cemintel™ fibre cement systems residential … expresswall.… · fire rated wall systems 30 –...

CEMINTEL™ FIBRE CEMENT SYSTEMs

RESIDENTIAL EXPRESSWALL™oct 2008external cladding systems

fc936

2

CEMINTEL RESIDENTIAL EXPRESSWALL™

ContentsContents 2

Description 2

Applications 2

Advantages 3

Components 4 – 6

Design Considerations 7 – 10

Architectural Specification 33

Top Hat Framing 12 – 13

Panel Preparation 14 – 15

Panel Installation 16 – 18

Curved Facades 19

Construction Details 20 – 29

Fire Rated Wall Systems 30 – 32

Material Properties 33

Handling & Storage 34

Safety 34

Panel Cutting 35

Health & Safety 36

Guarantee 36

DescriptionThe Cemintel Residential ExpressWall™ FacadeSystem provides a versatile and durable facade witha modern style for residential buildings. CemintelResidential ExpressWall™ is a highly adaptablesystem which can be used to conceal most commonstructural materials such as masonry, precastconcrete, and steel or timber stud framing.Residential ExpressPanel™ is an 8mm thick,autoclaved, cellulose fibre reinforced cement sheetwhich is purpose manufactured for use on residentialbuilding facades. It is a square edge sheet with asmooth flat surface suitable for painting. The panels are supported by vertical top hat framingand fixed with concealed screws. The panels may bearranged in a variety of patterns, and surface reliefis produced by expressed joint finishing. Residential ExpressPanel™ can be finished with awide variety of exterior grade acrylic paint oraggregate finishes resulting in a high degree ofdesign freedom.

ApplicationsThe Residential ExpressWall™ System has beendesigned to be used for external cladding ofbuildings such as:

• Residential Homes.• Duplex and Town House Developments.

It however remains the responsibility of the buildingdesigner to verify that the Cemintel ResidentialExpressWall™ Facade System is suitable for theparticular requirements of any given project.The Cemintel Residential ExpressWall™ System hasbeen designed as a drained cavity system (similarto traditional cavity brick systems), and is suitablefor exposed applications.The Cemintel Residential ExpressWall™ System canalso be used as an exterior ceiling. Contact Cemintel™

Fibre Cement Systems for details.

3


AdvantagesDESIGN FEATURES.

• Expressed joint appearance.• Flat, smooth surface.• Countersunk and covered fasteners.• Tested drained cavity system.• Lightweight construction and low maintenance.• Readily accepts many forms of decorative finish.• Suitable for curved applications.• Edges of the Panels are primed with a black

pigmented sealer to accentuate the ExpressedJoint. (No difficult cutting-in is required whenpainting).

CONSTRUCTION FEATURES.

• Prefabrication opportunities.• Rapid installation.• Set-out tolerance for fixing framing.• Dimensionally accurate panels.• Highly durable gasket.

Residential ExpressWall™ Backing Strip

Structural support

Residential ExpressWall™ Vertical Gasket

Adhesive

Residential ExpressWall™ Top Hat

Residential ExpressWall™ Intermediate Top Hat

DuPont Tyvek HomeWrap™ or Rigid Air Barrier

Residential ExpressPanel™

Countersunk HeadFastener

4


Width(mm)8921192

1192✓(39866)✓(39838)

1792✓(39840)

✗

2992✗

✓(86315)

Length (mm)

RESIDENTIAL EXPRESSPANEL™ IS AVAILABLEIN THE FOLLOWING PANEL SIZES.

(All panels 8mm thickness)

RESIDENTIAL EXPRESSWALL™ TOP HAT.

A purpose designed rolled steel section forsupporting the vertical edges of the ResidentialExpressPanel™. The unique profile also acts toaccommodate movement of the sheets at the verticaljoints. It is designed to be used in conjunction withthe Residential ExpressWall™ Vertical Gasket.Residential ExpressWall™ Top Hat is manufacturedfrom galvanised (Z275) BHP steel of 0.75mm basemetal thickness, and has a mass of 1.97kg/m.Residential ExpressWall™ Top Hat is the subject ofpatent application Nº2003 900205.

Order Nº Length39375 3000mm

RESIDENTIAL EXPRESSPANEL™ SEALED EDGES.

External facesuitable for coating

Edges of panels are primedwith pigmented sealer

RESIDENTIAL INTERMEDIATE TOP HAT.

Used to support the Residential ExpressPanel™ atlocations other than vertical joints. ResidentialIntermediate Top Hat is manufactured fromgalvanised (Z275) BHP steel of 0.75mm base metalthickness, and has a mass of 0.95kg/m.


20 2050

35

24 24236623

35

57

163

RESIDENTIAL EXPRESSPANEL™

DRILLING JIG.

Provides a fast and accurate guide for drilling fixingholes at sheet corners.

Order Nº Qty39444 1

ComponentsRESIDENTIAL EXPRESSPANEL™.

An autoclaved, cellulose fibre reinforced cementsheet which is purpose manufactured for use inresidential building facades. ResidentialExpressPanel™ is factory sealed on the face, and alledges are coated with a pigmented sealer toeliminate the need for painting. The face is ready toaccept a wide range of finishes. ResidentialExpressPanel™ is 8mm thick, has a mass of 11.7kg/m2,and is available in the following panel sizes.

COUNTERSINKING TOOL.

A tungsten carbide tipped tool specifically designedfor drilling and countersinking the required 6mmdiameter screw holes in Residential ExpressPanel™.It is suitable for use with screw guns and drills, andhas an adjustable depth setting. This is the only toolrecommended by CSR for this purpose. Use only forcountersunk head screws.

Order Nº Description22116 Countersinking Tool

5


RESIDENTIAL EXPRESSWALL™ SCREW.

Designed for the Residential ExpressWall™ System.They are the only screws recommended by CSR forfixing Residential ExpressPanel™ to the steel top hats.

• Countersunk Head Screw.

The countersunk head allows concealed fixing, andthe buttress thread is designed to provide maximumholding power in light gauge steel. It has a Class 3finish and is gray in colour.

Order Nº Description28624 Countersunk Head

Class 3 Finish 1000/pack

30mm

Class 3 finish

RESIDENTIAL EXPRESSWALL™ VERTICALGASKET.

Made from EPDM closed cell foam which has highUV resistance. The gasket has adhesive on one side(with a release paper), and is adhered to theResidential ExpressWall™Top Hat to prevent moistureentry at vertical joints.

Order Nº Description22106 3.2mm x 48mm x 25m roll

(Tesa 61102)

RESIDENTIAL EXPRESSWALL™ BACKINGSTRIP.

A rolled steel section designed to support the gasketand/or sealant behind the horizontal expressed joints.ExpressWall™ Backing Strip is manufactured fromhigh tensile BHP Colorbond steel, and is black incolour.

Order Nº Length21089 1194mm21088 2394mm21087 2994mm

EXPRESSWALL™ EXTERNAL PVC CORNERMOULD.

A weather resistant corner angle that can be beinstalled as an option for corner construction.


30mm

Stainless Steel

30mm

Class 3 finish

• Exposed Head Screw.

(Suitable for ExpressWall™Top Hat 1.15. ONLY).The Exposed Head Screw has a buttress thread which isdesigned to provide maximum holding power in light gaugesteel. It is available in Class 3 finish and Stainless Steel (grade410).

Order Nº Description28625 Wafer Head

Class 3 Finish 1000/pack28626 Wafer Head

Stainless Steel 1000/pack

6


RESIDENTIAL BACKING STRIP ADHESIVE.

Used for fixing Residential ExpressWall™ BackingStrip to Residential ExpressPanel™. NOTE: Thisproduct is NOT recommended for filling expressedjoints.

Order Nº Description44510 Sikaflex® 11FC, 310ml tube,

(colour black)

JOINT SEALANT.

Used to seal Residential ExpressPanel™ joints for highwind zones.

Order Nº Description39488 Sikaflex® PRO, 310ml tube

(colour black)11378 Sikaflex® PRO, 310ml tube

(colour grey)

Other sealants may be used for decorative purposes,when approved by the manufacturer.

EPOXY.

Epoxy is used to conceal the countersunk fastenerheads, to prevent moisture penetration,and toprovide a flat surface for decorative coating. Epoxyproducts must be installed to the manufacturer’srecommendations.

Order Nº Description25464 Megapoxy P1

BACKING ROD.*

Backing rod is used toenable correct filling ofjoints with sealant. It isrecommended that backingrod be of open cell type to enable sealant to curefrom behind. The diameter of backing rod must beappropriate for the width of the gap being filled.

FLASHINGS & CAPPINGS.*

Flashings are to be designed and installed inaccordance with SAA-HB39 1997 and good buildingpractice.

SARKING.*

A range of sarkings are available to suit variousenvironments. Please contact CSR Bradford foradditional information.

NOTE: Products marked with * are supplied byothers.

PVC CORNER MOULD.

Used for optional corner construction..

Order Nº Description39377 Length 3000mm

50mm

20mm

36mm

AIR BARRIER.*

It is important to note that air barriers must beinstalled correctly as they are an integral element ofa pressure equalised self-draining cavity system.Cemintel™ Fibre Cement Systems recommendsDuPont Tyvek HomeWrap™ is installed and sealed inaccordance with this guide and the manufacturer’sliterature. (Suitable for up to 2kPa design windpressure installations).DuPont FlexWrap™ is used to seal the Tyvek air barrierat corners of openings and at flashings.

Recommended products are: Air barrier: DuPont Tyvek HomeWrap™

Air barrier sealing: DuPont Flexwrap™

RESIDENTIAL EXPRESSWALL™ PVC CAVITYBAFFLE.

Used at the wall base and above window openings.

Order Nº Description38651 Length 3000mm

7


DesignConsiderationsThis guide represents good practice, though it is notintended as an exhaustive statement of all relevantinformation. It remains the responsibility of thebuilding designer to verify that the CemintelExpressWall™ system is suitable for the particularrequirements of any given project.

AIR BARRIER.

It is important to note that air barriers must beinstalled correctly as they are an integral element ofa pressure equalised self-draining cavity system.Cemintel™ Fibre Cement Systems recommendsDuPont Tyvek HomeWrap™ as an air barrier for designwind loads of up to 2kPa, provided it is installed andsealed in accordance with this guide and themanufacturer’s literature. For installations exceeding 2kPa, a rigid air barriermust be installed to the project engineer ’sspecifications.Condensation control should also be considered.

Condensation is a complex problem, and can occurunder a variety of conditions, not just cold conditions.Literature on this subject is available fromCSIRO/BRANZ/ ASHRAE and must be consulted whenbuilding in areas where condensation is likely to occur. In these cases, the appropriate use of a building wrapas a vapour barrier or as thermal insulation, or both,can be effective in controlling condensation.

INSULATION.

It is recommended that insulation materials beinstalled to enhance thermal insulation propertiesand occupant comfort. Insulation also improves theacoustic performance of the wall against outsidenoise. The level of insulation provided by a wall isdetermined by its R-value. Cemintel ResidentialExpressWall™ systems incorporating Bradford R1.5Gold Insulation can provide a thermal rating of R1.75.The higher the R-value the greater the insulationprovided.

ExpressWall™

INSULATION MATERIALS Total WallR-Value

(a) Building Wrap under top hats + Bradford R1.5 Gold Batts in cavity. 1.75

• 1 layer Cemintel ExpressPanel™ fixed to CemintelExpressWall™ top hat framing system.

• Building Wrap • Timber or Steel Studs (90mm min.) at 600mm maximum

centres. • 1 layer x 10mm Plasterboard fixed to the inside of framing.

THERMAL PERFORMANCE.

8


DURABILITY.

Cemintel Residential ExpressPanel™ has manyproperties which make it a very durable product,including:• Immune to permanent water damage in both

short and long-term exposure.• Will not rot, burn or corrode, and is unaffected by

termites, air, steam, salt and sunlight.• Not adversely affected over a temperature range

of 0ºC to 95ºC.• Conforms with the Building Code of Australia

(BCA) requirements for external wall applications.The durability of the Residential ExpressWall™ systemcan be enhanced by periodic inspection andmaintenance. Inspections should includeexamination of the coatings, flashings and seals.Paint finishes must be maintained in accordance withthe manufacturer’s recommendations. Any crackedor damaged finish or seals which would allow wateringress, must be repaired immediately by recoatingor resealing the effected area, or by removing thepanel and replacing gaskets. Any damaged flashings,sheets or gaskets must be replaced as for new work.The durability of the system can also be increasedby the additional treatment of steelwork, and bypainting all exposed sealants to the sealantmanufacturer’s recommendations.

CONTROL JOINTS.

Control joints in the Residential ExpressWall™ systemare required to correspond to control joints in thesupporting structure and anywhere that significantstructural movement is expected.A horizontal control joint is required beneath slabsto accommodate any expected deflection. Themagnitude of the deflection must be verified by thebuilding designer. Refer to FIG 27. Vertical control joints to allow for differentialmovement are also required at the supports of deepfascia trusses and at the junction of structuralelements of different stiffness, such as betweenconcrete columns and stud frames. Refer to FIG 29.

STRUCTURAL SUPPORT.

Residential ExpressWall™Top Hats and IntermediateTop Hats must be installed vertically, and supportedby a primary structural system. Residential ExpressWall™ framing can be fixed toappropriately designed steel or timber framing. Theframe must be designed to support the top hats atthe top and bottom of the wall, and at noggingswithin the span of the wall. As the Residential ExpressWall™ system uses theprimary frame noggings as support for the metal tophats at the mid height of the wall, the connection ofthe nogging to the frame may require special design.Steel frame noggings must also be adequatelydesigned.

Stud Framing

Concrete footing

DuPont Tyvek HomeWrap™ or Rigid Air Barrier


Noggings and connections to project engineer’s specifications


FIG 1. FIXING TO TIMBER FRAMING.

It is the responsibility of the project engineer to

adequately design the primary frame to support the

Residential ExpressWall™ system. Alternatively,horizontal top hats can be installed to support theResidential ExpressWall™ framing. AS/NZS1170.0 Table C1 suggests that support framingbe designed for a maximum deflection of span/250.

9


Residential ExpressWall™ framing can also be fixedover masonry or concrete walls. All top hatconnections must be designed by the projectengineer.

Concrete footing

DuPont Tyvek HomeWrap™

Structural steel frame and connections to project engineer’s specifications

Top track



Bottom track



Masonry wall

FIG 3. FIXING TO EXISTING MASONRY WALL

FIG 2. FIXING TO STEEL FRAMING. PANEL LAYOUT.

Panel layout for the Residential ExpressWall™ systeminvolves the coordination of the following:• Aesthetic Design. • Top Hat Spacing.• Type of Structural Support.• Openings – Size and Location.• Building Size.• Residential ExpressPanel™ Size and Joint Width.

(Horizontal and vertical joints are nominal 8mm).• Building Control Joint Location.

FIG 4. HORIZONTAL SHEETINGALIGNED GRID PATTERN.

FIG 5. SYMMETRICAL SHEETING PATTERN.

Panel layout must be in a grid pattern where verticaland horizontal joints are continuous. Panels may bepositioned vertically or horizontally.In these layouts, construction joints may bepositioned behind any vertical or horizontal sheetjoint. For details on control joints, refer to page 24.

10


VERTICAL JOINT GASKET.

A gaskets is used at vertical joints to maintainweather resistance.The vertical gasket is made from EPDM rubber whichhas good weathering and UV resistance. It has verylow compression set and water permeability.The Residential ExpressWall™ Top Hat has beendesigned to elastically deform when pressure isapplied during panel fixing. This ensures that onlythe required pressure is applied to the vertical gasket.

HORIZONTAL BACKING STRIP.

The horizontal backing strip is adhered behind thetop edge of the ExpressPanel™ using Sikaflex 11Fcadhesive.

Residential ExpressWall™ Backing Strip


Sikaflex 11FC Adhesive



FIG 8. JOINT DETAIL.

FIG 7.VERTICAL GASKET COMPRESSION.

ResidentialExpressPanel™

ResidentialExpressWall™Vertical Gasket

ResidentialExpressWall™ Top Hat

Backing Strip

Residential ExpressPanel


Sikaflex-11FC

™

FIG 6. HORIZONTAL JOINT.

11


ArchitecturalSpecificationSCOPE.

The contractor shall furnish all materials, labour andequipment for the installation of the CemintelResidential ExpressWall™ Facade System whereindicated on the drawings and/or as specified.The Cemintel Residential ExpressWall™ FacadeSystem shall be installed in accordance with CSR™

manual NºFC936 Cemintel Residential ExpressWall™

Facade System.

RESIDENTIAL EXPRESSPANEL™.

Residential ExpressPanel™ shall be 8mm cellulosereinforced sheet manufactured by Cemintel™ FibreCement Systems in accordance with AS/NZS 2908.2.Residential ExpressPanel™‚ shall be coated with*............................, colour *......................., which shallbe installed to the manufacturer’s recommendations.

EXPRESSWALL™ FRAMING.Cemintel Residential ExpressWall™ steel framingsystem shall be Cemintel Residential ExpressWall™

Top Hat and Residential ExpressWall™ IntermediateTop Hat as supplied by Cemintel™.

AIR BARRIER.Air barrier material shall be *DuPont TyvekHomeWrap™ (or product of equivalent or betterperformance). Installation shall be in accordance withCSR™ manual NºFC936 Cemintel ResidentialExpressWall™ Facade System, and relevant DuPontliterature, ORA rigid air barrier system shall be installed inaccordance with project specifications.

CAVITY INFILL INSULATION.Cavity infill shall be *Bradford ........................ (orproduct of equivalent or better performance).

FLASHING.Flashings not supplied by Cemintel™ Fibre CementSystems shall be designed and installed inaccordance with SAA–HB39, 1997, Installation Codefor Metal Roofing and Wall Cladding. Flashing to be*.......................... colour/colour matched to the panels.

FIXINGS.Screws for fixing Residential ExpressPanel™ to tophats shall be *Residential ExpressWall™ CountersunkHead Screws, Class 3 finish. All counter sunk headscrews in the Residential ExpressPanel™‚ shall becovered with *..................... epoxy, and sanded flushwith the panel surface.

ACCESSORIES.Tapes, gaskets, sealants, backing strip, corner mould,cavity baffle and the like shall be as detailed in CSR™

manual NºFC936 Cemintel Residential ExpressWall™

Facade System (*or products of equivalent or betterperformance).

FIRE RATED WALL SYSTEM.The contractor shall supply and install wall system*Nº CSR™ ............... in accordance with CSR™ GyprockFire & Acoustic Design Guide, NºGYP500. The wallshall have a Fire Resistance Level *FRL...../...../..... inaccordance with the requirements of AS1530.4.Installation shall also be carried out to the levelspecified for an acoustic performance of *Rw...........using cavity infill of *Bradford ...............................

FRAMING, FIXING & JOINTS.All Residential ExpressWall™ framing, fixing andjoints shall be designed and installed to comply withthe requirements for *Wind Category/Wind Zone/kPaof ............ minimum.

Note: *Insert or select appropriateproduct/information.

12


Top Hat Spacing

Top Hat Span (Table 1)

Cantilever

Cantilever

FIG 9. SINGLE SPAN INSTALLATION.

Maximum Cantilever = 0.2 x Adjacent Top Hat Span

Top Hat FramingThe design capacities of the Residential ExpressWall™

system are in limit state format and intended for usewith AS/NZS1170.2. The capacity of the top hats as detailed in Table 1 andTable 2 has been calculated in accordance withAS4600 : Cold Formed Steel Structures. The deflection of the top hats as detailed in Table 1and Table 2 is no more than span/250 when subjectedto serviceability wind loads of 68% of ultimate windloads.

TABLE 1. MAXIMUM TOP HAT SPAN.(REFER TO FIG 9).

SINGLE SPAN INSTALLATION.

Wind Classification

Australia

(Wind Category)

N1

N2

N3, C1

N4, C2

N5, C3

N6, C4

New Zealand

(Wind Zone)

Low

Medium

High

Very High

300mm

Spacing

1800

1600

1400

1300

1150

1050

1900

1700

1500

1400

450mm

Spacing

1600

1400

1250

1150

1000

900

1600

1500

1400

1250

600mm

Spacing

1500

1350

1150

1050

900

850

1500

1400

1250

1150

300mm

Spacing

1500

1350

1150

1050

900

800

1500

1400

1250

1150

450mm

Spacing

1300

1200

1050

900

800

750

1350

1250

1100

1050

600mm

Spacing

1200

1100

950

850

750

650

1250

1150

1000

950

General Zone Edge Zone

NOTE: Edge zone is defined as area within 1200mm of edges (Appendix B - AS4055-1992)

13


Cantilever

Cantilever

Top Hat Spacing



FIG 10. DOUBLE-SPAN INSTALLATION.

If adjacent spans differ by more than 25% then single span values must be adopted.Maximum Cantilever = 0.2 x Adjacent Top Hat Span

TABLE 2. MAXIMUM TOP HAT SPAN. (REFER TO FIG 10).

DOUBLE SPAN INSTALLATION.

Wind Classification

Australia

(Wind Category)

N1

N2

N3, C1

N4, C2

N5, C3

N6, C4

New Zealand

(Wind Zone)

Low

Medium

High

Very High

300mm

Spacing

2500

2200

1900

1700

1500

1400

2500

2300

2100

1900

450mm

Spacing

2100

1900

1700

1500

1350

1200

2200

2000

1800

1700

600mm

Spacing

2000

1800

1600

1400

1200

1050

2000

1900

1700

1600

300mm

Spacing

2000

1800

1600

1400

1250

1150

2000

1900

1700

1600

450mm

Spacing

1700

1600

1400

1250

1100

1000

1800

1600

1500

1400

600mm

Spacing

1600

1400

1300

1150

1000

850

1600

1500

1400

1300

General Zone Edge Zone

NOTE: Edge zone is defined as area within 1200mm of edges (Appendix B - AS4055-1992)

Fixing


FixingResidential ExpressWall™ Intermediate Top Hat

FIG 11.TOP HAT FIXING

TOP HAT FIXING.(Refer to FIG 11)

NOTE: It is the responsibility of the project engineer

to specify the connection of the top hats to the

support structure.

Each fastener is required to have a minimum 14mmdiameter head, such as a 12g hex head screw, forsatisfactory top hat performance.

14


Panel PreparationThe following procedures may be performed off-siteprior to installation:Step 1 – Pre-drill and countersink holes for screws.Step 2 – Affix Residential ExpressWall™ backing strip

behind the top edge of the panel and allowadhesive to set. (Alternatively, the backingstrip may be affixed after panel is partiallyscrew fixed. Refer to Panel Fixing fordetails.)

All cut edges should be sealed with exterior gradeacrylic paint such as Dulux Weathersheild X10™Black.

PANEL FIXING SET-OUT.

Residential ExpressPanel™ must be fixed inaccordance with Table 3. Appropriate panel fixinglayout should be selected for the project based onWind Category, Top Hat Spacing and Panel FixingType. (Refer to FIG 13 and 14). For curved facades, please refer to page 19.

45mm*

45mm*

45mm*

Fixing Spacing at Panel Edge (refer to Panel Fixing Table)

Fixing Spacing at Intermediate Top Hat(refer to Panel Fixing Table)

FIG 12. PANEL FIXING SET-OUT.

* Minimum distance of fastener to edge of 35mm.

Top Hat spacing Top Hat spacingTop Hat spacing

FIG 14. PANEL FIXED TOTHREE OR MORE TOP HATS.

FIG 13. PANEL FIXED TO TWO TOP HATS ONLY.

TABLE 3. PANEL FIXING REQUIREMENTS.

Wind Classification

Australia (Wind Category)

N1

N2

N3, C1

N4, C2

N5, C3

N6, C4

New Zealand(Wind Zone)

Low

Medium

High

Very High

Panels Fixedto Two

Top Hats

600

600

600

450

450

300

600

600

600

600

Panels Fixedto Three or

more Top Hats

600

600

600

600

450

300

600

600

600

600

At Panel Edge

500

500

500

450

300

350

500

500

500

500

AtIntermediate

Top Hat

450

300

200

125

125

125

500

350

250

200

Panels Fixedto Two

Top Hats

450

450

450

450

300

300

450

450

450

450

Panels Fixedto Three or

more Top Hats

600

600

600

450

300

300

600

600

600

600

At Panel Edge

500

500

350

250

250

175

500

500

500

350

AtIntermediate

Top Hat

250

175

100

100

100

75

250

200

150

100

General ZoneMax. Top Hat Spacing (mm) Max. Fixing Spacing (mm) Max. Top Hat Spacing (mm) Max. Fixing Spacing (mm)

Edge Zone

NOTE: Edge zone is defined as area within 1200mm of edges (Appendix B - AS 4055-1992)

15


PRE-DRILLING HOLES.

Holes for screws must be pre-drilled. Use therecommended counter sinking tool for countersunkhead screws, and a 6mm masonry bit for exposedhead screws. Holes must be 6.2mm to 6.3mm indiameter. Do not use hammer action when drilling.Clean dust out of holes.NOTE: Use only the recommended tool as suppliedby CSR. The use of other tools for this purpose mayreduce fixing capacity or reduce the weatherresistance of the system. Refer to Componentssection for details.

FIG 15. 6MM MASONRY DRILL FOR EXPOSEDHEAD SCREWS.

HINT: One way of drilling holes is to drill the top sheetof a pack with the counter sinking drill set toapproximately 12mm depth. This will give a starterhole on the sheet below, saving on set out time.

6mm

CORNER DRILLING TEMPLATE.

The Cemintel Residential ExpressPanel™ CornerDrilling Template provides an easy method forlocating the correct position for fixing holes at thecorners of panels. The template locates on the cornerof the sheet and the appropriate drilling position forthe left or right corner of the panel is used to locatethe drill bit.

FIG 16. CORNER DRILLING TEMPLATE.

Residential ExpressWall Backing Strip adhesive fixed behind top edge of panel

3mm 3mm


FIG 17. BACKING STRIP POSITIONING.

16


When top hat is discontinuous, butt ends togethertightly and continue gasket over the joint. If a gap ispresent, install a steel strip to support the gasket.

Steelstrip

10mm max.

FIG 19. GASKET SUPPORT AT DISCONTINUOUS TOP HAT JOINT.

Panel InstallationResidential ExpressPanel™ must be in a dry conditionwhen fixed. If panels become wet after installation,allow to dry before covering screw heads.Panels must only be fixed using Cemintel ResidentialExpressWall™ Screws. Recommended panel installation procedure is::

1. Install Vertical Gaskets to Residential ExpressWall™

Top Hats.

2. Screw fix Residential ExpressPanel™ to top hats,leaving top edge screws out at this stage.

3. Install and adhesive fix Residential ExpressWall™

backing strip behind the top edge of the panel.(Alternatively, panels may be prepared withbacking strip prior to installation. Refer to FIG 17for details.)

4. Install remaining panel fixing screws.

5. Cover fastener heads.

CSR recommends the use of torque control screwguns.If it is necessary to remove and replace a panel, avoidreusing screw holes in the top hats by adjustingfixing locations in the panel.

Residential ExpressWall™Top Hat

Residential ExpressWall™Vertical Gasket applied centrally on top hat

FIG 18.VERTICAL GASKET INSTALLATION.

INSTALLING VERTICAL GASKET TO TOP HAT.

Install vertical gasket to central section of theResidential ExpressWall™Top Hat for the full extent ofpanels. Be careful not to stretch the gasket wheninstalling. When joining gasket, cut ends cleanly andpush together before adhering.

FIXING PANELS USING COUNTERSUNKHEAD FASTENERS.

Drive the countersunk head screw into the top hatusing an electric screw gun. CSR recommends theuse of a screw gun with torque control to preventoverdriving of screws.


Residential ExpressWall™ Countersunk Screw


Residential ExpressWall Top Hat™


Residential ExpressWall™ Exposed Head Screw

FIG 20. FIXING WITH COUNTERSUNK SCREWS.

FIG 20A. FIXING WITH EXPOSED HEAD SCREWS.

30mm

Class 3 finish

17



Residential ExpressWall™Vertical Gasket

8mm


FIG 21. EXPRESSED VERTICAL JOINT DETAIL.

FIG 22. EXPRESSED HORIZONTAL JOINT DETAIL.

Residential ExpressWall™Backing Strip



45mm*

45mm*

8mm nominal

Backing Strip Adhesive

JOINTS.

Residential ExpressPanel™ is generally installed witha nominal 10mm width, horizontal and verticalexpressed joints between adjacent panels. Joints upto 20mm nominal width can be formed, providedadditional care is taken during installation to ensurethat panel edges cover the joint gaskets by aminimum of 10mm.


For Cemintel Residential ExpressWall™ systemssubjected to design wind pressure in excess of2.0kPa, all horizontal and vertical joints must be filledwith recommended joint sealant. Sealant must beinstalled in accordance with the manufacturer’sinstructions.Sealant filled joints may also be used as an aestheticpreference.


Joint sealant (refer to Components) Residential

ExpressWall™Vertical Gasket

8mm


FIG 23. SEALED VERTICAL JOINT DETAIL

FIG 24. SEALED HORIZONTAL JOINT DETAIL

Residential ExpressWall™Backing Strip

Backing Strip Adhesive



Joint Sealant (refer to Components)

45mm*

45mm*

8mm nominal


18


FIG 25. EPOXY COVERING OF SCREW HEADS.

SCREW HEAD COVERING FORCOUNTERSUNK SCREWS.

All countersunk screw heads must be covered withepoxy compound and flush finished with theResidential ExpressPanel™ face. Epoxy shall be installed in the following manner:• Mix epoxy accurately in accordance with the

packaging/manufacturer’s instructions.• Immediately use mixed epoxy.• Slightly overfill holes and level off before epoxy

fully cures.• When cured, sand epoxy level with Residential

ExpressPanel™ face.• Repeat if necessary to achieve a flush finish.

ExpressPanel™

Thin aluminiumstrip

ExpressWall™ Screw

ExpressPanel™

Cover screw head andfill hole with Epoxy

ExpressPanel™

Sand Epoxy levelwith ExpressPanel™ face

HINT: One way of applying epoxy is through a 20mmhole in an aluminum sheet. This will minimise spill-over and allow for some shrink back of the epoxywithout having to repeat the application.

Residential ExpressWall™ Screw

Screw head covered with epoxy

Top Hat

19


Curved FacadesWhere there is an architectural requirement for acurved facade, this can be achieved in three ways. For radii less than 10m, CSR recommends the use ofpre-fabricated glass reinforced cement (GRC) fixedand finished in accordance with the manufacturer’sspecification.For radii greater than 10m, use 8mm ResidentialExpressPanel™ fixed to framing.In general, framing must be set-out on a true curveto enhance appearance and not locally overstressthe panels.For curved facades greater than 2m radius, framingshall be installed in accordance with Table 4.

Curve Radii Panel Type Top Hat SpacingPanel Width

(m) 900mm 1200mm or Greater

10m-15m 1 x 8mm 300* 400*

Cemintel Residential ExpressPanel™

>15m 1 x 8mm 450 As per Table 3

Cemintel Residential ExpressPanel™

TABLE 4. CURVED WALL FRAMING & FACADE PANEL.

* Provide 2 additional fixings per metre to each top hat.

20


FIG 26. BASE DETAIL FOR INLINE SLAB.

Concrete footing

Sealant (optional)

Tyvek fixed to frame under metal strips


Flashing

Tape Tyvek to flashing with DuPont FlexWrap


Open joint to allow for self-draining cavity

Flashing Upstand

Residential ExpressWall™ framing

PVC Cavity Baffle

Construction DetailsWALL FLASHINGS.

In general, flashings shall be designed and installed in accordance with SAA – HB39 1997 – Installation Codefor Metal Roofing and Wall Cladding. Stop ends shall be incorporated with all flashings. All flashings aresupplied by others.

FIG 27. DEFLECTION HEAD.

Deflection gap to be specified by project engineer

DuPont TyvekHomeWrap™

Continuous sealant bead between angle and panel with expressed joint

Fix angle to top hat


Residential ExpressWall™ framing

Drip groove Backing rod

and sealant air seal

Soffit

Backing rod and 10mm min. depth sealant positioned to suit flush or expressed finish


Support framing

FIG 28. HEAD DETAIL AT EAVES.


Residential ExpressWall™ system

Tyvek sheet fixed under metal strip

Eaves lining (eg. CemintelTM Eaves Lining Sheet)

s

21


FIG 29. ABUTMENT DETAIL.

Wall or column

8mm nom. gapsealant filled


Residential ExpressWall™ IntermediateTop Hat

ExpressPanel™

Stud


Backing rod and sealant air seal

FIG 30. FRAMED SOFFIT DETAIL.



Soffit lining


Tape Tyvek to flashing with DuPont FlexWrap

Flashing behind top hat






Residential ExpressWall™ PVC External Corner Mould


Install Dupont Tyvek HomeWrap™ to manufacturer’s specifications



Support Framing

Support Framing

FIG 31. EXTERNAL CORNER DETAIL WITH PVC CORNER MOULD.

22


Rigid structure at corners

Residential ExpressWall™Intermediate Top Hat





Install Dupont Tyvek HomeWrap™ to manufacturer’s specifications

Continuous bead of sealant

Top Hat spacing

Top Hat spacingSupport Framing

Support Framing

Angle 1mm galvanised steel by others

8mm nom.

FIG 33. INTERNAL CORNER DETAIL.




Angle 1mm galvanised steel by others


8mm nom.

Structural framing

Structural framing


FIG 32. EXTERNAL CORNER DETAIL - RIGID STRUCTURE.

23



Maximum 50% of Top Hat spacing

Support

Framing

Support Framing




Maximum 50% of Top Hat spacing

Angle 1mm galvanised steel supplied by others


FIG 34. ANGLED CORNER DETAIL.

FIG 35. CAPPING DETAIL – OPTION 1.

Cap

pin

g ov

erla

p

(ref

er t

o Fl

ashi

ng T

able

)


30mm min.

Fall

Top Hat

Clip to suit capping fixed through oversize hole in panel

Overlap and fix Tyvek under metal strips

Splice and seal capping

Subframe member


FIG 36. CAPPING DETAIL – OPTION 2.


Fall

Bead of Sealant

ResidentialExpressWall™Backing Strip

Subframe member

Top Hat

Gasket to extend to top of ExpressPanel™

Screw fix capping to backing strip over continuous bead of sealant

Overlap and fix Tyvek under metal strips

Splice and seal capping


Parapet capping shall be designed and fastened in accordance with SAA – HB39 1997 – Installation Code forMetal Roofing and Wall Cladding. Stop ends shall be incorporated to all flashings.

Ultimate Design Flashing Upstand

Wind Pressure Minimum

(kPa) (mm)

2.5 150

3.5 200

4.0 250

5.0 300

6.0 350

7.0 400

WALL FLASHINGS

In general, flashings shall be designed and installedin accordance with SAA - HB39 1997 - InstallationCode for Metal Roofing and Wall Cladding. Stopends shall be incorporated with all flashings. Allflashings are supplied by others.

FLASHING UPSTAND.

24


FIG 38.VERTICAL CONTROL JOINT.

Movement joint in structure to engineer's specifications

100mm max.



Allow a ‘loop’ forframe movement

100mm max.

8mm nom. joint

Continuous beadof sealant

SealantTop Hat Top Hat

Continuousbead of sealant

Support anglesBacking Rod



FIG 37. HORIZONTAL CONTROL JOINT.



Fix Residential ExpressWall™ Horizontal Backing Strip

Top Hat

Wall Plate

Wall Plate

Stud

Stud

Joist

8mm nom. joint

5mm clearance

5mm clearance

25


FIG 40.WINDOW JAMB DETAIL

Window Frame

Support Framing

8mm nom.Residential ExpressPanel

FlashingSealant

DuPont FlexWrap over Tyvek at corners of opening

Tyvek to continue 10mm min. past inside face of window frame (fix Tyvek to frame under metal strips)

Backing rod and 5mm min. depth sealant


™

DuPont FlexWrap to seal Tyvek at corners of openings

STEP 1: Fix Tyvek under metal strip

STEP 2: Fold Tyvek back over strip and fix under second metal strip

FIG 39. PREPARATION OF WALL WRAP AT OPENINGS.

26


FIG 41.WINDOW HEAD DETAIL.

Flashing

DuPont FlexWrap over Tyvek and flashing


PVC Cavity Baffle

10mm gap to allow for self-draining cavity





Window Frame

Support Framing

Tyvek to continue 10mm min. past inside face of window frame (fix Tyvek to frame under metal srtips) DuPont FlexWrap

over Tyvek at corners of openingBacking rod and

5mm min. depth sealant

FIG 42.WINDOW SILL DETAIL.

Window Frame





Residential ExpressWall™Vertical Gasket

SupportFraming




27


Window frame

Continuous beadof sealant behindflashing

STEP 1Install Head Flashingand fix to framing

STEP 2Install PVC Cavity Baffle and fix to framing

Tape flashing to Tyvek with DuPont FlexWrap

STEP 5Install Vertical Gasket (down to bottom of cavity baffle)

STEP 6Install Residential ExpressPanel™

10mm gap to allow for self-draining cavity

STEP 7Fill joint with sealant

WINDOW FLASHING PROCEDURE.

STEP 3Install Intermediate Top Hat

STEP 4Install flashing angle

The installation of window flashings will depend on the chosen windows and framing methods. The followingdetails show a typical installation procedure.

FIG 43. FIG 45.

FIG 44. FIG 46.

28


FIG 47.WINDOW HEAD WITH PREFORMED EXTERNAL REVEAL.



Proprietary window flashing taped to Tyvek with DuPont FlexWrap

Proprietary window flashing


Window Frame

Support Framing

Tyvek to continue 10mm min. past inside face of window frame (fix Tyvek to frame under metal strips) DuPont FlexWrap

over Tyvek at corners of opening

Cemintel™ Fibre Cement Preformed Reveal - fix with Sikaflex™ 11FC


Bevel on site if required.

FIG 48.WINDOW SILL WITH PREFORMED EXTERNAL REVEAL.

Window Frame


SupportFraming




Cemintel™ Fibre Cement Preformed Reveal





29


FIG 49.WINDOW JAMB WITH PREFORMED EXTERNAL REVEAL.






Window Frame

CemintelTM Fibre Cement Preformed Window Reveal

Support Framing



30


NOTE:For additional fire and acoustic systems, please refer to the CSR Gyprock Fire & Acoustic Design Guide, NºGYP500.

Cemintel Residential ExpressWall™ can be used witha variety of CSR Gyprock® and Cemintel™ FibreCement fire rated wall systems.These can provide a fire rating from one or both sidesof the wall depending upon the internal liningmaterials chosen.

Refer to the system tables for detailed information.For detailed information on fixing fire rated linings,refer to the CSR Gyprock® Fire & Acoustic DesignGuide, NºGYP500.

Fire Rated Wall Systems

FRL

60/60/60

from both

sides of

the wall

Report/OpinionFCO 1387

STUD DEPTH92 150

CAVITY INFILL Rw(a) Nil 41 44(b) R1.5 Bradford Gold Batts 46 48(c) S4 Bradford Polyester 70mm 600g/m2 46 48

TYPICAL WALL WIDTH (excluding wall frame) mm 168 226TYPICAL WALL MASS (excluding wall frame) kg/m2 47.5 49.3

Residential ExpressWall™

+ CSR 055

EXTERNAL SIDE OF WALL FRAMING

• 1 layer Cemintel Residential ExpressPanel™ fixed toCemintel Residential ExpressWall™ top hat framingsystem.

• Building Wrap.• 1 layer x 16mm GYPROCK FYRCHEK MR™

plasterboard fixed to framing.

• Steel stud framing as required.

INTERNAL SIDE OF WALL FRAMING

• 1 layer x 16mm GYPROCK FYRCHEK™ plasterboard fixed to framing.

Rw

41 – 48

31


NOTE:For additional fire and acoustic systems, please refer to the CSR Gyprock Fire & Acoustic Design Guide, NºGYP500.

FRL

60/60/60

from

outside of

the wall

only

Report/OpinionFCO 1404

STUD DEPTH90

CAVITY INFILL Rw(a) Nil 41(b) R1.5 Bradford Gold Batts 46(c) S4 Bradford Polyester 70mm 600g/m2 45

WALL WIDTH mm 160WALL MASS kg/m2 44.2

Residential ExpressWall™

+ CSR 055

EXTERNAL SIDE OF WALL FRAMING

• 1 layer Cemintel Residential ExpressPanel™ fixed toCemintel Residential ExpressWall™ top hat framingsystem.

• Building Wrap.• 1 layer x 16mm GYPROCK FYRCHEK MR™

plasterboard fixed to framing.

• Timber stud framing as required.

INTERNAL SIDE OF WALL FRAMING

• 1 layer x 10mm GYPROCK® plasterboard CD fixed toframing.

Rw

41 – 46

32


16mm GYPROCK FYRCHEK MR™ Plasterboard

Non-combustible eaves lining (eg. CemintelTM Eaves Lining Sheet)

CSR Bradford Fibertex Rockwool

Timber blocking (45mm min. thickness) to form fire barrier

10mm GYPROCK® plasterboard

10mm GYPROCK® plasterboard

Concrete slab


Dupont Tyvek HomeWrap™

Top Hat

Control joint in ExpressWall™ (refer to detail)

Control joint in plasterboard (15mm high) filled with Gyprock® Fire Mastic

Ground clearance to regulatory requirements

Refer to base flashing detail

Gyprock® Fire Mastic

Tape with DuPont FlexWrap

FIG 51.TYPICAL EXPRESSWALL™ FIRE RATED INSTALLATION.(FRL 60/60/60 FROM OUTSIDE ONLY).

33


MaterialPropertiesRESIDENTIAL EXPRESSPANEL™

MANUFACTURING TOLERANCES.

Length +0 to -2mm.

Width +0 to -2mm.

Thickness +10% to -0%.

Diagonals Difference (max) 2mm.

Edge Straightness deviation (max) 1mm.

Ignitability 0

Spread of Flame 0

Heat Evolved 0

Smoke Developed 0

SYSTEM TESTING.

The Cemintel Residential ExpressWall™ System hasbeen designed and tested by CSR Gyprock & FibreCement Research & Development. The ResidentialExpressWall™ System has passed testing to thefollowing parts of AS/NZS4284 ‘Testing of BuildingFacades’.• Structural Test• Water Penetration by Static Pressure.• Water Penetration by Cyclic Pressure.• Proof Test.The system has been tested to AS4040.3 ‘Methodsof testing roof and wall cladding, Method 3 :Resistance to wind pressure for cyclonic regions.

FIRE RESISTANCE.

Under the Building Code of Australia, C1.1 Clause2.5(e), Cemintel™ Fibre Cement is deemed to be non-combustible. When tested in accordance withAS1530.3, the Early Fire Hazard Indices are asfollows:

34


Handling & StorageAll Cemintel Residential ExpressPanel™ must bestacked flat, clear of the ground, and supported ona level platform. Care must be taken to avoid damage to edges, endsand surfaces. Material must be kept dry, preferably by being storedinside the building. Protect from contaminants suchas silicone spray.Where it is necessary to store panels outside, theymust be protected from the weather. Panels must be dry prior to fixing and finishing.

SafetyWhen cutting Residential ExpressPanel™ using powertools, always ensure the work area is well ventilated.An approved dust mask (AS1715 and AS1716) andsafety glasses (AS1337) must be worn. CSRrecommends that hearing protection be worn.

35


Panel CuttingPOWER SAW.

When it is necessary to use power tools for cuttingCemintel Residential ExpressPanel™, CSRrecommends using the Hitachi Fibre Cement PowerSaw Blade. This blade is specifically designed for usewith fibre cement and produces a superior cutcompared to conventional blades.It is ideal for use with the Hitachi C7YA dustlesscircular saw and other 185mm circular saws fittedwith vacuum extraction systems.

Hitachi C7YA DustlessCircular Saw with DustExtraction System.

Order No - 10836Dust extractor - 10833Hitachi Fibre Cement

Power Saw Blade.

Order No - 10837

DRILLING.

Cemintel Residential ExpressPanel™ fixing holes shallbe drilled and countersunk with the recommendedcountersinking tool. All general purpose drilling shallbe done with a masonry drill bit. NOTE: In all cases DO NOT use hammer action whendrilling.

Panasonic EY3532,18 volt Saw

36


GuaranteeCSR Building Products Limited warrants its FibreCement products to be free of defects in materialsand manufacture. If a CSR product does not meetour standard, we will, at our option, replace or repairit, supply an equivalent product, or pay for doing oneof these.This warranty excludes all other warranties andliability for damage or loss in connection with defectsin CSR's product, other than those compulsorilyimposed by legislation, notably the Trade PracticesAct.

Health & SafetyWARNING: Fibre Cement products contain crystallinesilica. Repeated inhalation of fibre cement dust maycause lung scarring (silicosis) or cancer. Do notbreathe the dust. When cutting sheets, use themethods recommended in this brochure to minimisedust generation. If power tools are used, wear anapproved dust mask (respirator). These precautionsare not necessary when stacking, unloading orhandling fibre cement products.For further information and for a Material Safety DataSheet, phone 1800 807 668.

©Cemintel™ Fibre Cement Systems, CSR Building Products Limited A.B.N. 55 008 631 356.

CEMINTEL™ FIBRE CEMENT SYSTEMs

RESIDENTIAL EXPRESSWALL™oct 2008external cladding systems

fc936cemintel™ fibre cement systems, csr building products limited, A.B.N 55 008 631 356 BMS8240.0505

CONTACT DETAILS Cemintel™ Fibre Cement Sytems Web Site.

www.cemintel.com.au

Cemintel™ Fibre Cement Sytems Sales Support.

Telephone: 13 17 44. Facsimile: 1800 646 364.

CSR designLINK® Technical Support Service.

Telephone: 1800 621 117.

New South Wales and ACT.

376 Victoria Street, Wetherill Park NSW 2164.

Queensland.

768 Boundary Road, Coopers Plains QLD 4108.

Victoria.

277 Whitehall Street, Yarraville VIC 3013.

South Australia.

Lot 100 Sharp Court, Mawson Lakes SA 5095.

Western Australia.

21 Sheffield Road, Welshpool WA 6106.

Tasmania.

PO Box 61, Glenorchy TAS 7010.

Northern Territory.

Cnr Stuart Hwy & Angliss St, Berrimah NT 0828.

www.cemintel.com.au

cemintel™ fibre cement systems residential … expresswall.… · fire rated wall systems 30 –...

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