Jan 12

QT Design

Material Properties

Width Length Thickness Weight
900mm x 2250mm x 50mm (nom) 40kg (nom)
  • Total Square Metres per Panel = 2.0 m2.
  • Number of 50mm Panels per Pallet = 23 panels Pallet Weight:- 940kg (approx) (± 20 kg safety factor).
  • Pallet Size – 900mm Width x 2250mm Length x Max. 1350mm Height (nom).

Thermal Performance

The Thermal performance of the QT EcoSeries Wall System is calculated in accordance with AS 2627.1 Thermal Insulation of Dwellings. QT EcoSeries Wall Panel has a k-value of 0.07 w/mk.

Wall System Composition

* Note: R-Values in table have been rounded up or down to the nearest R0.5 as permitted under AS 2627.1.

Impact Resistance

QT EcoSeries Wall Panel when coated with a cement base render, can provide resistance for hard body impacts typically found under normal situations.

(Refer coating manufacturers for details).

Acoustic Performance

The QT EcoSeries Wall System was tested in accordance with AS/NZS 1276.1 for Airborne Sound Transmission and achieved STC41 and Rw41(-3;-8)(Wall Composition: 50mm QT EcoSeries Wall Panel with 30mm (nom) cavity on a 70mm x 35mm stud frame and 10mm plasterboard) CSIRO TL399. Acoustic performance can be significantly increased with the addition of bulk or acoustic insulation batts.

Fire Performance

QT EcoSeries Wall Panels when tested to AS/NZS 3837 and in accordance with BCA Specification C1.10a Section is classed as a GROUP 1 material.

Early Fire Hazard Indices (Test to AS/NZS 1530 Part 3)

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

 Durability

In normal conditions and when maintained properly in a weatherproof condition, the cladding systems should exceed 30 years of trouble free serviceable life. When the system is installed in high corrosion zones, such as coastal locations within distances of up to 500m from the sea, particular care must be taken to ensure that openings through the cladding panels are kept to a minimum to prevent corrosive salt aerosols from entering the wall cavity and affecting metal components. (Permitted openings are base weepholes, soffit vents and openings beneath window joinery at sills).

Wildlife Attack

The panels will not support growth of micro-organisms such as fungi or bacteria and do not hold any nutritional value for ants or rodents.

Cavity

Cavities form an important role in the weathertightness and life cycle of any wall system QT EcoSeries Wall Panels constructed without a cavity will void any warranty. The cavity acts as a secondary barrier against wind driven rain penetration entering the wall framing. The cavity also allows the wall to ventilate and drain which is essential for a healthy wall.

Vapour Permeable Sarking

Vapour permeable sarking must be installed to the face of the building framing prior to installation of the battens and panels. The vapour permeable sarking has two main functions, weathertightness and thermal resistance. In its weathertightness role it protects the building framing from direct contact with moisture generated by wind driven rain penetration, while allowing the condensation of moisture from interior artificial heating and cooling to escape. Thermally the vapour permeable sarking divides the wall into two separate air spaces, which significantly increases the thermal performance of the wall.

Weepholes

On the first horizontal course (ground level) weep holes are to be installed at centres not exceeding 1200mm immediately above any damp proof membrane or flashing. Weepholes are also required in areas where there is a possibility of moisture build up. Weepholes must be limited to 8mm in width to reduce the potential for vermin access.

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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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Dec 29

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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Dec 28

DURAGRID FACADE SYSTEMS RESIDENTIAL

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

DURAGRIDSHEETING 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 DURAGRID FACADE SYSTEM:

  • IS LIGHTWEIGHT
  • IS HIGHLY DURABLE
  • PANELS WILL NOT ROT, BURN OR CORRODE.
  • PANELS ARE NOT AFFECTED BY TERMITES, AIR, STEAM, SALT OR SUNLIGHT.
  • CAN BE EASILY DECORATED IN A NUMBER OF DESIGN FINISHES.
  • QUICK AND SIMPLE TO INSTALL USING MANUAL NAILING, GUN NAILING OR SCREW FIXING.
APPLICATIONS
Duragrid Facade system utilises BGC fibre cement panels and graded, primed timber or steel battens to form a strong and durable facade cladding system.

BGC Duragrid is ideally suited for versatile architectural applications in domestic and multi storey residential buildings.

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

BGC Duragrid panels are available in 9mm thickness and may be finished with site applied acrylic paint systems or a factory applied high quality polyurethane plain finish. These may need alternative fixing methods. Please contact your BGC office for advice.

NOTE: The fitting of the Duragrid Facade system should only be attempted by a professional contractor. Your local BGC Fibre Cement office can provide you with a list of recommended Duragrid installers.

ADVANTAGES

  • Lightweight cladding system
  • Readily accepts many forms of decorative finish
  • Highly durable
  • Dynamic architectural style
  • Face sealed 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.

PRODUCT INFORMATION

BGC Duragrid panels are an autoclaved, cellulose fibre reinforced silica/cement panel, specially formulated and prepared to meet the requirements for use in external applications. Duragrid 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 2908.2-2000 Cellulose-Cement Products, Part 2: Flat sheets and Duragrid is classified as Type A Category 3.

FIRE RESISTANCE

BGC Fibre Cement 9mm 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 Duragrid physical properties ensure it’s durability in exposed applications.

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

Vapour permeable sarking must be installed under the timber or steel batten in ccordance with the AS/NZS 4200.2 – ‘Pliable building membranes and underlays – Installation’ and the sarking manufacturers’ guidelines. The sarking should have the following properties:

  • Vapour barrier – low or medium
  • Water barrier – high

Vapour permeable sarking is used to prevent moisture ingress by acting as a drainage plane whilst enabling water vapour build up from inside the frame to escape.

THERMAL CONDUCTIVITY

Duragrid panels have relatively low thermal conductivity: R-value. At Equilibrium Moisture content the approximate R-Value of Duragrid is;- 0.55 W/m°C.

PANEL SIZES AND MASS

Duragrid panels are available in the following sizes
THICKNESS
mm
MASS
KG/M2
WIDTH
mm
LENGTH mm
1190 1790 2390 2990
9 11.7 590 x
890 x
1190 x x

SHEET TOLERANCES

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

HANDLING AND STORAGE

BGC Duragrid must be stacked flat, up off the ground and supported on equally spaced (max 400mm) level gluts. Care should be taken to avoid damage to the ends, edges and surfaces.

  • Sheets must be kept dry. When stored outdoors it must be protected from the weather. 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.

ACCESSORIES AVAILABLE FROM BGC

DURABATTEN-PRIMED, GRADED TIMBER 19 x 70 x 3000mm  
19 x 70 x 2700mm
HORIZONTAL BACKING STRIP 1190mm  
2390mm
2990mm
CAVITY VENT STRIP uPVC  
19 x 2700mm
SEALANT Sika 11FC or similar  
COUNTER SINKER Countersinking Tool  
Tungsten Carbide

FASTENERS

DURABATTEN TO FRAME

DURABATTEN TIMBER TO TIMBER FRAME
Class 3 Corrosion resistant Ring shank nail – 2.8 x 65mm

DURABATTEN TIMBER TO STEEL FRAME
Builders Class 3, 8 x 35mm Wingtek Self Embedding Head Screw, 8 x 40mm Wingtek Self Embedding Head Screw

DURABATTEN STEEL TO STEEL FRAME
Class 3 Hex Head Screw, 12-14 x 20mm

DURAGRIDT TO DURABATTEN

DURAGRID DURABATTEN TIMBER
C25 304 Stainless Steel Brads

2.8 x 30mm Fibre Cement nail

8 x 10 x 25mm Class 3 Countersunk wood screw

DURAGRID TO DURABATTEN STEEL
No.8 x 30mm Countersunk self drilling

FASTENERS

Select fasteners with suitable durability for the prevailing conditions. Please consult your supplier for:

  • Minimum requirements Class 3
  • Stainless steel may be required in some applications

All screw holes must be filled with an epoxy sealer such as Megapoxy P1, Hilti CA125 or Hilti CA273 and sanded flush to provide a flat surface for finish coating.

PRE COUNTERSINK

When using screws to fasten Duragrid, pre countersinking is required so that the fastener is 2mm under the sheet surface for filling with Epoxy filler.

DESIGN CONSIDERATIONS

The designer should determine the wind pressure for the project and specify the layout, spacing and fixing of the Durabatten to the structure.

The deflection of the supporting structure should be limited to 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 Duragrid panels and the supporting substructure are installed, particular care should be taken to ensure 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 Duragrid panels and the sub-framing.

It is recommended that the designer consider the need for control joints in the following cases:

  • Where Duragrid crosses a building control joint.
  • Where there is likelihood of movement in the sub-framing.
  • Continuous lengths greater than 8 metres in length.
  • At a change in the structural substrate; eg masonry to steel framing.

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

GROUND CLEARANCE

Maintain a minimum 150mm clearance to earth or as required by local building regulations.

GROUND CLEARANCE & FOUNDATION DETAIL

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).

BACKING STRIP INSTALLATION & SEALING

At the horizontal joints between the Duragrid panels, the Horizontal Backing Strip should be bonded to the back of the Duragrid panel to form a socket to which the Duragrid panels
above are fixed over.

Set the backing strip 2mm from the edge of the Duragrid panel. Seal the cut edge with BGC Edge Sealer.

The backing strip can be fixed using:

  • SIKA 11FC. Ensure that the sealant has cured fully before panel installation.
  • 3m 12.7mm VHB4901 double sided tape.

The contact surfaces to be cleaned with 3M HIPA 300 Adhesive cleaner.

NOTE: SIKA 11FC is the preferred option for fixing the backing strip.

NOTE: Ensure the sealant fills the void in the back of the Horizontal Backing Strip to prevent moisture ingress.

SEALANT (Preferred Option for Optimal Adhesion and Sealing ) – FRONT VIEW

BACKING STRIP TAPE – FRONT VIEW

BACKING STRIP SEALANT – REAR VIEW 

FASTENER SPACING – RESIDENTIAL

FIXING DURAGRID TO DURABATTEN
Fix cladding to batten via a continuous 6mm bead of SIKAFLEX 11FC polyurethane adhesive to all contact surfaces and brad nails at 200 centres.

FIXING DURABATTEN TO TIMBER WALL FRAMES
Spans should be approximately equal (within 25%)
Battens can be installed either ON stud (batten fixed directly to stud) or OFF stud (batten fixed to noggin)
Where battens are fixed OFF stud, noggins are to be evenly spaced with maximum centres of 800mm.
Fix timber batten to timber wall frame with:

ON-stud
1Nº 65 x 2.87 Ring Shank nails @ 300 centres.

OFF-stud
Fix timber battens to noggins with:

1 x 65 x 2.87 Ring Shank nails.
C1 (max 1.61kN pullout load)
Fix timber battens to noggins with:
1 x 65 x 2.87 Ring Shank nails. Or: 8-15 x 40mm screws.

FIXING TIMBER NOGGINS TO TIMBER STUDS
Where noggins support battens, noggins must be securely fixed to studs.
Noggins should not be spaced more than 800mm.

N1-N3
Fix noggins to studs via minimum 2Nº ø3.75 nails at each end.

BATTEN SPAN/WIND PRESSURE LOAD

Wind
 Classification
 AS4005
Durabatten
 Off Stud
 Fix
Durabatten
& Stud
Spacing
Durabatten Fixing Centres Durabatten Span Duragrid Fixing Centres
N1, N2, N3 OK 600 300 850 200
N4, N5 No 450 200 n/a 200
N6 No 300 200 n/a 150
C1 OK 450 200 800 200
C2 No 450 200 n/a 200
C3 No 450 200 n/a 200
C4 No 300 200 n/a 150

NOTE: Durabatten can be fixed off stud in N1, N2, N3, C1 wind classification areas.

Duragrid can be fixed with C25 304 stainless brads and SIKA 11FC as specified in N1, N2, N3, C1, C2 locations.

Duragrid should be screw fixed in other locations.

FRAMING

Ensure that the frame is square and work from a central datum line. The frame must be straight and true to provide a flush face to receive the panels.

BGC recommend a maximum tolerance of 3mm-4mm in any 3000mm length of frame. Duragrid will not straighten excessively warped or distorted frames and any warping may still be visible after Duragrid is applied.

FRAME STRAIGHTNESS

Durabatten can be fixed on stud or off stud –
Refer to Span Table 1. Off stud fixing is restricted to low wind areas and noggings are required at maximum 800mm centres – Refer to span tables in all instances.

The vertical expressed joins must coincide with the centre line of the Durabatten. Stud centres may have to be designed to coincide with express joins.

TIMBER FRAME
Use of a timber frame must be in accordance with AS1684
Residential timber-framed construction and the framing manufacturers’ specifications.

Use only seasoned timber. Do not use unseasoned timber as it is prone to shrinkage and can cause sheets and frames to move up.

“Timber used for house construction must have the level of durability appropriate for the relevant climate and expected service life conditions including exposure to insect attacks or
to moisture which could cause decay” – Reference AS 1684.2

Stud framing members must be a minimum of 70x35mm.

DURABATTEN INSTALLATION TO TIMBER

TIMBER DURABATTEN
Install over Timber Durabatten either off stud or on stud.

ON STUD

OFF STUD

BATTEN JOINING

INSTALLATION DETAILS

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

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

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

PANEL POSITION – FRONT VIEW

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

INSTALLATION DETAILS

PANEL INSTALLATION

TYPICAL SEALANT APPLICATION

FASTENER SPACING

Duragrid panels are to be fixed with a continuous 6mm bead of SIKA 11FC or similar polyurethane sealant/adhesive to all contact surfaces with required fasteners at specific centres.

Duragrid panels should be sealed and fixed 1 panel at a time. Only apply sealant to the contact surfaces of the next panel to be fixed.

SOFFIT DETAIL

FOUNDATION DETAIL

INTERNAL CORNER DETAIL

EXTERNAL CORNER DETAIL

FASTENER POSITION

ENCLOSED BALUSTRADE/PARAPET WALL

PENETRATIONS, WINDOW & DOOR OPENINGS

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 following diagrams are a guide only and the designer should consult with the appropriate manufacturers for the detail design to ensure adequate weather proofing.

WINDOW JAMB

WINDOW HEAD

WINDOW SILL

THERMAL BREAKS

Thermal breaks are required for steel framed buildings, in walls enclosing habitable and or usable 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 steel Durabatten sections and the Duragrid 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 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 are beyond the control of BGC and as such is not warranted by BGC.

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