DURACOM FACADE SYSTEMS

THE DURACOM FACADE SYSTEM UTILISES BGC FIBRE CEMENT COATED COMPRESSED SHEETING, OFFERING THE IDEAL SOLUTION FOR CLADDING THE EXTERIOR OF LOW TO MEDIUM RISE BUILDINGS. DURACOM GIVES BUILDINGS A MODERN AND EXTREMELY DURABLE FINISH.

DURACOM SHEETING HAS A SMOOTH, FLAT SURFACE AND SQUARE EDGE FINISH WHICH IS SUITABLE FOR EXPRESSED JOINTING AND PROVIDES A FACADE SUITABLE FOR A NUMBER OF FINISHES – FROM PAINTED TO TEXTURED COATINGS.

THE DURACOM FACADE SYSTEM:

  • IS LIGHTWEIGHT AND HIGHLY DURABLE
  • IS WEATHER RESISTANT AND IS IMMUNE TO WATER DAMAGE – RATED FOR WEATHERABILITY BY CSIRO
  • USES FULLY SEALED AND BALANCED PANELS
  • PANELS WILL NOT ROT, BURN OR CORRODE
  • CAN BE EASILY DECORATED IN A NUMBER OF DESIGN FINISHES
  • FAST TO INSTALL
  • ACHIEVES BAL 40 AS REQUIRED IN AS3959:2009 – CONSTRUCTION OF BUILDINGS IN BUSHFIRE PRONE AREAS

 APPLICATIONS

Duracom™ Facade System, utilizing BGC Fibre Cement Compressed panels and Peer Industries; Cold Formed Section (CFS) steel support framing, to form a strong and durable facade cladding system.

BGC Duracom™ panels fixed to the Peer Industries CFS steel support framing, are ideally suited for versatile architectural facades and parapet applications in industrial, institutional, commercial and multi-storey residential buildings.

Duracom™ panels are designed for installation in a variety of patterns, including vertical, horizontal, brick-bond or diamond inclined.

BGC Duracom™ panels are available in 9 mm and 12 mm thicknesses and may be finished with site applied acrylic paint systems or factory applied high quality polyurethane plain, metallic and special finishes.

ADVANTAGES

  • Lightweight cladding system.
  • Readily accepts many forms of decorative finish.
  • Highly durable product.
  • Dynamic architectural style.
  • Fully sealed and balanced panels.

ENERGY EFFICIENCY CONSIDERATIONS

Energy efficiency requirements have been introduced into the Building Code of Australia (BCA) for both commercial and residential buildings.Thermal heat transfer into and out of the building envelope will effect the running cost of the building and careful consideration of thermal heat transfer needs to be addressed by the architects, engineers and building designers.Thermal bridging through steel framing will diminish the total R-Value; thermal conductance, of the wall. Thermal breaks are required for steel framed buildings and should be installed between the Peer top hat sections and the Duracom™ cladding. Thermal break tapes should have a minimum R-Value of 0.2.

PRODUCT INFORMATION

BGC Duracom™ panels are a compressed, autoclaved, cellulose fibre reinforced silica/cement panel, specially formulated and prepared to meet the requirements for use in external applications.

Duracom™ panels have a smooth flat surface and a neat square edged finish, for enhanced expressed joint facades.

BGC Fibre Cement products are manufactured to the Australian / New Zealand Standard AS/NZS 2908.2-2000Cellulose-Cement Products, Part 2: Flat sheets and Duracom™ is classified as Type A-Category 3.

FIRE RESISTANCE

BGC Compressed Fibre Cement 9 mm has been tested for and passed the Early Fire Hazard Property criteria in compliance with AS/NZS 1530.3 and AS/NZS 3837 and is deemed a Group 1 Material in accordance with the Building Code of Australia (BCA), Volume 1, Specification A2.4; Fire Hazard Properties. AS/NZS 1530.3; Early Fire Hazard Properties.

 Ignition Index 0
Spread of Flame Index 0
Heat Evolved Index 0
 Smoke Developed Index 0-1

DURABILITY

BGC Duracom physical properties make it a very durable product.

  • Duracom panels are immune to permanent water damage in both short and long-term exposure.
  • Duracom panels will not rot or burn and are unaffected by termites, air, steam, salt and sunlight.
  • Duracom panels are not adversely affected over a temperature range of 0°C to 95°C.

THERMAL CONDUCTIVITY

  • Duracom™ Facade System conforms to the Building Code of Australia (BCA) requirements for external wall applications.
  • Duracom™ facade system has been tested to AS/NZS 4284 Testing of Building Facades.

PANEL SIZES AND MASS

 

1800 2100 2400 2700 3000
900 x x x x x
1200 x x x x x
900 x x
1200 x x

SHEET TOLERANCES

  • Width +0/-1 mm
  • Length +0/-2 mm
  • Thickness +10%/-0%
  • Diagonals difference (max) 2 mm
  • Edge straightness deviation (max) 1 mm

HANDLING AND STORAGE

  • BGC Compressed fibre cement sheeting must be stacked flat, up off the ground and supported on equally spaced (max 400mm) level gluts.
  • Sheeting must be kept dry. When stored outdoors it must be protected from the weather.
  • Care should be taken to avoid damage to the ends, edges and surfaces.
  • Sheets must be dry prior to fixing, jointing or finishing.

COASTAL AREAS

The durability of galvanised nails and screws used for external cladding in coastal or similar corrosive environments can be as low as 10 years.
For this reason BGC recommend the use of stainless steel fasteners within 1km of the coast or other large expanses of salt water.

DURACOM ACCESSORIES AVAILABLE FROM BGC

 

PRIMARY TOP HATGALVANISED STEEL 120 x 35 x 1.15mm BMT – 6000mm
120 x 35 x 1.15mm BMT – 7200mm
INTERMEDIATE TOP HATGALVANISED STEEL 50 x 35 x 1.15mm BMT – 6000mm  
50 x 35 x 1.15mm BMT – 7200mm
HORIZONTAL BACKING STRIP 1100mm  
2390mm
2990mm
EPDM FOAM GASKET STRIP 25m  

FASTENER

DURACOM TO TOP HATS

DURACOM TO TOP HATS (CONCEALED FIXING) NO.10 X 30 COUNTERSUNK SELF DRILLING SCREW.

DURACOM TO TOP HATS (EXPOSED FIXING) NO.10 X 25MM PAN HEAD SELF DRILLING SCREW

NO.10 X 25 WAFER HEAD SELF DRILLING SCREW

  • Fasteners must comply with AS 3566, with a minimum Class 3 coating.
  • All screw holes must be filled with an expoxy sealer such as Megapoxy PI, Hilti CA125 or Hilti CA273, and sand flush to provide a flat surface for the finish coating.

TOP HATS TO FRAME

CLASS 3 HEX HEAD SCREW, 12-14 X 20MM

DESIGN CONSIDERATIONS

It is recommended that project specific facade designs be undertaken by a consultant experienced in such detailing.

The design engineer should determine the wind pressure for the project and specify the layout, spacing and fixing of the top hats to the structure.

The deflection of the supporting structure should be limited span/250 for Serviceability Wind Load, or as limited by AS/NZS1170.

In areas where there is a probability of wind loading, care should be taken in the design detailing, especially around all openings, corners and other junctions, to ensure the weather resistance of the total system.

Before the Duracom™ panels and the supporting substructure is installed and fixed, particular care should be taken that all flashing and waterproofing work is complete, including all vapour permeable building wraps and damp proof coursing.

CONTROL JOINTS

In many cases, control joints will not be required as typical expressed joints permit some differential movement of the Duracom™ panels and the sub-framing.
It is recommended that the designer consider the need for control joints in the following cases:

  • Where the facade crosses a building control joint.
  • Where there is likelihood of movement in the sub-framing.
  • Continuous facades greater than 8 metres in length.
  • At a change in the structural substrate; eg masonry to steel framing.
  • Refer to P16-17, drawings 12, 13 & 14.

PANEL PREPARATION

For insitu paint finish applications, Duragrid™ panels are supplied sealed with a proprietary sealer applied during manufacture for durability.

Where it is necessary to cut sheets, cutting tools should have a dust extraction system.

Cut edges must be sealed with BGC Edge Sealer or an acrylic coating to eliminate moisture absorption.

A saw blade such as BGC Durablade with a poly crystalline diamond tip specifically designed to cut fibre cement sheets is recommended.

Ensure work area is well ventilated and wear an approved dust mask (AS/NZS1715 and AS/NZS1716) and safety glasses (AS/NZS1337).

TOP HAT SPAN / WIND LOAD PRESSURE LOAD

Structural sub-frame spacing must be installed in accordance with Peer Industries specifications. Table 4 provides guidance on the Maximum Span of Top Hat Profile.

Peer Industries Top Hat Facade System design capacities. The design capacities of Peer Facade System are in limit state format and are based on AS/NZS1170.2–2002. Wind Loads.

The Top Hat capacities have been calculated in accordance with AS/NZS4600 – cold formed steel structures.

The deflection of the Top Hats is based on serviceability factor of 0.6 x ultimate wind loads and is limited to Span/250.

The Peer Industries Top Hat section can be used for Cyclonic wind areas – region C & D based on wind pressures.(For further information, refer Peer Industries Top Hat Facade
Design Manual)

It is the responsibility of the Project Engineer to specify the connection of top hats to the support structure.Minimum 12g screw on each leg of Top Hat i.e. two 12g screws at each crossing of Top Hat & purlin.

TABLE 4 

DESIGN WIND PRESSURE KPA SINGLE SPAN DOUBLE SPAN THREE SPANS
Top Hat Top Hat Top Hat
Spacing mm Spacing mm Spacing mm
450 600 450 600 450 600
Up to0.75 MAXIMUM SPAN OF TOP HAT PROFILE
1950 1750 2450 2150 2400 2200
1.0 1750 1600 2150 1850 2200 2000
1.5 1550 1400 1750 1500 1900 1700
2.0 1400 1250 1500 1300 1900 1700
2.5 1300 1200 1350 1200 1500 1300
3.0 1200 * 1250 * 1400 *
4.0 1050 * 1050 * 1200 *

INSTALLATION

Position the Top Hats according to predetermined and marked spacings and ensure that they are vertical (check with a spirit level).

Fix the Top Hats to the Purlins using self-drilling hex head wafer screw fasteners ensuring that both legs of the Top Hats are fixed to the structural purlins or framing.

Also, ensure that the Top Hats are mounted vertical using a spirit level to check.

For inclined or diamond patterns, check that the inclined angle of the Top Hats are correct.

The Top Hats must be fixed on both legs to minimise flexing of the Top Hats.

Apply the EPDM Foam Gasket Strip to the primary 120 mm Top Hat. The seal can be applied to the mounted top hat insitu or it can be applied to the Top Hat, before it is fixed to the purlins.

Ensure that the EPDM Foam Gasket Strip is applied to the centre of the purpose designed Primary 120mm Top Hat.

Set out, pre-drill and countersink the holes in the panels to be mounted, as set out in the table hereunder.
Screw holes must be pre-drilled, allowing 1 mm clearance over diameter of screw.
Holes must be drilled using a masonry drill bit.
Do not use an impact drill.
Where screws are to be countersunk, depth must be controlled by gauge to restrict head depth to 3 mm maximum.
Refer to Table 5 for Maximum Spacing of Panel Fasteners.

TABLE 5, FASTENER SPACING FOR 9 MM AND 12 MM DURACOM PANELS

DESIGN WIND
PRESSURE.
KPA
MAX. TOP HAT
SPACING.mm
MAX.
FASTENER
SPACING AT
PANEL EDGE
SUPPORTS.
mm
MAX.
FASTENER
SPACING AT
INTERMEDIATE
SUPPORTS.
Up to 1.0 600 300 600
1.5 600 300 400
2.0 600 250 400
3.0 450 400 400
4.0 450 300 250
5.0 450 300 250
6.0 450 300 200

Fix the bottom row of boards allowing a 15 mm overlap over the EPDM seal. Leave the top row of screws in the board loose to facilitate the insertion of the backing strip to the board.

 Use the backing strip to space the vertical joint of successive boards ensuring a uniform 10 mm space between successive boards.

Prepare the backing strip for installation by applying an appropriate sealer to the bottom (9 mm) edge of the backing strip or by applying the sealer to the top edge of the panel.

Insert the backing strip behind the top of the board.Leave fasteners loose, along the top edge of the panelsto facilitate insertion of backing strip.

Backing strip joint details – the backing strip has been designed to overlap whilst retaining a flush fit behind the board. Backing strip joints must overlap over a Top Hat and be sealed with two (2) beads of sealant to ensure a weather resistant joint.

Overlapping backing strip joint with two (2) beads of appropriate sealant, in position over
Top Hat section.

Installation of the next layer of board – Apply a bead of the appropriate sealer to the top of the backing strip and then rest a pre-drilled panel on the top of the horizontal backing strip.

INSTALLATION DETAILS

The architectural intent and details of buildings vary from one designer to the next, and the variety of facade details would be impossible to catalogue.

The detail diagrams following are intended to assist the designer in achieving a high quality weather resistant Duracom™ Facade.

The designer should not digress from the specification set out in this manual.

PENETRATIONS, OPENINGS, WINDOWS AND DOORS

There are numerous varieties of penetrations, openings, and windows and door treatments available, and each weather proofing detail will be dependent on the material, style and manufacturer’s specifications.

Adequate weather proofing of the opening application

must be considered by the building designer, in conjunction with the penetration, window and door manufacturer. The diagrams below are a guide only and the designer should consult with the appropriate manufacturers for the detail design to ensure adequate weather proofing.

CONTROL JOINT DETAILS

Structural movement vertical and horizontal control joints are required to match existing structural control joints and should pass through the facade.

The Duracom™ system utilises a flat galvanised 0.75 mm BMT steel strip.

This strip bridges the Top Hats on each side of the control joint and is riveted to one side only.

Sealant is applied between the strip and the Duracom™ panel creating a floating weather resistant seal that allows for joint expansion and contraction.

THERMAL BREAK DETAILS

Thermal breaks are required for steel framed buildings, in walls enclosing habitable and or useable spaces. Careful consideration of thermal heat transfer and the position of thermal breaks need to be addressed by the architects, engineers and building designers.

Thermal breaks should be installed between the Peer Top Hat sections and the Duracom™ cladding.

Balustrades, parapets, and other non-enclosing wall elements may not require thermal bridging, except where the possibility of high thermal heat transfer exists through the steel CFS sections to the main structural steel element of the building.

MOISTURE MANAGEMENT

Designers, specifiers and builders have a duty of care to identify moisture-associated risks with any individual building design.

Wall construction design should consider both the interior and exterior environments of the building to effectively manage moisture. Special consideration should be given to buildings that are in extreme climates or at higher risk of wind driven rain.

In addition, all wall openings, penetrations, junctions, connections, window heads, sills and jambs must incorporate appropriate flashing for waterproofing. All other components, materials and installation methods used to manage moisture in walls should comply with the relevant standards of the Building Code of Australia (BCA).

WARRANTY BGC FIBRE CEMENT PANELS

BGC warrants its products to be free from defects caused by faulty manufacture or materials. If any of its products are so defective the Company will at its option, repair or replace them, supply equivalent replacement products or reimburse the purchase price.

This warranty shall not apply to any loss or consequential loss suffered through or resulting from defects caused by faulty manufacture or materials.

Fittings or accessories supplied by third parties is beyond the control of BGC and as such is not warranted by BGC.

WARRANTY ON PEER INDUSTIES METAL COMPONENTS

For warranty information on the Peer Industries metal components specified in this design manual please contact Peer Industries on 1300 725 675 from anywhere in Australia.

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