Rondo panther Acoustic and Fire-Tested Wall & Ceiling Access Panels. revised: october 2008

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1 Rondo panther Acoustic and Fire-Tested Wall & Ceiling Access Panels revised: october 2008

2 design considerations introduction The Rondo Panther range of Acoustic and Fire rated Access Panel Systems have been designed to perform to the new requirements of the Building Codes of Australia and New Zealand for both Domestic and Commercial installations. Rondo Panther Access Panel Systems are designed for internal installation only in both stud and masonry walls and suspended ceiling systems as required. The prime purpose is to provide access to concealed services such as the adjustment of mechanical equipment, electrical installations and data cabling. note 1 Access panels are not intended for persons to access plenum areas unless the surrounding area has been designed for that purpose. Ref AS Fixed Walkways, Stairways Design, Construction and Installation. note 2 The Rondo Panther range of Access Panel Systems are for internal use only. For access panels that are for use externally consult a Rondo Technical Representative. safety Test reports are available for all Rondo Panther Sound Rated and Fire Rated Access Panels. Standard non rated panels are warranted against faulty workmanship. Two hinges are fitted to all Rondo Panther Access Panels. Safety chains fitted to all panels exceeding 450mm square. Safety instructions fitted to the inside of Rondo Panther Access Panel doors. Installation details for acoustic and fire rated panels attached to the rear of the panel door. Access panels over 530mm x 530mm should be independently supported as the ceiling grid furring channels will have to be cut and the plasterboard will not support the self-weight of the access panel. features & benefits FEATURE Standard panel design tested to meet the requirements of the Building Code of Australia Sound Isolation performance ratings of R w +C tr 28 or R w 30 Five standard sizes. Low profile 55mm deep. Custom manufactured systems. High profile 76mm deep. High moisture resistance panel doors. Strong robust steel frame. Selection of surround finishes. Three standard lock options. Concealed hinges on all panels. BENEFIT One standard panel design can be used in rated or non-rated sound installations reducing the risk of the incorrect panel being installed. Designed to fit between standard drywall stud spacing and suspended ceiling furring spacing reducing installation times. Ideal for when plenum space is limited. Panels can be easily tailor made to suit wall or ceiling design requirements up to 1200mm wide. Manufactured from 16mm (HMR-MDF board) with a 0.4mm galvanised steel plate laminated to the back and painted with white primer, eliminating buckling and twisting. Manufactured from 0.90bmt Z275 galvabond steel with mitred and welded corners to eliminate distortion and deflection. Design flexibility is provided with a Set Bead finish providing a flushconcealed surround, whilst the white Feathered Edge surround profile requires no setting. Flexibility and safety are offered with the choice of a Square Key Budget Lock, Numbered Key Cam Lock or a Concealed Touch Lock. Added security for keyed panels. Aesthetically more pleasing. State of the art manufacturing and assembly plant. Consistently assured quality of all panels. Individually packed in product identifiable cartons. Ensures panels are delivered undamaged with panel type clearly identified. Panels available through over 400 Rondo Stockists across Australia and New Zealand, and throughout Asia. Easy availability for the customer. 2

3 standards The Low Profile Rondo Panther Acoustic Access Panel Systems have been tested as an insertion loss and certified to AS by PKA Acoustic Consultants, Project test number May (Australian Standard AS is based on and conforms closely to the essential principles of the International Standard ISO: 1140 Part 1 and Part 3.) Fire tests conducted to AS by BRANZ on behalf of Fyreguard Qld Pty Ltd. ASTME (Without Hose Steam) BS476: Part 22 And will perform to those standards when installed by an approved fixer to the standard s requirements. contents Page No Low Profile Sound Loss Insulation Access Panels srap30 4 Fire Rated Ceiling and Wall Panels Frap 1H 6 Fire Rated Ceiling and Wall Panels Frap 2H 8 Metal Faced Budget Access Panel mfap 10 Other Rondo PANTHER Access Panels: Tile Access Panel System 11 HP51 High Performance Access Panel 12 Lift Motor Room Hatch Panel 14 Access Panel Hardware 15 Installation Details Ceilings 16 Installation Details Walls 17 Architectural Specifications 18 Additional Rondo Products 19 Lloyd s Register Quality Assurance (LRQA) has certified Rondo Building Services Pty Ltd s Quality Management System as complying with ISO9001 in New South Wales, Queensland, Victoria, South Australia & Western Australia Rondo Building Services. panther and Rondo are registered trademarks of Rondo Building Services Pty Ltd. ABN The contents of this manual are covered by copyright laws. Reproduction of all or any part without the owners permission is prohibited. All illustrations are subject to change. Whilst every care has been taken in the preparation of this product guide, Rondo Building Services Pty Ltd expressly disclaims all and any liability to any person whether a purchaser of any product details of which are set out in this product manual, or otherwise in respect of anything done or omitted to be done and the consequences of anything done or omitted to be done, by any such person in reliance, whether in whole or in part upon the whole or part of the within information. 3

4 low profile sound loss insulation access panels srap 30 Rondo Panther sound loss insulation access panels have been designed and tested to meet the requirements of the BCA when installed to the manufacturers recommendations to provide access to services in a sound rated wall or ceiling. Precision manufacturing processes ensure each panel when installed correctly assists in minimising any possible sound flanking. Pre-formed holes in all four sides of the frame are positioned to match wall and ceiling metal structures for secure screw fixing of the panel to the structures. note To avoid cutting furring channels or studs installed at 450 or 600mm centres, use 400 x 400mm or 530 x 530mm sized panels. For installation details, refer Pages

5 panel description: Application Ceilings and Walls Acoustic RatingR w + C tr 28 or R w 30. Tested by PKA Acoustic Consultants Profile Panel Frame Panel Door Low Profile 55mm deep Precision manufactured from 0.90bmt galvabond steel with a corrosion resistant zinc coating of Z275 16mm MDF High Moisture Resistant panel with a 0.40mm galvanised steel plate laminated to the rear of the door. Door face is painted with two coats of high quality oil-based primer. Final paint finish by others. Trim Feathered Edge Set Bead Locks Square Key Budget Lock Keyed alike numbered key (can be keyed to differ) Touch Lock (standard panels only) Hinges 110 Concealed Hinges with safety screws through hinge arms to prevent separation Safety Features Safety chains fitted to all Touch Latch panels and all panels exceeding 450 x 450mm in size Identification and safety labels attached to the inside of the panel door Standard Sizes 300 x 300mm 400 x 400mm 450 x 450mm 530 x 530mm Pack Size One per carton access panel profiles srap30 low profile acoustic panel 5

6 fire rated ceiling and wall panels frap 1H note To avoid cutting furring channels or studs installed at 450 or 600mm centres, use 400 x 400mm or 530 x 530mm sized panels. For fire rated access panels that require an acoustic rating, these can be supplied upon request as a special panel. Please consult a Rondo Technical Representative for further advice. panel description: Application Ceilings and Walls Fire Rating FRL 60/60/60 Tested by Branz (reports available) Profile Panel Door Trim Feathered Edge Set Bead Locks Square Key Budget Lock Hinges Safety Features 110mm deep zincalume 1.1mm thick metal frame Promatect based core faced with a 4.75mm MDF board laminated to the face, with a 30mm wide grafitex intumescent heat-activated seal located along all four edges. Primed and painted by others. Concealed Identification and safety labels attached to the inside of the panel door with installation details Standard Sizes 300 x 300mm; 400 x 400mm; 450 x 450mm; 530 x 530mm; 600 x 600mm Pack Size One per carton SET BEAD FEAThERED EDgE RONDO BUILDING SERVICES PH: access panel profiles 110mm (nominal) Set bead and feather edge detail lightweight wall fixing detail 6

7 installation details ceiling hatch (Refer Figure 1) 1. Mark and cut out opening in ceiling to match dimensions of hatch (eg 530 x 530). 2. Cut and place 51mm steel stud trimmers on all four sides 16mm back from edge of opening. Position 16mm fire-rated plasterboard facing strips on the face of all four studs and screw-fix. 3. Fit the access panel into the opening, ensuring it is positioned square and the profiled trim is hard against the plasterboard surface. Fix through the pre-formed holes located on all four sides of the frame into the stud supports using a minimum of two 45mm x 8 self-fastening screws per side. 4. Seal around hatch surrounds and fire-rated plasterboard with Promaseal Mastic. 5. Connect safety chain and lock hatch door. lightweight wall (Refer Figure 2) 1. Frame opening with steel stud on all four sides and trim with 16mm fire-rated plasterboard to required opening size. 2. Match hatch to wall opening. 3. Fit the access panel into the opening, ensuring it is positioned square and the profiled trim is hard against the plasterboard surface. Fix through the pre-formed holes located on all four sides of the frame into the stud supports using a minimum of two 45mm x 8 self-fastening screws per side. 4. Seal around hatch surround and fire-rated plasterboard with Promaseal Mastic. 5. Shut hatch and engage lock. masonry wall (Refer Figure 3) 1. Match hatch to wall opening. 2. Fit the access panel into the opening provided, ensuring it is positioned square and the profiled trim is hard against the masonry surface. Secure frame to masonry wall using a minimum of two 60mm x 8mm masonry anchors to all four sides. 3. Seal around hatch frame surround and masonry with Promaseal Mastic. 4. Shut hatch and engage lock. 51mm steel stud frame 45 x 8 SF screws notes All penetrations and joint sealing shall be done in accordance with AS Maintenance shall be done in accordance with AS Promaseal Mastic figure 1: installation of ceiling hatch 45 x 8 SF screws Rondo steel stud Fixing hole Promaseal Mastic 30mm heat-activated intumescent seal Promaseal Mastic figure 2: installation in lightweight wall Promaseal Mastic 30mm heat-activated intumescent seal Promaseal Mastic Promaseal Mastic 16mm fire-rated board Two layers of fire-rated board Fire-rated plasterboard 60mm x 8mm masonry anchors 30mm heat-activated intumescent seal figure 3: installation in masonry wall 7

8 fire rated ceiling and wall panels frap 2H notes To avoid cutting furring channels or studs installed at 450 or 600mm centres, use 450x450mm or 530x530mm sized panels. All penetrations and joint sealing shall be done in accordance with AS Maintenance shall be done in accordance with AS For fire rated access panels that require an acoustic rating, these can be supplied upon request as a special panel. Please consult a Rondo Technical Representative for further advice. panel description: Application Ceilings and Walls Fire Rating FRL 120/120/120 Tested by Branz (reports available) Profile Panel Door Trim Feathered Edge Set Bead Locks None. Screw fixed Hinges Safety Features 64mm deep zincalume 1.5mm thick metal frame Promatect based panel with a 4.75mm MDF board laminated to the face, with a 30mm wide grafitex intumescent heat-activated seal located along all four edges None. Screw fixed Identification and safety labels attached to the inside of the panel with installation details Standard Sizes 300 x 300mm; 450 x 450mm; 530 x 530mm; 600 x 600mm; 1200 x 600mm Pack Size SET BEAD One per carton FEAThERED EDgE RONDO BUILDING SERVICES PH: Set Bead Feathered Edge frap 2H access panel profiles 8

9 installation details figure 4: installation figure 5: shaftwall detail Steel Stud M4 steel self-tapping screws at 300mm max. centres Min. 50x 50x1mm galv. steel angle frame IBS gasket 50x10 65mm CSK screws 30mm heat-activated intumescent seal figure 6: steel stud wall detail Min. 50x 50x1mm galv. steel angle frame M4 steel steel expanding anchors at 300mm max. centres IBS gasket 50x10 figure 7: masonry wall detail 65mm CSK screws 9

10 metal faced budget access panel mfap A budget-priced all-steel acccess panel for use in isolated areas where acoustics or fire ratings are not required. It should not be used in areas where moisture or dampness may be of concern, use only in dry, protected areas. Panels must be painted for extra protection. note To avoid cutting furring channels or studs installed at 450 or 600mm centres, use panel sizes that are in between them. panel description: Application Acoustic Rating Profile Panel Door Ceilings and Walls None 30mm deep zinc plated, primed for painting. 1.5mm thick metal frame 1mm zinc plated pressed door, primed for painting Trim Feathered Edge Set Bead Locks Square Key Budget lock Touch Lock (set bead only) Hinges Safety Features Concealed Safety chain on panels 600 x 600mm and over Standard Sizes 300 x 300mm; 450 x 450mm; 550 x 550mm; 600 x 600mm Pack Size Four panels per carton Fixing brackets attached to frame rear view of mfap mfap showing set bead Set Bead Feathered Edge 21 mfap access panel profiles 10

11 other rondo panther access panels tile access panel system (rptp) An access panel designed for a ceramic tiled or panelled wall where access maybe required to service plumbing works in the event of leaks, etc. or other concealed services. important information Hinge arrangement is always placed at bottom of penetration, not at side. (i.e. 450H x 600W 10mm tile panel will have the hinge on the 600 dimension.) This prevents the panel from falling out of the wall, due to the fact that the locks are at the top of the panel and hinges are always at the bottom of the panel. When nominating a panel for tiling: 1. If a panel is nominated, this is overall frame size, therefore tile must be trimmed. 2. If a tile is not to be cut, then an overall panel of is required. This allows the tile to fit within the steel trim, but the overall panel will be in line with outside of grout lines. panel description: Application Profile Panel Frame Panel Door Walls only, 6mm or 10mm deep tile Standard Profile 76mm deep (this panel can also be manufactured with a frame depth of 21mm Budget Lock only) Precision manufactured from 1mm galvanised steel 9mm CFC with a 0.40mm galvanized backing sheet Locks Touch Lock only (Touch Lock cannot exceed ) Safety Features Standard Sizes tile access panel system Identification, safety chains and safety labels attached to the inside of the door There are no standard sizes in this panel. All Tile Panels are made to order. 120mm minimum clearance Touch Latches 9mm fibre cement door Nominal Acoustic seal Handshake hinge always at bottom of door once installed 54mm 6-10mm tile by customer figure 8: installation detail 11

12 other rondo panther access panels HP-51 High-performance access panel (CONTINUED) The high performance HP-51 access panel provides the effective acoustic control now required by the BCA in situations within multi-storey buildings where floor and ceiling cavities, ducts and risers containing pipe-work for soil, waste and water supply pass through both habitable and non habitable areas and the provision of service access hatches would potentially give rise to noise issues. The HP-51 meets and exceeds the BCA standard with an Rw Rating of 51 and an Rw + Ctr rating of 41. The unit features a flanged steel outer frame with a screw fixed outer door, a lead blanketed lockable inner door, and acoustic seals where appropriate. Figure 9 shows how the panel can be installed in both plasterboard-lined steel stud walls and also masonry walls. When installing, ensure that the opening for the panel is cut no more than 10mm overall greater than your panel size (that is 5mm all around) and that the frame is sealed, as shown, to the substrate with suitable acoustic compound. This panel is necessarily heavy and is therefore only recommended for insertion into walls or into the vertical face of a properly constructed bulkhead. The Panther HP-51 Access Panel can be made to order in various sizes however lead times may apply. panel description: Application Profile Panel Frame Primary Panel Door Secondary Panel Door Locks Safety Features Standard Sizes hp51 cross-section & profile Strictly wall applications only Flange only, 100mm deep frame including primary and secondary acoustic seals Precision manufactured from 1mm zincanneal steel HD3 18mm thick MDF 8kg M2 Wave Bar between 1mm and 1.6mm steel Slotted coin lock (no key required)or keyed cam locks Identification and safety labels attached to door All HP-51 panels are custom made (no standard sizes) 100mm 12

13 Acoustic sealant Acoustic sealant Acoustic sealant Acoustic sealant Typical Installation in plasterboard-lined steel stud wall Typical Installation in masonry wall and plasterboard-lined masonrywall figure 9: installation in plasterboard-lined steel stud wall or masonry wall 13

14 other rondo panther access panels lift motor room hatch panel (lmrh2h) (CONTINUED) panel description: For further information on lead times and other specially designed panels please contact a Rondo state office and ask to speak to one of our technical representatives. Application Floor Fire Rating FRL 120/120/120 Tested by Branz (reports available) Profile Standard depth 125mm Panel Door Top Doors precision manufactured from 5mm chequer plate. Fire Door constructed of a two-hour fire rated core with a 50 x 2mm intumescent heat activated strip Safety barricade between outer doors constructed from 24 x 25 x 1.6SHS Hinged safety mesh panels from 25 x 25 x 4mm galvanized steel Hinges Heavy duty broad butt/steel tube hinges to top door Safety Features Safety Mesh panels comply with AS Installation and safety instructions attached to each frame Standard Sizes There are no standard sizes in this panel. All Lift Motor Room Hatches are manufactured to order. Other Panels not detailed: Security Panels Slim Line Panels 21mm Deep Shadow Bead Profile Panels 14

15 access panel hardware budget lock Sealed keyhole lock back for acoustic performance One key per panel cam lock Two keys per panel Locks are keyed alike (can be keyed to differ) concealed hinge Two per panel Safety screws are fixed directly through hinge into panel to prevent separation touch latch Two per panel Safety screws are fixed directly through hinge into panel to prevent separation 15

16 installation details rondo panther sound loss insulation access panels ceilings step One Selection of the correct sized access panel and its location is most important standard spacings for furring channels in ceilings are 450 or 600mm centres. To eliminate the need to cut these sections and install additional support framing, it is recommended that 400 x 400mm sized panels be used in 450mm spacing and 530 x 530mm sized panels in 600mm spacing. If for logistical reasons furring channels or studs have to be cut, see Figures for correct installation details step two surface penetration suspended ceilings For an access panel being installed in a finished ceiling where the furring channel does not have to be cut, the opening in the building board should be cut 5mm larger than the access panel size (i.e. a 530 x 530mm access panel requires an opening of 535 x 535mm) allowing the access panel to be adjusted for square, both vertically and horizontally. Trim around the opening using 64mm stud, screw-fixed to the plasterboard. (Refer Figure 9, Detail 1A.) Before installing the frame, a thick layer of acoustic sealant should be placed inside and on to the front edge of the plasterboard opening. The frame should then be installed into the opening, ensuring that the acoustic sealant squeezes out around the flanges of the panel and the plasterboard. Check that the panel is square and parallel on all four sides in the opening before securing the panel to the framing members on all four sides with a minimum two fixings per side through the holes provided. If possible, squeeze a run of acoustic sealant along the back of the plasterboard opening and on all four sides of the frame to ensure a complete seal is obtained. Clean away any squeezedout acoustic sealant around the flanges, at the same time checking to ensure no gaps have been left. Note: An acoustic sealant is not required if a sound loss insulation performance is not required. step three Where an access panel is being installed in a plasterboard suspended ceiling and is over 530 x 530mm in size or when the furring channel has to be cut to allow installation it should be independently supported from the ceiling suspension system. (See Figures 10 & 11.) Set bead profile Figure 9 section through access panel Access panel fixed to 64mm stud on four sides through preformd holes Detail 1a assembly detail Mimimum 2 screws per side using pre-formed holes Panel door acoustic seal Set bead figure 11 suspended ceiling low profile assembly detail Acoustic seal Acoustic seal on all four sides to the inside of the door Figure 10 access panel layout Acoustic sealant figure 12 low profile access panel detail Acoustic sealant to all four sides 16

17 rondo panther sound loss insulation access panels walls step One Selecting the right size access panel to fit between the stud spacing is most important and can save in having to cut installed studs and having to install additional framing sections. Generally studs are spaced at 450mm or 600mm centres with the ideal access panel sizes to use being a 400 x 400mm or a 530 x 530mm. Panel fixed central between studs step two When installing an access panel into a finished wall where the studs do not have to be cut a penetration into the building board 5mm larger than the access panel and central between the studs if possible should be cut. A nogging should be fitted top and bottom to the inside of the opening and screw fixed to the plasterboard. Before installing the frame, a thick layer of acoustic sealant should be placed inside and on the front edge of the plasterboard opening. cut studs fixed to nogging track Nogging track fixed to full studs The frame should then be installed into the opening, ensuring that the acoustic sealant squeezes out around the flanges of the panel and the plasterboard. Check that the panel is square and parallel on all four sides in the opening before securing the panel to the framing members on all four sides with a minimum two fixings per side through the holes provided. If possible, squeeze a run of acoustic sealant along the back of the plasterboard opening and on all four sides of the frame to ensure a complete seal is obtained. Clean away any squeezedout acoustic sealant around the flanges, at the same time checking to ensure no gaps have been left. Note: An acoustic sealant is not required if a sound loss insulation performance is not required. Slimline access panels should always be installed with the hinges at the bottom of the penetration (walls only). step three If when installing an access panel requiring a stud to be cut, nogging tracks should be fitted at the top and bottom of the opening and connected to the uncut studs on either side as well as the cut stud to provide stability and a fixing frame for the access panel (see Figure 14). The plasterboard should be fixed to the nogging tracks and studs as normal. The panel should then be installed as per the details in Step Two. cut studs fixed to nogging track Figure 13 stud wall installation Access panel frame screw-fixed to noggin track. Minimum 2 screws per side using pre-formed holes Figure 14 stud wall installation detail 17

18 architectural specifications Scope The contractor is to furnish all materials, labour and equipment for the installation of a Rondo Panther access panel, where so indicated on the architectural drawings. material All materials supplied by Rondo Building Services meet the relevant Australian and New Zealand Standards. installation The penetration in the wall/ ceiling (accurately levelled) is to be 5mm larger than the access panel. For access panels under 530 x 530mm square, the penetration is to be framed out as detailed prior to the access panel being installed. For access panels over 530 x 530mm square, the access panel is to be independently suspended from the ceiling system. important Rondo Panther access panels can be installed into virtually any wall/ceiling application. Even though the access panel is a very strong product, it is still part of a system. The access panel is not designed to be used as a lever to pull through into the ceiling space. advisory service Individual projects may require special detailing and development. Technical assistance is available from our engineering staff, such as detailed drawings and custom access panels (specials). guarantee Rondo Building Services Pty Ltd supplies both Acoustic (R w 30 R w +C tr 28) and Fire (1 & 2-hour fire rated) access panels which are warranted to be free from defects in material and workmanship, and will replace and/or repair any product found to be defective, if installed in accordance with our technical literature and standard guarantee details. This warranty is in addition to any rights the customer may have at law. All of Rondo Building Services products are designed to satisfy Australian and New Zealand conditions. note As new technology is introduced, or industry standards are altered, Rondo reserves the right to alter existing specifications without notice. 18

19 additional rondo products ceiling SYSTEMS Rondo key lock Concealed Suspended Ceiling Systems. Rondo duo Exposed Suspended Ceiling Systems. Rondo tag lock Aluminium Exposed Suspended Ceiling Systems. Rondo wa l k about Trafficable Ceiling Systems. Rondo Metal Ceiling Batten Systems for Residential Construction. drywall steel stud wall framing systems Rondo Drywall Steel Stud Partition Systems (fire-rated, loadbearing/non-loadbearing, internal partition and curtain wall framing systems). Rondo Shaftwall Framing Systems. Rondo quiet stud Drywall Sound Insulation Systems. sound isolation assemblies for walls & ceilings Rondo Acoustic Isolation Assemblies for sound-rated wall & ceiling systems. wall & ceiling access panel systems Rondo panther Access Panels (acoustic & fire-rated systems). finishing sections Rondo exangle Drywall Finishing Sections. Rondo exangle RT Render and Texture Finishing Sections. ezy-drive Rondo ezy-drive Roadside Guide Posts. Rondo ezy-drive Utility Markers & Poly-Flex Safety Products. Rondo ezy-drive Roadside Accessories. Rondo ezy-drive steel-flex Flexible Steel Guide Posts. OTHER services Rondo Custom Roll Forming Services. Rondo Technical Design and Research & Development Services. Rondo Freight & Logistics Services. 19

20 Rondo Offices australia rondo building services pty ltd customer service hotline: rondo ( ) new south wales 3 33 Glossop Street St Marys NSW 2760 (PO Box 324 St Marys NSW 1790) Phone: Fax: victoria queensland Dunlop Road Mulgrave VIC 3170 Phone: Fax: Lot 512 Binary Street Yatala QLD 4207 Phone: Fax: south australia 39 George Street Greenfields SA 5107 Phone: Fax: western australia 5 Hazelhurst Street Kewdale WA 6105 Phone: Fax: Head Office export PO Box 324 St Marys NSW 1790 Phone: Fax: Phone: Fax: new zealand rondo building services pty ltd 117A Captain Springs Road Onehunga Auckland Phone: Fax: free call: RONDO ( ) malaysia rondo metal products sdn bhd Lot 606, off Jalan SS 13/1K, Subang Jaya, Selangor Phone: Fax: rondo ( ) for calls within australia rondo ( ) for calls within new zealand panther and rondo are registered trademarks of Rondo Building Services Pty Ltd. ABN Revised: october 2008.