Low Rise Multi-Residential Party Walls. Design & Installation Guide

Transcription

1 Low Rise Multi-Residential Party Walls Design & Installation Guide HBLA041 LRPW July 2006

2 Contents 1.0 Introduction Benefits Typical Applications Regulatory Issues Selecting a Hebel PowerWall Performance Characteristics Sound Transmission & Insulation Fire Resistance Performance Structural Provisions Design & Detailing Considerations Design, Detailing & Performance Responsibilities Components Installation Sequence Panel Handling Delivery & Storage Construction Detail PowerWall Construction Detail PowerWall Appendix A: Hebel Material Properties 30 Appendix B: Architectural Specification 31 Health & Safety, Performance & Certification, Guarantee & Disclaimer 32 The design of party wall systems for a building requires the services of professional consultants. This design guide has been prepared as a source of information to provide general guidance to the professional consultants, and in no way replaces the services of the professional consultants on the project. No liability can therefore be accepted by CSR Hebel or other parties for its use. The systems and performance specifications detailed in this guide are guaranteed only for laboratory tested conditions. Actual site conditions should be checked, and advice obtained from an appropriate consultant. Any variation or substitution of materials or assembly requirements, or any compromise in assembly or in quality of the system components may result in failure under critical conditions. CSR Hebel is continuously developing its products. This on-going development may result in changes to product specifications, range and the performance characteristics from time to time. Please visit: to check for current information. The specifications, range and performance characteristics on which the Hebel It is the responsibility of the architectural designer and engineering par ties to ensure that the details in the Hebel PowerWall Low Rise Multi-Residential Par ty Walls Design & Installation Guide are appropriate for the intended application. The recommendations of this guide are formulated along the lines of good building practice, but are not intended to be an exhaustive statement of all relevant data. CSR Hebel accepts no responsibility for or in connection with the quality of the recommendations or their suitability for any purpose when installed. PowerWall Low Rise Multi-Residential Party Walls Design & Installation Guide, NºHBLA041 LRPW are based, are those current in July, 2006.

3 1.0 Introduction CSR Hebel CSR Hebel is 100% owned by CSR Building Products Limited, one of Australia s leading building products companies. CSR Hebel manufactures and markets a range of lightweight Autoclaved Aerated Concrete (AAC) products. The current product range includes blocks, reinforced panels, cladding panels and lintels for use in the residential and commercial construction industry. CSR Hebel also sells complimentary mortars, tools and accessories. In 1989, CSR became involved with Hebel and established the Australian operation. Since then CSR Hebel has manufactured products that have won wide acceptance as innovative and environmentally friendly building materials. This is due to their lightweight yet solid nature, excellent thermal, fire and acoustic properties and design versatility. The inherent properties of CSR Hebel products help achieve quick and cost efficient construction practices as well as providing for comfortable operating environments inside the buildings all year round. Design Overview As environmental consciousness and social responsibility increases, CSR Hebel is striving to exceed these ideals and set new standards in building materials and residential living. Designed for inner comfort With CSR Hebel wall and floor solutions, clients can enjoy a comfortable interior in their home, and be comfortable with the choice for the environment. Manufacture of CSR Hebel materials uses a fraction of the energy and natural resources used in manufacturing conventional masonry, producing almost no waste or byproducts. And CSR Hebel AAC s highly efficient insulation saves power in heating or cooling the home. Designed for inner peace CSR Hebel wall and floor solutions help create a tranquil inner space. We have worked closely with acoustic experts and testing authorities to engineer inherently superior acoustics from our wall and floor systems. They create a sound barrier to external noise and from other rooms within the home. Designed for peace of mind Although it s remarkably lightweight, CSR Hebel AAC is solid and durable. CSR Hebel panels are reinforced with steel for extra strength. CSR Hebel is also extremely fire-resistant and is not a food source for termites. Designed to save As they re lightweight, CSR Hebel materials are quick to assemble, saving building time and costs. They also minimise the need for supporting materials, saving budget resources and energy. Use CSR Hebel for Better Sound Insulation With advances in technology (particularly the home theatre system) and consumer s demand for home listening pleasure the need for wall and floor systems offering excellent sound insulation has developed. Recognising the unique properties of AAC, CSR Hebel was one of the first building products manufacturers to respond to this growing need by developing a range of acoustic wall systems. Since then the peace and amenity of thousands of multiunit households and commercial developments have benefited from Hebel PowerWall. As of the 1st May 2004 the Australian Building Codes Board (ABCB) announced that the minimum Building Code of Australia (BCA) sound insulation requirements have been increased. CSR Hebel s acoustic performance will help you reach the new standard, while also benefiting from the unique lightweight yet solid feel of CSR Hebel products. Hebel PowerWall Low Rise Multi-Residential Party Walls Hebel PowerWall Low Rise Multi- Residential Party Walls have been developed to provide an effective fire barrier and to satisfy the evergrowing demand for noise abatement in multi-residential framed dwellings. The systems provide cost effective, slender wall sections, with acoustic and fire performance conforming to and exceeding the BCA requirements. Hebel PowerWall systems can achieve Rw + Ctr ratings of 50dB or better. These PowerWall systems consist of specific combinations of Hebel, CSR Bradford insulation and CSR Gyprock plasterboard or CSR Cemintel fibre cement sheet. These are used to create a symmetrical wall system, which have minimal components and are relatively compact. The resulting walls exhibit high acoustic insulation and fire resistance performance, which have been proven through registered test facilities. The primary component of the wall is the Hebel, which is a 75mm thick, steel reinforced panel, manufactured from CSR Hebel AAC. The AAC in CSR Hebel products is manufactured from sand, lime and cement, to which a gasforming agent is added. The liberated gas expands the mixture, forming extremely small, finely dispersed air pockets, resulting in lightweight aerated concrete. As with other CSR Hebel products, Hebel exhibits excellent thermal and fire resistance properties. Hebel is lightweight and easily handled, typically by only two people.

4 2.0 Benefits The many benefits of using Hebel PowerWall in low rise multi-residential party walls include: Image 2.1: installed in ground floor PowerWall. n Acoustic Performance: Significantly reduced sound transmission between units and rooms. n Good Impact Noise Resistance: Hebel PowerWall 001 has discontinuous construction and can be selected to reduce the transfer of impact noise. n Fire Protection: Tested systems have very good fire rating properties. n Lightweight: Lighter loads on structures compared to masonry block, for equivalent Rw + Ctr rating. Image 2.2: Awaiting installation of base track and panels for second storey. n Slender Walls: Wall thicknesses range from 275 to 325mm. n Cost Effective: Cost savings compared to traditional masonry construction. n No Wet Trades: Less mess and a cleaner, safer work area. n Less Wastage: Greatly reduced waste, as panels are available in a range of standard lengths. This allows for bestsuited panel length selection, which eliminates or reduces off-cut waste. n Speed of Construction: Fast installation and assembly speeds with smaller construction crew requirements. Image 2.3: Second storey panel installation. n Security: Steel reinforced AAC panels provide a high degree of security between units. n Thermal Resistance: Excellent thermal resistance performance. n Technical Support: Competent technical staff can assist with systems information. The following images show a typical Hebel PowerWall two storey party wall installation.

5 3.0 Typical Applications Hebel PowerWall systems detailed in this guide are loadbearing or nonloadbearing party wall solutions for low rise multi-residential framed construction. These wall configurations consist of Hebel panels secured to the structural loadbearing framing. A distinct difference between the systems is the to framing connection methods and the resulting acoustic performance qualities. Hebel PowerWall 001 utilises an aluminium bracket system. The bracket system provides the wall with a Discontinuous Construction rating. Hebel PowerWall 002 offers a top hat connection where the panel is secured to the framing with horizontal steel top hats. Detail 3.1: Hebel PowerWall 001 Detail 3.2: Hebel PowerWall 002

6 4.0 Regulatory Issues Dwellings Constructed Side- By-Side on a Single Allotment Where it is proposed to construct single dwellings side-by-side on a single allotment the internal wall between dwellings is a fire separating wall as defined in the BCA. The fire separating wall must start from the ground level (top of concrete footings or top of floor slab) and achieve a 60/60/60 FRL if load bearing, or /60/60 FRL if nonload bearing. The wall must go to the underside of a non-combustible roof covering and any gaps be filled with fireresisting material as described in Detail of Volume Two of the BCA. Dwellings Constructed Side-By-Side on Separate Allotments Where it is proposed to construct single dwellings side-by-side on separate allotments, or if subsequent subdivision is proposed, the wall might also be considered an external wall and each dwelling may be required to have its own wall starting from the ground level (top of concrete footings or top of floor slab) and each achieving a 60/60/60 FRL if load bearing, or /60/60 FRL if non-load bearing. Contact your local authorities, as there may also be applicable legislation or discretionary powers available to vary these provisions. Dwellings Constructed Side- By-Side on a Single Allotment Where Subdivision May Subsequently Occur. Where it is proposed to construct single dwellings side by side on a single allotment and it is known that subsequent subdivision will occur, or that subdivision might occur (and this will probably apply to most multi-dwelling developments) then, after subdivision, the internal fire separation wall might also be considered an external wall and each dwelling may be required to have its own wall starting from the ground level (top of concrete footings or top of floor slab) and achieving a 60/60/60 FRL if load bearing, or /60/60 FRL if non-load bearing. Contact your local authorities, as there may also be applicable legislation or discretionary powers available to vary these provisions. Hebel PowerWall Solutions Where the internal fire separation wall is required to be an external wall, contact CSR Hebel Engineering Services for advice on PowerWall external wall solutions. Compliance with the Building Code of Australia (BCA) All building solutions, such as walls, floors, ceilings, etc. must comply with the regulations outlined in the Building Code of Australia (BCA) or other authority. The BCA is a performance based document, and is available in two volumes which align with two groups of Class of Building : Volume 1 Class 2 to Class 9 Buildings; and Volume 2 Class 1 & Class 10 Buildings Housing Provisions. Each volume presents regulatory Performance Requirements for different Building Solutions for various classes of buildings and performance provisions. These Performance Provisions include: n Structure n Fire Resistance n Damp & Weatherproofing n Sound Transmission & Insulation n Energy Efficiency This design guide presents tables and information necessary to design a Hebel PowerWall installation that complies with the Performance Requirements of the BCA. The designer must check the adequacy of the building solution for Performance Requirements outlined by the appropriate authority. Detail 4.1: Typical Applications. Separating wall continued up to underside of non-combustible roof Separating wall continued down to ground Fire rated Wall above lower roof Dwelling 1 Dwelling 2 Dwelling 3 Dwelling 4 Dwelling 5 Suspended floor

7 5.0 Selecting a Hebel PowerWall STEP 1: STEP 2: STEP 3: STEP 4: Scan the System Selection table for the required characteristics. Turn to Section 6.0 and select the appropriate Hebel PowerWall solution. Confirm the selected Hebel PowerWall solution has adequate Fire Resistance Level (FRL) rating and acoustic performance level. If an appropriate Hebel PowerWall can not be selected, contact CSR Hebel Engineering Services for advice. Table 5.1: System Selection for Hebel PowerWall Low Rise Party Walls Wall System Hebel PowerWall 001 System Characteristics Bracket system Discontinuous construction Maximum building height no more than 12m Low cost solution Simple construction and easy installation Installed at framing stage Satisfies strata construction Hebel PowerWall 002 Top hat system Not discontinuous construction Maximum building height no more than 12m Low cost solution Simple construction and easy installation Installed at framing stage Satisfies strata construction

8 6.0 Performance Characteristics Table 6.1: Hebel PowerWall 001 Hebel PowerWall 001 has been assessed to comply with the BCA requirements for Discontinuous Construction. This table must be read in conjunction with all the information provided in this Design Guide, NºHBLA041 LRPW July, 2006, and acoustic opinion (PKA A034) provided by PKA Acoustic Consulting P/L and fire assessment (WFRA ) provided by Warrington Fire Research (Aust) Pty Ltd. Selection of a Hebel PowerWall from Table 6.1 should be taken with specialist consultant s advice. Hebel PowerWall 001 Typical Layout Wall Description Acoustic Lining material as per system table Timber framing in accordance with AS1684 or AS1720.1* Cavity insulation as per system table 10-20mm separation between frame and Hebel + aluminium bracket connection 75mm thick Hebel (3m max. length) 10-20mm separation between frame and Hebel + aluminium bracket connection Cavity insulation as per system table Timber framing in accordance with AS1684 or AS1720.1* Lining material as per system table PKA-A034 Deemed Discontinuous Construction by BCA Vol. 2 Clause and Clause 1.2.2(vi) Option FRL Wall Lining Cavity Insulation /90/90 90/90/90 -/90/90 90/90/90 -/90/90 90/90/90 -/90/90 90/90/90 -/90/90 90/90/90 BOTH SIDES 1 x 10mm GYPROCK plasterboard CD* BOTH SIDES 1 x 13mm GYPROCK plasterboard CD BOTH SIDES 1 x 13mm GYPROCK SOUNDCHEK BOTH SIDES 1 x 10mm GYPROCK AQUACHEK BOTH SIDES 1 x 9mm CEMINTEL fibre cement sheet Rw/Rw+Ctr Stud Depth 70mm 90mm a) NIL - both sides 47/36 49/38 b) 90mm Bradford Comfortseal R2.0 - both sides 61/48 63/51 c) Autex ASB4 or Tontine TSB4 - both sides 56/43 59/47 a) NIL - both sides 49/38 50/39 b) 90mm Bradford Comfortseal R2.0 - both sides 63/51 64/52 c) Autex ASB4 or Tontine TSB4 - both sides 58/46 60/48 a) NIL - both sides 52/41 53/42 b) 90mm Bradford Comfortseal R2.0 - both sides 66/54 67/56 c) Autex ASB4 or Tontine TSB4 - both sides 61/49 63/52 a) NIL - both sides 48/37 50/39 b) 90mm Bradford Comfortseal R2.0 - both sides 62/49 63/51 c) Autex ASB4 or Tontine TSB4 - both sides 57/44 59/47 a) NIL - both sides 50/39 51/40 b) 90mm Bradford Comfortseal R2.0 - both sides 65/52 66/55 c) Autex ASB4 or Tontine TSB4 - both sides 60/47 62/51 Note: * Timber framing requires studs at 450mm maximum spacings and mid-height nogging (refer PKA A034), and for steel framing, frames to

9 Table 6.2: Hebel PowerWall 002 This table must be read in conjunction with all the information provided in this Design Guide, NºHBLA041 LRPW July 2006, and acoustic opinion (PKA A044) provided by PKA Acoustic Consulting P/L., and Fire assessment (WFRA ) provided by Warrington Fire Research (Aust) Pty Ltd. Selection of a Hebel PowerWall from Table 6.2 should be taken with specialist consultant s advice. Hebel PowerWall 002 CAN NOT be used with steel framing. Hebel PowerWall 002 Typical Layout Wall Description Acoustic Lining material as per system table Timber framing in accordance with AS1684 or AS1720.1* Cavity insulation as per system table 20-25mm separation between frame and Hebel + steel top hat connection 75mm thick Hebel (3m max. length) 20-25mm separation between frame and Hebel + steel top hat connection Cavity insulation as per system table Timber framing in accordance with AS1684 or AS1720.1* Lining material as per system table PKA-A044 NOT Discontinuous Construction by BCA Vol. 2 Clause Option FRL Wall Lining Cavity Insulation /90/90 90/90/90 -/90/90 90/90/90 -/90/90 90/90/90 -/90/90 90/90/90 -/90/90 90/90/90 BOTH SIDES 1 x 10mm GYPROCK plasterboard CD* BOTH SIDES 1 x 13mm GYPROCK plasterboard CD BOTH SIDES 1 x 13mm GYPROCK SOUNDCHEK BOTH SIDES 1 x 10mm GYPROCK AQUACHEK BOTH SIDES 1 x 9mm CEMINTEL fibre cement sheet Rw/Rw+Ctr Stud Depth 70mm 90mm a) NIL - both sides 45/34 47/36 b) 90mm Bradford Comfortseal R2.0 - both sides 59/46 61/49 c) Autex ASB4 or Tontine TSB4 - both sides 54/41 57/45 a) NIL - both sides 47/36 48/37 b) 90mm Bradford Comfortseal R2.0 - both sides 61/49 62/50 c) Autex ASB4 or Tontine TSB4 - both sides 56/44 58/46 a) NIL - both sides 50/39 51/40 b) 90mm Bradford Comfortseal R2.0 - both sides 64/52 65/54 c) Autex ASB4 or Tontine TSB4 - both sides 59/47 61/50 a) NIL - both sides 46/35 48/37 b) 90mm Bradford Comfortseal R2.0 - both sides 60/48 62/50 c) Autex ASB4 or Tontine TSB4 - both sides 55/45 58/46 a) NIL - both sides 48/37 50/39 b) 90mm Bradford Comfortseal R2.0 - both sides 63/51 64/53 c) Autex ASB4 or Tontine TSB4 - both sides 57/45 60/49 Note: * Timber framing requires studs at 450mm maximum spacings and mid-height nogging (refer PKA A044). 9

10 7.0 Sound Transmission & Insulation 7.1 Overview The Building Code of Australia (BCA) presents the Performance Requirements for sound insulation ratings. The sound insulation ratings set minimum values to consider two types of sound: airborne sound and impact generated sound. The Performance Requirements for airborne sound insulation and impact sound insulation ratings are dependent upon the form of construction (i.e., walls or floors), Class of Building, and the type of areas being separated. The airborne sound performance requirement is a value that could be the weighted sound reduction index (Rw) or weighted reduction index with spectrum adaptation term (Rw +Ctr). The impact sound performance requirement is a value called the weighted normalised impact sound pressure level with spectrum adaptation term (Ln,w + Cl). The BCA does provide Performance Requirements for the airborne sound and impact generated sound insulation ratings for an party wall. Refer to Tables 6.1 and 6.2 for sound insulation resistance level of the Hebel PowerWall systems. 7.2 Impact Sound Performance Impact sound is caused by vibrations, which are transferred directly through the wall and re-radiated as sound in the adjacent room. These sound vibrations can be generated by actions such as closing of a cupboard door. The transfer of impact sound can be minimised by ensuring no mechanical connection exists between the two sides of the wall. For impact rated walls the new BCA requires walls to be of discontinuous construction. This refers to a wall maintaining a minimum 20mm cavity between two separate leaves except at the periphery. Note: For gap widths 20mm, CSR Hebel has obtained expert opinion that discontinuous construction performance will not be compromised 7.3 Acoustic Performance Design Recommendations 1) CSR Hebel recommends engaging a specialist acoustic consultant on a project-by-project basis to provide design advice, confirmation of anticipated field performance, detailing and installation inspections. 2) When selecting the appropriate Hebel PowerWall, the designer or specifier must be aware that the laboratory Rw values are almost always higher than the field measured values. Therefore, allowances should be made for the lower expected field values during the selection of the system. 3) Separate advice from a specialist acoustic consultant should be sought to determine the effect on acoustic performance due to any changes to the Hebel PowerWall systems, and any required modification of the installation details pertaining to the systems. 4) Increasing of cavity widths, using higher density or thicker insulation or plasterboard, will generally maintain or increase the acoustic performance of the Hebel PowerWall. 5) The acoustic performance values of the Hebel PowerWall systems shown in Tables 6.1 and 6.2 are a guide only as to consistently achievable field performance. They do not constitute a field performance guarantee as factors such as the presence of flanking paths, quality of installation of the system, on-site detailing of junctions, room shapes and size, etc can significantly affect field performance. Maximising the field performance depends on the following factors: n The systems are installed in accordance with the manufacturer s standard installation details. n Good quality installation practices including the sealing of all junctions and joints and maintaining specified clearances. n The systems are installed with all junctions acoustically sealed so that negligible sound transmission occurs at these points. n Flanking paths are eliminated and the structures into which the systems are installed are capable of allowing the nominated rating to be achieved. n Site testing conditions. n To minimise the transfer of sound through the Hebel PowerWall system into the adjacent unit, it is suggested that a control joint be provided to break the mechanical path for the transmission of impact sound and other vibration. 10

11 8.0 Fire Resistance Performance 8.1 Fire Resistance Level (FRL) Rating of PowerWall Systems The fire resistance level (FRL) rating performance of the Hebel PowerWall system detailed in this guide have been derived from Warrington Fire Research assessment WFRA , WFRA and Warrington Fire Research, fire resistance test report, WFRA Refer to Tables 6.1 and 6.2 for the fire resistance levels of the wall systems. This design guide has no recommendations for penetrations through the PowerWall system. CSR Hebel recommends contacting the appropriate consultant for design and detailing advice. 8.2 System Variations Certain variations to the Hebel PowerWall installation will not affect the fire-resistance levels listed in Tables 6.1 and 6.2. However these variations need to be approved by the project fire consultant or project certifier. The possible variations to the systems include: 1) Changing the type of insulation between polyester, glasswool and rockwool; 2) Putting the insulation on both sides of the ; 3) The reduction of a cavity between the wall frame and the Hebel /plasterboard down to 10mm for Hebel PowerWall Structural Provisions 9.1 Structural Performance The Hebel PowerWall system can be either a loadbearing or non-loadbearing wall. The Hebel within the wall system is non-loadbearing with the exception of self weight. 9.2 Construction Loadings During construction, the Hebel could be subject to wind loading. The builder shall provide the necessary temporary bracing of the panel until both structural frames are installed. Note: The screw connections may not be adequate to stabilise the panel against construction loadings. 9.3 Cutting of Hebel The standard Hebel can be reduced in length by cutting 150mm maximum from each end, and to a minimum width of 270mm. All exposed steel reinforcement shall be liberally coated with the Fentak anti-corrosion coating available through CSR Hebel. 9.4 Wall Frame The wall framing presented in this Design Guide for various wall systems are nominated for the acoustic and fire performance values. It is the designer s responsibility to determine an appropriate wall framing system to satisfy structural adequacy. Several items the designer must allow for are: n lateral loadings n wall height n deflection limits n offset distance (gap) from the panel n building movement n control joint locations 9.5 Wall Height The overall wall height limit is 12m for both PowerWall 001 and PowerWall 002. The wall shall be constructed of Hebel of 3000mm maximum length. Walls constructed with panel lengths exceeding 3000mm are outside the scope of this guide. 9.6 Earthquake Loading Earthquake loading has not been considered in this design guide. It is the designer s responsibility to ensure the connection system has adequate capacity to resist any imposed earthquake loading. 9.7 Fixings Fasteners & Fixings Most screw fixings are timber type, which is sufficient for penetrating the metal thicknesses outlined in this design guide. Connections that have larger metal thicknesses may require a metal type screw and will need to be designed and approved by the project engineer. Fixings Deflection head track to substrate The fixing to secure the angles and tracks to the concrete slab shall be capable of withstanding a shear load of 0.75kN. For high wind pressures during construction, the designer shall determine if mechanical fasteners are required: n Drive pins and concrete nails (check size and suitability for fire rated situations with the manufacturer); n 8mm diameter mechanical fasteners. Table 9.1 outlines the connection type and requirements for constructing Hebel PowerWall 001 and PowerWall 002 detailed in this design guide. 11

12 Table 9.1: Fixings Fixings for PowerWall 001 Fixing Type Number of Fixings and Spacing Bottom angle/track to structure M8 Dynabolt + 25 x 3mm load sharing washer 600mm max. centres Bottom angle to x 90mm hex head Type 17 screws 2 fixings per panel, 50mm min. from panel edge. Track back-to-back x 16mm wafer head screws 600mm max. centres Aluminium bracket to timber frame x 25mm hex head Type 17 screws 2 fixing per bracket Aluminium bracket to steel frame x 16mm hex head self-drilling screws 2 fixing per bracket Aluminium bracket to x 50mm hex head Type 17 screws or 12-8 x 60mm button head screws 2 fixings per bracket Gyprock Fyrchek to 10 x 50mm Bugle Head Laminating Screws 400mm centres maximum Plasterboard to framing Refer to the Gyprock Plasterboard Residential Installation Guide, NºGYP547 Fixings for PowerWall 002 Fixing Type Number of Fixings and Spacing Top hat to timber stud x 25mm hex head Type 17 screws 2 fixing per stud Top hat to x 65mm hex head Type 17 screws 2 fixings per panel 10.0 Design & Detailing Considerations 10.1 Control Joints Control joints must be provided at a maximum of 6m spacing. Recommended control joint widths should be 10mm minimum between Hebel and another building component. Control joints must also be provided to coincide with any control joint in the main structure. Larger joint width maybe required to accommodate building movements, and these values shall be nominated by the designer. The top hat and back to back track must be discontinuous at a structural control joint Wet Area Wall Construction Wet area wall construction requires a system that enables services to be installed in a cavity. All plumbing should be acoustically treated as required by the BCA. All wet area walls shall be lined and waterproofed in accordance with Australian standards and to BCA requirements. Gyprock Aquachek or Cemintel Fibre Cement Wallboard are suitable lining materials for wet area applications Non-Hebel Components Used in PowerWall Components, which are not manufactured by CSR Hebel, such as CSR Gyprock plasterboard, timber and steel stud wall frames, CSR Bradford insulation and others must be designed, installed and handled in accordance with their manufacturer s guidelines and recommendations. CSR Building Products Limited, guarantees only the products that are manufactured by CSR Building Products Limited, not the components, products or services supplied by others. 12

13 11.0 Design, Detailing and Performance Responsibilities CSR Hebel engages independent acoustic testing laboratories to test and report on the performance of a wall in accordance with the relevant Australian Standards. Consultants use these reports as the basis for opinions (estimates of laboratory performance) they issue for variations or different arrangements to the tested system, and also to design and specify walls that meet appropriate criteria for a particular project. Using their experience, consultants will make judgements about on-site installed performance of various walls. The performance levels of walls documented in this Design Guide are either what is reported in a test or the documented opinion of an consultant. Performance in projects is typically the responsibility of; Project Consultants (Acoustic, Fire, Structural, etc.): n Opinions on expected laboratory performance of wall configurations that vary from actual test configuration, such as substitution products and components. n Judgements about expected field performance using laboratory test reports and practical experience. n Design, specification and certification of acoustic, fire, structural and any other required performance for individual projects. This involves the design and selection of building elements, such as walls and floors and their integration in the building considering the following: Interface of different building elements and to the structure/ substrate Wall and floor junctions Penetrations Flanking issues Room/building geometry Acoustic field testing Project Certifier &/or Builder: n Identifying the performance requirements for the project in accordance with the Building Code of Australia and clearly communicating this to relevant parties. n Applicability of any performance requirements supplied by CSR Hebel including tests and opinions for the project. n The project consultant s responsibilities detailed above if one is not engaged in the project. CSR Hebel does not provide consulting services. CSR Hebel only provides information that has been prepared by others and therefore shall not be considered experts in the field. Any party using the information contained in this design guide or supplied by CSR Hebel in the course of a project must satisfy themselves that it is true, accurate and appropriate for the application, consequently accepting responsibility for its use. It is the responsibility of the architectural designer and engineering parties to ensure that the details in this design guide are appropriate for the intended application. The recommendations of this guide are formulated along the lines of good building practice, but are not intended to be an exhaustive statement of all relevant data. CSR Hebel accepts no responsibility for, or in connection with, the quality of the recommendations or their suitability for any purpose when installed. CSR Building Products Limited is not responsible for the performance of constructed walls, including field performance, and does not interpret or make judgements about performance requirements in the Building Code of Australia. 13

14 12.0 System Components Detail 12.1: Hebel Hebel The core component of Hebel PowerWall systems is the 75mm thick, steel mesh reinforced Hebel. The panel is manufactured in a range of stock sizes with a nil edge profile, as detailed in Table Table 12.1: Hebel Stock Sizes & Weights Panel Type Average Panel Weight kg/m 2 ) Length (mm) Width (mm) Standard NOTES: Average panel weight calculated at 30% moisture content Hebel Mortar Hebel Mortar is used to provide a level base for panel installation as well as providing acoustic and fire protection at the base of the panels. Used in some PowerWall 002 wall base arrangements. Supplied in 20kg bags Hebel Adhesive Hebel Adhesive is used for bonding the panels together at vertical and horizontal joints. Supplied in 20kg bags Hebel Patch Minor chips or damage to panels are to be repaired using Hebel Patch. Supplied in 10kg bags. 14

15 12.5 Anti-corrosion Coating Agent Reinforcement exposed when panels are cut shall be coated with a liberal application of Fentak Deflection Head Track For positioning and restraining the bottom and mid connection of the panels. n Galvanised deflection head track Rondo Nº x 50 x 0.75mm BMT or Rondo Nº x 35 x 0.75mm BMT Wall Brackets The brackets are proprietary components which enable the Hebel to be fixed to the wall frame. This provides a cavity space, which can result in increased acoustic insulation performance. The bracket is nominally 75 x 40 x 1.6mm x 50mm wide aluminium angle. Used in Hebel PowerWall mm 75mm Panel Clip 12.8 Top Hat Section The top hat detailed in this guide is the Lysaght Topspan mm nominal 50mm 12.9 CSR Bradford Insulation Hebel PowerWall 001 and 002 systems incorporate CSR Bradford Insulation materials. Tables 12.2 and 12.3 present basic information on the glasswool and polyester insulation materials. Hebel PowerWall systems that use Bradford Glasswool insulation generally have a better acoustic performance than systems using Polyester insulation. Additional information regarding Bradford insulation materials is available from CSR Bradford, mm Table 12.2: CSR Bradford Glasswool Insulation Glasswool Mass g/m 2 50mm mm 810 In Hebel PowerWall 002, the top hats are used to fix the Hebel to the structural support framing. For alternative top hat types, the top hat manufacturer or project engineer will be responsible for approving the substitute product as adequate for performance requirements. 90mm mm 683 Table 12.3: Polyester Insulation Polyester Mass g/m 2 S1 250 S2 350 In PowerWall 001, the top hats are used to provide easy alignment of the panels during installation. The top hats are installed temporarily between the framing and panels, and MUST BE removed after the aluminium brackets are installed. S3 500 S4 650 S5 800 S

16 12.10 Fasteners & Fixings Table 12.4 outlines the connection types and requirements for constructing the Hebel PowerWall systems detailed in this guide. Table 12.4: Fixing Fixings for PowerWall 001 Bottom angle/track to structure Bottom angle to Track back-to-back Aluminium bracket to timber frame Aluminium bracket to steel frame Aluminium bracket to Gyprock Fyrchek to Plasterboard to framing Fixings for PowerWall 002 Top hat to timber stud Top hat to Plasterboard to framing Fixing Type M8 Dynabolt + 25 x 3mm load sharing washer x 90mm hex head Type 17 screws x 16mm wafer head screws x 25mm hex head Type 17 screws x 16mm hex head self-drilling screws x 50mm hex head Type 17 screws or 12-8 x 60mm button head screws 10 x 50mm bugle head laminating screws Refer to the Gyprock Plasterboard Residential Installation Guide, NºGYP547 Fixing Type x 25mm hex head Type 17 screws x 65mm hex head Type 17 screws Refer to the Gyprock Plasterboard Residential Installation Guide, NºGYP Gyprock Plasterboard Hebel PowerWall 001 and 002 incorporate Gyprock Plasterboard on both sides. The type, thickness and densities of plasterboard will be as per the specified wall requirements. Additional information is available from CSR Gyprock, at Fire & Acoustic Sealant To attain the specified FRL and/or Rw requirements, all perimeter gaps and penetrations must be carefully and completely filled with an appropriate flexible polyurethane sealant installed to manufacturer s specifications Backing Rod Backing rod is used to enable correct filling of joints with sealant. It is recommended that backing rod be of open cell type to enable sealant to cure from behind. The diameter of backing rod must be appropriate for the width of the gap being filled. 16

17 13.0 Installation Sequence General Before commencing any installation work, clean and tidy up the work area. Mark out the location of the walls. Wall Framing Ensure frames are installed plumb and mechanically fixed to the substrate. All timber framework is to be fabricated and installed to the manufacturer s specifications and AS1684 or AS Services Ensure all services are installed within the wall frame and not on the face of the. Deflection Head Track When the wall locations have been set out, fix the deflection head tracks to the substrate. This is done using suitable fixings (see Section 12.0) at 600mm maximum centres and maximum 100mm from ends. At changes in wall directions, ensure deflection head track is mitred with no gaps at the corners. Seal all butt joints with polyurethane sealant. Hebel Mortar Mortar is placed on the substrate and should only be run out roughly 3 panels (1800mm) ahead of panel installation. The mortar bed fills the gap at the base. Generally, the mortar is 10mm thick and shall extend the full width of the panel. Mixing of the mortar should be done in accordance with the instructions on the bag. Wall Brackets Screw fix the wall bracket to the top and bottom plates of the wall frame and to the at 600 centres. Locate within 50mm of the centre width of each panel using fixings specified in Section Top Hats Top hats should be cut to size before securing them to timber or steel studs. At control joints the top hats should be discontinuous. For number, location, spacing and fixing of top hats, refer to the s. The project classification (Torrens or Strata) will determine the future external loading parameters of the panels and associated top hat and fixing arrangement required. Hebel The panels can be cut on-site using a circular saw equipped with diamond tipped cutting blade (for panel cutting limitations refer to Section 9.0). All the loose AAC particles should be brushed off the panel with a rough broom. Steel reinforcement that is exposed during cutting must be coated with a liberal application of corrosion protection coating (see Section 12.0). Any minor damage and chips to the panels must be repaired using Hebel Patch. Use packers at the base to maintain the gap and ensure gap is full of mortar (if specified). The preferred method of fixing should be to screw through the top hat/bracket into the panel Fix the panel to the deflection head (if specified). For following panels, apply Hebel Adhesive to the vertical edge and install the next panel. Repeat the installation process until the wall is complete. Hebel Adhesive Hebel Adhesive is applied to the panel with a 75mm Hebel notched trowel. When the panels are pushed together the joints are to be 2-3mm thick. Sufficient pressure must be applied to the panels when gluing to ensure the adhesive is fully bedded across the joint. Scrape off any excess adhesive protruding from the joints and fill any gaps. Adhesive is to be mixed to the proportions and consistency as per the instructions on the bag. CSR Bradford Insulation Installation of CSR Bradford insulation should be completed in accordance with manufacturer s handling and installation guidelines. The insulation provided should completely fill the space between the stud framing and form a continuing barrier. If there is any gap in the insulation the acoustic performance of the system may be adversely affected. Gyprock Plasterboard Plasterboard sheets must be cut to fit neatly and should not be forced into position. The plasterboard is to extend the full height of the wall frame, with gaps at top and bottom for the specified sealant. Plasterboard is fixed directly to the stud framework in accordance with the Gyprock Plasterboard Residential Installation Guide, NºGYP547. Sealants All movement joints and other gaps should be sealed off and finished neatly with fire and acoustic rated sealants. Installation of sealants must be carried out in accordance with the manufacturer s specifications. Installation of Electrical, Plumbing and Other Services Installation of services into walls should be carried out at an appropriate construction sequence. This will allow easy access to cavities and wall frames, where services can be easily installed and neatly hidden. CSR Hebel suggests installing the plumbing and cabling after the panels have been installed. The builder or project manager should confirm appropriate construction sequence for services on a project-by-project basis. Fasteners & Fixings All fixings and fasteners should be installed in accordance with the manufacturer s specifications. 17

18 14.0 Panel Handling 14.1 Manual Handling CSR Hebel recommends using a trolley or other mechanical apparatus to move the panels around the work site. Manual handling where people physically move a panel, should be kept to a minimum, with the weight being supported by an individual kept as small as possible. Any concerns regarding the weight to be handled should be discussed with the panel installation contractor. To minimise the possibility of manual handling injuries, CSR Hebel suggests the following: n Use mechanical aids, such as trolleys, forklifts, cranes and levers, or team lifting to move panels n Keep the work place clean to reduce the risk of slips, trips and falls, which can cause injury n Plan the sequence of installation to minimise panel movements and avoid awkward lifts n Train employees in good lifting techniques to minimise the risk of injury 14.2 Health, Safety & Personal Protective Equipment (PPE) CSR Hebel AAC products are cementbased, which may irritate the skin, resulting in itching and occasionally a red rash. The wearing of gloves and suitable clothing to reduce abrasion and irritation of the skin is recommended when handling CSR Hebel AAC and other concrete products. Approved respirators (AS/NZS1715 and AS/NZ1716) and eye protection (AS1336) should be worn at all times when cutting and chasing. Refer to the appropriate CSR Hebel Material Safety Data Sheet (MSDS). For further information, contact CSR Hebel or visit the website: Cutting The use of power tools when cutting concrete products may cause dust, which contains respirable crystalline silica, with the potential to cause bronchitis, silicosis and lung cancer after repeated and prolonged exposure. When using power or hand tools, on CSR Hebel products, wear a P1 or P2 respirator and eye protection. When cutting, routing or chasing CSR Hebel products with power tools, use dust extraction equipment and wear hearing protection. Refer to the appropriate CSR Hebel MSDS. For further information, contact CSR Hebel or visit the website: Reinforcement exposed during cutting is to be coated with a liberal application of CSR Hebel anti-corrosion coating agent Trolley Assisted Handling CSR Hebel has developed a trolley to allow easier and safer handling of Hebel on-site (refer Image 14.1). There is a range of trolleys to suit panels from 1.2m to 3.9m in length. Guidelines for handling Hebel using the Hebel Trolley or panel lifters are detailed in Technical Bulletin, CSR Hebel Handling & Installation Guidelines, NºHTB791. Image 14.1: Hebel Trolley for 2700mm panels Detail 14.1: Typical Personal Protective Equipment 18

19 15.0 Delivery & Storage 15.1 Unloading Panels Panels shall be unloaded and moved with only approved lifting devices. Before use, the lifting devices should be checked for the required lifting tags. Panels should be unloaded as close as possible to the intended installation area. This will increase work efficiency and minimise the need for secondary lifting. Detail 15.1: Hebel Shipping Bundle Metal strapping Note: Secondary handling increases the risk of panel damage. The repair of damage sustained during lifting and moving is the responsibility of the lifter. Where damage is excessive, panels must be replaced. Plastic shrink wrap cover Handling Guidelines Support pallet 15.2 Storage All materials must be kept dry and preferably stored undercover. Care should be taken to avoid sagging or damage to ends, edges and surfaces. All CSR Hebel products must be stacked on edge and properly supported off the ground, on a level platform. Panel bundles can be stacked two high. The project engineer should be consulted as to the adequacy of the structure to support the stacked bundles. Each bundle contains 10 panels (refer Detail 15.1). Where bundles are stacked two high, the supporting cleats must be vertically aligned, to ensure minimal bending of the lower panels. Refer to Detail Detail 15.2: Stacking Bundles of Hebel Panel Width Panel Width Panel Length Strapping Temporary joists may be required on uneven ground Panel Thickness If Hebel is stored outside, it must be stored off the ground and protected from the weather. Only single bundles positioned on the ground can be opened. To provide a level surface, we recommend placing temporary joists beneath the supporting cleats. 19

20 16.0 Construction Detail PowerWall Overview of Hebel PowerWall 001 System Detail : Typical Layout of PowerWall 001 Services may penetrate decorative wall without fire caulking See details for base options Hebel Adhesive at edge joints Services must run through wall frame and must not be fixed to the No penetrations permitted through the Hebel For wet area lining use CSR Gyprock Aquachek plasterboard or CSR Cemintel fibre cement sheet Note: Detailing of elements, such as flashings, gutters, capping, roofing, etc. shown in this section are for indicative purposes only. 20

21 Detail : Vertical Cross Section of PowerWall 001 Mineral fibre or other fire-resisting material as per s Bracket fixed to framing and (refer to fixing detail) Refer to Detail 3000mm max. panel height Wall brackets each side of 3000mm max. panel height 3000mm max. from bracket to bracket Floor joists may be perpendicular or parallel to wall Refer to horizontal joint detail Floor joists may be perpendicular or parallel to wall 600mm max. from bracket to joint in Additional noggings and clips required in offset floor level applications Wall bracket 3000mm max. panel height Timber or steel framing as per s 75mm Hebel Base detail refer to alternative methods mm gap on each side Concrete slab 21

22 Detail : Base Connection - Option 1 Continuous Hebel Mortar Damp proof course Continuous Hebel Mortar Damp proof course Detail : Base Connection - Option 2 Continuous 75mm Hebel Mortar Hebel Continuous Hebel Mortar Damp proof course Gyprock plasterboard to system specification Timber or steel framing as per project specifications 16.2 Construction Details for Hebel PowerWall 001 Continuous Hebel Mortar Damp proof course 75mm Hebel Damp proof course Gyprock 10-20mm plasterboard gap to system specification Timber Insulation or to steel system framing as specification per project specifications 75mm Hebel Gyprock 10-20mm plasterboard gap to system Aluminium specification bracket fixed Timber Insulation to frame or with steel to system 2 framing x 2mm x as specification 25mm per project gal nails or 2 x specifications x 25mm hex head 75mm type 17 Hebel screws for timber 10-20mm framing, or gap 2 x x 16mm wafer head screws Aluminium for steel framing bracket fixed Insulation to frame with to system 2 x 2mm x specification 25mm gal nails or 2 x x 25mm hex head 75mm type 17 Hebel screws for timber framing, or 2 x x 16mm wafer head screws Aluminium for steel framing bracket fixed to frame with 2 x 2mm x 25mm gal nails or 2 x x 25mm hex head type 17 screws for timber framing, or 2 x x 16mm wafer head screws for steel framing NOTE: This frame to be constructed first Gyprock plasterboard to system specification Timber or steel framing NOTE: as per This project frame to be constructed specifications first 10-20mm gap Gyprock plasterboard to Insulation system specification to system specification Timber or steel framing as per project specifications fixed to continuous 10-20mm gap steel angle with Nº14 10 x 95mm hex head screws at Insulation to system 600mm max. ctrs specification Continuous steel angle fixed to slab fixed with to continuous masonry anchors steel angle at with 600mm Nº14 max. 10 x ctrs 95mm hex head screws at 600mm max. ctrs Continuous steel angle fixed to slab with masonry anchors at 600mm max. ctrs Detail : Horizontal Joint Fixing - Option 1 Fixed back to back with x 16mm wafer head screws at 600mm max. centres Continuous steel channel 76 x 32 x 0.75mm BMT OR 76 x 50 x 0.75mm Deflection Track or J-track Bracket fixed to frame with 2 x 2mm x 25mm gal nails or 2 x x 25mm hex head type 17 screws for timber framing, or 2 x x 16mm wafer head screws for steel framing Fibre Cement packer or non-combustible equivalent Backing rod and fire and acoustic rated sealant to project specifications Bracket fixed to with 2 x Nº12-11 x 50mm hex head type 17 screws, or 2 x Nº12-8 x 60mm button head screws Detail : Horizontal Joint Fixing - Option 2 150mm min. 150mm min. 16mm Gyprock Fyrchek Plasterboard fixed to Hebel with 10 x 50mm bugle head laminating screws at 400mm centres max. Detail : Base Connection - Option 3 Detail : Bracket Fixing Gyprock plasterboard to system specification Timber or steel framing as per project specifications 10-20mm Gyprock plasterboard gap to system specification Insulation Timber or to steel system framing specification as per project specifications 10-20mm gap 600mm wide Hebel (one panel) Centreline of panel 75mm Hebel 75mm Hebel Insulation to system Continuous steel specification channel (Rondo 76 x 32 x 0.75mm) fixed with masonry anchors at 600mm max. ctrs Continuous steel channel (Rondo 76 x 32 x 0.75mm) fixed with masonry anchors at 600mm max. ctrs 50mm 50mm Wall bracket shall be fixed to panel within a 100mm wide central region of the panel 22