panel wall construction

4.0 How to Design a Hebel PowerWall

CSR Hebel Detached & Low Residential Design Guide No Responses »

Jun 292012

4.1 Design Process

This section outlines the design process for determining the adequacy of Hebel PowerWall.

STEP 1: Determine the wind category, stud framing layout and PowerPanel height requirements.

STEP 2: Design Criteria. Where required identify the BCA Performance Requirements:

Fire Resistance Level (FRL).
Sound insulation performance (R_w values).
Energy Efficiency (R-Value).

STEP 3: The flowchart below can be used to select a type, spacing and quantity of top hats and fixings to suit requirements.
STEP 4: Select insulation and/or sarking material to suit energy efficiency and condensation requirements.
STEP 5: Check adequacy of sound insulation and fire resistance level.
STEP 6: Complete detailed design and documentation.

4.2 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 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; and Energy Efficiency.

This design guide presents tables, charts and information necessary to design a Hebel PowerWall 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.

Fig. 4.1 Flow Chart for Design Process

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

9.0 Sound Transmission & Insulation Power Wall

CSR Hebel Detached & Low Residential Design Guide No Responses »

Jun 292012

9.1 Overview

Current BCA Sound Transmission and Insulation Requirements

Hebel PowerWall is primarily used in buildings that have a domestic type of activity purpose. The BCA generally classifies these buildings into class 1 or 10. The acoustic performance requirements for external walls in these buildings or their building elements are not currently stated in the BCA. If a building using Hebel PowerWall was required to provide acoustic performance, then the performance level requirements for a building envelope and elements would be set by the relevant authorities (i.e. Local Councils, client specific requirements and etc).

Design Recommendations

Acoustic design is a complex science, and there will be instances where a specialist acoustic consultant is required.

For walls requiring acoustic performance CSR Hebel recommends:

1. Engaging a reputable acoustic consultant on a project-by-project basis to provide design advice and installation inspections.

2. When selecting the appropriate components for Hebel PowerWall, the designer or specifier must be aware that the laboratory R_w values are almost always higher than the field measured values. Therefore, allowances should be made for the lower expected field values during the selection of the system.

3. Separate advice from a specialist acoustic consultant should be sought to determine the effect on acoustic performance due to any changes to Hebel PowerWall, and any required modification of the installation details pertaining to the systems.

4. Increasing cavity widths, using higher density or thicker insulation or plasterboard, will generally maintain or increase the acoustic performance of Hebel PowerWall.

9.2 CSR Sound Control Systems

The CSR External Sound Control Systems guide provides solution for various external sound environments, the home can be designed so the interior noise is reduced to a selected level. The purpose of this guide is to provide solutions for the design of new residential buildings subject to certain types of external noise.

External Noise

External, or environmental noise in urban areas is pollution that can intrude into homes. It has many sources and can have a number of undesirable impacts.

Common external noise sources include:

Road, air and rail transport.
Industrial operations.
Entertainment venues.
Sporting activity.
Pool and garden equipment.
Neighbourhood noise such as
television, parties.
Barking dogs and lawn mowers.

Noise Source

Noise levels from various sources have been divided into four bands measured as LAeq (see GYP 572 August – 2005):

Quiet suburban, 50 – 55dB(A).
Medium suburban, 55 – 60dB(A).
Noisy suburban, 60 – 65dB(A).
Inner city, 65 – 70dB(A).

Interior Noise Levels

The noise levels within a home that result from external noise are measured as LAeq in the same way as the noise source. The term is a measure of the loudness of a sound, with units dB(A). The A weighting indicates that the value has been filtered to focus on the frequencies to which the ear is sensitive.

Note the noise levels experienced in a home are affected to some extent by the interior furnishings. An interior noise level of LAeq 35dB(A) for road, train, industrial and neighbourhood noise, selected from Australian Standard AS/NZS2107.

Acoustics – Recommended Design

Sound Levels And Reverberation Times For Building Interiors, is considered the upper limit for sleeping areas in houses near minor roads and within the range recommended for houses near major roads.

Note the noise level 35dB(A) is very quiet. Occupants could expect to hold a conversation without raising their voices, listen to TV at low volume, and sleep unaffected. Windows and doors must be closed to achieve the stated result.

It is possible to choose a lower level of internal noise, however, the designer should consider the ability of a system to reach the level, the higher cost to achieve lower noise levels, and the sensitivity of the occupants to noise.

Fig. 9.1 Interior Noise Level Reduction Through CSR Sound Control System

CSR System HB1		CSR System HB2
• 90mm Timber or Steel Framing • 1 x 10mm Gyprock Soundchek plasterboard direct fixed to frame • Bradford SoundScreen R1.6 • Hebel PowerPanel Wall System	• 90mm Timber or Steel Framing • 2 x 10mm Gyprock Soundchek plasterboard direct fixed to frame • Bradford SoundScreen R2.0 • Bradford EnviroSeal • Hebel PowerPanel Wall System
Acoustic Rating R_w/R_w + C_tr – wall 60/50	Acoustic Rating R_w/R_w + C_tr – wall 63/54

CSR System HB1

CSR System HB2

• 90mm Timber or Steel Framing

• 1 x 10mm Gyprock Soundchek plasterboard
direct fixed to frame

• Bradford SoundScreen R1.6

• Hebel PowerPanel Wall System

• 90mm Timber or Steel Framing

• 2 x 10mm Gyprock Soundchek plasterboard
direct fixed to frame

• Bradford SoundScreen R2.0

• Bradford EnviroSeal

• Hebel PowerPanel Wall System

Acoustic Rating R_w/R_w + C_tr – wall 60/50

Acoustic Rating R_w/R_w + C_tr – wall 63/54

For further information see page 16 and 17 of GYP572 August 2005 “Sound Control External Noise Systems”.

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.

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.

15.0 Panel Handling Power Wall

CSR Hebel Detached & Low Residential Design Guide No Responses »

Jun 132012

15.1 Manual Handling

CSR Hebel recommends using a trolley or other mechanical apparatus to move the PowerPanels around the work site. Manual handling where people physically move a PowerPanel 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 PowerPanel 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 PowerPanels.
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 PowerPanel movements and avoid awkward lifts.
Train employees in good lifting techniques to minimise the risk of injury.

15.2 Mechanically Assisted Handling

Moving and handling Hebel PowerPanel should be done as much as possible using mechanical aids such as forklifts, cranes and special PowerPanel lifting trolleys.

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

Fig. 15.1 Personal Protective Equipment

15.3 Health, Safety & Personal Protective Equipment (PPE)

Hebel 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 Hebel 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 CSR Hebel Material Safety Data Sheets. Refer to the back of this Design & Installation Guide for further information regarding health and safety.

15.4 Cutting

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

Reinforcement exposed during cutting must be coated with a liberal application of Hebel corrosion protection paint.

Fig 15.2 Hebel PowerPanel Trolley

16.0 Delivery and Storage Power Wall

CSR Hebel Detached & Low Residential Design Guide No Responses »

Jun 132012

16.1 Unloading Panels

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

NOTE
Secondary handling increases the risk of PowerPanel damage. The repair of damage sustained during lifting and moving is the responsibility of the lifter. Where damage is excessive, PowerPanels must be replaced.

16.2 Storage

All materials must be kept dry and preferably stored undercover. Care should be taken to avoid sagging or damage to ends, edges and surfaces.

All Hebel products must be stacked on edge and properly supported off the ground, on a level platform. Panel bundles can be stacked two high. The project engineer should be consulted as to the adequacy of the structure to support the stacked bundles.

If outside, Hebel PowerPanels must be stored off the ground and protected from the weather. Only single bundles positioned on the ground can be opened. To provide a level surface, we recommend placing temporary joists beneath the supporting cleats.

Fig. 16.1 Hebel PowerPanel Shipping Bundle

*Unstrapping Bundles

Ensure appropriate bracing is installed to bundles prior to removal of strapping to prevent panels from falling. Panels can be held together with sash clamps, ratchet straps or Hebel stabilising bars.