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 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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Jan 09

CSR Hebel Structure

Slabs and Strip Footings

Site Classification

Site Classifications are generally carried out for new housing developments, be they part of a subdivision or an individual allotment. The purpose of the site classification is to assess the subsurface conditions and therefore enable determination of the most appropriate foundations/ floor slabs (i.e. the classification will generally determine the appropriate dimensions for house footings and / or floor slabs).

Site Classification is carried out in accordance with the Australian Standard AS2870-1996: “Residential Slabs and Footings”.

The available Classes include S (slightly reactive), M (moderately reactive), H (highly reactive), E (extremely reactive), or P (problem site). Classes S, M, H, and E refer generally to sites in which clayey soils will form the founding strata. The classification indicates how reactive the clay subsoil is to changes in moisture content. The reactivity (shrinking and swelling) of the clay can have a significant impact on the footings/slabs of a building slab, which need to be designed to counteract the movements of the clay soils.

Sites classified as Class P generally present difficulties for the proposed construction. The P classification more often than not suggests deep and/or uncontrolled fill, which cannot provide suitable bearing for the house. In these situations, the house is either founded on the stable materials beneath the fill (i.e. deep footings/piers), or the fill is removed and replaced with compacted, controlled fill.

Slab Design

All Hebel PowerBlock homes must have footings and slabs designed to AS 2870Full Masonry”. Local engineering advice should always be sought.

Fig 7.1.1 Isometric Concept House Fig 7.1.2:  Slab on Ground Table 7.1.1 Slab on Ground

SITE CLASS TYPE OF CONSTRUCTION EDGE AND INTERNAL BEAMS SLAB MESH
Depth (d) mm Bottom Reinforcement Max. Spacing Centre to Centre (m) Setdown (s) mm Width (b) mm Slab Length <18m Slab Length <18m & <25m Slab Length <25m & <30m
CLASS ‘A’ Hebel Masonry Wall 400 3-L8TM 50 350 SL72 SL82 SL92
400 3-L8TM 100 350 SL72 SL82 SL92
400 3-L8TM 150 400 SL72 SL82 SL92
400 3-L8TM >200 450 SL72 SL82 SL92
CLASS ‘S’ Hebel Masonry Wall 400 3-L11TM 5.0 (Note 1) 50 350 SL72 SL82 SL92
400 3-L11TM 5.0 (Note 1) 100 350 SL72 SL82 SL92
400 3-L11TM 5.0 (Note 1) 150 400 SL72 SL82 SL92
400 3-L11TM 5.0 (Note 1) >200 450 SL72 SL82 SL92
CLASS ‘M’ Hebel Masonry Wall 500 3-L12TM 4.0 50 350 SL82 SL82 SL92
500 3-L12TM 4.0 100 350 SL82 SL82 SL92
500 3-L12TM 4.0 150 400 SL82 SL82 SL92
500 3-L12TM 4.0 >200 450 SL82 SL82 SL92
CLASS ‘M-D’ Hebel Masonry Wall SITE SPECIFIC ENGINEERING REQUIRED
CLASS ‘H’ Hebel Masonry Wall SITE SPECIFIC ENGINEERING REQUIRED
CLASS ‘H-D’ Hebel Masonry Wall SITE SPECIFIC ENGINEERING REQUIRED
CLASS ‘P’ Hebel Masonry Wall SITE SPECIFIC ENGINEERING REQUIRED

GENERAL NOTE: This table is to be read in conjuntion with the requirements of AS2870 and AS3600. NOTES:

  1.  A 10% increase in the spacing is permitted where the spacing in the other direction is 20% less than specified.
  2. Where the number of beams in a particular direction satisfies the requirements of the maximum spacing given above, the spacing between individual beams can be varied provided that the spacing between any two beams does not exceed the spacing given in the above figure by 25%. These allowances for increased beam spacings do not override the maximum spacings between edge beams and first internal beams as required by clause 5.3.9.
  3. For two storey timber framed floor or Hebel floor panel construction, the width of the edge beams must be increased by 100mm and the bottom reinforcement must be increased by one bar of the same diameter.

Fig 7.1.3:  Strip Footing, Double Brick Sub-Floor

Fig 7.1.4:  Strip Footing, Concrete PowerBlock Sub-Floor

Table 7.1.2 – Strip Footing

Site Class Type of Construction Depth (d) mm Width (b) mm Reinforcement
CLASS  ‘A’ Hebel Masonry Wall 300 450 4-L8TM
CLASS ‘S’ Hebel Masonry Wall 400 450 4-L11TM
CLASS ‘M’ Hebel Masonry Wall 600 450 4-L12TM
CLASS ‘M-D’ Hebel Masonry Wall Site Specific Engineering Required
CLASS ‘H’ Hebel Masonry Wall Site Specific Engineering Required
CLASS ‘P’ Hebel Masonry Wall Site Specific Engineering Required

GENERAL NOTE: This table is to be read in conjunction with the requirements of AS2870 and AS3600. NOTES:

  1. For all beams 700mm or deeper, as specified in the table above, internal footings shall be provided at no more than 6m centres, and at re-entrant corners to continue the footings to the opposite external footing.
  2. Internal strip footings shall be of the same proportions as the external footing and run from external footing to external footing ‘side slip joints’ consisting of a double layer of polyethylene shall be provided at the sides of the footing only.
  3. Provide ventilation to the sub-floor in accordance with the BCA.

Sub-Floors On Elevated Sites Hebel PowerBlock must not be used at or below ground level. When building a Hebel PowerBlock structure on a sloping site that is not suitable for a concrete slab, a solid core-filled concrete block or brick substructure may be erected on a strip footing to raise the building and floor system to a level that is clear of the ground resulting in a level building platform that allows sufficient airflow under the floor. The first course of Hebel PowerBlocks must be laid on a DPC to stop rising damp and to act as a bond breaker between the different building elements. Termite Protection Hebel PowerBlocks are not a food source for termites. Solid wall construction still requires termite protection. There are many methods to protect your home against a termite invasion and a qualified professional pest control should be consulted to determine the most suitable method for your design. The Building Code of Australia recognises an exposed slab edge to a depth of 75mm above finished ground level as adequate termite prevention. For masonry sub-floor construction a continuous ant cap installed between the brick/ concrete block work and the Hebel PowerBlock also satisfies the Building Code of Australia termite protection requirements.

Hebel PowerBlock Walls

Generally, the minimum recommended wall thickness is:

  • 250mm for external walls
  • 150mm for internal load-bearing walls.
  • 100mm for internal non-load bearing walls.

Hebel suggests considering a wall as having top and bottom lateral restraints only (one-way vertical span) and designing the appropriate wall thickness, so that retrofitting or changing the location of the movement joints will not be detrimental to the lateral load capacity of the wall. In determining the appropriate wall thickness, the designer shall consider a range of factors relating to relevant codes and project specific considerations, these factors may include:

  • Movement joint location
  • Bracing considerations
  • Vertical (compression) loading
  • Out of plane wind/earthquake (lateral) loading
  • Required fire rating level (FRL).

The particular project loading configurations could result in walls that exceed the above minimum requirements. Ring Beam (for standard trussed roofs) A ring beam must be provided at the base and top of perimeter Hebel walls. The ring beam is 60mm x 60mm with 1N12 bar centrally located. Shear connection ties are to be placed at the location of control joints at 600mm spacings (vertically). See Fig 7.2.1 for ring beam details.

Fig 7.2.1 Typical Hebel Ring Beam Detail

Bond Beam (for vaulted roofs) A bond beam is a continuous beam around the perimeter of a building for the purpose of providing lateral stability and bracing to the walls for vaulted/ cathedral roofs, to minimise cracking at openings. As a minimum, bond beams are to be located at the top of the walls for each floor level, or at a maximum vertical spacing of 3m. Bond beams are constructed of reinforced concrete which is poured in situ between two Hebel PowerBlocks. The minimum dimension of the bond beam must be 100mm wide and 200mm high. Bond beam reinforcement should be not less than 2 rows of 12mm deformed bars placed top and bottom in the centre of the beam (overlapped at least 400mm where it joins). Where bond beams intersect a control joint, it is important to continue the control joint through the beam. The reinforcing bars must pass through the control joint and terminate 400mm past the joint. Where the reinforcing bars are bridging the control joint, the bars that extend for the 400mmshould be fitted into conduit sleeves to allow the wall to expand and contract without causing excessive stress on the wall. Bond beams must be continuous around a built-in corner. The ring beam at the base is still required. See Fig. 7.2.1.

Fig 7.2.2 Typical Hebel Bond Beam Detail

Compression The assessment of Hebel PowerBlock wall compression capacity in this Design and Installation Guide is based on the scope of this design guide (see Section 6.0 and Table 6.1). Three top support conditions are applicable:

  1. Supporting concrete slab above (see Section 14 and Fig. 14.26).
  2. Supporting floor other than concrete slab above (see Section 14 and Fig. 14.28).
  3. Face supported framed floor (See Section 14 and Fig. 14.27).

No vertical support of the wall is considered as worst case in the compression capacity assessment. Under that constraint and for wall heights up to 3000mm:

  • 250mm load-bearing external PowerBlock walls have adequate compression capacity for all top support conditions.
  • 150mm load-bearing internal PowerBlock walls to 3000mm height have adequate compression capacity for the first two top support conditions, but is not suitable for face loaded framed floors. If face loaded timber framed floors are designed both sides of the wall, their spans are within 20% and loading is the same, this can be considered top support condition 2. Otherwise 250mm Hebel PowerBlock wall is required.

Roof loading on top of the wall through the top plate is considered top support condition 2. Bending 250mm Hebel PowerBlock walls up to 3000mm height have adequate bending capacity without edge support in wind classifications N1 to N3. Table 7.2.1 provides maximum wall lengths between edge restraints for wind classifications N4 to N6 and C1 to C4. Both ends of these walls must have edge support. Edge support must be an engaged perpendicular wall (bracing wall) or a built-in 89x89x5 SHS column. The designer must detail the plate connections at the base and top of the SHS column and specify adequate ties to the Hebel PowerBlock work. Shear Horizontal forces, such as wind and earthquake loading, applied to a building are to be resisted by bracing walls. Bracing walls are located generally at right angles to the walls subjected to these forces. All bracing components in the building shall be interconnected to adequately transfer the imposed loads to the footings.

Table 7.2.1

Wind Classification Maximum Wall Length Between Edge Supports (m)
N4 3.4
N5 2.6
N6 2.1
C1 3.7
C2 2.8
C3 2.1
C4 1.8

Refer to Appendix K in AS3700 for total ultimate racking forces for houses in wind classifications up to N4/C2. Those tables are based on wall height up to 2700mm. For wall height greater than 2700mm up to 3000mm, factor up the loads by 15%. Earthquake categories H1 and H2 are covered by N3/C1 tables and earthquake category H3 is covered by N4/C2 tables. Table 7.2.2 provides ultimate racking capacities of unreinforced 150mm and 250mm Hebel PowerBlock walls. This table does not include sliding which the designer must also check depending on compression loads on wall in all wind cases and dowel action at base of wall through hold-down rods. Lintels General The minimum bearing lengths at the end of all Hebel lintels is 150mm or L/8, whichever is greatest. The bearing PowerBlock must extend past the end of the lintel by min. 100mm. Hebel Lintels Hebel lintels are reinforced sections similar to panels. The lintels are used as supports over doorways, windows and other opening. Lintels shall be installed so that the surface marked ‘THIS SIDE UP’ is uppermost, as the section reinforcement may not be symmetrical. Hebel lintels are not to be cut on-site. Table 7.2.4 presents the range of standard Hebel lintels and the associated capabilities. For larger spans, use structural steel lintels as designed by the project structural engineer. Steel Lintels Can be used to support PowerBlock work above openings. refer to Tables 7.2.5 and 7.2.6. Control Joints During the life cycle of a building, the building and the materials that it is constructed from will move. These movements are due to many factors working together or individually, such as foundation movement (shrinkage and swelling), thermal expansion and contraction, differential movements between materials, climate and soil condition. This movement, unless relieved or accommodated for, will induce stress in the materials, which may be relieved in the form of cracking. To accommodate these movements and relieve any induced stresses, control joints (vertical gaps) shall be installed to minimise cracking in Hebel masonry walls. Location of Control JointsWhere control joints are required they are best positioned:

  • At no more than 6m spacing unless more stringent requirements are specified in accordance with AS 2870.1996.
  • At intersecting walls and columns.
  • At changes of wall height or thickness, or where chases occur.
  • To coincide with movement joints in adjacent elements of structure (floor or roof).
  • At junctions of dissimilar materials.
  • Where architectural or structural features create a ‘weak’ section.

Movement joints are not normally required below DPC level. Construction of Control Joints Straight, unbonded vertical joints are the most common type of control joint. Typically, the vertical joint is 10mm wide and filled with an appropriate backing rod and flexible sealant. Where stability of the design requires continuity across the joint, Hebel control joint ties should be set in every second bed joint. Movement joints must be continuous through the entire block wall and all surface finishes. When the control joint is aligned with a window or door opening, the joint must be continuous and may need to be offset to deal with the lintel spanning the opening. In such a case a slip joint must be provided under that end of the lintel. Control joints must also be continuous through any bond beams which have been installed in the wall. This can be achieved by breaking the bond beam at this joint during it’s construction. To maintain lateral strength and continuity of the bond beam, the reinforcing rods should bridge the joint with one side of the beam having conduits cast in for the rods to slide while still keeping the wall in plane. The control joints should be installed as the wall is being constructed as the joint ties must be installed in the centre of the block ensuring the tie is fully bonded with Hebel adhesive. Service Penetration To penetrate services through Hebel walls, core out an appropriate sized hole (typically 10mm larger diameter than the service) and run the service through. A flexible sealant should be used to seal the gap around the service, this will also prevent any cracking/movement issues that may occur with the stress imposed on the blocks if the services were placed hard against the Hebel PowerBlock.. For penetrations through fire rated walls, an appropriate fire collar must be used with fire rated sealants. To affix the services to the Hebel walls please refer to the fixing guide in this manual. Chasing Services Into Hebel

  • Services should be run through cavities where possible to avoid unnecessary chasing into Hebel.
  • Where chasing is necessary some basic guidelines need to be followed.
  • – All Hebel products 100mm or less must not be chased
  • – All chases must comply with the BCA
  • – The depth of the chase must not exceed 25mm
  • – The width of the chase must not exceed 25mm
  • – The maximum number of chases allowed is 2 chases per 1 metre length of wall.
  • – All chases must be backfilled with a material that will adhere to the wall (Hebel Patch or a sand /cement patching mix).
  • – Chasing can be done with a Hebel Hand Router or a power router fitted with dust extraction.

Table  7.2.2 Unreinforced Wall

Wall Length (mm) Ultimate Racking Capacity (kN)
150mm PowerBlock 250mm PowerBlock
900
1200 0.5
1800 1.0 1.5
2400 1.5 2.5
3000 2.5 4.0
3600 3.5 6.0
4800 6.5 10.5
6000 10.0 16.5

Table 7.2.3 Top-Plate & Hold-Down selection Table

Wind Classification Top Plate & Hold-Down
Tile Roof Sheet Roof
N1 A / B / C B / C
N2 A / B / C D / F
N3 D / F D / F
N4 D / F D / F
N5 E / G E / G
N6 E / G E / G
C1 D / F D / F
C2 E / G E / G
C3 E / G E / G
C4 G G
Legend
A 90×45 F7 timber top plate / 700mm deep strap @ 1200mm ctrs.
B 90×45 F17 timber top plate / 1700mm deep strap @ 2400mm ctrs.
C 90×45 F17 timber top plate / Ф12mm rod @ 2400mm ctrs.
D 90×45 F17 timber top plate / Ф12mm rod @ 1200mm ctrs.
E 90×45 F17 timber top plate / Ф12mm rod @ 900mm ctrs.
F 100x50x3.0 RHS top plate / Ф12mm rod @ 2400mm ctrs.
G 100x50x3.0 RHS top plate / Ф12mm rod @ 1200mm ctrs.

Table 7.2.4: Lintel Selection – Hebel Lintel

Opening Width (mm) Single Storey or Upper Level of Double Storey Lower Level of Double Storey
Tile Roof Sheet Roof
Tiled Roof Sheet Roof Floor Panel PowerFloor Floor Panel PowerFloor
900 A A A A A A
1200 B B B B B B
1500 B B B B B B
1800 C C C C C C
2100 D D D D D D
2400 D D D D D D
2700 E E E E E E
3000 E E E E E E
3300
3600
3900
4200
Legend (Hebel product code)
A 22046 + 22047
B 22038 + 22039
C 22041 + 22042
D 22043 + 22044
E 82066 + 82067

NOTE:Hebel lintel for 250mm external wall comprises 100mm lintel on outside face and corresponding 150mm lintel on inside face. Top plate to bear across both lintels, min. 25mm bearing on 100mm lintel.

Table 7.2.5: Lintel Selection – Equal Angle

Opening  Width  (mm) Single Storey or Upper Level of Double Storey Lower Level of Double Storey
Tile Roof Sheet Roof
Tiled Roof Sheet Roof Floor Panel PowerFloor Floor Panel PowerFloor
900 A A A A A A
1200 A A A A A A
1500 A A D C D B
1800 A A E E E E
2100 B A F E E E
2400 D B F F
2700 E C
3000 E E
3300 E E
3600 E
3900 E
4200 F
Legend
A 2/100X100X6 EA
B 2/100X100X8 EA
C 2/100X100X10 EA
D 2/100X100X12 EA
E 2/150x100x10 UA
F 2/150x100x12 UA

Table 7.2.6: Lintel Selection – Galintel

Opening  Width  (mm) Single Storey or Upper Level of Double Storey Lower Level of Double Storey
Tile Roof Sheet Roof
Tiled Roof Sheet Roof Floor Panel PowerFloor Floor Panel PowerFloor
900 A A A A A A
1200 A A A A A A
1500 A A A A A A
1800 A A A A A A
2100 B A A A A A
2400 E D D D D B
2700 E D D D E D
3000 E E E D E D
3300 E E E
3600 F E
3900 E
4200
Legend
A Multi-Rib T-Bar – 200x200x7
B Multi-Rib T-Bar – 200x200x9
C Traditional T-Bar – 200×10/200×10
D Traditional T-Bar – 250×10/200×10
E Traditional T-Bar – 250×12/200×10

Floor Panel Systems

Hebel Floor Panels are reinforced AAC panels designs as loadbearing components in commercial, industrial and residential construction applications. A preliminary thickness of the floor panel can be determined from table 7.3.1 in this guide. Contact your local distributor to confirm the selected floor panel thickness is adequate for the design parameters of span, load, deflection, limit and fire resistance level rating. After the panels are laid, reinforcing bars are placed between the panels in the recess and around the perimeter of the floor to form the ring anchor system in accordance with Hebel specifications. The joints and ring anchor sections should be lightly pre-wetted, filled with minimum 15 MPa concrete grout, and rodded to ensure complete and level filling of the notch and groove. A mix of CI:S3:A2 (5mm maximum coarse aggregate) with 150mm slump is usually suitable. The grout should completely cover the reinforcing. The hardness of Hebel Floor Panels is greater than the PowerBlocks. When ring anchors are placed accurately and mortar is poured carefully and screeded properly, the surface is level and smooth. When Hebel panels are used in external floor areas such as patios or balconies, it is important to use an approved waterproofing membrane. Hebel Floor Panels provide an excellent, solid, stable base for tile, slate, marble and other hard surface flooring, including bathroom, laundry and other wet area applications. The smooth flat surface is also perfectly suited to carpet, vinyl, timber boards, parquetry and decorative plywood flooring. Panels in General Panels should not be cut on site unless they are ordered as cuttable. It is preferred they are ordered from the factory at the desired length. Where panels have been cut the exposed reinforcing should be with coated with Hebel corrosion protection compound or an approved equivalent. Hebel panels are supplied ready for use. They can be simply and easily laid into position with only the joints needing to be mortared. Installation is therefore largely dry and generally no formwork or bracing is necessary. The reinforcing in the panels is custom designed for each project. Panels installed on Hebel PowerBlock work or steel beans can offer a flooring system that can be laid down exceptionally fast. As well as providing the benefits of rapid construction, differential movement between floors and walls is minimised. Framed Floors Hebel PowerBlock construction can incorporate floor construction using joists. Typically the joists are installed onto bearing plates which distribute the floor loads evenly into the supporting blocks. Hebel PowerBlocks are easily shaped to infill between the joists. The infill blocks will provide support for the blocks above the floor framing. Image 7.3.1:  Installed Floor Panels Table 7.3.1: Hebel® Structural Floor Panels With Flexible Coverings / No Walls Above (L/250 deflection)

Maximum Panel Length (metres)
Live Load (kPa) 1.5 2.0 3.0
Superimposed Dead load (kPa) 0.0 0.5 1.0 0.0 0.5 1.0 0.0 0.5 1.0
PanelThickness(mm) 150 (4.00) 4.00 3.82 3.60 3.94 3.68 3.49 3.64 3.45 3.30
175 (4.50) 4.50 4.40 4.16 4.50 4.25 4.03 4.20 4.00 3.83
200 (5.00) 5.00 5.00 4.73 5.00 4.83 4.60 4.78 4.56 4.38
225 (5.50) 5.50 5.50 5.24 5.50 5.35 5.10 5.30 5.06 4.86
250 (6.00) 6.00 6.00 5.77 6.00 5.88 5.63 5.83 5.58 5.37

With Rigid Coverings / Walls Above (L/600 deflection

Maximum Panel Length (metres)
Live Load (kPa) 1.5 2.0 3.0
Superimposed Dead load (kPa) 0.0 0.5 1.0 0.0 0.5 1.0 0.0 0.5 1.0
PanelThickness(mm) 150 (4.00) 3.77 3.55 3.39 3.54 3.36 3.22 3.20 3.07 2.96
175 (4.50) 4.31 4.09 3.92 4.05 3.87 3.73 3.68 3.55 3.44
200 (5.00) 4.88 4.66 4.48 4.60 4.41 4.26 4.19 4.05 3.94
225 (5.50) 5.42 5.18 4.98 5.11 4.91 4.75 4.66 4.51 4.39
250 (6.00) 5.94 5.70 5.50 5.62 5.42 5.25 5.13 4.98 4.85

NOTES TO FLOOR PANEL TABLES: • Length is calculated based on the minimum bearing. • Minimum bearing is panel length /80 but not less than 60mm. • Maximum clear span is panel length less than 2x minimum bearing. • (Length) is maximum standard panel length in metres. Decks, Verandahs and Pergolas When attaching a deck, verandah roof or pergola to your Hebel PowerBlock Wall, the building designer / project engineer must calculate and determine the loads that will be imposed on the Hebel PowerBlocks. For conditions equal to or less than those outlined in table 7.4.2, a timber or steel waling plate may be attached to the block wall as shown in Section 14 details 14.34 and 14.35. This must be affixed using the appropriate number and type of fixings as outlined in Tables 7.4.1 and 7.4.2. The fixings must be either Fischer Injection Mortar 10mm x 80mm long or Ramset Injection Mortar 12mm x 160mm long. Where the loads that will be imposed on the waling plate exceed the table or the structure is to be detached from the Hebel PowerBlock™ Walls, a detached post and beam structure may be erected adjacent to the Hebel wall which will ultimately transfer the load directly into the foundation. This type of construction must be designed and certified by the project engineer. Table 7.4.1 Deck/Verandah Floor Walling Plate Connection

Deck Flooring     Type Maximum Anchor Spacing (mm)
Joist Span = 1.2m Joist Span = 2.4
Timber 800 400
Tile 600 300

Table 7.4.2 Roof Walling Plate Connection

WindClassification Maximum Anchor Spacing (mm)
Rafter Span = 2.4m Rafter Span = 4.0m
Sheet Roof Tile Roof Sheet Roof Tile Roof
N1 1500 900 900 500
N2 1300 800 750 450
N3/C1 1000 650 600 400
N4/C2 700 550 400 300
N5/C3 450 400 250 250

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Jan 09

CSR Hebel Tools and Equipment for Construction

Hebel PowerBlocks can be laid using construction tools/equipment.

String Line – A string line is required to accurately set out and lay Hebel® PowerBlock Walls.

Brick/Blocklaying Profiles – used to gauge the block course are being laid level.

Mixing Bucket – a minimum 20 litre bucket is required for mixing Hebel® Mortar, Hebel® Adhesive and Hebel® HighBuild™ render.

Electric Drill – an electric drill is required to mix the Hebel® Mortar, Hebel Adhesive and Hebel HighBuild render. It is also used to drill clearance holes in the blocks so they can be
placed over the tied down rods where required.

Stirrer – fitted to the electric drill, the stirrer is used to mix the Hebel® Mortar, Hebel Adhesive and Hebel HighBuild render inside the mixing bucket.

Notched Trowel – the notched trowel is used to apply the Hebel® Adhesive to the Hebel® surfaces. The width of the trowel must match the block thickness to ensure the adhesive is applied with full and even coverage.

Rubber Mallet – a rubber mallet is required to ‘tap’ the Hebel® PowerBlocks onto the adhesive and into place.

Spirit Level – required to install the blocks level and plumb.

Hand Saw – a Hebel® handsaw can be used to cut Hebel® PowerBlocks to length and height.

Powered Bandsaw – a bandsaw is ideal for cutting Hebel® PowerBlocks. (perfect when there are many site cuts to be performed).

Hebel® Square – a purpose built square is available for use when marking and cutting Hebel® PowerBlocks.

Steel, Plastic and Timber Trowels – these trowels may be required for the installation of the Highbuild render and texture coatings.

Sanding Float – used to even out inconsistencies in the Hebel® PowerBlock Wall in preparation for render/texture coats.

Hebel® Hand Router – may be used to chase services into solid Hebel® walls.

Circular Saw – (fitted with a diamond blade) may be used to chase services into solid Hebel® walls.

Electric Router – may be used to chase services into solid Hebel® walls.

Crane – may be required to lift large Hebel® Lintels and Hebel® custom floor panels.

Lifting Grabs – required for use in conjunction with crane for lifting Hebel lintels and custom floor panels.

Scaffold – Scaffold is required when building block walls. The amount of scaffold depends on the height of the walls.

Sealant Gun – required to fill the control joints in the Hebel® PowerBlock Walls.

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Jan 05

Hebel Design & Installation Guide Appendix A – Carpet Installation

Panel Surface Preparation

Sweep the floor surface to remove debris and loose particles. Expose all surface blemishes such as chips, cracks, gaps, ridges or the like. Fill all unacceptable locations with an appropriate and compatible patching compound such as Hebel® Patch or levelling compound as required.
Ensure panels are then dry.

Carpet Smooth Edge Installation

Installation of Carpet Smooth Edge (Gripper) is to be in accordance with AS/NZS 2455.1:1995.
Installation of carpet gripper prior to laying carpet requires the use of specifically selected nails or course threaded screws. Standard fixings supplied with the carpet gripper are not suitable for fixing to Hebel® PowerFloor™ panels. Carpet gripper strips are available without factory supplied nails. For carpet gripper installation near the panel edge, only glue is recommended. If relying on glue only, the carpet can not be stretched until the glue is set after approximately 24 hours.

Table A.1 – Carpet Smooth Edge Fixings.

Fixing Type Description Application
Method
Installation Notes
Twist Nails 51mm dome
head twist nail
Coil Nail Gun
(Refer to Fig A.1)
The head of the twist nail
should finish flush with
the surface of the gripper
strip
Screws Type 17 point
– course thread
No. 8g x 50mm
– Countersinking
screw
Makita 6834
Auto Feed
Screwdriver
(Refer to Fig A.2)
The head of the twist nail
should finish flush with
the surface of the carpet
gripper strip
Screws Type 17 pointTrimhead deck
Screw.
4.2 x 50mm
4.2 x 65mm
Quickdrive auto feed The head of the screw
should be flush with the
smooth edge

Fig A.1

Fig A.2

Underlay Installation

Minimum medium duty underlay is to be used. No other special requirements.

Carpet Installation

As per carpet manufacturer’s guidelines.
No other special requirements.

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