EQUITONE [materia] Tergo+ Undercut Anchor To Aluminium Frame

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1 EG-10/112/en/v2 1. General Description EQUITONE [materia] is unique in the world of fibre cement, in that it is an uncoated panel with a special mechanical surface treatment which reduces the effect of visual efflorescence. Nevertheless, the panel will have an increased risk of efflorescence as a result of unsuitable storage or careless installation. Therefore extra care and attention is needed in these areas. Extra precautions are recommended to help reduce this risk of efflorescence forming on the surface. As EQUITONE [materia] is a natural product. Differences in colour, structure and texture are surface characteristics. Efflorescence or small, visible inclusions are not defects. Differences in the surface appearance, which do not affect the fitness for purpose of the panels, are permitted under EN Design Advice The following advice must be followed: Only use 12 mm thick EQUITONE [materia] Only highly experienced installers should install this system This is a precision fixing system with low tolerances Contact is to be made with Local Fischer Representative Consult the Fischer Drilling and Anchor Installation Guideline Respect the material when storing, handling and installing Prevent concentrated flow of water area on the surface of the panel Protect the top of the panels during installation process Leave all horizontal joints open The cavity air space width behind the panel is to be a minimum of 40mm Increase distance to the Ground level (300 mm) to prevent splash back Perforations through the panel should prevent water resting on the panel For further information, please contact Tel: Fax: info@marleyeternit.co.uk Marley Eternit Limited, Lichfield Road, Branston, Burton-upon-Trent, DE14 3HD page 1 / June 17

2 3. Panel Preparation Storage before attaching anchors EQUITONE [materia] must be stored flat on a pallet, inside and undercover in dry conditions. Stack the pallets in a way so that the panels are ventilated. If condensation or moisture is allowed to penetrate between the stored panels, permanent surface staining in the form of efflorescence will occur. The outer plastic protection may cause condensation if it is not ventilated. Do not deliver any panels to site which cannot be installed immediately or unloaded into a suitable well protected storage area. Store pallets clear of the ground and on level bearers at a maximum of 600 mm centres. Individual stacks can be 240 mm high, and not more than 5 stacks can be put on top of one another. EQUITONE [materia] panels are supplied with protective foil between the decorated faces. This protection should not be removed. The protection foil must always be replaced where panels are re-stacked following fabrication. Stack the panel s front face-to-front face or rear surface-to-rear surface. Storage after attaching anchors Once the panel hangers are attached, the panels should be stored in a vertical position with ample protection for the decorated face and their edges. Alternatively when storing on the flat soft spacers of adequate size (25 mm) should be used to prevent the anchiors damaging the upper panel. This spacers should be strips which makes placing and removing easier and faster. These strips should be placed at 300 mm centres. Handling Always lift panels off each other, never slide them over one another, since scratching may occur. To carry the panels, stand them on their back edge and lift with two people (one person at each end) protecting the face from scratching or damage. Always lean panel towards back edge to avoid damaging the visible front edge. Use soft bearers (carpet, foam, etc) to rest the panel edge on, especially on scaffold or access lifts or any surface which will damage the panel edge. Prevent suction pads marks, sun protection lotion or any grease or oils from staining the panel surface. These will be difficult to remove. Use clean textile gloves when handling the panels to help prevent finger print staining and eliminate cleaning time. page 2 / June 17

3 Panel Fabrication All fabrication of EQUITONE [materia] in terms of cutting to size, drilling the undercut anchor holes must be done by professional fabricators. As this fixing suystem is a highly precision solution, accuracy is vital. Therefore the drilling of the undercut anchor holes must be done using a CNC machine to ensure accuracy of the holes. Consult the Fischer Drilling and Anchor Installation Guideline for information on the drilling procedure, checking the hole guidelines and anchor insertion. Where the panels need to be drilled on site for holes for cables, use the EQUITONE fibre cement drill bits. At no time should drilling the panel be carried out in the rain. On site drilling of panel to be drilled face up. Immediately after drilling clean off all dust with a soft brush and compressed air. Panel Cutting In situations where on site cutting is needed, for example trimmimg oversized panels at windows. This must be only in isolated cases. Use only EQUITONE saw blades to cut the panels on site.the blade should be set to extend approximately 5 mm below the panel to allow the debris material to escape. Many portable saws are available to cut EQUITONE. The main criteria: Saw with blade speed of between rpm Guide rail to keep saw straight and steady Enclosed saw blade with a vacuum system to remove all dust Saw with correct bore size to suit the blade When cutting a panel, place it on a solid workbench indoors. At no time should cutting the panel be carried out in the rain. Panels to be cut face down. Immediately after cutting clean off all dust with a soft brush and compressed air. Plan cutting in a way that will not interfer or damage the Tergo+ anchors. Curved cut-outs For cut outs or curved cuts a jigsaw using a Bosch T141HM blade can be used. The jigsaw pendulum function is to be switched off. The panel is also cut face down. Immediately after cutting clean off all dust with a soft brush and compressed air. Plan cutting in a way that will not interfer or damage the Tergo+ anchors. Edge Treatment Sand the edges of panels after cutting them. This reduces the possibility of damage and improves the appearance. A block of wood, 400 mm x 100 mm in size, with a piece of sandpaper (80-grit) affixed to it can be used to sand the edges. No edge sealing treatment is needed. page 3 / June 17

4 Cleaning of New Panels Preventing dust from resting on the panel surface is preferred to having to clean the panel after installation. This will speed up the installation process. One successful option is to utilise the scaffold protective sheeting. Cutting or drilling dust contains cement and that can permanently stain the surface of the panels if allowed to dry in. When dry, remove all dust with a soft brush and compressed air duster gun or blower. It is strongly recommended that the panel is not drilled when placed on the façade as the dust will spread over large areas. Cleaning of installed panels The finished ventilated facade areas should be cleaned down following fixing of panels. Any partial cleaning may cause minor visual impairments. To clean off dust use a soft brush and compressed air. WARNING The use of abrasive materials, such as steel-wool, scourers etc. is not permitted as these cleaning items will leave irreparable scratches on the surface. 4. Joints between Panels Joint Width The optimum width of the joints between panels is 10 mm. Aesthetically a 10 mm joint is the best. 10 mm also offers the installer a greater level of tolerance when fitting the panel. The minimum permissible joint is 8 mm while the maximum would be 12 mm. Vertical Joints Tergo+ fixing system normally has open joints. With standard aluminium rails the grey or silver colour can be prominent especially when used with dark coloured panels. This could be an unappealing feature. To eliminate this, the best solution is to use black coated rails. Alternatively, the visible areas can be painted on site prior to fitting the panels. Make sure the rails are prepared correctly before painting as new rails can have an oily surface. Note, the painting of the rails on site will not endure as long as factory coated rails. Horizontal Joints Horizontal joints can ONLY be left open. By having open joints the likelihood of dirt spoiling the façade reduces as the joint remains clean. The retention of water will also be reduced thus reducing the risk of efflorescence. Remember the supporting frame is visible with open horizontal joints and they may need to be hidden by using black rails. In cases where a closure piece is unavoidable then horizontal joint profile must be designed to throw the water away from the panel surface. page 4 / June 17

5 5. Tergo+ Anchor Fixing Depending on which support frame is being used will determine the length of the anchor. For EQUITONE [materia] use the anchor with the yellow washer as this ensures the correct insertion for the 12 mm panels Designation Tergo+ 11x8 M6/T/10 PA Tergo+ 11x8 M6/T/13 PA Embedment depth [mm] 8 8 Colour of shim washer yellow yellow Installed anchor length [mm], a Thread length [mm], b Packaging unit 250 pcs 250 pcs 6. Tergo+ Anchor Centres As a guideline for initial design purposes the maximum centres for the Tergo+ anchors should be 700 mm. However, many factors influence the design when considering the Tergo+ anchors position. Factors such as: Height of Building Normally the higher the panels are on the façade, the greater the number of Tergo+ anchors. However some country s calculation methods will treat a façade the same using the highest value only. Panel Layout - The Tergo+ anchors centres commonly differ between vertical and horizontal orientated panels. Wind Loading The factor which influences the number of Tergo+ anchors per panel the most is the wind load the panel is expected to be subjected to. Site Location The buildings location will play a major factor in determining the number of Tergo+ anchors. Is the building in an urban or rural setting, close to the sea or at altitude. Panel position on the façade Certain zones on façade such as the corners can require closer Tergo+ anchors centres. Most regions around the world have their own unique standard for structural calculations and these need to be adhered to. In Europe all calculations have been based on Eurocode guidance. However each country has its own unique annex to the standard. This may affect the calculations. Therefore it is vitally important that the final number of fixings per panel is to be calculated and specified by the project engineer. page 5 / June 17

6 Position for Corner Tergo+ Anchors From the horizontal edges of the panel the dimension is mm. From the side edges of the panel the dimension is mm. The centres for the rest of the Tergo+ anchors are determined based on the engineers wind load calculations. 7. Tergo+ Anchor Installation Procedure Place the pre-drilled panel face down on a clean, smooth work table so the panel surface will not be damaged. Ensure all dust and debris is removed from the undercut hole. Insert the anchor into the undercut hole. Put the hanger over anchor, and apply either tighten: 1. with locking liquid, spring washer and nut or 2. combined locking nut washer as shown here. Protect the hanger against turning when fixing into place, e.g. by holding it with one hand. Protection gloves need to be used. Put the power tool on the nut and hold it perpendicular to panel surface. Carefully tighten the nut (Max torque for tightening the nut is 5 KN.m). The anchor is correctely installed, when the yellow washer lays flush on the panel backside. There should be no gap between the washer and the panel. page 6 / June 17

7 8. Panel Hangers Arrange the hangers to suit the design drawings for fixed point hangers and sliding point hangers. The hangers that are used at the top corners of the panel have threaded bolts which allow the panel to be moved up and down to ensure the correct alignment. These hangers also support the weight of the panel. Depending on the size of the panel these 2 levelling hangers may need a double undercut anchor connection to the panel. Set the adjusting bolts to half-way to allow up and down movement of the panel once it has been placed on the facade. To prevent the sideways movement of the panel, locking screws or clips can be fixed to the horizontal hanging rail to one of the top corner hangers. Ensure that this happens to the same side of the panel, either all the right side or all the left side levelling hangers. It is important that whichever option is used that if necessary it can be removed without damaging the panel. The other hangers have no means of adjustment and are used to resist the wind loads. page 7 / June 17

8 9. Sequence for Installing the Panels The panels are usually mounted from the bottom upwards. Set the adjustment screws to half way. This will allow up and down adjustment to level the panel. Lift the panel in and over the horzontal rails ensuring the interlock of the hangers line up with the horizontal rail. Gently lower the panel down so it interlocks. Adjust to correct position and level in place. Insert one hanger lock as described by the frame supplier to prevent the panel moving sideways. 10. Special installation situation All flashings must be designed to throw the water away from the panel. They must not allow water to run onto the panel. How and the location of flashing joints should be made to prevent concentrated flow of water running on the panel surface. 11. Cavity Cavity Width The minimum cavity width should be 40mm direct behind the horizontal rails. Tolerances When designing the width of the cavity, it is important to allow for a tolerance of 20mm. Building irregularities, especially uneven backing walls, insulation holders and the supporting frame must never compromise the width of the cavity. Ventilation A through flow of air is achieved by utilising the stack-effect, in which a current of air enters at the base of the cladding and exits at the top. As well as cavities being ventilated at the top and bottom of the façade, it is also important that air is allowed to enter and exit under and over openings such as windows. 12. Details Base Detail At ground level the end of the panel is to be positioned a minimum of 300 mm above the finished ground level. This will help prevent rain splash-back from the ground staining the ends of the panel. page 8 / June 17

9 Parapet A minimal 20 mm (50 mm in case of copper) gap should be left between the front of the panel and the rear of the capping. The front edge of the capping must offer adequate cover to the panels and provide a minimum of 50 mm by buildings up to 8 m 80 mm by buildings up to 20 m 100 mm by buildings over 20 m high Fix parapet capping in place once top row of panels has been fixed. When using the top-down sequence the parapet will protect the cavity space from the rain. Window A window cill must be used to throw the water from the window away from the panel. Air from the cavity must be allowed to exit under the metal cill. A minimum of a 10 mm gap should be left between the panel and the base of the cill. A perforated profile can be used for wider gaps to prevent entry of birds or vermin. The front edge of the cill must be between 20 mm - 50 mm away from the front of the panel and offer adequate cover to the panels. The cill should extend down over the panels by a minimum of 50 mm. Pipe Penetrations or Breakthroughs Basically, as far as possible, it is best to avoid breakthroughs. A gap of 10mm should be left around all pipes or breakthroughs. To avoid concentrated water dripping on the panel, measures need to be taken. To prevent this dripping place a collar 20mm in front of the panel surface. 13. Aluminium Supporting Frame All suppliers of the hanging system have their own requirements and reference should be made to each supplier details. Allowance must be made if windows/parapet copings are already installed as the hanging hooks need to sail over the rails by 15mm. There are many manufacturers and suppliers of aluminium ventilated façade supporting frames. Each supplier will have its own design and recommendations on how best to use its products. However, the principles for this system are common and the information given in this section is generic and offered as guidance. Structural Design All components of the external cladding must be designed according to the safety factors and permissible design load as stipulated in the Eurocodes or to local codes where Eurocodes are not used. The supporting structure must be able to resist the wind forces exerted on the building facade and its own weight and that of the panels. Maximum buckle under the influence of strain: SPAN/300 page 9 / June 17

10 All parts of the aluminium supporting structure are made of a high quality aluminium alloy to EN AW Anchoring the frame to the Wall The supporting frame needs to be securely anchored to the wall. The design and selection of the anchor to suit the wall s substrate characteristics and the wind load should be based on engineering calculations together with on-site tests. This is important with renovation projects. These calculations will determine the amount of anchors required in each bracket. Angle Brackets Anchor the angle brackets on the wall at centres in accordance with Architect s / Engineer s details. Many designs of angle brackets have some form of clip which will hold the rail in place until final fixing. Using this clip, insert the L rail. When final positioning is confirmed fix the rails. The rails are held in place with either rivets or self tapping screws. L Adjustable Vertical Rails The vertical rails are normally supplied as L configurations. These rails are normally 2mm thick. Be aware that thinner aluminium rails are available (1.8mm) but the number of brackets and anchors will increase. The L rails are normally 40x50mm or 40x60mm and can be used in both directions. The rails can overhang the last bracket by a up to 250mm. Cut each vertical rail to length. Ensure all joints in the rails are at the same level around the building. Leave a 20mm expansion gap between the ends of the vertical rails. Check that the rails are true and level. It is easier to level the vertical rails than the horizontal ones. Any uneven rails will cause stresses on the panels and may be visible once the façade is completed. Horizontal Rails The hangers on the rear of the panel hang on horizontal rails. The hangers and horizontal rails interlock with each other. The horizontal rail is rivet or screw fixed to the vertical L profiles. This is done with fixed and gliding points. Each horizontal rail is normally 3.0m long. Leave a 20mm expansion gap between adjoining rails. Set the first horizontal rail in place and then position the other rails to carry the first panel. Check that the panel is a good fit. The next set of rails can now be set allowing for the 10mm joint between the cladding panels. We do not recommend fixing all the continuous horizontal rails at the same time, but to work together in stages as this will allow adequate tolerance should the panels require adjustment/leveling. Movement One characteristic with aluminium as a material is that it can expand and contract depending on the surrounding temperature. The aluminium support frame system must be designed in a way that allows the material to expand and contract. This must happen without creating stresses in the structure or the panels. Therefore, a system of fixed points and gliding points is used. page 10 / June 17

11 It is important that the fixed point brackets are kept at the same levels around the building envelope. Each length of vertical rail has only one fixed point wall bracket. Failure to do this will result in the panel cracking. It is vital that the joints between the profiles coincide with the horizontal joints between the panels. A minimum 20mm gap should be left between the profiles. The joints in the profiles should be at the same levels around the building envelope. No panel should be fixed to two different rails as the movement in the metal will cause the panel to crack. 14. Use of different materials When using different materials in combination or close proximity to each other care should be exercised to ensure compatibility. Water run-off from fibre cement is alkaline. Therefore it is not recommended to allow this water to drain freely from fibre cement panels over glass or non-coated metals. If windows and facades run on the same level, water flow from the façade onto normal glass is best avoided. For specific glass types, please contact your local glass producer. Marine Environment In severe marine type environments, the use of uncoated aluminium supporting frames will need to be substituted with an anodised aluminium or stainless steel support frame. Aluminium and Concrete All uncoated aluminium components in direct contact with cement surfaces such as fresh concrete walls shall always be isolated with protective pads Disclaimer The information in this Technical Note is correct at time issuing. However, due to our committed program of continuous material and system development we reserve the right to amend or alter the information contained therein without prior notice. Please contact your local EQUITONE Sales Organisation to ensure you have the most current version. All information contained in this document is copyrighted. All figures contained in this document are illustrations and should not be used as construction drawings. This information is supplied in good faith and no liability can be accepted for any loss or damage resulting from its use page 11 / June 17