CEMINTEL FIBRE CEMENT SYSTEMs RESIDENTIAL EXPRESSWALL. fc936 oct external cladding systems

Transcription

1 CEMINTEL FIBRE CEMENT SYSTEMs RESIDENTIAL EXPRESSWALL external cladding systems fc936 oct 2008

2 Contents Contents 2 Description 2 Applications 2 Advantages 3 Components 4 6 Design Considerations 7 10 Architectural Specification 33 Framing Panel Preparation Panel Installation Curved Facades 19 Construction Details Fire Rated Wall Systems Material Properties 33 Handling & Storage 34 Safety 34 Panel Cutting 35 Health & Safety 36 Guarantee 36 Description The Cemintel Facade System provides a versatile and durable facade with a modern style for residential buildings. Cemintel is a highly adaptable system which can be used to conceal most common structural materials such as masonry, precast concrete, and steel or timber stud framing. is an 8mm thick, autoclaved, cellulose fibre reinforced cement sheet which is purpose manufactured for use on residential building facades. It is a square edge sheet with a smooth flat surface suitable for painting. The panels are supported by vertical top hat framing and fixed with concealed screws. The panels may be arranged in a variety of patterns, and surface relief is produced by expressed joint finishing. can be finished with a wide variety of exterior grade acrylic paint or aggregate finishes resulting in a high degree of design freedom. Applications The System has been designed to be used for external cladding of buildings such as: Homes. Duplex and Town House Developments. It however remains the responsibility of the building designer to verify that the Cemintel Facade System is suitable for the particular requirements of any given project. The Cemintel System has been designed as a drained cavity system (similar to traditional cavity brick systems), and is suitable for exposed applications. The Cemintel System can also be used as an exterior ceiling. Contact Cemintel Fibre Cement Systems for details. 2

3 Advantages DESIGN FEATURES. Expressed joint appearance. Flat, smooth surface. Countersunk and covered fasteners. Tested drained cavity system. Lightweight construction and low maintenance. Readily accepts many forms of decorative finish. Suitable for curved applications. Edges of the Panels are primed with a black pigmented sealer to accentuate the Expressed Joint. (No difficult cutting-in is required when painting). CONSTRUCTION FEATURES. Prefabrication opportunities. Rapid installation. Set-out tolerance for fixing framing. Dimensionally accurate panels. Highly durable gasket. Countersunk Head Fastener or Rigid Air Barrier Structural support Vertical Gasket Intermediate Backing Strip Adhesive 3

4 Components RESIDENTIAL EXPRESSPANEL. An autoclaved, cellulose fibre reinforced cement sheet which is purpose manufactured for use in residential building facades. is factory sealed on the face, and all edges are coated with a pigmented sealer to eliminate the need for painting. The face is ready to accept a wide range of finishes. is 8mm thick, has a mass of 11.7kg/m 2, and is available in the following panel sizes. RESIDENTIAL EXPRESSWALL TOP HAT. A purpose designed rolled steel section for supporting the vertical edges of the. The unique profile also acts to accommodate movement of the sheets at the vertical joints. It is designed to be used in conjunction with the Vertical Gasket. is manufactured from galvanised (Z275) BHP steel of 0.75mm base metal thickness, and has a mass of 1.97kg/m. is the subject of patent application Nº Order Nº Length mm RESIDENTIAL EXPRESSPANEL IS AVAILABLE IN THE FOLLOWING PANEL SIZES. (All panels 8mm thickness) Width (mm) (39866) (39838) Length (mm) 1792 (39840) 2992 (86315) RESIDENTIAL EXPRESSPANEL SEALED EDGES. Edges of panels are primed with pigmented sealer External face suitable for coating RESIDENTIAL EXPRESSPANEL DRILLING JIG. Provides a fast and accurate guide for drilling fixing holes at sheet corners. Order Nº Qty RESIDENTIAL INTERMEDIATE TOP HAT. Used to support the at locations other than vertical joints. Intermediate is manufactured from galvanised (Z275) BHP steel of 0.75mm base metal thickness, and has a mass of 0.95kg/m. Order Nº Length mm

5 RESIDENTIAL EXPRESSWALL VERTICAL GASKET. Made from EPDM closed cell foam which has high UV resistance. The gasket has adhesive on one side (with a release paper), and is adhered to the to prevent moisture entry at vertical joints. Order Nº Description mm x 48mm x 25m roll (Tesa 61102) RESIDENTIAL EXPRESSWALL SCREW. Designed for the System. They are the only screws recommended by CSR for fixing to the steel top hats. Countersunk Head Screw. The countersunk head allows concealed fixing, and the buttress thread is designed to provide maximum holding power in light gauge steel. It has a Class 3 finish and is gray in colour. Order Nº Description Countersunk Head Class 3 Finish 1000/pack Class 3 finish 30mm RESIDENTIAL EXPRESSWALL BACKING STRIP. A rolled steel section designed to support the gasket and/or sealant behind the horizontal expressed joints. Backing Strip is manufactured from high tensile BHP Colorbond steel, and is black in colour. Order Nº Length mm mm mm Exposed Head Screw. (Suitable for ONLY). The Exposed Head Screw has a buttress thread which is designed to provide maximum holding power in light gauge steel. It is available in Class 3 finish and Stainless Steel (grade 410). Order Nº Description Wafer Head Class 3 Finish 1000/pack Wafer Head Stainless Steel 1000/pack Class 3 finish 30mm Stainless Steel 30mm EXPRESSWALL EXTERNAL PVC CORNER MOULD. A weather resistant corner angle that can be be installed as an option for corner construction. Order Nº Length mm COUNTERSINKING TOOL. A tungsten carbide tipped tool specifically designed for drilling and countersinking the required 6mm diameter screw holes in. It is suitable for use with screw guns and drills, and has an adjustable depth setting. This is the only tool recommended by CSR for this purpose. Use only for countersunk head screws. Order Nº Description Countersinking Tool 5

6 CEMINTEL RESIDENTIAL EXPRESSWALL RESIDENTIAL EXPRESSWALL PVC CAVITY BAFFLE. Used at the wall base and above window openings. Order Nº Description Length 3000mm RESIDENTIAL BACKING STRIP ADHESIVE. Used for fixing ExpressWall Backing Strip to. NOTE: This product is NOT recommended for filling expressed joints. Order Nº mm Description Sikaflex 11FC, 310ml tube, (colour black) 50mm JOINT SEALANT. Used to seal ExpressPanel joints for high wind zones. 20mm Order Nº PVC CORNER MOULD. Used for optional corner construction.. Order Nº Description Length 3000mm Description Sikaflex PRO, 310ml tube (colour black) Sikaflex PRO, 310ml tube (colour grey) Other sealants may be used for decorative purposes, when approved by the manufacturer. EPOXY. AIR BARRIER.* It is important to note that air barriers must be installed correctly as they are an integral element of a pressure equalised self-draining cavity system. Cemintel Fibre Cement Systems recommends HomeWrap is installed and sealed in accordance with this guide and the manufacturer s literature. (Suitable for up to 2kPa design wind pressure installations). DuPont FlexWrap is used to seal the Tyvek air barrier at corners of openings and at flashings. Recommended products are: Air barrier: HomeWrap Air barrier sealing: DuPont Flexwrap Epoxy is used to conceal the countersunk fastener heads, to prevent moisture penetration,and to provide a flat surface for decorative coating. Epoxy products must be installed to the manufacturer s recommendations. Order Nº Description Megapoxy P1 BACKING ROD.* Backing rod is used to enable correct filling of joints with sealant. It is recommended that backing rod be of open cell type to enable sealant to cure from behind. The diameter of backing rod must be appropriate for the width of the gap being filled. FLASHINGS & CAPPINGS.* Flashings are to be designed and installed in accordance with SAA-HB and good building practice. SARKING.* A range of sarkings are available to suit various environments. Please contact CSR Bradford for additional information. NOTE: Products marked with * are supplied by others. 6

7 Design Considerations This guide represents good practice, though it is not intended as an exhaustive statement of all relevant information. It remains the responsibility of the building designer to verify that the Cemintel system is suitable for the particular requirements of any given project. AIR BARRIER. It is important to note that air barriers must be installed correctly as they are an integral element of a pressure equalised self-draining cavity system. Cemintel Fibre Cement Systems recommends as an air barrier for design wind loads of up to 2kPa, provided it is installed and sealed in accordance with this guide and the manufacturer s literature. For installations exceeding 2kPa, a rigid air barrier must be installed to the project engineer s specifications. Condensation control should also be considered. Condensation is a complex problem, and can occur under a variety of conditions, not just cold conditions. Literature on this subject is available from CSIRO/BRANZ/ ASHRAE and must be consulted when building in areas where condensation is likely to occur. In these cases, the appropriate use of a building wrap as a vapour barrier or as thermal insulation, or both, can be effective in controlling condensation. INSULATION. It is recommended that insulation materials be installed to enhance thermal insulation properties and occupant comfort. Insulation also improves the acoustic performance of the wall against outside noise. The level of insulation provided by a wall is determined by its R-value. Cemintel systems incorporating Bradford R1.5 Gold Insulation can provide a thermal rating of R1.75. The higher the R-value the greater the insulation provided. THERMAL PERFORMANCE. 1 layer Cemintel fixed to Cemintel top hat framing system. Building Wrap Timber or Steel Studs (90mm min.) at mm maximum centres. 1 layer x 10mm Plasterboard fixed to the inside of framing. INSULATION MATERIALS (a) Building Wrap under top hats + Bradford R1.5 Gold Batts in cavity. Total Wall R-Value

8 CONTROL JOINTS. Control joints in the system are required to correspond to control joints in the supporting structure and anywhere that significant structural movement is expected. A horizontal control joint is required beneath slabs to accommodate any expected deflection. The magnitude of the deflection must be verified by the building designer. Refer to FIG 27. Vertical control joints to allow for differential movement are also required at the supports of deep fascia trusses and at the junction of structural elements of different stiffness, such as between concrete columns and stud frames. Refer to FIG 29. STRUCTURAL SUPPORT. s and Intermediate s must be installed vertically, and supported by a primary structural system. framing can be fixed to appropriately designed steel or timber framing. The frame must be designed to support the top hats at the top and bottom of the wall, and at noggings within the span of the wall. As the system uses the primary frame noggings as support for the metal top hats at the mid height of the wall, the connection of the nogging to the frame may require special design. Steel frame noggings must also be adequately designed. DURABILITY. Cemintel has many properties which make it a very durable product, including: Immune to permanent water damage in both short and long-term exposure. Will not rot, burn or corrode, and is unaffected by termites, air, steam, salt and sunlight. Not adversely affected over a temperature range of 0ºC to 95ºC. Conforms with the Building Code of Australia (BCA) requirements for external wall applications. The durability of the system can be enhanced by periodic inspection and maintenance. Inspections should include examination of the coatings, flashings and seals. Paint finishes must be maintained in accordance with the manufacturer s recommendations. Any cracked or damaged finish or seals which would allow water ingress, must be repaired immediately by recoating or resealing the effected area, or by removing the panel and replacing gaskets. Any damaged flashings, sheets or gaskets must be replaced as for new work. The durability of the system can also be increased by the additional treatment of steelwork, and by painting all exposed sealants to the sealant manufacturer s recommendations. FIG 1. FIXING TO TIMBER FRAMING. Stud Framing Noggings and connections to project engineer s specifications Intermediate or Rigid Air Barrier Concrete footing It is the responsibility of the project engineer to adequately design the primary frame to support the system. Alternatively, horizontal top hats can be installed to support the framing. AS/NZS Table C1 suggests that support framing be designed for a maximum deflection of span/250. 8

9 FIG 2. FIXING TO STEEL FRAMING. PANEL LAYOUT. Top track Structural steel frame and connections to project engineer s specifications Panel layout for the system involves the coordination of the following: Aesthetic Design. Spacing. Type of Structural Support. Openings Size and Location. Building Size. Size and Joint Width. (Horizontal and vertical joints are nominal 8mm). Building Control Joint Location. Intermediate FIG 4. HORIZONTAL SHEETING ALIGNED GRID PATTERN. Concrete footing Bottom track framing can also be fixed over masonry or concrete walls. All top hat connections must be designed by the project engineer. FIG 3. FIXING TO EXISTING MASONRY WALL Panel layout must be in a grid pattern where vertical and horizontal joints are continuous. Panels may be positioned vertically or horizontally. In these layouts, construction joints may be positioned behind any vertical or horizontal sheet joint. For details on control joints, refer to page 24. Masonry wall FIG 5. SYMMETRICAL SHEETING PATTERN. Intermediate 9

10 HORIZONTAL BACKING STRIP. The horizontal backing strip is adhered behind the top edge of the using Sikaflex 11Fc adhesive. FIG 6. HORIZONTAL JOINT. ExpressPanel VERTICAL JOINT GASKET. A gaskets is used at vertical joints to maintain weather resistance. The vertical gasket is made from EPDM rubber which has good weathering and UV resistance. It has very low compression set and water permeability. The has been designed to elastically deform when pressure is applied during panel fixing. This ensures that only the required pressure is applied to the vertical gasket. Backing Strip Sikaflex-11FC FIG 7. VERTICAL GASKET COMPRESSION. Vertical Gasket FIG 8. JOINT DETAIL. Vertical Gasket Backing Strip Sikaflex 11FC Adhesive 10

11 Architectural Specification SCOPE. The contractor shall furnish all materials, labour and equipment for the installation of the Cemintel Facade System where indicated on the drawings and/or as specified. The Cemintel Facade System shall be installed in accordance with CSR manual NºFC936 Cemintel Facade System. RESIDENTIAL EXPRESSPANEL. shall be 8mm cellulose reinforced sheet manufactured by Cemintel Fibre Cement Systems in accordance with AS/NZS shall be coated with *..., colour *..., which shall be installed to the manufacturer s recommendations. EXPRESSWALL FRAMING. Cemintel steel framing system shall be Cemintel and Intermediate as supplied by Cemintel. AIR BARRIER. Air barrier material shall be * (or product of equivalent or better performance). Installation shall be in accordance with CSR manual NºFC936 Cemintel Facade System, and relevant DuPont literature, OR A rigid air barrier system shall be installed in accordance with project specifications. FLASHING. Flashings not supplied by Cemintel Fibre Cement Systems shall be designed and installed in accordance with SAA HB39, 1997, Installation Code for Metal Roofing and Wall Cladding. Flashing to be *... colour/colour matched to the panels. FIXINGS. Screws for fixing to top hats shall be * Countersunk Head Screws, Class 3 finish. All counter sunk head screws in the shall be covered with *... epoxy, and sanded flush with the panel surface. ACCESSORIES. Tapes, gaskets, sealants, backing strip, corner mould, cavity baffle and the like shall be as detailed in CSR manual NºFC936 Cemintel Facade System (*or products of equivalent or better performance). FIRE RATED WALL SYSTEM. The contractor shall supply and install wall system *Nº CSR... in accordance with CSR Gyprock Fire & Acoustic Design Guide, NºGYP500. The wall shall have a Fire Resistance Level *FRL.../.../... in accordance with the requirements of AS Installation shall also be carried out to the level specified for an acoustic performance of *Rw... using cavity infill of *Bradford... FRAMING, FIXING & JOINTS. All framing, fixing and joints shall be designed and installed to comply with the requirements for *Wind Category/Wind Zone/kPa of... minimum. Note: *Insert or select appropriate product/information. CAVITY INFILL INSULATION. Cavity infill shall be *Bradford... (or product of equivalent or better performance). 11

12 Framing FIG 9. SINGLE SPAN INSTALLATION. Spacing The design capacities of the system are in limit state format and intended for use with AS/NZS The capacity of the top hats as detailed in Table 1 and Table 2 has been calculated in accordance with AS4 : Cold Formed Steel Structures. The deflection of the top hats as detailed in Table 1 and Table 2 is no more than span/250 when subjected to serviceability wind loads of 68% of ultimate wind loads. Cantilever Span (Table 1) Cantilever Maximum Cantilever = 0.2 x Adjacent Span TABLE 1. MAXIMUM TOP HAT SPAN.(REFER TO FIG 9). SINGLE SPAN INSTALLATION. Wind Classification General Zone Edge Zone Australia 300mm 450mm mm 300mm 450mm mm (Wind Category) Spacing Spacing Spacing Spacing Spacing Spacing N N N3, C N4, C N5, C N6, C New Zealand (Wind Zone) Low Medium High Very High NOTE: Edge zone is defined as area within 1200mm of edges (Appendix B - AS ) 12

13 FIG 10. DOUBLE-SPAN INSTALLATION. Cantilever Spacing TOP HAT FIXING. (Refer to FIG 11) NOTE: It is the responsibility of the project engineer to specify the connection of the top hats to the support structure. Each fastener is required to have a minimum 14mm diameter head, such as a 12g hex head screw, for satisfactory top hat performance. Span (Table 2) FIG 11.TOP HAT FIXING Fixing Span (Table 2) Cantilever If adjacent spans differ by more than 25% then single span values must be adopted. Maximum Cantilever = 0.2 x Adjacent Span Fixing ExpressWal Intermediate TABLE 2. MAXIMUM TOP HAT SPAN. (REFER TO FIG 10). DOUBLE SPAN INSTALLATION. Wind Classification General Zone Edge Zone Australia 300mm 450mm mm 300mm 450mm mm (Wind Category) Spacing Spacing Spacing Spacing Spacing Spacing N N N3, C N4, C N5, C N6, C New Zealand (Wind Zone) Low Medium High Very High NOTE: Edge zone is defined as area within 1200mm of edges (Appendix B - AS ) 13

14 Panel Preparation The following procedures may be performed off-site prior to installation: Step 1 Pre-drill and countersink holes for screws. Step 2 Affix backing strip behind the top edge of the panel and allow adhesive to set. (Alternatively, the backing strip may be affixed after panel is partially screw fixed. Refer to Panel Fixing for details.) All cut edges should be sealed with exterior grade acrylic paint such as Dulux Weathersheild X10 Black. PANEL FIXING SET-OUT. must be fixed in accordance with Table 3. Appropriate panel fixing layout should be selected for the project based on Wind Category, Spacing and Panel Fixing Type. (Refer to FIG 13 and 14). For curved facades, please refer to page 19. FIG 12. PANEL FIXING SET-OUT. Fixing Spacing at Intermediate (refer to Panel Fixing Table) 45mm* 45mm* Fixing Spacing at Panel Edge (refer to Panel Fixing Table) 45mm* * Minimum distance of fastener to edge of 35mm. TABLE 3. PANEL FIXING REQUIREMENTS. Wind General Zone Classification Edge Zone Max. Spacing (mm) Max. Fixing Spacing (mm) Max. Spacing (mm) Max. Fixing Spacing (mm) Australia (Wind Category) Panels Fixed to Two s Panels Fixed to Three or more s At Panel Edge At Intermediate Panels Fixed to Two s Panels Fixed to Three or more s At Panel Edge At Intermediate N N N3, C N4, C N5, C N6, C New Zealand (Wind Zone) Low Medium High Very High NOTE: Edge zone is defined as area within 1200mm of edges (Appendix B - AS ) FIG 13. PANEL FIXED TO TWO TOP HATS ONLY. spacing FIG 14. PANEL FIXED TO THREE OR MORE TOP HATS. spacing spacing 14

15 PRE-DRILLING HOLES. Holes for screws must be pre-drilled. Use the recommended counter sinking tool for countersunk head screws, and a 6mm masonry bit for exposed head screws. Holes must be 6.2mm to 6.3mm in diameter. Do not use hammer action when drilling. Clean dust out of holes. NOTE: Use only the recommended tool as supplied by CSR. The use of other tools for this purpose may reduce fixing capacity or reduce the weather resistance of the system. Refer to Components section for details. CORNER DRILLING TEMPLATE. The Cemintel Corner Drilling Template provides an easy method for locating the correct position for fixing holes at the corners of panels. The template locates on the corner of the sheet and the appropriate drilling position for the left or right corner of the panel is used to locate the drill bit. FIG 16. CORNER DRILLING TEMPLATE. HINT: One way of drilling holes is to drill the top sheet of a pack with the counter sinking drill set to approximately 12mm depth. This will give a starter hole on the sheet below, saving on set out time. FIG 17. BACKING STRIP POSITIONING. ExpressWall Backing Strip adhesive fixed behind top edge of panel 3mm 3mm FIG 15. 6MM MASONRY DRILL FOR EXPOSED HEAD SCREWS. 6mm 15

16 Panel Installation must be in a dry condition when fixed. If panels become wet after installation, allow to dry before covering screw heads. Panels must only be fixed using Cemintel Screws. Recommended panel installation procedure is:: When top hat is discontinuous, butt ends together tightly and continue gasket over the joint. If a gap is present, install a steel strip to support the gasket. FIG 19. GASKET SUPPORT AT DISCONTINUOUS TOP HAT JOINT. Steel strip 1. Install Vertical Gaskets to s. 2. Screw fix to top hats, leaving top edge screws out at this stage. 10mm max. 3. Install and adhesive fix backing strip behind the top edge of the panel. (Alternatively, panels may be prepared with backing strip prior to installation. Refer to FIG 17 for details.) 4. Install remaining panel fixing screws. 5. Cover fastener heads. CSR recommends the use of torque control screw guns. If it is necessary to remove and replace a panel, avoid reusing screw holes in the top hats by adjusting fixing locations in the panel. INSTALLING VERTICAL GASKET TO TOP HAT. Install vertical gasket to central section of the for the full extent of panels. Be careful not to stretch the gasket when installing. When joining gasket, cut ends cleanly and push together before adhering. FIXING PANELS USING COUNTERSUNK HEAD FASTENERS. Drive the countersunk head screw into the top hat using an electric screw gun. CSR recommends the use of a screw gun with torque control to prevent overdriving of screws. 30mm Class 3 finish FIG 20. FIXING WITH COUNTERSUNK SCREWS. FIG 18. VERTICAL GASKET INSTALLATION. Countersunk Screw Vertical Gasket applied centrally on top hat FIG 20A. FIXING WITH EXPOSED HEAD SCREWS. Exposed Head Screw ExpressWall 16

17 JOINTS. is generally installed with a nominal 10mm width, horizontal and vertical expressed joints between adjacent panels. Joints up to 20mm nominal width can be formed, provided additional care is taken during installation to ensure that panel edges cover the joint gaskets by a minimum of 10mm. For Cemintel systems subjected to design wind pressure in excess of 2.0kPa, all horizontal and vertical joints must be filled with recommended joint sealant. Sealant must be installed in accordance with the manufacturer s instructions. Sealant filled joints may also be used as an aesthetic preference. FIG 21. EXPRESSED VERTICAL JOINT DETAIL. FIG 23. SEALED VERTICAL JOINT DETAIL 8mm Vertical Gasket Joint sealant (refer to Components) 8mm Vertical Gasket FIG 22. EXPRESSED HORIZONTAL JOINT DETAIL. FIG 24. SEALED HORIZONTAL JOINT DETAIL Backing Strip 45mm* Backing Strip 45mm* 8mm nominal 8mm nominal Backing Strip Adhesive 45mm* Backing Strip Adhesive 45mm* Joint Sealant (refer to Components) * Minimum distance of fastener to edge of 35mm. * Minimum distance of fastener to edge of 35mm. 17

18 SCREW HEAD COVERING FOR COUNTERSUNK SCREWS. All countersunk screw heads must be covered with epoxy compound and flush finished with the face. Epoxy shall be installed in the following manner: Mix epoxy accurately in accordance with the packaging/manufacturer s instructions. Immediately use mixed epoxy. Slightly overfill holes and level off before epoxy fully cures. When cured, sand epoxy level with face. Repeat if necessary to achieve a flush finish. HINT: One way of applying epoxy is through a 20mm hole in an aluminum sheet. This will minimise spillover and allow for some shrink back of the epoxy without having to repeat the application. Thin aluminium strip FIG 25. EPOXY COVERING OF SCREW HEADS. Screw Screw Screw head covered with epoxy Cover screw head and fill hole with Epoxy Sand Epoxy level with face 18

19 Curved Facades Where there is an architectural requirement for a curved facade, this can be achieved in three ways. For radii less than 10m, CSR recommends the use of pre-fabricated glass reinforced cement (GRC) fixed and finished in accordance with the manufacturer s specification. For radii greater than 10m, use 8mm fixed to framing. In general, framing must be set-out on a true curve to enhance appearance and not locally overstress the panels. For curved facades greater than 2m radius, framing shall be installed in accordance with Table 4. TABLE 4. CURVED WALL FRAMING & FACADE PANEL. Curve Radii Panel Type Spacing Panel Width (m) 900mm 1200mm or Greater 10m-15m 1 x 8mm Cemintel >15m 1 x 8mm Cemintel 300* 400* 450 As per Table 3 * Provide 2 additional fixings per metre to each top hat. 19

20 Construction Details WALL FLASHINGS. In general, flashings shall be designed and installed in accordance with SAA HB Installation Code for Metal Roofing and Wall Cladding. Stop ends shall be incorporated with all flashings. All flashings are supplied by others. FIG 26. BASE DETAIL FOR INLINE SLAB. FIG 27. DEFLECTION HEAD. framing Tape Tyvek to flashing with DuPont FlexWrap PVC Cavity Baffle Flashing Flashing Upstand Soffit Deflection gap to be specified by project engineer Continuous sealant bead between angle and panel with expressed joint Fix angle to top hat Drip groove Backing rod and 10mm min. depth sealant positioned to suit flush or expressed finish Backing rod and sealant air seal Tyvek fixed to frame under metal strips Open joint to allow for self-drainin g cavity Tyvek fixed to frame under metal strips framing Support framing Concrete footing Sealant (optional) FIG 28. HEAD DETAIL AT EAVES. Tyvek sheet fixed under metal strips Eaves lining (eg. Cemintel TM Eaves Lining Sheet) system 20

21 FIG 29. ABUTMENT DETAIL. FIG 30. FRAMED SOFFIT DETAIL. Intermediate 8mm nom. gap sealant filled Tape Tyvek to flashing with DuPont FlexWrap Flashing behind top hat Tyvek fixed to frame under metal strips Stud Wall or column Backing rod and sealant air seal Tyvek fixed to frame under metal strips Soffit lining FIG 31. EXTERNAL CORNER DETAIL WITH PVC CORNER MOULD. Intermediate Vertical Gasket PVC External Corner Mould Vertical Gasket Support Framing Intermediate Support Framing Install Dupont Tyvek to manufacturer s specifications 21

22 FIG 32. EXTERNAL CORNER DETAIL - RIGID STRUCTURE. Angle 1mm galvanised steel by others spacing 8mm nom. Continuous bead of sealant Rigid structure at corners Support Framing Intermediate spacing Intermediate Support Framing Install Dupont Tyvek to manufacturer s specifications FIG 33. INTERNAL CORNER DETAIL. Structural framing Continuous bead of sealant 8mm nom. Intermediate Angle 1mm galvanised steel by others Structural framing Intermediate 22

23 FIG 34. ANGLED CORNER DETAIL. WALL FLASHINGS Intermediate Support Framing In general, flashings shall be designed and installed in accordance with SAA - HB Installation Code for Metal Roofing and Wall Cladding. Stop ends shall be incorporated with all flashings. All flashings are supplied by others. FLASHING UPSTAND. Maximum 50% of Top Hat spacing Ultimate Design Wind Pressure (kpa) Flashing Upstand Minimum (mm) Angle 1mm galvanised steel supplied by others Continuous bead of sealant Maximum 50% of Top Hat spacing Intermediate Support Framing Parapet capping shall be designed and fastened in accordance with SAA HB Installation Code for Metal Roofing and Wall Cladding. Stop ends shall be incorporated to all flashings. FIG 35. CAPPING DETAIL OPTION 1. FIG 36. CAPPING DETAIL OPTION 2. Clip to suit capping fixed through oversize hole in panel Overlap and fix Tyvek under metal strips Fall Splice and seal capping Screw fix capping to backing strip over continuous bead of sealant Backing Strip Fall Overlap and fix Tyvek under metal strips Splice and seal capping Capping overlap (refer to Flashing Table) Bead of Sealant Gasket to extend to top of 30mm min. Subframe member Subframe member 23

24 FIG 37. HORIZONTAL CONTROL JOINT. Stud 5mm clearance 8mm nom. joint 5mm clearance Wall Plate Fix Horizontal Backing Strip Joist Wall Plate Stud FIG 38. VERTICAL CONTROL JOINT. 100mm max. 8mm nom. joint 100mm max. Continuous bead of sealant Continuous Sealant bead of sealant Backing Rod Support angles Allow a loop for frame movement Movement joint in structure to engineer's specifications 24

25 FIG 39. PREPARATION OF WALL WRAP AT OPENINGS. STEP 1: Fix Tyvek under metal strip STEP 2: Fold Tyvek back over strip and fix under second metal strip DuPont FlexWrap to seal Tyvek at corners of openings FIG 40. WINDOW JAMB DETAIL Tyvek to continue 10mm min. past inside face of window frame (fix Tyvek to frame under metal strips) Backing rod and 5mm min. depth sealant Support Framing DuPont FlexWrap over Tyvek at corners of opening Window Frame Sealant 8mm nom. Flashing ExpressPanel 25

26 FIG 41. WINDOW HEAD DETAIL. Vertical Gasket Support Framing DuPont FlexWrap over Tyvek and flashing PVC Cavity Baffle Flashing 10mm gap to allow for self-draining cavity Tyvek to continue 10mm min. past inside face of window frame (fix Tyvek to frame under metal srtips) Backing rod and 5mm min. depth sealant DuPont FlexWrap over Tyvek at corners of opening Window Frame Continuous bead of sealant FIG 42. WINDOW SILL DETAIL. Tyvek to continue 10mm min. past inside face of window frame (fix Tyvek to frame under metal strips) Window Frame DuPont FlexWrap over Tyvek at corners of opening Continuous bead of sealant Backing rod and 5mm min. depth sealant Support Framing Vertical Gasket 26

27 WINDOW FLASHING PROCEDURE. The installation of window flashings will depend on the chosen windows and framing methods. The following details show a typical installation procedure. FIG 43. FIG 45. STEP 1 Install Head Flashing and fix to framing Tape flashing to Tyvek with DuPont FlexWrap 10mm gap to allow for self-draining cavity STEP 5 Install Vertical Gasket (down to bottom of cavity baffle) Continuous bead of sealant behind flashing Window frame STEP 2 Install PVC Cavity Baffle and fix to framing STEP 6 Install FIG 44. FIG 46. STEP 3 Install Intermediate STEP 7 Fill joint with sealant STEP 4 Install flashing angle 27

28 FIG 47. WINDOW HEAD WITH PREFORMED EXTERNAL REVEAL. Support Framing Proprietary window flashing taped to Tyvek with DuPont FlexWrap Bevel on site if required. Proprietary window flashing Tyvek to continue 10mm min. past inside face of window frame (fix Tyvek to frame under metal strips) Backing rod and 5mm min. depth sealant DuPont FlexWrap over Tyvek at corners of opening Window Frame Cemintel Fibre Cement Preformed Reveal - fix with Sikaflex 11FC FIG 48. WINDOW SILL WITH PREFORMED EXTERNAL REVEAL. Tyvek to continue 10mm min. past inside face of window frame (fix Tyvek to frame under metal strips) Window Frame DuPont FlexWrap over Tyvek at corners of opening Cemintel Fibre Cement Preformed Reveal Proprietary window flashing Backing rod and 5mm min. depth sealant Proprietary window flashing taped to Tyvek with DuPont FlexWrap Support Framing 28

29 FIG 49. WINDOW JAMB WITH PREFORMED EXTERNAL REVEAL. Tyvek to continue 10mm min. past inside face of window frame (fix Tyvek to frame under metal strips) Backing rod and 5mm min. depth sealant Support Framing DuPont FlexWrap over Tyvek at corners of opening Window Frame Cemintel TM Fibre Cement Preformed Window Reveal Proprietary window flashing Proprietary window flashing taped to Tyvek with DuPont FlexWrap 29

30 Fire Rated Wall Systems Cemintel can be used with a variety of CSR Gyprock and Cemintel Fibre Cement fire rated wall systems. These can provide a fire rating from one or both sides of the wall depending upon the internal lining materials chosen. Refer to the system tables for detailed information. For detailed information on fixing fire rated linings, refer to the CSR Gyprock Fire & Acoustic Design Guide, NºGYP CSR 055 FRL 60/60/60 from both sides of the wall Report/Opinion FCO 1387 EXTERNAL SIDE OF WALL FRAMING 1 layer Cemintel fixed to Cemintel top hat framing system. Building Wrap. 1 layer x 16mm GYPROCK FYRCHEK MR plasterboard fixed to framing. Steel stud framing as required. INTERNAL SIDE OF WALL FRAMING 1 layer x 16mm GYPROCK FYRCHEK plasterboard fixed to framing. Rw STUD DEPTH CAVITY INFILL Rw (a) Nil (b) R1.5 Bradford Gold Batts (c) S4 Bradford Polyester 70mm g/m TYPICAL WALL WIDTH (excluding wall frame) mm TYPICAL WALL MASS (excluding wall frame) kg/m NOTE: For additional fire and acoustic systems, please refer to the CSR Gyprock Fire & Acoustic Design Guide, NºGYP

31 + CSR 055 FRL 60/60/60 from outside of the wall only Report/Opinion FCO 1404 EXTERNAL SIDE OF WALL FRAMING 1 layer Cemintel fixed to Cemintel top hat framing system. Building Wrap. 1 layer x 16mm GYPROCK FYRCHEK MR plasterboard fixed to framing. Timber stud framing as required. INTERNAL SIDE OF WALL FRAMING 1 layer x 10mm GYPROCK plasterboard CD fixed to framing. Rw STUD DEPTH 90 CAVITY INFILL Rw (a) Nil 41 (b) R1.5 Bradford Gold Batts 46 (c) S4 Bradford Polyester 70mm g/m 2 45 WALL WIDTH mm 160 WALL MASS kg/m NOTE: For additional fire and acoustic systems, please refer to the CSR Gyprock Fire & Acoustic Design Guide, NºGYP

32 FIG 51.TYPICAL EXPRESSWALL FIRE RATED INSTALLATION. (FRL 60/60/60 FROM OUTSIDE ONLY). CSR Bradford Fibertex Rockwool Timber blocking (45mm min. thickness) to form fire barrier Non-combustible eaves lining (eg. Cemintel TM Eaves Lining Sheet) 16mm GYPROCK FYRCHEK MR Plasterboard 10mm GYPROCK plasterboard Dupont Tyvek Control joint in plasterboard (15mm high) filled with Gyprock Fire Mastic Control joint in (refer to detail) Tape with DuPont FlexWrap Gyprock Fire Mastic 10mm GYPROCK plasterboard Refer to base flashing detail Ground clearance to regulatory requirements Concrete slab 32

33 Material Properties RESIDENTIAL EXPRESSPANEL MANUFACTURING TOLERANCES. Length +0 to -2mm. Width +0 to -2mm. Thickness +10% to -0%. Diagonals Difference (max) 2mm. Edge Straightness deviation (max) 1mm. FIRE RESISTANCE. Under the Building Code of Australia, C1.1 Clause 2.5(e), Cemintel Fibre Cement is deemed to be noncombustible. When tested in accordance with AS1530.3, the Early Fire Hazard Indices are as follows: Ignitability 0 Spread of Flame 0 Heat Evolved 0 Smoke Developed 0 SYSTEM TESTING. The Cemintel System has been designed and tested by CSR Gyprock & Fibre Cement Research & Development. The System has passed testing to the following parts of AS/NZS4284 Testing of Building Facades. Structural Test Water Penetration by Static Pressure. Water Penetration by Cyclic Pressure. Proof Test. The system has been tested to AS Methods of testing roof and wall cladding, Method 3 : Resistance to wind pressure for cyclonic regions. 33

34 Handling & Storage All Cemintel must be stacked flat, clear of the ground, and supported on a level platform. Care must be taken to avoid damage to edges, ends and surfaces. Material must be kept dry, preferably by being stored inside the building. Protect from contaminants such as silicone spray. Where it is necessary to store panels outside, they must be protected from the weather. Panels must be dry prior to fixing and finishing. Safety When cutting using power tools, always ensure the work area is well ventilated. An approved dust mask (AS1715 and AS1716) and safety glasses (AS1337) must be worn. CSR recommends that hearing protection be worn. 34

35 Panel Cutting POWER SAW. When it is necessary to use power tools for cutting Cemintel, CSR recommends using the Hitachi Fibre Cement Power Saw Blade. This blade is specifically designed for use with fibre cement and produces a superior cut compared to conventional blades. It is ideal for use with the Hitachi C7YA dustless circular saw and other 185mm circular saws fitted with vacuum extraction systems. DRILLING. Cemintel fixing holes shall be drilled and countersunk with the recommended countersinking tool. All general purpose drilling shall be done with a masonry drill bit. NOTE: In all cases DO NOT use hammer action when drilling. Hitachi Fibre Cement Power Saw Blade. Order No Hitachi C7YA Dustless Circular Saw with Dust Extraction System. Order No Dust extractor Panasonic EY3532, 18 volt Saw 35

36 CEMINTEL FIBRE RESIDENTIAL CEMENT EXPRESSWALL SYSTEMs RESIDENTIAL EXPRESSWALL external cladding systems cemintel fibre cement systems, csr building products limited, A.B.N fc936 oct 2008 BMS Health & Safety WARNING: Fibre Cement products contain crystalline silica. Repeated inhalation of fibre cement dust may cause lung scarring (silicosis) or cancer. Do not breathe the dust. When cutting sheets, use the methods recommended in this brochure to minimise dust generation. If power tools are used, wear an approved dust mask (respirator). These precautions are not necessary when stacking, unloading or handling fibre cement products. For further information and for a Material Safety Data Sheet, phone Guarantee CSR Building Products Limited warrants its Fibre Cement products to be free of defects in materials and manufacture. If a CSR product does not meet our standard, we will, at our option, replace or repair it, supply an equivalent product, or pay for doing one of these. This warranty excludes all other warranties and liability for damage or loss in connection with defects in CSR's product, other than those compulsorily imposed by legislation, notably the Trade Practices Act. CONTACT DETAILS Cemintel Fibre Cement Sytems Web Site. Cemintel Fibre Cement Sytems Sales Support. Telephone: Facsimile: CSR designlink Technical Support Service. Telephone: New South Wales and ACT. 376 Victoria Street, Wetherill Park NSW Queensland. 768 Boundary Road, Coopers Plains QLD Victoria. 277 Whitehall Street, Yarraville VIC South Australia. Lot 100 Sharp Court, Mawson Lakes SA Western Australia. 21 Sheffield Road, Welshpool WA Tasmania. PO Box 61, Glenorchy TAS Northern Territory. Cnr Stuart Hwy & Angliss St, Berrimah NT Cemintel Fibre Cement Systems, CSR Building Products Limited A.B.N