM For FRL 60/60/60 TIMBER STUD WALLS are to have a minimum cavity of 90mm x 45mm stud frame and a 10mm sheet each side of frame min R 2.5 GLASS WOOL or R value to suit climate Zone of property but not below R 2.5. NOTE NOTE THE MAX FRL USING FCA ON TIMBER FRAMING IS FRL.../60/60 SINGLE FRAME and FRL.../90/90 ON DOUBLE STUD TIMBER FRAMING USE STEEL FRAMING for LOAD BEARING ( 55kN) FRL 60/60/60 to 90/90/90 and ABOVE AS/ (Approved steel framing min 1.15BMT ) Steel framed walls, floors and ceilings are to be constructed strictly in accordance with AS/NZS 4600 (Cold Formed Steel Structures), the Building Code of Australia and all relevant Standards. Fasten to the studs, joists and rafters min. 12mm to 15mm from edge and 50mm from the corner of boards and be staggered fixed each side of board joint at a maximum of 200mm centres. Fasteners to be,recommended corrosion proof,ribbed head bugle screws and finish 2mm below the surface of the FireCrunch boards. (2 pack fill) The boards are strong but care should be taken not to damage the core or face. FRL /60/60/60**** & 90/90/90**** TIMBER FRAMES:Use 2.5 Kg Glass wool fire batts min 90mm thick FRL.../60/60 for timber single frames. FOR FRL.../90/90 for double stud timber frames ALL min 90mm x 45mm. STEEL FRAMES LOAD /B (55kN) 60/60/60 R2.5 GLASS wool batts, but use 80Kg ROCKWOOL OR MINERAL WOOL batts for FRL 90/90/90. (min 1.15 BMT) IMPORTANT NOTE TO ABOVE **** AS ALL STRUCTURAL LOAD BEARING REQUIREMENTS VARY CONSIDERABLY THE FIRE TESTS ARE RELATED TO FIGURE 2 AND 3 ie STRUCTURAL INTEGRITY 90 MINS AND INSULATION 90MINS. THE REQUIRMENT IN LOAD BEARING (1ST FIGURE) (In timber framing only) MUST BE DETERMINED BY A STRUCTURAL ENGINEER RELATIVE TO EACH PROJECT SPECIFICATION All external walls must be surface and edge sealed with approved Rockcoat MgO sealer primers, (See recommended products products web site) before, or immediately after installation. Cavity of 90mm and (20ga) min (1.15 BMT) Galvanised steel frame filled with 90mm min 80Kg mineral wool batt. Use R 2.5 glasswool batts on timber frames, see recommended products web site. Movement or expansion control joints should be provided where the FireCrunch abuts dissimilar materials, where the construction changes within the plane of the wall, and at not more than 5 metre centres. External joints are to be filled with recommended fire sealants showing AS on package. Bostik Fireban, Tremstop PU, Sikka Fire stop ect Steel Frames minimum 20ga (min 1.15 BMT) Galvanised steel ) 90 X 45mm stud frames. TIMBER MIN 90X45mm STUD FRAMES. NOTES FOR TIMBER FRAMING FRL 60/60/60 and 90/90/90***** Fix 10mm FCA sheets to the outer SINGLE timber frame install vertically. Put the FRL 60/60/60 R2.5 fire batt in the 90mm created cavity and screw fix the outer 10mm FCA board as per instruction on technical ref sheet at 200mm centres. Before fixing THE OUTER WALL SHEET, see that the fire sealant is gunned down the outer face of each joined stud to board and the 4mm gap left between boards is further filled with fire sealant to 2/3mm from top of edges. Screw fix at 200mm centres with ribbed head self c/s bugle screws. See step by step instructions Technical specs /techical.specifications Suitable moisture barriers ( BCA) must should be used for all external walls between frame and board. *****NOTE: TIMBER FRAME LOAD BEARING, 1ST FIGURE, MUST BE ASSESSED BY THE PROJECTS STRUCTURAL ENGINEER. THE CAPABILITY IN MATERIAL INTEGRITY AND INSULATION 2ND AND 3RD FIGURE IS FIRE TEST ESTABLISHED BY CSIRO FIRE TESTS. INDICATIVE CONSTRUCTION DIAGRAM As every building is different the following diagram is provided as an indicative guide to the use of FireCrunch in fire rated area situations. Architects, designers and contractors should consult FireCrunch Australia if additional assistance is required. TIMBER AND STEEL FRAMING UP TO FRL 90/90/90 (LOAD BEARING) 4mm fire sealant gap joints in FireCrunch external lining sheets. (1.15 BMT) 90mm x 45mm steel frame FRL 90/90/90 max or 90mm x 45mm timber stud frame FRL 60/60/60 max RECOMMENDED PRODUCTS Products recommended for use with FireCrunch are continually being added as we test the compatibility of application products and systems. The latest products that have been tested and approved for use on the FireCrunch product can be viewed on the FireCrunch Support site under Recommended Products. more than mm from the top Minimum 10mm FireCrunch external lining and pest protection is provided. NOTE: FireCrunch is of no interest to Termites **** LOAD BEARING WALL NOTES:- Please note that Timber frames 90mmX45MMM have been tested in a non load bearing format. The 2nd figure MATERIAL INTEGRITY in containing no fire pass and the 3RD Figure INSULATION PERIOD have all been tested to the BCA standard under NCC. Because all load bearing walls will vary To QUALIFY the first figure STRUCTURAL ADEQUACY the project structural engineer must specify the timber framing dimensions to meet required load bearing in timber and type for 60 or 90 minutes. FIRE TEST REPORTS AVAILABLE technical@ For timber walls a structural engineer will be required to assess the project timber framing material 1st figure STUCTURAL ADEQUACY for the FRL required 60 OR 90, the 2nd figure material INTEGRITY and the INSULATION the 3rd figure have both passed the fire tests in 60 and 90 minutes. As all walls vary in LOAD bearing requirement, the structural engineer for each project will need to confirm the capability of the load bearing in timber framing. If this is not a viable solution in timber then the frame must be built of steel as per CSIRO/NATA FRL 60/60/60 and FRL 90/90/90 fire tests to MIN LOAD BEARING OF 55kN achieved on 1.15BMT. NOTE**** NO FRL can be obtained unless there is a corresponding FCA board on the INNER face of the Frame. Whilst all FCA board is NON combustible AS / and AS/3837, for a tested DTS system rated IN FRL,there must be an FCA sheet each side of frame to qualify FRL under BCA DTS. OTHERWISE NO FRL CAN BE RATED 8

9 NATA FIRE RATED WALL STEEL FRAME CONSTRUCTION GENERAL INSTALLATION - INTERNAL & EXTERNAL FIRE WALLS FireCrunch has fire rated tests certificates and assessments from the CSIRO up to FRL 90/90/90 and provides NCC Solutions based on NCC using two layers of 10mm FireCrunch each side for FRL 120/120/120 and over **** refer to technical@ FireCrunch over FRL 120/120/120 REFER FCA PL FRL 90/90/90 steel frame, load bearing 90mm cavity or FRL 90/90/60 steel frame, load bearing 90mm cavity or FRL 60/60/60 steel frame, load bearing 90mm cavity FRL 30/30/30 steel frame, load bearing 90mm cavity NON LOAD BEARING REFER FIRECRUNCH FRL.../120/120 plus refer FireCrunch FRL.../90/60 FRL.../60/60 FRL.../30/30 To achieve the fire rating in these formats FireCrunch must be installed in accordance with this installation manual. FRAME CONSTRUCTION SPECIFICATION See FireCrunch CSIRO fire test certificates for details under "Certification" of testing " Web Site : One layer of 10mm FireCrunch on studs, fixed vertically, to galvanised steel stud wall framing, with noggings. Board must be screw fixed to steel framing Stud adhesive MUST NOT BE USED IN FIRE WALLS Stud adhesive should not be used in flood prone areas FRL. FRL (FireCrunch side) STUD depth CAVITY INFILL* (DTS SOLUTION) 120/120/120**** 2 layers 10mm (offset joints) min. 90mm 1.15 BMT 90mm thick 80kG Rockwool / Mineral wool Fire batts (NCC) 90/90/90 1 layer 10mm min. 90mm 1.15 BMT 90mm thick R 2.5 GLASS WOOL BATT NCC /BCA TESTED 60/60/60 1 layer 10mm min. 90mm 1.15 BMT 90mm thick R 2.5 Fibre Glass batts NCC DTS /BCA TESTED * use recommended product only INTERNAL/EXTERNAL FIRE WALLS - FIRE RATED CONTROL JOINTS INTERNAL/EXTERNAL FIRE WALLS - FIRE RATED CONTROL JOINTS All joints must be backed by studs or back blocker. Screw at 200 centres at edges and on studs and nogs. Stagger edge fixing on studs. Approved AS/NZS fire rated sealant must be used on all joints. Studs should be at 450mm maximum centres STEEL FRAME FRL RATED INTERNAL / EXTERNAL WALLS Do not use fibre fuse type tapes and well 'pre soak' the recessed edge before applying the trade base coats and paper. USE RECESSED EDGE BOARD TYPE FCA (TE) FOR INTERNAL PLASTER SET Paper Tape and Base coat, topping and feather out 150mm usual practice. INTERNAL (INSIDE) WALL FireCrunch TE10 (10mm) Recessed edge 50mm wide Paper tape internal Screed 2-3mm recommended products Fire Sealant over stud face before fixing FCA board. Check recommended product section web site for plaster joint installs to retain FCA warranty Butt set the 10mm FCA TE board Stagger screws on either side 200mm centres at min. 12mm from edge Rock wool batt for FRL 90/90/90 and /or climatic area required. Stud EXTERNAL (OUTSIDE) WALL Moisture /vapour barrier Stagger screws on either side 200mm centres at min. 12mm to 15mm from edge. Use recommended corrosion proof screws for external applications. Note: Drawing not to scale in mm shown. Screed 2-3mm recommended products Fire Sealant over width and length of stud face under joints before fixing FCA board. 4mm min. gap, tool down 2mm from surface edge. FireCrunch approved fire rated sealant AS/NZS USE FCA 10MM (SE) SQUARE EDGE BOARD FOR EXTERNAL CLADDING Approx. 3mm thick gunned on approved AS/ fire sealant between stud face and sheet before fixing sheet. 9

10 NON LOAD BEARING FRL -/120/120 NATA FIRE RATED WALL - INTERNAL COLD ROLLED FORM, STEEL FRAME CONSTRUCTION INTERNAL FIRE WALLS - INSTALLATION NON LOAD BEARING FRL -/120/120 this FRL.../120/120 is an NCC BCA STANDARDS tested alternative solution / Certifiers can request the actual full fire test reports in each case technical@ Board Thickness Stud Depth Cavity Fill FRL Non Load Bearing 10mm Minimum 90mm 90mm min. R 2.5 GLASS WOOL BATT -/120/120 SCREWS Use only Self Countersink Ribbed Head screws. Screw fixing at 200mm centres 10mm gap between board and floor /footings. Caulk perimeter with approved fire rated sealant Stagger fixing at 200mm centres on join For 64mm and 76mm Steel Stud frames CONSULT FCA under NCC 10 gauge, 16 TPI, 25mm, CSK rib, X Drive#1, DP NOTE: DOUBLE 10mm LAYER INSTALL, FireCrunch sheets must be laid in vertical configuration with 75mm offset fire joints as per diagram page 7 ALL Fixings at 200mm Centres. Fastener Position Centre of board Recessed edges Butt joints Corners & openings Fastener Spacing staggered STEEL FRAME FRL -/120/120 (NON LOAD BEARING) Screw fix at 200mm Max centres top and bottom frame FireCrunch approved fire rated sealant must be used on all joints as per the instructions on page 7 NOTE: HORIZONTAL "single sheet " CLADDING CAN ONLY BE USED IN "NON LOAD BEARING" WALLS. SINGLE LAYER HORIZONTAL INSTALLATION Set joints with fire rated sealant Screw fixing at 200mm centres Stagger fixing at 200mm centres on join Screw fix at 200mm Max centres top and bottom frame Fastener Position Centre of board Recessed edges Butt joints Corners & openings Fastener Spacing Fix at each stud 10

11 NATA FIRE RATED WALL - EXTERNAL COLD FORMED SECTION - STEEL FRAME CONSTRUCTION EXTERNAL FIRE WALLS - INSTALLATION Board Thickness Stud Depth Cavity Fill FRL Load Bearing Screw fixing at 200mm centres 10mm 90mm (1.15 BMT) 90mm min. R 2.5 Glass wool batt FRL 90/90/90 AND FRL ---/90/90 SCREWS Use only recommended corrosion proof Self Countersink Ribbed Head screws. Stagger fixing at 200mm centres on join Suitable moisture barriers should be used for external walls. FRL 90/90/90 and FRL --/90/90 for 64mm and 76mm Steel Stud frames CONSULT FCA under NCC For screwing FireCrunch to steel framing use recommended stainless steel or corrosion proof screws. Maximum depth between surface of screw head and surface of FireCrunch should not be more than 1.5mm. 2 Pack fill exteriors Minimum fastening distance from edge of board should be 12mm. NOTE: VERTICAL CLADDING MUST BE USED IN "LOAD BEARING" FIRE WALLS DO NOT USE HORIZONTAL CLADDING SINGLE LAYER VERTICAL INSTALLATION LOAD BEARING WALL Install FireCrunch sheets in a vertical arrangement if using tapered/recessed or chamfered edge board. STEEL FRAME FRL 90/90/90 (LOAD BEARING) 4mm gap between board and floor. Caulk perimeter with approved fire rated sealant AS Fastener Position Centre of board Recessed edges Butt joints Corners & openings Top & Bottom Frame Fastener Spacing staggered NOTE: HORIZONTAL "SINGLE SHEET" CLADDING WITH BACK BLOCKING ON ALL HORIZONTAL JOINTS CAN ONLY BE USED IN "NON LOAD BEARING" FIRE WALLS. SINGLE LAYER HORIZONTAL INSTALLATION NON LOAD BEARING Install FireCrunch sheets in a horizontal arrangement if using square/straight edge board. Screw fixing at 200mm centres Stagger fixing at 200mm centres on join Fastener Position Centre of board Recessed edges Fastener Spacing Fix at each stud Butt joints Corners & openings Top & Bottom Frame Screw fix at 200mm Max centres top and bottom frame FireCrunch approved AS fire rated sealant must be used on all joints as per the instructions RECOMMENDED PRODUCTS FCA WEB SITE 11

12 NATA FIRE RATED WALL - EXTERNAL COLD ROLL FORM,STEEL FRAME CONSTRUCTION EXTERNAL FIRE WALLS - INSTALLATION Board Thickness Stud Depth Cavity Fill FRL Load Bearing 10mm 90mm (1.15 BMT) 90mm min. R 2.5 Glass wool batt 60/60/60 AND...60/60 SCREWS Use only recommended corrosion proof self countersink ribbed head screws. Screw fixing at 200mm centres Stagger fixing at 200mm centres on join Suitable moisture barriers should be used for external walls. FRL 60/60/60 and FRL ---/60/60 76mm Steel Stud frames CONSULT FCA under NCC For screwing FireCrunch to steel framing use recommended stainless steel or corrosion proof screws. Maximum depth between surface of screw head and surface of FireCrunch should not be more than 1.5mm. 2 Pack fill exteriors Minimum fastening distance from edge of board should be 15mm. SINGLE LAYER VERTICAL INSTALLATION LOAD BEARING Install FireCrunch sheets in a vertical arrangement if using tapered/recessed or chamfered edge board. STEEL FRAME FRL 60/60/60 (LOAD BEARING) 4mm gap between floor and board. Fire seal the perimeter with recommended products Fire Sealant. AS web site Fastener Position Centre of board Recessed edges Butt joints Corners & openings Top & Bottom Frame Fastener Spacing staggered all joints must be sealed with recommended products Screw fixing at 200mm centres Stagger fixing at 200mm centres on join SINGLE LAYER HORIZONTAL INSTALLATION NON LOAD BEARING Install FireCrunch "single" sheets in a horizontal arrangement and back block all horizontal joints and fire seal. Fastener Position Centre of board Recessed edges Butt joints Corners & openings Top & Bottom Frame Fastener Spacing Fix at each stud 20mm max. centres Screw fix at 200mm Max centres top and bottom frame FireCrunch approved AS fire rated sealant must be used on all joints as per the instructions RECOMMENDED PRODUCTS FCA WEB SITE 12

13 FRL 60 /60/60 can only be achieved if min 10mm FireCrunch is applied both sides as per the RESOLUTE LABS FIRE TEST. (Certification). Fire attack containment for attack each side requires FCA 10mm each side Interior and Exterior. FIRE RATED WALL - LOAD BEARING TIMBER FRAME CONSTRUCTION FIXING NOTES: (TESTED/ Solution NCC / BCA) Timber framed walls, floors and ceilings are to be constructed strictly in accordance with AS/NZS 1684 (Timber structures), the Building Code of Australia and all relevant Standards. Fasten to the studs, joists min. 15mm from the edge and 50mm from the corner of boards and staggered at a maximum of 200mm centres. Fasteners should finish with the head just below the surface of the FireCrunch. The boards are strong but care should be taken not to damage the core or face. Exterior FCA cladding must be properly weather sealed at the ends, edges and joints and drainage provided for any moisture that may develop. prior to or very soon after installation to avoid prolonged exposure to rain. board must allowed to completely dry out before painting or rendering. Pre seal with Roockcoat MgO sealer. SEE recommended products PRODUCTS Use recommended R 2.5 Glasswool batts 90mm x45mm timber stud frame FRL 60/60/60**** Movement or control joints should be provided where the FireCrunch abuts dissimilar materials, where the construction changes within the plane of the wall, and at not more than 5 metre centres. External joints are to be filled with a recommended expandable fire sealant. AS Approved product information is available on our support website Timber stud walls are to have a minimum cavity of 90mm. All walls are to have a cavity depth to accommodate a 90mm R 2.5 GLASSWOOL BATT fire batt for single framed timber stud walls. minimum R2.5 for TIMBER FRAMING Radiata Pine/ M10 or similar softwoods to FRL...60/60 ALL STUDS TO MAX 450mm CENTRES or LESS. **** LOAD BEARING WALL NOTES:- Please note that Timber frames 90mmX45MMM have been tested in a non load bearing format. The 2nd figure MATERIAL INTEGRITY in containing no fire pass and the 3RD Figure INSULATION PERIOD have all been tested to the BCA standard under NCC. Because all load bearing walls will vary To QUALIFY the first figure STRUCTURAL ADEQUACY the project structural engineer must specify the timber framing dimensions to meet required load bearing in timber and type for 60 or 90 minutes. FIRE TEST REPORTS AVAILABLE technical@ For timber walls a structural engineer will be required to assess the project timber framing material 1st figure STUCTURAL ADEQUACY for the FRL required 60 OR 90, the 2nd figure material INTEGRITY and the INSULATION the 3rd figure have both passed the fire tests in 60 and 90 minutes. As all walls vary in LOAD bearing requirement, the structural engineer for each project will need to confirm the capability of the load bearing in timber framing. If this is not a viable solution in timber then the frame must be built of steel as per CSIRO/NATA FRL 60/60/60 and FRL 90/90/90 fire tests to MIN LOAD BEARING OF 55kN achieved on 1.15BMT. Suitable moisture barriers to be used for all external walls. INDICATIVE CONSTRUCTION DIAGRAM As every building is different the following diagram is provided as an indicative guide to the use of FireCrunch in fire rated area situations. Architects, designers and contractors should consult FireCrunch Australia if additional assistance is required. IN SPECIFIC FRL SPECS RECOMMENDED PRODUCTS Products recommended for use with FireCrunch are continually being added as we test the compatibility of application products and systems. The latest products that have been tested and approved for use on the FireCrunch product can be viewed on the FireCrunch. Support site under Recommended Products. TIMBER FRAME FRL 60/60/60 (LOAD BEARING) Timber framed wall Use approved AS/NZS fire sealant with min 4mm gap on external FireCrunch 10mm lining sheets Ensure the finished ground level is more than mm from the top of the floor slab and appropiate vermin and pest protection is provided. Fire seal a steel furring chanel if required NOTE: FireCrunch is of no interest to termites Minimum 10mm FireCrunch external lining NATA 13

14 FIRE RATED WALL TIMBER FRAME CONSTRUCTION ALTERNATIVE FIRE WALL SYSTEM GENERAL INSTALLATION - INTERNAL & EXTERNAL FIRE WALLS FireCrunch has been FIRE TESTED at: FRL 60/60/60 for timber framing. FIRE ENGINEERING CERTIFICATE (NCC) RE RESOLUTE LABS FIRE TESTS NOTE: load bearing capability ( 1st fig) is to be determined by the project structural engineers specification To achieve the fire rating in these formats FireCrunch must be installed in accordance with this installation manual. One layer of 10mm F irecrunch fixed directly to frame, timber stud wall framing, with noggings. Board is SCREW FIXED directly to timber framing over sarking DO NOT NAIL,NAILING WILL VOID THE WARRANTY. Stud adhesive should not be used. FRL (FireCrunch side) STUD CAVITY INFILL* 60/60/60*** Min. 90mm x 45mm 90mm R 2.5 Glasswool fire batt * use recommended product only INTERNAL/EXTERNAL FIRE WALLS - FIRE RATED CONTROL JOINTS PLAN VIEW TOP HAT SECTION 1. Studs should be at 400mm or 600 maximum centres. to avoid 300mm run off with 12mm wide boards 2. FCA 10mm boards are 1200mm wide. 3. All fire joints must be backed by studs and or noggins 4. Screw at 200 centres at edges and on studs and noggs. Stagger edge fixing on vertical studs. 5. Approved AS fire rated sealant must be used on all joints. TIMBER FRAME FRL 60/60/60 (LOAD BEARING) INTERNAL (INSIDE) WALL FireCrunch (10mm) Timber frame FRL 60/60/60 use only R 2.5 Glasswool Fire batts EXTERNAL (OUTSIDE) WALL Moisture barrier 50mm wide stop tape Paper stopping tape do not use fibre mesh tape with FCA Stagger screws on either side 200mm centres at min. 12 to 15mm from edge. Use recommended corrosion proof screws for external applications. Screed 2-3mm recommended products Fire sealant over stud face before fixing FCA board. USE approved AS/NZS fire rated sealant on stud faces only internal For internal plaster set walls joint comb 2/3mm fire sealant down face of studs before fixing board NOTE: Leave 1mm gap Do not fill Do not fill plaster set gap with fire sealant if plaster setting joints. See special instructions for plaster set with FCA boards recommended product section web site to retain FCA warranty web site Stagger screws on either side and at 200mm centres at min. 12mm from edge Stud 4mm min. gap Fire System EXTERNAL Wall fire attack FRL 60/60/60 Timber Frame Construction FireCrunch approved fire rated sealant No separator battens required screw fix direct to frame. Note: Drawing not to scale in mm shown. Approx. 3mm of thick gunned on approved AS/ fire sealant ON STUD FACE before fixing sheets. FireCrunch (10mm) 14

15 FIRE RATED WALL - INTERNAL TIMBER FRAME CONSTRUCTION INTERNAL FIRE WALLS - INSTALLATION Board Thickness Stud Depth Cavity Fill FRL Load and Non Load Bearing fire walls 10mm min. 90mm 90mm. R 2.5 Glasswool Fire batts FRL 60/60/60 and -FRL -/60/60 SCREWS Use only Countersunk Ribbed Head Class 2 / 3 screws. NOTE: Do not nail FireCrunch or warranty will be voided. Screw fixing at 200mm centres For screwing FireCrunch panels to wood framing, we recommend using 8-10 Countersunk Ribbed Head Class 2 / 3 screws (depending on timber hardness). Maximum depth between surface of screw head and surface of FireCrunch should not more than 1.5mm. SINGLE LAYER 10mm each side VERTICAL INSTALLATION LOAD BEARING USE VERTICAL OR HORIZONTAL IN NON LOAD BEARING CONDITIONS FOR FIRE WALLS. TIMBER FRAME FRL -/60/60 (NON LOAD BEARING) 10mm gap between board and floor. Caulk perimeter with approved fire rated sealant Stagger fixing at 200mm ( 2 ref points) centres on join Fastener Position Centre of board Recessed edges Butt joints Corners & openings Top & Bottom Frame Fastener Spacing staggered SINGLE LAYER 10mm each side HORIZONTAL INSTALLATION NON LOAD BEARING NOTE: USE VERTICAL OR HORIZONTAL CLADDING IN NON LOAD BEARING CONDITIONS. FOR FIRE WALLS BACK BLOCK ALL HORIZONTALL CLADDING AND USE RECOMMENDED PRODUCTS FIRE SEALANT Set joints with recommended fire rated sealant Screw fixing at 200mm centres Stagger fixing at 200mm ( 2 ref points) centres on join Fastener Position Centre of board Fastener Spacing Recessed edges Fix at each stud Butt joints Corners & openings Top & Bottom Frame Screw fasten at 200mm Max centres. FireCrunch approved fire rated sealant must be used on all joints as per the instructions RECOMMENDED PRODUCTS FCA WEB SITE 15

16 FIRE TESTED DOUBLE FRAME, PARTY WALL SYSTEM TIMBER FRAME CONSTRUCTION FRL 90/90/90 **** (SEE NOTE BOTTOM OF PAGE 25) FireCrunch can be used in many situations where adjoining or party walls are required to be fire and acoustic rated. The FireCrunch BOARD IS TESTED TO FRL /90/90 ON 90mm X45mm TIMBER FRAMES AND APPLIES TO LOAD BEARING FRL 90/90/90***** ONSUITABLY SPECIFIED LOAD BEARING WALL SYSTEMS. For steel frames see page (18) On a timber frame, one layer of 10mm FireCrunch,each side with a Minimum R2.5 90mm thick Glasswool Batt and 10mm FCA boards suitably jointed with approved fire sealant will provide a minimum Fire Resistance Level (FRL) of FRL.../90/90 AND FRL 90/90/90 WITH APPROVED FIRE WALL SPECIFICATION FOR LOAD BEARING for fire attack equally from both sides and an acoustic minimum of Rw 62 plus ctr,net Rw 52. NOTE: Use only vertically set panels for "load bearing" Fire walls Use corrosion proof fasteners as per DATA sheets web site Fire separation walls between apartments meet BCA definition of discontinuous construction. UNDER BCA ( DTS) see certificates web site Concrete ground slab NOTE **** LOAD BEARING (1st FIG )TO BE ESTABLISED BY STRUCTURAL ENGINEER FRL 90/90/90 FireCrunch Board 1 x 10mm sheet each side of Timber frame (NCC ) Alternative solution BCA 3mm layer of approved fire resistant sealant combed down stud face AND GUNNED INTO THE 4mm BETWEEN BOARD JOINT. Minimum R2.5 90mm thick Glasswool Batt each side for FRL 90/90/90 **** timber frames. min. 20mm air space fire wall separation gap NATA Dual Framed FIRE SEPARATION WALL Total 1 x 10mm FCA each side FRL 90/90/90**** Timber frame Fire separation wall lining 10mm FireCrunch each side. Set approved fire sealant on stud faces 3mm thick and min 4mm wide in board edge or joisted floor base with 19mm FireCrunch TG board on top FIRE RATED DOUBLE STUD PARTY WALL SYSTEM Assembly System Non Width FRL Insulation R W R W +C tr Steel Frame FRL 90/90/90 LOAD BEARING 220mm width 1 x FireCrunch each side 3mm thick approved fire sealant on stud face between frame and board Min 4mm fire joint between boards Steel Stud frame (90mm) with insulation Min. 20mm fire wall separation air gap Acoustic TESTED system 1 layer 10mm each side Rw 62/52 Rws Min 220mm width 1 x 10mm FCA sheet system Load Bearing min. 90/90/90 both sides CSIRO TESTED Steel frame (R 2.5) 90mm thick mineral or Rockwool Fire batt 62 52^ Timber Frame FRL 90/90/90**** LOAD BEARING 1 x 10mm FCA sheet each side of tframe. 2/3mm thick approved fire sealant on stud face between frame and board Min 4mm fire joint between boards (Exterior only) Timber Stud (min.90mm) with insulation Min. 20mm fire wall separation air gap Acoustic is Rw 62 and Rw 52 net of ctr with 1 10mm sheet each side and R2.5 Glass wool batt in both cavities Min. 230mm width 2 x10mm sheet system Non load bearing FRL /90/90 and LOAD BEARING FRL 90/90/90**** WITH APPROVED STRUTURAL ENGINEERS SPECS (SEE NOTE BOTTOM OF PAGE 25) Timber frame R mm thick Glass wool fire batt 62 52^ FireCrunch approved are rated sealant must be used on all joints as per the instructions on WEB SITE 16

17 FIRECRUNCH (NCC) ALTERNATIVE SYSTEM FIRE SEPARATION WALL TIMBER AND STEEL FRAMING This assessment was effected under the (BCA) Alternative system (NCC) using NATA /CSIRO fire test report. FSV 1708/ ISO IEC and subsequent 90mmx 45mm Timber Framing with 600mm centre studs test by Resolute Labs QLD SEPT 2018 FRL... /90/90 AS/ and assessed under FRL 90/90/90 with suitable structural engineers framing assessment acccording to load bearing required FCA TESTS PROVED THE MATERIAL INTEGRITY 2nd FIG AND THE INSULATION 3rd FIGURE MEET THE AS STANDARD. THE STRUCTURAL ADEQUACY (1st fig) IS TO BE DESIGNATED BY THE STRUCTURAL ENGINEER IN EACH CASE AS ALL STRUCTURES and PROJECTS ARE DIFFERENT. ACOUSTIC TESTING Tested NATA (Kilargo) Acoustic Rw 62 net ctr 52, obtained on 1 x10mm sheet each side. see /certification. END ELEVATION DOUBLE TIMBER FIRE WALL FRL.../90/90 AND FRL 90/90/90*** FIRE SEPARATION WALL TIMBER FRAMING LOAD BEARING FRL 60/60/60**** Use 1 x 10mm sheet each side Timber Frame Double stud. Acoustic rating above Rw 62 minimum 1x10mm FCA board. Total separation wall width 220mm (SEE NOTE BOTTOM OF PAGE 25) 90mm 20mm 90mm USE ONLY R2.5 GLASSWOOL BATTS (90 mm thick) Studs to max 450 Centres IN 90 MINUTE FIRE WALLS 10mm FireCrunch Board (FCA) see under recommended products, plaster set instruction as internal recessed edge boards has a very different FIRE SEALANT APPLICATION and FCA BOARD JOINTS SPACING. End elevation view, total wall width 220mm FIRE Collars NOTE: (Fire wall penetrations) For interactive electrical and plumbing FRL protection to.frl../90/90 use SNAP SYSTEMS fire collars for carriage, in between and through fire separation walls. Both Snap and FireCrunch single sheet 10mm board have been fire tested (individually by the CSIRO) and ASSESSED TOGETHER to FRL../90/90 eliminating 2/3 layers of plaster board with 1 layer of 10mm FCA. See web site /certification/ FRL 90/90/90 BCA/NCC DISCONTINUOUS DOUBLE STUD TIMBER FRAME ACOUSTIC Rw 62/ net 52 17

18 FIRE TESTED DOUBLE FRAME, PARTY WALL SYSTEM STEEL FRAME CONSTRUCTION FRL 90/90/90 FireCrunch can be used in many situations where adjoining FIRE SEPARATION AND INTERTENANCY WALLS are required to be fire and acoustic rated. The FireCrunch NCC ALTERNATIVE SYSTEM is assessed based on the DTS AS NATA / CSIRO tests using 1 x 10mm sheet either side of a 92mm x45mm steel stud frame 1.15 BMT. This assesses a double stud steel frame 90 x 45 at using 300,400 or 450 centres studs able to to withstand FRL 90/90/90 when 1 x 10mm FCA sheet each side is used (IN Total ). FCA a single 10mm sheet replaces multiple layers of Fyrchek cuts at least 50% labour and materials. On a double stud steel frame 1.15 BMT, install one layer of 10mm FireCrunch each side, INSULATED with an HD Mineral or Rockwool fire batt or equivalent (based on suppliers specifications),. Fire seal joints with approved AS/ fire sealant, (See web site for support products which will provide a minimum Fire Resistance Level (FRL) of 90/90/90 *****from both sides. Use corrosion proof screws as per DATA sheets. website : NCC ALTERNATIVE SOLUTION. FRL.../120/120 If you do not require a structural Load Bearing rating, the installation stated above will provide a minimum FRL of -/120/120 on steel framing when 2 x10mm FCA sheets are used per side (NCC) (ask us) NOTE **** LOAD BEARING WALL REQUIREMENTS (1ST FIGURE) ARE DETERMINED BYTHE PROJECT STRUCTURAL ENGINEER ASSESSING THE MINIMUM 1.15 BMT TEST FRAME GAUGE USED BY FCA See fire wall penetrations SEE WEB SITE CERTIFICATION ASSESSMENT/ CSIRO 3mm layer of approved fire resistant sealant on stud faces and min 4mm fire joint 90mm R 2.5 Mineral or Rockwool WOOL FIRE BATT ( STEEL FRAMING ) min. 20mm gap Concrete ground slab See fixing details page... Dual STEEL Frames FRL 90/90/90 use10mm (FCA) FireCrunch each side wall lining Set approved fire sealant on stud faces 3mm thick and min 4mm wide in board vertical edge joints. Fill to board face and flush off to top on SQ edge TE board ( External only). Set sealant fill to use recessed edge (TE) for internal and soft butt the joints. Do not use fire sealant in internal plaster set joints, set 3mm fire sealant BEADS on stud face and comb down to provide even blanket cover where board joins on stud. FIRE RATED DOUBLE STUD PARTY WALL SYSTEM Assembly System Nom Width FRL Insulation R W R W +C tr Steel Frame FRL 90/90/900 LOAD BEARING 1 x 10mm FireCrunch each side 3mm thick approved fire sealant spread down stud face between frame and board Min 4mm fire joint between boards Steel Stud cavity (min. 90mm) with insulation Min. 20mm fire wall separation air gap betweeen frames Min. 220mm Load Bearing min. 90/90/90 both sides STEEL FRAME 90mm thick mineral or Rockwool fire batt 62 52^ instruction see web site /certification/ NATA 18

19 FIRE RATED CEILINGS AND FLOORS TECHNICAL MANUAL FIRE RATED SYSTEMS - OVERVIEW SEE PAGE 20 FOR END ELEV DETAILS FRL120/120/120 **** =1 X Layer 19mm TG plus 1 X Layer 10mm,Top side and same under side of joists 29mm. **** NOTE: The 1st figure load bearing must be assessed by the projects structural engineer based on these minimum BMT test specifications 289mm 250mm x 75mm x 2.4 BME C section Joists 2 x 10mm Firecrunch Sheets offset Joints 50mm / 75mm 19mm FireCrunch TG by using 19mm FireCrunch Tongue and Groove panels for TOP flooring, the rating from the top will be FRL.../90/90 TIMBER FRAME Min 300 mm Depth Laminated Timber Joists and min 90mm 0.75 BMT steel top hats or similar batten separators between joist and FCA 2 x 10mm ceiling boards. FLOORING: 19mm FireCrunch Tongue and Groove panels for flooring. ***** FRAME: 250mm Steel C section 2.4mm BMT. For min 300mm Timber (laminated Joists) - Max joist Centres 450mm (ref to NOTES at bottom of page 25 ) Ref to your structural engineer. CEILING: Apply 1 layer of 10mm FCA board and 1 layer of 10mm TE (recessed plaster set edge), as under finish board, offset joints (min 75mm) FireCrunch FCA board to maintain 20mm solid depth SCREW FIX at 200mm centres and set back 15mm from edges and 50mm from corners. Insert required HD 80Kg Rockwool or Mineral wool fire batt to 90mm cavity. Open cavity 2 x 10mm Firecrunch board 19mm Firecrunch board 100mm Rockwool 2x 50mm 64kg m2 Rockwool FIRE RATED CEILINGS AND FLOORS FireCrunch Solution 1 Layer 19mm FireCrunch TG flooring plus ceiling constructed with: 2 layers 10mm FireCrunch offset joints 75mm SE10 and TE10 type edges FRL (from above) FRL (from below) No Insulation RISF Rw+Ctr (from above) Rw+Ctr (from below) 120/120 90/ NOTE: TG board does not require back blocking. Apply fire sealant to groove section before finally fixing tongue section in each board. Screw fix only, nailing will void the warranty. SEE PAGE 20 FOR END ELEV DETAILS 250mm x 75mm x 2.4 BME C section Joists Open cavity 19mm Firecrunch board 289mm 100mm Rockwool 2x 50mm 64kg m2 Rockwool 2 x 10mm Firecrunch Sheets offset Joints 50mm / 75mm FRL...90/90 FLOORING: 19mm FireCrunch Tongue and Groove panels for flooring. ( TOP SIDE ). 2 x 10mm Firecrunch board STEEL FRAME: 250mm x 2.4mm BMT Steel C section TIMBER FRAME Min 300 mm Depth Laminated Timber Joists and min 90mm 0.75 BMT steel top hats or similar batten separators between joist and FCA 2 x 10mm ceiling boards. CEILING: CEILING: Apply 1 layer of 10mm FCA board and 1 layer of 10mm TE ( recessed plaster set edge), as under finish board, offset joints (min 50mm) FireCrunch FCA board to maintain 20mm solid depth SCREW FIX at 200mm centres and set back 15mm from edges and 50mm from corners. Insert required HD Rockwool or Mineral wool fire batt to 90mm cavity. FireCrunch Solution 1 Layer 19mm FireCrunch flooring Ceiling constructed with: 2 layers 10mm FireCrunch Use 1min R 2.5 Rockwool fire batts and relevant thickess of panels as recommended products by manufacturer for the final depth of interfloor space Rw+Ctr (from below) FRL (from above) FRL (from below) /120 90/90 RISF BCA 39 mins Rw+Ctr (above) 61+ NOTE: Apply fire sealant to groove section before fixing tongue section in each board. Screw fix only, nailing will void the warranty FireCrunch Ceiling and Flooring Manuals MUST be followed to ensure correct installation. For FRL ratings the FireCrunch Fire manual must also be followed and used in combination with the Flooring and/or Ceiling manual. Approved fire sealant (see website) must be used on all joints to manufacturers specifications. USE min 80kg Rockwool or Mineral Wool fire batts, fill depth 100mm (min) for 250mm Steel and 300mm Timber depth, consult BATT mfgs for installation. (SEE NOTE BOTTOM OF PAGE 25) 19

20 NATA FLOOR CEILING CSIRO FIRE TESTED SYSTEM AS/ DTS/ BCA FRL ----/90/90 LOAD BEARING FRL 90/90/90 TO ENGINEERING/ ARCHTECTURAL SPECIFICATIONS STEEL FRAME CEILING FLOOR 289MM TOTAL DEPTH TECHNICAL MANUAL GENERAL INSTALL PROCEDURE FIRE RATED CEILINGS AND FLOORS 250mm x 75mm x 2.4 BMT C section Joists Open cavity 19mm Firecrunch board 289mm 100mm Rockwool 2x 50mm 64kg m2 Rockwool 2 x 10mm Firecrunch Sheets SE10 AND TE10 offset Joints / 75mm 2 x 10mm Firecrunch board Specification floor ceiling system fire tested resolute Labs QLD Dec 2017 steel C section 250mm x 75mm x 2.4 BMT FRL.../90/90 Gun on 3mm beads of AS/ fire sealant to perimeters of the board installtion and the single visible under joint on each SE10 FCA board where it abuts on a joist face Fix the 10mm FCA sheets fixed direct to underside steel C section purlins, no intermediate battens required ( offset thru joints by 50mm/ 75mm ) ( STEEL FRAMING) A TE10 recessed edge board can be used for plaster set of the underside ceiling exposed area if required. 1 x 19mm FCA TG sheet fixed direct to the top ( floor area) of steel C section no intermediate battens required for plaster setting joints. 100mm depth Rockwool or mineral wool fire batt 64 kg in ceiling floor cavity check FCA tech support manual web site /technical 20

21 STORAGE & HANDLING Store flat, under cover on a horizontal pallet or on supports spaced at 450mm centres. Must be kept under cover away from all weather conditions. Always handle with at least one person at each end of the board. With hands apart, lift the board and tilt to prevent sagging. Always store FCA products out of the weather and off wet areas or ground do not leave exposed out in weather before use. Seal with Rockcoat MgO sealer immed after external installations recommended products PRODUCTS WEB SITE OCCUPATIONAL HEALTH AND SAFETY The work involved in sawing, drilling, sanding or otherwise cutting FireCrunch sheets should minimise dust generation with a bench saw vacuum extractor at cutting face and be carried out in a well-ventilated area. Use a replaceable filter or disposable half respirator to avoid respiratory issues Wear Industrial safety glasses or non-fogging goggles. see SDS web site GENERAL FIXING & INSTALLATION WHAT TOOLS ARE NEEDED? No special tools are required to use FireCrunch. It can be sawn, drilled, screwed and planed with timber tools.do NOT use stud adhesive for fire walls in flood prone areas to allow easy unscrew removal, dry out paint and and reset. DO NOT NAIL FireCrunch. CUTTING & MACHINING FireCrunch is easy to work and machine with normal woodworking tools and equipment. Cut sheets with a fine tooth handsaw or power saw. Edges may be trimmed with a smoothing plane, power plane or sandpaper. Panels 10mm thick and under can be scored with a cutting knife and snapped along the straight edge in the same way as you would with gypsum board. Where holes are required clean cutter bits or twist drills are satisfactory. Woodworking shapers, spindle moulders and high speed routers may be used to shape or mould the edges of FireCrunch. Tungsten carbide tipped cutters are preferred for long production runs. UNDERCOAT & SEAL FCA Before final installation undercoat /seal the board with Rockcote special MgO primer sealer. Do not nail this product screw fix only with recommended screw fixings Non attention to these important steps will invalidate the warranty See recommended products section web site main browser home page 21