Jan 11

QT Construction Detail

Slab & Floor

All foundations must comply with the relevant standards and local authority requirements, with appropriate consideration given to soil type. QT® EcoSeries Wall Panel is suitable for construction on concrete slab or suspended floors. The concrete slab can either be rebated or non-rebated. The slab rebate will need to be a minimum of 50mm below floor level and 100mm above paved level or 150mm above ground level (See local standards). To ensure a flush finish, the width of the slab rebate needs to allow for the thickness of the coating system, the thickness of the panel (40mm or 50mm), and the size of the extended wall cavity 20 – 50mm (30mm nom). Minimum ground clearances, must be maintained at all times during the life of the building. Insufficient clearance from the ground to the bottom of the wall panels will affect long-term durability.

Termites

The Building Code of Australia in conjunction with AS 3660 specifies the requirement for termite risk management. (See local standards).

The edge of a slab-on-ground may be used as a visual perimeter barrier. Provided that the slab edge is left exposed not less than 75mm above finished ground or paved level. The face of the perimeter must not be concealed by a flashing, rendered, tiled or clad.

The exposed edge of the slab must be kept clean and free of debris and regularly visually inspected for termite activity. QT® EcoSeries Wall Panel does not hold any nutritional value for ants or rodents.

Windows

Wherever possible windows and associated flashings should be installed prior to the installation of the QT EcoSeries Wall Panel. When ordering the window frame it is essential to plan where the window flange will be positioned either flush with the stud frame, flush with battens or even over the panel.

All materials that are susceptible to deterioration due to plastics migration or alkalinity of cement base products must be protected (check with product manufacturer).

Decorative Moulding

To provide added design flexibility, decorative mouldings or features can be made using QT To provide added design flexibility, decorative mouldings or features can be made using QT EcoSeries Wall Panels. The panel can be cut into bands or laminate multiple layers and shape to achieve the desired profile. Once installed, a coating system would then be applied. Alternatively, a wide range of decorative mouldings are available from various manufacturers. To provide added design flexibility, decorative mouldings or features can be made using QT EcoSeries Wall Panels. The panel can be cut into bands or laminate multiple layers and shape to achieve the desired profile. Once installed, a coating system would then be applied. Alternatively, a wide range of decorative mouldings are available from various manufacturers.

EcoSeries Wall Panels. The panel can be cut into bands or laminate multiple layers and shape to achieve the desired profile. Once installed, a coating system would then be applied. Alternatively, a wide range of decorative mouldings are available from various manufacturers.

EcoSeries Wall Panels can be cut into bands that can be installed around windows, doors, along horizontal control joints, etc to enrich the aesthetics of the project. They are installed so the top and bottom edge (bevelled at 15 degrees) falls away from the wall. Where bands
meet, they should be cut at a 45˚ angle, across the face of the corbel to help conceal the join and increase the adhered surface bond. Bands are bonded into place with polyurethane foam and corbel screws or nails to mechanically fix the bands until the foam is set.

Window Head Type 1

 Window Head Type  2

 Doors

Wherever possible windows and associated flashings should be installed prior to the installation of the QT EcoSeries Wall Panel. When ordering the window frame it is essential to plan where the window flange will be positioned either flush with the stud frame, flush with battens or even over the panel.

All materials that are susceptible to deterioration due to plastics migration or alkalinity of cement base products must be protected (check with product manufacturer).

Wall to Roof

Wall to roof details can often be unsightly as they are easily seen and hard to conceal without compromising the weathertighness of the dwelling. Because of its visibility, it is essential to create clean straight lines either by using a uPVC moulding or cover flashings.

Soffit & Eaves

The eaves or roof overhang play a significant role in the comfort performance of the building. Eaves or overhangs are used to shade the walls from the summer sun, while capturing the sun’s heat in the winter. Eaves will reduce glancing light, which highlights the wall surface. Glancing light is the light that is nearly parallel to the surface of the wall and casts visible shadows and uneven projections of the surface finish QT EcoSeries Wall Panels can be installed to suit various soffit designs and details.

 

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Jan 11

QT Coating System

Coating /Rendering

The proprietary coating systems consist of polymer-modified cement renders, which must be finished with an acrylic texture and paint. The proprietary coating manufacturer’s instructions and application requirements must be followed at all times. *(Available to download from the QT website) In most cases these coating systems must be applied by an approved applicator. High profile or heavy texture finishes can minimise surface imperfections or glancing light concerns. Light coloured coatings are recommended. Polymer-modified cement renders must not be applied over sealants or control joints.


Pre – Coating System Inspection

Check all internal and external corners are formed correctly and have good straight lines. Check the first horizontal course, and panels above rooflines have a good clean bottom line. Check weep holes have been installed in the first horizontal course. With a 1.8m spirit level check for variations greater than 3mm in the QT EcoSeries Wall Panels, especially where panels butt together. If variations are found, take the appropriate remedial action eg. rasp to an acceptable level, or re-fix the offending panels. It is important to eliminate large variations, as they may appear under critical or glancing light conditions. If the internal lining has not yet been installed, advise the building supervisor that internal wall lining cannot be installed using nails as the knocking vibrations will transfer through the frame and crack the render coatings (hairline cracking). Hence internal lining must be screwed. After the inspection has been completed, application of the base coat can begin.

Application of a Polymer Modified Render Base Coat.

Trowel an even coat of polymer-modified cement render over the entire QT® EcoSeries Wall Panel, embed QT® FullMesh into the wet Render, overlapping joints by 100mm minimum. Allow to firm and then screed and or float to a flat and level finish. The purpose of this coat is to even out the substrate and the porosity of the QT® EcoSeries Wall Panel. 150mm wide x 300mm long strips of QT® 45° Mesh are also required to be set into the base coat at 45° angle across the corner of all windows and door openings into wet render. Do not render or texture over control joints. The above is a generic guide only. Refer to the proprietary coating manufacturer’s instructions for a detailed description of application. Any proprietary coating system specified must meet or exceed the performance criteria of the BCA.

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Jan 11

Fire Rated Construction Details

Note: Prior to any firewalls being constructed it is essential that the builder consults with the project certifier to ensure that the certifier is aware of the firewall construction procedures and the certifier deems the installer competent.

Fire Resistance Level (FRL) is assessed by three performance measures:-

Structural Adequacy / Integrity /Insulation eg 90/90/90

FRL – 90 Mins. & External Fire Source

CSIRO Full-Scale Fire Test FS 3685/2695 has proven that the QT EcoSeries Wall System (shown right) is capable of achieving a fire resistance of 113 minutes Integrity and 115 minutes Insulation when tested in accordance with AS1530.4. Therefore for the purpose of Building Regulations in Australia, the QT EcoSeries Wall System achieved a fire resistance level (FRL) of 90/90/90. The FRL is applicable for exposure to fire source from the tested side (QT EcoSeries Wall Panel side).

Fire Test – FS3685-2695————– Specimen – Typical Cross Section Fire Rated Vertical Control Joint———— Fire Rated Horizontal Control Joint————

FRL – 90 Minutes

To achieve a 90 minute Fire Rating the wall must be constructed so as the wall consists of two layers of 13mm thick fire resistance plasterboard affixed to the timber frame internally and one layer of fire resistant building foil, one layer of 50mm QT EcoSeries Wall Panel with a 5-8mm render applied with finish, affixed directly to a 20-50mm battened out cavity. This system would be capable of achieving Fire Resistance Levels of -/90/90 for Non Load Bearing walls and 90/90/90 for Load Bearing Walls designed in accordance with AS1684 for fire exposure from either direction if tested in accordance with AS1530.4

90 Minute Fire Rated Wall

Extended Wall Areas

The Fire Resistance Levels of 60 & 90 minutes would still apply to the same system extended in height in modular form provided that the structural members are designed in accordance with the relevant structural design code for the height and load of actual installation and an approved joint system appropriate to the FRL and the width of the gap is used for the horizontal and vertical joints in a manner as detailed in the attached drawings.

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Jan 11

QT Finishing

Service

Ensure service pipes and wires are fixed or checked into the frame and not laid loose in the extended wall cavity. All materials that are susceptible to deterioration due to plasticiser migration must be protected (check with product manufacturer). Some PVC products or electrical cabling that penetrate the coating system and QT EcoSeries Wall Panel, require a conduit to ensure it is protected. Copper pipes require a sleeve, conduit or tape to prevent contact with the wall panel.

Penetrations

Voids or gaps created by service penetrations through the exterior wall require weatherproofing and or waterproofing. A common method is to inject with expandable polyurethane foam and seal with a long lasting exterior gap sealant to make a weather tight seal. Where practical add a flange or decorative feature over the hole or penetration.

Sealants

Use an exterior grade weatherproof sealant for exterior wall construction and as a general-purpose gap filling. Apply sealant in accordance to manufacturers recommendations. For a sealant to work effectively, the sealant must be applied as shown in the sketch below, Opening Width (D) x Depth (D/2) half the width. Use backing rod as required. Ensure surfaces are in good condition clean and free from oil, dust, loose materials including old sealant and release agents. Apply masking tape to surfaces where contact with sealant is not required. Tape should be removed before sealant cures. Smooth the surface of the sealant and ensure excess sealant is removed. Refer manufacturers curing or drying times before painting.


Heavy & Frequently Adjusted Fixtures

Heavy items are not to be fitted directly to the QT EcoSeries Wall Panel. They should have their own stand-alone supports or be tied to the supporting wall frame (eg. Clothes lines). Items subject to frequent handling (e.g. Flood-Lights and sensors) require a mounting plate, to be fixed across at least two or more frame studs to give longterm fixing support. The backing plate must be of a material that will offer, long-term weatherproof durability. If the internal lining is
already installed, the mounting plate can be installed externally prior to the installation of the QT
EcoSeries Wall Panel.

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Jan 11

QT Product Information

Storage and Handling

Care should be exercised in handling the QT®EcoSeries Wall Panels to avoid any damage to edges, ends and faces. Panels must be stacked flat, off the ground and supported on a level platform. Plastic Shrinkwrap applied to pallets of panels for transportation from the factory, must be removed at the destination (i.e. distributors warehouse or direct to site) to allow panel to continue drying and equalise with local humidity. The panels must be kept dry at all times by storing under cover, or providing weatherproof covers to the stack. Panels must be dry prior to fixing. Intermittent weather exposure is not detrimental to the panel. However if QT®EcoSeries Wall Panels become wet, allow thorough drying before fixing. Drying shrinkage may occur if the QT®EcoSeries Wall Panels are not allowed to dry sufficiently. The proprietary Coating System must be applied and completed within 1 month from the date of installation of the TEcoSeries Wall Panels.

QT®EcoSeries Wall Panels and cement based renders, will release their salts and/or fines if saturated; this condition is know as efflorescence. In order to prevent efflorescence the cement products must be sealed to prevent the ingress of moisture and/or installed with careful attention to the weather-tightness details to prevent the ingress of wind driven rain, gutter overflow or moisture tracking along a surface with capillary action. The water that has permeated through the panel and render will collect and dissolve any salts and/or fines that are then released through hairline cracking in the render which are caused by hydrostatic pressure build up. The dissolved salts and/or fines will crystallise on the external surface. Should efflorescence occur, it is essential that the moisture source be eliminated and any hairline cracking repaired to maintain weathertightness. Refer to coating manufacturer for suitable surface repair techniques.

Panels must always be carried on edge. Any minor damage should be repaired with joint compounds or polyurethane foam. Fixings and other accessories must be stored so that they are kept clean, dry and undamaged. All components must be used within the designated shelf life. Any damage to Clips and Channel may affect the integrity or performance of the wall system. Panel may be cut with an electric circular saw 60 pt tungsten tip blade, diamond blade or handsaw. Panels are best shaped with the use of an electric plane or a handrasping tool. Holes or services may be formed with the use of an electric fretsaw or drill. When power tools are used for cutting, grinding or forming.

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Jan 11

CSR Hebel Introduction

CSR Panel Systems is a division of CSR Building Products Limited, one of Australia’s leading building products companies.

CSR Panel Systems manufactures Hebel® Autoclaved Aerated Concrete (AAC). The AAC in Hebel® products is manufactured from sand, lime and cement to which a gas-forming agent
is added. The liberated gas expands the mixture, forming extremely small, finely dispersed air pockets, resulting in lightweight aerated concrete.

CSR Panel Systems has manufactured Hebel® products that have won wide acceptance as innovative and environmentally preferable building materials. This is due to their lightweight nature, excellent thermal, fire and acoustic properties and design versatility. These inherent properties of Hebel® products help achieve quick and cost efficient construction practices
as well as providing for comfortable operating environments inside the buildings all year round.

Build a premium home with Hebel PowerBlock.

Hebel® PowerBlocks are large AAC Blocks with a standard face dimension of 600mmx200mm, laid in much the same way as bricks but using Hebel® Adhesive to form
a monolithic structure. Typically, external walls use a single skin of 250mm thick blocks while internal, non-loadbearing walls use 100mm thick blocks. Hebel’s tight manufacturing tolerances deliver beautifully flat, true surfaces that are easily rendered and painted.

Walls built with Hebel® PowerBlock are strong and durable, providing the security of solid masonry coupled with exceptional thermal and acoustic insulation properties. With over three
times the thermal resistance of double brick, Hebel® PowerBlocks exceed the Building Code of Australia (BCA) for energy efficiency regulations for zones 1,2, 3 and 5 without the need for additional bulk insulation.

Hebel® PowerBlocks are non combustible and can achieve an Fire Resistance Level (FRL) of up to 240/240/240.

For detached houses, this is well above the requirements for building right up to the boundary line and making Hebel® an ideal choice for bushfire prone areas.

Compared to traditional double brick construction, Hebel® PowerBlock™ walls can be laid much faster, saving building time and costs. Building with Hebel Blocks may create more internal floor area for the same building dimensions. Hebel® Lintels can be used over windows, doors and garage door openings. Hebel® also supplies sill blocks for under windows to complement the overall look of your home.

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Jan 11

CSR Hebel Benefits

The many benefits of using Hebel PowerBlocks include:

Solid and strong:

Hebel PowerBlocks are made from Autoclaved Aerated Concrete (AAC), a strong, solid masonry building material with the advantage of being 25% the weight of conventional concrete.

Acoustic Performance: Significantly reduced sound transmission from room-to-room.

Thermal Resistance: Unique thermal properties result in a more stable inside temperature, reducing the energy required to heat and cool your home, thereby reducing energy bills.

Environmentally friendly: 73% less embodied energy and 61% less greenhouse gas emissions than comparative masonry products*. *Source: LCA Report GECA 2006.

Fire Protection: Non-combustible blocks with frameless construction deliver superior fire resistance. Hebel PowerBlock systems also allow you to build right up to your boundary line.

Pest resistance: Not a food source for termites or vermin and no cavity construction liminates the chance of harbouring pests.

Design Freedom: Hebel PowerBlock Wall Systems provide absolute freedom to design and build your ultimate dream home – without compromise.

Technical Support: Competent technical support through Hebel distributors.

Energy Efficiency

The unique combination of thermal resistance and thermal mass make building with Hebel
a smart choice for meeting Australia’s stringent building regulations.

The thermal performance of a building depends on a number of factors such as orientation and size and aspect of windows. The R-Value of walls and floors can significantly affect the energy-rating outcome of dwellings. A 250mm Hebel PowerBlock has 3 times the R-Value of a cavity brick wall (BCA Vol. 2 Figure 3.12.1.3). The use of Hebel in walls and floors will provide increased thermal performance that can allow more

flexibility with other design aspects of a building.

The thermal efficiency of Hebel systems will also reduce the reliance on heating and cooling appliances. The combined effects of running a heater less in winter and fans or air conditioning less in summer can have a big impact on energy costs and the environment.

Single Skin Construction

The AAC masonry constructed from Hebel PowerBlock products is called “Plain Masonry” and the blocks are masonry units referred to as a “Solid Unit”. The type of solid unit is “Autoclaved aerated concrete masonry unit” complying with AS/NZS 4455 – Masonry Units and Segment Pavers.The larger face dimension and being a single skin, Hebel PowerBlock walls are erected quickly when compared to double brick construction.

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Jan 11

CSR Hebel Energy Efficiency

Table 3.1 shows a number of different external wall configurations and identifies which satisfy the BCA requirement for Climate Zones 1 to 8. Table 3.2 lists the component R-Values used as a basis for Table 3.1. For more information on Hebel and energy efficiency refer to Section 3 and Appendix C and D of the Hebel Technical Manual.

Table 3.1:  BCA Energy Efficiency Compliance.

Wall Configuration Satisfies BCA Requirements
Climate Zone: 1* 2* 3* 4 5 6 7 8
Class 1 & Class 10a Minimum R-Value: 1.4 1.4 1.4 2.2 1.9 2.2 2.4 3.3
   1. 250mm Block Only Y Y Y N Y N N N
   2. 250mm Block + 25mm Cavity Y Y Y Y Y Y N N
   3. 250mm Block + 25mm Cavity + Sarkin Y Y Y Y Y Y Y N
   4. 250mm Block + 25mm Cavity + 75mm PowerPane Y Y Y Y Y Y Y N
   5. 250mm Block + 40mm Cavity + R1.0 InsulatioN Y Y Y Y Y Y Y N
   6. 250mm Block + 25mm Cavity + Double Sided RFL + 25mm Cavit Y Y Y Y Y Y Y Y
   7. 250mm Block + 90mm Cavity + R2.0 InsulatioN Y Y Y Y Y Y Y Y

*Note: For elevated ground floor slabs an R-Value of 1.9 is required.

Table 3.2:  Wall Element R-Value.

System Number Construction Overall Thickness R-Value Rw Rw
+ C
tr
401 8mm Render in Texture Coat and Paint
250mm Hebel PowerBlock
10mm Gyprock
268 mm 2.1 48 43
402 8mm Render in Texture Coat and Paint
250mm Hebel PowerBlock
28mm furring channels @600mm centres
10mm Gyprock
296mm 2.3 51 43
403 8mm Render in Texture Coat and Paint
250mm Hebel PowerBlock
28mm furring channels @600mm centres
Non reflective (normal sarking)
10mm Gyprock
296mm 2.3 51 43
404 8mm Render in Texture Coat and Paint
250mm Hebel PowerBlock
28mm furring channels @600mm centres
Reflective foil
10mm Gyprock
296mm 2.6 51 43
405 8mm Render in Texture Coat and Paint
250mm Hebel PowerBlock
28mm furring channels @600mm centres with 50mm 11kg – Bradford Glasswool
Non reflective (sarking)
10mm Gyprock
296mm 3.1 53 44
406 8mm Render in Texture Coat and Paint
250mm Hebel PowerBlock
8mm Render in Texture Coat and Paint
216mm 2.1 48 43

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Jan 11

CSR Hebel Fire and Acoustic

Fire

Hebel AAC has a BCA Group Number 1. Hebel PowerBlock  walls satisfy BCA2008
Vol.2 Clause 3.7.1.5 (a) (iii) masonry construction and therefore suitable for boundary wall construction on a Class 1 building.

Acoustic

Table 5.1 provides acoustic performance levels for PowerBlock walls. For alternatives and composite wall construction, Table 3.2 are acoustic performance for PowerBlock  systems.

Table 5.1:  Acoustic Performance

   PowerBlock Thickness Rw Rw+ Ctr
100 38 35
150 43 40
250 45 42

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Jan 11

CSR Hebel Design Approach

There are 2 methods of construction – typical and tie-down. Typical is the most common method of building whilst the tie-down method is required for cyclonic or high wind areas (as determined by an engineer). This guide provides information for both building methods.

Important Note

It is the responsibility of the architectural designer and engineering parties to ensure that the information in the Hebel PowerBlocks Design and Installation Guide is appropriate for the intended application. The recommendations of this guide are formulated along the lines of good building practice, but are not intended to be an exhaustive statement of all relevant data. Hebel  accepts no responsibility for or in connection with the quality of the recommendations or their suitability for any purpose when installed.

Scope

The Hebel® PowerBlocks Design and Installation Guide has been created to provide information for detached residential buildings. The design information in this guide has been condensed from the Hebel® Technical Manual and AS3700 Masonry structures. The design basis is AS3700 Masonry structures, Section 12 Simplified design of masonry for small buildings. The footing and slab design is based on AS2870 Residential slabs and footings – Construction.

Refer to Table 6.1 for Building Geometry Limitations.

Design Parameters

The structural design information in this guide is based on the data and assumptions in Table 6.2, 6.3 and 6.4.

Design Sequence

Fig. 6.1 details Hebel® recommendations for how to design a Hebel® PowerBlock home.

Design Flow Chart

Determine the soil classification, terrain category and wind region/loads

Footing type (slab or strip footing)

PowerBlock™ design based on BCA requirements, loadings, wall heights
and lengths (external & internal)

Design the bracing and tie down methods

Determine any additional BCA requirements (thermal, fire and sound ratings)

Complete project documentation (drawings & specification)

Table 6.1: Buiding Geometry Limitations

2 storeys max
Max. height to underside of eaves 6.0m
Max. height to top of roof ridge 8.5m
Max. building width incl. verandah but not eaves 16.0m
Max. building length 5x width
Max. lower storey wall height 3.0m
Max. upper storey wall heigh 2.7m
Max. floor load width on external wall 3.0m (6.0m single span floor)
Max. roof load width on external wall 3.0m (6.0m rafter/truss span)
Max. floor load width on internal wall 6.0m

 

Where the building geometry is outside the above limitations, the designer must refer to the Hebel® Technical Manual and AS3700 Sections 1-11.

Table 6.2: Design Parameters.

Hebel® PowerBlock™ material properties
Nominal Dry Density 470 kg/m2
Working Density (S.T.) 611 kg/m2
Working Density (L.T.) 500 kg/m2
Characteristic Compressive Strength, f’m 2.25 MPa
Characteristic Flexural Tensile Strength, f’mt 0.20 MPa
Characteristic Shear Strength, f’ms 0.30 MPa
Characteristic Modulus of Elasticity, EST 1125 MPa
Characteristic Modulus of Elasticity, ELT 562 MPa

 

Table 6.3 Design Parameters – Permanent and Imposed Actions

Permanent Actions (Dead Loads):
Floor – Superimposed 1.00 kPa
Roof – Tile 0.90 kPa
Roof – Sheet 0.40 kPa
Framed Floor/Deck – Timber 0.50 kPa
Framed Deck – Tile 0.50 kPa
Pergola Roof – Tile 0.80 kPa
Pergola Roof – Sheet 0.32 kPa
Hebel® PowerFloor System 0.80 kPa
Hebel® Floor Panel System – 250mm 1.90 kPa
Hebel® PowerBlock Wall – 250mm, 2700mm (H 4.60 kN/m
Hebel® PowerBlock Wall – 150mm, 2700mm (H) 2.76 kN/m
Imposed Actions (Live Loads):
In accordance with AS 1170. 1:2002
Floor – general 1.50 kPa
Deck 2.00 kPa

Table 6.4  Design Parameters – Wind Actions (General wall areas)

Wind Classification(AS4055) Wind Pressure (kPa)
Serviceability, Ws Ultimate, Wu
N1 0.41 0.69
N2 0.41 0.96
N3 0.61 1.50
N4 0.91 2.23
N5 1.33 3.29
N6 1.82 4.44
C1 0.61 2.03
C2 0.91 3.01
C3 1.33 4.44
C4 1.82 5.99

Hebel PowerBlock home

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