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 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 09

CSR Hebel System Components

Products

Hebel stocks many of the products and materials required to construct your Hebel home.

Product Description Product Description
  Hebel Thermoblocks
50mm – 300mm (25mm
increments).
  Hebel Adhesive
20 kg bag
Used for gluing the blocks
together at vertical and
horizontal joints.
  Sill blocks
600x200x50mm thick or
100mm thick, 30º slope.
  PowerFloor
Panels
1800mm x 600mm x 75mm
  Hebel Mortar
20 kg bag
Used as thick bed mortar base
to provide a level base for the
first course.
  Custom PowerFloor
Panels
150mm – 250mm x 600mm
by up to 6m
  Hebel Lintels
To suit openings up to 5m
  Hebel HighBuild render
20kg bag
Used as a preparation coat
to level surface providing an
even true surface.
  Stair treads
300mm x 175mm x 1m
or 1.2m
  Control joint tie
Used at every third
course in control joints.
  Hebel Patch
10kg bag
Used to prepare minor chips
or damage to blocks.
  Sliding joint tie
Fixed to RHS/SHS column
every second course.
  Corrosion Protection Paint
To coat exposed
reinforcement during cutting.

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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 09

CSR Hebel Delivery and Storage

PowerBlock  Delivery

PowerBlock pallets should be unloaded and moved with only approved lifting devices. Before use, the lifting devices should be checked for the required lifting tags. PowerBlock pallets should be unloaded and stored as close to the intended installation area as possible. This will increase work efficiency and minimise the need for secondary lifting.

It is good practice to inspect the delivery for damaged blocks. Unnecessary handling will increase the risk of damage to the Hebel® PowerBlocks.

Care should be taken when cutting the packaging straps, blocks may come away and cause injury or become damaged.

TIP – When a block is damaged it may be possible to cut away the damaged section and use the remaining portion in the wall.

Storage

All materials must be kept dry and preferably stored undercover. Hebel® PowerBlocks should be left on their pallet until they are required. Place the pallet on a level and stable surface. The project engineer should be consulted as to the adequacy of the structure to support Hebel® PowerBlocks if they are not stored directly on the ground or concrete slab.

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