Force 10 International Design Manual New Zealand

Transcription

1 Force 10 International Design Manual New Zealand Note: This document is subject to revision and updates are available on request from Force 10 International Pty Ltd. Ver: 1.3 Issue Date: January 2015

2 Contents 1 INTRODUCTION... 4 O CODEMARK NEW ZEALAND AND AUSTRALIA DESIGN SCOPE - PRODUCT DESCRIPTION... 5 O DISCLAIMER REFERENCES... 9 O FORCE 10 DESIGN CALCULATIONS MANUAL... 9 O FORCE 10 SPECIFICATION MANUAL... 9 O FORCE 10 TEST REPORT MANUAL... 9 O FORCE 10 CM-NZ DRAWINGS... 9 O FORCE 10 DT-NZ DRAWINGS B2 DURABILITY B1 STRUCTURE - FOUNDATIONS O GENERAL O PILED FOUNDATIONS O PILED FOUNDATION REQUIREMENTS O PILE SPECIFICATION TABLE O PILE FOOTING SIZE FOR BEARING: O PILE FOOTING DEPTH FOR UPLIFT: O K VALUES TABLE O CONTINUOUS REINFORCED CONCRETE OR MASONRY FOUNDATION WALLS O CONCRETE SLAB-ON-GROUND O OVERTURNING RESISTANCE: O BRACING RESISTANCE: Bracing resistance table O ANCHOR PILES Anchor pile resistance table B1 STRUCTURE - FLOORING DESIGN CRITERIA O FLOOR DESIGN AND LAYOUT O FLOOR FRAME SPECIFICATION AND ALLOWABLE SPANS O SUB FLOOR COLUMNS B1 STRUCTURE BRACING PORTAL AND PFC DESIGN CRITERIA WALL PANEL DESIGN CRITERIA O TEST RESULTS PANELS O PHYSICAL PROPERTIES PANELS O EQUIVALENT MODULUS OF ELASTICITY O SECTION CAPACITIES (ULTIMATE DESIGN) O COMBINED LOADING (ULTIMATE DESIGN) O ULTIMATE RACKING VALUE ROOF SYSTEM DESIGN CRITERIA O GEOMETRIC PROPERTIES O MEMBER PROPERTIES O DESIGN O CONNECTIONS O ROOF SHEETING O DESIGN Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 2

3 ANALYSIS CEILINGS DESIGN CRITERIA O CEILING LINING SUPPORTS O STRUCTURAL CEILING DIAPHRAGMS FIXINGS DESIGN CRITERIA STEEL COLUMNS /BEARERS O WALL BRACKETS O TRUSS BRACKETS O FLOOR /WALL BRACKETS O WALL PANEL BOLTS THERMAL RESISTANCE/ENERGY EFFICIENCY DESIGN CRITERIA O E3 INTERNAL MOISTURE O H1 ENERGY EFFICIENCY O PROPERTIES AND CALCULATIONS G6 AIRBORNE AND IMPACT SOUND COMPLIANCE C1- C6 FIRE RESISTANCE O WALL PANELS O PANEL EARLY FIRE HAZARD PROPERTIES O GENERAL CODES AND STANDARDS O INTERNATIONAL COMPLIANCE O AUSTRALIAN COMPLIANCE Figures Figure 1 Joist and Bearer Specifications Figure 2 Truss Design Document Control Revision Date Prepared By Approved By 1.0 February 2014 Peter Lehrke WJ Dalton April 2014 Update after CertMark review 30/3/14 Peter Lehrke WJ Dalton 1.2 8/5/14 CodeMark Certification NZ issue Peter Lehrke WJ Dalton 1.3 Jan 2015 layout and update NZ CodeMark Rev2 Peter Lehrke WJ Dalton Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 3

4 1 Introduction The Force 10 Engineered Building System is a modular system using cold formed steel floor framing and roof framing, and prefabricated wall panel units. Elements of the system, such as the foundation, wall panel lengths, spans etc. are based on multiples of the 1 metre module. This Design Manual is intended for use by architects, engineers, builders and territorial authorities for assessing the components of the home required to meet the relevant performance requirements of the New Zealand Building Regulations and the relevant clauses from the New Zealand Building Code. While most of the design information is non-specific, some aspects require specific design. Specific design will be required for roof trusses, piled foundations and may be required for other foundation types where the information in this document is not followed. Specific design will also be required for other elements such as strong backs, columns, beams, verandas etc. Specific design calculations will need to be prepared by appropriately qualified designers and a Design Certificate provided to cover each project. This manual refers to building elements which are constructed in accordance with NZS 3604:2011 and AS/NZS 1170 (parts) and AS/NZS Where indicated, this manual must therefore be read in conjunction with that standard. The design information presented in the manual has been derived from engineering calculations or from testing. Standard plans and layout are available for use however non-standard designs may be achieved by using the guidance and Tables in this Manual. All designs when submitted for approval to the territorial authority must meet all the relevant performance requirements of the New Zealand Building Code. o CodeMark New Zealand and Australia Force 10 International Pty Ltd has achieved New Zealand CodeMark CERTIFICATE OF CONFORMITY CMA CM40031 Issued 28/04/2014 for the Force 10 Building System which consists of prefabricated, ready to be assembled housing structures which are normally constructed for one and two storey construction on stumps pad footings or concrete slab-on-ground. Copy is available from the web site. Force 10 International Pty Ltd has achieved Australian CodeMark CERTIFICATE OF CONFORMITY CMA CM40123 the Force 10 Building System which consists of prefabricated, ready to be assembled housing structures which are normally constructed for one and two storey construction on stumps pad footings or concrete slab-on-ground. Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 4

5 2 Design Scope - Product Description This Design Manual outlines key design and construction requirements that are required to be addressed for the design of a building to comply with the New Zealand Building Code and the relevant compliance documents. The Force 10 Building System is suitable for Importance Level 2 buildings as defined in clause A3. To determine the design parameters for this Design Manual the data and reference documents must be read in conjunction with the New Zealand Building Code Clauses, CodeMark certification and this Design Manual. Complies with the New Zealand Building Code: 1. NZBC Clause B1 Structure- B1.3.1, B1.3.2, B1.3.3 (excluding (f) & (k)) & B1.3.4 (a), (b), (c), (d) & (e) for floor framing, external walls & roof framing. 2. NZBC Clause B2 Durability- B2.3.1 (b) & B2.3.2 (a) for floor framing, external walls & roof framing. 3. NZBC Clause C6 Structural Stability- C6.2 for walls. 4. NZBC Clause E2 External Moisture- E2.3.2, E2.3.3, E2.3.6 & E2.3.7 (b) for floor framing, external walls & roof framing. 5. NZBC Clause F2 Hazardous Building Materials- F NZBC Clause G6 Airborne and Impact Sound- G6.3.1 (g) for walls & G6.3.2 (h) for floors. 7. NZBC Clause H1 Energy Efficiency- H1.3.1 (b) for external walls. Subject to the following Conditions & Limitations: a. Terrain category up to and including C1. b. Construction must be in accordance with F10 Design Manual New Zealand V1.3. c. Maximum panel height 3000mm. For wind speeds of 65m/s and above max wall height 2400mm. d. Maximum building height including roof 10m. e. Roof pitch of 20 degrees. Variation from this requires individual engineering certification. f. Steel frame must be constructed in accordance with AS/NZS 4600:2005- Cold-formed steel structures. g. To meet Rw55 sound insulation criteria the Force 10 Wall System must be constructed in accordance with one of the acceptable configurations outlined in Ron Rumble engineering report 7476tst3b or Q F01 (rev 0). h. Applicable only to specific construction of 16mm Supaboard, 5mm impact mat, 22mm particle board, Gyprock resilient mount, 16mm + 13mm Fyrchek MR as detailed in Force 10 Drawing Impact Floor Resistance dated 23/02/11. i. This certification relates only to the NZBC Clauses as contained herein. Consequently any clause not included on this certificate are outside the scope of this Certificate. j. This certification relates only to the product that is described above, and has to be read, considered and used as a whole document it may be considered misleading and will be incomplete to be selective. k. For further information contact the certificate holder. Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 5

6 The Force 10 Building System consists of a floor system, a wall panel system and a roof truss system. Each part of the system consists of interlocking steel elements. The floor, roof and wall systems are integrated for one to three storey construction on stump or pad footings or for use with concrete slabs. The Force 10 building system designs are suitable for all areas and is used for housing, commercial buildings, hospitals, school buildings and classrooms and mining accommodation (refer to the CodeMark CM-NZ series of drawings). 1. Footings and Stumps: Metal stumps, Duragal finish with a steel plate, or with a 2 x 300mm long x 16mm diameter rods is welded to the bottom of the stump. The stump is positioned in a concrete pad; the bottom of the stump being at least 100 mm above the bottom of the stump hole and the concrete falling away from the steel at the top of the footing. The design of the footing is dependent on soil classification and loading. The typical design of the footings and stump fixing is shown in drawing CM-NZ Floor System: The floor uses 2.0mm Galvaspan G450 Z350 steel bearers and 1.2mmTrucore G500 AZ150 joists. Floor bearers are provided with pre-punched holes for ease of on-site assembly. The steel floor joists nest securely inside the structural bearers. Both bearers and joists are available in lengths of 1, 2 and 3 metres. The bearers are 2mm 179 x 106 mm Eye or ɪ section and the joists are 1.2mm 179 x 50 mm Z section. Maximum load is 1.5 kpa for 4000 mm joist span (domestic loading) and 3.0 kpa for 3000 mm joist span (commercial loading). The Type 1 building maximum joist span is 3 metres and for other types it is 2 metres. The typical design of the floor system fixing and loading is shown in drawing CM-NZ-01. Floor sheeting is magnesium oxide sheeting, compressed fibre cement sheeting or StructaFlor or TermiFlor (or similar) particleboard flooring. It is glued to all joists and bearers as well as being screwed. 3. Wall Panel System: The Force 10 wall panel system consists of two steel components that tab-lock together to form a rectangular frame. The steel frame consists of two steel studs made from 1.2mmTrucore G500 AZ150 bridged to the top and bottom with interlocking steel nogs manufactured from Zincalume F300. Cellulose fibre cement sheets of 6 mm thickness are bonded to the frame and non-toxic fire retardant polyurethane foam is injected into the cavity. Full height PVC conduit ducts are fitted to be used for electrical services. Panel widths are based on a modular width of 1000 mm and heights of 2435, 2700 and 3000 mm are available in a thickness of 76 mm. Panel weights are 58, 64 and 71 kg, respectively. The wall panels are fixed to the either the floor system or the concrete slab as shown in Drawing CM-NZ-01. Once installed, wall wrap, 20mm battens (vertical), minimum 9mm thick external cladding or Colorbond sheeting exterior wall panels are ready to apply the surface moisture sealing system for the joints. Texture coating or acrylic exterior paint are among the range of exterior finishes. Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 6

7 4. Roof System: The roofing system consists of two lightweight steel sections. All sections nest together to allow mechanical fixing. The trusses are fixed to the wall panels as shown in Drawing CM-02. o Disclaimer The trusses are cold-formed site manufactured from 1.2mmTrucore G500 AZ150 coil steel with a zinc coating of 300 g/m² minimum or AZ150 (in accordance with AS ). Roof widths are based on 1000 mm modules up to 20 metres (depending on the wind classification) and come in a standard 20 pitch truss design. The trusses fold flat for ease of transport. Roof Purlins are fixed by screws onto the top of the trusses and allow for the use of a variety of conventional roof sheeting. Every effort has been made and all reasonable care taken to ensure the accuracy of the material contained in this Design Manual. However, to the extent permitted by law, the Authors, Editors and Publishers of this publication: will not be held liable or responsible in any way; and expressly disclaim any liability or responsibility for any loss or damage costs or expenses incurred in connection with this Design Manual by any person, whether that person is the purchaser of this Design Manual or not. Without limitation, this includes loss, damage, costs and expenses incurred as a result of the negligence of the Authors, Editors or Publishers. Should expert assistance be required, the services of a competent professional person should be sought. For further information please contact Force 10 International Pty Ltd. Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 7

8 Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 8

9 3 References o Force 10 Design Calculations Manual Force 10 has prepared and maintains a Structural Design Calculations Manual that contains evidence of calculations to validate compliance. A copy of this Design Calculations Manual is available on request refer to F10 05 STRUCTURAL DESIGN CALCULATIONS MANUAL VER 3.2.docx o Force 10 Specification Manual Force 10 has prepared and maintains a Specification Manual that contains evidence of compliance and details of product standards used. A copy of this Specification Manual is available on request refer to F10 06 SPECIFICATION MANUAL_Ver 3.7.docx o Force 10 Test Report Manual The Force 10 Building System has been extensively tested by JCU-CTSD, QUT, CSIRO, BRANZ and by USA based testing organisations to ensure that the system meets the relevant codes and standards. A copy of the Test Report Manual or a listing of testing that has been completed and referenced standards is available on request refer to TEST MANUAL_Register. o Force 10 CM-NZ Drawings These drawings are attached as an appendix to detail specific design requirements and to provide details of the Acceptable Solutions to meet the clauses of the NZ Building Code. o Force 10 DT-NZ Drawings These drawings are details of specific design or construction requirements and are not limited to: DTNZ-000 TYPICAL SLAB DETAILS DTNZ DTNZ-001 DTNZ-002 PANEL DETAILS SHEET 1 DTNZ-003 PANEL DETAILS SHEET 2 DTNZ-003-F DTNZ-004 PANEL DETAILS SHEET 3 DTNZ-005 PANEL DETAILS SHEET 4 DTNZ-005-A DTNZ-006 PANEL DETAILS SHEET 5 DTNZ-007 PANEL DETAILS SHEET 6 DTNZ-008 TRUSS DETAILS DTNZ-009 DTNZ-010 TYPICAL SECTION DTNZ-010A TYPICAL SECTION DTNZ-011 DTNZ-012 DTNZ DTNZ-013 DTNZ-014 TYPICAL SLAB DETAILS GENERAL SPECS FOOTING, POST AND FLOOR DETAILS PANEL DETAILS SHEET 2A PANEL DETAILS SHEET 4A TRUSS SECTION BROKEN ROOF TYPICAL SINGLE STOREY STUMPS TYPICAL DOUBLE STOREY STUMPS TYPICAL SINGLE STOREY DROP CEILING TO BATH TYPICAL SINGLE STOREY SLAB TYPICAL SECTION DOUBLE STOREY ON SLAB Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 9

10 DTNZ-015 DTNZ-017 DTNZ-018 DTNZ-019 DTNZ-020 DTNZ-021 DTNZ-035 DTNZ-036 DTNZ-056 DTNZ-068 DTNZ-069 DTNZ-070 DTNZ-071 TYPICAL SECTION SINGLE STOREY HIGHSET TYPICAL SECTION BROKEN ROOF VERANDA TYPICAL SECTION BROKEN ROOF CARPORT 3M WIDE TYPICAL SECTION BROKEN ROOF ON SLAB 3M WIDE BEARER CONNECTION DETAILS FLASHING AND SET DETAILS 125MM X75MM RHS BEAM CONNECTION TO COLUMN AND PANELS TYPICAL FIRE WALL EXPLODED COMPONENTRY DETAILS TYPICAL WINDOW HEAD, SILL AND JAMB DETAIL 2 STOREY BEARER FLASHING DETAIL WALL WRAP & CAVITY BATTEN FIXING TYPICAL DOOR HEAD, SILL AND JAMB DETAIL 4 B2 Durability Steel floor framing, sub floor framing, steel roof trusses and connections have a zinc coating which provides protection against corrosion resulting from wetting during construction and temporary leakage associated with damaged cladding. The long term durability is dependent on the steel components being maintained in a dry condition. Where floor, wall and roof framing is protected from the exterior environment i.e. completely encapsulated by weather tight linings, flashings and claddings, this condition is met. For steel sub floor framing including steel piles to meet this condition the following requirements apply: Sub floor framing must not be used within 300m of the sea, in areas where geothermal activity is known to be high or in heavy industrial areas. The appropriate territorial authority should be consulted for advice about which areas are affected. Between 300m and up to 10km from the sea the sub floor must be enclosed with ventilators installed to provide the required ventilation. For a piled foundation the steel pile sections, fittings and bracing components must be coated with a high build epoxy mastic system to the region of ground content. Alternatively where the sub floor is left open or ventilation exceeds 4000mm 2 per m 2 of floor area all subfloor steel framing must be coated with a high build epoxy mastic system. Floor framing, used for decks, posts and beams for verandas must be completely enclosed. The strength and stiffness of wall panels is related to the sandwich panel action which in part relies on the durability of the polyurethane foam that fills the cavity. In normal circumstances, this is sufficient to avoid corrosion provided the steel components are maintained in a dry condition. In this regard, note that all wall and roof framing is protected from the exterior environment, i.e. completely encapsulated by weather tight linings, flashings and cladding. Termite resistant The Force 10 floor, wall and roof truss systems (the primary elements) are made from steel and are termite and borer resistant. Because of this, the panels, floor framing and roof trusses do not require additional chemical treatments to protect them from pest attack as they are not known to present a potential risk of attack from subterranean termites Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 10

11 4. B1 Structure - Foundations o General Foundations shall comprise one of the following: Steel square hollow section (SHS) ordinary braced or anchor piles Continuous perimeter reinforced concrete or masonry foundation walls in conjunction with an internal piled foundation Concrete slab-on-ground. Note: A combination of the above is permissible. All foundations must be designed for the loads given in AS/NZS1170 Part 0 as amended by section B1/VM1. The design of the foundations must be designed by a person who on the basis of experience or qualifications is competent to design them. o Piled Foundations The Force 10 braced or anchor steel pile system for resisting lateral loads is suitable for one and two storey housing in all Building Wind Zones up to and including Very High and in all Earthquake Zones. The exception is where the building height exceeds 1.7 times its width, in which case the building must be attached to a continuous foundation wall around its entire perimeter. o Piled Foundation Requirements All piled foundations must be subject to a specific design using the design information below. The general design requirements for piled foundations are as follows: All piles must directly support a bearer The minimum height of any pile above finished ground level shall be 300mm. Reinforcement is required in all footings wider than 275 mm. o Pile Specification Table Pile height (mm) Material 0 to x75 x3.0 SHS C to x75 x 5.0 SHS C350 Piles are hot dipped galvanised to AS1650. In addition one of the following systems must be factory applied to pile SHS surfaces, 100 mm above and 200 mm below the ground level. Epoxy powder coating Hi build epoxy mastic zinc to 175 microns Zinc/aluminium spray and sealer. Galvanised steel SHS piles must be ordered to the correct length for each project, with the above treatment applied over the appropriate pile height before the piles leave the factory. Where it becomes Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 11

12 necessary to cut the pile, this must only be done at the base where the pile will be buried in the concrete footing. Pile footings must have a minimum concrete strength of 20MPa at 28days and be designed in accordance with NZS3101 by an independent local engineer.. Pile footings must be sized to meet the requirements for soil bearing pressure, wind uplift and overturning, and pile bracing (for wind and earthquake loads). Footing sizes for bearing and uplift can be determined either by using the following non-specific methods, or alternatively, economies can be made by carrying out a specific design: o Pile Footing size for bearing: Allowing for roof, wall and floor load support and to limit the bearing pressure, due to building gravity loads, to an ultimate value of 300kPa, the minimum square footing size in m is: b = ( BS/ B + X ) b = ( JS/ J + X ) where joists run parallel to trusses, or where bearers run parallel to trusses. b is the length and breadth of the footing in m, B is the max bearer span, J is max joist span and S is the roof span. X is BJ for one storey external piles 2BJ for one storey internal piles and two storey external piles 4BJ for two storey internal piles. Note: B,J and S are in metres and X is in m 2 o Pile Footing depth for uplift: The minimum volume of pile footing concrete required to resist uplift in a NZS3604 Building Wind Zone is: C = b 2 d = ka m 3, Where b is the length and breadth of the footing, d is the footing depth and k is taken from Table k Values below, A is the roof area in m 2. o k Values Table NZS 3604 Building Single Storey Double Storey Wind Zone Very High High Medium Low o Continuous reinforced concrete or masonry foundation walls An external continuous reinforced concrete or masonry wall foundation may be used in all Building Wind and Earthquake Zones and must be used where the building height exceeds 1.7 times the building width. Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 12

13 The requirements for reinforced concrete or masonry foundation walls are given in Clause 6.11 of NZS3604, except that bearer connections are M10 U bolts at 1 m centres, to suit Force 10 steel bearers. M10 U bolts shall be cast-in and have a minimum embedment of 150 mm. A damp proof membrane (DPM) must be used between the steel bearer and the foundation wall. o Concrete slab-on-ground. Concrete slabs-on-ground foundations can be used in all Building Wind and Earthquake Zones. Concrete slabs must be subject to specific design based on a soil investigation. Where the soil investigation meets the criteria of Section 3 of NZS3604, the details may be those given in Clause 7.5 of that Standard, except that Force 10 wall panels shall be bolted to the slab at each end using the 85 x 50 x 8 mm thick galvanised steel slab brackets. The brackets shall be fixed to the concrete slab with cast in M12 x 300 mm long cranked bolts, or M12 bolts fixed in place with an epoxy resin based adhesive subject to a specific design. o Overturning resistance: Overturning resistance must be checked for all 2 storey buildings and for single storey buildings in Very High Building Wind Zones. This shall be carried out in accordance with NZS4203:1992, Clause o Bracing Resistance: Reinforced concrete or reinforced masonry walls in accordance with NZS3604: 1990 which are greater than 1.5m in length may be assumed to have the following bracing resistance Bracing resistance table Ratio of wall length/average wall height o Anchor Piles Bracing units per metre length for both wind and earthquake resistance 1 Kn = 20 Bracing Units < to to to > Anchor piles supporting floors up to 900 mm above ground and braced piles supporting floors between 900 mm and 3 m above ground have the following bracing resistance Anchor pile resistance table Pile Type Bracing units per metre Earthquake Wind Anchor pile Braced piles Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 13

14 5 B1 Structure - Flooring Design Criteria The Force 10 Engineered Building System flooring system consists of floor sheeting material fixed to an in-plane framework of cold rolled steel joists and bearers. Joists are at half module (0.5 m) spacing s and nest into and are screw fixed to the bearers at each end of the span. Bearers require screw fixing through the flanges to the joists to resist wind loading. The bearers consist of 2 C channel sections back to back. o Floor Design and Layout The orientation of bearers and floor joists are arranged to suit the project building floor plan. It is recommended that shorter module joists or bearer spans be located under lounge and dining room areas to limit floor vibration. All exterior and interior load bearing and bracing walls must be directly supported by bearers. Bearers must be supported by piles or a foundation wall. Floor joist spacing must not exceed 500 mm (one half a module). Note that some floor sheeting joins will need to be positioned to coincide with floor joists. To meet insulation requirements, foil must be draped over floor joists and have a minimum mid-span sag dimension of 100 mm. See section on Thermal Resistance o Floor Frame Specification and Allowable Spans. The joist and bearer spans and specification (Joists are 1.2mm G500 Trucore and Bearers are 2.0mm G450) are given below: Material 1.2mm G500 Thickness 178 Material G450 Z200 Thickness 2.00mm 178mm overall Figure 1 Joist and Bearer Specifications Allowable spans 1.5 kpa LIVE LOAD Performance Values Joist Spacing Beam Span Allowable spans 2.0 kpa LIVE LOAD Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 14

15 Performance Values Joist Spacing Beam Span mm Allowable spans 3.0 kpa LIVE LOAD Performance Values Joist Spacing Beam Span Circular holes for services are provided at mid-depth of joist and bearer webs 30 mm in diameter, bearers have 4 off 10mm holes for fitting of bearer washers all holes are to be spaced at no closer than 250 mm centres and not within 500 mm of any support. Any other holes shall be subject to specific design approval. Cantilevered floor joists must be subject to a specific design in accordance with AS/NZS4600. No in-span joist or bearer joints are permitted. The minimum bearing for floor joists within bearers is 50 mm. For openings in the floor, at least two opposite trimmers shall be bearers. o Sub Floor Columns The following column specifications are used for all Force 10 sub-floor designs: Column Height (mm) out of Material the ground dimension 0 to x75 x 2.5 SHS C to x75 x 5.0 SHS C450 Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 15

16 6 B1 Structure Bracing Portal and PFC Design Criteria Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 16

17 7 Wall Panel Design Criteria The Force 10 wall panel system comprises of 63x35 C section steel studs and a 60x73 C section top and bottom nog to give a steel perimeter channel frame that is then bonded on each face with a sheet of 6mm thick Fibre Cement board. The total thickness of the panel is nominally 76.2mm. Each panel interior cavity formed by the studs, nogs and sheeting is filled with injected rigid polyurethane foam (PUR). The polyurethane foam acts as the insulation material as well as a bonding agent. The polyurethane has a design density of 45 Kg /m 3. The panel is attached to the floor system using a Force 10 floor /wall bracket. A special Force 10 M16x40 reduced shank bolt is used to attach the bracket to the steel stud. Two M10x50 bolts are used to clamp the bracket to the flange of the bearer. The top of the panel is attached to the truss system using a 125mm truss fixing and the special Force 10 BOLT, M16 x 40 KWIKSPAN, ZINC PLATED. Alternatively the top of the panel can be attached to a second floor using a T section bracket and a reduced shank bolt. Panel Connections - Reference to Tensile Strength Test Cyclone Testing Station TS837. Tensile test was a panel assembly which is roof bolt to panel to floor bearer to stump using the Force 10 proprietary brackets. From this testing, the nominal tensile load (uplift) of the assembly is 45.3kN. For a capacity reduction factor of 0.65 tensile section capacity is 29.5kN. The Force 10 system includes prefabricated single and double module solid wall panels and single and double wall panels with openings. The upper portion of panels with openings function as a lintel. All load bearing and bracing walls must be set plumb and square and located only on module grid lines. Non-load bearing and non-bracing walls may be off grid lines. Force 10 wall panels have been tested for face loading and bracing resistance at the James Cook University (CTS), Queensland University of Technology and at Auckland University. Solid wall panels up to 3 m high in two storey buildings within the scope of application will resist gravity and face loads associated with earthquake and wind. Single panels with openings may be used without specific design if they are bounded on both sides by solid panels. Any other configuration of panels with openings, e.g. a double panel with an opening next to a solid panel or two single or double panels with openings together, will require strongback support and must be subject to a specific design. o Test Results Panels The Force 10 Engineered Building System has been subjected to a through testing programme to ensure that the section capacities are correct and are in accordance with the Australian Standard Codes. Testing has been undertaken at the James Cook University Cyclone Testing Station in The test results were recorded and recommended Ultimate Limit State values were determined. The design information presented has been derived from the F10 ENGINEERING DESIGN CALCULATIONS MANUAL and can be tabulated as follows: Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 17

18 Panel Type Standard Panel (a) 2435 (b) 2700 (c) 3000 A6 A7 Wind Classification W C4 Design (a) 2435 (b) 2700 (c) 3000 IPL4 Design (a) 2435 (b) 2700 (c) 3000 The series of tests were undertaken on the standard Force 10 Panels and for a panel developed for Australian C4 Region D and the NCC Importance Level 4 (IPL4) in accordance with Standards Australia AS Wind Actions. This panel is referred to as the IPL4 panel and the same panel design is used as a C4 panel (all regions). The results are summarised as follows: TEST REPORT STANDARD PANEL C4 PANEL IPL4 PANEL Bending Capacity Kpa Test Report - TS826 (a) Non Cyclonic Static Test 6.79 kpa 7.8 kpa 7.8 kpa (b) Cyclonic Cyclic Test 6.79 kpa 9.7 kn 9.7 kpa Impact Test - Test Report - TS829 - Passed Racking Resistance kpa 21.4 kpa Test Report - TS830 (3 panels) Tensile Strength Test Report - TS kpa 45.3 kpa 45.3 kpa These values are ultimate section capacities and are to be reduced by the appropriate section capacities reduction factors of AS/NZS4600 Table 1.6. The test results were for 2435 mm high panels and have been extrapolated to 2700 mm high by the ratio squared and similarly for 3000 mm high. Based on assessments of this testing, the following ultimate design capacities for the Force 10 panels can be summarized as follows: DESIGN CAPACITY Racking Resistance (kn/panel) (a) 2435 high (b) 2700 high (c) 3000 high All Bending kpa - Static (a) 2435 high 6.79 Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 18

19 DESIGN CAPACITY (b) 2700 high (c) 3000 high All o Physical Properties Panels DIMENSIONS WEIGHT 2435 x kg 2700 x kg 3000 x kg o Equivalent Modulus of Elasticity 2700 x ,000 MPa o Section Capacities (Ultimate Design) The following capacities can be used to resist axial loads and ultimate bending loads. All values have been determined by testing. Wall Height Lateral Bending Pressure Racking kn/panel (Ultimate) Wind Allowable Area Compression kn (Ultimate) o Combined Loading (Ultimate Design) The following formulae can be used to determine combined bending and axial limits: Wall Height Design Gravity Load (kn)* 2435 N* + M* (1 N* ) < 1.0 ( 307 ) 2700 N* + M* (1 N* ) < 1.0 ( 307 ) 3000 N* + M* (1-N* ) < 1.0 ( 285 ) Where: N* = Design Compressive Force (kn) M* = Design Bending Moment (knm) Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 19

20 o Ultimate Racking Value STANDARD PANEL ULTIMATE RACKING VALUE kn Panel Heights (mm) WP1 Consecutive Panels fixed to bearer /slab WP2 Single Panel fixed to bearer /slab WP3 Panels fixed to flooring only IPL4 /C4 PANEL ULTIMATE RACKING VALUE kn Panel Heights (mm) WP1 Consecutive Panels fixed to bearer /slab WP2 Single Panel fixed to bearer /slab WP3 Panels fixed to flooring only DT02 Standard Force 10 Panel design DT NZ C4 /IPL4 panel design as defined in Australian National Construction Code Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 20

21 8 Roof System Design Criteria All roofs must be subject to specific design subject to the following constraints: o Geometric Properties Base slope angle Standard 20 0 (over this requires engineering certification) Span range - 3m to 10m in 1.0 m modules Truss spacing m (module spacing ) Location of truss joints/nodes - at module joint positions (i.e. multiples of 1.0 metre) Bottom chord - one single length Top chord - 2 continuous lengths joined at the apex Load bearing internal walls - to be connected to bottom chord of truss. A vertical strut shall be inserted between the top and bottom truss chord if the wall does not coincide with a truss joint. o Member Properties ITEM SPECIFICATION Top and bottom chords section: - top hat thickness mm grade - G 500, AZ150 Web members section - top hat thickness mm grade - G 500, AZ150 Purlins section - top hat thickness mm grade - G 500, AZ150 spacing to 900 mm depending on wind speed Ceiling Battens section - top hat thickness mm grade - G 300, Z275 spacing - 500mm, but dependant on manufacturer s instructions. o Design Design shall be in accordance with AS/NZS 4600 (Cold-formed steel structures) Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 21

22 Figure 2 Truss Design Analysis o Connections Truss members - use x 25 Hex Tek screws - shear capacity 5kN/screw fixing. Note: the first No. is gauge size, the second threads per inch and the third length in mm. Truss to wall - use standard 125 mm truss bolt with 20 0 truss washer Purlin to truss - use 2 No x 25 Hex Tek screws per purlin flange Ceiling batten to truss - 2 No. 10 x 16 Hex Tek screws. o Roof sheeting Fixing of roof sheeting to purlins shall be in accordance with the roof manufacturer s specifications o Design Snow load kpa Loadings shall be in accordance with NZS 4203:1992 GENERAL structural design and design loadings for buildings Design shall be in accordance with AS/NZS 4600: Cold-formed steel structures - This Standard sets out minimum requirements for the design of structural members cold-formed to shape from carbon or low-alloy steel sheet, strip, plate or bar not more than 25 mm in thickness and used for load-carrying purposes in buildings. It may also be used for structures other than buildings provided appropriate allowances are made for dynamic effects. Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 22

23 9 Ceilings Design Criteria o Ceiling lining supports Ceiling battens consist of top hat sections which are spaced according to the requirements of the ceiling lining manufacturer (normally 500 mm centres) but at a maximum of 600 mm centres. The battens are run continuously under the bottom chords of the trusses and fixed in place with 2 No x 16 Hex screws at each crossing. Where a ceiling is designed to act as a structural diaphragm, the outside ceiling battens perpendicular to the roof trusses shall be positioned within 100 mm of the centreline of the wall panel section supporting the trusses. Attachment of the ceiling lining to the supports must be carried out in accordance with the ceiling lining manufacturer s specifications. Ceiling lining material shall comply with NZS Openings in ceilings shall comply with NZS 3604 o Structural ceiling diaphragms Where a ceiling acts as a structural diaphragm it shall meet the provisions of NZS The exception is that sheets must be fixed with No.6-20 x 25 bugle head Tek screws at 150 mm centres around the diaphragm boundary and each sheet perimeter; and at 300 mm centres to intermediate supports. Fixings must be a minimum 10mm from the edge of the sheets. Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 23

24 10 Fixings Design Criteria The following fixings are required to ensure that the Force 10 system performs to suit all conditions. The ultimate resistance value of the connection is also given. Steel Columns /Bearers Connection of bearers to steel columns will be by 4 x 10 mm mild steel bolts to column end plates in most cases. Ultimate resistance Uplift 29.5 kn o Wall Brackets Proprietary 86 x 49 x 8 mild steel plate with M12 mild steel threaded rod in all cases Ultimate resistance Uplift 29.5 kn o Truss Brackets Proprietary 86 x 49 x 8 mild steel plate with M12 mild steel threaded rod in all cases Ultimate resistance Uplift 29.5 kn o Floor /Wall Brackets Proprietary 8mm thick L brackets fixed to the flooring system with 2 x M10 bolts and 1 x M12 threaded rod in concrete slab. Ultimate resistance Uplift 29.5 kn o Wall Panel Bolts Panels to be bolted together top and bottom of panel with M16 mild steel bolts Ultimate resistance Uplift 29.5 kn per stud (59 kn per module). For a full listing of fixings used refer to F10 11 Construction Manual Screw Table Ver 8.1.docx and F10 12 Construction Manual_Brackets Ver 8.1.docx For Chemical anchor values refer to F10 05 STRUCTURAL DESIGN CALCULATIONS MANUAL VER 3.2.docx Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 24

25 11 Thermal Resistance/Energy Efficiency Design Criteria o E3 Internal moisture Force 10 wall panels meet the thermal resistance performance requirements of NZBC E3 because they have a thermal resistance value of 1.57W/m 20 C (BRANZ test). To minimise the likelihood of condensation, thermal breaks are included in some components and expanding foam type insulation is required in voids. In order to comply with E2 the specific details of waterproofing are detailed in the CM-NZ set of drawings attached to this Design Manual. Acceptable solution 1 (AS1) covers the weather tightness of the building envelope with specific Force 10 design elements shown on the CM-NZ drawings. o H1 Energy Efficiency FORCE 10 buildings will meet the performance requirements of NZBC Clause H1 Energy Efficiency, For Climate Zones 1 and 2 the Schedule Method of H1 (Table 1) gives the requirements for wall, roof and floor. FORCE 10 walls will meet the wall requirement. NZBC Clause H1 can therefore be complied with by providing the minimum roof and floor insulation requirements in Table 1 and by meeting the following two Table 1 conditions: glazing must not exceed 30% of the wall area suspended floors must have a continuous enclosed perimeter with 100 mm drooped foil. Where these conditions cannot be met the calculation method of NZS4218, Clause 3.2 must be used. o Properties and Calculations Thermal Resistance R m 2.K/W Roof Up Down External air film Steel roof sheet Insulbreak R Reflective ceiling space R3.5 ceiling insulation mm plasterboard Internal air film Total Walls External air film 0.04 External 9 mm fibre-cement sheeting 0.02 Internal air gap 20mm Internal wall wrap 0.02 Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 25

26 Thermal Resistance R m 2.K/W External 6 mm fibre-cement sheeting mm polyurethane 2.00 Internal 6 mm fibre-cement sheeting 0.02 Internal air film 0.12 Total 3.2 Floor Up Down Internal air film mm Supaboard sheeting Insulbreak R2.5 (drooped -air gap) External air film Total G6 Airborne and Impact Sound Compliance In summary: Rw + Ctr is used to describe the sound insulation performance Rw = The Weighted Sound Reduction Index and Ctr = A correction factor (and is a negative number) So if a building element has Rw of 60 and a Ctr of 10, its Rw + Ctr will equal 50. The Force 10 system Rw + Ctr values are tested to: 1 A standard Force 10 panel = 32 Rw + Ctr 2 A standard Force 10 panel with 2 layers of 16 mm sound-check applied each side = 40 Rw + Ctr 3 A standard Force 10 discontinuous wall panel with 2 layer of 16 mm sound-check and 40 mm rock wool applied to cavity = 57 Rw + Ctr. Specific requirements for projects will be designed and verified on as project by project basis by external engineers. DT57 Standard Panel Measurement of airborne Sound Reduction Indices (R) of the Force 10 Standard AX Panel in accordance with AS ISO Acoustics Measurement of Sound Insulation in Buildings and of Building Elements Part 3: Laboratory Measurements of Airborne Sound Insulation of Building Elements. Determination of Weighted Sound Reduction Indices (RW) and Spectrum Adaptation Terms (C1, and Ctr) in accordance with AS/NZS ISO 717.1: 2004 Acoustics Rating of Sound Insulation in Buildings and of Building Elements Part 1: Airborne Sound Insulation. Description : AX Panels Standard Acoustical Performance R W (C:C tr) 32 (-3,-5) Test Reference: CN/09/7476.Tst Test Date: 26 August 2009 Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 26

27 DT58 Standard Panel with 2x16 mm sound check each side Measurement of airborne Sound Reduction Indices (R) of the Force 10 Standard AX Panel with fyrecheck in accordance with AS ISO Acoustics Measurement of Sound Insulation in Buildings and of Building Elements Part 3: Laboratory Measurements of Airborne Sound Insulation of Building Elements. Determination of Weighted Sound Reduction Indices (RW) and Spectrum Adaptation Terms (C1, and Ctr) in accordance with AS/NZS ISO 717.1: 2004 Acoustics Rating of Sound Insulation in Buildings and of Building Elements Part 1: Airborne Sound Insulation. Description : AX Panels with Fyrecheck Acoustical Performance R W (C:C tr) 40 (0,-4) Test Reference: CN/09/7476.Tst2 Test Date: 26 August 2009 DT59 2 sets of AX Discontinuous Panels (with rockwool) Measurement of airborne Sound Reduction Indices (R) of the Force 10 Discontinuous AX Panel with Fyrchek in accordance with AS ISO Acoustics Measurement of Sound Insulation in Buildings and of Building Elements Part 3: Laboratory Measurements of Airborne Sound Insulation of Building Elements. Determination of Weighted Sound Reduction Indices (RW) and Spectrum Adaptation Terms (C1, and Ctr) in accordance with AS/NZS ISO 717.1: 2004 Acoustics Rating of Sound Insulation in Buildings and of Building Elements Part 1: Airborne Sound Insulation. Description : Discontinuous AX Panel with Acoustical Performance R W (C:C tr) Fyrchek 57 (-2,-5) Test Reference: CN/09/74763.Tst Test Date: 26 August 2009 Floor impact levels are prepared using the KNAUF KF 220-KF228 as shown and as described in drawing DT Further acoustic performance compliance is to be defined on a job by job basis using existing designs and in conjunction with the following Fire performance requirements. Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 27

28 13 C1- C6 Fire Resistance o Wall Panels Fire resistant The Force 10 wall panels are manufactured from fibre-cement and filled with fire retarded self-extinguishing polyurethane foam (PUR). o Panel Early Fire Hazard Properties IGNITABILITY SPREAD OF HEAT EVOLVED SMOKE INDEX FLAME INDEX INDEX DEVELOPED INDEX o General Materials used in the Force 10 system are also non-combustible, so its use significantly reduces the amount of flammable material in a home. The Fire Resistance Levels (FRLs) FRL of the Force 10 system for different classes of buildings is to be determined at the design stage by use of the DT Drawings and advice of a certified fire engineer. The FRL is expressed in the order (i.e. structural adequacy/integrity/insulation). For example, a wall that is required to meet an FRL of 120/60/30 means that the wall must maintain structural adequacy for 120 minutes, integrity for 60 minutes and insulation for 30 minutes, as tested to AS The design of FRL is integral to the acoustic design for the project. Further fire performance compliance is defined on a job by job basis using existing designs and in conjunction with the acoustic performance requirements. Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 28

29 14 Codes and Standards When designed in accordance with the requirements of this Design Manual and constructed in accordance with the Force 10 Construction Manual, the Force 10 Engineered Building System will meet the relevant clauses of NZ building regulations. The Force 10 Building System has been tested by James Cook University Cyclone Testing Station JCU-CTS, QUT, CSIRO, BRANZ and by USA based testing organisations to ensure that the system meets the relevant codes and standards. AS/NZS :2002 AS/NZS :2002 AS/NZS :2011 AS/NZS :2003 Structural design actions General principles This Standard specifies general procedures and criteria for the structural design of a building or structure in limit states format. It covers limit states design, actions, and combinations of actions, methods of analysis, robustness and confirmation of design. The Standard is applicable to the structural design of whole buildings or structures and their elements. This Standard covers the following actions: (a) Permanent action (dead load). (b) Imposed action (live load). (c) Wind. (d) Snow. (e) Earthquake. (f) Liquid pressure. (g) Ground water. (h) Rainwater ponding. (i) Earth pressure Structural design actions - Permanent, imposed and other actions Provides design values of permanent, imposed and other actions to be used in the limit state design of structures and members. It is intended to be used in conjunction with AS/NZS Other actions covered include liquid pressure, ground water, rain water ponding and earth pressure. Structural design actions - Wind actions This Standard sets out procedures for determining wind speeds and resulting wind actions to be used in the structural design of structures subjected to wind actions other than those caused by tornadoes. The Standard covers structures within the following criteria: (a) Buildings less than or equal to 200 m high. (b) Structures with roof spans less than 100 m. (c) Structures other than offshore structures, bridges and transmission towers. NOTES: 1 This Standard is a stand-alone document for structures within the above criteria. It may be used, in general, for all structures but other information may be necessary. 2 Where structures have natural frequencies less than 1 Hz, Section 6 requires dynamic analysis to be carried out (see Section 6). 3 In this document, the words this Standard indicate AS/NZS , which is regarded as Part 2 of the AS/NZS 1170 series of Standards (see Preface). 4 Further advice should be sought for geometries not described in this Standard, such as the roofs of podiums below tall buildings. Structural design actions - Snow and ice actions This Standard sets out procedures for determining snow actions on roofs and ice actions to be used in the structural design of structures. This Standard is to be read in conjunction with AS/NZS The principles given in this Standard are generally applicable to all structures. Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 29

30 AS/NZS 2312:2002 AS 4055: 2006 AS 4100:1998 AS/NZS 4600: 2005 Guide to the protection of structural steel against atmospheric corrosion by use of protective coatings This Standard covers the protection of structural steel work against interior and exterior atmospheric corrosion and also the protection of items of equipment manufactured from steel which are exposed to exterior atmospheric conditions. The Standard also covers, to a limited extent, the protection of steel work which is completely immersed in water or buried in soil, or which is subject to atmospheres severely contaminated with acidic or other chemical vapours such as may be encountered in some chemical manufacturing plants, and also the protection of ships. The systems recommended in this Standard can also be used on internal structures where wet or damp areas exist. Wind Loads for Housing This Standard specifies site wind speed classes for determining design wind speeds and wind loads for housing within the geometric limits given in Clause 1.2. The classes are for use in the design of housing and for design, manufacturing and specifying of building products and systems used for housing. Steel Structures This Standard sets out minimum requirements for the design, fabrication, erection, and modification of steelwork in structures in accordance with the limit states design method. Cold Formed Steel Structures This Standard sets out minimum requirements for the design of structural members cold-formed to shape from carbon or low-alloy steel sheet, strip, plate or bar not more than 25 mm in thickness and used for load-carrying purposes in buildings. It is also applicable for structures other than buildings provided appropriate allowances are made for dynamic effects. o International Compliance The Force 10 Engineered Building System has been tested and complies with the following standards: ASTM E 72 ASTM E 72, Method of Conducting Strength Tests of Panels for Building Construction: Wall Panel Transverse Load Tests Wall Panel Axial Load Tests Wall Panel Racking Shear Tests. ANSI/UL , Standard for Fire Test of Interior Finish Material. Test specimens have been tested and evaluated in accordance with the following Miami Dade and Florida Building Code Protocols: TAS , Impact Test Procedures. TAS , Criteria for Testing Impact and Non Impact Resistant Building Envelope Components Using Uniform Static Air Pressure Loading. TAS , Criteria for Testing Products Subject to Cyclic Wind Pressure Loading. Test specimens have been tested and evaluated in accordance with the following USA Building Code Protocol by Queensland University of Technology (QUT) and North Carolina State University (NCSU) to: ASTM E 72 ASTM E 72, Method of Conducting Strength Tests of Panels for Building Construction: Wall Panel Transverse Load Tests Document Reference: F10 04 Design Manual New Zealand Ver 1.3.docx Page 30