express - eternit australia · express technical manual. ... express is a great solution for the...

ExpressTechnical Manual

Table of Contents1 Introduction 1

1.1 Eternit 1

1.2 Etex 1

2 Express 2 2.1 Benefits 2

2.2 Technical Specifications 2

3 Working With Express 3 3.1 Accessories 3

3.2 Site work 5

3.2.1 Loading And Unloading 5

3.2.2 Transport To Site 5

3.2.3 Storage 5

3.2.4 Handling Of Express Panels 6

3.2.5 Kalsi® Cavity Batten Handling 6

3.3 Cutting 7

3.4 Drilling 7

4 Design Specifications 8 4.1 Compliance 8

4.2 Framing Considerations 8

4.3 Moisture Management 8

4.3.1 Vapour Permeable Membranes 8

4.3.2 Flashing 8

4.4 Wind Pressure 9

4.5 Fasteners 9

4.6 Kalsi® Cavity Batten Installation 9

4.6.1 Kalsi® Cavity Batten Fixing 11

5 Express Panel Installation 12 5.1 Panel Fixing 12

5.2 Fixing Express 13

5.3 Panel Joints 13

6 Detailing Express 16 6.1 Concrete Slab Detail 16

6.2 Soffit Details 16

c

Table of Contents6.3 Window Details 17

6.4 External Corner 17

6.5 Internal Corner 18

6.6 Parapet Detail 18

7 Finishing 19

8 Health & Safety 19

Notes 20

1

1.2 Etex

Etex is a Belgian industrial group that specialises and markets high quality building materials and systems. Headquartered

in Brussels, Belgium, Etex currently operates in 123 factories and 116 subsidiaries across 44 countries, employs more than

18,000 people and is one of the largest fibre cement producers in the world.

Through its subsidiaries, the Group offers an extensive range of products: small and large roofing materials, cladding and

building boards, passive fire protection systems and ceramic tiles.

Etex aims to be a professional, solid partner for all kind of building projects.

Founded in 1905, Etex has consolidated it's unique global presence thanks to strong expertise, technical knowledge, innovative culture and deep understanding of the local needs and requirements in the markets where it operates.

1 Introduction

1.1 Eternit

Eternit Asia Panels groups Etex’s companies in Asia Pacific, dedicating it efforts to provide the highest quality building

technologies available to the market.

The company has extensive product knowledge built up from more than a century of fibre cement expertise. Research &

Development Centres throughout the world ensure that our products perform at all levels.

Our products are proudly made with highest consideration for the environment and preservation of nonrenewable resources.

Tough, resistant and durable, are the perfect replacement for wooden products, concrete and masonry constructions.

2

2 ExpressExpress is a system comprised of fibre cement panels, timber studs and fibre cement

cavity battens to achieve an express joint cladding finish in residential projects.

Cost effective and rapid to install, Express is a great solution for the contemporary

architecture willing to explore that urban modern look.

2.1 Benefits

• Rapid Installation

Express panels and the fibre cement cavity battens are nail gun-able. As the boards are hydrophobated in their

front and four edges, they are protected during installation from rain and humidity.

• Smooth Surface

Express has a finely sanded and flat surface ready to receive glossy acrylic paints with minimum preparation.

2.2 Technical Specifications

Dimensions

Length (mm) Width (mm) Thickness (mm)

1190 1190 8.0

2390 590 8.0

2990 1190 8.0

2400 1200 8.0

2700 1200 8.0

2440 1220 8.0

General Technical Properties

Dimensional Conformity (tested to AS/NZS 2908.2) Pass

Density (tested to AS/NZS 2908.2) kg/m3 ≥1200

Modulus of rupture (tested to AS/NZS 2908.2) (Type A . Category 3)

MPa ≥7

Water permeability (tested to AS/NZS 2908.2) Pass

Moisture content 5%

Water absorption 31%

Moisture movement (25°C 30%RH - 25°C 90%RH)Strong direction Weak direction

mm/m mm/m

0.600.52

Thermal conductivity (tested to ASTM C518-76) W/m°K 0.27

Durability

Warm water performance (tested to AS/NZS 2908.2) Pass

Freeze-thaw performance (tested to AS/NZS 2908.2) Pass

Soak-dry performance (tested to AS/NZS 2908.2) Pass

Heat-rain performance (tested to AS/NZS 2908.2) Pass

3

3 Working with Express

3.1 Accessories

Kalsi® cavity battenFibre cement 2950mm x 70mm x 15mm thick*supplied by Eternit

Cavity Batten to Timber Frame Fasteners65 x 2.8mm galvanised ring shank nail75 x 2.8mm D or round head smooth shank nail

Express to Cavity Batten FastenersC25mm 16 gauge brad nails2.8 x 30mm corrosion resistant fibre cement nails2.6 x 26mm twist shank nail with minimum round head diameter of 5.3mm(Galvanised or stainless steel)

Nail guns

Backing Strip* Peer backing strip is the preferred product

Paintable exterior grade polyurethane joint sealant*Sikaflex 11FC is the preferred product

EPDM gasket/foam seal*Tesa EPD expanded foam seal 61102 is the preferred product.

Vapour permeable membrane

4

L corner flashing

Aluminium external box corner

Vermin closing/Cavity base closer

Vacuum extraction with HEPA filter

Dust–reducing saw

Fibre cement blade

5

3.2 Site Work

3.2.1 Loading And Unloading

Express panels and Kalsi® cavity battens are supplied on pallets suitable for forklift unloading. If crane offloading by

slings is envisaged, special notification must be made in advance or upon placing orders.

All pallets and crates can be safely handled by using a barge lift or hoisting equipment and straps. Steel cables should not be

used as these will damage both the pallet and the panels within.

When the crates have to be removed from a box container, care must be taken NOT to expose crates or pallets to the shock

of any impact. Shock of impact could result in cracks in the packing.

3.2.2 Transport To Site

Always drive the delivery vehicle as close as possible to the location where the panels are to be installed. When transporting

the panels and cavity battens, it is essential to firmly secure the pallets to prevent panels from sliding or moving while in

transit.

3.2.3 Storage

Express panels and Kalsi® cavity battens with protective plastic sheeting wrapped around the timber crates. This

protection should not be removed until site and structural conditions are prepared and ready for panel installation.

All Express panels and Kalsi® cavity battens must be stored flat on pallets and placed inside in covered and dry

conditions, optimising protection for stored panels against exposure to weather and other unfavourable conditions.

Figure 1

Protective Plastic Sheeting

6

3.2.4 Handling Of HD Panels

The following must be taken into consideration when handling Express panels.

Figure 2

Whenever possible, lift the panel from the stack

below rather than slide panel on panel or drag off

the stack. This will prevent damage by scratches

to the lower panel.

Figure 3

Always carry the panel on edge but DO NOT

store on edge.

3.2.5 Kalsi® Cavity Batten Handling

The following must be taken into consideration when handling Kalsi® cavity battens.

Figure 4

Never carry Kalsi® cavity batten on flat and

middle position, as this increases likelihood of

breakage.

Figure 5

Hold the Kalsi® cavity batten vertically at the

edge.

7

Figure 6

When a single person needs to carry the

Kalsi® cavity batten, hold it in the middle and

keep hands as far apart as possible to provide

maximum support to the length of the cavity

batten.

Figure 7

When two persons carry the Kalsi® cavity batten,

hold it near both end of the cavity batten.

3.3 Cutting

Express panels offer easy workability with conventional tools, on or off construction sites. The method of cutting

is dependent on the amount of cutting. Cutting of the panel can be achieved using stationary table saws, circular saw and

jigsaws. Cutting must take place in a dry environment. Dust control is advisable.

It is recommended that fibre cement saw blades (see Figure 8) are used to cut the panels on site. These blades have been

designed especially for fibre cement and when correctly employed a high level of finish can be achieved. The blade is uniquely

designed with vibration damping composite body construction and diamond tipped teeth shaped to give a tear-free edge.

When small amounts of cutting are required on site, an alternative to the recommended fibre cement saw blade is a carbide-

tipped flat trapezoidal tooth blade. This has a limited life and will need regular changing.

Figure 8

Fibre cement blade.

3.4 Drilling

Express should be drilled using preferred and more efficient tungsten carbide tipped drill bit with point angles of 60°

to 80° rather than the usual 120° type.

8

4 Design Specifications

4.1 Compliance

Designers and/or contractors responsible for the intended project should follow the details and recommendations specified in

this manual.

It is also wise to keep in mind that all building design and construction should comply fully with the appropriate and relevant

requirements of current legal building codes, regulations and standards, both domestic and international.

The information provided in this manual is valid at the time of publication. Please consult Eternit or its nearest official

representative for further versions or updates.

4.2 Framing Considerations

The most common arrangement for the panel’s support is onto timber framing.

Ensure timber products are properly seasoned and dry before installation. Refer to AS 1684.2 – Residential Timber Frame

Construction or the respective local standards compliance for the framing construction. Minimum timber stud must be of

dimension 70mm x 35mm.

Always check that all framing is straight and true before receiving the panels.

4.3 Moisture Management

Designers and/or contractors responsible for construction must ensure that building exteriors are appropriately waterproofed.

This includes all wall openings, window sills, junctions and connections.

Selection of materials and installation needs to take into account the requirements of relevant standards and building codes. It

is always recommended that project specific details are undertaken by an experienced consultant with local knowledge of this

specific field.

4.3.1 Vapour Permeable Membranes

Building underlays must be installed in accordance with AS/NZS 4200.2 and material properties complying with AS/NZS

4200.1 or the equivalent local standards, codes and regulations.

In addition to the above, installation of the building underlay must also be in accordance with the manufacturer’s

recommendations.

4.3.2 Flashing

Prior to fixing Express panels, appropriate flashing and weatherproofing needs to be applied at critical points, such

as:

• External corners

9

• Internal corners

• Window and door openings

• Penetration where pipes or wiring pass through the panels

4.4 Wind Pressure

It is the responsibility of the designated project engineer to determine the relevant and specific wind pressures. All structural

calculations must be achieved by following the relevant building codes. For the maximum capabilities of Express

please consult the Eternit Technical Department.

4.5 Fasteners

Consideration of fastener durability will be influenced by material choice, environmental factors and compatibility of materials

in contact with fasteners. In general, the fasteners of choice should be resistant to corrosion.

When Express is installed in coastal areas, Eternit recommends the use of stainless steel fasteners, especially within

1km of the coast or when local micro climatic conditions (exposure to salt environments, for example) require it.

Fasteners must be driven flush into the panels, as per Figure 9.

Figure 9

Nail fastener depth

4.6 Kalsi® Cavity Batten Installation

Kalsi® cavity battens can be installed into the framing, either on or off stud. Off-stud construction is designed only for low wind

areas and requires nogging to be firmly fixed to the framing to support the cavity batten. Refer to Table 2 for stud spacing.

Use a spirit level to ensure batten is plumb to true vertical.

On Stud Fixing

• Fix Kalsi® cavity battens vertically on main frame and over the water permeable membrane. See Figure 10.

• Ensure panel edge opening is located centrally over the cavity batten.

Off Stud Fixing

• As some design of panel layout require edge openings not on the main frame, battens can be installed off-stud depending

on the panel edges position. See Figure 11.

10

• Maximum nogging spacing for off-stud fixing is at 800mm centres.

• Ensure nogging is flush with outer face of framing to properly accommodate off-stud fixing.

Figure 10

On stud batten fixing

Figure 11

Off stud batten fixing

800mmMaximum

800mmMaximum

Butt jointed cavity batten can only be constructed within the storey height. Cut the end of the cavity batten at 45° angle

slopping down and seal with polyurethane joint sealant. See Figure 12.

1

2

3

1. Kalsi® cavity batten

2. Vapour permeable membrane

3. Joint sealant

Figure 12

Cavity batten jointing

50mm

50mm

11

4.6.1 Kalsi® Cavity Batten Fixing

Fix Kalsi® cavity battens with fastener as specified in Table 1 and spacing in Table 2. See Figure 13 for fixing guide.

Table 1: Fasteners fixing from cavity batten to frame

Batten Fixing to Framing Fasteners

Timber framing65 x 2.8mm galvanised ring shank nail75 x 2.8mm D or round head smooth shank nail

1

2

4

3



3. Joint sealant

4. Nail gun

Figure 13

Fixing Kalsi® cavity batten

12

5 Express Panel Installation

5.1 Panel Fixing

Spacing of fixing for Express 8mm panels must be determined in accordance with Table 2. See Figure 14 for panel

fixing layouts.

1

42 3 5

7

6

1. Express

2. Horizontal timber stud

3. Kalsi® cavity battens

4. Vertical timber stud


6. Backing strip

7. Finish

Figure 14

Panel fixing layout

Table 2: Design Table

Wind Classification AS 4055

Off Stud Fixing(mm)

On Stud Fixing(mm)

Cavity Batten Fastener Spacing

(mm)

Express Fastener Spacing

(mm)

N1, N2, N3 600 600 300 200

N4 - 450 200 200

N5 - 450 200 200

N6 - 300 200 150

C1 450 450 200 200

C2 - 450 200 200

C3 - 450 200 200

C4 - 300 200 150

13

5.2 Fixing Express

The panel can be fixed using options listed in following Table 3. See Figure 15 for panel fixing layout.

Table 3: Nail Requirement

C25mm 16 gauge brad nails2.8 x 30mm corrosion resistant fibre cement nails2.6 x 26mm twist shank nail with minimum round head diameter of 5.3mm(Galvanised or stainless steel)

2

1

3

6

5 4 7 1. Express


3. Nail fixing


5. EPDM gasket/foam seal

6. Finish

7. Joint sealant

Figure 15

Nail fixing panel to cavity batten

10mm

12mm

12mm

5.3 Panel Joints

Panels are generally installed with a nominal 10mm width of spacing for vertical and horizontal expressed joints. Both vertical

and horizontal spacing can be ensured by using the backing strip as a spacer, achieving a 10mm gap between panels. See

Figure 16.

Recommended use of Sikaflex 11 FC for polyurethane joint sealant to fix the baking strip.

Vertical Panel Joints

• Set the flexible paintable UV resistant EPDM rubber foam tape at the centre of the cavity batten. See Figure 16.

• Apply a continuous 6mm diameter bead of polyurethane joint sealant onto the cavity batten at each panel edge.

8

2

3

6

7

5 4 1 1. Express


3. Nail fixing



6. Finish

7. Backing strip

8. Joint sealant

Figure 16

Vertical panel joints

10mm

12mm

12mm

14

Horizontal Panel Joints

• Apply a continuous bead of polyurethane joint sealant on the bottom part of the backing strip. The backing strip must be

5mm shorter at each side of Express panel width. See Figure 17.

1

2 3 1. Express

2. Backing strip

3. Joint sealant

Figure 17

Apply sealant to backing strip

5mm

• Seal the back of the backing strip with polyurethane joint sealant and continue from the top until the back of the panel. Fill

the back of the rolled stop with 50mm length of polyurethane joint sealant at each side of the back of backing strip. See

Figure 18.

1

2

3

1. Express

2. Backing strip

3. Joint sealant

Figure 18

Seal backing strip end details

50mm

70mm

5mm

• Install the first panel. See Figure 19.

1

2

3 4 5

1. Express


3. Backing strip

4. Joint sealant


Figure 19

Install first panel

15

• Apply a continuous bead of sealant to top of backing strip. Install a new Express panel on top of the horizontal

backing strip. This panel must be properly pre-drilled. See Figure 16.

1

3 4 52

1. Express


3. Backing strip

4. Joint sealant


Figure 20

Installing subsequent top panel

16

6 Detailing Express

6.1Concrete Slab

5

1

6

1. Express


3. Joint sealant


5. Finish

6. Nail fixing

7. Cavity base closer

Figure 21

Concrete slab detail

4

3

2

7

6.2 Soffit Details

5

1

6

1. Express



4. Soffit

5. Finish

6. Nail fixing


8. Joint sealant

Figure 22

Soffit detail

4

3

2

7

8

17

6.3 Window Details

5

5

1

1

7

8

7

8

6

6

1. Express


3. Timber frame


5. Finish

6. Nail fixing

7. Metal flashing

8. Window frame

Figure 23

Cross section of window

4

4

2

2

3

3

1. Express


3. Timber frame


5. Finish

6. Nail fixing

7. Window frame


Figure 24

Window jamb details5

1

8

2

4

6

3

7

6.4 External Corner

2

3

6

1. Express


3. Timber frame


5. Finish

6. Nail fixing

7. Joint sealant

Figure 25

External corner detail option 1

4

1

5

7

18

2

3

6

8

1. Express


3. Timber frame


5. Finish

6. Nail fixing

7. External box corner

8. Joint sealant

Figure 26

External corner detail option 2

4

1

5

7

6.5 Internal Corners

3

2

7

5

1. Express


3. Timber frame


5. Finish

6. Nail fixing

7. Joint sealant

Figure 27

Internal corner1

6

4

6.6 Parapet Detail

9

1

5

6

2

4

1. Express


3. Timber frame


5. Finish

6. Nail fixing

7. Internal parapet board

8. Batten

9. Metal Flashing

Figure 28

Parapet detail

7

3

8

50mmoverlap

20°

19

7 Finishing Express panels need to be finished with a weatherproof coating to ensure durability and a long service life of the

panels.

Express panels can be coated with a wide range of attractive architectural finishes either on site or off site.

Use high grade exterior acrylic paint as a finishing coat.

Be sure to obtain and understand paint manufacturer’s recommendations before commencing work.

8 Health & Safety As for all products containing quartz (e.g. concrete and clay), Express architectural boards and panels, when

machined mechanically (cutting, sanding, drilling) will release dust which may contain quartz particles. Inhalation of high

concentrations of dust may irritate the airways. Dust may also cause irritation of the eyes and/or skin. Inhalation of dust

containing quartz, in particular the fine (respirable size) dust particulate matter, in high concentrations or over prolonged

periods of time, can lead to lung disease (silicosis) and an increased risk of lung cancer.

• Avoid dust inhalation by using cutting equipment which features dust extraction or suppression accessories where

practicable.

• Ensure adequate ventilation in the work place.

• Avoid contact with the eyes and skin and inhalation of dust by wearing appropriate personal protective equipment (safety

goggles, protective clothing) and approved respirator, a dusk mask of at least type P2.

For more information, consult the appropriate Product Data Sheet, available upon request.

20

Notes

© E

tern

it. D

ecem

ber

2014

.

Eternit Asia PanelsUnit 19-02-01, Level 2, Wisma TuneNo.19 Lorong Dungun, Damansara Heights50490 Kuala LumpurMalaysiaTel: +60 (3) 2095 5111Fax: +60 (3) 2095 6111Email: [email protected]

Eternit Australia1 Scotland RoadMile End South, SA 5031AustraliaTel: +61 (8) 8301 8288Fax: +61 (8) 8352 1014Email: [email protected]

www.eternit.com.au

Your local supplier

Disclaimer

Some of the project images shown in the document, not necessarily were built with the systems promoted in this publication. They were included with the intention to illustrate the reader about the look and appearance of our products. Most of the projects correspond to buildings using fibre cement boards manufactured by our sister companies in several parts of the world and their sole purpose to illustrate the versatility of our products and the international experience of Etex, Group to which we belong.

express - eternit australia · express technical manual. ... express is a great solution for the...

Documents