exterior wall system » Hebel Panel

3.0 Typical Applications Power Wall

CSR Hebel Detached & Low Residential Design Guide No Responses »

Jun 292012

Hebel PowerWall is designed for application in the domestic, residential markets. Basically, the types of buildings that are constructed using Hebel PowerWall are detached or attached 1 or 2 storey houses, duplexes and town houses. The Building Code of Australia (BCA) generally classifies these buildings as being predominantly of Class 1 or Class 10 building structures.

Structurally, Hebel PowerWall uses Hebel PowerPanel as non-loadbearing external cladding. Each PowerPanel is steel reinforced and installed vertically and secured to steel top hat battens. The top hat battens are secured to load carrying timber or steel stud frames.

Hebel PowerFloor is a complimentary system that can be used in conjunction with Hebel PowerWall. Hebel PowerFloor can be quickly installed over timber or steel floor framing using a construction adhesive & screw fixings.

Figure 3.1 shows an example of a typical home that uses Hebel PowerWall for Detached Houses & Low Rise Multi-Residential External Walls.

Fig. 3.1 Typical Home Construction Application

5.0 Structural Provisions Power Wall

CSR Hebel Detached & Low Residential Design Guide No Responses »

Jun 292012

5.1 Overview

Hebel PowerWall basically consists of Hebel PowerPanel secured to the framing via horizontal steel top hats. This section provides the basic information on the selection of top hat spacings for a given stud spacing and wind category, as well as considerations to assist the designer in determining the appropriate wall configuration.

The design information presented in Table 5.1 to 5.5 has been determined for the following top hat types:

Rondo 303 – Rondo Building Services Pty Ltd.
Lysaght Topspan 22 – Bluescope Steel Ltd.
FastStud 24TH42.

For other brands or types of top hats, contact the manufacturer for design information. Minimum performance requirements for the metal studs, top hats, fixings and Hebel PowerPanel have been provided to assist the designer.

IMPORTANT
The design and approval of the structural framing (cold-formed steel or timber) is to be provided by the framing product manufacturer and/or project engineer.

5.2 Principles of Design

The principles on which the design is based include:

a) The lateral wind loads applied to the PowerPanels are transferred into the horizontal top hats, then to the stud frame, which should be designed in accordance with the relevant Australian Standards for the imposed loads. The frame should be designed for all bracing and hold down requirements.

b) The design of the stud frame shall consider the weight of suspended PowerPanels (such as the upper storey of two-storey construction).

c) The system is not considered as cavity construction, as the top hat clearly bridges the cavity, hence the details show the necessity of sealing the windows and door frames, as well as applying a water resistant external coating.

d) The system specifications vary with wind load. The notation used in AS1684 Residential Timber Framed Construction has been adopted.

e) The localised effects of wind around corners of buildings have been considered in the design and included in the tables. The extent of this effect is discussed towards the end of this section.

Criteria for Corner Panels

Due to the increase of wind load around the corners of buildings, extra top hats and screws may be necessary (N3 and greater) for a distance of 1200mm in each direction from the corner.

Tables 5.1 to 5.5 identify the installation criteria in these areas, in the columns titled ‘Panel Location – Corner’.

Cyclonic Loading Effects

Hebel PowerWall for Detached Houses & Low Rise Multi-Residential External Walls has been tested at the James Cook Cyclone Structural Testing Station (Repor t No. T5 444) in Townsville. The pullout capacity of the screw into the back of the Hebel PowerPanel is the critical element in the design. The results from the cyclic testing showed that the system, in par ticular the pullout load of the screw, is unaffected by the cyclic loading. The detailing presented in this design guide is satisfactory for cyclonic areas.

Earthquake Loads

Earthquake loading has not been considered in this design guide.

5.3 Design Tables

This section presents tables to assist the designer in the selection of the number of top hats and number of screws for securing the Hebel PowerPanel to the framing, for a given wind category.

IMPORTANT
The wind category is to be used as a guide. The designer should check the project wind pressure against the valves given in the tables.

Panels Supported at Base

Table 5.1 Number of Top Hats – Panel Supported at Base (such as slab edge or shelf angle)

Wind Category	Maximum Permissible Suction Wind Pressure (kPa)	Stud Spacing (mm)	Number of Top Hats Per Panel
			Panel Length (mm)
			2400		2550/2700		2850/3000
			Panel Location		Panel Location		Panel Location
			Typical	Corner	Typical	Corner	Typical	Corner
N2	0.42	600	3	3 (4)	3	3 (4)	4	4
N3	0.66	600	3	3 (4)	3	4	4	4
N3, C1	0.66	450	3	3 (4)	3	3 (4)	4	4
N4, C2	0.98	450	3 (4)	4 (5)	3	4 (5)	4	5 (6)
N5, C3	1.40	450	4 (5)	4 (6)	5	5 (6)	5	5 (7)

Note:
1. Figures shown in brackets are the top hats required when using RONDO 303 top hats.
2. All top hats to be spaced evenly, with top and bottom top hats installed 150mm (typical) from the end of the PowerPanel.
3. Additional top hats will be required below all window openings and above openings if a PowerPanel or sill block is to be installed in this location.
4. Corner panel location applies to PowerPanels within 1200mm of corners. Permissible wind pressures have been increased by a factor of 2 in these PowerPanel locations.

Table 5.2 Number of Screws Per Panel at Each Top Hat Location – Panel Supported at Base (such as slab edge or shelf angle)

Wind Category	Maximum Permissible Suction Wind Pressure (kPa)	Stud Spacing (mm)	Number of Screws Per Panel Per Top Hat
			Panel Location
			Typical		Corner
			Top Hat Location		Top Hat Location
			Ends	Middle	Ends	Middle
N2	0.42	600	2	2	2	2
N3	0.66	600	2	3	2	3
N3, C1	0.66	450	2	2	2	3
N4, C2	0.98	450	2	3	2	3
N5, C3	1.40	450	2	3	3	4

Note:
1. For fire rated construction a minimum of 3 screws per middle top hat is required (FRL 240/180/180 for a fire source from the PowerPanel side of the wall only).
2. Type of screw used is the 14-10x65mm Hex Head Type 17 screw, fixed from inside the building, or 14-10x100mm MP Bugle Head Batten screw, fixed from outside the building (as per Table 5.6).
3. Corner panel location applies to PowerPanels within 1200mm of corners. Permissible wind pressures have been increased by a factor of 2 in these PowerPanel locations.

Panels Suspended from Frame

Table 5.3 Number of Screws Per Panel at Each Top Hat Location – Panel Suspended at Gable Ends

Wind Category	Maximum Permissible Suction Wind Pressure (kPa)	Stud Spacing(mm)	Number of Screws Per Panel Per Top Hat		Maximum Spacing of Top Hat(mm)
			Panel Location		Panel Location
			Typical	Corner	Typical	Corner
N2	0.42	600	2	3	800	800
N3	0.66	600	3	4	800	650
N3, C1	0.66	450	3	4	800	650
N4, C2	0.98	450	4	4	800	450
N5, C3	1.40	450	4	4	600	350

Note:

Top and bottom top hats installed 150mm (typical), and 250mm (max.) from the end of the PowerPanel.
Top hats to be installed horizontally with PowerPanels to span ver tically. Number of Screw Per Panel Per Top Hat Information is not suitable for soffits or any other areas where the PowerPanel is not ver tical.
Corner panel location applies to PowerPanels within 1200mm of corners. Permissible wind pressures have been increased by a factor of 2 in these PowerPanel locations.

Table 5.4 Number of Top Hats – Panel Suspended from Framing (such as, second storey construction)

Wind Category	Maximum Permissible Suction Wind Pressure (kPa)	Stud Spacing (mm)	Number of Top Hats Per Panel
			Panel Length (mm)
			2400		2550/2700		2850/3000
			Panel Location		Panel Location		Panel Location
			Typical	Corner	Typical	Corner	Typical	Corner
N2	0.42	600	4	4	4	4	4	4
N3	0.66	600	4	4	4	4	4	4 (5)
N3, C1	0.66	450	4	4	4	4	4	4 (5)
N4, C2	0.98	450	4	4 (5)	4	4 (6)	4	5 (6)
N5, C3	1.40	450	4 (5)	5 (6)	5	6 (7)	5	6 (8)

Note:
1. Figures shown in brackets are the top hats required when using RONDO 303 top hats.
2. All top hats to be spaced evenly, with top and bottom top hats installed 150mm (typical) from the end of the PowerPanel.
3. Additional top hats will be required below all window openings and above openings if a PowerPanel or sill block is to be installed in this location.
4. Corner panel location applies to PowerPanels within 1200mm of corners. Permissible wind pressures have been increased by a factor of 2 in these PowerPanel locations.

Table 5.5 Number of Screws Per Panel at Each Top Hat Location – Panel Suspended from Framing (such as, second storey construction)

Wind Category	Maximum Permissible Suction Wind Pressure (kPa)	Stud Spacing (mm)	Number of Screws Per Panel Per Top Hat
			Panel Location
			Typical		Corner
			Top Hat Location		Top Hat Location
			Ends	Middle	Ends	Middle
N2	0.42	600	2	2	2	3
N3	0.66	600	2	3	3	4
N3, C1	0.66	450	2	3	3	4
N4, C2	0.98	450	2	4	3	4
N5, C3	1.40	450	2	4	3	4

Note:
1. For fire rated construction a minimum of 3 screws per middle top hat is required (FRL 240/180/180 for a fire source from the PowerPanel side of the wall only).
2. Type of screw used is the 14-10x65mm Hex Head Type 17 screw, fixed from inside the building, or 14-10x100mm MP Bugle Head Batten screw, fixed from outside the building (as per Table 5.6).
3. Corner panel location applies to PowerPanels within 1200mm of corners. Permissible wind pressures have been increased by a factor of 2 in these PowerPanel locations.

5.4 Stud Frame

The stud frame shall be designed by the steel stud manufacturer or appropriate project engineer. Hebel PowerPanel is a masonry product and the support structure should be designed to provide sufficient stiffness.

The steel stud frame shall be designed and constructed in accordance with AS3623 and AS/NZS4600 (BCA Performance Requirement) with performance requirements for the studs of:

Properties:

Cold-formed steel studs.
Minimum yield strength 300MPa
Minimum thickness 0.75mm BMT.
Coating class Z275 (see Durability).
The designer shall specify the need for noggings.

5.5 Steel Top Hat

Other steel top hats than those referenced in this design guide shall be designed by the top hat manufacturer or appropriate project engineer.

The steel top hats shall be designed and constructed in accordance with AS3623 and AS/NZS4600 (BCA Performance Requirement) with performance requirements for the top hats, of:

Properties:

Cold-formed steel top hats.
Minimum thickness 0.42mm BMT.
Minimum yield strength 300MPa.
Coating class Z275 (see Durability).

Alternate steel top hats must have an equivalent or better performance than the top hat products outlined in Section 5.1.

5.6 Hebel PowerPanel

Design procedures for the verification of wall systems consisting of Hebel autoclaved aerated concrete (AAC) PowerPanels generally follow the design principles outlined in Australian Standard AS3600 – Concrete Structures, with the exception of cover requirements for durability and development length for reinforcement.

The strength design of the Hebel PowerPanels has been carried out using the Transformed Section Theory, as detailed in the text book, ‘Reinforced Concrete’ by Warner, Rangan and Hall (Longman Cheshire). The load carrying capacity of the Hebel PowerPanel is influenced by several factors, such as:

Imposed action (wind).
Lateral stiffness of the supporting structure (lightweight structural (cold-formed) steel framing).

• Stud size and spacings.
• Deflection limit.

Height of the wall.
Number and spacing of the top hats.
Number of screw fixings considered effective.

5.7 Fixings

Table 5.6 outlines the connection type and requirements for constructing Hebel PowerWall detailed in this design guide. The project engineer or framing manufacturer is responsible for specification of alternative details. The minimum performance requirement of the screw is:

Minimum screw coating class in accordance with AS3566: Class 3. (Refer Section 6.0 for Durability).

Table 5.6 Screws Types

Type of Screw	Application	Top Hat Type	Socket Type
12-11x25mm Hex HeadType 17 screw	Fix top hat to timber frame	Rondo 303Lysaght TopSpan 22FastStud 24TH42	5/16” Hex Mag. Socket
10-16x16mm Hex Headself drilling screw	Fix top hat to steel stud frame(1.2mm BMT max.)	Rondo 303Lysaght TopSpan 22FastStud 24TH42	5/16” Hex Mag. Socket
14-10x65mm Hex HeadType 17 screw	Fix PowerPanel to top hatfrom inside of building	Rondo 303Lysaght TopSpan 22FastStud 24TH42	3/8” Hex Mag. Socket
14-10x100mm MP Bugle HeadType 17 screw	Fix PowerPanel to top hatfrom outside of building	Rondo 303Lysaght TopSpan 22FastStud 24TH42	5mm Hex drive bit 50mm long

5.8 Design Considerations

5.8.1 Structural Framing Design

The use of Hebel PowerWall in two-storey construction involves a number of design issues that require attention. In conjunction with the following, refer to the Construction Details in Section 17.3 & 17.7.

Note, when PowerPanels are suspended from the stud frame the project engineer shall design the frame to support the weight of the PowerPanels.

Design Tip

In order to reduce the load of the upper storey PowerPanels and make installation easier, the lower storey PowerPanels should be specified as 2700mm/3000mm in length and the upper storey PowerPanels as 2400mm in length. The vertical dimensions can be adjusted to suit.

A garage is considered ‘attached’ when at least one full side of the garage is connected to the main dwelling.

5.8.2 Two Storey Construction

Steel Frame Construction

Two storey construction suits a steel framed dwelling as the weight of the upper storey PowerPanels bear directly on the lower storey PowerPanels. Note, lower storey PowerPanels are to bear on the slab. However, consideration should be given to the sectional size of the lintels over openings on the lower storey.

As the details reveal, only an ‘Ableflex’ joint is required at the horizontal PowerPanel junction between the upper and lower PowerPanels.

Timber Frame Construction

In contrast, the upper storey PowerPanels™ cannot rest on the lower storey PowerPanels™ in timber framed dwellings, due to the effects of timber shrinkage. Movements in the order of 25mm can occur in a two storey timber frame with a timber first floor. The fixing method used in Hebel™ PowerWall™ does not allow for this extent of differential movement between the external skin and the timber frame.

The allowances for shrinkage of timber framing in BCA 2006 Vol. 2, Section 3.3.1.10, by providing gaps between framing and masonry, should be adopted as a minimum.

It is therefore recommended that the upper storey PowerPanels™ be installed 35mm clear of the lower storey PowerPanels™. During construction a temporary packer is used to separate the PowerPanels™ and is then removed after the PowerPanels™ have been screwed to the top hats.

The impact of this construction is to load the lower storey frame with the weight of the upper storey PowerPanels™. In effect, an extra 51kg/m² (for the weight of the upper PowerPanels™) is being added to the load already carried by the timber frame. The load approximates 1.2 kN/m (2.4m PowerPanel™).

To simplify the design implications of this extra load, it is recommended to add an extra 1.4m of tributary width for a 90kg/m² Tile Roof load (for 2.4m long upper PowerPanels™) for the design of the lower storey frame and timber lintels, when using AS1684. The support of the full weight of the upper storey PowerPanels™ can be adequately supported by the top hat system. A full design using a safety factor of five has been undertaken and checked to confirm this. The number of top hats can be determined in Table 5.4 to support the suspended PowerPanels™, and the PowerPanels™ screw fixed as per Tables 5.5.

5.8.3 Secondary Support Framing

There is a need for secondary support framing when:

The layout of the main structural framing does not allow this framing to be used as a support. In this case a mullion is required to break up the span of the PowerPanel™, or cleats provided to act as support and connection points for the PowerPanels™.

Around openings: the PowerPanels™ adjacent to the opening may not have sufficient capacity or stiffness to resist the additional loads that are re-distributed from the opening and infill PowerPanels™.

In this case angles are required to transfer the loads from the opening (window) and infill PowerPanels™ back to the main structural framing.

5.8.4 Bracing of the Building

The walls of the dwelling should be braced using steel cross bracing wherever possible, to allow the fixing of the PowerPanels™ from inside the building, such as Teco Speed Bracing. Ply or sheet bracing should be used on the external wall, if the walls are too short for the steel cross bracing (Refer AS 1684-1999). In this case, the full length of the wall should be sheeted to prevent misalignment of the PowerPanels™.

Alternatively, localised strips of the sheeting can be fixed to the intermediate studs, between the areas of full sheet bracing, to maintain the PowerPanel™ alignment. The PowerPanels™ to be installed over the areas of full plywood sheeting will need to be fixed from the outside of the building using the 100mm long Bugle Head Batten screw (Refer Table 5.6). The extent of the bracing should be determined by the timber frame designer or project engineer.

NOTE
CSR™ Hebel™ does not recommend fixing Hebel™ PowerPanels™ from the inside when sheet bracing is installed. If sheet bracing is used over steel or timber frame construction then increase the length of the screw fixing the top hat to the stud by the thickness of the sheet bracing (refer to Section 5.7).

6.0 Durability Power Wall

CSR Hebel Detached & Low Residential Design Guide No Responses »

Jun 292012

6.1 Overview

Durability means the capability of a building or its parts to perform a function over a specified period of time. It is not an inherent property of a material or component. It is the outcome of complex interactions among a number of factors, including:

The service conditions.
Material characteristics.
Design and detailing.
Workmanship.
Maintenance.

(‘ABCB Guideline Document – Durability in buildings: 2003’) The following sub-sections of the durability topic are written in order to provide general guidelines in how best to provide, enhance and maintain adequate durability of Hebel PowerWall.

6.2 Maintenance and Enhancement of Durability

The durability of Hebel PowerWall can be enhanced by periodic inspection and maintenance. Inspections should include examination of the coatings, flashings and sealants. Paint finishes must be maintained in accordance with the manufacturer’s recommendations. Any cracked and damaged finish or sealants, which would allow water ingress, must be repaired immediately by recoating or resealing the effected area. Any damaged flashings or PowerPanels must be replaced as for new work.

The durability of the system can also be increased by using Class 4 fixings throughout, additional treatment of steelwork, and by painting all exposed sealants to the sealant manufacturer’s recommendations.

6.3 Coastal Areas

Hebel PowerWall can be used in coastal areas with additional precautions to ensure salt does not build up on the surface of the wall. For buildings, which are 200m to 1000m from a shoreline or large expanse of salt water, such as, Swan River (west of the Narrows Bridge), Sydney Harbour (east of the Harbour Bridge or Spit Bridge), one of the following is required:

All horizontal and vertical movement joints must be appropriately caulked; or
All walls must be sufficiently exposed from above so that rain can perform natural wash-down of the wall; or
Walls, which are protected by soffits above, must be washed down twice per year, to remove salt and debris build-up, particularly at the joints.
In all cases, Class 4 screws must be used.
For buildings less than 200m from the shoreline as defined above, CSR Hebel does not recommend that Hebel PowerWall be used without project specific consultation with CSR Hebel Engineering Services.

6.4 Hebel PowerPanel

Hebel PowerPanel has many characteristics which make it a very durable product, including:

Will not rot or burn.
Is not a food source for termites.
Unaffected by sunlight.
Not adversely affected over normal temperature ranges.
One quarter the weight of conventional concrete.
Solid and strong with corrosion protection coated steel reinforcement.

6.5 Durability of Components

It is the responsibility of the building designer to ensure that the components, such as screws, top hat battens and other steel components, have the appropriate corrosion protection to be able to maintain their strength and integrity to suit the required design life of the project.

IMPORTANT
The top hat section specified in this guide can ONLY be used on untreated and dry timber frames. CCA treated pine or green timber frames have a deleterious effect on the top hat coatings, which can lead to corrosion. Where timber is CCA treated, provide a barrier between top hat and timber member. Refer to screw manufacturer for appropriate screw specification for this application.

When assessing durability the following documents can be referred to for guidance:

ABCB Guideline Document – Durability in buildings: 2003.
AS/NZS 2312: 2002 – Guide to the protection of structural steel against atmospheric corrosion by the use of protective coatings.
ISO 9223: 1992 – Corrosion of metals and alloys – Corrosivity of atmospheres -Classification.
AS3566: 2002 – Self drilling screws for the building and construction industries.
AS2331 Series.

Reference to AS3566 should always be adhered to when selecting the screws corrosion resistance classification.

6.6 Wall Frames

6.6.1 Steel Frames

The designer needs to ensure that the steelwork and Hebel AAC products have adequate protective systems to ensure that durability is maintained. The durability of the stud frame can be enhanced by the provision of a membrane, such as sarking. The manufacturer of the steel stud frame can provide guidance on the appropriateness of this solution on a project-by-project basis.

IMPORTANT
The steel frame requirements outlined in the BCA Vol. 2, Part 3.4.2 should be considered in conjunction with steel frame design and construction advice from the steel frame manufacturer. These requirements consist of minimum protective surface coatings with restrictions on the location of the building and exposure condition of the steel frame.

6.6.2 Timber Frames

Information on the durability design of timber structures and components can be obtained from documents such as:
AS 1720.1 Timber Structures, Part 1: Design Methods.
AS 1684 Timber Framing Code.
State timber framing manuals.
AS 4100 Metal Connectors: Corrosion.
AS 3600 Subterranean Termites.

Fig. 6.1 Hebel Home

7.0 Fire Resistance Performance PowerWall

CSR Hebel Detached & Low Residential Design Guide No Responses »

Jun 292012

7.1 Overview

Hebel PowerWall can be subjected to a fire loading as the result of either an external fire source, or an internal fire source. When the wall requires a fire resistance level (FRL) rating, CSR Hebel provides the following guidance.

External Fire Source
For an external fire source, the excellent fire resistance qualities of the Hebel PowerPanel cladding protects the structural support framing, and provides a high fire resistance level for Hebel PowerWall.

NOTE
The FRL rating of the wall can be affected by the penetrations and the method adopted to protect these penetrations. A fire collar with a –/120/120 FRL rating will govern the FRL of the wall, even if the wall configuration has a FRL rating of –/180/180. Where required, the performance of the external coating when subjected to a fire loading shall meet the appropriate performance requirements outlined in the BCA. Joints & gaps need to be appropriately fire rated. Eg. vertical control joint will need fire rated sealant & horizontal joints must be blocked with compressible fire rated material.

Fire Certificates & Reports
Copies of the test reports and/or opinions can be obtained by contacting CSR Hebel. A certificate of test FSV0356 is provided in Appendix D of this guide. Hebel PowerWall achieves a FRL of 240/180/180.

Internal Fire Source
For an internal fire source the studs must be protected by the internal wall linings. Refer to CSR Gyprock Red Book for specifications.

External Walls in Fire – BCA Provisions
Where necessary, the designer and builder should ensure the structural support framing, its connections as well as the Hebel PowerPanel installation are satisfactory when subjected to fire conditions. The BCA Vol 2 (Part 3.7.1) outlines provisions for external walls for fire resistance in a residential building where the external wall is less than 900mm from an allotment boundary or 1.8m from another building on the same allotment. If this occurs an FRL of not less than 60/60/60 is required from the outside.

7.2 Fire Performance of Hebel PowerWall

Hebel PowerWall was tested at the CSIRO, North Ryde and a Fire Resistance Level (FRL) of 240/180/180 was achieved (refer to Appendix D). Note, the fire source was on the PowerPanel side. This excellent result enables Hebel PowerWall to be used in the following applications:

Walls on zero line allotment blocks.
Multi-storey residential dwellings – external walls.
Commercial developments.
Infill PowerPanels.

NOTE
In the above applications, each PowerPanel should be screwed as specified in this guide, except a minimum of three screws should be installed through the middle top hat into each PowerPanel (refer to the fire test certificate in Appendix D).

Fig. 7.1 Bushfire Area

7.3 Bushfire Areas

BCA 2006 Vol. 2 Part 3.7.4 describes the provisions applicable to construction in bushfire prone areas. The reference code is AS3959. Hebel PowerPanel is non-combustible and suitable for all bushfire exposure levels (refer to Appendix A.6).

7.4 Design Considerations

Fire Stop Penetrations
Penetrations through Hebel PowerPanel to accommodate pipework, electrical cabling or ductwork will have to be protected (fire stop), to prevent the spread of fire through the penetration. The penetration can be protected with proprietary products, such as:

Fire rated sealants.
Fire collars and intumescent wraps.
Fire rated mortars.
Fire rated pillows.
Fire rated switch boxes.

CSR Hebel recommends contacting the manufacturer to obtain the appropriate product/solution and installation method for the application and wall configuration.

11.0 Design, Detailing and Performance Responsibilities Power Wall

CSR Hebel Detached & Low Residential Design Guide No Responses »

Jun 292012

CSR Hebel engages independent testing laboratories to test and report on the performance of a wall in accordance with the relevant Australian Standards. Consultants use these reports as the basis for opinions (estimates of laboratory performance) they issue for variations or different arrangements to the tested system, and also to design and specify walls that meet appropriate criteria for a particular project. Using their experience, the consultant will make judgement about on-site installed performance of various walls. The performance levels of walls documented in this design guide are either what is reported in a test or the documented opinion of consultants. Performance in projects is typically the responsibility of:

Project Consultants (Structural, Fire, Acoustic, etc.)

These consultants are typically responsible for the following:

Opinions on expected laboratory performance of wall configurations that vary from actual test configuration, such as substitution products and components.
Judgements about expected field performance using laboratory test reports and practical experience.
Design, specification and certification of structural, fire, acoustic, durability, weather tightness and any other required performance criteria for individual projects.

This involves the design and selection of building elements, such as wall and floors and their integration into the building considering the following:

• Interface of different building elements and to the structure/ substrate.
• Wall and floor junctions.
• Penetrations.
• Flanking issues.
• Room/building geometry.
• Acoustic and water penetration field-testing.

Project Certifier and/or Builder

These professionals are typically responsible for :

Identifying the performance requirements for the project in accordance with the Building Code of Australia and clearly communicating this to the relevant parties.
Applicability of any performance characteristics supplied by CSR Hebel including test and opinions for the project.
The project consultant’s responsibilities detailed above if one is not engaged in the project.

CSR Hebel does not provide consulting services. CSR Hebel only provides information that has been prepared by others and therefore shall not be considered experts in the field. Any party using the information contained in this design guide or supplied by CSR Hebel in the course of a project must satisfy themselves that it is true, current and appropriate for the application, consequently accepting responsibility for its use.

It is the responsibility of the architectural designer and engineering parties to ensure that the details in this design guide are appropriate for the intended application. The recommendations in this design guide are formulated along the lines of good building practice, but are not intended to be an exhaustive statement of all relevant data. CSR Hebel is not responsible for the performance of constructed walls, including field performance, and does not interpret or make judgements about performance requirements in the BCA.

1.0 Introduction Party Wall

CSR Hebel Party Wall Design Guide No Responses »

Jun 192012

CSR Hebel

CSR Hebel is 100% owned by CSR Building Products Limited, one of Australia’s leading building products companies. CSR Hebel manufactures and markets a range of lightweight Autoclaved Aerated Concrete (AAC) products. The current product range includes blocks, reinforced panels, cladding panels and lintels for use in the residential and commercial construction industry. CSR Hebel also sells complimentary mortars, tools and accessories.

In 1989, CSR became involved with Hebel and established the Australian operation. Since then CSR Hebel has manufactured products that have won wide acceptance as innovative and environmentally friendly building materials. This is due to their lightweight yet solid nature, excellent thermal, fire and acoustic properties and design versatility. The inherent properties of CSR Hebel products help achieve quick and cost efficient construction practices as well as providing for comfortable operating environments inside the buildings all year round.

Design Overview

As environmental consciousness and social responsibility increases, CSR Hebel is striving to exceed these ideals and set new standards in building materials and residential living.

Designed for inner comfort

With CSR Hebel wall and floor solutions, clients can enjoy a comfortable interior in their home, and be comfortable with the choice for the environment. Manufacture of CSR Hebel materials uses a fraction of the energy and natural resources used in manufacturing conventional masonry, producing almost no waste or by-products. And CSR Hebel AAC’s highly efficient insulation saves power in heating or cooling the home.

Designed for inner peace

CSR Hebel wall and floor solutions help create a tranquil inner space. We have worked closely with acoustic experts and testing authorities to engineer inherently superior acoustics from our wall and floor systems. They create a sound barrier to external noise and from other rooms within the home.

Designed for peace of mind

Although it’s remarkably lightweight, CSR Hebel AAC is solid and durable. CSR Hebel panels are reinforced with steel for extra strength. CSR Hebel is also extremely fire-resistant and is not a food source for termites.

Designed to save

As they’re lightweight, CSR Hebel materials are quick to assemble, saving building time and costs. They also minimise the need for supporting materials, saving budget resources and energy.

Use CSR™ Hebel™ for Better Sound Insulation With advances in technology (particularly the home theatre system) and consumer’s demand for home listening pleasure the need for wall and floor systems offering excellent sound insulation has developed. Recognising the unique properties of AAC, CSR™ Hebel™ was one of the first building products manufacturers to respond to this growing need by developing a range of acoustic wall systems. Since then the peace and amenity of thousands of multiunit households and commercial developments have benefited from Hebel™ PartyWall. As of the 1st May 2004 the Australian Building Codes Board (ABCB) announced that the minimum Building Code of Australia (BCA) sound insulation requirements have been increased. CSR™ Hebel™’s acoustic performance will help you reach the new standard, while also benefiting from the unique lightweight yet solid feel of CSR™ Hebel™ products.

Hebel™ Low Rise MultiResidential Party Walls Hebel™ Low Rise Multi-Residential Party Walls have been developed to provide an effective fire barrier and to satisfy the ever-growing demand for noise abatement in multi-residential framed dwellings. The systems provide cost effective, slender wall sections, with acoustic and fire performance conforming to and exceeding the BCA requirements. Hebel™ PartyWall systems can achieve Rw+ Ctr ratings of 50dB or better.

These PartyWall systems consist of specific combinations of Hebel™ PowerPanel™, CSR™ Bradford insulation and CSR™ Gyprock plasterboard or CSR™ Cemintel fibre cement sheet. These are used to create a symmetrical wall system, which have minimal components and are relatively compact. The resulting walls exhibit high acoustic insulation and fire resistance performance, which have been proven through registered test facilities.

The primary component of the wall is the Hebel™ PowerPanel™, which is a 75mm thick, steel reinforced panel, manufactured from CSR™ Hebel™ AAC. The AAC in CSR™ 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. As with other CSR™ Hebel™ products, Hebel™ PowerPanel™ exhibits excellent thermal and fire resistance properties. Hebel PowerPanel is lightweight and easily handled, typically by only two people.

4.0 Regulatory Issues Party Wall

CSR Hebel Party Wall Design Guide No Responses »

Jun 192012

Dwellings Constructed SideBy-Side on a Single Allotment

Where it is proposed to construct single dwellings side-by-side on a single allotment the internal wall between dwellings is a fire separating wall as defined in the BCA. The fire separating wall must start from the ground level (top of concrete footings or top of floor slab) and achieve a 60/60/60 FRL if load bearing, or –/60/60 FRL if nonload bearing. The wall must go to the underside of a non-combustible roof covering and any gaps be filled with fireresisting material as described in Detail 3.7.1.11 of Volume Two of the BCA.

Dwellings Constructed Side-By-Side on Separate Allotments

Where it is proposed to construct single dwellings side-by-side on separate allotments, or if subsequent subdivision is proposed, the wall might also be considered an external wall and each dwelling may be required to have its own wall starting from the ground level (top of concrete footings or top of floor slab) and each achieving a 60/60/60 FRL if load bearing, or –/60/60 FRL if non-load bearing. Contact your local authorities, as there may also be applicable legislation or discretionary powers available to vary these provisions.

Dwellings Constructed SideBy-Side on a Single Allotment Where Subdivision May Subsequently Occur.

Where it is proposed to construct single dwellings side by side on a single allotment and it is known that subsequent subdivision will occur, or that subdivision might occur (and this will probably apply to most multi-dwelling developments) then, after subdivision, the internal fire separation wall might also be considered an external wall and each dwelling may be required to have its own wall starting from the ground level (top of concrete footings or top of floor slab) and achieving a 60/60/60 FRL if load bearing, or –/60/60 FRL if non-load bearing. Contact your local authorities, as there may also be applicable legislation or discretionary powers available to vary these provisions.

Hebel™ PartyWall Solutions in tiered applications

Where the internal fire separation wall extends beyond the roof line on one side only and becomes an external wall, contact CSR™ Hebel™ Engineering Services for advice on PowerWall™external wall solutions.

Compliance with the Building Code of Australia (BCA)

All building solutions, such as walls, floors, ceilings, etc. must comply with the regulations outlined in the Building Code of Australia (BCA) or other authority.

The BCA is a performance based document, and is available in two volumes which align with two groups of ’Class of Building’: Volume 1 – Class 2 to Class 9 Buildings; and Volume 2 – Class 1 & Class 10 Buildings – Housing Provisions. Each volume presents regulatory Performance Requirements for different Building Solutions for various classes of buildings and performance provisions.

These Performance Provisions include:

Structure
Fire Resistance
Damp & Weatherproofing
Sound Transmission & Insulation
Energy Efficiency

This design guide presents tables and information necessary to design a Hebel™ PartyWall installation that complies with the Performance Requirements of the BCA. The designer must check the adequacy of the building solution for Performance Requirements outlined by the appropriate authority.

Detail 4.1: Typical Applications.

14.0 Panel Handling Party Wall

CSR Hebel Party Wall Design Guide No Responses »

Jun 182012

14.1 Manual Handling

CSR Hebel recommends using a trolley or other mechanical apparatus to move the panels around the work site. Manual handling where people physically move a panel, should be kept to a minimum, with the weight being supported by an individual kept as small as possible. Any concerns regarding the weight to be handled should be discussed with the panel installation contractor.

To minimise the possibility of manual handling injuries, CSR Hebel suggests the following:

Use mechanical aids, such as trolleys, forklifts, cranes and levers, or team lifting to move panels
Keep the work place clean to reduce the risk of slips, trips and falls, which can cause injury
Plan the sequence of installation to minimise panel movements and avoid awkward lifts
Train employees in good lifting techniques to minimise the risk of injury.

14.2 Health, Safety & Personal Protective Equipment (PPE)

CSR Hebel AAC products are cement-based, which may irritate the skin, resulting in itching and occasionally a red rash. The wearing of gloves and suitable clothing to reduce abrasion and irritation of the skin is recommended when handling CSR Hebel AAC and other concrete products. Approved respirators (AS/NZS1715 and AS/NZ1716) and eye protection (AS1336) should be worn at all times when cutting and chasing.

Refer to the appropriate CSR Hebel Material Safety Data Sheet (MSDS).

14.3 Cutting

The use of power tools when cutting concrete products may cause dust, which contains respirable crystalline silica, with the potential to cause bronchitis, silicosis and lung cancer after repeated and prolonged exposure. When using power or hand tools, on CSR Hebel products, wear a P1 or P2 respirator and eye protection. When cutting, routing or chasing CSR Hebel products with power tools, use dust extraction equipment and wear hearing protection.

Reinforcement exposed during cutting is to be coated with a liberal application of CSR Hebel anti-corrosion coating agent.

14.4 Trolley Assisted Handling

CSR Hebel has developed a trolley to allow easier and safer handling of Hebel PowerPanel on-site (refer Image 14.1). There is a range of trolleys to suit panels from 1.2m to 3.9m in length.

Guidelines for handling Hebel PowerPanel using the Hebel PowerPanel Trolley or panel lifters are detailed in Technical Bulletin, CSR Hebel PowerPanel Handling & Installation Guidelines, NºHTB791.