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 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 Construction Notes

General Notes

    • These notes and details are to be read in conjunction with the project’s contract documentation.
    • All materials and workmanship shall be in accordance with this Installation Guide, the current edition of the Hebel® Technical Manual and other Hebel® documentation.
    • Refer to architectural drawings for all setting out dimensions.
    • Do not scale drawings, use written dimensions.
    • Should any omission, penetration, cutting of panels, discrepancy or fault exist, contact the designer immediately for a decision before proceeding with work.
    • All load-bearing walls, bearing on Hebel® floor panels, shall be supported separately in accordance with the project engineer’s design.
    • Hebel® accepts no responsibility for the design or selection of supporting walls, lintels, beams, columns or other structural members.
    • Corrosion protection of all structural steelworks shall be specified by the project engineer or architect.
    • The temporary restraint of walls is the responsibility of the builder or installer.
    • PowerBlocks on site should be protected against rain and water saturation. This can best be achieved by leaving the shrink-wrap cap on the top of pallets and covering the top of blockwork if rain threatens. PowerBlocks should not be laid in the rain.

IMPORTANT

  • Ensure engineering tie-down rods are present and located in accordance with the engineer’s documentation.
  • Ensure control joint locations are marked out in accordance with the engineering documentation.

 Coatings

Table 9.1 details Hebel recommendations for Coating System options for Low Rise and Detached Residential construction to deliver a durable, monolithic appearance.
Hebel and Dulux Acratex have developed coating systems designed specifically for the Hebel AAC substrate and warrant these systems for 7 years. Performance requirements for alternate system options are provided. In such circumstances, the project specifier must satisfy themselves that systems are engineered and suitable for relevant project requirements.
General purpose, site or pre-bagged sand and cement renders must not be used on Hebel PowerBlock™ walls, owing to potential variability and unsuitability of formulation for Autoclaved Aerated Concrete (AAC).

Conventional exterior low build paint systems must not be used, as their ability to accommodate normal expansion and contraction in order to maintain a crack free protective layer is not assured.

Refer to “High Performance Coating Systems” brochure on the website, for more information.

Reinforcing Mesh Installation

Fully meshing all rendered Hebel surfaces using alkali-resistant glassfibre mesh is recommended to assist in maintaining render integrity and minimising consequential cracking.
The minimum requirement is to mesh at corners of wall openings (doors and windows) to minimise corner cracking. The mesh should be embedded into the wet first pass of Hebel
HighBuild.

Linings

Plasterboard can be direct fixed to internal Hebel PowerBlock™ walls. It is recommended that battens be used behind plasterboard linings on the inside surface of external walls. Fibre
Cement sheet linings must be installed on battens.

Table 9.1 Coating systems for Hebel PowerBlock

Primer Acrylic Texture Body Coat Finish Coats
Hebel
Product
Finish
Style
Surface
Aignment
Base
Render or
Levelling
Coat
Product
Description &
Performance
Guide
Dulux
AcraTex
Specification
Product
Description &
Performance
Guide
Dulux
AcraTex
Specification
Product
Description &
Performance
Guide
Dulux
AcraTex
Specification
Comment
PowerBlock Uniform
Sand
Texture
profile
≤3mm Hebel
HighBuild™
(Render)
Relevant to
coatings supplier
recommendations
AcraPrime
501/1
OPTION 1:
1-2mm Acrylic
Texture
Trowel applied
Type: AS4548.4
Polymercontent (dry):
9% min.
Tuscany
orCoventry
Coarse
Elastomeric
Membrane
Type:
AS4548.1
Min DFT:
150 micron
AcraShield
Matt
or
Elastomeric
201
2nd coat
Elastomeric
Membrane
recommended
dependant on
project
complexity
eg. unbroken
broadwall,
scaffolding or
cutting in detail
and coastal areas.
OPTION 2:
Dependant on specifier
approval:
Sponge finishing of Hebel
HighBuild™ to a project
approved standard; plus
Elastomeric Membrane
finishing system.
Elastomeric
Membrane
Type:
AS4548.1
Min. DFT:
250 micron
Elastomeric
201
Hebel
recommends the
installation of
1-2mm Acrylic
Texture Coat over
the render base
coat providing
improved
consistency of
finish, system
flexibility and
durability.

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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 06

Hebel Construction Details – Tie-down

Required only if specified by design /project engineer.

Fig 15.1: Strip Footing, Double Brick Sub-Floor

Fig 15.2:  Strip Footing, Concrete Power Block Sub-Floor

Wall Length(mm) Min. No. of N12 Bars Ultimate Racking Capacity (kN)
150mm PowerBlock

250mm PowerBlock

900 2 5 6
1200 2 8 8
1800 3 16 18
2400 3 24 25
3000 4 36 38
3600 5 45 46
4800 6 54 56
6000 7 63 66

Tie down rods/engineering restraints must be embedded into the footing and pass up through the sub floor and into the Hebel PowerBlock work.

Table 15.1 Top-Plate & Hold-Down selection

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.

Fig 15.3 Hold Down Detail for Reinforced Bracing Walls

Table 15.2 provides ultimate racking capacities of reinforced 150mm and 250mm Hebel PowerBlock walls. The reinforcement is N12 bar or 12mm threaded rod at nominal 1000mm centres. The reinforcement must be tied to the footings and wall top plate through the bond beam.

Walls resisting racking forces should be evenly distributed within a house and spaced at a maximum of 8.0m. Ceiling and floor diaphragms must be adequately tied to walls to ensure transfer of forces through to the footings.

For more information about bracing, refer to Section 6.11 of the Hebel Technical Manual.

Fig 15.4 Roof Top to Plate Fixing to Hebel Wall – Strap (elevation)

Top Plate Hold-Down

Two tie-down methods are provided in this design guide.

1. Strap – 30×0.8mm cut into inside face of external wall min. 700mm deep.
2. 12mm threaded rod continuous from footing through bond beam to top plate.

Fig 15.5 Roof Top Plate Fixing to Hebel Wall-Tie-Down Rod (elevation)

Three top plates options are provided in this design guide:

1. 90×45 F7 timber
2. 90×45 F17 timber
3. 100x50x3.0 RHS

The type of hold-down method and spacing depends on the top plate, roof type/span, and wind classification. Refer to Table 15.1 for specifications. For high wind areas, the bracing design is likely to require tie-down rods which will drive that as the hold-down method.

Table  15.2 Reinforced Wall – N12 Bars at Nom. 1000mm CTRS

Wall
 Length
 (mm)
Min. No. of
 N12 Bars
Ultimate Racking Capacity (kN)
150mm PowerBlock 250mm PowerBlock
900 2 5 6
1200 2 8 8
1800 3 16 18
2400 3 24 25
3000 4 36 38
3600 5 45 46
4800 6 54 56
6000 7 63 66

Base of Wall

Fig 15.6 Hebel PowerBlock work on Stiffened Raft Slab Edge Foundation (elevation)

 Fig 15.7  Concrete PowerBlock Sub-Floor Detail (elevation)

 Fig 15.8  Double Brick Sub-Floor Detail (elevation)

Fig 15.9 Ring Beam Internal Non-Loadbearing Wall (elevation) (No tie down – as specified by design engineer)

Top of Wall

Fig 15.10 Roof Top Plate Fixing to Hebel Wall – Tie-Down Rod ( elevation)

Fig 15.11 Internal Hebel Load Bearing Wall and Timber Floor Frame Junction (elevation)

Wall Junctions

Fig 15.12  External Wall and Internal Partition Wall Junction  (plan).

Fig 15.13  External Corner with Control Joint (plan)

Control Joints

Fig 15.14 Control Joint detail (elevation)

Fig 15.15 Typical Bond Beam Control Joint – elevation (Location where no tie down required – as specified by engineer)

Fig 15.16 Typical Ring Beam Control Joint – elevation (Location where no tie down required – as specified by engineer)

Fig 15.17 Typical Control Joint – plan 

Fig 15.18 Hebel PowerBlock work Typical Movement Joint Detail (elevation)

Fig 15.19 Hebel PowerBlock work Typical Movement Joint Detail (plan)

Fig 15.20 Built-in Column Detail (plan)

Fig 15.21 Built-in Column Detail (elevation)

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 point Trimhead 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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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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