Kingspan rethinking the limits of design

Transcription

1 Kingspan rethinking the limits of design Wall façade systems design guide Publication date December 2007

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5 Kingspan rethinking the limits of design

6 Kingspan insulated wall façade design guide 2

7 Contents KS1000 Architectural Wall Panels (AWP) and KS1000 Longspan (LS) wall systems Introduction, benefits and key features 6-7 Product data 8-9 Model specification KS1000 AWP / FM horizontally laid Model specification KS1000 AWP / LS FM vertically laid Model specification KS1000 LS / FM horizontally laid Architectural Wall Panel / Longspan Construction details standard horizontally laid Architectural Wall Panel / Longspan Construction details standard vertically laid KS1000 RW wall panel Introduction, benefits and key features Product data Model specification KS1000 RW / FM vertically laid Model specification KS1000 RW / FM horizontally laid KS1000 RW wall panel Construction details standard vertically laid KS1000 RW wall panel Construction details standard horizontally laid KS1000 Optimo wall panel system Additional requirements Ancillaries Fasteners Sealants Site handling BCA Part J compliancy Sustainable construction to protect the environment Fire performance Load span tables for KS1000 AWP / LS and RW wall Kingspan technical services 120 3

8 KS1000 Architectural Wall Panels (AWP) and KS1000 Longspan (LS) wall systems

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10 KS1000 AWP and LS wall panel systems Introduction Kingspan Insulated Panels offer a range of wall panel systems suitable for developments in commercial, retail and industrial applications, amongst others. The Kingspan Architectural Wall Panel (or KS1000 AWP) is ideally suited to a range of wall and façade type applications and the Kingspan Longspan (or KS1000 LS) system is suitable for wall applications where longer spans are required. KS1000 AWP and KS1000 LS are both secret fixed wall systems which can be laid horizontally or vertically. They are available in a wide variety of colours and finishes. The KS1000 AWP and KS1000 LS wall systems provide a one stop solution to the new Part J thermal regulations. Equally they provide insurer approved solutions allowing simple and fast site installation with concealed fixing. The systems provide good economics, superior thermal and air leakage performance with long term lifecycle durability and are available in lengths up to 14 metres*. * Subject to transport charges. 6

11 Benefits Kingspan KS1000 AWP and LS systems offer a range of solutions for demanding specifiers. If you insist on constantly reducing overheads, KS1000 AWP and LS have been designed for accelerated build speed. They are preengineered for singlecomponent / single-fix installation which reduces site time by as much as 50%. If you insist on a high quality finish, these systems offer 100% reliable thermal performance and insulation continuity: with no cavities, no gaps, no cold bridges or interstitial condensation risk. If you insist on fire safety, this system is approved by Factory Mutual, the toughest test any building component can face. If you insist on durability, KS1000 AWP and LS have an overall lifecycle expectancy of 40 years. If you insist on the best, you ve got it. Key features Fully compliant with Building Regulations and Standards Building Code of Australia section J compliant Environmentally sustainable system Zero Ozone Depleting Potential (ODP) and non-deleterious Attractive enbodied energy AWP / LS introduction Insurer approved FM-approved Lifetime insulation continuity, thermal performance and airtightness Accelerated build speed through pre-engineered, single component, single-fix installation, reduces site time by up to 50% A true secret fix system the panel joints conceal all fixings Can reduce steel work requirements Energy efficient performance reduces plant and lifetime operating costs by up to 40% Environmentally sustainable solutions reduce lifetime Carbon Dioxide (CO 2) emissions by up to 40% Lifetime durability and overall life expectancy in excess of 40 years Quality approved to IS0 9001:2000 Made in Australia 7

12 Product data Application KS1000 MR / MM / EB wall and façade systems are secret fixed and can be laid horizontally or vertically. Suitable for most building applications, except Product reference KS1000 MR / MM / EB Application description AWP and Longspan with Factory Mutual (FM) approval for wall applications where there are low temperature internal conditions. Insurer approved system Dimensions and weight 1000mm Cover width thickness Micro-Rib (MR) outside 1000mm Cover width thickness Mini-Micro Rib (MM) outside thickness 1000mm Cover width Euro-Box (EB) outside AWP LS Core thickness (mm) Weight kg/m / 0.4 steel Product tolerance Length -5mm +5mm Width -2mm +2mm Thickness -2mm +2mm End squareness -3mm +3mm Flatness (per metre) -2mm +2mm Available lengths Standard lengths 1.8 to 14 metres*. Panels less than 1.8 metres costs are subject to additional charges. * Subject to transport charges. 8

13 Performance Thermal insulation Panel thickness (mm) R value m 2 k/w Biological Kingspan panels are normally immune to attack from mould, fungi, mildew and vermin. No urea formaldehyde is used in the construction and the panels are not considered deleterious. No ozone depleting substances are used in the manufacture of these panels. Fire Insurer approved panels are available with FM and LPCB certification. Packing The number of panels in each pack depends on panel thickness and length. Quantities are reduced for exceptionally long panels. Maximum pack height is 1200mm. Delivery All deliveries (unless indicated otherwise) are by road transport to project site. Off loading is the responsibility of the client. See pages of this book on site handling. Site installation procedure Site assembly instructions are available from Kingspan Technical Services. AWP / LS product data Acoustics All AWP and LS wall panels have a single figure weighted sound reduction Rw = 25dB. For further details on acoustic performance of Kingspan panel systems, contact Kingspan for a copy of our Acoustic Performance Guide. Sound reduction index (SRI) tested Frequency (Hz) SRI (db) k 2k 4k Rw 25 Quality and durability Kingspan Insulated Panels are manufactured from the highest quality materials, using state of the art production equipment to rigorous quality control standards, complying with ISO 9001:2000 standard, ensuring long term reliability and service life. Guarantees Kingspan will provide product guarantees on an individual project basis. 9

14 Model specification KS1000 AWP / FM horizontally laid Application The following specification is for the KS1000 AWP MR / MM / EB FM insulated wall panel laid horizontally on a building, where Factory Mutual (FM) Research Standard 4880 (2005) approved requirements for Class 1 fire classification where no height restriction is needed. For internal high humidity class environments specification ie. swimming pools contact Kingspan Technical Services. Materials and coatings External weather sheet Substrate to be a minimum 0.55mm thick Zincalume G300S AZ150 coated steel to AS1397. Colours as per Kingspan standard range Colorbond is also available. Note: Some colours carry longer lead times and additional prices please consult Kingspan Sales for more information. Profiles available are MR (Micro-Rib), MM (Mini-Micro) or EB (Euro-Box). Insulation core To consist of 50 or 80mm thick, closed cell, zero ODP, FM certified polyisocyanurate (PIR) insulation. The auto adhesive properties of the core, bond the external and internal sheets together and control the panel thickness achieved during manufacture. Internal liner sheet Substrate to be a minimum 0.40mm thick Zincalume G300S AZ100 coated steel to AS1397. Coating to be standard white liner microns thick. Performance Thermal Insulation The panel will have a Thermal Resistance (R value) of (see below), based on an aged thermal conductivity of W/mK. 50mm = 2.65m 2 K/W 80mm = 4.15m 2 K/W Fire The external and internal faces of the panel to be Class 0 in accordance with the Building Regulations when tested to BS476: Parts 6:1989 and Part 7:1987. The system has the following FM test results 4880 (2005) achieves Class 1 fire rating with no height restriction. Seals Horizontal panel joints To be a tongue (male) and groove (female) type of joint with a factory applied weather seal located within the groove (female) section. Junctions To be constructed and sealed as shown in the project detail drawing. Fillers Where top hat sections are positioned, AWP joint fillers should be used to seal and close the profile as per our standard details (Kingspan reference FILL). Fasteners Primary All primary fasteners must be self tapping, self drilling screws, manufactured from carbon steel, anti corrosion coated and fitted with a 16mm diameter bonded washer. All fasteners to be located through the tongue (male) section of the panel. To comply with the local requirements, it may be necessary to provide additional fixings through the male section, in areas of high local suction. See fixing chart on page 102 of this book for correct ITW Buildex fastener. Through fix Where panels have their male sections removed on site, they must be face fixed with a similar type of fastener. The fasteners if required can be covered by a flashing to maintain the concealed fix appearance. Base channel At the drip level a base channel ref: BC 50 or BC 80 runs for the full length of the panel, levelled with packers and is fixed to the floor slab at a maximum of 500mm centres. Secondary Flashings to be stitched at 450mm centres (maximum) with carbon steel stitching screws, complete with bonded 14mm diameter carbon steel washers. 10

15 Contruction details Vertical panel joints option 1 (TH1) Vertical panel joint to be (Kingspan reference TH1) extruded aluminium top hat section, polyester powder coated in standard colour, weather sealed along the full length using two runs of 9mm wide x 4.8mm thick sealant tape (Kingspan reference TH-S). Insert to be flush extruded aluminium snap in cover cap, polyester powder coated in standard colour. PIR board insulation to fill gap between back of top hat and steelwork (Kingspan reference THPUR 50 or 80). Foam fillers to be installed either side at horizontal joint locations and silicone sealed as per detail (Kingspan reference FILL). Rear of panel to have EPDM 100mm x 12mm self adhesive air seal bubble gasket (Kingspan reference THBUBBLE). Vertical panel joints option 2 (TH2) Vertical panel joint to be (Kingspan reference TH2) installed as per TH1 above. Insert to be recessed extruded aluminium snap in cover cap, polyester powder coated in standard colour. PIR board insulation and foam fillers to be installed as per TH1 above. Vertical panel joints option 3 (TH3) Vertical panel joint to be (Kingspan reference TH3) installed as per TH1 above. Insert to be black EPDM rubber push in gasket. PIR board insulation and foam fillers to be installed as per TH1 above. Flashings All external flashings to be made from 0.55mm thick steel, coated to the same specification as the outer sheet of the panel. Colour standard. All flashings to be weather sealed at laps and along the full length by an unbroken bead of 6mm wide x 4mm thick butyl rubber sealant tape (Kingspan reference S-EXT). All flashings to have butt straps and sealed with two unbroken runs of 6mm wide x 4mm thick butyl rubber sealant tape (Kingspan reference S-EXT). All internal flashings to be made from 0.4mm thick steel substrate, to the same specification as the inner sheet. Colour white. All internal flashings to be air sealed along the laps and full along length by an unbroken bead of 4mm diameter butyl rubber sealant tape (Kingspan reference S-INT). Steelwork tolerance The steel frame must be made and assembled to an accuracy of L / 600 between fixing planes of adjacent purlins, where L is the purlin spacing. Installation All fasteners and seals to be of correct specification and installed as indicated on the project construction drawings. Site cut panels must provide accurate, true lines with no distortion, panels to be cut with powered reciprocating type saw and all exposed site cut panels to be treated with a suitable edge protection lacquer. Cut openings for outlets, vents, flues etc to be the minimum size necessary. Remove all swarf and any foreign matter immediately from the external surface of panels. Fasteners to be checked and adjusted if necessary to ensure they are weather tight and external panel facing is not distorted. Safety The contractor is to determine and use a safe method of working throughout the installation and construction period, which complies with WorkSafe requirements. 11 AWP model specs horizontally laid

16 Model specification KS1000 AWP / LS FM vertically laid Application The following specification is for the KS1000 AWP / LS MR / MM / EB FM insulated wall panel laid vertically on a normal building, where Factory Mutual (FM) Research Standard 4880 (2005) approved requirements for Class 1 fire classification where no height restriction is needed. For internal high humidity class environments specification ie. swimming pools contact Kingspan Technical Services. Materials and coatings External weather sheet Substrate to be a minimum 0.55mm thick Zincalume G300S AZ150 coated steel to AS1397. Colours as per Kingspan standard range Colorbond is also available. Note: Some colours carry longer lead times and additional prices please consult Kingspan Sales for more information. Profiles available are MR (Micro-Rib), MM (Mini-Micro) or EB (Euro-Box). Insulation core To consist of 50 or 80mm (AWP) or 100 or 140mm (LS) thick, closed cell, zero ODP, FM certified polyisocyanurate (PIR) insulation. The auto adhesive properties of the core, bond the external and internal sheets together and control the panel thickness achieved during manufacture. Internal liner sheet Substrate to be a minimum 0.40mm thick Zincalume G300S AZ100 coated steel to AS1397. Coating to be standard white liner microns thick. Performance Thermal insulation The panel will have a thermal resistance (R value) of (see below), based on an aged thermal conductivity of W/mK. 50mm = 2.65m 2 K/W 80mm = 4.15m 2 K/W 100mm = 5.15m 2 K/W Fire The external and internal faces of the panel to be Class 0 in accordance with the Building Regulations when tested to BS476: Parts 6:1989 and Part 7:1987. The system has the following FM test results 4880 (2005) achieves Class 1 fire rated with no height restriction. Seals Vertical panel joints To be a tongue (male) and groove (female) type of joint with a factory applied weather seal located within the groove (female) section. Fasteners Primary All primary fasteners must be self tapping, self drilling screws, manufactured from carbon steel, anti corrosion coated and fitted with a 16mm diameter bonded washer. All fasteners to be located through the tongue (male) section of the panel. To comply with the local requirements, it may be necessary to provide additional fixings through the male section, in areas of high local suction. See fixing chart on page 102 of this book for correct ITW Buildex fastener. Through fix Where panels have their male sections removed on site, or due to loadings, they must be face fixed with a similar type of fastener. The fasteners must be covered by a flashing to maintain the concealed fix appearance. Secondary Flashings to be stitched at 450mm centres (maximum) with carbon steel stitching screws, complete with bonded 14mm diameter carbon steel washers. 140mm = 7.15m 2 K/W 12

17 Construction details Flashings All external flashings to be made from 0.55mm thick coated to the same specification as the outer sheet of the panel. Colour standard. All flashings to be weather sealed at laps and along the full length by an unbroken bead of 6mm wide x 4mm thick butyl rubber sealant tape (Kingspan reference S-EXT). All flashings to have butt straps and sealed with two unbroken runs of 6mm wide x 4mm thick butyl rubber sealant tape (Kingspan reference S-EXT). AWP fillers to be installed as per details. Panels must be assembled so that joint widths are consistent and parallel. Fasteners to be checked and adjusted if necessary to ensure they are weather tight and external panel facing is not distorted. Safety The contractor is to determine and use a safe method of working throughout the installation and construction period, which complies with WorkSafe requirements. AWP / LS model specs vertically laid All internal flashings to be made from 0.4mm thick steel substrate, to the same specification as the inner sheet. Colour white. All internal flashings to be air sealed along the laps and full along length by an unbroken bead of 4mm diameter butyl rubber sealant tape (Kingspan reference S-INT). Panel lengths Exact lengths to be determined by the cladding contractor from the steelwork drawing, but typically using 6000mm lengths. Steelwork tolerance The steel frame must be made and assembled to an accuracy of L / 600 between fixing planes of adjacent sheeting rails, where L is the rail spacing. Installation All fasteners and seals to be of correct specification and installed as indicated on the project construction drawings. Site cut panels must provide accurate, true lines with no distortion, panels to be cut with powered reciprocating type saw and all exposed site cut panels to be treated with a suitable edge protection lacquer. Cut openings for outlets, vents, flues etc. to be the minimum size necessary. Remove all swarf and any foreign matter immediately from the external surface of panels.

18 Model specification KS1000 LS / FM horizontally laid Application The following specification is for the KS1000 LS MR / MM / EB FM insulated wall panel laid horizontally on a where Factory Mutual (FM) Research Standard 4880 (2005) approved requirements for Class 1 fire classification where no height restriction is needed. For internal high humidity class environments specification ie. swimming pools contact Kingspan Technical Services. Materials and coatings External weather sheet Substrate to be a minimum 0.55mm thick Zincalume G300S AZ150 coated steel to AS1397. Colours as per Kingspan Standards Colorbond is also available. Note: Some colours carry longer lead times and additional prices please consult Kingspan Sales for more information. Profiles available are MR (Micro-Rib), MM (Mini-Micro) or EB (Euro-Box). Insulation core To consist of 100 or140mm thick, closed cell, zero ODP, FM certified polyisocyanurate (PIR) insulation. The auto adhesive properties of the core, bond the external and internal sheets together, and control the panel thickness achieved during manufacture. Internal liner sheet Substrate to be 0.40mm thick Zincalume G300S AZ100 coated steel to AS1397. Coating to be standard white liner microns thick. Performance Thermal insulation The panel will have a thermal resistance (R value) of (see below), based on an aged thermal conductivity of W/mK. 100mm = 5.15m 2 K/W 140mm = 7.15m 2 K/W Fire The external and internal faces of the panel to be Class 0 in accordance with the Building Regulations when tested to BS476: Parts 6:1989 and Part 7:1987. The system has the following FM test results 4880 (2005) achieves Class 1 fire rating with no height restriction. Seals Horizontal panel joints To be a tongue (male) and groove (female) type of joint with a factory applied weather seal located within the groove (female) section. Junctions To be constructed and sealed as shown in the project detail drawing. Fillers Where top hat sections are positioned, fillers should be used to seal and close the profile as per our standard details (Kingspan reference FILL). Fasteners Primary All primary fasteners must be self tapping, self drilling screws, manufactured from carbon steel, anti corrosion coated, and fitted with a 16mm diameter bonded washer. All fasteners to be located through the tongue (male) section of the panel. To comply with the local requirements, it may be necessary to provide additional fixings through the male section, in areas of high local suction. See fixing chart on page 102 of this book for correct ITW Buildex fastener. Through fix Where panels have their male sections removed on site, they must be face fixed with a similar type of fastener. The fasteners if required can be covered by a flashing to maintain the concealed fix appearance. Base channel At the drip level a base channel ref: BC 100 or BC 140 runs for the full length of the panel (except at top hat positions), levelled with packers and is fixed to the floor slab at a maximum of 500mm centres. 14

19 Secondary Flashings to be stitched at 450mm centres (maximum) All internal flashings to be made from 0.4mm thick with carbon steel stitching screws, complete with steel substrate, to the same colour and specification as bonded 14mm diameter carbon steel washers. the inner sheet. Colour white. All internal flashings to be air sealed along the laps and full along length Construction details by an unbroken bead of 4mm diameter butyl rubber sealant tape (Kingspan reference S-INT). Vertical panel joints option 1 (TH1) Steelwork tolerance Vertical panel joint to be (Kingspan reference TH1) extruded aluminium top hat section, polyester powder The steel frame must be made and assembled to an coated in standard colour, weather sealed along the accuracy of L / 600 between fixing planes of adjacent full length using two runs of 9mm wide x 4.8mm thick purlins, where L is the purlin spacing. sealant tape (Kingspan reference TH-S). Insert to be Installation flush extruded aluminium snap in cover cap, polyester All fasteners and seals to be of correct specification powder coated in standard colour. and installed as indicated on the project construction PIR board insulation to fill gap between back of top hat drawings. and steelwork (Kingspan reference THPUR 50 or 80). AWP / LS model specs vertically laid Site cut panels must provide accurate, true lines Foam fillers to be installed either side at horizontal joint with no distortion, panels to be cut with powered locations and silicone sealed as per detail (Kingspan reciprocating type saw and all exposed site cut panels reference FILL). Rear of panel to have EPDM 100mm x to be treated with a suitable edge protection lacquer. 12mm self adhesive air seal bubble gasket (Kingspan Cut openings for outlets, vents, flues etc. to be the reference THBUBBLE). minimum size necessary. Vertical panel joints option 2 (TH2) Remove all swarf and any foreign matter immediately Vertical panel joint to be (Kingspan reference TH2) from the external surface of panels. installed as per TH1 above. Insert to be recessed Fasteners to be checked and adjusted if necessary to extruded aluminium snap in cover cap, polyester ensure they are weather tight and external panel facing powder coated in standard colour. is not distorted. PIR board insulation and foam fillers to be installed Safety as per TH1 above. The contractor is to determine and use a safe method Vertical panel joints option 3 (TH3) of working throughout the installation and construction Vertical panel joint to be (Kingspan reference TH3) period, which complies with WorkSafe requirements. installed as per TH1 above. Insert to be black EPDM rubber push in gasket. PIR board insulation and foam fillers to be installed as per TH1 above. Flashings All external flashings to be made from 0.55mm thick coated steel to the same specification as the outer sheet of the panel. Colour standard. All flashings to be weather sealed at laps and along the full length by an unbroken bead of 6mm x 4mm thick butyl rubber sealant tape (Kingspan reference S-EXT). LS model specs horizontally laid 15

20 Architectural Wall Panel / Longspan Construction details standard horizontally laid

21 Contents Construction details KS1000 MR (Micro-Rib) / MM (Mini-Micro Rib) details 18 KS1000 EB (Euro-Box) profile details 19 Horizontal panel joint details 20 Typical layout for horizontally fixed panels 21 Eaves detail 1 22 Eaves detail 2 23 Parapet eaves detail 24 Verge details 25 Skillion roof detail 26 Drip details 27 Pre-formed corner detail 28 External corner detail 29 Internal corner detail 30 Abutment details 31 Vertical joint details 32 Panel joint to vertical top hat details 33 Cover strip for site cut panel detail 34 Window details 35 Window details 36 Personnel door details 37 Pre-formed unit details 38 Base channel details 39

22 KS1000 MR (Micro-Rib) / MM (Mini-Micro) profile details 18

23 KS1000 EB (Euro-Box) profile details KS1000EB (Euro Box) Panel joint details AWP / LS horizontal details LS model specs horizontally laid 19

24 Horizontal panel joint details 20

25 Typical layout for horizontally fixed panel details AWP / LS horizontal details 21

26 Eaves detail 1 22

27 Eaves detail 2 AWP / LS horizontal details 23

28 Parapet eaves detail 24

29 Verge details AWP / LS horizontal details 25

30 Skillion roof detail 26

31 Drip details AWP / LS horizontal details 27

32 Pre-formed corner detail 28

33 External corner detail AWP / LS horizontal details 29

34 Internal corner detail 30

35 Abutment details AWP / LS horizontal details 31

36 Vertical joint details 32

37 Panel joint to vertical top hat details AWP / LS horizontal details 33

38 Cover strip for site cut panel detail 34

39 Window details AWP / LS horizontal details 35

40 Window details 36

41 Personnel door details AWP / LS horizontal details AWP / LS horizontal details 37

42 Pre-formed unit details 38

43 Base channel details AWP / LS horizontal details AWP / LS horizontal details 39

44 Architectural Wall Panel / Longspan Construction details standard vertically laid

45 Contents Construction details KS1000 MR (Micro-Rib) / MM (Mini-Micro Rib) / EB (Euro-Box) 42 Eaves detail 1 43 Eaves detail 2 44 Eaves detail 3 45 Verge details 46 Verge details 47 Skillion roof detail 48 Drip detail 49 Corner detail 50 Corner detail 51 Abutment detail 52 Window details 53

46 KS1000 MR (Micro-Rib) / MM (Mini-Micro Rib) / EB (Euro-Box) 42

47 Eaves detail 1 AWP / LS vertical details AWP / LS verticall details 43

48 Eaves detail 2 44

49 Eaves detail 3 AWP / LS vertical details 45

50 Verge details 46

51 Verge details AWP / LS vertical details 47

52 Skillion roof detail 48

53 Drip detail AWP / LS vertical details 49

54 Corner detail 50

55 Corner detail AWP / LS vertical details 51

56 Abutment detail 52

57 Window details AWP / LS vertical details 53

58 KS1000 RW wall panel system

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60 KS1000 RW wall panel Introduction Suitable for a wide range of developments such as commercial, retail and industrial, amongst others, the Kingspan KS1000 RW wall systems are suitable for both wall and roof applications. KS1000 RW wall is a through fixed system which can be laid vertically or horizontally. valley or crown fixings using matching colour headed fasteners. The system provides good economic, superior thermal and air leakage performance with long term lifecycle durability and is available in lengths up to 14 metres*. * Subject to transport charges. The KS1000 system provides a one stop solution to the new Part J thermal regulations. Equally it provides an insurer approved solution allowing simple and fast site installation with options of 56

61 Benefits Kingspan KS1000 RW system offers a range of solutions for demanding specifiers. If you insist on constantly reducing overheads, KS1000 RW has been designed for accelerated build speed. It is pre-engineered for single-component / single-fix installation which reduces site time by as much as 50%. If you insist on a high quality finish, this system offers 100% reliable thermal performance and insulation continuity: with no cavities, no gaps, no cold bridges or interstitial condensation risk. If you insist on fire safety, this system is approved by Factory Mutual, the toughest test any building component can face. If you insist on durability, KS1000 RW has an overall lifecycle expectancy of 40 years. If you insist on the best, you ve got it. Key features RW introduction Fully compliant with Building Regulations and Standards Building Code of Australia section J compliant Attractive embodied energy Energy efficient performance reduces plant and lifetime operating costs by up to 40% Insurer approved FM-approved Lifetime insulation continuity, thermal performance and airtightness Accelerated build speed through pre-engineered, single component, singlefix installation, reduces site time by up to 50% Environmentally sustainable system Zero Ozone Depleting Potential (ODP) and non-deleterious Environmentally sustainable solutions reduce lifetime Carbon Dioxide (CO2) emissions by up to 40% Can reduce steel work requirements Lifetime durability and overall life expectancy in excess of 40 years Can incorporate safety and fall arrest systems Quality approved to IS0 9001:2000 Made in Australia 57

62 Product data Application The KS1000 RW wall system is suitable for all building applications and can be laid vertically or horizontally. Product reference KS1000 RW Application description Trapezoidal wall and roof panel with Factory Mutual (FM) approval for wall and roof applications Insurer approved system Dimensions and weight 1000 Cover width External weather sheet B A Internal liner sheet A Core thickness (mm) 30* 40 60** 100 B Overall dimension (mm) Weight kg/m / 0.4 steel These panel thicknesses can be used to comply with the BCA Part J thermal regulations: * wall ** roof climate zones 1-7 Product tolerance Cut to length -0.05% +0.1% Liner sheet length -0.1% +0.1% Cover width -1mm +1mm Thickness -5mm +1mm End square -2mm +2mm Available lengths Standard lengths 1.8 to 14 metres*. Panels less than 1.8 metres costs are subject to additional charges. Panel cut back All panels can be produced with the following options: Panel length square 75mm 150mm Cut back * Subject to transport charges. 58

63 Performance Thermal insulation Panel thickness (mm) R value m 2 k/w Biological Kingspan panels are normally immune to attack from mould, fungi, mildew and vermin. No-urea formaldehyde is used in the construction and the panels are not considered deleterious. No ozone depleting substances are used in the manufacture of these panels. Delivery All deliveries (unless indicated otherwise) are by road transport to project site. Off loading is the responsibility of the client. See pages of this book on site handling. Site installation procedure Site assembly instructions are available from Kingspan Technical Services. Fire Insurer approved panels are available with FM and LPCB certification. Acoustics All KS1000 RW panels have a single figure weighted sound reduction Rw = 25dB. RW product data Quality and durability Sound reduction index (SRI) tested Frequency (Hz) k 2k 4k SRI (db) Kingspan Insulated Panels are manufactured from the highest quality materials, using state of the art production equipment to rigorous quality control standards, complying with ISO 9001:2000 standard, ensuring long term reliability and service life. Guarantees Kingspan will provide external coating and product guarantees on an individual project basis. Packing KS1000 RW panels are stacked weather sheet to weather sheet (to minimise pack height). The number of panels in each pack depends on panel thickness and length. Quantities are reduced for exceptionally long panels. Maximum pack height is 1200mm. 59

64 Model specification KS1000 RW / FM vertically laid Application The following specification is for the KS1000 RW / FM insulated wall panel laid vertically on a building, where Factory Mutual (FM) Research Standard 4880 (2005) approved requirements for Class 1 fire classification where no height restriction is needed. For internal high humidity class environments specification ie. swimming pools contact Kingspan Technical Services. Materials and coatings External weather sheet Substrate to be a minimum 0.50mm thick Zincalume G300S AZ150 coated steel to AS1397. Colours as per Kingspan standard range Colorbond also available. Note: Some colours carry longer lead times and additional prices please consult Kingspan Sales for more information. Insulation core To consist of 30, 40, 60 or 100mm thick, closed cell, zero ODP, FM certified polyisocyanurate (PIR) insulation. The auto adhesive properties of the core, bond the external and internal sheets together and control the panel thickness achieved during manufacture. Internal liner sheet Substrate to be a minimum 0.40mm thick Zincalume G300S AZ100 coated steel to AS1397. Coating to be standard white liner microns thick. Performance Thermal insulation The panel will have a thermal resistance (R value) of (see below), based on an aged thermal conductivity of W/mK. Panel thickness (mm) R value m 2 k/w Fire The external and internal faces of the panel to be Class 0 in accordance with the Building Regulations when tested to BS476: Parts 6:1989 and Part 7:1987. The system has the following FM test results ASTM E-180 spread of flame test-pass Class A, Class 1 test (calorimeter) pass Class 1, wind uplift test-pass Seals and fillers Side lap All external side laps to be weather sealed along the full length by an unbroken bead of 6mm x 4mm butyl rubber sealant tape (Kingspan reference S-EXT). End lap All external end laps to be 150mm long and weather sealed along the full width using two unbroken runs of 6mm x 4mm butyl rubber sealant tape (Kingspan reference S-EXT). Fillers Where flashings are fixed across the profile of the insulated panel, closed cell polyethylene foam fillers should be used to seal and close the profile. Seal the top, bottom and sides of each profiled filler with non-curing gun-grade sealant. Fasteners Primary All primary fasteners must be the high threaded type manufactured from carbon steel, anti-corrosion coated, and fitted with a bonded 25mm diameter washer and colour matched plastic cap (if required). All fasteners to be located through every valley (or every crown) of the profile. To comply with local windload requirements and those of Factory Mutual it may be necessary to provide additional fixings in areas of high local suction See fixing chart on page 102 of this book for correct ITW Buildex fastener

65 Secondary Side laps and flashings to be stitched at 450mm centres (maximum) with carbon steel stitching screws, complete with 14.5mm diameter carbon steel washers (ITW Buildex ref: C4). Construction details Flashings All external flashings to be made from 0.55mm thick coated steel to the same specification as the outer sheet of the panel. Colour standard. All flashings to be weather sealed at laps and along the full length by an unbroken bead of 6mm x 4mm thick butyl rubber sealant tape (Kingspan reference S-EXT). All internal flashings to be made from 0.55mm thick steel substrate, to the same specification as the liner sheet of the panel. All internal flashings to be air sealed at laps and along the full length by an unbroken bead of 4mm diameter butyl rubber sealant tape (Kingspan reference S-EXT). Panel lengths Exact lengths to be determined by the cladding contractor from the steelwork drawing, but typically using 6000mm lengths. Site cut panels must provide accurate, true lines with no distortion. Panels to be cut with powered reciprocating type saw and all exposed site cut panels to be treated with a suitable edge protection lacquer. Cut openings for outlets, vents, flues etc. to be the minimum size necessary. Remove all swarf and any foreign matter immediately from the external surface of panels. Fasteners to be checked and adjusted if necessary to ensure they are weather tight and external panel facing is not distorted. Safety The contractor is to determine and use a safe method of working throughout the installation and construction period which complies with WorkSafe requirements. RW model specs vertically laid Construction requirements Steelwork tolerance The steel frame must be made and assembled to an accuracy of L / 600 between fixing planes of adjacent rails, where L is the rail spacing. Installation Panels to be laid with side lap joints away from prevailing wind unless otherwise shown on drawings. All fasteners, seals and fillers to be of correct specification and installed as indicated on the project construction drawings.

66 Model specification KS1000 RW / FM horizontally laid Application The following specification is for the KS1000 RW / FM insulated wall panel laid horizontally on a building, where Factory Mutual (FM) Research Standard 4880 (2005) approved requirements for Class 1 fire classification where no height restriction is needed. For internal high humidity class environments specification ie. swimming pools contact Kingspan Technical Services. Materials and coatings External weather sheet Substrate to be a minimum 0.50mm thick Zincalume G300S AZ150 coated steel to AS1397. Colours as per Kingspan standard range Colorbond also available. Note: Some colours carry longer lead times and additional prices please consult Kingspan Sales for more information. Insulation core To consist of 30, 40, 60 or 100mm thick, closed cell, zero ODP, FM certified polyisocyanurate (PIR) insulation. The auto adhesive properties of the core, bond the external and internal sheets together, and control the panel thickness achieved during manufacture. Internal liner sheet Substrate to be a minimum 0.40mm thick Zincalume G300S AZ100 coated steel to AS1397. Coating to be standard white liner microns thick. Performance Thermal insulation The panel will have a thermal resistance (R value) of (see below), based on an aged thermal conductivity of W/mK. Panel thickness (mm) R value m 2 k/w Fire The external and internal faces of the panel to be Class 0 in accordance with the Building Regulations when tested to BS476: Parts 6:1989 and Part 7:1987. The System has the following FM test results ASTM E-180 spread of flame test-pass Class A, Class 1 test (calorimeter) pass Class 1, wind uplift test-pass Seals and fillers Side lap All external side laps to be weather sealed along the full length by an unbroken bead of 6mm x 4mm butyl rubber sealant tape (Kingspan reference S-EXT). End lap All external end laps to be 50mm long and weather sealed along the full width using two unbroken runs of 6mm x 4mm butyl rubber sealant tape (Kingspan reference S-EXT). Fillers Where flashings are fixed across the profile of the insulated panel, closed cell polyethylene foam fillers should be used to seal and close the profile. Seal the top, bottom and sides of each profiled filler with non-curing gun-grade sealant. Fasteners Primary All primary fasteners must be the high threaded type manufactured from carbon steel, anti-corrosion coated, and fitted with a bonded 25mm diameter washer and colour matched plastic cap (if required). All fasteners to be located through every valley (or every crown) of the profile. To comply with local windload requirements and those of Factory Mutual it may be necessary to provide additional fixings in areas of high local suction. See fixing chart on page 102 of this book for correct ITW Buildex fastener. 62

67 Secondary Side laps and flashings to be stitched at 300mm centres (maximum) with carbon steel stitching screws, complete with 14mm diameter carbon steel washers (ITW Buildex ref: c4). Construction details Flashings All external flashings to be made from 0.55mm thick coated steel to the same specification as the outer sheet of the panel. Colour standard. Remove all swarf and any foreign matter immediately from the external surface of panels. Fasteners to be checked and adjusted if necessary to ensure they are weather tight and external panel facing is not distorted. Safety The contractor is to determine and use a safe method of working throughout the installation and construction period which complies with WorkSafe requirements. All flashings to be weather sealed at laps and along the full length by an unbroken bead of 6mm x 4mm thick butyl rubber sealant tape (Kingspan reference S-EXT). All internal flashings to be made from 0.55mm thick steel substrate, to the same specification as the liner sheet of the panel. All internal flashings to be air sealed at laps and along the full length by an unbroken bead of 4mm diameter butyl rubber sealant tape (Kingspan reference S-INT). RW model specs horizontally laid Panel lengths Exact lengths to be determined by the cladding contractor from the steelwork drawing, but typically using 6000mm lengths. Construction requirements Steelwork tolerance The steel frame must be made and assembled to an accuracy of L / 600 between fixing planes of adjacent rails, where L is the rail spacing. Installation Panels to be laid with side lap joints away from prevailing wind unless otherwise shown on drawings. All fasteners, seals and fillers to be of correct specification and installed as indicated on the project construction drawings. Site cut panels must provide accurate, true lines with no distortion. Panels to be cut with powered reciprocating type saw and all exposed site cut panels to be treated with a suitable edge protection lacquer. Cut openings for outlets, vents, flues etc. to be the minimum size necessary. 63

68 KS1000 RW wall panel Construction details standard vertically laid

69 Contents Construction details KS1000 RW panel dimension details 66 Wall panel vertically laid details 67 Drip details 68 Drip flashing detail 69 External corner details 70 Internal corner details 71 Abutment to brickwork detail 72 Abutment to brickwork detail 73 Soffit details 74 Window details 75 Personnel door details 76 Fixed wall louvre details 77 Wall extractor details 78

70 KS1000 RW panel dimension details 66

71 Wall panel vertically laid details RW vertical details 67

72 Drip details 68

73 Drip flashing detail RW vertical details. 69

74 External corner details 70

75 Internal corner details RW vertical details 71

76 Abutment to brickwork detail 72

77 Abutment to brickwork detail RW vertical details 73

78 Soffit details 74

79 Window details RW vertical details 75

80 Personnel door details 76

81 Fixed wall louvre details RW vertical details 77

82 Wall extractor details 78

83 RW vertical details

84 KS1000 RW wall panel Construction details standard horizontally laid IMAGE TO COME

85 Contents Construction details Wall panel horizontally laid details 82 Drip detail 83 External corner details 84 Internal corner detail 85 Abutment to brickwork details 86 Soffit detail 87 Soffit detail 88 Window details 89 Personnel door details 90 Roller shutter door details 91 Fixed wall louvre details 92

86 Wall panel horizontally laid details 82

87 Drip detail RW horizontal details 83

88 External corner details 84

89 Internal corner detail RW horizontal details 85

90 Abutment to brickwork details 86

91 Soffit detail RW horizontal details 87

92 Soffit detail 88

93 Window details RW horizontal details 89

94 Personnel door details 90

95 Roller shutter door details RW horizontal details 91

96 Fixed wall louvre details 92

97 RW horizontal details

98 KS1000 Optimo wall panel system 94

99 KS1000 Optimo represents a dramatic breakthrough in pre-engineered wall systems delivering a clean, optically smooth and aesthetically appealing modern solution. Whether considering a new build or refurbishment project, the Optimo wall system allows specifiers to be confident that there is a practical and cost effective solution which maximises visual impact. Optimo s slim sight lines create a visually striking appearance for the building s all-important wall envelope. Available in cover widths of 600, 900 or 1000mm, the system has a hidden joint true secret fix detail which conceals fasteners from view. The advanced Optimo system also includes a broad range of project specific accessories which ensures an integrated wall solution is achieved. Panel thickness (mm) R value m 2 k/w Weight kg/m /0.4 steel For information and details on Optimo contact Kingspan Technical Service department. Optimo wall panel 95

100 Additional requirements

101

102 Ancillaries There are a number of ancillary fittings that are available and can be used with Kingspan's AWP, Longspan and RW wall systems. AWP 50mm Horizontally laid Base channel BC50 / 80 / 100 / 140 Top Hat flush TH1 Top Hat recessed TH2 Top Hat rubber TH3 Sealant for Top Hat 9mm x 4.8mm THS AWP 50mm Vertically laid AWP 80mm Horizontally laid AWP 80mm Vertically laid LS 100mm Horizontally laid LS 100mm Vertically laid LS 140mm Horizontally laid LS 140mm Vertically laid RW Vertically laid RW Horizontally laid KEY: = not required NOTE: Fixings are to be sourced by installer see fixing guide for fastener information NOTE: Flashings are to be sourced by installer to clients colour Order forms available from Kingspan Sales KS1000 AWP with flush Top Hat TH1 KS1000 AWP with recessed Top Hat TH2 98

103 Sealant for external flashings 6mm x 4mm S-EXT Sealant for internal flashings 4mm diameter S-INT Fillers AWP / LS FILL PUR Block THPUR 50 / 80 / 100 / 140 Bubble gasket THBUBBLE RW fillers RW FILL KEY: = are required and need to be ordered with panel KS1000 AWP with rubber insert Top Hat TH3 Additional requirements 99

104 Fasteners Introduction Primary fasteners hold the insulated panels to the building frame, and secondary fasteners join panels to each other and to flashings etc. The fasteners are therefore an integral part of the building, their strength being weatherproofing, durability and appearance must be carefully considered as part of the overall design. The following general notes explain the various fasteners which are used with Kingspan Insulated Panels. Specific references from ITW Buildex fasteners are within this document. Primary fasteners Head Washer Support thread Thread to structure Drill point These fasteners are specially designed to drill through the panel, self tap into the framework and finally seal the outer sheet. This is achieved in one fast operation using a screwgun with a depth sensing nose piece. Various accessories for these tools are available from the fastener manufacturer. Fasteners are manufactured to suit the many materials and constructions in common use. The variations include: They may be made from high quality carbon steel or austenitic stainless steel. The drill point alters for drilling into different materials and thicknesses. The self tapping thread can vary with the type and thickness of material. The overall fastener length will vary depending on the thickness of the panel being fixed. For through fixed panels some fasteners have a secondary support thread directly under the head to withstand superimposed loads caused by foot traffic. This also draws the outer skin tightly up to the washer, thus ensuring a weatherproof seal. The fastener head may be coated to match the roof and wall panel colour (contact ITW Buildex for further information). Secondary fasteners These are the fasteners which join sheet to sheet, flashing to sheet, or flashing to flashing. The main types used are stitching screws or rivets. Stitching screws self drill and tap, draw the sheets together and seal in one operation, in the same way as the primary fasteners. They are available in high quality carbon steel and austenitic stainless steel and in several head forms to suit the various materials being fastened. Rivets are made from aluminium alloy and are installed in a two stage operation which involves drilling a hole through the two components, pushing the rivet into the hole and setting it with a rivetting tool. This tool draws the mandrel through the rivet body and deforms it so that it grips the materials together until it finally breaks. Other blind fasteners are used for special applications, such as the side laps of rooflights, where normal pop rivets and stitchers are unsuitable. These larger fasteners come in several forms, some require a rivetting tool and others use a bolt to pull an EPDM grommet up to the underside of the sheet. Installation and weathering Self drilling / tapping fasteners are supplied with a bonded washer which is designed to prevent water ingress into the building through the fixing point. To be sure of optimum performance it is important to install the fasteners correctly. The fasteners and washers are designed to be driven so that the washer is compressed evenly, giving the appearance shown. The screwgun is fitted with an adjustable, depth sensitive nosepiece which can be set to disengage the clutch when the fastener has been installed correctly. Stitching Screws Rivets Bulb-tite Rivet 100

105 Strength The primary fasteners hold the panels in place on the building and must be strong enough to resist the applied loads. In practice the most important load consideration for fasteners is often wind suction. In these circumstances ultimate failure of the fixing can happen in three possible ways: 1. Pull over The outer skin of the panel deforms around the head and washer of the fastener until the hole is large enough for the panel to pull over, leaving the entire fastener in place. Permissible loads (pull over) kn Panel KS1000 AWP / LS KS1000 RW 2. Pull out Steel thickness Fixing position Single double Single double Permissible loads Ultimate average pull out loads Pull over Load kn 16ø washer 19ø washer The fastener pulls out of the purlin/rail due to wind suction. For purlin/rail thickness greater than 6mm the limiting strength is the tensile strength of the fasteners. Hi Teks 1.0mm 1.2mm 1.5mm 1.9mm 2.4mm 3.2mm Pull out data for G450 steel (kn) Carbon steel Pull out data for G250 / G300 steel (kn) Carbon steel Mechanical properties Hi Teks Single shear Single Torsional Shear (kn), tensile (kn) and torsional strengths (Nm) Carbon steel Fastener tensile failure The fastener breaks in tension, part way down its length, leaving part of the thread in the frame. Permissible tensile load on a 5.5mm diameter carbon or stainless steel fastener is 6.0kN. Durability and appearance The ultimate life expectancy of the fasteners depends on their corrosion rate which can be affected by their material specification, the internal and external environments and the construction of the building. However, there may be appearance or performance problems long before ultimate failure occurs. These may be due to leakage at washers, rust staining, or faded / missing colour caps. Material specifications fasteners Corrosion can occur if there is moisture on the fastener. The rate of corrosion will depend on the fastener material, its coating, the materials being fixed, how long the moisture is present, corrosive elements and the ambient temperature of the environment. Under these circumstances it is difficult to make general predictions about the life expectancy of fasteners, although a number of statements can be made: 1. Coated carbon steel fasteners have performed well in Australian and New Zealand conditions on roofs and walls of insulated buildings. For warranties contact ITW Buildex. 2. Separate snap-on plastic colour caps may come off over time, but integral colour heads will not. The fastener recommendations for ITW Buildex products have been tabulated on page 102. In situations where there is industrial or marine pollution, or internally there are chemical or wet processes (ie. swimming pools), the fastener manufacturer should be consulted. Additional requirements 101

106 Fasteners ITW Buildex fastener selector guide Introduction ITW Buildex manufacture large ranges of fasteners and it is important, but sometimes quite difficult, to select the correct type for a particular application. To assist designers, a Fastener Selector Guide is shown below, which clearly identify ITW Buildex fasteners suggested for various building applications and panel types. For further information about any of the fasteners described here, please contact: ITW Buildex Australia KS1000 AWP and Longspan carbon steel with washer face, epdm seal and Class 4 to AS Description Panel thickness (mm) Secret fix Fix to steel 1.2mm-4mm Teks cold rolled Fix to steel 4mm-6.4mm Teks hot rolled Fix to timber type Z Z C C C C C C CS KS1000 RW carbon steel with washer face, epdm seal and Class 4 to AS Description Panel thickness (mm) Crown fix Vally fix Fix to steel 1.2mm-4mm Teks cold rolled Fix to steel 4mm-6.4mm Teks hot rolled Fix to timber type c cs* c z c z4* c c c c c c c c c c c c c c c4 Stitching screw for side lap and flashings Stitching M6-11 x C4 Note: For stainless steel fixings for certain environments (high humidity etc) please contact Kingspan Technical Department for recommendations. 102

107 Sitework tools and installation To be sure of optimum performance it is important that purpose designed tooling is used to install the fasteners correctly. The fasteners and washers are designed to be driven so that the washer is compressed evenly, thus ensuring a weather tight seal. The screwgun must be fitted with an adjustable, depth sensitive nose piece which can be set to disengage the clutch when the fastener has been installed correctly. Correct installation for primary and secondary fasteners Washer under compressed Correct Washer over compressed Tool requirements for primary fasteners Power tool Nose piece and depth locater Drive bar Fastener socket Fastener Tool requirements for secondary fasteners The following accessories can also be used with the standard power tool as above Locking sleeve and collar Depth locater sleeve Drive bar Fastener socket Fastener Faster installation method Insert fastener into socket Insert fastener through panel Adjust depth stop to ensure the correct compression of the washer (this only needs to be done on the first fastener to achieve the correct setting) Correct washer compression Additional requirements 103

108 Sealants and fillers Introduction Sealants are a fundamental part of wall and roof cladding specification and installation. They make an important contribution to satisfactory weathering, building physics and durability performance of the cladding envelope. It is therefore vital to specify the correct external and internal sealants and fillers at the design stage. Sealants Sealants and fillers used with Kingspan Insulated Panels can be supplied by Kingspan Australia / New Zealand. Preformed mastic tape Bostik 5250 preformed mastic tapes are nonhardening, permanently flexible, synthetic butyl rubber sealants with adhesive properties. They can withstand extreme heat and cold conditions, still retaining their seal, adhesion and resilience. These tapes are supplied on rolls with a release paper. Preformed PVC foam tape Tesa is a closed cell PVC foam tape with a self adhesive to one side. It is fungi, oxidation, UV and ozone resistant and is used to seal the top hat to the panel. Tape thickness mm approximately roll length metres Tape thickness (mm) Approximate roll length (mm) 6 x 4 12 (AWP / LS and RW) 4 dia. 12 (AWP / LS and RW) 9 x (AWP Top Hat only) Mastic sealants Silicone sealant is exclusively used with Kingspan Insulated Panels. Kingspan recommends the following grades: Neutral cure This low modulus silicone does not release any acid during cure, is softer than alternatives, and can accommodate + or -35% joint movement. Material Neutral cure Material Neutral cure Coated steel Lining enamel Permaguard GRP Glass Polycarbonate PVC Brick Concrete Non-settling Non-settling, non-skinning synthetic elastomers and plasticisers reinforced with inert pigments. The sealants have a life of more than 20 years in external applications and joints are normally designed to allow the seal to be removed and renewed, thus extending joint life almost indefinitely. Sealant applications The following table shows which materials to use in a variety of normal building applications for AWP / LS and RW wall. Detail Sealant type Size / shape (mm) External flashings Bostik x 4 Internal flashings Bostik dia. Top-Hat sections Tesa x 4.8 (AWP only) See model specifications and construction drawings in this document. AWP / LS fillers Tesa 7494 (PE) fillers are required to prevent water entering behind the top hat. See construction details for location. Tape thickness (mm) Approximate number per roll 24 x 24 x Sealant applications The following table shows which materials to use in a variety of normal building applications (RW only). See model specification and construction drawings in this document. Detail Sealant type Size / shape (mm) Side lap x 4 Internal side lap dia. End lap x 4 Flashing/trim x 4 and 4 dia. bead 104

109 Installation of sealants Tape sealants: 5250 On side and end laps the location of sealant tape is as indicated. On shallow roof pitches a double line of sealant should be used or alternatively a U section sealant can be supplied. All tapes are applied from the roll leaving the backing paper in place to avoid stretching the tape. The paper is removed after the tape is in position. It is important that the tape is fitted properly down the valley sides and across the troughs without stretching. If this procedure is not followed a good seal is unlikely to be made. TESA 97498, is 20mm thick and cut from closed cell polyethylene foam. This grade is available in black or white and is suitable for general use in non critical applications with a minimum life of 10 years. It should not be used in exposed applications near the coast as it may be subjected to damage by seabirds. When placing the panels care should be taken to avoid displacing the tape. When fixing the sheets, fasteners must not be over tightened as this could force the sealant out of the joint. In buildings where the internal air has a high humidity or low temperature, eg. swimming pools or chill stores, the liner side of the panel joint must also be sealed to form a vapour barrier. When it is not possible to make a butt joint, a backing tape or gap filling foam should first be inserted into the joint and the sealant is then applied so that it has an adequate bond area on both sides of the joint. Generally this should be at least 4mm, but in some instances it may have to be varied to accommodate surface profiles etc. All surfaces must be firm, clean, dry and free from dust, dirt, grease and water to enable the sealant to adhere to them. The surfaces should preferably be reasonably warm and never below 4 C. Profile fillers Where any flashings, such as at a ridge or hip are fixed to profiled roofing or cladding panels a series of gaps are created. To prevent wind, rain and wildlife entering the construction these gaps need to be closed with profile fillers. The following material specification of profile filler is available: Additional requirements 107

110 Site handling Packing, delivery, off-loading and site storage Packing The number of panels in each pack varies depending on panel thickness and customer requirements. Normally the maximum height of each pack is approximately 1200mm. Each pack is labelled with the customers name and contents. Delivery and off loading Using forklift with panels under 6 metres < Spreader bar with slings 2m Max 3m Max 3m Max 2m Max Panels are normally delivered to the site by road transport, the number of packs depending on panel and pack size. The packs are separated with bearers which create gaps between the packs to allow lifting straps or forklift tines to be inserted. It is the customer s responsibility to arrange lifting Using lifting beam with panels equipment and over 6 metres long labour to unload the packs. This usually requires using a crane, with or without a lifting beam, or a forklift, depending on panel length and weight. in prime condition until they are installed the following precautions should be taken: Store packs off the ground and on a slope, so that should rain water penetrate the wrapping, water will drain away. Support the packs evenly with bearers spaced at 1.2 metres. Bearers should always be placed one directly above another. Store packs in a secure area, where they will not be damaged or stolen. Inspect the storage site and the packs regularly to ensure the panels remain in good condition. Do not store packs where people will walk across them. Site handling Packs of panels up to 6 metres long can be lifted either with a forklift, or by crane with lifting straps, as illustrated on page 107. Care must be taken to ensure the forklift tines do not damage the bottom panel and When hoisting packs or panels into position protect the edges if necessary to avoid damage. Use flat slings and not chains for hoisting. Site storage It is often necessary to store packs of panels on site for a period before they are fixed. To ensure that panels remain

111 similarly using straps, protect the edge of the panels to prevent local damage. Packs longer than 6 metres should be lifted by cranes with a lifting beam with straps at a maximum of 3 metre centres. Individual panels should always be lifted from a pack and not dragged over others. The weight of individual panels for lifting can be determined from the information in the product data pages for the individual products. Generally panels can be placed into position manually, subject to OHS, weight and handling restrictions. For larger panels the contractor would normally arrange to use a crane, hoist, or other equipment to help lift the panels into position. Appropriate personel protective equipment should always be worn to avoid cuts and abrasions to operatives. Installers should always wear rubber soled footwear to avoid damage to the panel coating when installing panels. Protecting film When panels are supplied with a plastic protective film this should be removed immediately after site installation. 6m Max 1m Min Fork lift 2m Min Lifting straps 2m Max 3m Max 3m Max Lifting beam Additional requirements

112 BCA Part J compliancy Mandatory energy efficiency measures for non-residential construction The new BCA Part J, which came into force in 2006 will change the way we build. It sets new standards for long term insulation and environmental performance of components and construction methods. It is the responsibility of all involved in the construction industry to understand and comply with the new mandatory provisions of BCA Part J. This includes: designers specifiers engineers building contractors owners investors Part J covers all Class 2 to 9 buildings (residential and commercial buildings). It aims to reduce greenhouse gas emissions by increasing energy efficiency of structures. Affects all air conditioned and many non-air conditioned buildings. Specific areas of focus include: Loss of energy through heating / cooling leakage through building fabric roof, ceilings, walls and floors External glazing to reduce heat gain and place less pressure on air conditioning Sealing to reduce leakage around chimneys, flues, windows, doors and other projections Air movement and ventilation to reduce air conditioning needs Design of air conditioning systems to prevent excessive power consumption Part J regulations are different for each class of structure and climate zone in Australia. The Building Code of Australia Part J: Mandatory energy efficiency measures for non-residential construction The Building Code of Australia (BCA) Part J (mandatory energy efficiency measures for nonresidential construction) regulation aims to reduce greenhouse gas emissions from buildings. This regulation has been developed in consultation with state, territory and local governments, building practitioners, industry and the community. Implementation dates Energy efficiency measures were initially introduced into the BCA housing provisions in In 2005, State Australian Capital Territory Adoption date 1 May 2006 New South Wales 1 November 2006 Northern Territory 1 May 2006 Queensland 1 May 2006 South Australia 1 August 2006 Tasmania 1 May 2006 Victoria 1 May 2006 Western Australia 1 May 2006 mandatory measures were introduced into the BCA for Class 2-4 buildings. This was followed up in 2006 with similar measures for Class 5-9 buildings. All of the BCA provisions are now mandatory for Class 2 to 9 buildings (refer to the appendix description for building classes). Buildings with HVAC are particularly affected by the new regulations. Greenhouse gas emissions The Australian government has committed to achieving specific greenhouse reductions as part of the Kyoto Protocol, which came into effect in Part J in building construction is a key project in the steps taken to achieve these emission targets. Compliance to Part J Automatic compliance to Part J mandatory regulations can be achieved by meeting the BCA prescribed building solutions, called Deemed to Satisfy provisions. There is provision for alternative engineered solutions, which will require documentary evidence, verification, comparative analysis or expert judgement. New energy efficiency measures The incorporation of energy efficiency measures in the BCA is targeted towards ongoing operational efficiencies over the life of buildings. The BCA sets standards for the performance of buildings, including services that aid the efficient use of energy. Part J incorporates the use of the building, the method of construction, its geographic location, the effects of nearby features such as landforms, structures and buildings and solar radiation considerations. The mandatory energy efficiency requirements vary according to the Class of building and are also based on the climate zone. Australia is divided into 108

113 geographical zones (see map, also available on the ABCB website). Different levels of energy efficiency are required, based on the climate severity for each building being designed. Specific areas targeted by the BCA for improvement are: of the building and glazing orientation are also factors that can affect heat loss or gain. 3. Building sealing Building sealing effectiveness can not only influence the size of air conditioning HVAC in building design, it can also influence longer term energy operating consumption. The BCA requires sealing around chimneys, flues, windows doors and other projections. The building fabric around roofs, walls and floors also needs to be constructed to minimise air leakage. 4. Air movement Air movement within a building offers a form of cooling, so that air conditioning requirements can be reduced. Ventilation requirements vary by building class and climate zone. There are also restrictions on the fixing method and size for ceiling fans or evaporative coolers. 1. Building fabric The building fabric the basic components of a building, including the roof, ceilings, walls and floors should have sufficient thermal resistance to ensure that energy is not lost by heat transmission. Roof, ceiling, walls and floors must achieve a specified total R value (which is the total sum of the insulating performance of all individual component layers, including any building material, insulating material, airspace and associated surface resistances). 2. External glazing There are regulations to ensure that the amount of heat gain through windows is not excessive and that air conditioning needed to counteract the heat losses through windows is not excessive. Shading 5. Air conditioning and ventilation systems Air conditioning must be able to operate at different temperatures and times to meet the intended use of the building. The design of the HVAC system in terms of motor power and ventilation / exhaust must prevent excessive energy consumption. 6. Artificial lighting and power The number of lights and power consumption are to be regulated to within acceptable maximum levels. 7. Hot water supply Hot water systems must be designed and installed in accordance with Section 8 of AS / ANZ plumbing and drainage heated water services. 8. Access for maintenance There are maintenance measures that must be provided to all plant, equipment and components that require maintenance, to ensure that they operate at efficient levels. Summary Part J energy efficiency measures are implemented through the local standard building approvals process, involving building inspectors and surveyors, and often independent building certifiers and assessors. Building designers and builders themselves need to be aware of these new requirements. The Part J implications for building construction are complex, and vary according to the class of building and also with the climate zone. From Kingspan s experience worldwide where similar regulations have been introduced, it has been the signal / catalyst for further regulations to be developed. Likely further developments include mandatory air leakage testing, regulations being extended across all classes of buildings, the requirement for thicker insulation, the implementation of elemental calculations and the anticipation of change of tenancy. For further information contact your state based ABCB office. Additional information can also be obtained from their website at Additional requirements 109

114 BCA Part J compliancy Typical insulation requirements for the building envelope under Part J Walls Climate zone 1 2a 2b Class 2 or 3 building, Class 4 part of building or Class 9c aged care building Total R Class 5, 6, 7, 8, 9a or 9b building Total R Roofs and ceilings Climate zone 1 2a 2b Class 2 or 3 building, Class 4 part of building or Class 9c aged care building Total R Class 5, 6, 7, 8, 9a or 9b building Total R Where do current methods of construction prior to the introduction of Part J sit? Typical R values achieved with current roof construction Typical R values achieved with current wall construction Construction method and materials Typical R value** Construction method and materials Typical R value** Metal deck, cavity, reflective foil, cavity, bulk insulation*, plasterboard 1.14 Concrete tilt-up panel (100mm), bulk insulation*, with furring channel and plasterboard finish 0.28 Metal deck, bulk insulation* with reflective foil laminate, cavity, plasterboard mm brick wall with internal stud frame and plaster lining 0.53 These figures assume best practice installation and the absence of insulation voids * The value of the bulk insulation to be added to the typical R value. A typical R value fo bulk insulation of 50mm would be R and may vary depending on the product selected. ** Different levels of thermal performance can be achieved, based on summer or winter climatic conditions and the use of reflective foils. The minimum value (or winter condition) is the one that in general needs to meet the minimum BCA level of performance and is the value given here. Cement clad wall, reflective foil laminate, reflective cavity, bulk insulation*, plasterboard Double brick cavity wall, with furring channels and plasterboard

115 New concept insulated panels a compliance solution Kingspan insulated panels were developed for construction efficiency. They provide energy efficient solutions that are already compliant with BCA Part J and are widely used in markets where such regulations have long been in force. The external envelope must be procured under one package with a single point of responsibility for design detailing, supervision and installation, rather than as individual building elements. This is at the heart of the Kingspan concept. Thermal insulation thickness Minimum compliance requirements from May 2006 (November 2006 for NSW). Please note where light colours with high reflective values are used in certain climate zones there is a provision under Part J where the minimum thickness can be reduced from Kingspan 60mm to 40mm. Contact the Kingspan Technical Services for further information on KS1000 on walls AWP LS RW Core thickness (mm) R value (m 2 K/W) Weight kg/m / 0.4 steel An airtight envelope Building with Kingspan insulated panels guarantees you an airtight envelope. The inherent thickness and structural rigidity of Kingspan insulated panels together with factory-engineered joints and robust details ensures minimal air leakage. Long term thermal performance Kingspan insulated roof and wall panels are guaranteed to retain their thermal performance for the life of the product thereby helping to ensure that the building energy performance rating is maintained throughout the life of the building. The easy way to become compliant The easy way to become compliant in all cases is to choose Kingspan as your guide to selecting building systems. Kingspan s range of roofing and wall panel systems already complies with Part J. You can spend precious time trying to understand it or you can call Kingspan for expert advice on References 1. Australian Building Codes Board, BCA 2006, Class 2 to 9 Buildings, Volume One, 2006 Class 4: A dwelling part of a building in Class 5, 6, 7, 8 or 9 2. Australian Greenhouse Office, Tracking to the Kyoto Class 5: Office buildings Target Australia s Greenhouse Emissions Trends 1990 to and 2020, 2006 Appendix: BCA building classifications used in nonresidential construction Class 2: Two or more sole-occupancy Class 3: Boarding houses, guest houses, hostels, lodging-houses or backpackers accommodation. A residential part of a hotel, motel, school, a health-care building or a detention centre. Buildings for the aged, children or disabilities accommodation Class 6: Class 7a: Class 7b: Class 8: Class 9a: Class 9b: Class 9c: Shop or other buildings for the sale of goods, eg restaurant, barber s shop, laundry, market, showroom and service station Car parks Storage or display of goods Laboratories, production areas A health-care building Assembly buildings, trade workshops, laboratories in schools Aged care buildings Additional requirements 111

116 Sustainable construction to protect the environment Sustainability vision Our vision is to be the global leader in sustainable business and establish a leading position in providing sustainable, renewable and affordable best practice solutions for the construction sector. It is in the long-term interests of our business to act responsibly towards the environment and the communities in which we operate. We believe our products, which provide insulation that lowers the energy demand of buildings, can contribute to a more environmentally responsible economy. Sustainability is also becoming a key driver for our customers, who are typically involved across the whole commercial and industrial sector. Kingspan Insulated Panels is fully committed to developing, researching and investing in environmental standards and practices so as to install a framework for activities, product design, services and decision making that supports the sustainable construction. 112

117 Sustainable insulation achieves energy savings and climate protection In use energy savings are the most important issue because fossil fuel energy usage is leading to global warming and rising sea levels, raising the very real possibility of catastrophic climate change which may destroy life as we know it. Kingspan s insulated roof and wall systems can reduce energy use by up to 60%. This enables the design of HVAC systems to optimise energy efficiency and reduce CO 2 emissions. Sustainable manufacture and site installation Off-site pre-fabrication provides factory quality systems achieving higher quality, faster and safer site installation. The Australian Building Codes board has identified increased insulation and higher air tightness as keys to reducing energy use in buildings. This is consistent with their policy to promote sustainable construction principles. Kingspan Insulated Panels are CFC and HCFC free. That is they have a zero ozone depleting potential. Polyisocyanurate (PIR) is twice as thermally efficient as polystyrene (EPS), mineral fibre and rock fibre insulation. High thermal performance PIR insulated roof and wall systems optimise thermal efficiency and contribute to air-tightness criteria, thereby preventing unnecessary heat transfer. This provides substantial CO 2 emission savings and contributes to the Federal Government s goals of minimising global warming and consequential climate change. An additional value of insulated roof and wall systems is that they maintain their exceptional thermal performance throughout their lifetime, which is a key requirement for any sustainable solution. Additionally these solutions provide lower site costs, reduced construction programme times and greater certainty in project delivery. Pre-engineered solutions are delivered to the construction site with the correct dimensions therefore reducing site wastage. In use sustainability Embodied energy An important factor in a material specification is the embodied energy of the material. For base construction materials, the replacement of one material with an equivalent with lower embodied energy will reduce the overall energy impact. However, achieving low energy demand in-use is the most important factor in the selection of insulation materials. The significance of embodied energy can be particularly misleading for energy efficiency materials and systems where the embodied energy will typically only be in the order of 1%-3% of the energy saved over the building s lifetime. The chart clearly indicates that thermal efficiency, low air leakages and longevity of performance over the lifespan of the product are the key environmental issues for choosing insulation materials. Embodied energy Energy savings 3% 97% Building environment profile Resource efficienct Factory made quality low waste Easy lightweight time efficient low waste Very high energy efficiency Recovery IN USE ENERGY SAVINGS Raw material Manufacturing phase Construction phase Use phase Waste disposal Additional requirements 113

118 Fire performance 114

119 Insurers are demanding the use of insurer approved products in building construction. External cladding and internal panel systems should be compliant with Factory Mutual (FM) approval requirements in most projects. Certification for building, cladding and fire protection systems is necessary to facilitate efficient letting, re-letting and sale of the building. There are key differences between panel core types. Typical types of core include polystyrene (EPS), mineral fibre, polyurethane (PUR) and more recently, non-approved polyisocyanurate (PIR) and FM approved polyisocyanurate. Each core performs differently in fire. In recent years insurance companies have encountered considerable loss as a result of large fires particularly in the food and drinks industry. The vast majority involved EPS cored panel systems used as internal structures. Recent research confirms that the real insurance fire losses are associated with the use of unsuitable insulated internal panel systems. The construction market has been generally confused about the suitability of EPS cores in particular resulting from conflicting information, misinformation and misreporting. An important legal precedent was set in an important High Court Judgement in London where an architect was held liable for a fire loss resulting from the specification of polystyrene (EPS) panels. Kingspan has been working closely with brokers, insurers and re-insurers to assess the performance of polyisocyanurate (PIR) panels. The real life fire performance record of external envelope and internal insulated panels with FM-approved PIR cores is exemplary. Additional requirements 115

120 Fire performance Incident: Tip Top Bakery fire, Location: Fairfield, New South Wales Australia Insulation type: Polystyrene (EPS) core panels Total losses: $150 million Major fire in Australian food production facility The following extract from a NSW Fire Brigade report on the Tip Top Bakery Fire in Fairfield, NSW on 2nd June, 2002 acknowledges the fire susceptibility of polystyrene (EPS) foam insulation panels: Polystyrene foam is thermoplastic, that is, it softens when heated. Thermoplastic materials tend to melt and shrink away from heat long before ignition. This melting causes voids that reduce the structural strength of the panels. As the panels buckle, the joints tend to open introducing flame and air into the core. This results in internal flame spread between the panels and throughout the structure and there is likely to be a rapid loss of structural strength and subsequent collapse of walls and ceilings. Polyurethane (PUR) and polyisocyanurate (PIR) foams are both thermosetting materials, which means that they do not melt, flow or drip when exposed to fire. Rather, they form a strong carbonaceous char that helps to protect the foam core and prevent flame spread within the panels themselves. It would appear that the sandwich panels utilised in the construction of the Tip Top factory were constructed with EPS insulation. Construction using EPS sandwich panels presents several major difficulties for fire fighting: The loss of adequate structural integrity and subsequent likelihood of significant building collapse; The combustibility of the insulation material adds substantially to the fire load and results in the production of large amounts of heat, smoke and toxic products; Fire spread can be hidden within the panels, and This fire spread can be rapid, leading to conditions that favour flashover. There have been incidents in other countries where firefighters have lost their lives whilst engaged in offensive firefighting tactics in structures constructed with EPS sandwich panels. Firefighters need to be aware of the inherent dangers of this type of lightweight construction. Incident commanders must be aware that firefighting in these conditions can be extremely hazardous with early collapse, high fire load and massive smoke production being major factors affecting firefighter safety. Reference: 116

121 Frequently asked questions (FAQ s) Q. What is the difference between non-certified and certified polyisocyanurate (PIR)? A. Non certified PIR has not been through the rigorous test programme demanded by FM. Certified PIR uses a unique formulation that gives a highly fire resistant product which is capable of passing insurance industry tests. Companies such as FM Global have precise details of approved formulations and regularly audit manufacturers facilities to confirm compliance. Non certified PIR s or PUR s will not give the same fire performance as certified PIR s. Q. In real buildings the panel core is always exposed due to poor maintenance etc. Is this a fire risk? A. It is always good practice to inspect and repair damaged panel systems. Having said that, the reality is that a certified PIR core, even when exposed to a high intensity propane torch, cannot ignite the unprotected insulation core. This is in stark contrast to EPS where a very small fire source can ignite the material. This is then compounded by the tendency of EPS to shrink and melt leading to the formation of a cavity between the metal skins that can allow hidden fire spread. This phenomenon does not occur with certified PIR. impingement, radiant heat or high temperatures. Typical parameters normally measured include ignitability, flame spread and rate of heat release. The Kingspan range of insurer approved panels includes systems that have excellent performance in reaction to fire. Systems are also available that demonstrate high levels of fire resistance up to 1 hour insulation / integration. Q. My insurer / insurance premium is telling me it is OK to construct building using polystyrene (EPS) panels. Is this true? A. Over the past decade there have been numerous fires where EPS insulation cores have been used in a building s construction and the EPS has proven to contribute to the ferocity of the fires and subsequent damage. By selecting certified PIR cores you are safeguarding your business against consequential losses and against future, harder attitudes to EPS resulting in higher premiums. By outlining these characteristics to your broker you should benefit from lower premiums. Q. As an architect, how can I ensure that FM approved systems are installed correctly? A. Contractual documents must make reference to compliance with the appropriate specification model specifications and help in specification development are available from Kingspan Technical Services. Q. What is the difference between reaction to fire and fire resistance? A. Reaction to fire assesses how a specific material or composite product reacts when exposed to heat which can be in the form of direct flame Polystyrene (EPS) melting under the effects of fire Polyisocyanurate (PIR) after 30 minutes at over 1000 C Additional requirements 117

122 Product data load span tables KS1000 AWP Loading ratio: Pressure = L / 100 Suction = L / 100 SPAN CONDITION Panel thickness (mm) Load type Uniformly distributed loads (kpa) Span L in metres SINGLE SPAN DOUBLE SPAN L L L Pressure / Suction Pressure / Suction Pressure / Suction Pressure / Suction KS1000 LS Loading ratio: Pressure = L / 100 Suction = L / 100 SPAN CONDITION SINGLE SPAN L DOUBLE SPAN L L Panel thickness (mm) Load type Pressure / Suction Pressure / Suction Pressure / Suction Pressure / Suction Notes on tables 1. The values in all tables relate to the serviceability limit state and the following deflection limits have been used: Pressure loading L / 100 Suction loading L / 100 Uniformly distributed loads (kpa) Span L in metres All load values are unfactored. For calculation purposes the design windload values should be used unfactored KS1000 RW wall Loading ratio: Pressure = L / 100 Suction = L / 100 SPAN CONDITION SINGLE SPAN L SINGLE SPAN DOUBLE SPAN L L DOUBLE SPAN L L L Panel thickness (mm) Load type Pressure / Suction Pressure / Suction Pressure / Suction Pressure / Suction Pressure / Suction Pressure / Suction Pressure / Suction Pressure / Suction Notes on tables 1. The values in all tables relate to the serviceability limit state and the following deflection limits have been used: Pressure loading L / 100 Suction loading L / Uniformly distributed loads (kpa) Span L in metres All load values are unfactored. For calculation purposes the design windload values should be used unfactored

123 Uniformly distributed loads (kpa) Span L in metres SINGLE SPAN L DOUBLE SPAN L L Pressure / Suction Pressure / Suction Pressure / Suction Pressure / Suction Uniformly distributed loads (kpa) Span L in metres SINGLE SPAN L Pressure / Suction Pressure / Suction DOUBLE SPAN L L Pressure / Suction Pressure / Suction The allowable steelwork tolerance between bearing planes of adjacent sheeting rails is L / 600, where L is the rail spacing. 4. Results are calculated for zero temperature gradient across panels. For other applications contact Kingspan Technical Services. SINGLE SPAN L SINGLE SPAN L DOUBLE SPAN L L DOUBLE SPAN L L Pressure / Suction Pressure / Suction Pressure / Suction Pressure / Suction Pressure / Suction Pressure / Suction Pressure / Suction Pressure / Suction Uniformly distributed loads (kpa) Span L in metres 3. The allowable steelwork tolerance between bearing planes of adjacent sheeting rails is L / 600, where L is the rail spacing Results are calculated for zero temperature gradient across panels. For other applications contact Kingspan Technical Services Additional requirements 119

124 Kingspan technical services Kingspan have acquired over 30 years considerable building applications performance and specification expertise, which provides correct and best practice value engineered building solutions for any project. We provide a technical applications and solutions service to support investors, designers, specifiers, constructors and installers. This includes applications design, product and system performance specification data including site installation methods and project handover criteria. Technical services will advise on the best product and specification application to any building envelope design problem please contact or info@kingspanpanels.com.au 120

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